Fire & Safety in

Petroleum Oil Refinery

21 August 2020

AK Singh
General Manager(F&S)
IOCL, Gujarat Refinery, Vadodara
 Fire & Safety Management System in refineries

AIM: To reduce losses, due to fire / explosion and incidents

(including accidents) and help in providing safe and
healthy working environment.
Functions of F&S Dept

• Issue guidelines for improvement in level of safety compliance .

• Regular safety inspection to identify the gap in compliance level and draw action plan to bridge the gap.

• Safety training to all employees, contractor employees, CISF jawans, drivers/ khalasi and others. Safety briefings to
housewives and school children in refinery township.

• Safety campaign to involve all in safety activities through safety competitions, issue of safety magazines, display of safety
related posters/ boards/ banners, distribution of safety calendar, diary etc. and celebration of Safety days.

• Monthly safety meetings at floor level as well as at management level to discuss safety issues and involve all in safety
activities.

• Round the clock coverage to tackle any emergency situations. Firming up emergency response system and attending all
emergency calls.

• Regular fire drills and disaster drills to improve the emergency handling system and procedure.

• Standardizing the Incident reporting system, helping in investigation & follow up for implementations of recommendations.

• Work permit System- Firming up procedures, forms and formats and checking the compliance level.

• Inspection, testing and maintenance of fire & Safety related facilities and equipment.

• Procurement of F&S equipment/ appliances and Fire fighting chemicals and maintenance of inventory.
 Special Risks Associated with Petroleum Refining
∙ Highly flammable material
∙ High Temperature/Pressure
∙ Modern Technologies use Hydrogen extensively
∙ Harmful Chemicals/Solvents/Catalysts used in the Process
∙ Corrosivity /Reactivity
Subject
∙ Self Ignition on Leakage from System
∙ Uncontrolled Process Reactions
∙ Loss of Containment/Accidental Releases
REFINERY MAJOR POTENTIAL HAZARDS

• Fire & Explosion hazard

• Toxic gas ( H2S, Cl2, SO2, CO ) release hazard
• Hazardous chemical ( H2SO4, HCL,Sodium Hydroxide,IPN, Benzene, Mercaptan,Sodium
Hipo-chloride, additives and blending agents etc spill hazards.
• Oil spillage from process vessels, lines, storage tanks, tabnk wagons, POL road tankers etc
• Radiation hazard during radiography of welded lines and equipment during S/D and
construction
• Vapor cloud formation and UCVCE
• BLEVE in case of LPG
• Electrical hazard
• Fall from height
• Vehicle accidents
• Hazards of Natural calamities like Flood and storm , lightening etc
CAUSES OF FIRE IN THE REFINERIES: METHODS OF EXTINGUISHING FIRE:
 CLASSIFICATION OF PETROLEUM PRODUCTS

CLASS –A : Liquid which have flash point below 23oc.

CLASS – B :Liquids Which Have Flash Point Of 23oc And Above But Below 65oc
CLASS – C: Liquid which have flash point of 65oc and above but below 93oc.
EXCLUDED PETROLEUM : Liquid which have flash point of 93oc and above.
LPG do not fall under this classification but form separate category

DEFINITIONS
HAZARD :Situation with a potential for damage to men, machines and environment.
Ex : Fire / explosion in LPG storage , Toxicity in chlorine storage
RISK :Combination of hazard consequence and its probability of occurrence.
Ex : Likely death of two persons in 100 years due to loading hose failure.
FLASH POINT

The flash point of a liquid is the lowest temperature at which sufficient vapour given off to flash on
the application of flame in the presence of air.
AUTO – IGNITION
The lowest temperature to which a solid, liquid or gas requires to be raised to cause self-sustained
combustion without initiation by a spark or flame.
EXPLOSIVE LIMITS

Explosive limits are those concentrations of a vapor or gas in air below or above which propagation of
a flame does not occur on contact with a source of ignition.
The lower explosive limit is the minimum concentration below which the vapor air mixture is too lean
to burn or explode.
The upper explosive limit is the maximum concentration above which the vapor air mixture is too rich
to burn or explode.
 AUTO IGNITION, FLASH POINT AND EXPLOSIVE LIMITS OF SOME OF THE PETROLEUM PRODUCTS

SL. MATERIAL AUTO IGNITION FLASH POINT OC EXPOSING RANGE VOLUME % IN AIR
NO. TEMPERATURE oC LOWER LIMIT UPPER LIMIT
1 CRUDE OIL DEPENDS UPON THE 19 DEPENDS UPON THE NATURE OF CRUDE
NATURE OF CRUDE
2. HYDROGEN 585 GAS 4.1 74.0
3 METHANE 538 GAS 5.0 15.0
4 ETHANE 514 GAS 3.0 12.5
5 PROPANE 466 GAS 2.4 9.5
6 BUTANE 430 GAS 1.5 9.0
7 BENZENE 563 -11 1.3 7.1
8 TOLUENE 536 4.5 1.2 7.2
9 NAPHTHA 288 -18 1.1 5.9
10 GASOLINE 245 -7 1.4 7.6
11 ATF 254.4 38 0.7 5
12 SKO 254 35 0.7 5
 AUTO IGNITION, FLASH POINT AND EXPLOSIVE LIMITS OF SOME OF THE PETROLEUM PRODUCTS

SL. MATERIAL AUTO IGNITION FLASH POINT EXPOSING RANGE VOLUME % IN AIR
O
NO. TEMPERATURE C LOWER LIMIT UPPER LIMIT
13 HSD 256 32 0.7 5
14 LDO - 66 - -
15 LSHS 316 66-166 - -
16 HSHS - 65.6-148.9 - -
17 FO 262-407 - - -
18 BITUMEN 485 205 - -
19 RAW COKE - 315.6 - -
20 PHENOL EXTRACT 715 80 - -
21 SLACK WAX 245 198.9 - -
22 MINERAL TURPENTINE OIL 253.3 32.2 - -
23 LPG 405-450 GAS 1.8 9.6
 Regulations for the prevention of fire in refinery:
• Ban on carrying of a potential source of ignition- match
box/lighters etc .
• Ban on lighting fires in battery area.
• Ban on smoking
• Ban on carrying lamps/ordinary torches /mobile phones
• Use of PESO approved spark arrestors on vehicles exhaust
• Hot jobs like welding , cutting , grinding etc with approved hot
work permit
 Classification of Fires
TYPE MATERIAL

CLASS ‘A’ Fire involving solid carbonaceous materials (e.g. wood,

paper, cloth, rubber, plastics etc.) in which combustion
generally occurs with the formation of glowing ambers.
These fires require the cooling effects of water, water
solutions or the coating effects of certain dry chemicals
which retard combustion.
CLASS ‘B’ Fires involving flammable or combustible liquids or
liquefiable solids, greases etc. extinguishment is most
readily secured by excluding air (oxygen), inhibiting the
release of combustible vapour or interrupting the
combustion chain reaction.
CLASS 'C’ Fire involving gases or liquefied gases such as methane,
ethane, propane, butane, LPG etc. The only safe way of
extinguishing a gas fire is to shut off the supply of gas to
the fire. It is also necessary to dilute the burning gas at a
very fast rate with an inert gas or powder.
CLASS ‘D’ Fires involving certain combustion metals such as
Magnesium, Titanium, Zirconium, Sodium, Potassium
etc. Powdered metals like Aluminum can form explosive
dust cloud, whilst Sodium and Potassium react
vigorously and catch fire in contact with water, The
fumes from most metal fires are dangerous and fumes Clean
from Lead are extremely toxic. Agent
 FIRE RISK MANAGEMENT PHILOSOPHY

• Petroleum refinery stores and handles large quantity of flammable materials pose threat to the
surrounding in addition to its own safety. It therefore, necessitates the introduction of inbuilt fire
prevention & fire protection facilities.
• It is impractical and prohibitively costly to design fire protection facilities to control all catastrophic
fires. Usual requirement of a good system is to prevent emergencies from developing into major
threat to the installations and surroundings.

FIRE RISK MANAGEMENT

Fire risk is ‘the chance/possibility of loss due to fire. Three aspects to deal with fire risk management are:
Fire Prevention Fire Protection Fire Fighting

Fire Audit Fire extinguishers

Fire Inspection Active Fire Protection Steam
Fire risk Observation Passive Fire Protection Water mist/water spray
Use DCP/AFFF/AR AFFF
ACTIVE FIRE PROTECTION Essentially involves
fighting a flame. Examples :
• Portable Fire Extinguishers
• Fire hose reels
• Fire Hydrants/Fire water monitors/HVLR
monitors
• Fire blankets/Water Jel Blankets
• Semi Fixed Foam pourers/Water Sprinkler
/Deluge systems
• High Pressure Air Foam Mist System
• Smoke Detectors/alarms
• Fire fighters/emergency services
• Automated fire doors
• Heat and flame detectors
• Fire control systems
Mobile fire fighting appliances
• Foam /DCP tenders/Foam Nurser
• Hydraulic Platform
• Trailer Fire Pumps
• Rescue Tender
PASSIVE FIRE PROTECTION is a vital component of any
fire safety strategy. It is built into the structure of a
building /plant to safeguard people’s lives and limit the
financial impact of damage in localized manner.
Example:
• Fire resistant doors
• Fire walls/Fire Barriers compartments
• Fire Proofing as pre OISD Std 164
• Fire floors in high rise buildings
• Emergency exit lights
• Gas detector in central AC ducts to shut
Dampers
• Fire retardant paint /coatings on cables
• Glass wool /perlite insulation of Lines
• Protection of Escape doors
• Dyke wall
• Safety valves on equipment & Rupture disc in
process piping
• Water seal in separators
• Positive pressurization
• Flaring / venting
 Fire Protection Facilities
Fire Water System
Design Capacity, M3/hr 5959
Min. Header Pressure, 7.0
kg/cm2
Network Length, Km 100
Main Pumps, Nos. 10 (4 Electrical & 06 Diesel Driven)

Water Storage Capacity, m3 29900

Pump House, Nos. 02

Mobile Equipment
Foam Tender, Nos. 05
Foam Nurser, Nos. 02
DCP Tender, Nos. 01
Emergency Rescue Tender, No. 01
Multipurpose Tender, No. 02
Hydraulic Platform (50m) for Elevated fire 01
fighting & rescue operations
• Two number of Fire Stations
• Fire water system designed for double fire contingency
 VARIOUS FIRE FIGHTING CHEMICALS
For Liquid Hydrocarbon or inflammable liquid fires
Aqueous Film Forming Foam (AFFF)
For Polar Solvents fires (Benzene,
Toluene, Methyl Alcohol, IPN) : Alcohol
Resistant- Aqueous Film Forming Foam
(AR-AFFF)

Clean Agents Common Fire Suppression

Synthetic chemicals in liquid form and converted to gas in the discharge mode.
Extinguishes fire and prevents re- ignition. Inert gas systems reduces oxygen in the
space to below that required for combustion.

• Inert: A mixture of the inert gases: nitrogen, argon,

and carbon dioxide (CO2)
• Novec 1230 : A fluorinated ketone containing carbon,
fluorine, and oxygen
• FM-200: A hydrofluorocarbon (HFC) compound
containing hydrogen, fluorine, and carbon
 Dry Chemical Powder

Carbone Di- Oxide (Co2) Type

• Sodium carbonate
• Potassium Bi carbonate
• Mono ammonium Phosphate ( ABC Type )
• MONNEX Powder: Based on potassium allophanate, a potassium
bicarbonate – urea complex originally developed by ICI ,UK.
Comparison of Clean Agent Systems

Inert Gas Novec 1230 FM-200

A mixture of the inert A hydrofluorocarbon (HFC)
A fluorinated ketone
gases: nitrogen, compound containing
Type of Compound containing carbon,
argon, and carbon hydrogen, fluorine, and
fluorine, and oxygen
dioxide (CO2) carbon

Stored as a liquefied Inert Gas Fire Protection System

Storage Stored as a gas Stored as a liquid
compressed gas
Discharge Time 60 seconds 10 seconds 10 seconds

Clean Up None None None

Environmental Considerations

Inert Gas Novec 1230 FM-200

Novec™ 1230 Fire Protection Fluid
Ozone Depletion Potential
None None None
(ODP)
Global Warming Potential 1 (equivalent to that
None 3500
(GWP) of carbon dioxide)
Atmospheric Lifetime
None 0.014 36.5
(years)
HFC-227ea, HFC-227 or FM200
FM-200™ Clean Agent Fire Suppression System
 FIRE
Three elements are necessary for initiation of fire:

1. Fuel in the form of vapour, liquid or solid.

2. A source of ignition sufficient to initiate & propagate the fire.

3. Oxygen in sufficient proportion to form a combustible mixture.

Combustion process is observed in two modes.

For FLAMING COMBUSTION to occur, solid or liquid fuel must be converted into a
vapour, which then mixes with air and reacts with oxygen.

SMOLDERING COMBUSTION: On the other hand, involves a reaction between oxygen

and the surface of the fuel.This is a complex process and in general occurs with solid
fuels which char on heating.
 The Fire Triangle, Fire Tetrahedron & Dust Explosion Pentagon

Fire Tetrahedron
Fire triangle or combustion It adds presence of the chemical reaction Ex- the
triangle suppression effect of Halon is due to its interference in Dust Explosion Pentagon
the fire chemical inhibition.
Combustion is the chemical reaction that feeds a fire For any fire to occur, there must be fuel, ignition and
more heat and allows it to continue. In metal fires like oxygen (Classic Fire Triangle). However, for a
lithium, magnesium, titanium etc. (class-D fire), the combustible dust explosion, you must also add
energy release is more. The metals react faster with dispersion and confinement — the “Dust Explosion
water than with oxygen and thereby more energy is Pentagon.” Removal of any one element prevents an
released. Putting water on such a fire results in the fire explosion, though not necessarily a fire.
getting hotter or even exploding because the metals react
with water in an exothermic reaction. Therefore, inert
agents (e.g. dry sand) must be used to break the chain
reaction of metallic combustion. In the same way, as soon
as we remove one out of the 3 elements of the triangle,
combustion stops.
 METHODS OF EXTINGUISHMENTS OF FIRE

1. Starvation : Elimination Of Fuel

2. Smothering : Limiting Of Oxygen
3. Cooling : Limiting Temperature
STARVATION : Starvation is accomplished by removing combustibles from the neighbourhood
of the fire or by removing fire form the mass of combustible materials. It is also achieved by
subdividing burning materials to small isolated pockets of fire.

SMOTHERING : Smothering is accomplished by eliminating or diluting the available oxygen

with inert gas or covering the fuel surface by a smothering agent like foam.

COOLING : If the rate at which heat is generated by combustion is less than the rate at which
it is getting dissipated then the combustion cannot persist. Application of water jet or spray
to a fire results in its extinguishments by this fundamental principle.
METHODS OF EXTINGUISHING FIRE: METHODS OF EXTINGUISHMENT OF FIRE
The four ways to fight fire are:
Fire extinction usually consists of 1. Starvation : Elimination of fuel.
removal/limiting of one or more of three 2. Smothering : Limitation of oxygen.
factors of fire triangle. However, a fourth way 3. Cooling : Removal of temperature. (Heat)
i.e. chemical interference has also identified. 4. Chemical Interference :Interrupt in chain reaction
This converts the ‘Fire Triangle’ into a
‘Pyramid’.

Starvation Smothering Cooling Chain reaction

The combustion process

actually takes place
between free radicals and
not between molecules as
is usually depicted. Fire is
an example of a free
radical change reaction.

FIRE TETRAHEDRON PYRAMID)

 CLASSIFICATION OF FIRE
As per Indian Standards IS-2190:
CLASS A : Fires involving ordinary combustible material like wood, paper, textiles etc.
Where the cooling effect of water is essential for extinguishments of fire.
EXTINGUISHING MEDIA - Water
CLASS B : Fires in flammable liquids like oils, solvents, petroleum products, paints etc.
Where a blanketing effect is essential to extinguish the fire.
EXTINGUISHING MEDIA - Foam, Carbon Dioxide, Dry Chemical Powder.
CLASS C : Fires involving gases or liquefied gases in the form of a liquid spillage, or a liquid
or gas leak. Here it is necessary to dilute the burning gas at a very fast rate with an inert
gas or powder.
EXTINGUISHING MEDIA - Carbon dioxide, dry chemical powder. The best way to extinguish
such fires is by stopping the flow of fuel gas to fire. Container is kept cool with water spray.
 CLASSIFICATION OF FIRE
CLASS D : Fires involving metals like magnesium, aluminum, zinc, potassium etc. Where
the burning metal is reactive to water and which require special extinguishing media.

EXTINGUISHING MEDIA- Special dry powder.

ELECTRICAL FIRE : Electrical fires are not treated as a class of their own, since any fire
involving, or started by, electrical equipment must, in fact, fall into one of the other
categories.

The normal procedure for dealing with an electrical fire is to cut off electricity and use an
extinguishing media appropriate to what is burning.
 CLASS DESCRIPTION EXTINGUISHING MEDIUM INDIAN STANDARD
OF FIRE
*As per
IS:21901979

A Fire involving ordinary combustible Water 934-1976

materials like wood, paper, textiles, etc. 940-1976
Where the cooling effect of water is 6234-1971
essential for the extinction of fires
B Fire inflammable liquids like oils, solvents, Foam ** carbon dioxide dry 933-1976
petroleum products, varnishes, paints etc. chemical powder. Not 2878-1976
where a blanketing effect is essential suitable for alcohol and 2171-1976
other water miscible
(4308)-1982
flammable liquids
C Fires involving gaseous substances under Carbon dioxide dry chemical 2878-1976
pressure where it is necessary to dilute the powder. The best way to 2171-1976
burning gas at a very fast rate with an inert extinguish such fires is by (4308)-1982
gas or powder. stopping the flow of fuel gas
to the fire. Container is kept
cool with water spray
D Fires involving metals like magnesium, Special dry powder 2171-1976
aluminum, zinc, potassium etc. where the (4861) – 1968
burning metal is reactive to water and which
require special extinguisher media or
technique
 SOURCES OF IGNITION
Initial release of energy to trigger combustion (fire). It is necessary to understand the sources
of ignition and to eliminate them to prevent fires/explosions in our refinery.

SOURCES OF IGNITION EXAMPLE PREVENTIVE MEASURES

Electrical equipment Sparks from motors,
switches, lamps, hot
elements and electrical
defects
Friction Hot bearings, misaligned or
broken m/c parts, chocking,
jamming of material, poor
adjustment
Open flames Cutting and welding torches
gas & oil burners
1. Use of approved equipment
2. Follow nation electrical codes
3. Proper maint.
Preventive maint. And proper lubrication
Strict compliance of precautions stipulated
in the fire permit for hot jobs.
 SOURCE OF IGNITION
SOURCES OF IGNITION EXAMPLE PREVENTIVE MEASURES
Smoking as ignition Smoking booths in area 1. Smoking only in areas permitted.
where combustible are used 2. Use of prescribed receptacles for
cigarette butts
Spontaneous ignition Pyrophoric iron, hot oil 1. Keep pyrophoric iron wet are the
leakage time when it is taken out.
Hot surfaces Contact of combustible 1. Provide proper insulation and air
material without surfaces, circulation.
heated lines
Spark from engine POL trucks / DG set 1. Spark arrestor on exhaust
exhaust
Static electricity During splash loading and 1. Proper earthing of equipment.
loading at high velocities 2. Do not resort to splash loading
3. Loading velocity should be controlled
Lightening Thunderstorm cloud burst 1. Proper lighting arrestor and earth
continuity.
 FIRE STATION CONTROL ROOM
EMERGENCY
COMMUNICATION SYSTEM
AVAILABLE IN REFINERIES:
• Break glass type Fire Alarm or
MCP
• Walkie Talkies
• Auto Phones /FLP Phones in
plant
• FLP Mobile Phones with Sr
Management and key
personnel
• Fire /Disaster Siren
• SMS facility for group
communication
• AIR Raid Protection (
ARP)system in phones
• Group calling automated
messaging at residence phones
 OISD STD 116- EMERGENCY SIREN CODES
1) Small Fire : No Siren
2) Major Fire : Wailing type Siren for continuously two minutes

2 Minutes
3) On-Site Disaster : Repetition of Major fire (2 Min) siren 3 times with a gap of 1 minutes in between. Total
duration 8 minutes.

1 Minute 1 Minute
2 Minutes 2 Minutes 2 Minutes
4) All Clear Siren : Straight jetting sound for two minutes
5) Testing of Siren
Straight jetting sound for two minutes (Daily at 8.15 Hours).
Sirens are checked on all modes on 1st Day of every month at 10.30 Hrs
 VAPOUR CLOUD
When light hydrocarbons like naphtha, ms or flammable gases leak it vapourises and forms an
explosive mixture with air. When the leak is heavy an explosive cloud is formed. This cloud is
known as a vapour cloud.

Whenever this vapour cloud comes in contact with a source of ignition it can explode and causes
from the vehicles, smoking or other sources of ignition.

FORMATION OF VAPOUR CLOUD

1. LEAKAGE FROM PIPELINES: It may be on the road side, inside the units or in the tank farm.

2. LEAKAGE FROM TANKS OR TANK OVERFLOW: It may be in the tank farms or from the tanks
in the units area.

3. LEAKAGE FROM TANKERS OR OVERFLOW OF TANKER: It may be in wagon loading gantry area.
 VAPOUR CLOUD
LEAKAGE OF LPG: It may be in the following areas;

i) Inside process units or along road side line leakage

.Leakage from road tanker, wagons, filling hoses,
horton spheres or from connecting pipes.

ii) Leakage from cylinders, filling machines, pumps or

connecting pipes.

HOW TO IDENTIFY VAPOUR CLOUD:

i) BY SMELL: If it is extra ordinary on higher side.

ii) BY MIST : In most of the cases mist formation

takes places.

iii) BY LEAK: If hydrocarbon leak is visible.

 VAPOUR CLOUD
Important Do’s and Don’ts in case of vapour cloud:

Do’s Don’ts
Inform concerned unit personnel and fire Never allow any vehicle to enter in the area. Do
station . not operate any electrical switches.
Cordon-off the area Never allow any vehicle to start in the affected
area.
Guide the unit personnel/fire personnel If vehicle is already in the affected area, remove it
by pushing.

In case of vapour smell, try to detect the During patrolling if strong smell of hydrocarbons or
source of leak any leak detected stop the engine immediately and
move on foot to detect the leak.

Stop all hot jobs and smoking booths Never smoke or allow the smoking inside the
battery area.
 FIRE PROTECTION

FIRE PROTECTION PHILOSOPHY :

Fire protection philosophy is based on loss prevention & control. Because of the inherent
hazard a refinery carries,no plant is absolutely safe. A fire in one part/section of a plant can
endanger other sections of plant as well
Types :
• Active fire protection system
• Passive fire protection system

Refinery Fire protection System design Basis:

• OISD STD 116

• NFPA Codes and sound engg practices
• Industrial best practices
 FIRE PROTECTION
Following fire protection facilities are provided depending on the nature of the installation
and risk involved:

• Fire water system

• Foam system

• Rim Seal protection System ( रम सील अि न सुरक्षा प्रोटे क्शन सस्टम)

• Clean agent system

• CO2 system

• DCP extinguishing system

• Detection and alarm system

• Communication system
 रम सील अि न सुरक्षा प्रोटे क्शन सस्टम

रम सील अि न सुरक्षा प्रोटे क्शन सस्टम

• पहले से मक्स कया पानी और फोम 200 लीटर के वेस्सेल मे, नाइट्रोजन गॅस के प्रैशर
पर रखा गया है ।

• 1.5 मटर के अंतराल पर लगभग 40 मीटर का रम सील ए रया फोम डस्चाजर्ज नोज़्ज़्ल
से प्रोटे कटे ड रखे गए हैं।

• रम सील अि नशमन सुरक्षा प्रोटे क्शन सस्टम 50 सेकंड से कम समय मे डस्चाजर्ज करने
लगेगा और आग बुझा दे गा।
 Fire water System
• Refinery Fire Protection System designed as per OISD
STD 116
• Double fire contingency( One unit fire and other
Storage tank fire)
• Water storage capacity is minimum for 4 hrs
continuous fire fighting
• Supplementary supply to make up
• Total Fire Water network in ring construction – 100
KM
• Pressure in remotest hydrant Min 7.0 Kg/CM2
 FIRE FIGHTING
Objective : To extinguish the fire with minimum loss

It is the last line of the defense. It comes into force when there is actual fire. Main purpose is
to extinguish the fire with suitable equipment and materials with an aim to reduce damage due
to fire

• Portable fire fighting equipment

• Mobile fire fighting equipment

• Fixed fire fighting system

 FIRE FIGHTING
Mobile fire fighting equipment

•Foam tenders

•DCP tenders

•Foam Nurser

•Trailer fire pump

•Trolley mounted monitors

•Fire fighting hose & other accessories like foam branch, nozzles etc.

•Fire fighting chemicals like foam compound, dry chemical powder etc.
 Fire Protection Facilities
Fire Water System
Design Capacity, M3/hr 5959
Min. Header Pressure, kg/cm2 7.0
Network Length, Km 100
Main Pumps, Nos. 10 (4 Electrical &06 Diesel Driven)

Water Storage Capacity, m3 29900

Pump House, Nos. 02

Mobile Equipment
Fire Stations 2
Foam Tender, Nos. 05
Foam Nurser, Nos. 02
DCP Tender, Nos. 01
Emergency Rescue Tender, No. 01
Multipurpose Tender, No. 02
Hydraulic Platform (50m) for Elevated fire 01
fighting & rescue operations
Emergency Response
∙ Dedicated Fire fighting facilities
∙ Fire tenders/Nursers/ DCP Tender/Hydraulic Platform
Hydrant system/Fire Water Storage/Pumps/Alarms etc.
∙ Gas Detectors for Early Warning
∙ Well trained fire crew round the clock

Mock Drills
∙ Regular operation of Fire fighting equipment &
testing of facilities
∙ Emergency Management Plans (ERDMP)
- On site
- Off site
∙ On site drills once in 3 months
∙ Off site drill with Dist. Administration once in a year
∙ Mutual Aid Agreements with Neighbouring
industries/District Fire Services.
Safety System of Gujarat
Refinery
Why safety is our First Job ? Safety Beliefs
∙ To protect human life
• All injuries can be prevented.
∙ To protect company’s property
• Working safely is a condition of employment.
∙ To protect surrounding environment/
• Employees involvement is essential.
community.
• All operating exposures can be safeguarded.
∙ To efficiently run the business &
reduce Losses. • Training employees to work safely is essential.

∙ To enhance productivity. • Prevention of personal injuries is good

business.
∙ To build up morale & team spirit.
• Management audits are a must.
∙ To enhance Corporate image.
• Management is responsible for preventing
injuries.
 VARIOUS SAFETY SYSTEMS FOLLOWED IN REFINERY
1. Observation of Monthly Safely Day on1st Day of each month
2. Safety Meetings/month Three tier- Shop floor(16), DGM/GM level(9) Management level (MHSCM)
3. Practice of SAM (Safety Action Meeting) at unit level with participation of executive & staff to find out solution to
issues regarding routine activities through brainstorming session and their implementation.
4. Observance of Monthly Safety Day on 1st working day of every month on various Safety themes including
discussion on lessons learnt from past incidents & hipo near miss incidents.
5. Various safety awareness programs conducted during National safety day week/Fire Service day /week invoving
participation of executive, staff and contractor personnel.
6. During MHSCM rolling trophies are awarded to department contributing maximum no. reporting and closing of NM
and individual reporting maximum nos of NM.
7. Online Safety quizes are conducted during celebration of National safety day week/Fire Service day /week and also
on the monthly safety theme.
8. Reporting of unsafe conditions/acts and Nearmiss incidents for early compliance through on line reporting system.
and receiving work permits .
9. Participation in preparation of Job Safety Analysis
 Audits and Inspection
10. Participation during process mock drills and Monthly mock drill at various units
11. Participation during Emergency handling & preparedness drills conducted on Quarterly basis.
12. Participation in inspections and various audits like Construction Safety Audit, OHSAS, Internal Safety Audits,
External Safety Audits, System audits etc.
13. Participation in various safety awareness surveys and Safety suggestions.
14. Participation in APEX level Safety Committee meetings chaired by Unit head on monthly basis.
15. Participation in Monthly safety theme online safety quiz on monthly basis for employees.
16. Preparation of Operating manuals
17. Selection of Basic Personal protective Equipment like Safety Shoes.
18. Participation in various Safety Awareness Training programs and First Aid training programs
19. Participation in Hazard Analysis, Risk assessment, Management of change etc. for any process modifications.
Emergency Planning and Response management

1. ERDMP plan approved by PNGRB notified agency.

2. On-site emergency plan approved by DISH (Directorate of Industrial safety and health of Factories), Govt. of
Gujarat.

3. Well established Disaster Control Room and its alternative DCR at Main Admin building availaible in case of
unable to activiate Maind DCR then alternative DCR can be used and available at JR

4. Mutual aid agreement available with neighbouring industries .

5. Three Nos. onsite mock drills & 1 No. offsite mockdrill is conducted yearly with involvement of ERDMP
coordinators, mutual aid partners, district authorities and other stake holders

6. Liquidation of action points in time bound manner.

7. Mock drill is conducted on monthly basis on emergency scenerios at unit / offsite areas. 8. Water Mist Fire
Extinguishers provided near all identified hot column bottom pumps. 9. Provision of Toxic Gas Neutraliser made
at all identified locations.
INCIDENT INVESTIGATION INCLUDING ANALYSIS AND NEAR MISS
1.On line SEED Portal available for formation of committee for Incident investigation and recording of report. Also
online portals are available for reporting of unsafe conditions, acts, near miss incidents and being used by all
employees.
2. All Hi potential near miss incidents are investigated by a team and reports sent to RHQ.
Recommendations of the incidents are followed up for compliance.
3. Detailed analysis shared in RSM Chaired by Apex committee and Sectional Safety Committee meetings for
shop floors employees.

4. All First- Aid Incidents are investigated and analysis shown in MSCM

5. Lessons learnt from incidents in other industries are shared during various safety awareness programs

6. Incident reporting & investigation is done as per guidelines circulated by CO-HSE.

 F&S Training and mandatory Briefings
1. Mandatory Safety Briefing / Safety Induction Training to all contract workers prior to entry inside refinery premises and
same is linked up with CISF gate pass to ensure that without safety briefing not a single contractor workers/visitor allowed
inside refinery.
2. Before and after completion of safety training pre and post assesement done for contract workers in local language.
3. Contract workers those who are illeterate and engaged in Civil related activity like grass cutting or other relevant jobs
visual pre and post assessment done in local language.
4.Specailsed training (ISMS) to contract worker those are engaged in Height work job, hot job, confined space job etc. After
completion of class room training taken them at SAFETY PARK for visaul training relevant to there respective job for better
understanding.
5. Annual Training calendar is prepared for employees including officers, staff, Security (CISF) personnel on F&S training on
Fortnighlty ,Monthly, Quarterly and half yearly basis and same is followed througout out the year.
6. OJT training on Daily basis for contract workers engaged inside refinery on monthly safety theme and related to the job they
are 7. Daily Tool Box talks prior to start of any job
8. Weekly on spot training to truck drivers and helpers
9. Weekly skill development training planned for F&S personnel.
10. Monthly on the job and hands on training to employees and contract workers on use of emergency F&S equipment,
gadgets & PPE.
11. Quarterly Training on First- Aid by medical department.
12. Training to plant personnel on HVLRM, PPEs, BA set, extinguisher operation etc.
13. A vertigo test module has been installed which is used to conduct vertigo testing in presence of Doctor. Medical
parameters relevant of vertigo /height phobia is done before and after the test performed and If any medical parameters
found not meeting the concerned contract worker is not allowed for working at height job.
Indian Oil Safety Management System (ISMS) Standards :(14 Safety Standards)
S.N Standards Implemented
1 ISMS-1001 Work at Height
2 ISMS-1002 Confined Space Entry
3 ISMS-1003 Safety during Excavation Work
4 ISMS-1004- Hot Work
5 ISMS-1005 Energy Isolation (Electrical)
6 ISMS-1006 Work Permit System
7 ISMS-1007 Scaffold Safety
8 ISMS-1011 Management Of Change
9 ISMS-1012 Start up clearance
10 ISMS-1013 Storage & Handling of Chemicals
11 ISMS 1005 : Energy Isolation (Process)
12 ISMS 1008 : Incident Reporting & Investigation
13 ISMS 1009 : Behaviour Based Safety
14 ISMS 1014 : Job Safety Analysis
 Latest Initiative for Improvement in Safety Management
system
Emphasis on Behavioural Based Safety – to improve safety culture
For the 1st time in any IOCL Refinery, M/s DUPONT lined – up for a 3 year comprehensive program
Main Aims of the program include
• Integrated Safety Management System

• Building Capability for Leading

• Safety Observations

• Safety Rules, Procedures and Training

• Incident Investigation

• Process Safety Management

• Contractor Safety Management

Improvement in Safety Management
Improved safety performance of Gujarat Refinery is broadly linked to 3 major
milestones for us to achieve…
Improved Safety Management
System

People –Value and

Organization structure

Belief
Integrated Safety

Processes
Existing Safety Management
System 3. Creating value towards safety rather than priority

2. Integrate safety in to existing business processes

1. The right Integrated Safety organization structure is in place

50
SEED Bradley Curve

Na
tur
al
Ins
tin
cts
Injury Rates
Sup
erv
is ion
Self
Teams
Reactive Dependent Independent Interdependent
• Safety by Natural • Management • Personal Knowledge, • Help Others
Instinct Commitment Commitment, & Conform
• Compliance is the • Condition of Employment Standards • Others’ Keeper
Goal • Fear/Discipline • Internalization • Networking
• Delegated to • Rules/Procedures • Personal Value Contributor
Safety Manager • Supervisor Control, • Care for Self • Care for Others
• Lack of Emphasis, and Goals • Practice, Habits • Organizational
Management • Value All People • Individual Recognition Pride
Involvement
• Training
0 1.25 2.5 3.75 Proactive 5
Reactive Proactive
 Safety Observations (SO)
Observation Categories
• Reactions of People
• Positions of People
• Personal Protective Equipment
• Tools and Equipment
• Procedures
• Orderliness Standards
6 Steps of Observation
1. Observe; Stop the work safely, then get the
person’s attention.
2. Comment on what the employee was doing safely.
3. Discuss with the employee
The possible consequences of the unsafe act.
Safer ways to do the job.
4. Get the employee’s agreement to work safely in
the future.
5. Discuss other safety issues of the job.
6. Thank the employee.
PROCESS SAFETY MANAGEMENT

53
 Some examples of Process Incidents
• Loss of primary containment –
Leaks/spills of hazardous chemicals
• Fire
• Explosion
• Tank collapse
• Run away reaction
• Failure of Emergency protection
device on demand (when required)
……
 Procedure for Investigating Incidents (II)- 8 step process
1. Make initial response and report.
2. Form investigation team.
3. Determine the facts.
4. Determine the key factors (Physical/Human/System)
5. Determine systems to be strengthened.
6. Recommend corrective & preventive actions.
7. Document and communicate findings.
8. Follow up.
 Incident Investigation –Employee’s Role
✔ Get involved –
• Report – understand the categories
• Preserve evidence
• Participate in Investigation
• Work promptly to close the observations.
• Share the learning – tool box/safety contact etc.
✔ Appreciate the learning and efforts in
investigation.
✔ Look out for each other.
Contractor Safety Management(CSM)
Contractor 1. Select contractors with demonstrated satisfactory safety
Selection performance.
2. Document safety performance expectations, standards for
Contract execution of the work, capabilities of key personnel, expected
Preparation behaviors.
3. Communicate and test for understanding of the safety
Contract expectations documented in the contract.
Award 4. Prepare contractor team for project success including safety
regulatory compliance.
Orientation 5. Ensure that we’re following the plan outlined in Steps 1
and Training through 4 – Executing the plan, managing the progress and
managing the change.
Managing 6. Assess level of success and lessons learned. Determine whether
to use the contractor again.
the Work

Post-Contract
Evaluation
 Safety Management Process – SRPT
Objective
• To standardize the risk perception and understanding of Safety Rules and Procedures by all employees

Enablers
• Identified & prioritized high risk activities of refinery to work upon
• Developed the process of development of Safety standard of prioritized high risk activities and the
implementation plan
• Tracker of Implementation
Standards developed and implemented
• SEED Hot work standard
• SEED Work at Height standard
• SEED PPE standard
• SEED LOTO Standard
• SEED Confined space entry standard

Focus is on Readiness To Implementation of New Standard 58

Safety Action Meetings
• Leader
1. States purpose.
2. Outlines facts.
3. Gives question for discussing.
• Group
1. Brainstorms ideas.
2. Selects actions.
3. Decides responsibilities and timing.

Upload in the SAM Portal

 Safety Management

∙1 In the early stage of industrialization safety was managed through training

and following safe procedures, compliance of rules and regulations, etc.
2∙ Next stage witnessed enhanced safety feature through technological
up-gradation , safe processes, safety features in built- in design and
prescriptive statutory rules.
3∙ Finally safety is managed through systems approach. The ‘Cullen Report’,
1990 on Piper Alpha Disaster stressed the need for formal safety
management system.

Safety Management System

An integrated approach of Management, Leadership Commitment and
Coordinated Technical Interventions from concept to commissioning to
commercial operations
Safety Management Systems

∙ EPA Risk Management Programme

∙ API RP 750 : Management of Process Hazards
∙ CMA (Chemical Manufacturers Association) Systems
∙ CCPS Guidelines for Technical Management of Chemical Process
Safety
∙ OSHA - Process Safety Management
∙ OHSAS –18001
∙ OISD
Elements of Safety Management Systems

∙ Management Leadership, Commitment and Accountability

∙ Work Permit System
∙ Employee Participation
∙ Mechanical Integrity
∙ Process safety Information
∙ Incident Investigation
∙ Process Hazard Analysis
∙ Management of Change
∙ Operating Procedures
∙ Emergency Planning and Response
∙ Training
∙ Safety Audits
∙ Contractors
∙ Regulatory Compliance
∙ Pre-commissioning Checks and Audits
Management Commitment & Leadership Employee Participation
∙ Corporate safety policy ∙ Abide by safety rules/regulations
∙ Allocation of resources ∙ To follow safe operating practices
∙ Actively participate in safety committees
∙ Development of systems & guidelines
∙ Feed back on unsafe practices and acts
∙ Performance of systems & guidelines
∙ Train co-workers and assist them in performing safely
∙ Nurturing positive safety culture ∙ Help in controlling safety and environmental

∙ Rewarding outstanding performance incidences

∙ Use Personal Protective Equipment (PPE)
∙ Occupational Health

∙ Compliance with Regulations

∙ Environmental Protection

∙ Community Awareness
 Safety Audits
∙ To check and affirm System Effectiveness
∙ Done on structured check list by Multi Disciplinary Teams
Audit Types followed in IOCL Refineries:

∙ Internal Safety Audit as per OISD Std- 145 - Every Year

∙ External Safety Audit (once in 3 years) & Surprise Audit (once in a year) by OISD
∙ OHSAS 18001 and EMS 45001 Audit six monthly
∙ System Audits – 17 Audits /year ( Internal)
∙ Electrical Safety Audit( Internal)
∙ Construction Safety Audit(Internal)
∙ Tank Farm Safety Management Audit ( Internal)
∙ Cross refinery safety Audit( External)
∙ ERDMP compliance audit by external agency ( External)
∙ Pre commissioning Safety Audit for new plants ( Internal)
∙ OISD Audit before commissioning new plants( External)
∙ PESO safety Audit before commissioning new plants( External)
∙ Implementation of recommendations
∙ Review
Statutory Compliance

∙ The Factories Act, 1948

∙ State Govt Factories Rules
∙ The Petroleum Rules, 1976
∙ Indian Explosive Act
∙ The Gas Cylinder Rules, 1981
∙ The SMPV (U) Amendment Rules, 2000
∙ The MSIHC Rules, 2000
∙ The EP Act, 1986
∙ Indian Electricity Act
∙ Boiler Regulations
∙ Central Motor Vehicle Rules
∙ Consent to Operate from GPCB
 OISD STD 116- EMERGENCY SIREN CODES
1) Small Fire : No Siren
2) Major Fire : Wailing type Siren for continuously two minutes

2 Minutes
3) On-Site Disaster : Repetition of Major fire (2 Min) siren 3 times with a gap of 1 minutes in between. Total
duration 8 minutes.

1 Minute 1 Minute
2 Minutes 2 Minutes 2 Minutes
4) All Clear Siren : Straight jetting sound for two minutes
5) Testing of Siren
Straight jetting sound for two minutes (Daily at 8.15 Hours).
Sirens are checked on all modes on 1st Day of every month at 10.30 Hrs
 FIRE FIGHTING
Objective : To extinguish the fire with minimum loss

It is the last line of the defense. It comes into force when there is actual fire. Main purpose is
to extinguish the fire with suitable equipment and materials with an aim to reduce damage due
to fire

• Portable fire fighting equipment

• Mobile fire fighting equipment

• Fixed fire fighting system

 REFINERY MAJOR POTENTIAL HAZARDS
• Fire & Explosion hazard
• Toxic gas ( H2S, Cl2, SO2, CO ) release hazard
• Hazardous chemical ( H2SO4, HCL,Sodium Hydroxide,IPN, Benzene, Mercaptan,Sodium
Hipo-chloride, additives and blending agents etc spill hazards.
• Oil spillage from process vessels, lines, storage tanks, tabnk wagons, POL road tankers etc
• Radiation hazard during radiography of welded lines and equipment during S/D and
construction
• Vapor cloud formation and UCVCE
• BLEVE in case of LPG
• Electrical hazard
• Fall from height
• Vehicle accidents
• Hazards of Natural calamities like Flood and storm , lightening etc
 FIRE PROTECTION
Following fire protection facilities are provided depending on the nature of the installation
and risk involved:

• Fire water system

• Foam system

• Rim Seal protection System ( रम सील अि न सुरक्षा प्रोटे क्शन सस्टम)

• Clean agent system

• CO2 system

• DCP extinguishing system

• Detection and alarm system

• Communication system
 रम सील अि न सुरक्षा प्रोटे क्शन सस्टम

रम सील अि न सुरक्षा प्रोटे क्शन सस्टम

• पहले से मक्स कया पानी और फोम 200 लीटर के वेस्सेल मे, नाइट्रोजन गॅस के प्रैशर
पर रखा गया है ।

• 1.5 मटर के अंतराल पर लगभग 40 मीटर का रम सील ए रया फोम डस्चाजर्ज नोज़्ज़्ल
से प्रोटे कटे ड रखे गए हैं।

• रम सील अि नशमन सुरक्षा प्रोटे क्शन सस्टम 50 सेकंड से कम समय मे डस्चाजर्ज करने
लगेगा और आग बुझा दे गा।
 SAFETY, HEALTH & ENVIRONMENT (S,H&E) POLICY

Indian oil corporation is committed to conduct business with strong environment conscience
ensuring sustainable development, safe workplaces and enrichment of quality of life of
employees, customers and the community. we at Indianoil, believe that good S,H&E
performance is integral part of efficient and profitable business management.

We shall :
• establish and maintain good standards for safety of the people, the processes and the
assets.
• Comply with all rules and regulations on safety, occupational health and environment
protection.
• Plan, design, operate and maintain all facilities, processes and procedures to secure
sustained safety, health and environmental protection.
 SAFETY, HEALTH & ENVIRONMENT (S,H&E) POLICY

• Remain trained, equipped and ready for effective and prompt response to accidents and
emergencies.
• Welcome audit of our S,H&E conduct by external body, so that stakeholder confidence is
safeguarded.
• Adopt and Promote Industry Best Practices To Avert Accidents And Improve Our S,H&E
Performance.
• Remain Committed to be a Leader in Safety, Occupational Health And Environment
Protection Through Continuing Improvement.
• Make efforts to preserve ecological balance and heritage.
Various PPE
WORK PERMIT
SYSTEM
Basic Purpose:
To ensure that work is carried out in the safest possible manner to
prevent injuries to personnel, protect property from damage, avoid
fire etc.

What it is?
• A document that categorically spells out task, equipment involved, its location,
personnel involved, time duration, precautionary safety measures to be taken
together with likely hazard to be encountered, if any.

• Written agreement between issuer and receiver for doing the job safely, avoiding any
communication gap.

• Predetermined checklist of various safety precautions and safety conditions .

Work Permit System
∙ Duly authorised written permit is a pre-requisite for carrying out any job in hazardous premises
other than by the operating personnel
∙ The system operates on ‘Owner-Incharge’ concept. Management issue appropriate authority limits.
∙ Generally Permits are printed, serially numbered and colour coded. Now On line SAP based System
is followed in IOCL refineries
∙ Before issuing permit, proper isolation of equipment, gas test, oxygen deficiency tests to be
ensured.
∙ Permits not issued to contractors . Issued only to IOCL Job Executing officers.
∙ For critical jobs like dyke cutting, approval from CGM(Tech) required.
∙ After completion of the job, area is cleaned and the permit is returned to the issuer who also signs
and keeps record for one month.
 WORK PERMIT REQUIRMENT
Permit Required Permit No required:
• Major & Minor Maintenance work,
• Routine work inside
• Inspection Workshops, QC
• Construction Laboratory etc. (except
• Alteration hot works)
• Process Equip. cleaning
• Entry into confined space & box-up • Works carried out by
• Excavation, Road Cutting
Operation Dept. as a
part of routine
• Vehicle entry into battery areas,
operation.
• Work at height
• Radiography • Area designated as
• Electrical isolation and Energisation permit free by
• Construction of temporary shed etc. management.
• Dyke Cutting, Road Closure
 Types of permits (19)
• Cold work permit Electrical Permits
• Hot Work permit : Types A • Temporary electrical power supply permit
• Hot Work permit : Types –B • Electrical Energisation permit
• Vehicle entry permit • Electrical De-energisation permit
• Permission for Temporary Shed • e LOTO Permit for electrical Sub Stations
• Radiography Permit
• Excavation Permit
• Road Cutting Permit
• Road Closure Permit
• Tank Dyke Cutting Permit
• Work at height permit
• Pre erection scaffold permit
• Scaffolding Checklist for certification
• Confined Space Entry Certificate( CSEC)
• Confined space entry permit Associated with ( CSEC)
 ACCIDENT REPORTING SYSTEM
All accidents are to be reported however small may be. Specific format to be used for reporting the accident

TYPES OF REPORTING FORMATS:

• A-I ( Incident report form): to be filled by the supervisor immediately half an hour for human injury and 24 hrs for
other incidences

• A-II ( Loss time accident report): to be filled up by the medical in case of human injury which calls for absence from
duty.

• A-III ( Certificate of fitness): to be filled up by medical on discharge of the injured person.

• A-IV ( Permanent Disability Certificate): To Be Filled Up By Medical In Case Of Permanent Disability Arising Due to
Accident.

• A-V ( Incident Investigation Report): To Be Filled Up By Supervisor Within 48 Hrs.)

Thank You