Safety in Oil Movement &

Storage Operations

Reliance Jamnagar
Jamnagar Refinery Overview
Jamnagar Refinery Overview

Tank farm facilities (OM&S)

3
Jamnagar Refinery Overview

JETTY MTF RTF UNITS

RAIL ROAD GAIL PPL 4

 MARINE TANK
OM&S facilities overview FARM
SHORE LINK
ONSHORE PIPELINES
Security Boat Patrolling Routes Chart-II 1.4 km
2 km

APPROACH
TRESTLE ZERO POINT
3.6 km
KNUCKLE PLATFORM
LO-LO JETTY
BERTH A A
BERTH B B
BERTH C C PORT OPERATIONS BUILDING

BERTH D D
4.1 km
RISER PLATFORM

SPM-4
22.8 km

28 km

SPM-5 48” PIPELINES

26 km
9.5 km
11.1 km

SPM-3
Anchorage Area

SPM - 2 3.1 km

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 . 6
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.

7
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.
8
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

9
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.

10
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.

11
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.

12
Storage Tank / Sphere Design Basis
Physical Properties - Product Vapor Pressure
Tank Type Vap. Pr. in Advantages
kg /cm2
Cone Roof <0.05
Floating Roof 0.05-0.85 Reduces Breathing
loss, fugitive emission
Int. Float Roof 0.05-0.85 IFR used wherever
quality/safety is of
importance
Dome Roof 0.85-1.06
Horton Sphere >1.06 Used for handling
Liquifed Gases such as
LPG/Propylene
13
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. PSV’s and PVRV’s.
• 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.

14
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

15
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
• CTM’s 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. )

16
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(PIB’s)
• 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.

17
OM&S Fire protection measures
Fire Protection Measures
Salient details of F&G system
S.No Type of detectors Purpose Locations
Combustible gas Plant process area, HVAC,
1 detector Hydrocarbon detection Pump houses
2 Flame detectors Detect flames Near hot Pumps, Gantries
Senses continuous rise in
3 Linear Heat detectors Temperature On Tank Roof
Rate of rise Heat Detects rise in Temperature
4 detectors at Pre defined rate Battery rooms

5 Manual call point To raise Alarm Plant area

Optical smoke In substations/PIB's/Control
6 detector Detect thick smoke rooms
Ionization Smoke In substations/PIB's/Control
7 detector Detects invisible smoke rooms
8 Toxic gas detector Toxic Gas leak HVAC, Plant process area
Battery rooms, Compressor
9 Hydrogen gas detector Hydrogen Gas release house, Analyzer houses

Open path LEL

10 detector Hydrocarbon detection Pump house
18
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.

19
Automation interface in OM&S

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20
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 .
21
Safety Management

Layout

In-built Safety Design

Safety
Management
Process Safety
Management

Operating Discipline

22
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 ,
9 Slip, trip and fall.
9 Fall from height .
9 Falling objects.
9 Struck by moving objects.
9 Caught in between.
9 Exposure to toxic vapors / substances.
9 Electric flash.
Most of these result due to improper housekeeping or non
compliance to proper procedures.

24
Accident / Incident Pyramid

Disabling injuries /
Loss time case (LTC)
1
First aid case (FAC) &
Medical treatment case
30 (MTC)

Incidents ( Without
injuries )
300
( Near Misses )

Unsafe acts / conditions

?000 / habits
( critical situations )

25
History of Major Incidents)

1998: Longford Gas 2005: Texas City Refinery

1988: Piper Alpha (Occidental) Explosion (Esso) (BP)
167 killed 8 killed, 69 injured 15 killed, 170 injured
Cost: US$1.2 billion Cost: US$1 billion Cost: US$3 billion+
2001: P36 Sinking
1984: Union Carbide, Platform (Petrobras)
Bhopal 1991: Sleipner A Platform
Collapse (Statoil) 10 killed
Reported 3000 killed
Cost: US$1.2 billion Cost: US$515 million
Cost: Disappearance
of Union Carbide 1996: Enron Gas 2005: Bombay High
Pipeline explosion) North Platform (ONGC)
33 killed, 69 injured 22 killed
Enchova Central Platform
(Petrobras) Cost :US$195 million

1984: Explosion, 37 killed

1988: Gas Blowout
Total Cost: US$461 million
1995: Nigerian Oil Rig 2006: Pipeline Explosion
Explosion (Mobil) (Nigerian National
Petroleum Corporation)
13 killed, 25 injured.
200 killed

____________________________________________________________
__________
1984 1990 1995 2000 2005
26
Worldwide recent incidents
1. Fire and Explosion incident in Jaipur terminal, India. Oct 2009

2. BP, Gulf of Mexico, Louisiana coast. Explosion and fire on the Mobile
Offshore Drilling Unit Deepwater Horizon.20th April 2010

3. Total group, Britain Lindsey Oil Refinery Fire heater Explosion.

June 2010

4. Asphalt Tank leak in Paramount Petroleum corporation, June 2010.

5. 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

Process safety
Accidents

measures
No. of

BP -Deepwater
horizon incident
Bhopal
Accident
Human Factor
measures

1970 1980 1990 2000 2010

28
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.

29
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.
31
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”
32
Process Safety Management Model

33
“Safety and health of personnel and
protection of environment overrides
all production targets.”
Mukesh D.Ambani
34
HSEF Organization
Corporate HSEF council

Site
Site President
President
Apex
Apex Committee
Committee
Corporate-Group
Corporate-Group
Central Manufacturing-
Manufacturing- HSEF
Central HSEF
HSEF Committee
Committee HSEF

District
District Safety
Safety Committee
Committee

HSEF
HSEF CHIEF
CHIEF

OCCUPATIONAL
OCCUPATIONAL SAFETY
SAFETY ENVIRONMENT
ENVIRONMENT FIRE
FIRE
HEALTH
HEALTH CHIEF(DTA&SEZ)
CHIEF(DTA&SEZ) CHIEF
CHIEF CHIEF
CHIEF
CHIEF
CHIEF

DOCTORS
DOCTORS SAFETY
SAFETY MANAGERS
MANAGERS ENVIRONMENT
ENVIRONMENT FIRE
FIRE OFFICERS
OFFICERS
(DTA+SEZ)
(DTA+SEZ) MANAGERS
MANAGERS

MEDICAL
MEDICAL STAFF
STAFF FIREMEN
FIREMEN
35
Process safety Management
Management of PSM Elements
• PSM element committee
• Committee Charter
• Plan of activities
• KPI’s 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

36
Operational Discipline
Operational Discipline elements
(Operational 
4. OD Discipline)

• KRA
• Resources
3. Implement 
• Training and competency PSM Program
• Communication
• Participation
• Procedures 2. Management Leadership and 
Commitment
• Job cycle checks
• RESOP
• Audits
1. Build a Safety Culture
• Assessment / Review

37
Operation discipline elements
• KRA : Site KRA/ Team KRA / Individual KRA and KPI system
• Resources : Process Safety, Fire protection, special PPE’s, 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 SOP’s 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.
38
 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/ SMP’s.
• 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 )
39
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
40
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

41
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

42
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 43
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.

44
Performance review

• TRC (FAC + MTC)

Safety
• LTC
• Fire all category
• Spill all category
• Overdue recommendations
(Incidents & accidents investigation)
Reliability
•Audit recommendations
•F & G device disabled
• DVs isolated > 24 hrs (Other than
M&I Purpose)

Monitoring • Isolation of Fire Water network

• QSP rating

45
Performance review

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

46
Performance review

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

47
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,

9 Monitoring & Control

9 Process Safety, SOP
9 Supervisory Control
9 Reliability
9 Static electricity

48
Best operating Practices
Monitoring & Control
1. Close coordination with process units during start up and shut
down.
2. All product routings and the changes shall be done with prior
information.
3. Close monitoring of product Rundown temperature and quality.
4. Monitor trend of important process parameters.
5. Deviation from standard operating condition(SOC’s) to be
checked promptly.
6. Nitrogen blanketed tanks shall be closely monitored.
7. Floating roof drains should be checked for any leaks during
routine rounds.
8. Inter tank gravitation operations shall be done in controlled
manner to ensure transfer- rates with in specified limits.
9. Piping joints of LPG / Naphtha / lighter service products to be
closely monitored under LDAR checks.
10. Pump out and receiving rates from tanks shall be monitored.
49
Best operating Practices
Process Safety / SOP
1. No gas blow back from process units ( H2S ,H2 , N2 , Lighters etc.)
to storage tanks .
2. Defloating of roof shall be avoided during normal operations .
3. Non process connections shall be adequately safe guarded for
hydrocarbon mix-up.
4. Tank dyke interceptor valves should be always kept in close
condition.
5. Process safety system bypass shall be done with authorization and
proper procedure / safe guards.
6. Non routine operations shall be done as per proper procedures.
7. Ensure thermal expansion of idle and blocked process lines.
8. Any job / modification pertaining to OWS system should be done
under proper SOP / Supervision.
9. All the facilities shall be properly marked / stenciled for clear
identification.
10. Pyrophoric iron hazards and safe work practices.

50
Best operating Practices
Supervisory Control

1. Water draining from the tanks shall be done under

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

51
Best operating Practices
Reliability
1. Oil soaked insulation shall be promptly replaced.
2. Steam tracer leaks under insulation to be identified and promptly
attended.
3. Stagnant lines shall be periodically checked ( by draining
/inspection ).
4. Small bore connection to be included in periodic inspection
program.
5. Valves which are not operated normally should be checked and
greased.
6. Periodic checks for the earthing and cathodic protection
facilities of tanks shall be done .
7. Periodic greasing of floating roof ladder hinges for free moment.
8. Avoid use of flame arrestors in the heavier product service tanks.
9. Spare safety valve to be kept isolated and normal safety valve to
remain inline.
10. Wafer type NRV’s are not safe for LPG/Naphtha/Light product
services. 52
Best operating Practices
Static electricity
1. Side entry mixers ( SEM’s) shall be operated in adequately
submerged condition (0.60 – 1.00 m).
2. Tank mixing operation shall be done after draining of water.
3. Maintain safe velocity while commissioning the tanks.
4. Steam coils operations ( Charging or isolation) shall be done when
these are fully submerged.(Product level 1 M above the coil).
5. Use only cotton rope for sample thief.
6. Dip tape and sample thief should be of non-sparking material.
7. Proper earthing continuity to be ensured during tank truck / wagon
operation.
8. Do not allow switch loading of products.
9. Only cotton dress / overall shall be used in plant area.
10. Anti static additive to be used for products where conductivity is
less than 50 ps/m.
11. Stop loading / dipping and sampling operations during severe
electrical storms.
12. Bottom loading shall be provided with splash deflectors.
53
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.

54
Thank you