Hira Aruisom - 2

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BPCL MUMBAI REFINERY
Document No. : MR.OPS.ARU.05.02 Revision No: 00 Date: 01.09.2019
A1 EHS “ASPECT”, “IMPACT”, “HAZARD IDENTIFICATION & RISK ASSESSMENT” AND CONTROL MEASURES WORKSHEET
Completed By: Radhika Raut Date: 1st SEPT 2019 Reviewed & Approved by: U B Raut Date ; 01st SEPT 2019
UNIT: AROMATICS COMPLEX (RFU, ARU, NHT, ISOM, MTBE, N2 PLANTS and OTHER ASSOCIATED FACILITIES)
# Note: Gaps – Technological / Engineering /Operational / Training / Competence / Monitoring / Signages / PPE
Input for Control Measure (LC/ DC/ PP/IPC)
LC: Legal Concern, DC: Domino Concern, PP: People Prevention, IPC: Interested Party Concern
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Sr Activity EHS Hazard Identification Residual EHS Risk Assessment Input Is EHS Risk EHS Risk
No for level control
EHS Aspect, Categor Condition Adequacy of EHS Risk Control EH S Risk Total EHS Risk
Contr acceptable additional
Impact, Hazard & y Measures = Level
ol (Yes / No) measures
Risk (Enviro LxS
Meas required
nment, D/I R/ N Existing Gaps #, Likelih Severi ure
Health NR /AN if any ood ty (LC/
and /E (L) (S) DC/
Safety)
PP/IP
C
1 PUMP (HC) 1) Safety Manual chapter-

OPERATION: 8, 9, 10, 20.
1. Exposure to HC / E/H/S D R N 2) Operating Manual for
Commissioning toxic vapors. ARU Section- 13, MTBE
and Contact with hot Section -11, NHT/ISOM
decommissionin surface. Section -12,
g of pumps. Release of HC/ in 3) On Job training and
2. Oiling of vicinity. Training on “Safety in
pump bearings. Refining & Behavior based
3.Mech seal Air pollution Safety”
NIL
leak May cause Fire 4) Standing instruction - 1 2 2 Trivial DC Yes
4. Change over Section-5 and Section-3:
for checklist. chapter- 36, 37, 38 and 41
5)HC detector provided in
plant and P/T-7&9
5) BA set is available in
plant area in case of
emergency.
6) Firefighting systems
available like HVLR/
sprinklers
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1) Safety Manual chapter-
8, 9, 10, 20.
2) Operating Manual for
ARU Section - 13, MTBE
Section 11, NHT/ISOM
Spillage chapter-12
3) Standing instruction
Land pollution and Section-5
Ground/undergrou E 4) On Job training and NIL
D R AN - 1 1 1 Trivial PP Yes
nd water Training on “Safety in
contamination due Refining & Behavior based
to oil/Catalyst Safety”
spillage 5) Routing of oil
contaminated water
through proper channel to
the oil catcher
6) Display of MSDS
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PUMP 1) Safety Manual chapter- Non 1.Counseling to
2. (BENZENE) 8, 9, 10, 11,17, 20. adheren non-compliance of
OPERATION: 2) Operating Manual for ce to SOP
1. ARU Section - 13 SOP or 2. Periodic
Commissioning 3) Installation of benzene Use of calibration of
and analyzers at critical zone. PPE by Analyzers.
decommissionin 4) On Job training and some 3. Conducting
Exposure to
g of pumps. Training on “Safety in workme discussion on
vapors.
2. Oiling of Refining & Behavior based n “Hazards in
Contact with hot
pump bearings. Safety” and Use PPE Benzene plant” in
surface. 2 4 8 moderate DC Yes
3.Mech seal E/H/S N/ 5) Standing instruction Safety forum (if
Accumulation of D/I R
leak AN Section-5 and Section-3: need arises).
benzene vapors in
4. Change over chapter- 36, 37, 38 and 41. 4. PHE benzene
the vicinity.
for checklist. 6) Ambient benzene medical test (once
analyzers provided in ARU in 6 months).
Air pollution
area and SRR.
7)BA set is available in
plant area incase of
emergency.
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3. HEAT Body Injury due to 1) Safety Manual chapter-

EXCHANGERS Slipping/ tripping, 8, 9, 10.
OPERATION: Burn injury due to 2) On Job training and
1. touching hot Training on “Safety in
Commissioning surface, Refining & Behavior based
and de Breathing Safety”
commissioning problems/irritation 3) Standing instruction
of coolers/ to skin/eyes due to Section-5
condensers/ exposure to 4)On the Job Training
exchangers. hydrocarbon/ toxic before taking charge, job
2. Isolation of vapors certification, other
E/H/S D/I R AN - 1 2 2 Trivial DC Yes Nil
standby heat Spillage of oil measures like
exchangers. Usage of PPE -
3. Removal of Land pollution and 5)F & S Regulation
non Ground/undergrou Chapter 17, Lagging/
condensable. nd water cladding jobs are identified
contamination due and attended on priority
to oil/Catalyst 5) Routing of oil
spillage contaminated water
Air pollution through proper channel to
the oil catcher
6) Display of MSDS
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COMPRESSOR Exposure to high 1) Safety Manual chapter Non 1. Counseling to
OPERATION: noise. 8, 9, 10, 17, 20. adheren non compliance of
4 1.Commissionin Contact with hot 2) Operating Manual of ce to SOP.
g and de- surface. ARU Section -15, SOP or 2. Regular
commissioning Body injury due to NHT/ISOM Section-11. Use of monitoring of
of compressor slipping or tripping 3) On Job training and PPE by housekeeping.
1
Training on “Safety in some 2 2 Trivial
Noise pollution E/H/S D R N Refining & Behavior based workme DC Yes
due to high noise. Safety” n
5)Use of PPE/ ear plugs.
6) Display of sign board
“high noise “at site.
Spillage of oil 1) Safety Manual chapter- Non Nil

8, 9, 10. adheren
2) On Job training and ce to
Land pollution and Training on “Safety in SOP
Ground/undergrou Refining & Behavior based
nd water Safety”
contamination due 3) Standing instruction
E D R AN 1 2 2 Trivial PP yes
to oil/Catalyst Section-5
spillage. 5) Routing of oil
contaminated water
the oil catcher
6) Display of MSDS
7) use of PPE
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5. HOT WELL
SYSTEM Exposure to HC 1) Safety Manual chapter Non Conducting
1. vapors. E/H/S D R N 8, 9, 10, 17. adheren 1 3 3 Tolerable DC Yes awareness
Commissioning/ Contact with hot 2) Operation Manual- ARU ce to sessions on
de- surface Section -13. SOP or “Hazards of HC” in
Commissioning Body injury due to 3) On the Job Training Use of safety forum (if
operation slipping or tripping before taking charge, job PPE by need arises) and
including certification, other some importance of
ejectors and Air pollution, Noise measures like Usage of workme PPES.
coolers. pollution due to PPE n
2. Isolation of high noise. 4)F& S Regulation Chapter
system when 17
not in use. 5) Toxic gas detectors
3. Draining of 6) Display of MSDS
HC/Condensate 7) Steam lance/water hose
into CBD/ OWS. while draining
4. Removal of 8).Stand alongside the
non wind direction.
condensable 9) Draining to be done at
from coolers. slow rate.
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Spillage E D R AN 1) Safety Manual chapter- - 1 2 2 Trivial PP Yes Nil

8, 9, 10.
Land pollution and 2) Operating Manual for
Ground/undergrou ARU Section -13.
nd water 3) On Job training and
contamination due Training on “Safety in
to oil/Catalyst Refining & Behavior based
spillage. Safety”
Section-5 and Section-3:
chapter-63.
5) Routing of oil
contaminated water
the oil catcher
6) Display of MSDS
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6. FD –ID FAN/
BLOWERS Exposure to high 1) Safety Manual chapter - 1 2 2 Trivial DC Nil Nil
OPERATION: noise 8, 9, 10, 17.
1. Contact with hot 2) On Job training and
E/H/S D/I R N
Commissioning/ surface Training on “Safety in
de- Body injury due to Refining & Behavior based
commissioning tripping or slipping Safety”
operation. 3) Operation Manual of
2. Isolation of Noise pollution ARU Section -11
suction and 4) Usage of PPE -F& S
discharge Regulation
dampers.
3. Oiling of shaft
bearings.
1. Awareness to
1)Use of PPE be increased
2) reference Fire & safety regarding use of
Accident with regulations PPE
rotary part of BPM/FNS/I/018/05 2. Counseling of
AFC fan equipment (chapter: 17), the workmen who
7 H/S D R AN - 2 4 8 Moderate DC Yes
starting. 3)provide guard to moving are not adhering
Noise pollution parts to SOP.
&air pollution 4) Standing Instruction; 3. Regular
BPM/OPS/I/070/02 monitoring of area
housekeeping.
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8 EJECTORS
AND SURFACE 1) Safety Manual chapter- - 1 2 2 Trivial - Yes Nil
CONDENSERS Body Injury due to 8, 9, 10, 17.
OPERATION: Slipping/ tripping, H/S D R N 2) Operating Manual for
1. Burn injury due to NHT/ISOM Section 12.
Commissioning/ touching hot 3) On Job training and
de- surface, Training on “Safety in
commissioning Breathing Refining & Behavior based
operation. problems/irritation Safety”
2. Isolation of to skin/eyes due to 4) Standing instruction
ejectors and exposure to Section-3: chapter- 35, 51.
coolers hydrocarbon/ toxic
(standby) vapors
3. Removal of Noise pollution
non
condensable
from coolers.
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9 FUEL GAS
KOD: Breathing
1. problems due to 1) Safety Manual chapter-
Commissioning/ exposure to HC / 8, 9, 10.
de- toxic vapors, 2) ) Operating Manual for
commissioning Body injury due to ARU Section - 13,
operation. slips/trips/wrong NHT/ISOM Section -12
2. Draining of body postures. 3) Installation of HC
liquid HC into HS D/I R AN analyzer at critical zone. H2s meter to be
- 1 3 3 TOLERABLE - Yes
CBD/ OWS. 4) Standing instruction used.
3. Operation of Air pollution Section-5
relief valves. 5) On Job training and
4. Leaks from Training on “Safety in
valve gland Refining & Behavior based
packing. Safety”
6) Portable meters for HC /
toxic gases
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10 STEAM
TURBINE: Exposure to high 1) Safety Manual Chapter-
1. noise. 8, 9, 10, 11, 17.
Commissioning/ Contact with hot 2) Operating Manual for
de- surface or flash ARU Section - 10,
commissioning steam. NHT/ISOM Section -11
operation. Body injury due to 3) On Job training and
2. Draining of tripping or slipping. Training on “Safety in
steam Refining & Behavior based
H/S D/I R N - 1 2 2 Trivial - Yes Nil
condensate Noise pollution Safety”
through trap 3) Aromatics Standing
bypass. instruction Section-3:
3. removal of chapter – 53,
non 4) On the Job Training
condensable before taking charge, job
4. Keeping on certification, other
idling or warm – measures like
up operation. Usage of PPE.
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11 FURNACE/
HEATER
OPERATION: Body injury due to
1. Inserting or slips/ trips, 1) Safety Manual chapter -
Removal of oil Burn Injury due to 8, 9, 10, 11, 17.
gun. exposure to heat, 2) Operating Manual for
2. Burners lit- Problems in ARU– Section-11
up. hearing due to NHT/ISOM Section -11
3. Servicing or high noise, 3) Installation of HC
cleaning of Breathing analyzer at critical zone. Non
burners during problems, skin 4) Aromatics standing adheren
Awareness to be
normal irritation due to Instruction Section -4 ce to
increased
operation. exposure to HC / H/S D/I R AN 5) On Job training SOP or
regarding use of
4. Removal of toxic vapors like before taking charge, job Use of 2 3 6 MODERATE DC Yes
PPE. Emergency
coke deposition fuel gas, certification, PPE by
shutdown system
by steaming. Eye injury due to other measures like Usage some
5. Adjusting exposure to “UV” of PPE workme
primary and radiation. (Furnace goggles / cobalt n
secondary face shield),
registers. 6) Portable meters for HC /
6. Pilot lit-up in Noise pollution & toxic gases
furnace air pollution. Use of ear muff/ plug. High
7.Checking of Noise are boards are
draft gauge, provided.
adjusting Furnace Interlock,
dampers
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Burns due to
leakage of
pressurized hot
liquid,
Burns/ plant
On the Job Training, job
damage due to
certification, Supervision of
fire/ explosion
seniors, All the valves
cause of leakage,
Safe operating procedures including valves
Body injury due to
are available in manual non pressurized
slips/ trips/ hitting
Usage of PPE parts like bushing
Operation of of valve wheel due -
12 HS D R AN Fire & safety regulations: 3 2 6 MODERATE DC Yes needs to be
valves to snapping of
BPM/FNS/I/018/05 following specific
bushing, Wrong
(chapter: 10, 11, 17) and standard approved
Body Posture,
Standing Instruction; by BPCL
hitting of stem due
BPM/OPS/I/070/02
to stem nut
damage, injury
due to improper
usage/selection of
wheel key
1)On job training of

Ergonomical workmen 1. Counseling to
Hazard 2) Safety manual section- non compliance of
H/S D R N - 2 2 4 Tolerable Yes
10 SOP.
3) Usage of PPE and -
Standard design.
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1) Safety Manual chapter
8, 9, 10.
Spillage of oil 2) Standing instruction
E I R AN chapter- 63.
Air pollution 3) On Job training and - 1 Nil
2 2 Trivial Nil Yes
Training on “Safety in
Refining & Behavior based
Safety”
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13. HOT OIL

SYSTEM
(F320): Snap up of hoses
1. while draining. H/S I R AN 2 4 8 Moderate
1. Counseling to
Commissioning/ Mech seal leak
non compliance as
de- from hot pumps 1) Safety Manual chapter
per SOP.
commissioning Exposure to hot 8, 9, 10, 11 Non
2. Use of certified
operations. oil/HC fumes 2) Operation Manual ARU adheren PP
hoses for the job.
2. Replacement Section -10. ce to
3. Segregation
of used oil from Air pollution 3) On Job training and SOP or
and disposal of
system. Training on “Safety in Use of YES
rupture hoses on
3. Flushing of Refining & Behavior based PPE by
timely basis.
F320 system by Safety” some
4. Conducting
Gas oil. workme
discussion on
4. Pump/ n
“PPE- importance”
suction filter
in safety forum if
operation
need arises.
5. CBD draining
and pumping.
6. Expansion
vessel (V-320)
gauging
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8, 9, 10.
Spillage of oil 2) Standing instruction
E I R AN chapter- 63.
Air pollution/ land 3) On Job training and - 1 2 2 Trivial Nil Yes Nil
pollution Training on “Safety in
Safety”
H/S D/I R Non Nil

14. TANK FARM – adheren 2 2 Trivial
FLOATING Exposure to HC/ 1) Safety Manual chapter- ce to 1 YES
ROOF toxic gas vapors. 8, 9, 10, 14.03, 20. SOP or
(PRODUCTS, 2) Operating Manual for Use of
FEED Air pollution N ARU Section - 12,13, PPE by Nil
INTERMEDIAT MTBE Section -11, some
ES) 3) Installation of HC workme
1. analyzer at critical zone. n
Commissioning/ 4) On Job training and
de- Training on “Safety in
commissioning Refining & Behavior based
of tanks. Safety”.
2. Flushing of 5) Standing instruction
tanks. Section-5 and Section-3:
3. Confined chapter- 65, 28. In case of
space entry for benzene/ toluene tank
cold and hot leaks, refer section-4
works (M&I (page 24)
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jobs)
4. Receiving/
delivery mode.
5. Normal
operation
1. Counseling to
Suffocation non compliance of
HC vapor release ) Safety Manual chapter- 8, SOP.
due to line/ tank 9, 10, 14.03, 20. 2. Periodic
leaks. 2) Operating Manual for calibration of HC
ARU Section - 12,13, analyzers.
Air pollution MTBE Section -11, 3. Conducting
3) Installation of HC Discussion on
H/S D/I R E analyzer at critical zone. 1 4 5 Tolerable DC YES “Hazards involved
4) On Job training and in HC plant “in
Training on “Safety in safety forum.
Refining & Behavior based 4. Use of portable
Safety”. Meters for gas
5) Standing instruction test.
Section-5 5. Safe disposal of
benzene
contamination
H/S D/I R E 1) Safety Manual chapter- Non 1. Counseling to
8, 9, 10, 20. adheren non compliance of
Release of HC due 2) Operating Manual for ce to 2 4 8 Moderate SOP.
to tank overflow ARU Section - 12,13, SOP 2. Periodic
MTBE Section -11. DC YES calibration of HC
4) Standing instruction analyzers.
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Section-5
3. Conducting
4) On Job training and
Discussion on
“Hazards of HC” in
Air pollution/ land Refining & Behavior based
safety forum (if
pollution Safety”.
need arises).
5) Installation of HC
4. Manual dip at
analyzers at critical zone.
high tank level
6) Closed Blow down
taken for better
systems available.
monitoring.
1) Safety Manual chapter-
Spillage 8, 9, 10, 20.
ARU Section - 12, 13,
E I R N MTBE Section -11.
Section-5 and Section-3: -
1 2 2 Trivial PP Yes Nil
chapter- 63.
4 On Job training and
Safety”
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15. LIQUID
1) Counseling to
NITROGEN Cold burn injury.
non compliance of
HANDLING: Release of N2 into
standard
1. Preparation vicinity (N2 1) Safety Manual chapter
procedure.
of converters for accumulation). 8, 9, 10, 17. Non
2) Conducting
receiving and 2) Operation Manual adheren
discussion on
delivery mode. “ARU” Section 15. ce to
“Hazards of N2” in
2. Draining of 3)) Standing instruction SOP or
safety forum (if
LN2 into waste Air pollution/skin H/S D/I NR AN Section-5 Use of Tolerable IPC YES
1 3 3 need arises).
chamber during injury like cold 4) On Job training and PPE by
3) Display of sign
plant upset/ burn Training on “Safety in some
board “N2- MSDS”
start-up and Refining & Behavior based workme
at site.
shut down. Safety” n
3) Use of O2
3. Offloading of
portable meter for
LN2 from
plant entry in case
tankers into
of N2 leak.
converters.
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16 STEAM:
1. Header Exposure to flash
commissioning/ steam or high 1) Safety Manual chapter
de- noise. 8, 9, 10, 11, 17.
commissioning Contact with hot 2) On Job training and
operation surface Training on “Safety in
including de Line leaks due to Refining & Behavior based
H/S D R N - 1 2 2 Trivial - Yes Nil
superheater. hammering. Safety”
2. Draining of 3) Standing Instruction
condensate Noise pollution Section-3: Chapter- 49, 57
from steam trap and 58
bypass.
3. Operation of
B/L valves.
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17. CATALYST
LOADING/ Exposure to HC/
REGENERATI toxic gas
ON/ (sampling), Body
SAMPLING/DIS injury due to
POSAL slipping/ tripping.
1) Collecting of
gas sample Air pollution
from reactor O/L
(NHT) during
regeneration.
2) KL5847MD
(NHT Reactor 1. Counseling to
catalyst) non compliance of
1) Safety Manual chapter -
3) SI-2TM SOP.
8, 9, 10, 11, 20. Non
(ISOM Reactor 2. Conducting
2) Operating Manual for adheren
catalyst) discussion on
ARU Section - 13,15, ce to
4) KL6516-CY H/S D/I R N “Hazards involved
MTBE Section -11, SOP or
1.2 (FGH in HC/ H2” and
NHT/ISOM Section -12 Use of
polishing “Catalyst- MSDS”
PPE by
Reactor in safety forum.
3) On Job training and some
catalyst. 3. Display of sign
Training on “Safety in workme DC/
5) Actisorb S7 1 3 3 Tolerable Yes board “sampling
Refining”. n IPC
Adsorbent catalyst
(Sulfur Guard procedure” and
Bed) “MSDS of HC/ H2”
Section-5
6) UNIMOL 5A at site.
Adsorbent 4. Use of portable
(Make up gas Meters during job
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8, 9, 10.
Spillage of 2) Standing instruction
Catalyst E I NR AN Section-5 and Section-3:
chapter- 63. - 1 2 2 Trivial Nil Yes Nil
Safety”
E D/I R E 1) Safety Manual Chapter- Non PP YES 1. Counseling to
18 COLUMN & 8, 9, 10. adheren non compliance of
VESSEL: 2) Operating Manual for ce to SOP.
1. ARU Section -13, MTBE SOP or 2. Periodic
Commissioning/ Release of hot HC Section-11, NHT/ISOM Use of calibration of HC
de- vapors/Sulfolane section-12. PPE by 2 3 6 Moderate analyzers.
commissioning due to line/ valve 3) Installation of HC some 3. Conducting
operation. leak analyzer at critical zone. workme discussion on
2. HC freeing 4) On Job training and n “Hazards of HC” in
(water washing Air pollution Training on “Safety in safety forum (if
and N2 Refining & Behavior based need arises).
purging). Safety” 4. Use of gas
3. Operation of 5) Standing Instruction -5 mask for entry into
associated affected area
equipments during HC release.
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(coolers,
pumps,
reboilers).
4. ARU solvent
(Macro/Micro) /
MTBE feed
filters
commissioning/
decommissionin
g/Changed over
operation
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19. SAMPLING OF 1) Safety Manual chapter- 1. Counseling to
LPG: 8, 9, 10, 17, 20. non-compliance of
1. Draw off C4 Exposure to HC 2) Operation Manual Non SOP.
Raffinate from vapors. MTBE Section -11, adheren 1 3 3 Tolerable DC Yes 2. Awareness to
sample point for Cold burn NHT/ISOM Section -9, ce to be increased
BT testing Air pollution 3) Installation of HC SOP or regarding use of
(MTBE). analyzer at critical zone. Use of PPE.
2. Draw off 4) On Job training and PPE by 3. Conducting
C3/C4 from Training on “Safety in some discussion on
sample point for H/S D R AN Refining & Behavior based workme “Hazards involved
BT testing Safety” n in HC plant” in
(ISOM) 5) Standing instruction safety forum (if
Section-5 and Section-3: need arises).
Chapter-14.05. 4. Display of Sign
6). SOP for CLOSED board “Sampling
LOOP procedure” at site.
SAMPLING SYSTEM
(CLSS) in Standing
Instruction
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1) Safety Manual chapter- 1. Counseling to
8, 9, 10, 11, 20. non compliance of
2) Operation Manual SOP.
HC vapor MTBE Section -11, Non 2. Periodic
accumulation in NHT/ISOM Section -12, adheren 1 3 3 Tolerable PP Yes calibration of gas
the vicinity. 3) Installation of HC ce to analyzers.
analyzer at critical zone. SOP 3. Conducting
E D R AN
4) ) On Job training and discussion on
Training on “Safety in “Hazards of HC” in
Refining & Behavior based safety forum (if
Safety” need arises).
4. Use of gas
mask at affected
area.
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20. EQUIPMENTS
ACCESSORIES Exposure to HC/ 1) Safety Manual chapter-
(CONTROL toxic gas vapors. 8, 9, 10. 1. Counseling to
Non
VALVE, Body injury due to 2) Operating Manual for 1 3 3 Tolerable non-compliance of
adheren
GAUGE tripping/ slipping. ARU Section - 13, MTBE SOP.
ce to
GLASS, Section -11, NHT/ISOM 2. Regular
SOP or
DISPLACER Air pollution Section -12 monitoring of
Use of
ETAL) H/S D R N 3) On Job training and Nil YES housekeeping.
PPE by
1. Training on “Safety in 3. Conducting
some
Commissioning/ Refining & Behavior based discussion on
workme
de- Safety” “Hazards of HC” in
n
commissioning 4) Standing instruction safety forum (if
operation. Section-5 and Section-3: need arises).
2. Removal for chapter-55.
cleaning/ Maint
job.
Page 28 of 67
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Close Spillage & sample E/H/S D R AN 1. Trained for the job Non 2 2 4 TOLERABLE Nil Yes Use of PPE
Sampling: might flash before taking charge adheren Behavior
1.Ensure Standing Instruction ce to monitoring
sample valve manual SOP or Awareness
close. Hot burns. Operating Manual Use of Closed loop
2.Establish 3. Usage of PPE, water PPE by sampling system
line up for curtains -F& S Regulation some for LPG, Gasoline,
sampling. Chapter 17) workme Close C3, sour water,
3.Ensure flare n Loop Fuel gas, Ligtht
line up. 4. OPS/MANUAL sampl Cut, Mid cut,
4.Cooling NHT/ISOM Section 9: pg ing. Heavy Cut and
water lineup. 53 sponge gas
5.Drain 9.10 STANDARD sampling
21
stagnant OPERATING
portion to PROCEDURE (SOP) FOR
OWS. CLOSED LOOP
6.Use canister SAMPLING SYSTEM
mask (CLSS)
7.Draw
sample after
keeping
sample bottle
in the sample
box.
Page 29 of 67
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22 LIQUID 1) Safety Manual chapter-

SAMPLING spillage 8, 9, 10. 1 3 3 Tolerable PP Yes
(Non closed E D R N 2) Standing instruction
sample Section-5 and Section-3: 1. Counseling to
system): chapter- 34 Close non compliance of
Draw off feed 3) On Job training and loop SOP.
and products Training on “Safety in sampl 2. Regular
from sample Refining & Behavior based ig. monitoring of
Non
point. Safety” housekeeping.
adheren
4) OPS/MANUAL Closed loop
ce to
NHT/ISOM Section 9: pg sampling system
SOP
53 for Gasoline, sour
9.10 STANDARD water, Fuel gas,
OPERATING Ligtht Cut, Mid cut,
PROCEDURE (SOP) FOR and Heavy Cut
CLOSED LOOP sampling
SAMPLING SYSTEM
(CLSS)
Page 30 of 67
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1) Safety Manual Chapter-
. 1 .Counseling to
23 SOUR GAS/ 8, 9, 10.
non compliance of
LIQUID 2) Operating Manual-
SOP.
HANDLING Exposure to toxic NHT/ISOM Section -12.
2. Conducting
(NHT): gas. 3) Standing instruction
discussion on
1. Diversion of Body injury due to Section-5 and Section-3:
“Hazards involved
sour water to tripping/ slipping. chapter- 13, 34 Non
in H2S plant” in
SWS units or 4) On Job training and adheren
safety forum if
CBD/OWS. Air pollution Training on “Safety in ce to
need arises.
2. Diversion of Refining & Behavior based SOP or DC
H/S D R AN 3. Display of sign
sour gas to Safety” Use of 2 3 6 Moderate YES
board “H2S-
DHDS/FCCU/R 5) OPS/MANUAL PPE by
MSDS” at site.
MP or flare NHT/ISOM Section 9: pg some Use
4. Regular
header. 53 workme H2s
monitoring of
3. Sample draw 9.10 STANDARD n meter
housekeeping.
off sour water OPERATING
Closed loop
(V104/ boot PROCEDURE (SOP) FOR
sampling system
water & NV-121 CLOSED LOOP
for sour water and
boot). SAMPLING SYSTEM
sponge gas
(CLSS)
sampling
Page 31 of 67
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Toxic gas 8, 9, 10. 1. Counseling to
accumulation in 2) Operating Manual- non compliance of
the vicinity. NHT/ISOM Section -12. SOP.
Non
3) Standing instruction 2. Use of acid gas
E D R AN adheren
Section-5 and Section-3: 2 3 6 Moderate DC YES mask for entry into
ce to
chapter- 13, 34 affected area.
SOP
4) On Job training and 3. Display of sign
Training on “Safety in board “H2S-
Refining & Behavior based MSDS” at site.
Safety”
24. PIPE TRACK

LINE Exposure to HC
OPERATION: vapors/ toxic gas 1) Safety Manual Chapter- 1. Counseling to
1. Diversion of due to line/ valve 8, 9, 10. Non non compliance of
feed, leak. 2) ) Operating Manual for adheren 2 3 6 Moderate SOP.
intermediate Body injury due to ARU Section - 13, MTBE ce to 2. Periodic
and product to/ slipping/ tripping Section -11, NHT/ISOM SOP or calibration of gas
ex plant H/S D R N Section -12 Use of Nil Yes analyzers.
respectively. Air pollution 3) Installation of HC PPE by 3. Regular
2. analyzer at critical zone. some monitoring of
Decommissioni 4) ) On Job training and workme housekeeping.
ng of pipelines Training on “Safety in n 4. Use of gas
for isolation. Refining & Behavior based mask for entry into
3. Water Safety” affected area.
flushing of pipe
lines for outage.
Page 32 of 67
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25 BOOT WATER 1. Counseling to

DRAINING: Exposure to non compliance of
1. Draining of benzene/ H2S /HC 1) Safety Manual Chapter - SOP.
Non
Benzene OPA vapors. H/S 8, 9, 10. 2 3 6 Moderate 2. Display of Sign
adheren
boot water into Body injury due to 2) Operating Manual for board “Benzene &
ce to
CBD/ OWS. slipping/ tripping. ARU– Section- 13, H2S MSDS” at
SOP or
2. Draining of NHT/ISOM Section-12 site.
Use of
RFU Splitter-1 Air pollution 3) ) Standing instruction 3. Use of Organic
PPE by
boot water into D R AN Section-5 and Section-3: DC Yes gas mask/ B A set
some
CBD/ OWS. chapter- 13 YES for entry into
workme
3. Draining of 4) ) On Job training and affected area.
n
NHT Product Training on “Safety in 4. PHE- benzene
Non
Separator and Refining & Behavior based medical test (once
adheren
stripper OPA Safety” in 6 months).
ce to
boot Perform Benzene
SOP
dragger test .use
H2S meter
Page 33 of 67
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26. COOLING Non
WATER 1) Safety Manual Chapter- adheren
TOWER AND 8, 9, 10. ce to
OWS SYSTEM: 2) Operating Manual for SOP or
1. Normal ARU Section - 13, MTBE Use of
Carryover of HC
operation of Section -11, NHT/ISOM PPE by
into system
cooling water N Section -12 some 1 2 2 Trivial Nil Yes Nil
H /S D R
system. 3) Online detection for HC workme
Air pollution
2. Normal carryover in CW lines. n
operation of 4) On Job training and Non
OWS system. Training on “Safety in adheren
Refining”. ce to
SOP
8, 9, 10.
Overflow of water
due to nozzle plug N - DC YES Nil.
–up. 1 2 2 Trivial
Safety”
Non
27 STEAM LANCE adheren 1. Conducting
ce to discussion on
8, 9, 10, 17.
Exposure to heat SOP or “PPE- importance”
2) ) On Job training and
H/S D/I R N Use of Nil Yes in safety forum if
Noise pollution PPE by 1 3 3 Tolerable need arises.
some 2. Counseling to
Safety”
workme non compliance of
n SOP.
Page 34 of 67
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1. Counseling to
28. BICYCLE 1) Safety Manual chapter non compliance of
RIDE: 8, 9, 10. SOP.
Riding of bicycle 2) On Job training and Non 1 4 4 Tolerable 2. Regular
Cycle skidding
in plant Training on “Safety in adheren monitoring of
H D R AN Nil Yes
premises. Refining & Behavior based ce to housekeeping.
Physical injury
Safety” SOP 3. Display of sign
3) Standing Instruction board “no cycling
Section-3: Chapter-3. in plant area” at
site.
1) Safe disposal as per
29 WASTE
Government norms.
DISPOSAL:
Contact with Skin, 2) Safety Manual
1. Hazardous
Exposure to HC Chapter-8, 9, 10, 14.05. LC/ Perform Benzene
Catalyst waste
vapors and 3 ) Standing instruction DC/ dragger test .use
disposal. H/S/E D/I NR AN - Yes
catalyst fines Section-5 PP/ H2S meter
2. Used/ empty 1 2 2 Trivial
4) Operating Manual for IPC
drum disposal
Air Pollution ARU Section - 13, MTBE
3. Electronic/
Section -11, NHT/ISOM
Plastic waste
Section -12
disposal.
Page 35 of 67
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30. FURNACE 1) Safety Manual Chapter- 1. Counseling to

TUBE LEAK: Fire / explosion E/H/S D NR AN 8, 9, 10. Non 1 5 5 Moderate DC/ Yes non compliance of
2) Operation Manual ARU adheren LC SOP.
Section-9, NHT/ISOM ce to 2. Conducting
section-12. SOP discussion on
3) On Job training and “Furnace
Training on “Safety in explosion and
Refining & Behavior based fatality” in safety
Safety” forum (if need
arises).
Page 36 of 67
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31. LADDER:
Use of ladder
for Body injury due to
1. Counseling to
1. Filing oil into free fall. 1) Safety Manual chapter- Non 1 3 3 Tolerable
non compliance of
pump tandem 8, 9, 10, 11. adheren
SOP.
seal pot. 2) On Job training and ce to
2. Regular
2. For plant Training on “Safety in SOP or
DC/ monitoring of
servicing H/S D/I NR AN Refining & Behavior based Use of Yes
IPC housekeeping.
activity. Safety” PPE by
Perform Benzene
3. For cleaning 3) Standing some
dragger test .use
underground instructionSection-3: workme
H2S meter
pits. Chapter-6. n
4. For
miscellaneous
job (fixing
posters etc).
Page 37 of 67
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32 TANK 8, 9, 10, 14.03, 14.12.
EXPLOSION 2) Operating Manual for
Fire/ explosion ARU Section- 13, MTBE 1 5 5 Moderate 1. Counseling to
LC/
Floating roof Section -11. Non non compliance of
DC Yes
tank M&I job E D/I R E 3) ) On Job training and adheren SOP.
IPC
activity Training on “Safety in ce to 2. Use of portable
Refining & Behavior based SOP meters during job
Safety” execution.
Section-5 and Section-3:
Chapter-28.
33. PROCESS Exposure to HC

LINES INSIDE vapors/ toxic gas.
PLANT: Contact with hot
8, 9, 10.
1. surface.
Commissioning/ Body injury due to
ARU Section- 13, MTBE
de- slipping/ tripping.
Section -11, NHT/ISOM
commissioning
H/S D R N Section -12, - DC Yes Nil
operation. Noise pollution
2. Flushing/
analyzer at critical zone.
purging of 1 2 2 Trivial
process lines for
outage.
3. Diversion of
Safety”
streams through
pipelines.
Page 38 of 67
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34 CRANE Accidental collision
OPERATION with obstacles or 1. Counseling to
1. Normal Falling of the non compliance of
1) Safety Manual chapter Non
operation of crane sling, boom, SOP.
8, 9, 10, 13, 14.06, 14.07, adheren
crane. (upper part of the 2. Periodic load
17, 18. ce to
2. In transit crane) test check of
2. Work permit system. SOP or
movement. crane for its
3) On Job training and Inaccura
H/S D/I NR AN Tolerable Nil Yes healthiness.
Training on “Safety in te
1 4 4 3. Display of sign
Refining & Behavior based estimati
board or area
Safety” on of
barricading for
4) Use of certified crane for weight
crane operation.
operation bearing
4. Regular
monitoring of
housekeeping.
Page 39 of 67
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35. CLAY
HANDLING:
1. Off/ On 1) Safety Manual Chapter- 1 2 2 Trivial

Exposure to
loading of clay 8, 9, 10.
trapped HC
from/ into tower. 2) Operation Manual- ARU
vapors/ toxic gas.
2. Working Section-13. Perform Benzene
Contact with hot
inside tower for 3) Installation of HC DC/ dragger test. use
surface. H/S D R N . Yes
cleaning/ mesh analyzer at critical zone (In IPC H2S meter
Body injury due to
repairing. case of HC leaks in plant).
slipping/ tripping.
3. Segregation/ 4) On Job training and
sieving of clay Training on “Safety in
Air pollution
from support Refining & Behavior based
elements Safety”
externally.
Land Pollution due

1) Safe disposal as per
to spillage/
Government norms. DC/
disposal of clay. H/S/E D/I NR AN - Yes Nil
2) Safety Manual Chapter- PP
Clay/ sand Dust 1 2 2 Trivial
8, 9, 10, 14.
inhalation
Page 40 of 67
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36 PLANT Body Injury due to
ROUND: Slipping/ tripping,
Visit the Burn injury due to
assigned areas, touching hot
Checking of surface/ hot water,
pumps. Breathing
Checking of problems/ nausea/
exchangers and irritation to
condensers. skin/eyes due to
Check for any exposure to
leak in pipe hydrocarbons/
track/pipe rack, toxic gases,
Check for Hearing problems
product due to high noise,
routings, Check Body injury due to
8, 9, 10.
gauge glasses, slippage from Non Alertness to the
2) Operation Manual- ARU
control valve stairs/ monkey adheren activity being done
Section-13.
openings and ladder ce to is a must.
local Use of Awareness to be
HS D R AN analyzer at critical zone (In 2 2 4 TOLERABLE - Yes
transmitter. Noise pollution/air PPE by increased
case of HC leaks in plant).
Check pollution some regarding use of
housekeeping workme PPE
(Steam lance, n
extinguishers,
Safety”
pump beds,
steam trap)
Check
availability of
chemical
Page 41 of 67
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Non
1. Awareness to
Slip due to oil adheren
be increased
spillage ce to
1)Safety Manual Chapter- regarding use of
Equipment SOP or
10, 11, 17, 20 PPE
damage S D/I R AN Use of 2 2 4 Tolerable Nil Yes
2)Standing Instruction 2. Counseling of
Physical injury PPE by
Section-3 the workmen who
(obstructions, line some
are not adhered to
leaks) workme
SOP.
n
1)On job training of

workmen and On job
Ergonomical training certification
H/S D R N NIL 1 2 2 Trivial Nil Yes NIL.
Hazard 2) Safety manual section-
10
3) Usage of PPE and
Standard design.
Page 42 of 67
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37 BENZENE/ E D/ I R AN 1) Safety Manual chapter- Non 2 4 8 Moderate PP/ Yes 1. Counseling to

TOLUENE Spillage 8, 9, 10, 11, 17, 20. adheren IPC non compliance of
SPILLAGE ON 2) Operating Manual for ce to SOP.
GROUND. Air pollution ARU Section- 13 SOP 2. Use of gas
3) On Job training and mask in affected
Training on “Safety in area.
Refining 3. Display of
4) Installation of benzene Benzene MSDS at
analyzers at critical zone site.
4. Periodic
calibration of
analyzers (if any).
5. Use of
clay(used) or sub
soil for absorbing
benzene spills and
safe disposal.
Perform Benzene
dragger test .use
H2S meter.
Page 43 of 67
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38 PLANT Exposure to HC 1) Installation of HC 1) Regular

OPERATION due to leaks/ E/H/S D/I R N analyzers at designated Non monitoring of
(inclusion of spillage for varying area. adheren SCBA for working
tank farm and concentration in 2) ) Operating Manual for ce to in affected area.
offsite pump ambient air (for ARU Section- 13, MTBE SOP 2) Regular
house area) short duration) Section -11, NHT/ISOM calibration of
1)low Section -12, 2 2 4 Tolerable LC/ Yes portable meter for
(giddiness) 3) On Job training and DC/P HC estimation in
2)Medium Training on “Safety in 2 3 6 Moderate P Yes air.
(alcoholic) Refining & Behavior based IPC 3) Compliance to
3)high Safety” 2 4 8 Moderate Yes scheduled
(paralysis) checklist of
*prolong exposure mountable HC
causes death. detectors located
in the field.
Air pollution 4) Ensuring the
healthiness of
windsocks for
assessing the
affecting area.
4) Conducting
Discussion on
“Hazards involved
in HC plant” in
safety forum (if
need arises).
Use H2S meter or
dragger test as
Page 44 of 67
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39 CHEMICAL Chemical spillage/

HANDLING spraying on body HS D R N
FOR PLANT parts while
OPERATION handling. 2 2 4 Tolerable 1. Counseling to
(SULFOLANE, non compliance of
MEA, Breathing SOP.
1) Safety Manual Chapter - Non
METHANOL, problems/ nausea/ 2. Display of Sign
8, 9, 10. adheren
LUBE OIL, irritation to board “MSDS and
2) ) Operating Manual for ce to
DMDS, skin/eyes due to handling
ARU Section- 13, MTBE SOP or
Corrosion exposure to DC/ procedure for
Section -11, NHT/ISOM Use of
Inhibitor) chemical vapors IPC chemicals” at site.
Section -12. PPE by Yes
1. Loading/ un 3. Use of Organic
3) Standing instruction some
loading/ transfer gas mask for entry
Section-5 workme
of chemicals into affected area.
4) On Job training and n
and Lube oil. 4. PHE medical
2. Related Perform Benzene
Pump/tanks/ dragger test .use
Safety”
pipelines/ H2S meter
equipment
commissioning
and
decommissionin
g
Page 45 of 67
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40 1.Awareness to be
increased
regarding use of
PPE
Painting
1. Non- 2. Counseling of
activity in plant
adheren the workmen who
area
1. F & S regulation 10.8.9 ce to are not adhering
& 10.8.14 for working at SOP to SOP and
 Painting
height 2. having casual
on
2. Ensure Ladder should Casual approach towards
structures
Fall from height be in good condition approac safety while
 Painting S D/I NR AN 1 3 3 Tolerable IPC Yes
Air pollution before use. h carrying out
on process 3. Scaffolding erected as 3. Not painting job.
and utility per BPCL standard and Using 3. Regular
lines Safe to use board PPE by monitoring of area
including displayed at site some housekeeping.
cladding workme Perform Benzene
provided n dragger test .use
lines H2S meter
Page 46 of 67
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1. Behavior
1. All required PPE are monitoring by
provided and used. surprise checks
2. Contractor trained for Non- through plant
Touching hot the job. Complia personals
S D R N 2 2 4 Tolerable NIL Yes
surface 3. Clearance issued to nce of 2.Awareness to be
contractor before carrying SOP increased
out job. regarding use of
PPE
Page 47 of 67
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1. In case of
multiple floors, use
aluminum sheets/
Asbestos cloth on
gratings to avoid
fall of paints on
hot surfaces
1. Fire and safety
beneath the
regulations available to
working floor.
ensure safety and fire 1. Non
2. Counseling of
prevention. adheren
the workmen who
Document No. ce to
are not adhering
BPM/FNS/I/018/05 SOP &
to SOP and
2.Job safety plan to judge Job
Spillage of paint having casual
and take action on ‘what safety
on hot surface can S D/I NR AN 3 2 6 Tolerable NIL Yes approach towards
can go wrong’ plan
lead to smoldering safety while
3. Painting not allowed in 2.
carrying out
case of hot work in close Casual
painting job.
vicinity. Painting should approac
3. Identify hot
not be carried out on hot h
lines (Surface
surfaces of the pipeline
temp greater than
4. Work carried out in day
55 OC) along with
light
Ops. before
starting of painting
activity & painting
of these surfaces
to be avoided.
4. Safety talk to be
conducted
Page 48 of 67
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41 Decontaminati 1. Awareness to
on using 1. Liquid draining done in be increased
chemical, CBD/OWS. regarding use of
1. Flashing of
steam and 2. Usage of proper PPE PPE.
liquid while Non-
BFW during 3. System depressuriza- Complia 2. Counseling of
draining
shutdown E/H/S D NR AN tion done to flare. 2 2 4 Tolerable IPC Yes the workmen who
nce of
4. Handling of chemical SOP are not adhering
2. Chemical
storage to SOP.
exposure
3. Regular
monitoring of area
housekeeping
1. Fire & safety
regulations; 1. Awareness to
BPM/FNS/I/018/05 be increased
Non
(chapter: 10, 11, 14, 17) regarding use of
adheren
2. Emphasis on “Safety in PPE.
ce to
Burn injury due to Refining “ training 2. Counseling of
SOP or
hot surface of schedule the workmen who
S D NR AN Use of 2 2 4 Tolerable Nil YES
BFW/Steam 3. Safety talk taken to are not adhering
PPE by
improve behavioral safety to SOP.
some
4. Standing instructions 3. Regular
workme
available (Document No. monitoring of area
n
BPM/OPS/I/070/02) housekeeping.
5. Proper steam hoses
used for steam service
Page 49 of 67
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1. Inform the
vendor carrying
out the job about
the risk associated
and ensure that he
1. Ensure that temporary
has taken enough
piping/hoses, flanges &
measures to
equipments used are as
mitigate the same.
per design.
Leak/bursting of Non 2. Awareness to
2. Check certificates of
temporary complia be increased
E/H/S D NR AN equipments being used. 2 4 8 Moderate Nil Yes
piping/connection nce to regarding use of
3. Job safety plan
Air pollution standard PPE.
4. Proper
3. Counseling of
training/information to all
the workmen who
plant personnel about the
are not adhering
activity
to SOP.
4. Regular
monitoring of area
housekeeping.
Page 50 of 67
Risk (Enviro LxS
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42 Housekeeping: 1. Awareness to
be increased
Cleaning water
Ignoranc regarding use of
washing floors /
Reference of MSDS, Fire e/ PPE.
Pump bed,
& safety regulations; Negligen 2. Counseling of
cleaning plant Oil/toxic vapour
BPM/FNS/I/018/05 ce the workmen who
areas. inhalation H D/I R N 2 4 8 Moderate IPC Yes
(chapter: 10, 11, 14, 17, towards are not adhering
Air pollution
20) and Standing houseke to SOP.
Instruction; eping, 3. Regular
BPM/OPS/I/070/02 monitoring of area
housekeeping,.
Use of H2s meter
1. Awareness to
be increased
regarding use of
Use of PPE; reference PPE.
MSDS and Fire & safety 2. Counseling of
Slip due to oil
S D/I NR AN regulations: 2 4 8 Moderate PP Yes the workmen who
spillage
BPM/FNS/I/018/05 are not adhering
(chapter: 17, 20) to SOP.
3. Regular
monitoring of area
housekeeping.
Page 51 of 67
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1. Awareness to
be increased
regarding use of
PPE.
Use of PPE; Fire & safety 2. Counseling of
regulations: the workmen who
Burn injury S D/I R AN 2 4 8 Moderate DC Yes
BPM/FNS/I/018/05 are not adhering
(chapter: 17, 20) to SOP.
3. Regular
monitoring of area
housekeeping.
1. Awareness to
be increased
regarding use of
PPE.
2. Counseling of
Fire & safety regulations;
the workmen who
Accident S D R E BPM/FNS/I/018/05 2 4 8 Moderate DC Yes
are not adhering
(chapter: 7, 8, 9)
to SOP.
3. Regular
monitoring of area
housekeeping.
43 Process Release of HC in E D NR AN Regular rounds Perform Benzene

Emergency of atmosphere Safe operating procedures dragger test .use
AFC Leak Regular Inspection - 1 3 3 TOLERABLE DC Yes
H2S meter
soil/ air pollution Usage of PPE
Page 52 of 67
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Body injury due to HS D NR AN Regular rounds
slippage due to Safe operating procedures
HC on floor, Regular Inspection
Breathing Usage of PPE -F& S
problems due to Regulation Chapter
exposure to HC Fire extinguishers are
vapors, placed as per Norm - 1 3 3 TOLERABLE DC Yes -
Burn injury due to
heat radiations
Air pollution.
Page 53 of 67
Risk (Enviro LxS
Meas required
and /E (L) (S) DC/
Safety)
PP/IP
C
44 Chemical spillage/ EHS D/ I R AN On the Job Training Awareness to be
spraying on body 2.Usage of PPE - increased
parts due to wrong F & S Regulation Chapter regarding use of
postures/ 17 PPE Maintaining
Breathing 3. Training on “Safety in Standard
problems/ nausea/ Refining” procedures.
irritation to 4. Following MSDS sheets Aware of Safety
skin/eyes due to and proper batch shower location.
exposure to preparation procedures Awarene Appropriate
Chemical chemicals. Land ss to be pumps to be used
batch pollution and increase for loading and
preparation for Ground/undergrou d 2 3 6 MODERATE Nil Yes unloading of
Dosage nd water regardin chemicals. Only
purposes contamination due g use of trained workers
to spillage. PPE should be allowed
to do the job.
Perform Benzene
dragger test.use
H2S meter
.
Page 54 of 67
Risk (Enviro LxS
Meas required
and /E (L) (S) DC/
Safety)
PP/IP
C
45 SO2 Emission E/H D/I R N Standard operating Awarene
NOx Emission procedures ss to be
Furnace Stack SPM Continuous stack increase
H2S meter to be
(Normal Toxic vapors monitoring stations. d 1 2 2 TRIVIAL LC Yes
used
Running) causes air regardin
pollution g use of
PPE
46 SO2 Emission E/H D/I NR AN Standard operating
Awarene
NOx Emission procedures
ss to be
SPM Continuous stack
Unbalanced increase
Soot monitoring stations. H2S meter to be
Firing in d 1 2 2 TRIVIAL PP Yes
Toxic vapors used.
furnace regardin
causes air
g use of
pollution
PPE
47 Body injury due to HS D/I R AN Standard operating
Non
exposure to procedure.
adheren
trapped Usage of PPE -F& S
ce to Make sure that
Air rumbling of pressurized air/ Regulation Chapter 17,
Use of 1 2 2 TRIVIAL IPC Yes hoses are
coolers hose snap-off While removing the hose it
SOP or connected well
should be depressurized
PPE.
Noise pollution/ Air
pollution
Page 55 of 67
Risk (Enviro LxS
Meas required
and /E (L) (S) DC/
Safety)
PP/IP
C
48 NHT Stripper Burn injury due to H D/I R N On the Job Training, job Commissioning
Column exposure to hot certification, Supervision of and
Bottom / Stab HC liquid, seniors, decommissioning
Not
Bottom / Breathing Safe operating procedures procedures are
following
Splitter Bottom problems, skin/eye are available in manual available in
procedur
pump DWC irritation due to HC ES Usage of PPE - 1 3 3 TOLERABLE DC Yes Standing
es,(UA)
bottom pump vapors, F & S Regulation Chapter Instruction
Without
commissionin Leakage may 17 Proper usage of
PPE
g/ result in fire Fire extinguishers are PPE is a must
decommissioni leading to burns/ placed as per Norm H2S meter to be
ng plant damage used
49 gas leak/exposure HE D R N After isolation of high
to heat pressure valve check for
passing by opening Regular greasing
bleeder drain valve. Both the
Greasing of to be done after
(Greasing to be done to valves
high pressure 1 4 4 Tolerable Nil Yes sampling. Do not
Air pollution avoid metal to metal are
valve:- grease if valves
contact between seat and passing. are passing.
body.)
A2 DETERMINING EHS RISK LIKELIHOOD – GUIDANCE CRITERIA
Likelihood Adequacy of Control Measures or Frequency of incident Event in the Past
Highly Unlikely If almost no gap exists in control of the identified EHS haz- Improbable
Page 56 of 67
(1) ard as technology, operational control, competence, mea- Has occurred in

surement monitoring in place
world-wide industry but not in Group Company
Unlikely If there is any minor gap / weakness in control of the identi- Remote
fied EHS hazard
(2) Has occurred in another
Group Company
Likely There are unreasonable gaps in control of the identified Occasional

EHS hazard with respect to adoption of technology, opera-
(3) tional control, measurement monitoring and competence Has occurred in company
Very Likely There are unreasonable major gaps in control of the iden- Probable
tified EHS hazard with respect to adoption of technology,
(4) operational control, measurement monitoring and compe- It Happens several times each year in company
tence
Certain There are almost no controls in place in controlling the Frequent

identified EHS hazard and have occurred in the past but ig-
(5 ) nored. Happens several times per year in same location or Opera-
tion
NOTE: Apply both the above Criteria i. e. adequacy of Control Measures and Frequency and then select the most critical / suitable one for
EHS Risk Assessment
A3 DETERMINING EHS RISK SEVERITY LEVEL – GUIDANCE CRITERIA
People / Community Asset Compliance level with Consumption of

Level of Harm respect to prescribed Resources
(Extent of damage EHS Standard / Expo-
to equipment / ma- sure Levels (TLV for 8
chinery / plant / En- hours)
vironmental Dam-
age)
Page 57 of 67
Insignificant Momentary Discomfort / No action required Below / equal to pre- Controls are well established with effective
inconvenience scribed Standards bench-marking (No opportunity for further re-
(1) duction)
< or = Rs. 5000
Slightly Harmful Minor injuries (Non re- Minor damage Above than prescribed Controls are established however minor op-
portable) requires first-aid Standards; portunity for improvement (Random opportu-
(2) nity for further reduction)
however < 20%
> Rs. 5000 but < or =
Rs. 50,000
Harmful Injuries, absence from the Moderate damage Above than prescribed Controls are established however specific
work less or equal to 48 Standards; consumption can be further improved
(3) hrs / temporary disability
however within 20% -
> Rs. 50,000 but < or 40%
= 5 Lakh
Very harmful Major injuries, absence Severe damages Above than prescribed Controls are in place however largely ineffec-
from the work more than Standards; however tive
(4) 48 hrs / temporary disabil- within
ity (Substantial opportunity for further improve-
> 5 lakh but < or = 50 40-50% ment in specific resource consumption)
Lakhs
Extremely Harmful Fatal / Permanent Disabil- Annihilation (complete Above than prescribed No Control at all including, Uncontrolled Gen-
ity / Chronic diseases. destruction) Standards; eration of waste (Substantial opportunity for
(5) Major incidents involving improvement in specific consumption)
large number of people AND > 50%, leading to
chronic notifiable dis-
> 50 Lakhs ease

Page 58 of 67
A4 EHS RISK LEVEL INDICATORS
Severity  INSIG-NIFICANT SLIGHTLY HARMFUL VERY HARMFUL EXTREMELY HARM-

HARMFUL FUL
Likelihood (1) (3) (4)
(2) (5)

HIGHLY UN- TRIVIAL TRIVIAL TOLERABLE TOLERABLE MODERATE

LIKELY
(1) (1) (2) (3) (4) (5)
UNLIKELY (2) TRIVIAL TOLERABLE MODERATE MODERATE SUBSTANTIAL
(2) (4) (6) (8) (10)
LIKELY TOLERABLE MODERATE MODERATE SUBSTANTIAL SUBSTANTIAL (15)

(3)
(3) (6) (9) (12)
VERY LIKELY TOLERABLE MODERATE SUBSTANTIAL SUBSTANTIAL (16) INTOLERABLE
(4) (4) (8) (12) (20)
CERTAIN (5) MODERATE SUBSTANTIAL SUBSTANTIAL INTOLERABLE INTOLERABLE

(10)
(5) (15) (20) (25)
EHS Risk Level Action and Time Scale
TRIVIAL No action is required and no documentary record needs to be kept.

A5 DEFINITION OF LEVEL OF EHS RISKS
No additional controls are required. Consideration may be given to a more cost-
TOLERABLE effective solution or improvement that imposes no additional cost burden. Moni-
toring is required to ensure that the controls are maintained.
MODERATE Efforts should be made to reduce the EHS risk, but the cost of prevention should
be carefully measured and limited. EHS risk reduction measures should be im-
plemented.
SUBSTANTIAL Work should not be started until the EHS risk has been reduced. Considerable
resources may have to be allocated to reduce the EHS risk where the EHS risk
involves work in progress, urgent action should be taken.
Work should not be started or continued until the EHS risk has been reduced. If it
INTOLERABLE is not possible to reduce EHS risk even with unlimited resources, work has to re-
main prohibited.
Page 59 of 67
A. 6 Checklist to be filled during the Identification of OHS hazards, risk assessment and determining controls for verification of inclusion of
all items.
Activity Status
(Included / Non
included)
Master list of activities done by the department including associated hazards such as : Included
 Electrical hazards
 Fire Hazards
 Mechanical Hazards
 Physical hazards
 Chemical hazards
 Biological hazards
 Ergonomical hazards
Hazards associated with Infrastructures, equipments and materials at the work place Included
Activities of all personal having access to work place (including Contractors, sub contractors, transporters & visitors) including facilities Included
at the work places, whether provided by the organization or others.
Consider all activities where previous records of Incidents, Accidents have occurred Included
Consider records of the previous unsafe acts and unsafe conditions Included
Consider the up to date site layout diagram/ process flow sheets for identification of activities where possible hazards could be Included
Consider all routine and non routine activities (refer to definition of routine and non routine as given in procedure) Included
Consider the inputs from regular Plant & Management Review meetings/ Safety inspections/ records Included
Page 60 of 67
Study the human behavior of the departmental and contract employees and the out put of this behavior study shall be an input for the Included
hazard risk identification.
Refer to the Material Safety Data Sheets to identify the possible associated OHS hazards based on the exposure levels Included
Consider the results of competence mapping for the departmental personnels, contractors, contract manufacturers Included
Consider the violations noticed during the implementation of the work permit system in the department Included
Consider the past data on weather conditions & earthquakes Not Included
Consider the past data on the utilities disruptions Included
Included
Consider the Likely domino effects from the neighborhood and other hazards from outside the work place which are capable of affecting
the health and safety of personnel’s under the control of the organization.
Consider the potential emergency which may occur due to or from the vehicles which are transporting the materials from the organiza - Included
tion or to the organization.
Consider the records of past safety audits Included

Consider the reports of the monitoring carried out for Illumination, noise, ventilation, ergonomics and work place air quality monitoring. Included
Consider the modifications to the OHS management systems including temporary changes Included
Consider any changes in the infrastructure, equipments, materials, processes, installations, machinery and include in the hazard risk Included
identification.
Consider the changes in operating procedures, changes or proposed changes in the organizations, its activities, materials are to be in- Included
cluded in the hazard risk identification.
During introduction of new projects, processes, activities, modifications to the OHS management systems, temporary changes which Included
may impact the operations of the department are included in the hazard risk identification
The changed processes, activities, changes in the hardware and software (including the change in the composition of the man power in- Included
volved in various manufacturing operations) are included in the hazard risk identification.
Changes in the employees which are likely to affect the operations of the departments are identified / evaluated and included in the reg- Included
ister of OHS hazards.
A7 TERMS RELATING TO QMS

Process
Set of interrelated or interacting activities which transforms inputs into outputs
Quality
Page 61 of 67
Degree to which a set of inherent characteristics fulfils requirements
Management
Coordinated activities to direct and control an organization
System
Set of interrelated or interacting elements
Quality management system
Management system to direct and control an organization with regard to quality
Correction
Action to eliminate a detected nonconformity
Corrective action
Action to eliminate the cause of a detected nonconformity (3.6.2) or other undesirable situation
Preventive action
Action to eliminate the cause of a potential nonconformity (3.6.2) or other undesirable potential situation
Document
Page 62 of 67
Information and its supporting medium
Competence
Demonstrated personal attributes and ability to apply knowledge and skills
Audit
Systematic, independent and documented process for obtaining audit evidence and evaluating it objectively to determine the extent to which audit cri-
teria are fulfilled
Audit criteria
Set of policies, procedures or requirements used as a reference
Audit scope
Extent and boundaries of an audit
A8 DEFINITIONS OF QMS/ EHS
ENVIRONMENT
Auditor Person with the competence to conduct an audit.
Continual improvement Recurring process of enhancing the environmental management system in order to achieve improvements in over-
Page 63 of 67
all environmental performance consistent with the organizations environmental policy.
Corrective action Action to eliminate the cause of a detected nonconformity
Document Information and its supporting medium
Environment Surrounding in which an organization operates, including air, water, land, natural resources, flora, fauna, humans
and their interrelation
Environmental aspect Element of an organization activity or product or services that can interact with the environment
Environmental impact Any change to the environmental whether adverse or beneficial wholly or partially resulting from an organizations
environmental aspects
Environmental manage- Part of an organizations management system used to develop and implement its environmental policy and manage
ment system its environmental aspects
Environmental objective Overall environmental goal, consistent with the environmental policy that an organization sets itself to achieve
Environmental perfor- Measurable results of an organizations management of its environmental aspects

mance
Environmental policy Overall intentions and direction of an organization related to its environmental performance as formally expressed
by top management
Environmental target Detailed performance requirement, applicable to the organization or parts thereof that arises from the environmen-
tal objectives and that needs to be set and met in order to achieve those objectives.
Interested Party Person or group of persons concerned with or affected with the environmental performance of the organization
Internal audit Systematic, independent and documented process for obtaining audit evidence and evaluating it objectively to de -
termine the extend to which the environment management system audit criteria set by the organization are fulfilled
Non conformity Non fulfillment of a requirement
Organization Company, corporation, firm, enterprise, authority or institution or part or combination thereof whether incorporated
or not public or private that has its own functions and administration
Preventive action Action to eliminate the cause of a potential non conformity
Prevention of Pollution Use of processes, practices, techniques, materials, products, services or energy to avoid, reduce or control the cre -
Page 64 of 67
ation, emission or discharge of any type of pollutant or waste in order to reduce environmental impacts
Procedure Specified way to carry out an activity or a process
Record Document stating results achieved or providing evidence of activities performed
OCCUPATIONAL HEALTH AND SAFETY
Acceptable risk risk that has been reduced to a level that can be tolerated by the organization living regard to its legal obligations and
its own OH&S Policy
Audit systematic, independent and documented process for obtaining “audit evidence” and evaluating it objectively to deter-
mine the extent to which “audit criteria” are fulfilled
Continual Improvement recurring process of enhancing the OH&S management
system in order to achieve improvements in overall OH&S performance consistent with the organization’s OH&S
policy
Corrective Action actions to eliminate the cause of a detected nonconformity or other undesirable situation
Document information and its supporting medium
Hazard source, situation, or act with a potential for harm in terms of human injury or ill health or a combination of these
Hazard Identification process of recognizing that a hazard exists and defining its characteristics
Ill Health identifiable, adverse physical or mental condition arising from and/or made worse by a work activity and/or work-re-
lated situation
Incident work-related event(s) in which an injury or ill health (regardless or severity) or fatality occurred, or could have oc-
curred
Interested Party person or group, inside or outside the workplace, concerned with or affected by the OH&S performance of an organi-
zation
Page 65 of 67
Nonconformity non-fulfillment of a requirement

Occupational health and conditions and factors that affect, or could affect, the health and safety of employees or other workers (including tem-
safety (OH&S) porary workers and contractor personnel), visitors, or any other person in the workplace
OH&S management sys- part of an organization’s management system used to develop and implement its OH&S policy and manage its OH&S
tem risks
OH&S objective OH&S goal, in terms of OH&S performance that an organization sets itself to achieve
OH&S performance measurable results of an organization’s management of its OH&S risk
OH&S policy overall intentions and direction of an organization related to its OH&S performance as formally expressed by top man-
agement
Organization company, corporation, firm, enterprise, authority or institution, or part or combination thereof, whether incorporated or
not, public or private, that has its own function and administration
Preventive action action to eliminate the cause of a potential nonconformity or other undesirable potential situation
Procedure specified way to carry out an activity or a process
Record document stating results achieved or providing evidence of activities performed
Risk combination of the likelihood of an occurrence of a hazardous event or exposure(s) and the severity of injury or ill
health that can be caused by the vent or exposure(s)
Risk Assessment process of evaluating the risk(s) arising from a hazard(s), taking into account the adequacy of any existing controls,
and deciding whether or not the risk(s) is acceptable
Workplace any physical location in which work related activities are performed under the control of the organization
A9 Input for Control Measures
In addition to the quantitative criteria, all EHS Risks shall also be reviewed for inputs of control measures. These
inputs shall also determine the additional control measures:
Operations and processes which can trigger / multiply the EHS

Domino Concern (DC)
Page 66 of 67
risk that are of increasing magnitude and create potential
emergency
Any EHS hazard and risks covered by existing and applicable

Legislative Concern (LC)
EHS Legislation and other notifications issued from time to time
including the EHS requirements to which the company has
subscribed
Meaningful opportunity for resource conservation / waste

Pollution Prevention (PP)
minimization
A 10 Determining the EHS Control Measures
Based on the EHS Risk Level, the control measures shall be undertaken on the principles of the following hierarchy
Environmental Risk OHS Risk
 Energy efficient  Elimination

 Product stewardship  Substitution with less hazardous
 Cleaner technology materials, processes, operations or
 Substitution equipment’s.
EHS Risk  Pollution prevention /  Engineering controls
Control Waste management  Signage / warning / administrative
Measures
 Recycle / reuse / controls
reconditioning  Personnel protective equipment’s
 Waste treatment  Behavior monitoring
 Waste disposal  Supervision
 Human factor
Page 67 of 67
In addition to above, the control measures shall also include the following:
 New technology / modification in technology / physical improvements / substitution of equipment / chemicals
 Emergency preparedness and response plan
 Training and competence improvement
 Task observations / contractor’s control mechanism
 Strengthening of inspections and supervision systems
 Monitoring and measurement, including preventive & ill health monitoring
 Identification of Management Programmes
 Any other as relevant

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Page 1 of 67

BPCL MUMBAI REFINERY

Document No. : MR.OPS.ARU.05.02 Revision No: 00 Date: 01.09.2019

1 PUMP (HC) 1) Safety Manual chapter-

3. HEAT Body Injury due to 1) Safety Manual chapter-

Spillage of oil 1) Safety Manual chapter- Non Nil

Spillage E D R AN 1) Safety Manual chapter- - 1 2 2 Trivial PP Yes Nil

1)On job training of

13. HOT OIL

H/S D/I R Non Nil

22 LIQUID 1) Safety Manual chapter-

24. PIPE TRACK

25 BOOT WATER 1. Counseling to

30. FURNACE 1) Safety Manual Chapter- 1. Counseling to

33. PROCESS Exposure to HC

1. Off/ On 1) Safety Manual Chapter- 1 2 2 Trivial

Land Pollution due

1)On job training of

37 BENZENE/ E D/ I R AN 1) Safety Manual chapter- Non 2 4 8 Moderate PP/ Yes 1. Counseling to

38 PLANT Exposure to HC 1) Installation of HC 1) Regular

39 CHEMICAL Chemical spillage/

43 Process Release of HC in E D NR AN Regular rounds Perform Benzene

A2 DETERMINING EHS RISK LIKELIHOOD – GUIDANCE CRITERIA

Likelihood Adequacy of Control Measures or Frequency of incident Event in the Past

(1) ard as technology, operational control, competence, mea- Has occurred in

Likely There are unreasonable gaps in control of the identified Occasional

Certain There are almost no controls in place in controlling the Frequent

A3 DETERMINING EHS RISK SEVERITY LEVEL – GUIDANCE CRITERIA

People / Community Asset Compliance level with Consumption of

< or = Rs. 5000

A4 EHS RISK LEVEL INDICATORS

Severity  INSIG-NIFICANT SLIGHTLY HARMFUL VERY HARMFUL EXTREMELY HARM-

HIGHLY UN- TRIVIAL TRIVIAL TOLERABLE TOLERABLE MODERATE

UNLIKELY (2) TRIVIAL TOLERABLE MODERATE MODERATE SUBSTANTIAL

(2) (4) (6) (8) (10)

LIKELY TOLERABLE MODERATE MODERATE SUBSTANTIAL SUBSTANTIAL (15)

VERY LIKELY TOLERABLE MODERATE SUBSTANTIAL SUBSTANTIAL (16) INTOLERABLE

(4) (4) (8) (12) (20)

CERTAIN (5) MODERATE SUBSTANTIAL SUBSTANTIAL INTOLERABLE INTOLERABLE

TRIVIAL No action is required and no documentary record needs to be kept.

Consider the records of past safety audits Included

A7 TERMS RELATING TO QMS

Set of interrelated or interacting activities which transforms inputs into outputs

Degree to which a set of inherent characteristics fulfils requirements

Coordinated activities to direct and control an organization

Set of interrelated or interacting elements

Quality management system

Management system to direct and control an organization with regard to quality

Action to eliminate a detected nonconformity

Information and its supporting medium

Demonstrated personal attributes and ability to apply knowledge and skills

Set of policies, procedures or requirements used as a reference

Extent and boundaries of an audit

A8 DEFINITIONS OF QMS/ EHS

Auditor Person with the competence to conduct an audit.

all environmental performance consistent with the organizations environmental policy.

Corrective action Action to eliminate the cause of a detected nonconformity

Document Information and its supporting medium

Environmental perfor- Measurable results of an organizations management of its environmental aspects

Non conformity Non fulfillment of a requirement

Preventive action Action to eliminate the cause of a potential non conformity

Procedure Specified way to carry out an activity or a process