NUMALIGARH REFINERY LIMITED

Emergency Response & Disaster Management Plan

and Best Practices at NRL
 THE GENESIS

1. Proposal for Refinery included in “Assam Accord” : August 15, 1985

2. “Numaligarh Refinery Limited” incorporated : April 22, 1993

3. Commercial Production commenced : Oct. 1, 2000

4. NRL became subsidiary of BPCL : March 31, 2001

2
 OUR LOCATION- IN THE STATE OF ASSAM

AOD
BRPL

IOC,GHY
NRL

N
W E Refinery Capacity DST. from
(MMTPA) NRL (Km)
S
IOCL, Ghy 1.00 260

AOD, Digboi 0.65 310

BRPL 2.35 460

NRL 3.00 ----

4
 NRL PLOT PLAN

PANKA GAON CRUDE PIPE LINE IN

STORM WATER OUTLET

GREEN BELT
101D 101C 101B 101A
CRUDE TANKS
(FUTURE) CRUDE TANKS
CRUDE TANKS
FLARE
WET SLOP

250 KV
V R V D S K O DG set
DRY SLOP C H S D NAPHTHA
FO

R O C D A T F

(White oil.)
Pump house
CPC WARE HOUSE
HCU CDU/VDU DCU C

COMPLEX
C

LOADING GANTRY

CISF
Black oil White oil

BOTTLING
AREA FOR
Gantry A Gantry B
CENTRAL
U

PLANT
CONTROL
ROOM Oil loading gantry
ETP
H2U Scaling platform

HORTON SPHERE
HOUSE
WARE

N2 Compressor

CONTROL ROOM
Plant house

GREEN BELT
RAiL
SRU
RWTP STORE
CENTRAL OPEN COOLING
WORKSHOP STORAGE
YARD TOWER
CONTROL ROOM
S
RW CTC MEDICAL S
NRL

P&T I LPG
RESERVOIR CANTEEN T CENTRE LAB ADM.
E R LOADING
FW Adm GANTRY BLDG.
RESERVOIR PO
EIL
FIRE STATION U
bldg
BANK CISF MATERIAL GATE NRMT MAIN GATE

CISF MAIN GATE

GREEN BELT

<--- NH - 39---> /
 OUR PROMOTERS

Share holding pattern of the refinery

26

12.35 61.65

BPCL GOA OIL

 THE PROJECT AT A GLANCE

 Installed Capacity : 3 MMTPA

 Area : Refinery - 750 Acres

Township - 250 Acres

 Approved Project Cost : Refinery - Rs. 2489.12 Crores

Marketing Terminal - Rs. 235.52 Crores

---------------------------------------------------------
Total - Rs. 2724.64 Crores

 Both Refinery and Marketing Terminal completed within approved Project Cost

Annual turn over Rs.7874Crore

Gross Profit for the financial year 2009-10 is Rs. 521Crore
Profit After Tax Rs.232Crore

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 HIGHLIGHTS

 Eco-friendly Refinery

 First Sulfur Recovery Unit

for processing Assam
Crude

 Installation of Ground Flare

Clean & Green Environment

8
 MILESTONES

Management Systems:

•IMC Ramakrishna Bajaj National Quality awards for 2009.

•Jawaharlal Nehru Centenary Awards for Energy Performance of Refineries for the year
2004-05 and for 2007-08.
•National Energy Conservation Award consecutively for 2007(2nd Prize in refinery sector)
and 2008 by Bureau of Energy Efficiency.
•Oil & Gas Conservation Award in 2008 by Centre of High Technology.
•TERI Corporate Environmental excellence Award consecutively for 2007 and 2008.

Safety Management:

•Oil Industry Safety Awards for the year 2005-06 and for 2008 by OISD.
•National Safety Award in 2008.
•Shrestha Suraksha Puraskar consecutively for 2006 and 2007 by National safety council.
•Green Tech Safety Gold Award for 2005-06 by Greentech Foundation,
Hyderabad and for 2007-08 by Greentech Foundation, Delhi.

9
 MILESTONES (Contd.)

Environment Management:

• Best green Location: Refinery in 2009 by BPC Mumbai Refinery

• Chairman's award for Excellence in Green (Refinery) in 2007-08 by Corporate
HSE& S award , BPCL

Information Technology:

• Awarded Best Industry Status in IT Agency National Petroleum Management

Programme for year 2001-02.

• Fastest implementation of SAP

 HSE – Our Primary Concern

 Achieved 15.96 Million LTA free man-hours (3292 days).

 Regular study of water quality of Dhansiri river
 Continuous monitoring of the status of ambient air quality.
 Waste Management System

- Solid Waste Disposal Yard

- Secured Land Fill
- Melting Pit
 Post commissioning Environment Audit by NEERI.
 Use of sweet fuel for internal consumption

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 SAFETY MANAGEMENT SYSTEM OF NRL

• NRL is certified by DNV for OHSAS 18001 since 2002

along with ISO 9001 & 14001 for Quality & Environment
also. NRL also achieved ISRS level -9
1) Safety points covered under internal and external management system
audit.
2) Safety points are discussed everyday in the morning meeting.
3) Quarterly the status of various safety points implementation are
reviewed at the level of Director (Technical) in Apex safety Committee
Meeting.
4) Every month, in Functional Co ordination meeting, Managing Director
takes monthly report on safety performance.
5) Safety Audit by OISD

• Status of OISD related points are regularly sent to

OISD every three months.
• The DGFASLI audit compliance report are also sent to
RLI, Kolkata periodically.
 SAFETY COMMITTEES
NRL has 3-tier safety committees:

 Sectional safety Committee

- Conducted monthly by Shift In Charges’ of the various units
 Area Safety Committee
- Conducted quarterly with equal participation of
management and Non-management staff
 Apex Loss Control Committee
- Conducted quarterly with all unit heads,VKNRL & non-
management staff and convened by Director (T)
 FIRE PROTECTION FACILITIES AT NRL
• Fire water system
I. Fire water pumps and Reservoir.
II. Fire Water Network (As per OISD 116 , other relevant codes & IS standards)
Fire water network of length 55 km is laid in closed loop multidirectional flow.
It includes:
* Hydrants
* Monitors
* Water spray system
* Deluge system

• Foam Protection System

* Fixed Foam System &
* Semi fixed Foam System

• CO2 Total Flooding System

• First Aid fire fighting Appliances
• Mobile fire fighting equipments
• Gas Detection & Alarm system
 FIRE PROTECTION FACILITIES

I. Fire Water Pumps: •100% back up with 4 Diesel driven

pumps
PA-101
•Second Source of Fire water : Raw water
reservoir of capacity (2 x 12000) m3
PA-102

PA-102A

PA-103

PA-104

PA-105

PA-106

LEGEND CAPACITY Pump Head

PA-107

3 JOCKEY PUMPS 65 M3/Hr. 11kg/cm2

(Electric Driven) PA-108

4 MAIN FW PUMPS 700 M3/Hr. 10.5 kg/cm2 PA-109

(Electric Driven)

4 MAIN FW PUMPS 700 M3/Hr. 10.5 kg/cm2 PA-110

(Diesel Driven)
 FIRE PROTECTION FACILITIES (Contd.)

II. Fire Water Network

Particulars Location
Refinery Marketing terminal
Hydrants 445 nos. 170 nos.
Medium range 145 nos. 131 nos.
Monitors
Long range 22 nos. 1 no.
Monitors
Water Spray System Storage Tanks , Hot & light H/C pumps, Loading
gantries
Deluge System CPP fuel Day Tanks, LPG sphere, LPG
CPP Transformer Area bottling Plant
 FIRE PROTECTION FACILITIES (Contd.)

III. Foam System

Particulars Location
Refinery Marketing terminal
Semi fixed Foam In all the storage tanks -
system except FO tank
Fixed Foam System Storage tank of Co- In all the storage tanks
Generation Plant except FO Tank

IV. CO2 System

CO2 Total flooding In the GTG , cable cellar room of Co-Generation
System Plant

V. FM200 (Compound of Carbon, Fluorine & Hydrogen) System

FM200 flooding ERP Server room
system
 FIRE PROTECTION FACILITIES (Contd.)
VI. Mobile Fire Fighting Units

Particulars Nos.
Foam cum water Tender 4 nos.
DCP Tender 1 no.
Mobile Oil Spill Recovery Unit 1 no.
Foam Trailer 4 nos.
Mobile Foam Units 4 nos.
Trailer Pump 2 nos.

VII. First Aid Fire Fighting Equipments (Approx 1200 nos.)

Location
Particulars Refinery Marketing Offices , Buildings
terminal
DCP 10 kg 643 141 41
extinguisher 75 kg 72 29 -
Cleaning 6 kg 4 1 8
Agent
CO2 6.5 kg 73 04 11
extinguisher 9 kg 64 18 12
 VII. Gas Detection & Alarm System
 The Fire Detection and alarm system is micro-processor based
and covers the entire refinery and NRMT. The system consists
of Fire detecting sensors & manual call points

LOCATION Total No of Fire Detecting Sensor (Ionization,

Smoke, Heat & Optical photo detector)
Main Control Room 374
ETP Control Room 54
Administrative Building 220
Warehouse 128
NRMT Control Room 239

Total 279 nos. of Manual Call points are installed in around the road
network.
 A separate Fire Detection ,Alarm & Suppression System is installed in
CPP (Captive Power Plant)
 SOME SAFETY EQUIPMENTS
• Safety Kit box located at strategic locations
containing:
• Canister Mask: SO2, Cl2, NH3, H2S
• Hand Gloves: Chemical, Lather, Kelver, Cotton, Electrical
• Face Shield: Chemical, Furnace
• Goggles: Bocal Blue, Safety Goggles
• Ear Protection: Muff, Plug
• Safety Torch
• Dust Musk
• Water Gel

• Compressed Air Breathing Equipment

• Articulated Boom
• Mobile Oil Spillage Recovery Unit
Mobile Fire Fighting Units
Mobile Fire Fighting Units

DCP TENDER
Mobile Fire Fighting Units
 EQUIPMENTS

MOBILE OIL SPILLAGE RECOVERY

UNIT

ARTICULATOR
 COMMUNICATION FACILITIES

1. Intercom / BSNL / Fax

2. LAN / Internet / VSAT.
3. Group Dialing System
4. Public Address System
5. Siren at 9 locations including 2 at township.
6. Multi channel VHF sets with eleven Base stations
Range - Base Station : 25 Km, Hand sets :5 km
7. Fire alarm & Detection system.

Remarks : All the above facilities have UPS or

emergency power.
 MANUALS & DOCUMENTS

• CONSTRUCTION SAFETY MANUAL (ENGLISH / ASSAMESE)

• SAFETY MANUAL
• FIRE MANUAL
• ONSITE DISASTER MAMAGEMENT PLAN
• OFFSITE DISASTER MANAGEMENT PLAN
• FIRE ORDER
• MATERIAL SAFETY DATA SHEET
• CONTRACTOR SAFETY MANUAL
• FIRE PROTECTION & SAFETY POCKET MANUAL
• VISITOR’S FAMILIARISATION & SAFETY CARD
• LEAFLET ON LPG SAFETY
Onsite & Offsite Disaster Management Plan
 ORGANOGRAM FOR OFFSITE EMERGENCY PREPARDNESS PLAN

Hospital Co- ordinator Supdt Of Police SDO Office, Bokakhat

Tel : 280505/ 280373 Tel. : 285233 (O), Tel : 268382 (O), 268387 ( R) 94351-54221(M)
284234 (R) Jt. Director Health Service
OIL Co-ordinator
Tel : 282438 (O), 280397(R)
Supdt. Engg. : 265561(O) 4429 (R)
NRL Authority, Civil Supply Officer Tel : 280532 (O)
CHIEF OFFSITE
D(T) : 265401 (O), 266425 (R) EMMERGENCY Dist. Transport Officer
GM(O) : 265529(O), 266423(R) CO-ORDINATOR
Tel : 282181 (O)
Fire Service Co- ordinator DEPUTY COMMISSIONER
Golaghat Fire Brigade : 280300 Tel. : 280222 (O),280221 (R) Ex. Engineer, PWD (Road)
94350-95420 (M)
Bokakhat Fire Brigade : 269733(O) Tel : 280226 (O), 280426 (R)
alternate
Railway Authority ADDL. DY. COMMISSIONER Asst. Ex. Engineer, PWD (Bldg)
(R&R)
Div. Rly. Engineer, TSK Tel : 280365 (O),
Tel. : 280261(O),281019(R)
Tel : 0374 -2333570 (O) 94350-54474 (M) Ex. Engineer, PHED
CONTROL ROOM
Tel:284763(O) 94350-90808(M)
Divisional engg. Tel AT OFFICE OF
Mob :9435000384 DC / ADC
CO Marangi
Tel : 9401088312 (M)
Ex. Engineer ASEB
Panchayat VDP DIPRO Inspector of Factories Tel : 280312 (O),
Ex. Engineer NH
Mob:9854872854 Mob:9435002199 Mob :9435160729 94350-54337(M) Tel : 280319(O)
ORGANOGRAM FOR ONSITE EMERGENCY PREPARDNESS PLAN
 FIRE & SAFETY TRAINING

TRAINING FACILITIES:
• TRAINING HALL AT FIRE STATION
• FIRE TRAINING GROUND AS PER OISD 116
• TRAINING POLICY AS PER OISD - 154

TYPES OF TRAINING:
• FRESHER TRAINING FOR NEW EMPLOYEES
• RE-FRESHER TRAINING FOR ALL EMPLOYEES
OTHERS
• CONTRACTOR’S SUPERVISORS / WORKMEN
• CISF & OTHER SECURITY STAFF
• POL DRIVERS
 Fire Fighting Training

Fire Fighting Training to CISF Jawans Fire Fighting demonstration in public

 MOCK DRILLS

1) MINOR FIRE
• DRILLS ARE CONDUCTED ONCE A MONTH
2) MAJOR FIRE

• DRILLS ARE CONDUCTED ONCE IN A QUARTER

3) ONSITE DISASTER
• DRILLS ARE CONDUCTED HALF-YEARLY

4) OFFSITE DISASTER
• CONDUCTED ON ONCE A YEAR
MOCK DRILL REPORT
GLIMPSES OF MOCK DRILL

Rescue operation by
NDRF persons
GLIMPSES OF MOCK DRILL

High Expansion Foam

Generator
 GLIMPSES OF MOCK DRILL

Relief Camp during off

Rescue Operation site disaster mock drill

Review Meeting after Mock Drill

 SAFETY INCENTIVE SCHEMES

• INCENTIVE LINKED WITH MILLION LTA FREE MAN HRS.

• OUTSTANDING SAFETY PERFORMANCE AWARD.
• HOUSEKEEPING AWARD (FOR UNITS).
• SECTIONAL SAFETY AWARDS.
• SAFETY AWARD FOR CONTRACTORS.
• TURN AROUND SAFETY AWRAD
• BEST SAFETY AWARD FOR NRL EMPLOYEES
• BEST SAFETY AWARD FOR CONTRACTS EMPLOYEES
(AMC/PROJECT)
 RECENT PROJECTS

COMPLETED PROJECTS

• Motor Spirit Unit

• Utilization of Natural Gas
• Diesel Quality Up gradation Project
• 12 MW Steam Turbine Generator
• Pipeline Dispatch & Receipt Terminal

FUTURE PERSPECTIVE

• Naphtha Splitter Project

• Wax Project
• Production of Needle Coke
 Key Tasks Adopted in NRL for Improvement of
Health & Fire
1. Health Hazard Survey for Employees:
• As a good corporate citizen among oil industries in India, NRL has
under taken the health hazard survey for critical tasks and high hazard
areas in plants and other areas
2. On the site Safety training for employees:
• A specific training programme adopted for training of employees at the
site.
3. Contractor Safety Evaluation for Turn Around Jobs:
• NRL was having a full-fledged contractor safety evaluation during turn
• The system of evaluation for contractors is very elusive considering all
aspects of HSE.
4. Survey of fire fighting and safety equipments:
• The fire fighting and safety items in refinery are surveyed by a
multidisciplinary team of operation, Maint and F&S to exactly evaluate
the correct equipments for fire fighting and safety. All required actions
are taken by F&S for the same.
5. Internal Safety Audit by members from group companies:
• The system of Internal Safety Audit is being prevailed in NRL as per
OISD guidelines.
 EXAMPLES OF POSITIVE ACTION TAKEN
• From last year onwards, NRL’s all meetings starts with a “safety moment”
where safety points are discussed.
• NRL is always meeting MOU target of Training of NRL personnel, workers
of contractors, CISF & security guards etc on safety.
• General Loss Control Rules/Dos/Don’ts
• Hazard Communication:
– Contractor must familiarize himself from NRL EICs about all known
potential fire, explosion or toxic release hazards related to his contract.
He in turn will ensure that same information has been passed to his
supervisors and workmen.
• Contractors Penalty clause
– In order to improve and maintain safe working environment we are
planning to introduce a special conditions of contracts for HSE (Health
Safety and Environment) regulation for contractors.
• Note: Generally we do counseling to the workers if they are found practicing
unsafe acts or work in unsafe condition before imposing the above penalty
clauses.
• PPE: NRL has adopted colour code for PPEs to improve safety culture
at NRL with effect from 1st January, 2011.
Thank You