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SAFETY ASPECTS & THEIR AUDIT

SAFETY ASPECTS & THEIR AUDIT. PROTECTION OF PERSONNEL PROTECTION OF PLANT AND PROPERTY UNINTERRUPTED OPERATIONS HEALTHY ENVIRONMENT SAFETY OF THE COMMUNITY REPUTATION. WHY SAFETY?. VIOLATION OF PROCEDURES / RULES. INADEQUATE INSPECTION / MAINTENANCE. INATTENTION / NEGLIGENCE.

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SAFETY ASPECTS & THEIR AUDIT

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  1. SAFETY ASPECTS & THEIR AUDIT

  2. PROTECTION OF PERSONNEL • PROTECTION OF PLANT AND PROPERTY • UNINTERRUPTED OPERATIONS • HEALTHY ENVIRONMENT • SAFETY OF THE COMMUNITY • REPUTATION WHY SAFETY?

  3. VIOLATION OF PROCEDURES / RULES. • INADEQUATE INSPECTION / MAINTENANCE. • INATTENTION / NEGLIGENCE. • NON-USAGE OF PROTECTIVE EQUIPMENT. • LACK OF COMMUNICATION. • USAGE OF IMPROPER TOOLS / EQUIPMENT. • PREVELANCE OF UNSAFE CONDITIONS. • UNSAFE ACTS. • POOR JUDGEMENT. • POOR HOUSEKEEPING. 10 CAUSES OF ACCIDENT.

  4. WHAT IS FIRE? The Fire Triangle Fuel OxygenTemperature FIRE IS A GOOD SERVANT , BUT A BAD MASTER

  5. CLASSIFICATION OF FIRES Class A SOLID FIRE Class B LIQUID FIRE Class C GAS FIRE Class D METAL FIRE

  6. EXTINGUISHING FIRES SOLID FIRE – By Water. LIQUID FIRE – Foam, CO2, Dry Chemical Powder, Halon. GAS FIRE – Isolation of source. METAL FIRE – Special Powder to form layer.

  7. REGULATORY BODIES EXTERNAL • O I S D • C C O E • FACTORIES INSPECTORATE • POLLUTION CONTROL BOARD • LABOUR INSPECTORATE • ELECTRICAL SAFETY AUDIT INTERNAL • MDSA • SHE • FIRE & SAFETY

  8. OISD • Because of various collaborative agreements, a variety of international codes, standards and practices have been in vogue. • Serious accidents that occurred in the recent past in India eg. Bhopal Gas Tragedy emphasised the need for the industry to review the existing state of art in designing, operating and maintaining oil and gas installations. • The Ministry of Petroleum and Natural Gas constituted a Safety Council assisted by theOil Industry Safety Directorate (OISD) in 1986 • Formulation of self regulatory measures, standardising and upgrading the existing standards

  9. WORK PERMIT SYSTEM • COLD WORK PERMIT • HOT WORK PERMIT • ELECTRICAL WORK PERMIT • EXCAVATION PERMIT PRE – COMMISSIONING SAFETY AUDIT

  10. FIRE FIGHTING SYSTEM • FIRE WATER STORAGE TANKS • FIRE WATER PUMPS • F.W. LINES, HYDRANTS, MONITORS • F.W. SPRINKLERS • FOAM DISPENSING FACILITIES • CO2 / DCP EXTINGUISHERS

  11. FIRE WATER STORAGE TANKS • Type of Storage Tanks • MS Tank • RCC Tank • Adequate Water storage capacity • Healthiness of storage tanks • Source of water & reliability

  12. FIRE WATER PUMPS • Pumping capacity - as per OISD -144 (50% of standby capacity) • Jockey pump should be on auto. (LPG plants) • 50% of fire water pumps on DG sets. • Fire water pump operation records. • Checking operational health. • Maintenance facilities / arrangements

  13. F. W. LINES, HYDRANTS, MONITORS • Maintenance of Fire water header pressure in LPG plants / Terminals. • Fire water header system connected at both ends. • Checking of supports, condition of piping etc. • Checking of operability of valves. • Approach to fire hydrants /monitors • Location / operability • Vegetation • Obstruction by pipelines • Drains / pits in vicinity

  14. F. W. SPRINKLERS • Cooling. • Coverage area. • Water consumption. • Sprinklers used. • Functioning of sprinklers. • Supporting of sprinkler lines. • Location of sprinklers.

  15. OTHER EQUIPMENTS • Adequacy of fire fighting equipments. • Adequacy of PPE. • Specifications of Extinguishers. • Foam storage tanks and allied facilities. • Foam trolleys. • Fire Hoses.

  16. TYPE OF FOAMS CHEMICAL FOAM: • When two or more chemicals are added, foam is generated due to chemical reaction. • Common ingredients used are sodium bicarbonate and aluminium sulphate with stabilizer. • Used in Fire extinguishers. MECHANICAL FOAM: • Produced by mechanically mixing water / air to foam concentrate. • Various types of foam concentrates used for generating foam.

  17. MECHANICAL FOAM COMPOUNDS • LOW EXPANSION FOAM: 5:1 to 15:1 • PROTEIN BASE FOAM • FLUORO PROTEIN FOAM • AQUEOUS FILM FORMING FOAM (AFFF) • FILM FORMING FLOURO PROTEIN (FFFP) • MEDIUM EXPANSION FOAM: 51:1 to 500:1 • SYNTHETIC FOAM CONCENTRATE • HIGH EXPANSION FOAM: 501:1 to 1500:1 • SYNTHETIC FOAM CONCENTRATE

  18. FIRE FIGHTING-GENERAL • Communication system (VHF Sets, internal phones, etc.). • Automation in fire fighting system. • Display of important phone numbers. • Emergency exit to be free for vehicular movement. • Mutual agreement with neighbouring companies. • Location of wind socks.

  19. FIRE FIGHTING-GENERAL • History of fires - recommendations - implementation. • MDSA recommendations and implementation. • OISD recommendations and implementation. • Actions to be taken in case of fire. • Automatic Fire Extinguishing System with CO2. • Discussions with personnel to judge their competence.

  20. SIREN SYSTEM

  21. FIRE DRILLS • Periodic Fire drills. • Conducting Mock Fire drill • Response time. • Clarity of role. • Tools and tackles brought to site. • Time taken to connect hoses, nozzles etc. • Time taken to start the fire pump. • Pressure at the farthest point.

  22. PRODUCT TANKS • NRV on floating roof. • Emergency nozzle/ drains on floating roof. • Roof water drain valves. • Gap between floating roof and shell. • Water sprinkler system. • Tank inspection. • Dyke wall height. • Dyke wall volume. • Inter distances between tanks. • Earthing of shell and rolling ladder. • Foam dam.

  23. LPG BULLETS / SPHERES / UNLOADING/ LOADING • Safety Valves. • ROVs. • Sprinkler system. • Water drains with double isolation valves. • Inter locking of earthing system and LPG unloading / loading system.

  24. LPG CONTROLS – GMS • Effective working of GMS. • Testing of sensors on random basis. • Provision of UPS for GMS. • Displaying GMS alarming system at security cabin. • Hourly recording of the output of sensors. • AMC for GMS. • Location of GMS sensors.

  25. LPG CONTROLS – Evacuation System • Inter locking of evacuation system with LPG carousel. • Flexible connections at ID fan.

  26. ELECTRICAL SAFETY • Separate earthing for lightening arrestors. • Insulation from other structures. • Location of 2 pole/ 4 pole structure. • Earthing system. • Earth Resistance values in LPG /depot. • Maintaining Earth pit values. • Adequacy of lighting system: • watch towers. • walk way around boundary wall.

  27. ELECTRICAL SAFETY • Electrical Audit recommendations and implementation. • Location of Lightening arrestor. • Flame proof electrical fittings. • Static Electricity. • Exhaust of DG sets. • Diesel should be stored away from the DG sets.

  28. SAFETY- GENERAL • Usage of cell phones • Approach towards safety: • persons • records • priorities.

  29. STATIC ELECTRICITY • WHAT IS STATIC ELECTRICITY ? • Static Electricity is a phenomenon of electrification of materials through physical contact and separation and the various effects that result from the positive and negative charges so formed. • In general, static electricity results form removal of electrons from the atoms of one material (leaving it with positive charge) and absorption of these electrons on the second material (negative charge) during physical separation of the two materials.

  30. Charged Conductor Uncharged Conductor Start Induced Opposite Bound Charge Induced Like Free Charge Insert Charged Ball Opposite Bound Charge Remains Like Charge Removed by Ground Temporary Ground Ground Free Opposite Charge Original Charge Distant Ground Voltage Remove Ball

  31. STATIC ELECTRICITY SPECIFIC GUIDELINES FOR CONTROL OF STATIC ELECTRICITY • Storage Tanks : • Ensure earthing of tanks • Ensure no metal objects/appurtenances projecting from roof/shell plates which will attract highly charged spots in fuel for dissipation. • Ensure reduced rate of flow initially into tank/vessel until fill point/nozzle is completely submerged in fluid (filling rate initially restricted to 1 mtr. per second).

  32. STATIC ELECTRICITY • Storage Tanks : • Ensure that all tanks are provided with Dip pipes extending to tank bottom. If Dip pipes are not provided, give a relaxation time of 30 minutes before sampling/gauging. • Ensure nylon rope/cord is not used for sampling /gauging which is to be lowered into product tanks.

  33. STATIC ELECTRICITY • Loading/unloading operations in Tank Wagon Gantries : • Ensure proper earthing of gantry structure. • Ensure tank wagons are electrically bonded to gantry structure. • Ensure that the tank cars are fully bonded with the chassis for electrical continuity.

  34. STATIC ELECTRICITY • Loading/unloading operations in Tank Wagon Gantries : • Ensure use of continuous electrically bonded decanting hoses. • Ensure rails on which tank wagons stand are effectively earthed. • Ensure rail siding is insulated/ isolated from main running track. • Ensure electrical bonding of wagon with under carriage for electrical continuity.

  35. STATIC ELECTRICITY • Loading/Unloading Operations In Tank truck Gantries : • Ensure use of electrically continuous hoses having jumper wire between flanges coiled around hose. • Ensure proper earthing and bonding of tank truck.

  36. Earthing : Earthing is the provision of a safe path of electrical current to ground, in order to protect structures, plant and equipment from the effects of stray electrical current, and electrostatics discharge.

  37. THANK YOU

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