Gujarat Refinery — Where Growth is Essence of

Gujarat Refinery - Where Growth is Essence of Life 1

1 Brief Introduction to IOCL, Gujarat Refinery 2 Systems in Place 3 ERDMP Exercise 4 Challenges & Suggestions Gujarat Refinery - Where Growth is Essence of Life 2

(Figures in Million Metric Ton/Annum) Panipat 15. 0 Mathura 8. 0 Koyali 13. 7 Digboi 0. 65 BGR 2. 35 Barauni 6. 0 Guwahati 1. 0 Haldia 7. 5 Installed Capacity: Paradip 15. 0 CPCL/ CBCU 10. 5 54. 2 MMTPA Subsidaries: 11. 5 MMTPA Total Capacity as on 01. 04. 2012: 65. 7 MMTPA Under Construction Refinery: 15. 0 MMTPA Gujarat Refinery - Where Growth is Essence of Life 3

PANDIT JAWAHARLAL NEHRU LAYING FOUNDATION STONE OF GUJARAT REFINERY ON 10 TH MAY 1963 WORK IN PROGRESS FIRST GENERAL MANAGER OF GUJARAT REFINERY MAJ. GEN. SHARDANAND SINGH PRESENTING MODEL OF GUJARAT REFINERY TO PRESIDENT DR. S. RADHAKRISHNAN PM ADDRESSING GATHERING AFTER LAYING FOUNDATION STONE • Foundation stone laid on 10 th May 1963 • Commissioned in October 1965 with 2. 0 MMTPA • Current Refining capacity upgraded to 13. 7 MMTPA in 1999 Gujarat Refinery - Where Growth is Essence of Life 4

4. 3 MMTPA Capacity expansion is under final approval YEAR Gujarat Refinery - Where Growth is Essence of Life 5

RIL PF B LA GUJARAT REFINERY A MOTHER INDUSTRY NIRMA EN M BITU TOLUENE S H LS GNFC HUL, SILVASA FS LABFS CRMB, IOCL RC FS PP B IOBL SULPHUR GSFC FG H VEG. OIL INDUSTRY CHEMICAL INDUSTRIES Gujarat Refinery - Where Growth is Essence of Life 6

Product LABFS Gujarat Refinery Location NIRMA FGH Rajasthan, MP, Gujarat PFRCB Taloja (Mumbai), Chennai Reformate Guwahati (for blending) ATF Delhi, Hyderabad, Bangalore LSHS Punjab, Mumbai, Bangalore Gujarat Refinery - Where Growth is Essence of Life 7

Indian Railways TATA Power Gujarat National fertilizers Ltd. Gujarat State Electricity Corp. Ltd. National Fertilizers Limited IPCL Reliance Nirma Industries National Alumiunium Company Ltd. National Highway Authority of India Hindalco Hindustan Unilever Limited Common public Gujarat Refinery - Where Growth is Essence of Life 8

ED(I/C) ED(T) DGM (MNI/C) GM(P&U) DGM (TSI/C) GM (F) DGM (PJI/C) Gujarat Refinery - Where Growth is Essence of Life GM (HSE) 9

GACL To Ahmedabad RIL To Mumbai GSFC Gujarat Refinery VADODARA Railway Station Gujarat Refinery - Where Growth is Essence of Life 10

GR PLOT PLAN Gujarat Refinery - Where Growth is Essence of Life 11

TANKS Coker unit VGO-HDT unit , MEROX Units under RUP Crude Tanks TANKS Crude Tanks MODEL UNIT FCC TANKS AU 3 TANKS MTBE/FGH UDEX FLARE SRU MSQU GRE H 2 -III/ DHDT L A B AU-5 Tanks SRU Green Belt PROD TANKS AUII AU-I C R U DHDS/H 2 -II GHC/ H 2 -I GHC STORES 2 nd Fire Station 3 rd Green Belt NEW GT TPS TRG LPG Tech. Bld Main Fire Station 500 M WIDE GREEN BELT CGP Refinery Main Gate To Township To Koyali PROD TANKS TANKS CETP PROD TANKS K A P L Gantry Crude Tanks TANKS Calico Land For Coke yard KAPL NORTH PROD TANKS SMPL BITUMEN PROD FILLING TANK S PLANT Admin Building To Bajwa Gujarat Refinery - Where Growth is Essence of Life 12

DESCRIPTION AREA IN ACRES Plant Area including MKT & PPL 859 Ecological Park + 3 Nos. Green belt area 148 Others (Town ship, CISF, Parks, etc. ) 258 Total 1265 Gujarat Refinery - Where Growth is Essence of Life 13

SYSTEMS IN PLACE Gujarat Refinery - Where Growth is Essence of Life 14

Sr Description Certifying Agency Year Implemented 1 ISO 9001 DNV 1995 2 ISO-14001 DNV 1997 3 OHSAS-18001 DNV 1999 4 5 -Star rating British Safety Council BSC 2002 5 ISRS Level-9 DNV 2003 IOCL 2009 BV 2011 6 7 ISMS (Study by M/s. Du. Pont in 2006) ISO 14064 Verification Green House Gas Emission Gujarat Refinery - Where Growth is Essence of Life 15

Indianoil Safety Management System (ISMS) Sr Description Year Implemented 1 ISMS-1001 Work at Height 2009 2 ISMS-1007 Scaffold Safety 2009 3 ISMS-1003 Safety during Excavation Work 2009 4 ISMS-1012 Start up Clearance 2009 5 ISMS-1011 Management Of Change 2009 6 ISMS-1002 Confined Space Entry 2010 7 ISMS-1004 - Hot Work 2010 8 ISMS-1006 Work Permit System 2010 9 ISMS-1013 Storage & Handling of Chemicals 2010 10 ISMS-1005 Energy Isolation (Electrical) 2011 Gujarat Refinery - Where Growth is Essence of Life 16

Disaster Management Plan MAIN POINTS Updated : August 2011 • CLASSIFICATION OF EMERGENCIES & BRIEF DESCRIPTION OF REFINERY • ON SITE DISASTER MANAGEMENT PLAN • PROCEDURE FOR ACTIVATION OF THE EMERGENCY PLAN • ROLES & RESPONSIBILITIES OF DISASTER COORDINATORS • STATUTORY STIPULATIONS • HAZARD IDENTIFICATION & SCENARIO SELECTION • BOMB THREAT CONTINGENCY PLAN • RESPONSE • TRAINING / SIMULATION EXCERCISE • RESOURCES TO CONTROL EMERGENCY Gujarat Refinery - Where Growth is Essence of Life 17

EMERGENCY PREPAREDNESS Fire Monitors at fire site On-site Disaster Drill during night Fire Drills : Once in a Month On-site Disaster Drill : Once in three months Off-site Disaster Drill: Once in a year Debriefing Sessions after mock drills Gujarat Refinery - Where Growth is Essence of Life 18

CREDIBLE SCENARIOS • LPG leakage followed by unconfined vapor cloud explosion and fire in LPG area • CO Gas leakage from FCC unit Regenerator • Oil Spillage from largest storage tank followed by vapour cloud explosion / fire • Hydrogen Sulphide gas leakage • Water flooding Scenario • Double Fire Contingency Gujarat Refinery - Where Growth is Essence of Life 19

Details of Emergency Response Disaster Management Plan (ERDMP) Mock Drill Dt. 25. 08. 2012 for Accreditation by DMI, Bhopal Gujarat Refinery - Where Growth is Essence of Life 20

Details of Mock Drill • Mock drill conducted on 25 th Aug 2012 at 3. 00 PM • Witnessed by personnel from – DMI, Bhopal – District Administration • Second IOCL Refinery after Mathura Refinery Gujarat Refinery - Where Growth is Essence of Life 21

OBJECTIVES OF DRILL • Petroleum & Natural Gas Regulatory Board (PNGRB) constituted codes of practices for Emergency Response and Disaster Management Plan (ERDMP) regulations 2010. • To fulfill the requirements of the regulation, ERDMP of Gujarat refinery to be verified by third party {i. e. M/s DMI (Disaster Management Institute) Bhopal}. Gujarat Refinery - Where Growth is Essence of Life 22

SELECTION OF SCENARIO • SCENARIO: H 2 S gas leak in SRU-III due to failure of Pressure Transmitter (PT) tapping point (3” dia. ) on feed line (30” dia. ) to Acid Gas KOD at SRU-III battery limit line located at 18 m from ground level. • WHY THIS SCENARIO: – As per Comprehensive Risk Analysis Report, H 2 S gas leak has emerged as the only scenario falling under Offsite emergency for Gujarat Refinery. – Considering the nearest source of release of H 2 S from plant boundary is from SRU 3 block and that is at a distance of about 130 Meters. Gujarat Refinery - Where Growth is Essence of Life 23

H 2 S LEAK SCENARIO DRAWING Gujarat Refinery - Where Growth is Essence of Life 24

REFINERY PLOT PLAN SRU III Gujarat Refinery - Where Growth is Essence of Life 25

SRU III PLOT PLAN LOCATION OF LEAK IN SRU III Gujarat Refinery - Where Growth is Essence of Life 26

LOCATION OF LEAK AND H 2 S DETECTOR LOCATION OF LEAK IN SRU III H 2 S HOOTER AND Gujarat Refinery - Where Growth is Essence of Life DETECTOR BEACON 27

RISK CONTOUR DIAGRAM Gujarat Refinery - Where Growth is Essence of Life 28

ROLE DEFINITION • PN Department: Ø Operational actions required to arrest the leak Ø Evacuation measures • F&S Department: Ø Role briefing and training. Ø Incident assessment, Area evacuation and Siren. Ø Respiratory protection, Rescue operation, Area cordoning-off Ø Water curtain – Up-wind & Down-wind side • Medical Department: Ø Placement of ambulance inside & outside Refinery premises Ø Mobilization of Doctors & Paramedical staff Ø Site medical camp Gujarat Refinery - Where Growth is Essence of Life 29

ROLE DEFINITION(Cont’d) • HR Department: Ø Coordination / communication with District Administration Ø Communication to Sarpanch of local villages (Koyali) Ø Announcement through PA System in neighbourhood Ø Relief / rehabilitation measures • CISF: Ø Gate management Ø Contract workers – Assembly ØSecurity outside Refinery premises COMPLIANCE TO ROLE DEFINITION OF DMP Gujarat Refinery - Where Growth is Essence of Life 30

Minute to Minute Activity Plan for Mock Drill TIME 3. 00 PM ACTIVITY Hooter goes off at SRU III (Tag No. 2111 -XA-005). High level alarm is noticed in the H 2 S detectors in the vicinity. RESPONSIBILITY MN (INST) to force the hooter. Panel Officer - SRU III 3. 01 PM Panel Officer informs shift-in-charge & instructs field operator to investigate after wearing gas mask & personal H 2 S monitor. Panel Officer - SRU III 3. 05 PM Field operator reports leak from Pressure tapping on Acid gas line at about 18 M level near battery area (Tag No. 2111 -PT-2001) and breaks the glass. Field operator – SRU III 3. 07 PM Shutdown action taken by PN and initiation of depressurization of system. PNM – SRU III 3. 10 PM Shift-in-charge, CPNM & DGM (PN) arrive at site and after assessing the situation calls for sounding the major fire siren. DGM (PN) 3. 15 PM Evacuation calls from Assembly point # 9 & # 11 SMNM (KKM) SPUM (NRC) 3. 15 PM Search operation starts. (4 casualties – unconscious state) F&S DGM (PN) requests ED (T)’s permission for declaration DGM (PN) Gujarat Refinery - Where Growth is Essence of Life of Disaster and seeking mutual aid. 31

Minute to Minute Activity Plan for Mock Drill TIME ACTIVITY RESPONSIBILITY 3. 15 PM 3. 25 PM Disaster siren is sounded. All personnel will report to DCR / Site 3. 25 PM PNM – SRU receives information from Panel Officer that H 2 S is high at ONGC terminal. PNM informs the same to DGM (PN) Panel Officer, PNM, DGM (PN) 3. 27 PM DGM (PN) informs DCR & ED (T) regarding apprehension that gas may move outside the boundary wall and requests monitoring at ONGC terminal. DGM (PN) 3. 28 PM GM (HSE) informs ED (T) for declaration of Offsite disaster. After taking permission, he informs District authorities. DGM (PN) informs F&S about offsite disaster and take action of sending offsite crew. GM (HSE) 3. 33 PM Offsite team comprising Fire tender, ambulance, jeep with loudspeaker, CISF, Police and other Security personnel reach the road near ONGC terminal F&S Medical HR 3. 35 PM Evacuation call received from ONGC terminal F&S member 3. 45 PM Completion of depressurization. PNM – SRU III 3. 50 PM All clear at Site by DGM (PN) and from offsite by DCR DGM (PN) & F&S 3. 55 PM Sounding of all clear siren. F&S 4. 10 PM Debriefing at ED Conference Room DGM (PN) & CMFS Gujarat Refinery - Where Growth is Essence of Life & Coordinators All Observers 32

GLIMPSES OF ERDMP MOCK DRILL Gujarat Refinery - Where Growth is Essence of Life 33

Gujarat Refinery - Where Growth is Essence of Life 34

Gujarat Refinery - Where Growth is Essence of Life 35

CHALLENGES IN DEVELOPMENT OF ERDMP Gujarat Refinery - Where Growth is Essence of Life 36

BRIEF of Disaster Management Plan • ERDMP of Gujarat Refinery has been revised as per PNGRB guidelines issued in 2010. • ERDMP of Gujarat Refinery is in two parts - first part is Onsite and second part is Off-site Emergency Plan. • The probable scenarios identified after detailed study of past incidents. • Outcome of Comprehensive Risk Analysis study by EIL. • The ERDMP is dynamic in nature & updated every year to address all the changes in the organizational structure and/or to incorporate the major changes. Gujarat Refinery - Where Growth is Essence of Life 37

Content of Regulation & Its Application in ERDMP Preparation 1. Classification of emergencies 2. Implementation schedule 3. Statutory requirements 4. Pre-emergency planning 5. Emergency mitigation measures 6. Emergency preparedness measures 7. Emergency response procedures and measures 8. Emergency organization and responsibilities 9. Infrastructure requirements 10. Declaration of on-site and off-site emergency Gujarat Refinery - Where Growth is Essence of Life 38

Content of Regulation & Its Application in ERDMP Preparation 11. 12. 13. 14. 15. 16. 17. 18. Resources for controlling emergency Demographic information Medical facilities Evacuation Public relations and information to public Reporting of the incident Emergency recovery procedures ERDMP for tank trucks and pipelines carrying petroleum products 19. Integration of the ERDMP with National Disaster Management Authority (NDMA) guidelines and action plan on Chemical Disasters (Industrial) 20. Security threat plan and action plan to meet the eventualities. Gujarat Refinery - Where Growth is Essence of Life 39

OUR SUGGESTIONS 1. Validity of the third party certification of ERDMP should be specified in the Regulation. (Atleast 3 years validity). 2. There should be different ERDMP regulation for different Industries and for different functional divisions like Refinery, Pipeline, Marketing etc. 3. ERDMP format is different as per State Authorities. 4. Proximity to city entails a greater role of State Administration thereby curtailing the role of main Industry during Offsites emergency. Gujarat Refinery - Where Growth is Essence of Life 40

DISCUSSION Gujarat Refinery - Where Growth is Essence of Life 41

Gujarat Refinery - Where Growth is Essence of Life 42