OISD Newsletter

Hirak Dutta with MD, Toyo at CCPS Conference, Mumbai

JIC Meeting Fare Thee Well

Major OISD activities during April-June, 2012 External & Surprise Safety Audits (ESA): Pledge taking JIC Meeting ISO Awareness Program Oil Industry Safety Directorate IOCL lqj{kk loksZifj • Haldia-Barauni crude pipeline during 9th-13th April, 2012 • POL terminal, Cherlapalli- during 13th-15th June, 2012. • LPG bottling plant Kandla during 19th-22nd June, GAIL 2012 • Gandhar gas processing plant during 13th - 15th June, 2012. ONGC • Offshore (chartered hired) drilling rigs M.G. Hume and ADANI D.S. Mat drill located in East Coast during 8th-11th ED-OISD at Exida/Chola Conference, Mumbai ED-OISD at HPCL, Pune • SPM & Onshore/offshore facility at Mundra during April, 2012. th th 24 -26 May, 2012. • 8 Nos. onshore installations and drilling rigs under Mehsana asset of ONGC during 16th-20th April, 2012. • 4 Production installations at Rajahmundry Asset during BPCL 25th -27th April, 2012. • POL terminal, Bijwasan, Delhi during 26th-29th June, • Production installation, three drilling rigs & two work 2012. Oil Industry Safety Directorate over rigs of Tripura asset of onshore during 30th April lqj{kk loksZifj th – 4 May, 2012. Cairn India OIL INDUSTRY SAFETY DIRECTORATE OIL • Production installation (onshore) & SPM, unmanned Ministry of Petroleum & Natural Gas, • Duliajan onshore asset (4 production installations, 2 platform (offshore) at Ravva field (Andhra Pradesh) st th 8th Floor, OIDB Bhawan, Plot No 2, Sector-73, Noida, Uttar Pradesh-201301, (STD Code : 0120, Fax No. 2593802 & 2593858 work over rigs and 2 drilling rigs) during 21 -25 during 23rd – 24th April, 2012. Web site www.oisd.gov.in) May, 2012. Opinions expressed by the authors are there personal and do not necessarily represent or convey the organisation's point of view. 02 03

Consent to Operate accorded:

ONGC Proliferation of Safety Management • Operation accorded to offshore production platforms nd Issues: GS-15-1 & GS-15-4 on 2 April, 2012 • Operation accorded to offshore rig Aban-II on • ED-OISD delivered Inaugural address on “Safety Pre-commissioning Audit (PCSA): 13th April, 2012. Issues in HC Sector” at 3rd Asia Pacific Summit at • Operation accorded to Offshore (Mumbai) drill ship Mumbai on 17th May, 2012, organised by Centre for th Energy Driller on 16 April, 2012. Chemical Process Safety (CCPS), USA. IOCL • Operation accorded to offshore (Mumbai), MODU (drill • LPG Bottling plant at Muzaffarpur (Bihar) during th • ED-OISD delivered inaugural address on “Process th th ship) 'Noble Duchess' on 26 April, 2012. 26 -27 April, 2012. • Operation accorded offshore drilling rig Badrinath on Safety Management” in a seminar organised by Chola th • Viramgam pump station of VKPL crude pipeline during 1st May, 2012. MS & Exida Singapore at Mumbai on 7 June, 2012. 6th -7th June, 2012. • Operation accorded to offshore Jack up drilling rig • ED-OISD delivered Key note address in a seminar on • Sulphur Solidification, Handling, Storage and Dispatch Unit (SSHDU) CE Thornton on 15th May, 2012. of Panipat Refinery on 9th June, 2012 “Hazardous Waste, Battery Waste & E-waste • Operation accorded to HOEC's Jack-up rig th Management” on 11 June, 2012 at IIT, Roorkee. Perro Negro-III on 8th June, 2012. HPCL • Operation accorded to Jack-up rig Aban-VII of • ED-OISD addressed and presented “Case Studies on th • White Oil terminal at Vishakhapatnam during 9th-11th May, 2012. Adani-Welspun Exploration Ltd. On 19 June, 2012 Safety Management” for officers of HSE &Operations • Hazira LPG bottling plant during 6th-8th June, 2012. group of HPCL at Management Development Institute, • Additional TLF gantry at POL terminal, Raipur on 16th June, 2012. Meetings: Nigdi, Pune. CMD, Director (F) and other senior • Standing Committee on Petroleum& Natural Gas executives of HPCL attend the HSE meet. reviewed status on implementation of MB Lal GAIL rd • Bawana-Nangal NG pipeline (18” dia., 80 Km) second time during Committee recommendations on 3 April, 2012. 7th-8th June, 2012. • Functional Committee meeting on Draft OISD-STD- Others : 244 held on 19th -20th April, 2012. • Joint Implementation Committee (JIC) held at Mumbai • HMEL’s Bhatinda Refinery dedicated to the Nation by th th th Hon’ble Prime Minister of Indian on 28 April, 2012. Surprise Safety Checks (SSC) Audit: on 4 -5 May, 2012. • Functional Committee meeting on OISD-STD-194 • M/s Bureau VERITAS and DNV made presentations on “Standard for storage and handling of LNG” held on issues pertaining to fit-for-use certifications accorded 24th -25th May, 2012 at OISD office. IOCL th to upstream oil companies. OISD raised concerns th th • 17 National Oil Spill Disaster Contingency Plan • CPCL Manali Refinery during 11 -12 April, 2012. th regarding issuing “Fit for Use” certificate for offshore th th (NOSDCP) meeting with Coast Guard on 12 June, • LPG installation at Budge Budge during 25 -26 May, 2012. installations particularly in light of assumptions made 2012. • Joint Implementation Committee (JIC) meeting at for the RBI study carried out by the certification BPCL Mumbai on 14th -15th June, 2012. agencies. nd • POL terminal at Patna (Bihar) on 5th May, 2012. • 29th Safety Council meeting held on 22 June, 2012 • World Environment Day (WED-2012) was celebrated • POL depot at Budge Budge during 22nd -23rd May, 2012. which was chaired by Secretary, P&NG. The plan of at OISD, Noida on 5th June, 2012. Besides Tree OISD activities for the year 2012-13 and amendment plantation, release of WED booklet, slogan/essay of OISD-STD- 116 and 117 and five other Standards competition special talk was delivered by eminent Refineries & Gas Processing Plants have been approved. speaker Dr. Muzzafar Ahmad, Member-NDMA. • GAIL’s Petrochemical Complex, Pata during 4th-5th May, 2012. Training/Seminar: GAIL • M/s RAGASCO made a technical presentation on th th Composite Cylinder for storage of pressurised gases on • Petrochemical Complex, Pata during 4 -5 May, 2012. th 15 May, 2012. • Discussion held with M/s DuPont on use of gas based fire extinguishing media on 18th May, 2012. • Awareness program on ISO-9001 for OISD employees held on 30th June, 2012 by TQMI. 04 05

EDITORIAL OIL INDUSTRY SAFETY AWARDS CEREMONY

Bill Gates insisted that CEOs and senior management group of enterprises must make a habit of listening to the bad In a glittering function organised by Oil Industry Safety Directorate, the Oil Industry Safety news. He went a step further and articulated that CEOs have to create an appetite to accept bad news throughout the organization and reward the bearer of the bad news and not punish them. What prevents us to inculcate this? It may Awards for the year 2009-10 & 2010-11 were presented by the Chief Guests, Shri S. Jaipal not be a sweet music to our ears but surely a bitter pill that would help us to progress. , Hon’ble Union Minister of Petroleum & Natural Gas, Shri R.P.N. Singh, Hon’ble Minister I was purview to the HSE officers’ meet of HPCL at its Management Development Centre at Nigdi, Pune. The meeting of State for Petroleum and Natural Gas and Corporate Affairs, to the award winning Companies. was business-like and professional. CMD, HPCL who participated through the day long business transaction urged the Shri G.C. Chaturvedi, Secretary, Petroleum & Natural Gas presided over the function. Other HSE fraternity of HPCL to create a culture of internal disclosures and sharing bad news. Creating a climate of such dignitaries present during the ceremony included CEOs of awards winning Oil and Gas openness coupled with strict vigil on operation and reliability is pre-requisite not only for safe operation but to gain unmatched competitive and comparative edge. Organisations, Joint Secretary (R), Ministry of Petroleum and Natural Gas, senior On my part, I shared a few live case studies pertaining to the oil industry with the HSE officers of HPCL; highlighted the representatives from entire Oil & Gas Sector and team from OISD. common mistakes, omissions that we commit in our duties that lead to unsafe practices. Re-emphasised the The Oil Industry Safety Awards are given for the recognition of the efforts made by Oil and Gas importance of near miss incidents. Reporting the near misses. Sharing & Documenting. And learning from such rich experiences. Learning not to commit the same mistakes and even learning from mistakes done elsewhere. Industry Organisations in enhancing safety performance of their installations. During the The long awaited 29th Safety Council Meeting was held on June 22, 2012 at the Conference Hall of Ministry of ceremony, safety awards were also presented to the individuals including contract labourers of Petroleum & Natural Gas. The meeting was chaired by Shri GC Chaturvedi, Secretary, MoP&NG, Chairman, Safety the Companies who had made significant contribution in mitigating unsafe situations. The Council and was attended by CEOs of all public sector oil companies both upstream and downstream, Essar Oil Limited, criteria for selection of Oil Safety Awards are based on various parameters like complexity, the Cairn Energy India, DGH, PESO, Senior representatives’ of Ministry, yours truly with team members of OISD & other senior representatives of oil industry. volume, the safety management system including safety performance parameters. Although the safety council met after one and a half year but there were regular review meetings in between on safety The programme started with the Lighting of Lamp by the Hon’ble Ministers, Secretary, of oil installations, implementation status of OISD 116 & 117 and MB Lal committee recommendations with CEOs of the Petroleum & Natural Gas, JS (R) and ED, OISD. This was followed by invocation of Saraswati oil companies. The Joint Implementation Committee also held its regular monthly review meetings and took stock on the progress of implementation including recommending measures for enhancing safety. Vandana. The highlights of the programme included administering of “Safety Pledge” by Safety council accorded approval to amendment of seven existing standards including re-amendment of OISD Hon’ble Union Minister of Petroleum and Natural Gas, Shri S. . standard 116 & 117. Besides, other key issues viz. in-depth analyses on various incidents & accidents that took place in Shri S. Jaipal Reddy in his speech while congratulating the award winners mentioned that the oil industry and major OISDs external and surprise safety audit recommendations were deliberated at length. The leaders of the oil industry took note that majority of accidents in FY 2010-11 & 2011-12 were due to dis-regard to the safety of Oil & Gas Installations is of paramount importance and that nothing is as important as extant system & procedures coupled with lack of supervision. The consensus decision of the house was the need to safety and nothing is more difficult than maintaining safety in this inherently highly tighten the belt with renewed thrust on learning. inflammable Oil and Gas Industry. Hon’ble Ministers advised that these being highly hazardous We celebrated the World Environment Day on 5th June at OISD. Besides taking pledge, tree plantation, release of a on account of inherent associated risks, extreme physical conditions Organisation must adopt booklet commemorating the occasion with special message from Secretary, MoP&NG, lecture session was organised on Green Initiatives. Dr. Muzzafar Ahmed, Member, NDMA and Heads of OIDB, CHT, ISPRL, DGH best practices to ensure that no unsafe situation take place in this vital sector which provides graced the occasion. We also organised essay and slogan writing competition amongst our employees. energy security to the country. He articulated that safety practices including good operations I had the opportunity to address at 3rd Asia-Pacific CCPS conference organised by Toyo & CCPS, USA on and maintenance practices ensure steady flow of Oil and Gas that maintains the wheels of th th 17 May, 2012; Seminar on LOPA & SIL organised by Chola MS & Exida on 7 June, 2012 at Mumbai. prosperity of the country. Besides sharing the broad perspectives on safety issues, the layers of protection, some of the good practices to enhance safety, the conference provided me an opportunity to interact with large number of line managers and HSE professional besides experts from Exida, Singapore and CCPS, USA. Addressing a group of 35 lecturers, associate professors, professors from various academic institutes at IIT, Roorke on 10th June, 2012 was indeed a learning process and rewarding. Heat waves are abetting; monsoon is setting in. I am sure pre-monsoon jobs at all our oil installations have been completed. Refineries and other installations’ are geared up for rain water harvesting. Availability of water would be scarce; similarly many other resources. dge Ple Therefore, let’s recycle, reuse and retreat for survival. fety Sa the ing Looking forward for your valuable comments and suggestions!! Tak

Hirak Dutta Award handed over to Shri Gurmail Singh POL Lorry Driver, HPCL, Bhatinda By Hon’ble Union Minister of Petroleum and Natural Gas, Shri S. Jaipal Reddy 06 07 SAFETY ALERTS Shri R.P.N. Singh, Minister for State, Petroleum & Natural Gas and Corporate Affairs mentioned that preventive Accident while cleaning an acid gas knock-out vessel in a Refinery measures should be in place on a sustained basis to eliminate untoward incidents in the Oil and Gas Sector. He -YP Gulati, JD,OISD emphasis that safety must be considered as a core activity in the organisation. Shri R.P.N. Singh congratulated the Oil

& Gas Industry Organisations for the good work that has been done in the field of operations, reliability and process A. INTRODUCTION: C. SOME CRITICAL OBSERVATIONS safety. A fatal incident occurred at one of the Refinery on 23rd Original bottom drain of the vessel being cleaned had Shri G.C. Chaturvedi, Secretary, Petroleum & Natural Gas during his address articulated that the modern best practices July 2012 at around 1635 Hrs. During the incident a got completely plugged during normal operations of the for safety system design, implementation, enhancement and upkeep must be applied so that design and engineering contract employee died while carrying out hydro jetting plant. For draining the vessel, an alternate nozzle (N5) job of an acid gas knock out vessel in Sulphur Recovery which is at about 0.6 meters height from the dish-end of the plant, process control and instrumentation including inbuilt safety features are adequate even if there is an error Unit (SRU-A). As reported in the first information report bottom (See mechanical drawing and other photographs due to human intervention. Shri Chaturvedi mentioned that OISD has developed 111 Standards on operations, (FIR), the deceased person was found to be in of the vessel in following pages) was in use for the last process safety, design and asset integrity which are instrumental in maintaining safe operation. unconscious state at the site of the accident. He was three to four years. Due to choking of the bottom drain immediately shifted to Hospital where he was declared there was hold up of hydrocarbon sludge in this portion Shri L.N. Gupta, Joint Secretary (R) while addressing the leaders of Oil Industry articulated that the reputation of Oil & brought dead at about 1700 Hrs. of the vessel. Gas Companies in the international arena besides others also depend upon accident free man-hours that the B. THE INCIDENT companies have achieved. He articulated that Oil Companies must move towards the objective of achieving nil incidents in their installations. As part of the ongoing shutdown jobs related to SRU unit at the Refinery, it was decided to internally clean the acid Earlier while welcoming the Hon’ble Ministers, dignitaries and leaders of the Oil Industry, Shri Hirak Dutta, ED, OISD gas knock out vessel with hydro jetting using a rigid mentioned that from a petroleum deficit country today the Oil and Gas Sector earns a revenue of US $ 58 billion lance from outside the vessel. The vessel size is around 0.6 Meters Diameter and height around 1.8 Meters. Due through export of petroleum products. The Oilmen in the country relentlessly work 24x7 to maintain steady supply of to constructional features of the vessel (About 20 inch Oil and Gas through out the length and breadth of the country. Congratulating the Oil & Gas Industry regarding the dia opening at the top and demister pad support as various safety measures that have been undertaken which resulted in gradual decline in number of accidents, Shri internal), entry of the personnel inside the vessel is not Dutta mentioned quoting for Robort Frost – “But we have promises to keep, And miles to go before we sleep, And miles possible. In addition to general internal cleaning of the Stagnant Sludge vessel, the prime reason for using the hydro jetting in the vessel to go before we sleep”. process with the provision of a rigid lance of about 1.5 In totality 18 and 8 nos. Oil Industry Safety Awards were presented for the year 2009-10 and 2010-11 respectively. Meters length was to unplug the fully choked bottom drain of the vessel (As shown in photograph) The safety awards were also given to the individual employees and contract workmen for enhancing safety to 11 and 5 individuals for the year 2009-10 and 2010-11 respectively. Shri Gurmail Singh, POL Lorry Driver, HPCL, Bhatinda got The job of vessel cleaning was started at around 14:30 thunderous applause when the individual award was handed over to Shri Singh by Hon’ble Union Minister of Petroleum Hrs. At about 16:35 Hrs production engineer of the plant during his normal field round suspected something and Natural Gas, Shri S. Jaipal Reddy.To commemorate the occasion, a special brochure was released by Hoin’ble wrong and climbed up to the second deck platform from Minister of State for Petroleum & Natural Gas and Corporate Affairs, Shri R.P.N. Singh and a CD containing the OISD where the hydro jetting of the vessel was being carried Standards including the recently amended OISD-STD-116 & 117 was released by Hon’ble Union Minister of Petroleum out. On reaching the incident site he found the contract man in unconscious state with his head leaning into the General Mechanical and Natural Gas Shri S. Jaipal Reddy. Arrangement of vessel. Both the hands of the person were also observed the Vessel to be inside the vessel clutching the rigid lance used for The programme concluded with the “Vote of Thanks” proposed by Shri S.L. Chakravorty, Director (Process & Engg.), ing hydro jetting purpose. The workman was immediately how h s OISD who thanked the Hon’ble Ministers and Secretary for not only being present during occasion but also lauding the rap rushed to the Hospital where he was declared brought tog sel ho ves dead at around 17:00 Hrs. P f the ion o ocat the l

Alternate nozzle (N5) in use for draining the vessel

Original choked drain nozzle (N3) 08 09

the help of high pressure jet streams from the hydro • The modification of drain line from nozzle N3 to N5 jetting machine which might have resulted in sudden execution of the was carried out by the concerned management release of much higher concentration of toxic H2S. job. The job procedure without following the Management of Change • Possibility of release of unacceptable high level adopted lacked adequate process as per OISD 178. P&ID available at site was preparedness to deal with any not updated to depict the change. concentration of toxic H2S release from the stagnant sludge contained within the vessel should have been probable exigency during its • The top manhole cover of the vessel was opened on assessed and suitable precautionary measures execution. 19/07/2012 i.e. four days prior to the incident. 100% should have been identified prior to start of the job. Inadequate training for contract positive isolation of the vessel was not ensured prior For example the person employed for hydro jetting of workmen to opening the top cover of the vessel. One of the the vessel should have been equipped with portable There is no program for proper training of contract blinds on the Safety valve bypass line to flare was H2S detector and other suitable PPEs. He should also missed out (See Photograph). Though, this (Not workmen to educate them about the hazards of working have been briefed about the appropriate instructions in H2S environment. Interview with few contract blinding the bypass line) did not result in any mishap to deal with any emergency while carrying out the (PSV discharge line of the vessel to Flare) workmen during the investigation revealed that they during the vessel opening but such lapses are job. avoidable. Bypass valve not blinded prior to opening the vessel have never been educated about the exposure limits of This aspect assumes all the importance in view of the H2S during the course of their employment. Many of • There is no blinding register maintained for the unit. fact that person carrying out the job was supposed to these contract men are regularly working in SRU for • Though the top manhole cover of the vessel was de-choke the bottom drain of the vessel. To achieve years without any awareness about the hazards opened four days prior to the incident but the this objective (De-choking of drain line at the bottom involved with handling of H2S gas. decanting of the stagnant portion of liquid containing of the vessel) the person might have inserted his neck concentrated oily sludge inside the vessel could not E. RECOMMENDATIONS AND LEARNINGS FROM deep inside the vessel which amounts to entry into a be carried out as the bottom drain of the vessel is THE INCIDENT: confined space. (Please see the attached photograph completely plugged. The vessel drain is still fully wherein the possible posture of the person carrying 1) Work permit system of the Refinery needs to be choked with liquid content visible upto the upper out the job has been made for reconstructing the reviewed and strengthened. drain nozzle even at the time of investigation. event.) 2) Besides streamlining work permit system it must be • It is gathered that there is knowledge gap on the part • From the evidence gathered at the site it is clear that ensured that tool box talk is done for such critical of personnel responsible for the execution of this job the job of hydro jetting of this vessel was started jobs handling H2S. Following items are to be on this count. The aspect that agitation of the oily through verbal instructions to the vendor from the ensured: sludge in the vessel could result in release of higher concerned officials. concentrations of H2S along with hydrocarbon • Positive isolation of the equipment prior to opening vapors above the lower explosive limits (LEL), was • Work permit prepared for the job was not formally the same must be ensured. PSV bypass valve blind P e was not put prior to opening the vessel. rs not visualized. It is pertinent to note here that no gas issued for execution. This is a serious systemic lapse on m test was carried out before as well as during the job of the Refinery work permit system as no job should • Job Safety Analysis for all critical Jobs prior to issue ig h Vessel Opening from was underway. be started without a valid work permit in place. t of the permit must be carried out. For example for h a the top from where cleaning the present job (wherein the equipment handling ve was attempted • H2S is known to dissolve easily in water and oil, and it • Even if one considers that the job was started by the c toxic H2S was involved) all the precautions related ar may be released when these liquids are heated, vendor without being instructed to do so, it is all the ri ed more serious a matter and needs attention of the top to working in a confined space should have been depressurized, or agitated. During the course of the ou t management of the company to review the overall checked prior to the start of the job. h investigation an experiment at the site was y d r performed to demonstrate this aspect. Water was work permit system of the Refinery. • Adequate safeguard systems need to be developed o (P je put inside the vessel through a 2 inch fire water hose h tt D. ROOT CAUSE OF THE INCIDENT and implemented for ensuring that no job in the ot in og g to see the effect of same on the stagnant portion of Refinery is carried out without a valid work permit. ra o p f Inadequate awareness and deficient assessment of h th the oily sludge present inside the vessel. Within two ta e 3) Identification of a comprehensive list of all k v minutes of opening the water inside the vessel, situation Though the vessel top cover was opened four en e o ss days prior to the incident but the bottom portion of the equipment where such types of cleaning activities nl el concentration of H2S was measured with the help of y in are envisaged during normal operations as well as fo vessel was still having significant amount of hydrocarbon r th a portable H2S detector suspended at a height of re e sludge which contained very high concentration level of d u r i n g s h u t d o w n o f t h e u n i t ( s ) . c p about one and a half feet from the top of the on o Maintenance/cleaning procedure specific to the st st dissolved H2S as well. Officials concerned with execution ru u vessel. The concentration of H2S measured was c re equipment should be thoroughly reviewed and tin a found to be 7.5 ppm. This demonstrates that of the job were completely unaware about the fact this g s th d stagnant sludge had the potential to generate H2S learnings from this incident must also be captured in e ep there is still significant concentration of e i the final reviewed procedure(s). ve ct vapours along with unacceptable levels of hydro carbon n ed dissolved H2S in the sludge t) vapours. There was still a large amount of hydrocarbon ab accumulated in the vessel and the 4) All the modifications in the plant should be carried ov sludge in the vessel bottom that got agitated in the e. same gets released when out following MOC procedure as per OISD 178. Drain agitated. It is pertinent to cleaning process resulting in the release of very high line modification of the vessel was done without mention here that agitation concentration of hydrocarbon and H2S vapours leading following the MOC procedure. to the fatality of the workman performing the job. of this sludge on the day 5) Safety competencies of all the personnel including of accident was Inadequate job procedure the contract employees, involved with handling of carried out with While cleaning the vessel the sludge containing H2S handling need to be enhanced by providing hydrocarbons was agitated, this released vapours. No appropriate training at regular intervals. gas test was carried out either prior or during the 10 11

Flash Fire at LPG Tank Truck Loading Gantry • There was a siren and due to breaking of the QB, the sprinkler started automatically in the bulk TT loading gantry. -Rakesh Agarwal & SK Bagchi To control the fire of the tyres, 75 kg DCP was operated and the fire was extinguished within 5 minutes. • Meanwhile the driver of another bulk TT rushed to extend help to the TT driver at bay 5 and managed to remove his cloths that were on fire. In the process, this driver too sustained minor burn injury.

A. Introduction: • The drivers were immediately rushed to thehospital;the driverat bay 5 who sustained about 70% burn injury succumbed to death after 11 days during treatment. There was a flash fire at Tank Truck Loading gantry at one of the Bottling Plants in which the driver of Bulk TT suffered burn injury and subsequently succumbed to the said injuries. Another driver also C. Critical observations: sustained minor burn injuries during the incident. 1) The loading arms deployed at the bulk TT loading bays have quick release couplings which connects via specially made flange attachment with the bulk TTs. As per the design, the coupling has an interlock to prevent liquid flow B. Incident / Sequence of events: out of the arm content even if the said content has not been flared off. In normal circumstances, during decoupling of loading arm, the internal plunger is supposed to go back on the polyurethane seat so as to close the • On the date of incident in the morning shift, 6 nos. of bulk tankers flow of the LPG completely so that decoupling from the tanker flange can take place safely. were taken inside the plant after due physical checking of the tankers and verification of the documents by the Officer assigned 2) All the couplings were procured from M/s Alfa Process Controls, U K. to look after Bulk loading. The tankers were taken for loading 3) The main reason of the LPG leakage (of loading arm content only) was the failure of the said interlock of the operation. Another 6 nos. of tankers were also coupling. It appears that LPG gushed out with high velocity under the operating pressure and the same resulted in physically checked; documents verified for recoil of the loading arm and/or the coupling. Due to this recoil of the loading arm and/or the coupling, it might Flash F arranging the next batch of loading have collided with the adjoining structure resulting in a source of ignition creating the flash fire with the leaking ire at LPG Botting p lant operation. LPG pool creating enough vapour to produce a combustible mixture in the open.

4) The LPG might have also pooled by gravity near the 3) Since the couplings were imported long back at the tyres of the TT and thus with the flash fire the wheels time of commissioning of the plant, availability of of the TT caught fire. quality spare in adequate quantity must be ensured for all such couplings so that timely maintenance work for enhanced reliability and integrity of the D. Root Cause Analysis: said couplings can be undertaken. 1) As per SOP, the loading arm must be depressurized to remove the residual LPG content by cold flaring after 4) As the interlock system of these couplings is the completion of every loading operation. This step of critical feature for mitigation of the risk of leakage of SOP was not followed. liquid LPG in the open, periodic preventive 2) This coupled with the failure of the interlock of the maintenance schedule needs to be drawn in quick release coupling, the armcontent of LPG leaked consultation with the OEM for all such couplings. in open. The consequent recoil of the arm / coupling • The subject bulk TT, in which the caused metal to metal contact with the structure and flash fire took place, was at bay no.5. The created spark that led to flash fire. 5) The bulk TT loading of LPG is a critical activity; the Operator assigned to bulk loading section advised work needs to be supervised by capable technically 3) The operation was done by a driver instead of plant the driver at bay no.5 that the loading operation of the said qualified dedicated officer so that such violation of operator which was a deviation of SOP. bulk TT have been completed and that he has closed the SOP does not recur. manifold valve of the bulk TT as well as the isolation valve of the loading arm. He also instructed the driver to wait there and E. Learnings: proceeded to bay no.2 for some other job. 6) The concerned driver was helped during the fire by 1) The SOP must be followed i.e. the cold flaring of LPG driver of another bulk TT but the helper, the second from the metallic arm before decoupling of the member of the crew of this bulk TT, is conspicuous • Around this time, the driver of the bulk TT at bay no.5 decoupled loading arm from the Tank Truck. by his absence. The SOP must specifically ensure his the loading arm in spite of the absence of the operator when the presence in the vicinity of the bulk TT under loading flash fire took place in which the driver was engulfed and 2) The decoupling operation shall be done by the to lend immediate support in case of such sustained severe burn injury. The rear wheels of the bulk TT also trained manpower assigned for the job. exigencies. caught fire during the incident. 12 13

Fatal incident during lifting operation in E&P

Description: A lifting operation was being conducted on the seabed by a saturation diver using a parachute lift bag. An uncontrolled ascent of the load and lifting bag occurred. The diver's umbilical was entangled in the load and rigging, which pulled him from the seabed at 200 feet to 70 feet from the surface. The diver was rescued back into the diving bell but later died from his injuries.

What caused it: A 12 000 Kg Parachute lifting bag was used for a 6 000 Kg Load, thus prone to easy excess lift due to over inflation of the lifting bag. The use of a hold back line to an anchor point at the seabed, to contain the load should it have excess lift, was identified in the Job hazard analysis but not applied. Applying an invertor line from the top of the lift bag to a secure anchor or weight on the seabed, as protection should the Lift bag break free was done improperly. The invertor line was attached to an anchor that was of insufficient weight and consequently was lifted with the uncontrolled ascent of the lift bag and load. World Corrective actions: 1. The Risk assessment process should have identified that two smaller lifting bags if used, rather than one large one, would enable more control of the lifting force being applied. DAY 2. Use of hold back lines and anchor points of sufficient SWL to secure the load against uncontrolled ascent.

3. Invertor line should be attached securely to an anchor point of sufficient strength to Prize Winning Slogans ensure the lifting bag is secured and inverts should it break free from its rigging. ENGLISH SLOGANS IMCA guidelines on Underwater air lift bags ( IMCA D016 rev 3) should be referred

It is provided for information purpose. This information should be evaluated to determine if it 1st Prize Natural resources are precious,Don’t exploit, be judicious. is applicable in your operations, to avoid reoccurrence of such incidents.

2nd Prize Plant a Tree , Green the earth I Clean the air, Live HAPPILY II

3rd Prize Say no to Pollution, it’s only solution.

HINDI SLOGANS Editorial Board izFke iqjLdkj tu tu ls ;g dguk gS] o`{k /kjrh dk xguk gSA Hirak Dutta, ED-OISD DK Adhikari, Dir (MO)

SL Chakraborty, Dir (P) S Thangaraj, AD (P) f}rh;?????? ? iqjLdkj ???????? iznw"k.k dks gVk;saxs] thou esa [kq'kgkyh yk;saxsA Anup Walia, Dir (E&P) Tarsem Singh, AD (E&P) i;kZoj.k dks u cpk;k x;k] rks oks fnu tYnh gh vk,xkA S Mazumdar, Dir (MO) SK Nandy, AD (PPL) r`rh;???? ? iqjLdkj???????? KC Nandi, AD (MO) tc /kjrh ij gj balku] cl ikuh&ikuh fpyk;xkA 14 15

Sustainable Development Social Angle is the Only Way of Development While conventional Economic development leads to elimination of several traditional occupations, the process of sustainable development leads to creation of new jobs for people with traditional skills alongside conservation of environment. We live in world with a highly lopsided development wherein 20% of population consumes 80% of the world's resources. Development has to be Varun Prakash equitable and inclusive for it to be sustainable.

Economic Angle You have to decide whether development means affluence or whether With increasing purchasing power, wasteful consumption and consumerism is burdening the resource base of developing development means peace, prosperity and happiness. countries like India. It is of paramount importance to counter this through appropriate mechanisms including education, public awareness, incentives and legislation. -Sunderlal Bahuguna Environmental Angle Among others, the formidable challenge faced by us in 21st century is that of water shortage. Specific and specialized agencies to regulate water governance to protect the ecological integrity of natural water bodies and man-made The year 2012 marks 20 years since the UN conference on Environment and Development (UNCED), catchments is need of the hour. popularly known as “Earth Summit” held at Riode-Janeiro, Brazil in 1992, when 108 Heads of State and other international agencies met to discuss the issues around 'Sustainable Development' and arrived at Agenda 21. The world will come together once again at Rio in June, 2012 to take stock of where we are at What is being done? addressing sustainability concerns. There are several examples of development with sustainability across. Kalundborg, an industrial town in Denmark, has established eco-industrial parks with businesses that utilize the by- This term 'Sustainable Development' was coined by 'Brundtland Commission' of UN in 1983 which defined it as that pattern of economic growth that “meets the needs of the present without compromising the products of other manufacturers for example waste generated by a power-station in the park is used for making cement ability of future generations to meet their needs”. This fixes the onus on the present generation to restore by another firm. And other businesses use heat generated by power plant and cement factory for their processes. the ecological damage and also to resist any further damage. Sustainability requires that human activity Business models of such eco-friendly industrial set-ups are the need of the hour. should only use up natures resources at a rate at which nature is capable of replenishing them and Technology has to come in confluence with will of the decision makers of the countries. Excess use of water for irrigation environment should be as pristine as possible. of crops can be avoided by techniques like Drip-irrigation wherein water is allowed to flow on drip slowly and directly into On the contrary, the long-term result of environmental degradation is the inability of our planet to sustain the roots of the plant. human life. There are 3 types of capital in sustainable development – Social, Environmental and Economic Practices like 'green buildings', denoted to efficient use of energy, water resources while simultaneously protecting Capitals. Their healthy interaction can only ensure a development that is inclusive and sustainable. occupant's health and reducing generation of wastes, could answer some of our problems.

Sustainable Development in India India has its own role to be played in the worldwide drive towards sustainable development. India is a party to several multi-lateral environmental agreements like UNFCC, Kyoto Protocol (2002) and Convention on Biological Diversity. Harnessing Wind energy is probably the cleanest form of energy generation. At Jaisalmer, Rajasthan India has installed SOCIAL one of the world's largest wind farm (1064 MW). Also, India has world's 5th largest installed wind capacity. Sustainable Development Conclusion Equitable Bearable After all this the only home of humankind, our planet earth. Human nature is such that it takes time before it can arrive at a resolve. The challenge that lies before us is daunting and formidable. There have been species that have come and gone from this planet because the environmental conditions could not sustain them. But this is probably the first time in the history of the planet that the dominant species knows the exact reason and causes that could probably lead to its doom. Environmental Viable Economic Initiative along with awareness is required by the decision makers and policy makers. Individual on the other hand, needs to realize his share of responsibility towards environmental degradation. 16 17

Safety Council meeting in progress

Interaction with M/s. DNV Officials on ISO implementation at OISD 29th Safety Council Meeting

29th Safety Council meeting was held on 22-06-2012 in the Conference Hall of MoP&NG, New Delhi at 1530 hrs.

The meeting was chaired by Shri G.C. Chaturvedi, Secretary, P&NG and Chairman, Safety Council, and was attended by CEO of both Public & Private Oil Companies, DGH, PESO, FASLI, EIL, Joint Secretary, Ref, MoP&NG and senior members of rsy m|ksx lqj{kk funs'kky; Ministry of Petroleum & Natural Gas, ED-OISD, Member Secretary of Safety Council and other representatives of oil companies & OISD. isVªksfy;e o izkd`frd xSl ea=ky; ds funs'kkuqlkj gekjs dk;kZy; esa fnukad 17-08-2012 dks lnHkkouk During the meeting, various business transactions were deliberated as per the agenda items. The activities undertaken fnol euk;k x;kA bl volj ij gekjs lHkh vf/kdkjh ,oa deZpkjh izkr% 11 cts lHkkd{k esa mifLFkr gq,A by OISD were reviewed by Safety Council Members. It was observed that OISD surpasses its target for most of its loZizFke vfrfjDr funs'kd ¼iz'kklu½ Jh ih-ds-[kqjkuk us tkudkjh nh fd Hkkjr ds iwoZ iz/kkuea=h Lo- Jh activities vis-à-vis the plan. The OISD activities for the year 2012-13 were deliberated and approved by Safety Council. OISD was advised to increase the number of audits for marketing terminals as well as to complete the work related to jktho xka/kh th dk tUeksRlo iwjs jk"Vª esa izfro"kZ 20 vxLr dks ln~Hkkouk fnol ds :i esa euk;k tkrk gSA transfer of PESO job to OISD expeditiously. It was informed that a reputed consultant for undertaking the study would be lnHkkouk dk mÌs'; lHkh /keksZa] Hkk"kkvksa vkSj {ks=ksa ds yksxksa esa jk"Vªh; ,dhdj.k vkSj lkEiznkf;d lkSgknZ dk lined up within 2 months' time. lao/kZu djuk gSA ln~Hkokuk fnol eukus ds ihNs eq[; fopkj fgalk dks lekIr djuk rFkk yksxksa esa ln~Hkkouk

Various OISD standards those were amended following the laid down procedure were placed before the members for dk lao/kZu djuk gS A bl fopkj dks vkxs c<+kus ds fy, izfro"kZ 20 vxLr dks lnHkkouk fnol ds :i esa approval by Safety Council. Safety council approved amendment of five numbers of OISD standards besides re- euk;k tkrk gSA amendment of OISD 116 & 117 that included equivalency clause for rim seal protection system. Safety council members pw¡fd 20 vxLr] 2012 dks jktif=r vodk'k gS blhfy, fnukad 17 vxLr] 2012 dks ln~Hkkouk fnol appreciated the efforts of OISD in releasing the standards at crucial juncture. euk;k x;kA During the meeting, ED, OISD, also shared the statistics and analysis of various accidents that took place in oil industry for bl tkudkjh ds ckn gekjs dk;kZy; ds funs'kd ¼izfØ;k ,oa bath-½ Jh ,l-,y- pØorhZ us lHkh mifLFkr the year 2010-11 and 2011-12 including major observations and recommendations of audits that were undertaken for oil O;fDr;ksa dks fgUnh esa ln~Hkkouk fnol dh izfrKk fnykbZA blds i'pkr~ gekjs dk;kZy; ds v/;{k vFkkZr~ companies. Industry members were advised to liquidate the pending audit recommendations expeditiously and also take dk;Zdkjh funs'kd Jh ghjd nÙkk us lHkh dks vaxzsth esa ln~Hkkouk fnol dh izfrKk fnykbZA appropriate measures to improve upon the safety performances. bl volj ij lHkh vf/kdkfj;ksa o deZpkfj;ksa us ,drk cuk, j[kus vkSj fgalk dk lgkjk fy, fcuk lHkh Secretary, MoP&NG advised all the safety Council and Industry members to work in unison for enhancing safety in oil izdkj ds erHksn ckrphr vkSj laoS/kkfud ek/;eksa ls lqy>kus dh izfrKk yhA installations. The activities undertaken by OISD were appreciated by Secretary, PNG and lauded by the House. 18 19

Hon'ble Minister Shri Jaipal Reddy being welcome Release of special booklet by the dignitaries Safety Award to HPCL Safety Award to IOCL with flowers by Shri Hirak Dutta, ED-OISD

Lighting of Lamp Safety Award to EOL Safety Award to BPCL Safety Award to ONGC

Hon'ble Minister Shri Jaipal Reddy administering the safety pledge Safety Award to MRPL Individual Safety Award Safety Award to