Safety in Oil Movement &

Storage Operations

Reliance Jamnagar

Jamnagar Refinery Overview

Jamnagar Refinery Overview

Tank farm facilities (OM&S)

Jamnagar Refinery Overview

JETTY

RAIL

MTF

RTF

ROAD

UNITS

GAIL PPL

MARINE TANK
FARM

OM&S facilities overview

Security Boat Patrolling Routes Chart-II

SHORE LINK

APPROACH
TRESTLE

ONSHORE PIPELINES

1.4 km

2 km

ZERO POINT
3.6 km

KNUCKLE PLATFORM

BERTH A

BERTH B

BERTH C

BERTH D

LO-LO JETTY

PORT OPERATIONS BUILDING

4.1 km

RISER PLATFORM

SPM-4
22.8 km

28 km

SPM-5

48 PIPELINES
26 km
11.1 km

9.5 km

Anchorage Area

SPM-3
SPM - 2

3.1 km

SPM - 1
5

Introduction
Petroleum Refining Industry handles large quantities of highly
flammable liquids and gases, which are potentially associated
with fire and explosion hazards ..
To support the refining processes all the Products , Crude oil
and Intermediate streams are stored and handled via Oil
Movement & Storage (OM&S) Section.

Due to storage of huge quantum of hydrocarbons, Safety

Management in OM&S operations becomes a very vital
function .

OM&S Mission
Oil Movements & Storage (OM&S) Sector of Reliance, Jamnagar is
committed to seamless integration of their Refining and Petrochemical
business with the entire supply chain by means of ,
Uninterrupted receipt and supply of raw materials,
Storage of intermediate streams / finished products,
Blending optimally to meet product specifications and evacuating the
finished products by appropriate mode as per customer requirements,
Meeting relevant statutory requirements, quality standards and best
industry practices.
While maintaining excellent housekeeping and HSEF standards.
7

Corporate HSE - Objectives

Safety of a person overrides production targets. HSE Policy

Conduct all activities in such a manner as to avoid harm to employees,

contractors and the community.
Promote Occupational Health of its employees and contractors.
Sustainable development by continuously improving its environmental
and practices and performance.
Minimize adverse impact on environment and risks to the community that
arise due to its operations and during transport and distribution of goods.
Utilize energy resources in a responsible and efficient manner so as to
reduce emissions and generation of Effluent and waste products.
Comply will all statutory requirements concerning Health, Safety and
Environment.
Create a culture of learning and practicing Health, Safety and
Environment system, Procedures and practices among its employees and
contractors.
8

OM&S Objectives
HSEF :
Zero Incidents
PSM implementation
Emissions better than statutory regulations

Quality:
Integrated Management System
Minimize Quality deviation and reblending / reprocessing
Ensure Customer delight

Reliability:
24 x 7 Plant and Equipment availability

OM&S Objectives
Process Automation:
APC & Online optimizers implementation
Refinery at desktop
Automate operation management processes

Production:

Production as per EPS plans

Zero Operational upsets
Maximize Plant availability

Productivity:
Optimize specific consumptions.
Continuous improvement in efficiencies
Maintain optimum inventory levels.
10

OM&S Objectives
Energy Management:
Eliminate Energy Wasters
Develop Low energy options in equipment & Processes

Audits & Benchmarking:

Improve through effective & Optimized Audits
Improve through Benchmarking

Innovation:
Develop and improve upon Best Practices
Implementation of suggestion scheme
Six Sigma culture

HR/Training and development :

Effective Training & Validation system in place.
11

OM&S Design Basis

All the storage facilities are designed as per Industry/OISD
standards and specifications for ensuring intrinsic safety. This
covers proper layout, interspacing, proper equipment /
instrument selection ,safety release system and drainage
facilities etc.
API 650 : Welded steel tanks for oil storage.
API 620 : Welded low pressure storage tanks.
Further to above state of art DCS based automation facilities are
provided in OM&S to ensure safety during normal operations.
Various improvements carried out at the Design stage of SEZ
Refinery based on the experience of DTA Refinery Operations.

12

Storage Tank / Sphere Design Basis

Physical Properties - Product Vapor Pressure
Tank Type

Advantages

Cone Roof

Vap. Pr. in
kg /cm2
<0.05

Floating Roof

0.05-0.85

Int. Float Roof

0.05-0.85

Reduces Breathing
loss, fugitive emission
IFR used wherever
quality/safety is of
importance

Dome Roof
Horton Sphere

0.85-1.06
>1.06

Used for handling

Liquifed Gases such as
LPG/Propylene
13

OM&S Safety features

Inbuilt safety features of storage tanks and spheres:

Auto tank RADAR Gauging ( ATG )

Tank overflow protection ( With dedicated ATG)
Double seal / Liquid mounted seal
Fire detection system in Rim seal area
Tank roof safety valves i.e. PSVs and PVRVs.
Double deck pontoons on the roof
Side entry mixers trip on Tank low level
Tank Auto change over through advanced software
ESD switch for Emergency shutdown of Spheres.
Pivot master for Floating roof drains.
Tank dyke walls made of Concrete.
14

OM&S in Built safety features

Inbuilt safety features of Pump houses:

Automatic pump changeovers via OMIS

F&G system ( Gas, Fire detectors )
PLC based Pump managers
Machine condition monitoring system ( MCMS ) for critical
pumps
Pump trip on Tank low level /Flow.
Emergency pump stop facility from remote location
Mechanical seals.
Pressure differential transmitters ( PDT ) for suction strainers.
Sprinklers in LPG pump house
15

OM&S Safety features

Other Safety features:
Inbuilt protection for over pressurization of lines due to
Thermal expansion
Process monitoring through Aspen software
LPG Driers facility
CTMs for material accountal
Access control for Control rooms, Process buildings.
CCTV cameras for process area monitoring.
Emergency Sphere release to Flare system
Loading arms with overflow protection system.
Loading arms/SPM hoses provided with Breakaway couplings.
Tank truck/wagon loading through meters.
Effective communication system ( Walkie talkies, Paging, hot
lines etc. )
16

OM&S Fire protection measures

Fire and Gas detection system.

Fixed foam pourer system .
Automatic sprinkler system .
Rim seal Fire detection for larger floating roof tanks.
Gaseous Fire suppression system ( FM200 ) for plant interface
buildings(PIBs)
Placement of portable Fire fighting equipment at strategic
locations.
Fire water monitors and hydrants.
Round the clock Fire management team.
State of the art fire fighting equipment (Tenders, Foam nursers
etc) .
Regular checks and audits.
17

OM&S Fire protection measures

Fire Protection Measures
Salient details of F&G system

S.No Type of detectors

Combustible gas
1 detector
2 Flame detectors

Purpose

Locations
Plant process area, HVAC,
Pump houses
Near hot Pumps, Gantries

Hydrocarbon detection
Detect flames
Senses continuous rise in
Linear Heat detectors Temperature

Rate of rise Heat

detectors

Detects rise in Temperature

at Pre defined rate
Battery rooms

Manual call point

To raise Alarm

Plant area

Optical smoke
detector

Detect thick smoke

In substations/PIB's/Control
rooms

7
8

Ionization Smoke
detector
Toxic gas detector

Hydrogen gas detector Hydrogen Gas release

In substations/PIB's/Control
rooms
HVAC, Plant process area
Battery rooms, Compressor
house, Analyzer houses

10

Open path LEL

detector

Pump house

Detects invisible smoke

Toxic Gas leak

Hydrocarbon detection

On Tank Roof

18

OM&S Automation- Salient points

Automatic Tank Gauging System (ATG)

Tank Inventory System (TIS)
Oil Movement Information System (OMIS)
Blending Optimization & Supervisory System (BOSS)
Crude blending supervisory system ( CBSS )
Terminal Automation system ( TAS )
ESD and DCS interlocks
PLC based Pump manager.
Motor Operated valves
CCTV/ Paging systems/Video walls.

19

Automation interface in OM&S

r aw
e
th IS.
e
i v to T
g
l
il ion
w
S mat
C
D for
in

DCS

MOV operation
and feed backs

ATG , ANALYSERS
ETC.
DB
fo wi
r c ll
o n co
tro nve
an l v rse
d f alv w
e e e o it h
db p
D
ac era CS
t io
k
n

TIS
OMIS

DB

TI
st a S w i
tu ll g
s a i ve
nd th
BO qu e t
SS alit ank
yt
o

Movement
Information

BOSS

he
t
e B
v
i
D
li l g to
w tio
S
a
S
r
O
B end
bl
20

Salient points of Automation:

TIS :
Real time Tank inventory system All the Tank inventory calculations
will be done by this software.
OMIS:
Automatically execute all specified types of movements and Tank
swings.It minimizes line up errors and does the compatibility checks.
BOSS :
It controls the ratios of the components in a way that the blended
product meets all the product quality specifications in optimum
manner.
TAS:
Performs plant control functions such as Pump control, measurements,
interlocks etc. Also helps in Traffic management by controlling access
Automation helps in minimizing manual intervention there by ensuring
complete process safety and efficient plant operations .
21

Safety Management

Layout

In-built Safety Design

Safety
Management
Process Safety
Management

Operating Discipline

22

Process safety Management

Process Safety Management is the application of management

systems and controls (standards, procedures, programs, audits,

evaluations) to a manufacturing process in a way that process hazards
are identified, understood and controlled so that the process related
injuries and incidents are prevented.
Process Safety Management is targeted at the prevention of
catastrophic events which can result in a large number of fatalities and
injuries, significant environmental and health damage, significant
property damage, business interruption, loss of the right to operate,
and resulting high costs that can jeopardize the existence of the
business.
In view of above Process Safety Management ( PSM ) is key to ensure
continual improvement in the safety performance.
23

Process safety Management Why?

Historically greater emphasis has been given to Incident, Injury
and related data to measure the safety performance .
Main Causes of incidents ,
9 Slip, trip and fall.
9 Fall from height .
9 Falling objects.
9 Struck by moving objects.
9 Caught in between.
9 Exposure to toxic vapors / substances.
9 Electric flash.
Most of these result due to improper housekeeping or non
compliance to proper procedures.

24

Accident / Incident Pyramid

30

300

?000

Disabling injuries /
Loss time case (LTC)
First aid case (FAC) &
Medical treatment case
(MTC)
Incidents ( Without
injuries )
( Near Misses )
Unsafe acts / conditions
/ habits
( critical situations )
25

History of Major Incidents)

1988: Piper Alpha (Occidental)

1998: Longford Gas

Explosion (Esso)

2005: Texas City Refinery

(BP)

167 killed

8 killed, 69 injured

15 killed, 170 injured

Cost: US$1.2 billion

Cost: US$1 billion

Cost: US$3 billion+

1984: Union Carbide,

1991: Sleipner A Platform
Bhopal
Collapse (Statoil)
Reported 3000 killed
Cost: US$1.2 billion
Cost: Disappearance
of Union Carbide

2001: P36 Sinking

Platform (Petrobras)
10 killed
Cost: US$515 million
1996: Enron Gas
Pipeline explosion)

2005: Bombay High

North Platform (ONGC)

33 killed, 69 injured

22 killed

Enchova Central Platform

(Petrobras)

Cost :US$195 million

1984: Explosion, 37 killed

1988: Gas Blowout
Total Cost: US$461 million

1995: Nigerian Oil Rig

Explosion (Mobil)
13 killed, 25 injured.

2006: Pipeline Explosion

(Nigerian National
Petroleum Corporation)
200 killed

____________________________________________________________
__________
1984
1990
1995
2000
2005
26

Worldwide recent incidents

1.

Fire and Explosion incident in Jaipur terminal, India. Oct 2009

2.

BP, Gulf of Mexico, Louisiana coast. Explosion and fire on the Mobile
Offshore Drilling Unit Deepwater Horizon.20th April 2010

3.

Total group, Britain Lindsey Oil Refinery Fire heater Explosion.

June 2010

4.

Asphalt Tank leak in Paramount Petroleum corporation, June 2010.

5.

Crude oil pipe line leak in Iran, Abdan Refinery. June 2010

6. Pipeline Explosion in North eastern port city of Dalian, China. July 2010
7. Fire in residue Desulphurization unit of Mailiao Refinery, Formosa
Petrochemical Corporation, Taiwan July 2010
8. Fire and Explosion in Petrochemical complex due to Gas pipeline rupture
in Iran Aug 2010
27

Trend of Accidents

Technical
Measures

No. of
Accidents

Process safety
measures
BP -Deepwater
horizon incident

Bhopal
Accident

Human Factor
measures
1970

1980

1990

2000

2010
28

Human Factor

As per Domino theory Unsafe conditions and Unsafe acts

result into accident which arise from improper habitual
behavior.
All the Accidents and incidents , Whether of a technical or
operating nature have human factor amongst their causes
(88% -Henrich 1936 ).
Identification of unsafe conditions, unsafe acts & improper
behavior and elimination of same can prevent the accidents.
Human error arises if Hazards are not clearly perceived and
understood.

29

Human Factor
Determinants of Human Behavior,

Experience,
Learning process,
Motivation
Attitude

Behavior modification,

Training.
Development of skills .
Communication.
Motivation.

Safety contacts, Tool box talks, Safety observations, Validation of

work procedures and Operating discipline are effective tools for
bringing positive behavior.
30

Human Factor

Incident investigation and safety /risk analysis are

complementary processes towards reduction of accidents.
31

Process safety Management

A positive Safety culture and commitment from higher
management is essential for good process safety performance.
Baker Panel Observations BP Texas city Refinery incident
2005.
While BP has a inspirational goal No accidents ,No harm to
people.BP has not provided effective leadership in making
certain its management and US refining work force understand
what is expected of them regarding process safety performance.
BP mistakenly interpreted improving personal injury rates as
an indication of acceptable process safety performance at its US
refineries
32

Process Safety Management Model

33

Safety and health of personnel and

protection of environment overrides
all production targets.
Mukesh D.Ambani
34

HSEF Organization
Corporate HSEF council

Site
Site President
President
Apex
Apex Committee
Committee
Corporate-Group
Corporate-Group
ManufacturingManufacturing- HSEF
HSEF

Central
Central HSEF
HSEF Committee
Committee
District
District Safety
Safety Committee
Committee
HSEF
HSEF CHIEF
CHIEF

OCCUPATIONAL
OCCUPATIONAL
HEALTH
HEALTH
CHIEF
CHIEF

SAFETY
SAFETY
CHIEF(DTA&SEZ)
CHIEF(DTA&SEZ)

DOCTORS
DOCTORS

SAFETY
SAFETY MANAGERS
MANAGERS
(DTA+SEZ)
(DTA+SEZ)

MEDICAL
MEDICAL STAFF
STAFF

ENVIRONMENT
ENVIRONMENT
CHIEF
CHIEF

ENVIRONMENT
ENVIRONMENT
MANAGERS
MANAGERS

FIRE
FIRE
CHIEF
CHIEF

FIRE
FIRE OFFICERS
OFFICERS

FIREMEN
FIREMEN

35

Process safety Management

Management of PSM Elements

PSM element committee

Committee Charter
Plan of activities
KPIs for the committee.
Compliance Audits.
Review meetings
Progress report to site Apex team.
Awareness and Training on each PSM element to plant
personnel ( all levels ), this is one of the important step
towards PSM implementation
36

Operational Discipline
OperationalDiscipline elements
4.OD

KRA
Resources
Training and competency
Communication
Participation
Procedures
Job cycle checks
RESOP
Audits
Assessment / Review

(Operational
Discipline)

3.Implement
PSMProgram

2.ManagementLeadershipand
Commitment

1.BuildaSafetyCulture

37

Operation discipline elements

KRA : Site KRA/ Team KRA / Individual KRA and KPI system
Resources : Process Safety, Fire protection, special PPEs, Software etc.
Training and competency : Required competency system.
Communication : Pocket cards, HSE Flash, LFI, Tool box talks, Safety
alerts, Quarterly safety performance , Corrective action tracking system,
PSSR audits and Information sharing from other sites.
Participation : Safety meetings, Suggestion schemes, Safety campaigns ,
Tool box talks, Table top exercises and Task validation.
Procedures : SOP,SMP, SOC, MSDS, information on HSEF, Risk
assessment and Job checklists.
Job cycle checks for SOPs and checklists.
Safety observation : Safety Observation and field discussion/ Counseling.
Audits : PSM, Work permit , Contractor, Work place, Housekeeping, Fire
protection facilities etc..
Assessment / Review : Periodic performance review, Improvement plans.
38

HSEF - KPI

Zero accident / incidents.

Incident reporting and investigation.
Near miss reporting and investigation, wherever required.
Compliance of recommendations .
Safety awareness training.
PME compliance.
Validation of SOP/ SMPs.
Permit audit compliance.
Contractor safety performance.
House keeping Audits .
Mock drills and recommendation compliance.
District safety committee meeting.
Safety observations etc.
Learning's from incidents ( In-house and outside )
39

PSM Operational safety practices

Incident reporting and compliance monitoring system

Interlock bypass procedure
F&G bypass procedure
Control valve bypass procedure
Safety system bypass procedure
Fire water network isolation procedure
Deluge wet and dry testing schedules
Preventive maintenance of fire fighting equipment.
Procedure compliance audits
Self safety audits
Alarm monitoring and rationalization
Work place audits
Periodic Operational safety performance review
40

Emergency Management Plan

Well documented Emergency Response & Control Planning
Document to incorporate MCA Analysis findings
Emergency Management Organization
Clear Roles & Responsibilities
Resource Identification & mobilization including Mutual Aid
Assistance
Emergency Communication System
Training & Validation of emergency teams
Periodic rehearsal of the plan

41

Emergency Management Plan

Mock drills level 1 & 2 are carried out at plant level and the
observations are duly discussed for closeout.
Table top exercises are carried on the various emergency
scenario to bring awareness and clear understanding of various
aspects of emergency handling.
Training on incident command course is mandatory for shift
supervisory level.
Level -3 Mock drills are carried out along with district
administration and mutual aid members

42

PSM Safety training

HSEF refresher
Live Fire Fighting
Fire fighting class room study
Process Safety management familiarization
Work permit system
Safe Handling of Chemicals
Personal Protective Equipment (PPE)
Emergency management
Risk Assessment
First Aid, CPR
Confined Space Entry
Safety Audit Technique
What went wrong
Learning from Incidents (LFI) workshop

43

Safety Campaign
To enhance Safety Awareness as well as compliance to various
safety procedures periodic safety campaigns are launched on
important safety elements like Line break , Confined space ,
Work permits , Scaffolds ,work at height and contractor safety
etc.
The above is carried by means of Safety contacts in routine
meetings ,Tool box talks ,Training to target groups ,Issue of
safety pamphlets , HSEF messages on desktop, Safety quiz and
Inter plant audits etc.
These measures help in continuous improvement in the overall
safety performance.

44

Performance review
TRC (FAC + MTC)
Safety

LTC
Fire all category
Spill all category

Reliability

Overdue recommendations
(Incidents & accidents investigation)
Audit recommendations
F & G device disabled
DVs isolated > 24 hrs (Other than
M&I Purpose)

Monitoring

Isolation of Fire Water network

QSP rating

45

Performance review
ESD bypassed
Safety

Trips / Interlock bypassed

Controllers on manual
DCS Alarms Per shift

Reliability

Tank Relief Devices disabled /

incapacited
PSV disabled / incapacited
PSV overdue for calibration
Online sealing
No.of tanks/spheres under M&I

Monitoring

Emergency DG sets status

46

Performance review
SOC's deviation
Safety

ISO / OSHAS / IMS audits

compliance
Concession deviation requests, ISO
SOC Deviation

Reliability

No of MOC's under review

PSSR- A category pending points
Leaking Roof Drain
Pump Seal Leak
Stem leaks

Monitoring

No of Critical jobs for the today

47

Best operating Practices

Based on experience and learning's some of the important

control measures for the operations of Oil movement &
storage facilities are given below.

This is not an exhaustive list but covers some of the

important functions like,
9
9
9
9
9

Monitoring & Control

Process Safety, SOP
Supervisory Control
Reliability
Static electricity
48

Best operating Practices

Monitoring & Control
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Close coordination with process units during start up and shut

down.
All product routings and the changes shall be done with prior
information.
Close monitoring of product Rundown temperature and quality.
Monitor trend of important process parameters.
Deviation from standard operating condition(SOCs) to be
checked promptly.
Nitrogen blanketed tanks shall be closely monitored.
Floating roof drains should be checked for any leaks during
routine rounds.
Inter tank gravitation operations shall be done in controlled
manner to ensure transfer- rates with in specified limits.
Piping joints of LPG / Naphtha / lighter service products to be
closely monitored under LDAR checks.
Pump out and receiving rates from tanks shall be monitored.
49

Best operating Practices

Process Safety / SOP
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

No gas blow back from process units ( H2S ,H2 , N2 , Lighters etc.)
to storage tanks .
Defloating of roof shall be avoided during normal operations .
Non process connections shall be adequately safe guarded for
hydrocarbon mix-up.
Tank dyke interceptor valves should be always kept in close
condition.
Process safety system bypass shall be done with authorization and
proper procedure / safe guards.
Non routine operations shall be done as per proper procedures.
Ensure thermal expansion of idle and blocked process lines.
Any job / modification pertaining to OWS system should be done
under proper SOP / Supervision.
All the facilities shall be properly marked / stenciled for clear
identification.
Pyrophoric iron hazards and safe work practices.
50

Best operating Practices

Supervisory Control
1.
2.
3.
4.
5.

Water draining from the tanks shall be done under

constant supervision.
High risk /critical jobs shall be carried out under close
supervision.
Erection jobs around the operating facilities shall be done
with proper procedures under close supervision.
Horton spheres and tank M&I activities shall be closely
supervised.
Close monitoring of Permit jobs, Modifications and
Construction activities.

51

Best operating Practices

Reliability
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Oil soaked insulation shall be promptly replaced.

Steam tracer leaks under insulation to be identified and promptly
attended.
Stagnant lines shall be periodically checked ( by draining
/inspection ).
Small bore connection to be included in periodic inspection
program.
Valves which are not operated normally should be checked and
greased.
Periodic checks for the earthing and cathodic protection
facilities of tanks shall be done .
Periodic greasing of floating roof ladder hinges for free moment.
Avoid use of flame arrestors in the heavier product service tanks.
Spare safety valve to be kept isolated and normal safety valve to
remain inline.
Wafer type NRVs are not safe for LPG/Naphtha/Light product
services.
52

Best operating Practices

Static electricity
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Side entry mixers ( SEMs) shall be operated in adequately

submerged condition (0.60 1.00 m).
Tank mixing operation shall be done after draining of water.
Maintain safe velocity while commissioning the tanks.
Steam coils operations ( Charging or isolation) shall be done when
these are fully submerged.(Product level 1 M above the coil).
Use only cotton rope for sample thief.
Dip tape and sample thief should be of non-sparking material.
Proper earthing continuity to be ensured during tank truck / wagon
operation.
Do not allow switch loading of products.
Only cotton dress / overall shall be used in plant area.
Anti static additive to be used for products where conductivity is
less than 50 ps/m.
Stop loading / dipping and sampling operations during severe
electrical storms.
Bottom loading shall be provided with splash deflectors.
53

Thrust areas OM & S

Full tank fire fighting capability for large capacity storage
tanks.
Process Safety Management to become the way of life.
Continual effort on Training and development , participation
in PSM program there by building strong Safety culture.
Technical exchange program with World leaders ( DuPont,
Shell, Exxon mobil )
Mechanized handling and treatment of storage tank sludge.
Ensuring M&I activities as per plan.
Incident / accident free plant operations with full compliance
to HSEF standards and Operational discipline.

54

Thank you