hse&f mgtepcl 2011

8/13/2019 Hse&f Mgtepcl 2011

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WELCOME

Mr BOB WALLACE,

BRITISH SAFETY COUNCIL

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HSE&F Management in EPCL

Port Harcourt

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Indonesia: Polyester Yarns & Fibers,

PET Resins, Spun Yarns, Fabrics,

Medical Gloves, Real Estate

Thailand:

PTA, Polyester Yarns& Fibers, PET Resins

Wool Yarns, Furfural

Sri Lanka:

Spun

Yarns

Turkey: Spun Yarns

Lithuania: PET

Resins

UK: PET

Rotterdam: PTA/PET

Egypt: Spun Yarns,

Ammonia

Nigeria: Olefins,

PE & PP

USA: PET

Resins

Global Footprint

- - IVL

18 Manufacturing Sites, 11 Countries, 4 Continents

Indorama

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The EPCL’spetrochemicals complex is

located nearby the town of

Eleme, about 15 minutes

from Port Harcourt, capital

city of Rivers state, Nigeria.

EPCL location

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OLEFINS671 K T/Y

BUTENE-122 K T/Y

POLYETHYLENE

270 K T/Y

POLYPROPYLENE

80 K T/Y

NGL AGIP

FUEL GAS AGIP

583 K T/Y

CRACKED C5+

40 K T/Y

PE RESINS

PP RESINS

HDPE – 162 K T/Y

LLDPE – 108 K T/Y

80 K T/Y

PPU

ETHYLENE

ETHYLENE

PROPYLENE

Kellogg Brown & Root

Chiyoda

IFP

Kobe Steel Ltd.

Nova Chemicals

Kobe Steel Ltd.

Basell

Technimont & JGC

(May 1995)

(September 1995)

(September 1995)

(August 1995)

Ethylene

300,000 MT/Y

Propylene

126,000 MT/Y

(1994)

PRF PHRC

88 K T/Y

Fuel Gas

145 KT/Y

Key Plants - Description

Cracking Naphtha / Virgin C5

120 K T/Y

PHRC

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OLEFINS PLANT

KBR Technology

Designed to Produce

300 KT/Y of Ethylene

126 KT/Y of Propylene

(Both Polymer Grade)

Also 120 KT/Y of

V/C C5+

Other by-products:Fuel gas

Hydrogen

Light/Heavy Oil

Feed: NGL (Natural Gas Liquids)

from Agip

VC5+ / Light Naphta

PRF (Propylene Rich Feed)

from PHRC

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POLYETHYLENE PLANT

SclairtechTM

TechnologyNOVA Chemicals

Designed to Produce

270 KT/Y of Polyethylene

HDPE – 162 K T/Y

LLDPE – 108 K T/Y

Solution Process

More than 140 differentpolymer grades

Feed: Ethylene from Olefins Plant

Butene-1 from Butene-1 Plant

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POLYPROPYLENE PLANT

Spheriphol Technology

Basell

Designed to Produce

80 KT/Y of Polypropylene

HomopolymerCo-Polymer (Ethylene)

Feed: Propylene from Olefins Plant

Ethylene from Olefins Plant

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BUTENE-1 PLANT

Alfa-Butol Technology

IFP - AXENS

Designed to Produce

22 KT/Y of Butene-1

Other by-products:Hexenes+ (C6+)

Feed: Ethylene from Olefins Plant

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HSE&F

ORGANOGRAM

ENVIRONMENTOCCUPATIONALHEALTH

FIRE SERVICES

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HEAD HSEF

HEAD

DOCTOR

DOCTOR

NURSES &

PARAMEDICAL

STAFFS

HEALTH SECTION ORGANOGRAM

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OCCUPATIONAL HEALTH MANAGEMENT

The section caters to the need of

• First aid to the employees

• General medical diagnosis &

treatment• Handling of medical emergency, if

any occurs.

• Periodic medical check up

• Monitoring general hygiene

• Monitoring all occupational healthrisks within.

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Key Responsibilities of Safety Department

Formulate HSE policy and general safety rules and ensure its

implementation .

Develop HSE procedures based on standards and ensure

implementation.

Formation of HSE committees (top level/ Departmental) and ensure

effective functioning of these committees.

Co ordinate periodic internal safety audits and observation compliance

follow up.

Procedure compliance audit and work place inspections.

Safety information sharing and publicity.

PPE- Selection, inventory , training and use enforcement.

Investigation and Analysis of Near Miss/Injury incidents.

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Co-ordination for risk assessment and participating in Task bases risk

assessments.

Making need based safety training modules and conducting safety

trainings to company and contractors employees.

Safety promotional activities – Safety contests/ incentives.

Management MIS on HSE&F and statutory compliance.

Ensuring HAZOP and PSUSR of selected MOCs.

Development of Safety Intranet- loading of safety films, safety bulletins,MSDS, HSE&F report etc.

Key Responsibilities of Safety Department

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SAFETY MANAGEMENT (Procedures) 1. HSE Policy and Organization

2. Safety Guidelines

3. Safety Districts

4. Safety ‘Ambassadors’

5. ‘Entry Pass for restricted areas and gate passes’

6. Work Permit System

7. Management of Change8. Gas Testing

9. Accident reporting & Investigation

10.Line Breaking

11.Positive Isolation

12.Excavation and Cordoning

13. Confined Space entry

14. Vehicle Entry Permit

15. Electrical Work Permit

16. Safety Aspects in Nitrogen Distribution

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SAFETY MANAGEMENT (procedures contd.)

17. Changing of Instrumentation pre alarms / alarms/trips

18. Personal Protective Equipment (PPE)

19. Guidelines for Handling Flammable Hydrocarbon

20. Classification of Hazardous Area

21. Selection of Electrical Apparatus for Hazardous Areas

22. Job Safety Analysis (JSA)23. HSE suggestion scheme

24. Contractors’ Safety

25. Safety Relief Valve

25. Procedure for risk assessment

26. Procedure for scaffolding

27. Procedure work permit for non plant building and areas.

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SAFETY DEPARTMENT’S ROUTINE ACTIVITIES

All Hot job preparation certification including LEL monitoring

Scaffold inspection and certification

Confined space entry Gas test and certification.

Hazardous chemical loading unloading safety audit.

Monthly noise level monitoring

Monthly Radiation sources surrounding exposure monitoring.

Contractors employee training and validation (Daily Basis)

PTW audits

Safety talk on critical jobs

Supplying special safety equipment to plant on need base.

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FireMinor Injury

Nearmiss

Lost timeFire 3 8 8 5 11

Minor Injury 10 26 16 15 5

Nearmiss 2 19 31 19 22

Lost time 0 1 1 1 4

2006 2007 2008 2009 2010

FOR LAST 5 YEARS

INCIDENT/ACCIDENT TREND

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FOR LAST 5 YEARS


3

8 8

5

1110

26

16 15

5

2

19

31

19

22

0 1 1 1

4

0

5

10

15

20

25

30

35

2006 2007 2008 2009 2010

Fire

Minor Injury

Nearmiss

Lost time

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SEVERITY RATE VS YEARS

3.86

5.79

1.5 1.5

0

1

2

3

4

5

6

7

2007 2008 2009 2010

YEARS

S

e v e r i t y R a t e

In 2010 there were three LTI which are non plant related incidents & happened out side the plant

battery limit.

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FREQUENCY RATE VS YEAR

7.3

2.3 2.3 2.3

0

1

2

3

4

5

6

7

8

2007 2008 2009 2010

YEARS

In 2010 there were three LTI which are non plant related incidents &

happened out side the plant battery limit.

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HEAD HSEF

HEAD Safety

Safety officer

Shift

SAFETY SECTION ORGANOGRAM

Safety officer

Shift

Safety officer

Shift

Safety officer

Shift

Safety Officer

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Fire Minor Injury Near Miss Lost time

Fire 1 2 1 0 2 0 0 3 1 1 0 -

Minor Injury 0 1 2 0 0 1 0 0 1 0 0 -

Near Miss 1 1 2 0 3 7 3 1 0 1 3 -

Lost time 1 0 0 0 0 0 0 0 2 1 0 -

JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC


YEAR-2010

Incident 2009 2010

Fire 5 11

Minor

Injury

15 5

Near

miss

19 22

Losttime 1 4

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TYPEWISE 2009

FALL

8%

STRUCK BY

45%

HIT AGAINST

8%

CHEMICAL

CONTACT

31%

ELECTRICAL

CONTACT

8%

FALL

STRUCK BY

HIT AGAINST

CHEMICAL CONTACT

ELECTRICAL CONTACT

TYPEWISE 2010

FALL

34%

STRUCK BY

33%

CAUGHT IN

BETWEEN

22%

HIT AGAINST

11%

FALL

STRUCK BY

CAUGHT IN BETWEEN

HIT AGAINST

Injury accident analysis Type wise.

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INJURYWISE 2010

CUT

67%

BURN

0%

FRACTURE

11%

IRRITATION

0%

FATALITY

22%

CUT

BURN

FRACTURE

IRRITATION

FATALITY

INJURYWISE 2009

CUT

62%

BURN

23%

FRACTURE

0%

IRRITATION

15%

FATALITY

0%

CUT

BURN

FRACTURE

IRRITATION

FATALITY

Injury accident analysis Injury wise

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BODY PART - 2009

HEAD

8%

LEG

15%

FACE

23%

EYE

15%

SHOULDER

8%

FACE & BODY

23%

EYE & BODY

8%

HEAD

LEG

FACE

EYE

SHOULDER

FACE & BODY

EYE & BODY

BODY PART - 2010

HEAD

33%

FINGER

11%

LEG

45%

FACE

11%

HEAD

FINGER

LEG

FACE

Injury accident analysis Body part wise.

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6Safety

Audits-

External

Audit by M/s British

safety Council

Complete audit of Five star

safety Management system By

M/s BSC

Nos 0 1

7Safety

Audits-

Internal

Audit frequency /

weekly / Plant

Work permit procedure

compliance audit

Nos 30 40

Audit

frequency/yearly

Trip/interlock bypass for complex Nos 1 1

Audit

frequency/yearly

PSV audit for complex Nos 1 1

Audit

frequency/yearly

Tools & tackles audit Nos 1 1

Audit

frequency/yearly

Tank farm (Offsite) Nos 1 1

Nos of Audits / Six

monthly

Non plant building audit Nos 1 2

Nos of Audits / Six

monthly

Canteen Hygiene audit Nos 0 2

HSE&F Objectives and Targets 2011

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8 Procedures for

Safety

Nos of

procedures

To prepare & add the Safety

Procedures for plant

Nos 30 30+4

9 Participation in

trainings

Training

modules

Number of training Modules

prepared

Nos 1 5

Nos of

participants

Live Fire Fighting training Nos 518 540

Nos of

participants

Induction training to contactors/

visitors

Nos 1285 2500

Nos of

participants

FSE Refresher training Nos 60 100

Nos of

participants

First aid training Nos 150 200


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10 Safety

meetings

Nos of meetings/

Quarterly

Apex HOD/ HOF level meeting Nos 2 4

Nos of meetings/

Monthly

Plant/ Department level

meetings

Nos 90 96

11 Safety

Promotion

Nos of program/

Six monthly

Safety Competition- complex

level

Nos 1 2

12 Statutory

compliance

License renewal /

biyearly

Factory license renewal Nos 0 1

License

renewal/Yearly

NNRA license renewal Nos 1 1

Compliance to

Environment

related

government norms

Complete all government norms % 100 100

Compliance to

Factory Act related

government norms

Complete all government norms % 100 100


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HEAD HSEF

HEAD

ENVIRONMENT

ENV.ENGINEER

WASTE

EVACUATION

STAFF

MONITORING

STAFF

ENVIRONMENT SECTION ORGANOGRAM

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ENVIRONMENT

The function of Environmental

Section is to ensure that –

1. Control of all emission.

2. Proper treatment of all waste.

3. Compliance of all Statutorynorms.

4. Monitoring all emissions.

5.Resource Optimisation.

6. Involvement of employees in

conservation of the environment

7. Keeping a cleaner ambience

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CHRONOLOGY OF ACTIONS

Environmental Evaluation Report

• EER (EIA) was done to establishthe baseline conditions and identify

the action point areas.

• EER covered water environment,

air environment, receiving water body

environment, soil environment, noise study.• Soil environment condition study

was done as presence of hydrocarbon was

Observed in some location.

Reports submitted to FMENV, DPR, IFC and

River State Ministry of Environment

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CHRONOLOGY OF ACTIONS

• Received initial provisional consent in 2007 from Federal

Ministry of Environment on following areas

– Operation of ETP and discharge of effluent

– Operation of sludge incinerator

– Operation of polymer incinerator

• Third party environmental audit was conducted and its

was approved by above regulatory authority.

• Received final consent for discharge in 2008, renewed by

FMEnv. upto 2012.

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ENVIRONMENTAL MONITORING

• Daily monitoring of treated effluent discharged• Regular monitoring of storm water drains

• Monthly monitoring of ambient air quality at four

locations around complex periphery and recently started

two outside station of the complex ( AKPAJO and ALETO)

• Monthly monitoring of stacks ( Sludge incinerator,

polymer incinerator, olefins heater, Boiler and GTG

stacks)• Monthly analysis of ash from incinerators.

• Regular physiochemical analysis of waste water at

recipient water body.

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WASTE MANAGEMENT

•The system is based upon following hierarchy:

Reduce

Reuse

Recover/Recycle

Disposal

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WASTE MANAGEMENT STEPS

•Identification

• Characterization

• Collection

• Transportation• Disposal including Reuse, Recycle

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FIRE SECTION

Prevent Fire

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HEAD HSEF

HEAD

FIRE

SR.FIRE

OFFICER

FIRE MEN

1st shift

FIRE MEN

2nd shift

FIRE MEN

3rd shift

FIRE SECTION ORGANOGRAM

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The section handles following activities – • Response for any emergency call for 24 hours

and 365 days

• Mitigate & fight fire or any gas leakage and savepeople, property & environment.

• Prevent and reduce fire risks through firefighting training

•Oversee the fire preventionwhile any hot work is being performed

• Keep all fire fighting equipment in workingcondition

• Conduct ONSEM and surprise mock drill

FIRE SERVICES

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ACTIVE FIRE PROTECTION SYSTEMS

FIRE DETECTION SYSYTEM:

• Manual call points• Gas & Smoke alarm

FIRE FIGHTING SYSTEM:

• Extinguisher : DCP,CO2 and Foam• Pressurised network with 4 main pumps of capacity

900m³/hr each

• 3nos Multipurpose trucks

• 1no emergency truck

• 1 no water tender

• 1 no Hydraulic lift platform

• 2 nos utility trucks

• 2nos Mobile foam trailer

• 1 no DCP trailer

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Thank you

hse&f mgtepcl 2011

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