OIL INDUSTRY SAFETY AWARDS Input Data Sheet Group 2 P O L MARKETING ORGANISATION Data to be furnished zone wise as well as overall as under** (Read Notes on Sheet 5 of 19 before filling in the format) 1. Year (1st April to 31st March) : 2. Name of Organisation : B.P.C.L. 3. Manhours worked during the year - in millions : (Refer note 1 of sh 5 of 19) Man hours in POL Marketing Operation Project Man-hours within installation Employees Contractors's Employees Z1 Z2 Z3 Z4 CUMULATIVE Z1 Z2 Z3 Z4 CUMULATIVE Note : Project manhours will include manpower for only Grass root projects within POL marketing installation 4. Sale of products during the year in million tonnes Sale of Products Type of Products Z1 Z2 Z3 Z4 CUMULATIVE Note: Light Distillates - (Naphtha, MS etc.) Middle distillate - (viz ATF, Kerosene & HSD) Lubes & Heavy ends **Evaluation shall be based on Zone wise as well as Overall basis (for Organisation) and for BPCL s POL zones are as under: Zone-1 (Z1) : East Zone-2 (Z2) : West Zone-3 (Z3) : North Zone-4 (Z4) : South Page 1 of 19
5. Total lost time due to injuries in man-hours : (Refer note 2 of sheet 5 of 19) Man hours lost in accidents related to POL Marketing operation Man hours lost in accidents in Project area within installation Z1 Z2 Z3 Z4 CUMULATIVE Z1 Z2 Z3 Z4 CUMULATIVE Employees Contractors's Employees 6. Fatalities in Nos. (Refer note 2 of sheet 5 of 19) Fatalities in POL operation Fatalities in Projects within Installation Fatalities outside POL installation including transportation Z1 Z2 Z3 Z4 C UM. Z1 Z2 Z3 Z4 C UM. Z1 Z2 Z3 Z4 C UM. Employees Contractors's Employees 7. Fires (Major) in Nos. (Refer note 3 of sheet 5 of 19) Major Fires in Nos. Locations Within installations Transport & distribution Customer premises Z1 Z2 Z3 Z4 CUMULATIVE Page 2 of 19
8. Material Losses - in Lakhs : (Refer note 3 & 4 of sheet 5 of 19) (Direct Loss) Direct Losses in Lak Locations Within installations Transport & distribution Customer premises Z1 Z2 Z3 Z4 CUMULATIVE Indicate if there is any loss of Production/Handling due to shut down because of fires and accidents in Million and Material loss in Lakhs. (Refer note 3 of sh 5 of 15) 9. Production/Handling Loss due to shutdown because of fires & accidents - in Million (Refer note 4 of sheet 5 of 19) Incidents Date Caused by Facilities affected Duration of S/Down Products affected Potential Production/ Handling loss ( Million) Z1 Z2 Z3 Z4 CUMULATIVE 10. Detailed Analysis of Incidents in : To be submitted Zone wise (To be filled in table provided in Sheet 8 of 19) 11. Questionnaire on Safety Management System : To be submitted Zone wise (To be filled in table provided in sheet 10 to 19) 12. Furnish clause wise compliance/ Deviation to OISD standards: To be submitted Zone wise (Details to be filled in separate sheet for standards mentioned in Annexure-IV) 13. The nomination for Individual Award category should be submitted in the prescribed format attached as Annexure-II. To be submitted Zone wise. 14. Furnish the information Zone wise as well as on Overall basis on availability of SPCB Consent for air, water and authorisation for Hazardous Waste handleing for the period from April 2013 to March 2014. Page 3 of 19
15. Compliance report of the Pre Commissioning Safety Audits recommendations carried in the year 2013 2014. 16. Non-compliance notice(s) received during & subsequent from statutory authorities like PESO, DGMS, Factory Inspector, Boiler authority, Electric Authority, MoFE, OISD, CEA, CPCB/SPCB, Coast Gaurds and their status to be submitted Zonewise. 17. Furnish the information Zone wise as well as on Overall basis on oil spill incident details. 18. Status of progress of implementation of M B Lal committee s recommendations Zone wise and Overall. Above data is filled in as per the guidelines given below and is verified by me. Signature of Principal panelist/ Head HSE Name/ Designation Date: Page 4 of 19
NOTES 1. Man-hours include overtime as well as the contractor's man hours worked during the year. 2. Fatalities should not be converted into lost time but shall be indicated separately. Fill up Sheet 7 of 19. 3. Material losses (Direct losses) include the loss/damage to equipment, products, public property, cost of fire-fighting materials, medical expenses involved, compensations paid in money etc. Fill up Sheet 8 of 19. 4. Potential loss of production will be accounted by the product slate i.e. increase/decrease of all the individual products (with reference to the planned / committed targets) as a result of fire or accident. It shall be assumed that all the units operate at their peak capacities under normal conditions and any increase / decrease of product slates because of shutdown cannot be corrected. The increase / decrease of each product viz. MS, Kerosene, HSD, SKO etc. should be calculated and loss of revenue thereof to be reported in Million. Fill up Sheet 8 of 19. a) Potential loss of handling of the product is the quantity of products that could not be handled due to fire or accidents. It shall be assumed that facilities operate at peak loads and shortfall in 'Handling' cannot be made up. The loss due to shortfall in handling shall be calculated and reported in Million. Fill up Sheet 8 of 19. 5. Each Organisation shall submit one data sheet for the entire organisation as applicable by combining the data of various units/ facilities under this group. 6. Data submitted in the application shall be provided for the period from April 2013 to March 2014. Page 5 of 19
7. OISD shall carry out site verification through External Safety Audit / Surprised Safety Checks for locations where ESA / SSC has not been carried out so far. 8. Pipelines to/ from jetties/refineries/terminals/ neighbouring industries, well fluid lines and group gathering station lines in oil fields shall be considered as part of the process or marketing complex and not cross the country pipelines. 9. Corporate / Head Offices, Regional Offices and Townships which are away from process installations shall not be considered in filling the above format. Also grass root projects away from the process complexes should not be considered. However, project and construction activities within the process complexes shall be considered. 10. Data shall include that of contractor personnel employed. 11. Project manhours will include manpower for only Grass root projects within POL marketing installation. Page 6 of 19
DETAILS OF FATALITIES Date Location & Brief on Incident Zone * Type of Incident # At Project-site (Employee) Fatalities (Nos.) Within installation (Employee) In POL operations Outside installation (Employee) Company Contractor Company Contractor Company Contractor Note: Indicate Companies Employee/Contractors Employee also within brackets under Nos. of Fatalities. # Incidents should be categorized as Fire, Explosion, Electrocution, fall from height, gas inhalation, slip/trip, road accidents and others (to be specified). * Fill the data zone wise as well as cumulative for the entire organisation. Page 7 of 19
DETAILS ABOUT FIRE, MAN-HOURS LOST, DIRECT LOSS AND PRODUCTION / HANDLING LOSS Sr. No Date Location Type of incident # Zone * Man-hrs Lost, in Million manhours Direct Production / Handling Loss Loss in Name of the Qty in Potential Lakhs Product Thousand MT Loss of Revenue in Million Total Note: # Incidents should be categorized as Fire, Explosion, Electrocution, fall from height, gas inhalation, slip/trip, road accident and others. * Fill the data zone wise as well as cumulative for the entire organisation. Page 8 of 19
DETAILED ANALYSIS OF INCIDENTS IN (ZONE WISE) * S. NO. Description Manufacturing Marketing Company Employee Contract employee For all employees Company Employee Contract employee 1 Total million Man-hours worked 2 No. of fatal incidents 3 Number of Fatalities 4 Fatality Accident Rate (FAR) 5 Fatal Incident Rate (FIR) 6 No. of lost time work injury Incidents resulting in > 1 day absence from job (LTI) 7 Total Recordable injury rate (TRIR) 8 Number of road accidents 9 Number of fatalities in Road accidents 10 Distance traveled in KM 11 Road Accident Rate (RAR) 12 FAR in Road Accidents (FARR) For all employees * Fill the data zone wise as well as cumulative for the entire organisation. Page 9 of 19
NOTES: 1) Details of all incidents involving company employees as well as contract employees should be included in the table above. 2) Total Man-hours worked = Total man days worked for the period X man hrs worked per day (Where number of man days worked for a period is number of men at work on each day of the period.) 3) Incase employee (Company or contractor) resume duty after some time and subsequently again get disabled due to same injury which caused his earlier disablement; the period of such subsequent disablement is also to be included in man days lost. The day of injury as well as day of resumption of job should be excluded from man day s loss calculations. 4) Fatality accident rate (FAR) = Number of fatality X 10 8 hrs worked Number of man hours worked 5) Fatal Incident Rate (FIR) = Number of fatal incidents X 100,000,000 hrs worked Number of man hours worked 6) Total Recordable injury rate = No. of injuries in all reportable (fatalities+workday lost) incidents X 10 6 hrs worked (TRIR) Number of man hours worked 7) Road Accident Rate (RAR) = Number of Road accidents X 10 6 Kms Total Distance traveled (in KMs)/ year by all trucks for product movement by the location. 8) Fatality Rate in Road Accident = Number of fatalities in Road accidents X 10 6 Kms (FARR) Total Distance traveled (in KMs) in the year by all trucks involved in product movement for the location. Page 10 of 19
QUESTIONNAIRE ON SAFETY MANAGEMENT SYSTEM 1.0 EXTERNAL SAFETY AUDITS: (FROM THE FIRST ROUND OF AUDIT ONWARDS) (A) STATUS OF IMPLEMENTATION OF RECOMMENDATIONS OF THE EXTERNAL SAFETY AUDITS: Zones Round Date of audit Zone-1 Total no. of Recommen dations Reccomendati ons not complied as on 31.03.2013 Progress during Year Plan for the year Actual complied in Schedule for balance Recco. Remarks Zone-2 Zone-3 Zone-4 Overall Page 11 of 19
2.0 MANAGEMENT OF CHANGE: 1. Please attach a copy of the approved procedure of management of Change showing the name and designation of the approving authority & the date of issue. 2. Indicate who maintain the records for changes taken place through management of change procedure (designation of the Person)? 3. Please furnish the information in following table: Zones Changes in 2013-14 Approving authority (Designation) Updation of P&ID/ Manuals / Drawing Verified by (designation & date) Certified by (designation & date) Zone-1 Zone-2 Zone-3 Zone-4 Overall Please attach comments of internal safety audit team on compliance to stipulated procedure of Management of change for the changes taken place during the year? Page 12 of 19
3.0 OPERATING PROCEDURE: 1. Fill in the details in the following format about the operating manuals available in the control room Sr. No. Unit/Facility Last date of updation Due date for next updation Prepared (Designation) by Approved (Designation) by 2. Whether following are covered for each unit in the separate operating manual/ procedure: a) Steps for each of the operating phases viz. Normal Operation, Start-up and Shut down, Emergency operation, Emergency Shutdown etc. b) Operating Limits indicating consequence of deviation, steps required for correcting or avoiding deviations. c) Safety and Health consideration viz. hazards of chemicals used in the process, precautions to prevent exposure including engineering controls, administrative controls and personal protective equipment, control measures to be taken if physical contact or airborne exposure occur, quality control of raw materials and control of hazardous chemical inventory level, any special or unique hazards. d) Safety system and their functions (Interlocks, PSVs, Trips, Alarms, Detection System etc.). Attach observations of Internal Safety Audit team who audited the unit / facility indicated. during the year is required to be Page 13 of 19
3. List out the documents accessible to employees and contractor employees respectively for their awareness on operating procedures. Document Availability to Contractor s employee Availability to Employees Zone* * Fill the data zone wise as well as cumulative for the entire organisation. 4. Whether operating procedure are in place to include safe work practices for : a) Control of hazard during lock out / strike. b) Confined space entry. c) Handing over and taking over process equipment? (Attach the copy of the relevant portions from the documents) 5. Whether operating manuals / procedures explain clearly the system of control over the entry into the restricted areas under the process units / facilities for a) Maintenance personnel b) Contractors personnel c) Laboratory personnel d) For any other personnel If yes, indicate in brief the system for authorization for entry (viz. Work Permit, Gate Pass etc.) and designation of the authorizing person in the plant for such entries? Page 14 of 19
4.0 TRAINING: 1. Please furnish following details (Indicate total no. of employees) Training imparted to new employees before taking Charge during No. of Management Employees Duration (in days) No. of Non- Management employees Duration (in days) Training imparted to existing employees before taking charge of new assignment during No of Management employees Duration (In Days) No. of Non- Management employees Duration (In Days) Certifying authority 2. Indicate the percentage of employees exposed to refresher training during. 3. What is the frequency of refresher training for any employee? 4. Indicate the system being followed to record the training courses attended by any employee is computerized or manual system? Also indicate the name and designation of the person maintaining these records. 5. Based on records, Indicates the means used to verify that the employee had understood the training? If yes, indicate the method used for such evaluation/ certification? 6. Indicate the percentage in each category as under exposed to safety training during the year : Contract employees Drivers (For POL, etc.) Khalasis (For POL, etc.) CISF/ Contract Security persons 7. When was the fire training ground facility commissioned (as per OISD -STD- 116)? If not, what is the completion schedule? Page 15 of 19
5.0 RELIABILITY AND CONTROL DEFEAT OF CRITICAL SYSTEM AND DEVICES: (SHUTDOWN SYSTEMS, ALARMS, GAS DETECTION SYTEMS, INTERLOCK SYSTEM ETC.) 1. Furnish the list of all critical systems and devices (identified as last line of defense), failure of which can cause serious process accidents or release of materials causing serious environmental impact? Indicate designation of the persons maintaining records for maintenance and inspection of these devices. 2. Who is the approving authority (Name & Designation) for the above list and when was it approved? 3. Please indicate in the format below, the hierarchy of official(s) empowered to allow the temporary disarming or deactivation or defeat of a critical system or device for the period specified? Designation of the official Period for which he is empowered to disarm/deactivate the system/device 6.0 MAINTENANCE AND INSPECTION: 1. Please attach the copy of approved procedure to train each employee involved in maintaining the integrity of process equipment and familiarize him about the process and related hazards. 2. Indicate designation of the officer who maintains documents for inspection and testing procedures. Who is the approving authority for the procedures and when it was last approved? When is the next review scheduled? 3. Indicate designation of the officer who maintains the records on the inspection and test conducted on process equipment? 4. Please attach the list of lifting tools and tackles tested as per statutory requirement during the year? Also mention the frequency of testing for these tools. 5. Indicate the frequency of updation of as built drawings (including P&IDs and engg. Drawings)? Who is maintaining the record of updation of these drawings? Page 16 of 19
Name of Employee : (Contractor / Company) Employee Identification No : Organization / Location : Brief Description ** ANNEXURE-1I Nomination Form for Oil Industry Safety Award Individual Category Justification**: Why the performance is considered significant? Proposed By : Name : Signature : Date : Authentication of Unit Head : Name : Designation : Unit / Location: Signature : Date : Note: ** The description should specify under which of the following area (s) the employee / contract employee has made the significant contribution. 1) Prevention of any incident of fire or accident from its potential occurrence. 2) Effective handling of plant abnormality & emergency in plant operation to prevent escalation to unsafe situation. 3) Prompt response & control of the incident & preventing damage through effective fire-fighting and rescue. 4) Innovative suggestions for enhancing safety & its implementation etc. 5) The justification should be well supported by the documentary evidence. 6) The nomination should be duly authenticated by the unit head. Page 17 of 19
ANNEXURE-1II DETAILS OF NEAR MISSES AND MILLION MAN HOURS WORKED Sl. No. Location Type of Near Miss Fire Incident Date & Time Duration Description of the Near Miss Whether Near Miss incident submitted to OISD?( Furnish the reference & date) Corrective implemented measure Page 18 of 19
COMPLIANCE / DEVIATION TO OISD STANDARDS Annexure IV OISD Standard Name of the Standard Compliance/ deviation status OISD STD 105 Work Permit System OISD-STD-108 Recommended Practices on Oil Storage and Handling OISD-STD-113 Classification of Area for electrical installations at Hydrocarbon processing and handling facilities OISD-STD-117 Fire Protection Facilities for Petroleum Depots, Terminals, Pipeline Installations and Lube Oil Installations OISD-STD-118 Layouts for Oil and Gas Installations OISD-STD-129 Inspection of storage tanks OISD-STD-164 Fire Proofing in Oil & Gas Industry OISD-GDN-178 Guidelines on Management Of Change OISD-GDN-207 Contractor Safety Page 19 of 19