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CHAPTERCHAPTERCHAPTERCHAPTER ---- XVIXVIXVIXVI

SAFETYSAFETYSAFETYSAFETY

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11116666.0.0.0.0 SAFETYSAFETYSAFETYSAFETY PRECAUTIONS & PRACTICESPRECAUTIONS & PRACTICESPRECAUTIONS & PRACTICESPRECAUTIONS & PRACTICES

Safety is the prime responsibility of every employee. You cannot do the job properlyunless you do it safely.

11116666.1.1.1.1 Safety ResponsibilitySafety ResponsibilitySafety ResponsibilitySafety Responsibility

Safety is the most important consideration in any operation. BPCL-KochiRefinery considers safe working conditions and safe working habits an absolutenecessity for the operation of the plant. No unit or part of a unit should beoperated in an unsafe condition or manner. Also no operator should performany work in an unsafe manner. There is a safe way to do a job and it is theresponsibility of the operator to be aware of this way. Do not proceed with ajob if you are not clear of the consequences of the steps taken by you.Consult your Supervisor when in doubt and get with the job only after

understanding thoroughly every phase of it.

Accomplishing a job efficiently and without injury to oneself or othersnecessitates clear thinking and attention to the job. The operator must guardagainst the possibility of daily routine dulling his senses resulting in carelesshandling of even the simplest of jobs.

It is the responsibility of the operators to be familiar with characteristics ofthe product and chemicals which he handles, as they apply to fire and personalprotection. Safety instructions and proper procedures for working inoperating area have been issued. Equipments are designed with safety in mind.Personal protection gears have been provided at operating areas for operatorsuse. In addition to all these operators must act safety and do their job in asafe manner.

Every employee should develop safety consciousness. It is the responsibilityof the operator to bring to the attention of the supervisor, any potentialhazards involved in their job in the process area and recommend properprotective equipment / remedial action.

All employees are required to go through The safety Hand Book, Chemical

Safety Hand Book, Pocket Fire Guide and Fire Emergency Procedure issuedto them and thoroughly acquaint themselves with the contents.

11116666.2.2.2.2 House keepingHouse keepingHouse keepingHouse keeping

In general a clean plant is a safe plant. Always keep your work area clean andin order. Allow no debris to collect. You should not allow any spills or leaks.In case they happen, clean them off immediately, provided ample space, do not

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allow it to get filled. See that the materials that must be kept in the area arealways kept in an orderly manner. Place all trash in containers provided.Form a habit of daily clean up.

11116666.3.3.3.3 Few Cardinal RuFew Cardinal RuFew Cardinal RuFew Cardinal Rules of Safetyles of Safetyles of Safetyles of Safety

1. Use your common sense on the job and mentally check outevery action before you do the job.

2. When in doubt ask your Supervisor.3. Do not sacrifice safety for haste.4. Do not day dream. Keep alert. Think of your job.5. Use protective equipment and cloth wherever required.6. Keep alert to unsafe working conditions, fire hazards etc.

Remove any hazards within your power, also report them toyour supervisor.

7. Safety is a major part of your job. You cannot do your jobunless you do it safely.

16161616.4.4.4.4 DraiDraiDraiDraining or venting Hydrocarbon & Other dangerous chemicalsning or venting Hydrocarbon & Other dangerous chemicalsning or venting Hydrocarbon & Other dangerous chemicalsning or venting Hydrocarbon & Other dangerous chemicals

When it is required to drain/vent hydrocarbon or other dangerous chemicals,it is necessarily required that a man should be present at the spot till thedraining or venting is stopped. Hot and heavy hydrocarbon pose a fire hazardon contact with air. It should be ensured that such products are cooled downto a safe temperature before they are drained and steam hose or water spraykept nearby for use in case of emergency. Likewise, light hydrocarbons willevolve flammable vapour when drained or vented and they should be drainedor vented in controlled quantities. The operator draining such product shouldstand upwind, so as to avoid these products spraying on to his body or cloth.In case of body contact, wash the area immediately with lot of water. Careshould be taken in opening plugged drain/vent valve. If valve is openedbeyond normal there is the danger of plug blowing out under pressure andhydrocarbon gushing out at an uncontrolled rate. So do not open a pluggedvalve beyond its normal opening. In this case either get a new valve attachedto the plugged one or use a pressure proof bleed reamer.

11116666.5.5.5.5 Sign BoardsSign BoardsSign BoardsSign Boards

Various sign boards indicating Note, Caution and Warning can be seen atvarious points inside the Refinery. These sign boads indicate:

Note : Highlights and essential elements of a procedure to assurecorrectness.

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Caution : Indicates a procedure, practice etc. which, if notstrictly observed could result

in damage or destruction of equipment.

Warning: Indicates a procedure, practice, etc. which could result in

personal injury orloss of life if not followed correctly.

11116666.6.6.6.6 Hazards of Petroleum ProductsHazards of Petroleum ProductsHazards of Petroleum ProductsHazards of Petroleum Products

16161616....6666....1111 Physiological effectPhysiological effectPhysiological effectPhysiological effectAll petroleum products give out vapours in quantity depending upon the typeof product. These varpours in a confined space will tend to make theatmosphere leaner in oxygen content, thus making it difficult to sustain

breathing. (asphyxiation). The hydrocarbon vapours heavier than air collectedat low points near ground level. The vapours have anaesthetic effects. Ifinhaled for 5 minutes at a concentration of 0.1%, the person feels giddy.

If concentration is 0.5% and exposure is A minute, the person exhibitssymptom similar to drunkenness. A concentration of 1.0% will cause rapid onset of drunkenness which may lead to unconsciousness and death if exposurecontinuous. At 2% concentration, paralysis may occur rapidly followed bydeath.

16.6.2 Explosion/FireExplosion/FireExplosion/FireExplosion/Fire

When the proportion of hydrocarbon in the hydrocarbon air mixture fallwithin the explosive limits (table 16.1) an explosion or fire could occur,triggered by a source of ignition. The hydrocarbon air mixture can spread onthe ground over a considerable distance initiating a flash back. When theexplosive mixture get ignited an explosion takes place which could lead toother explosions or fires, even at large distances, depending upon its intensity.Hydrocarbon dust or vapour cloud can also get ignited causing severe

damages of catastrophic proportions.

Table 1Table 1Table 1Table 16666.1.1.1.1 Explosive limits of HydrocarbonsExplosive limits of HydrocarbonsExplosive limits of HydrocarbonsExplosive limits of Hydrocarbons

Product Lower Higher explosive

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explosivelimit (LEL %vol/vol air)

limit (HEL %vol/vol air)

Hydrogen 9.5 65.2

Methane 5.3 14

Ethane 3.2 12.5Ethylene 2.75 28.6

Propane 2.37 9.5

Propylene 2.0 11.1Butane 1.6 8.5

Pentane 1.45 7.5

Hexane 1.2 6.9

Gasolene 1.3 6.0

Naphtha 1.1 6.0

Kerosene 0.7 5.0

Hydrogen sulfide 4.5 45Ammonia 15.5 27

Toluene 1.27 7.0

LPG 1.9 9.0

Diesel 0.7 5.0

Benzene 1.3 7.1

11116.6.6.6.7777 Sources of IgnitionSources of IgnitionSources of IgnitionSources of Ignition

11116666.7.1.7.1.7.1.7.1 Auto IgnitionAuto IgnitionAuto IgnitionAuto Ignition

Normally for combustion, a combustiable material, sufficient quantity ofoxygen and a source of heat are required. In free air there is no risk ofignition if the hydrocarbon vapour temperature is less than the ignitiontemperature. However, if the temperature of the hydrocarbon vapour equalsits ignition temperature, the vapour can catch fire on mixing with oxygenfrom atmosphere even without the help of a flame or spark. This is known asauto ignition. The risk of auto ignition is generally more as the molecularweight of hydrocarbon increases. Table 16.2 lists the auto ignitiontemperatures of some of important hydrocarbons.

11116666.7.2.7.2.7.2.7.2 Electrical ApparatusElectrical ApparatusElectrical ApparatusElectrical Apparatus

Electrical apparatus includes all machines, equipments and fittings in whichconductors are used or of which they form a part, eg. Electric switches, pushbuttons, circuit breakers, starters, motors, etc. These may provide arcs or

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sparks and are capable of raising surface temperatures above the spontaneousignition temperature.

Table 1Table 1Table 1Table 16666.2.2.2.2 Auto ignition temperatureAuto ignition temperatureAuto ignition temperatureAuto ignition temperature

Product TemperatureoC

Hydrogen 530

Ethane 576

Ethylene 450Propane 466

Butane 430

Pentane 309

Hexane 247

Gasolene 257

Kerosene 254

Lube oil(light) 417

Hydrogen sulphide 250

Ammonia 651

Lube oil (Heavy) 248

Reduced crude 300

Naphtha 287

Diesel 257

Furnace oil 407

Toluene 580

11116666.7.3.7.3.7.3.7.3 Stray Electric CurrentsStray Electric CurrentsStray Electric CurrentsStray Electric Currents

It may occur when very high voltage is applied. Welding machines may alsobecome sources.

11116666.7.4.7.4.7.4.7.4 StaticStaticStaticStatic ElectricityElectricityElectricityElectricity

Static electricity is produced by friction or by the mere contact and separationof unlike substances. Explosions and fire can be caused by a static spark

whenever flammable or explosive chemicals, liquid, gases or dusts are beinghandled.

Static electric is generated when :

- Liquid passes through pipes/filters (tanker loadings/fillings)- Solids settle in liquid (rust and sludge settles in tanks)\

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- Droplets of liquid settle down in another liquid (water in oil)- Free fall of a liquid column is interrupted (overhead tank filling)- Gas bubbles through liquid (trapped air rising through liquid)- Jets or bubbles are broken up by splashing (splash filling of tanks,

high speed ejection of liquid from nozzles).

- Solids and solids impinge (sand blasting)11116666.7.5.7.5.7.5.7.5 LightningLightningLightningLightning

Lightning can fall on metallic object, especially tall objects such as chimneys,towers, tanks and buildings. Lightning may lead to damage as well as ignition.Vents and safety relief at high points are vulnerable.

11116666.7.6.7.6.7.6.7.6 Non ElectriNon ElectriNon ElectriNon Electrical Sourcescal Sourcescal Sourcescal Sources

- Smoking- Internal combustion engines spark ignition system, dynamo, battery,

hot particles or flame from exhaust system.- Spontaneous ignition (Oil soaked rags/insulation)- Pyrophoric Iron (Fes): Pyrophoric substances (Black or grey powder)

can be seen inside the column at its top section, over head system,flare and fuel gas lines, effluent treatment and sewerage system. Ingeneral, pyrophoric iron can be present in the scales of all systemshandling hydrocarbon containing sulphur. This is so exothermic thatit can melt metal and start ignition.

- Frictional heat/spark (Falling of iron tools).11116666.8.8.8.8 Hazards in handling ChemicalsHazards in handling ChemicalsHazards in handling ChemicalsHazards in handling Chemicals

11116666.8.1.8.1.8.1.8.1 Caustic Soda(NaOH)Caustic Soda(NaOH)Caustic Soda(NaOH)Caustic Soda(NaOH)

This is extremely alkaline and highly corrosive to body tissue. Contact withbody tissue will result in severe burn and tissue damage. Continuous contactof dilute solution may result in dermatitis. Contact with eyes is extremelydangerous and may result in blindness.

In case of body contact, wash affected area with running water as long aspossible before getting medical attention. Always wear protective equipmentviz face shield, rubber gloves, gum boots, apron etc, while handling causticsoda. Identify and familiarise the location of eye wash and safety shower in thearea.

11116666.8.2.8.2.8.2.8.2 ChloriChloriChloriChlorine Clne Clne Clne Cl2222

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Chlorine is detected even at a very small quantities due to its pungent odor. Itis very corrosive when wet and will damage any mucous membrane ( eye,throat, lungs etc.) by forming HOCl/HCl.

Chlorine cylinder should always be kept in a well ventilated area and also makesure that the cylinder outlet is from the gas side. In case of any leaks,respiratory protective equipment which gives full protection for eyes also areto be used. If leak developed in the liquid side, turn over the cylinder toensure that only gas is leaking out. Affected person may give soda or limewater and oxygen if he has breathing troubles. He should be allowed to restand given glucose rich diet.

16161616....8888....3333 Diethanol Amine(HOCHDiethanol Amine(HOCHDiethanol Amine(HOCHDiethanol Amine(HOCH2222CHCHCHCH2222))))2222NHNHNHNHDEA is used as absorbent for acid gases like hydrogen sulphide from LPG. Itcauses irritation to skin, mucous membrane and eyes. Breathing vapours maycause coughing, a smothering sensation, nausea, headache. Unconciousness orconvulsion may occur if DEA is swallowed.

The affected part should be immediately flooded with plenty of water. Noproblem is likely to occur when inhaled. Get medical attention if ill effectsdevelop.

16.8.416.8.416.8.416.8.4 AmmoniaAmmoniaAmmoniaAmmonia

Uses: For neutralizing acid vapours in distillation columns.

Physical Properties:

Boiling point : 33.4oCPhysical state : Liquefied compressed gas.

Odour : Strong pungent odour.Soluble in water : Moderately soluble in Alcohol.

Fire & Explosion data :

Flammability : LEL 16%UEL : 25%Auto ignition temperature : 651oC

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HazardousCombustion products : Emits toxic fumes ofammonia and NoxNot flammable.

Health Hazard data:

Routes Of entry : Inhalation, skin or eyes.Effects of exposure : 700 ppm causes eye

irritation and permanent injury mayresult if prompt remedial measuresare not taken. 5000 ppm maycause death from spuminflammation, or EDEMA of theLARYNX. Contact of the liquidwith skin freezes the tissues and

causes the caustic burns.

Emergency treatment:

Inhalation : Remove the victim to freshair and provide artificialrespiration or oxygen.

Skin & Eyes : Wash the affected area withplenty of water for 15 minutes.

Permissible exposure limit: 25 ppmLD50(Oral-rat) : 350 mg/Kg.TLV : 25 ppmSTEL : 35 ppm

Personal Protection Equipment:

Rubber boots, safety goggles, self contained breathingapparatus(SCBA), gas mask and protective clothing in case ofliquid ammonia.

Emergency/Fire Aid measures:

Fire : Fire extinguishing media: use water sprayor fog.

Keep containers cool by spraying water ifexposed to heat or flame.

Unusual hazard : Gas is suffocating.

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16.8.516.8.516.8.516.8.5 PhosphatePhosphatePhosphatePhosphate

Moderately toxic by injestion, irritant to tissue. Flush the affected area withsufficient quantity of water, seek medical attention.

16.916.916.916.9 GENERAL SAFETY GUIDELINESGENERAL SAFETY GUIDELINESGENERAL SAFETY GUIDELINESGENERAL SAFETY GUIDELINES

The following general safety rules are applicable to plant operations. Thismust be known to and strictly observed by all personal.

Safety Rules in genSafety Rules in genSafety Rules in genSafety Rules in generaleraleraleral

1. Smoking is strictly prohibited inside the refinerypremises

2. Contaminated clothes must be removed immediately anda shower taken

3. Defective tools should not be used.4. Only non-sparking tools should be used5. Use the proper tool for the work involved6. Do not overstress tools or equipments7. Use safety belts of life lines when working above 3 meter

height, where it is not practical, make other provisionsto prevent falling.

8. To prevent falls:- Look around while going around- Do not run / jump in work place- Stand on ladders or platforms and not on makeshifts.- Use handrails on stairs and do not run- Face trolley when carrying load on the same.9. Tools and objects should not be dropped from height.10. Do not stand/walk under suspended object.

Electrical SafetyElectrical SafetyElectrical SafetyElectrical Safety

1. Do not tamper with electrical apparatus2. Do not remove light bulbs to plug in power equipment3. Use only approved fittings4.

Electrical equipment must be properly grounded5. An extension wire, if used, must be properly laid

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16.9 SAFETY PRACTICES FOR PARTICULAR OPERATIOSAFETY PRACTICES FOR PARTICULAR OPERATIOSAFETY PRACTICES FOR PARTICULAR OPERATIOSAFETY PRACTICES FOR PARTICULAR OPERATIONSNSNSNS

11116666.10.1.10.1.10.1.10.1 Sampling and purgingSampling and purgingSampling and purgingSampling and purging

Before opening a purge/sample connection ensure that the product isnot hot enough to start a fire or cause burns. Hot & heavy productsare most dangerous as they are near their auto ignition temperature.Sample connections of hot products are normally through coolers.Vents/drains of hot products which are not in regular use should becapped/blinded. If a hot product is to be vented, connect it through acooling coil. Vents must be opened slowly and the person doing soshall be present on the spot till the same is closed. Also theplug/cap/blind should be put back when the operation is complete.Sample and purge connections on iquefied products shall have two

valves. Always open the upstream valve fully and adjust flow by thedownstream valve. By doing so in case of frosting, u/s valve will beoperable.

16.10.216.10.216.10.216.10.2 Isolation of safety valvesIsolation of safety valvesIsolation of safety valvesIsolation of safety valves

Safety valves are provided with bypass and also with valves upstreamand downstream. This is to facilitate maintenance. Always ensure thatthe safety valve is in line.. When one valve is taken out of line thespare should be put on line. An equipment should never be taken online without a safety valve.

16.10.316.10.316.10.316.10.3 Furnace operationFurnace operationFurnace operationFurnace operation

While lighting burners in a furnace, it should be purged thoroughlywith steam/air. Sometimes a number of trails are to be taken to light aburner. It is important to purge the furnace every time a burner failsand trial for relighting is made. It should also be noted that eachburner be lighted by pilot burner and not by the flame or heat of theadjoining burner. Sometimes during a furnace shutdown all the burnersare put off. If it becomes necessary to relight some burners do not

forget to purge the furnace.

16.10.416.10.416.10.416.10.4 High poinHigh poinHigh poinHigh point vents and relief valve dischargest vents and relief valve dischargest vents and relief valve dischargest vents and relief valve discharges

These are normally on closed system with the flare. In rate casesventing to atmosphere may be unavoidable but pose hazard due tolightning. So in this case purging steam must be opened to the ventespecially during monsoon seasons.

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16.10.516.10.516.10.516.10.5 Flare system operationFlare system operationFlare system operationFlare system operation

It is essential that the pilot burner at the flare tip is always is on.Always maintain a small purge gas to prevent air ingress into the

system. Maintain proper hydraulic seal in the water seal drum all timeswhen flare is operating.

16.1116.1116.1116.11 FIRE FIGHTING FACILITIESFIRE FIGHTING FACILITIESFIRE FIGHTING FACILITIESFIRE FIGHTING FACILITIES

In case of fire, operating personnel should identify the source of fuel andcut out the same as soon as possible. Movement of all process fluids tothe affected area should be stopped. Attempts should be made toextinguish fire immediately using extinguishers, water, steam, sand etc,provided in the plant area. If this is not possible convey the emergency asfast as possible to the fire station by breaking the nearest fire alarm points

glass or by phone or by informing the supervisor or by all three at thesame time. The personnel should be fully conversant with the fire fightingsystem provided in the plant and with the reporting procedure. Everyperson must attend the fire training conducted every Friday by the FireDept. atleast once a year. They should also be familiar with the disasterplan organogram displayed in the notice board. The fire fighting systemscomprises of the following:

1)1)1)1) Fire Alarm PointsFire Alarm PointsFire Alarm PointsFire Alarm Points

Whenever a fire is sighted and external help is required, first break theglass of the fire alarm point. The alarm is received at the fire stationwith exact location indication and also at all control rooms, medicalcentre, and other important locations for caution and action. If it is amajor fire it may be decided to sound the fire siren for informationand caution to neighbours as well. We also have a mutual aid schemebetween BPCL-KR, HOC & FACT (CD). In case of a fire in any of thismember industries, to fight the same together. In case the fire turnsout to be of disastrous proportions, our disaster plan will startfunctioning with immediate effect.

2)2)2)2) Portable Fire ExtinguishersPortable Fire ExtinguishersPortable Fire ExtinguishersPortable Fire Extinguishers

Fire should be killed at the initial stage before it can cause muchdamage or it can spread. Portable extinguishers are very useful to fightsmall fires. All strategic areas are provided with a 10 kg/75 kg wheeledDCP extinguishers

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3)3)3)3) Gas Alarm Monitor systemsGas Alarm Monitor systemsGas Alarm Monitor systemsGas Alarm Monitor systems

Gas sensing elements are provided at different locations in the plantwhich sense the hydrocarbon vapour/gas and H2S present in theatmosphere and the convey the same as percentage of lower explosive

limit to the main control room which houses the gas alarm monitorpanel. The alert sign is flashed at 20% of LEL and alarm is sounded at60% of LEL. This gives time for remedial action in case of gas leak.

4)4)4)4) Fire Water NetworkFire Water NetworkFire Water NetworkFire Water Network

a. Type of Fire Protection SystemsThe following type of fire protection systems are envisaged forthe plant.

1. Pressurised automatic hydrant system2. Fixed water spray system for tanks3. Fixed water spray system for equipments4. Semi fixed manually operated foam system for HSD and

LSD tanks5. Clean agent total flooding system for control room6. Fire detection and alarm system for control room &

substation.7. Portable fire extinguishers.

b. Hydrant SystemThe hydrant system shall mainly consist of fire water pumps,reservoir, pipe net work, hydrants, and monitors. The pipe linesare laid in rings around each area. Hydrants are fixed at regularintervals of 30 meters for plant and storage area and 45 metersfor utility area on stand posts tapped from the ring mains. Themains are constantly charged with water to the system designpressure. The operation of the system is automatic through thepressure switches installed in the system.

System Operation In case of fire

In case of fire, one or more hydrants shall be opened. Thesystem pressure shall fall down from the normal level.Immediately jockey pump shall comes into operation tocompensate the loss of pressure in the system. Since the jockeypump cannot meet such high water demand the pressure shall

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fall down further. When the pressure reaches 10.5 kg/cm2gpressure switch shall switch on the main fire water pump intooperation.

c. Fixed Water spray system

d. Foam System.

16.1216.1216.1216.12 GAS MASKGAS MASKGAS MASKGAS MASK

There are three types of gas mask in general refinery service. They arecanister type mask, the fresh air mask, and self contained breathingapparatus(trolley mounted BA set). Their uses are described below:

I. The Canister Mask utilises a filter element to absorb the poisonous gasfrom the air. Different gases requires different type of filters.Information about the filtrs may be obtained from the Safety Dept.

1. Use this mask only in the open air or where the gasconcentration is less than 2%, not in a tank or other confinedspace, except in an extreme emergency. A canister type ofmask does not protect the user against the deficiency ofoxygen. A lifeline should be used in questionable location.

2. As seal is removed from a canister mask and after one yeardiscard it regardless of how little it has been used.

3. A record of amount of time that the canister has been usedmust be kept on a tag attached to the canister. Do not exceedthe permissible time for a particular canister being used.

II The fresh air mask has a remote air supply provided by hand operatedblower through a lengthy hose. It is used mostly for rescueoperations.

1.

When a man must enter a tank, sewer or other confined area,where the atmosphere is 20% or more of the lower ExplosiveLimit or contain evidence of hydrogen sulphide or other toxicmaterial, a fresh air mask must be used.

2. The blower must be placed where only fresh air can enter it, butnot more than 100 ft. of hose should be used.

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3. A life belt and the rope should also be used with the end fixedso that it will not fall back into the tank or sewer.

4. Be sure that the harness is buckled close to the wearers body sothat it will not slip over his shoulder, if a rope rescue is

necessary.

5. One man who knows artificial respiration must be present onthe outside.

III. The self contained breathing apparatus has a self contained air supplycarried on the back of the user. It is the only one of the three typesthat is completely independent of outside air.

1 This mask is to be used only be specially instructed personnelwhere there is little or no ventilation.

2 It is used principally in emergencies.3 After use always notify the Safety / Fire Dept. so that they can

recharge the tank.

16.13 GENERAL

a. Maintaining Electrical ground continuity of system.In addition to the individual earthing of equipments and motors, aseparate grounding system for the pipeline network is given.

b. Centralised communication & monitoring

Personnel protection and first aid personnel protection equipments(PPE) of all ranges from disposable paper masks, canister masks, selfcontained masks with cylinder back up and remote air blowing facilityto face shields, rubber, plastic and canvassed gloves and gum boots areprovided within easy access.

Two first aid boxes with all facilities to handle minor burns and injuriesand water gel blankets for burn injuries are also provided in thecontrol room. Further operating personnel are trained on first aid.Plant area is also provided with eye washes and drip showers.

Notice boards displaying dos and donts as well as first aid practices forparticular chemical contacts are provided at appropriate places.

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FIRE PROTECTION AND COMMUNICATION SYSTEMFIRE PROTECTION AND COMMUNICATION SYSTEMFIRE PROTECTION AND COMMUNICATION SYSTEMFIRE PROTECTION AND COMMUNICATION SYSTEMFIRE FIGHTING FACILITIESIn case of fire, the operating personal, should identify the source of fuel and cut outthe same as soon as possible. Movement of all process fluids to the affected areashould be stopped. Attempts should be made to extinguish fire immediately using

extinguishers, water, steam sand etc, provided in the plant area. If this is not possibleconvey the emergency as fast as possible to the fire station by breaking the nearestfire alarm points glass or by phone or by informing the supervisor or by all three atthe same time.The personnel should be fully conversant with fire fighting systems provided in the

plant and with the reporting procedure. Every person must attend the fire trainingconducted by the fire section at least once a year. They should also be familiar withthe disaster plan organogram.A) FIRE WATER NETWORKA reliable and adequate supply of water for fighting fire/cooling surface at all points

in and around the plant is ensured by a pressurised fire water net work (12 kg/cm2g).Double outlet fire hydrants are provided spaced approximately every 30metre apart.Water monitors are also provided in the loop that can reach a height of 80metre.Inside the plant, fire hose reels are separately provided in hose boxes along withregular pressure hose reels. A fire proof suit is also provided for rescue operationetc. in daring situations.Eight sets of fire water pumps of capacity 616 m3/hr are provided for the hydrantsystem. Out of the eight pumps, four act as main fire water pumps and the otherfour are kept as standby. Four pumps are electric motor driven and the rest are dieselengine driven pumps. 2 numbers of electric motor driven jockey pumps of capacity66 m3/hr are provided to maintain the system pressure and to compensate for anyleakages. All the pumps are located in the fire water pump house. The fire waterpumps are common for hydrant systems, water spray system and foam system.B) FIRE WATER RESERVOIR

This is an exclusive fire water reservoir of capacity 15500m3 in two compartments.The bottom level of the tank is above the centerline of the fire water pumps inorder to facilitate the fire water pump to work under positive suction. The totalcapacity of the fire water

Total flooding system for control room (NAF SIII):Total flooding system for control room (NAF SIII):Total flooding system for control room (NAF SIII):Total flooding system for control room (NAF SIII):NAF SIII Gas is a blend of hydro chloro fluro carbons (HCFCs). NAF SIII ismanufactured in Italy by Saftey Hi-tech.Srl, under licence from North American FireGuardian Technology Inc. NAF SIII is a clean, electrically non conductive and isefficient on class A, class B and class C fires. It leaves no residue on discharge. It iscolourless and non corrosive. NAF SII is listed as an acceptable alternative to Halon1301. NAF SII total flooding system is for control room, console area, engineering

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room, equipment and rack room. 13 cylinders are used for maintaining 8.65%concentration. 13 cylinders are kept stand by, cylinder pressure is 25 bar.Smoke detection and alarm system:Smoke detection and alarm system:Smoke detection and alarm system:Smoke detection and alarm system:In order to ensure life safety and property loss there is a need to detect fires in theincipient stage which will provide a reasonable interval of time for inmates to escape

to a place of safety and give fire fighters a reasonable chance to control andextinguish the fire with the minimum loss. Therefore the basic objective of any firedetective system is to respond to a fire and transform the response into anaudiovisual signal, which would simultaneously alert the building occupants andinform others related to fire safety to take immediate measures.

Smoke is the product of combustion and it refers to solid or liquid particles that arereleased during combustion. The traditional method of detecting smoke, have beenwith either ionisation or photoelectric smoke detectors. The ionisation smokedetectors, which are installed in our control rooms respond faster to those firescontaining smaller particles and are more effective for detecting incipient fires from

wood, paper etc., especially where very low amounts of visible smoke are generated.Portable fire extinguishers.Portable fire extinguishers.Portable fire extinguishers.Portable fire extinguishers.Fire should be killed at the initial stage before it can cause much damage or it canspread. Portable extinguishers are very useful to fight small fires. All strategic areasare provided with 10kg and 75kg wheeled DCP extinguishers. All personnel must beacquainted with the exact location of these.COMMUNICATICOMMUNICATICOMMUNICATICOMMUNICATION NETWORKON NETWORKON NETWORKON NETWORK1) FIRE ALARM POINTSFire alarms are provided at several convenient places through out the plant. Whenevera fire is sighted and external help is required, first break the glass of the point. Thealarm is received at the fire station with the exact location indication and also at allcontrol rooms, medical centre and other important locations for caution and action.If it is a major fire it may be decided to sound the fire siren for information andcaution to neighbours as well.We also have a mutual aid scheme between BPCL KR, HOC and FACT (CD). In caseof a fire in any of these member industries, to fight the same together. In case thefire turns out to be of disastrous proportions, our disaster plan will start functioningwith immediate effect.2) PHONE NUMBERSi) EMERGENCY TELEPHONE NUMBERS:Fire station 101Main fire station control room 1905/1922DHDS fire station control room 1913CDU-2 fire station control room 1908ii) MEDICAL SERVICES:Medical centre 1425

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Medical officer 1422/1428iii) SECURITY:Main gate 2235DHDS gate 2206

Jwalagiri main gate 2236

iv) DISASTER CONTROL ROOM: 1130-34v) OTHER IMPORTANT NUMBERS:GM (O) 1104DGM (MFG) 1800CM (DHDS) 1802

CM (SHA) 1121/11225) FIRE ALARM:A centralised fire alarm hooters are provided in fire stations and inside the controlrooms. The DGFAP (Data Gathering Fire Alarm Points) is replaced with M/sHONEYWELL (CPU 16 and 17) system in DHDS control room. The hooter will be

sounded in DHDS control room and fire station in case of actuation of any MCP/smoke detectors in DHDS area, which is displayed in M/s HONEYWELL system (CPU16 and 17). The alarm will be sounded with displaying MCP number in M/sHONEYWELL system (CPU 16 and 17) in DHDS control room and fire station in caseof actuation of any MCP/ smoke detectors any where in the refinery.6) FIRE SIREN:The fire siren will be sounded in case of minor fire/ major fire/ disaster. Test sirenwill be sounded every Thursday at 13:30hrs which will be a continuous siren for2minutes.Note: Closed Circuit TV (CCTV) system is provided in control rooms for closelymonitored the plant area and flare flame.ONSITE EMERGENCY PLANONSITE EMERGENCY PLANONSITE EMERGENCY PLANONSITE EMERGENCY PLANThe type of emergency primarily considered here is the major emergency which maybe defined as one which has the potential to cause serious danger to persons and /or damage to property and which tends to cause disruption inside and / or outsidethe site and may require the use of outside resources.Emergency is a general term implying hazardous situation both inside and outside thefactory premises. Thus the emergencies termed on-site when it confines itselfwithin the factory even though it may require external help and off-site whenemergency extends beyond its premises. It is to be understood here, that if anemergency occurs inside the plant and could not be controlled, it may lead to an off-site emergency.The On-Site Emergency plan will come into effect on sounding of the fire siren(Wailing sound) as follows:

i) Sound the fire siren continuously for 2 minutes.ii) Stop the fire siren for 1 minute.

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iii) Sound the fire siren continuously for 2 minutes.iv) Stop the fire siren for 1 minute.v) Sound the fire siren continuously for 2 minutes.

SOUND STOP SOUND STOP SOUND2 MIN. 1 MIN. 2 MIN. 1 MIN. 2 MIN.

Total duration of Siren for enforcement of On-Site Emergency plan will be eightminutes.Signal for withdrawal of On-site emergency control plan. / Fire siren will soundcontinuously for 2 minutes (Straight run siren).Signals for enforcement and withdrawal of the On-site emergency Plan are to be

followed by announcement over the internal PA system, by AdministrationSection, on Chief Co-ordinators instruction, as to the enforcement/withdrawal ofthe OEP. For details please refer OEP manual.

16.1416.1416.1416.14 SAFETY MEASURES PERTAINING TO THE UNITSAFETY MEASURES PERTAINING TO THE UNITSAFETY MEASURES PERTAINING TO THE UNITSAFETY MEASURES PERTAINING TO THE UNIT

11116666.14.1.14.1.14.1.14.1 Mechanical Design SafetyMechanical Design SafetyMechanical Design SafetyMechanical Design Safety ---- Fire & Explosion Proof DesignFire & Explosion Proof DesignFire & Explosion Proof DesignFire & Explosion Proof Design

The sulphur plant normally operates under low pressure, at about 0.8kg/cm2.g. However, the minimum design pressure of all equipment handlingacid gas is 3.5 kg/cm2.g . Pressure safety valves designed for external fire areprovided on all the KO drums.

Possibility of explosion is greater during start-up of the unit with fuel gas andthe system is cold than when unit is hot and switched to acid gas burningmode. Thus explosion proof design of Main burner & combustion chamber,waste heat boiler and Burner & Mixing chamber of incinerator will be asafeguard against possible explosion during start-up, shut-down and hot-standby mode.

11116666.14..14..14..14.2222 Personnel Safety EquipmentPersonnel Safety EquipmentPersonnel Safety EquipmentPersonnel Safety Equipment

1. H2S Detectors at strategic locationsThe following information deals with the prevention of possible dangerhazards encountered in the Sulphur Recovery Unit.

For the protection of the operating personnel H2S detector system is installed.

Meter range : 0 - 100 PPM H2S.

When the concentration of H2S in the atmosphere, after the alarm isactuated, appears to increase considerably, the unit has to be shut-down

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manually. The alarm is set at a value of 20 PPM by volume of H2S.

It is advised to check the sensors every six months.

Process gas leaks of minor nature can be detected by means of cotton waste

soaked in ammonia. If this is brought into the vicinity of the leak, whitefumes of ammonium salts will be formed. Also, filter paper wetted with leadacetate solution can be used. The lead acetate turns black when exposed toH2S.

2. Special Safety Measures and Industrial Hygiene

This paragraph describes how to prevent hydrogen sulphide and sulphurdioxide poisoning and some suitable protecting equipment.

a) Carelessness, negligence or ignorance of danger are often the causes ofH2S and SO2 poisoning. Operators must be instructed to avoidinhalation of gas whenever possible, by working on the windward sideof the place where gas is escaping. Furthermore, they should not stayunnecessarily without protection under process gas lines or equipment,since H2S and SO2 are gases heavier than air.

b) Process staff and senior operating personnel have an additionalresponsibility and they should show by their own example thatprecautions should be taken. Instructive bulletins issued by the safetydepartment and education are also very important.

c) In places where high concentrations of gas may occur, especially inenclosed spaces, one should wear a compressed air breathing apparatusor hose masks connected to a clean air supply. If air is supplied by anair blower, care must be taken that the air blower has been placedupwind and clear of any source of gas, in order that the personwearing the mask will have a supply of uncontaminated air.

d) When the aforementioned masks are in use an attendant should bestationed at the air supply point. As an extra precaution somebodyequipped with a compressed air breathing apparatus should watch eachhose and safety line and prevent them from becoming entangled.

e) Personnel should not enter an enclosed space without a belt with a lifeline. Also an attendant should remain in a safe location at the other

end of the life line at all times.f) Even at low concentrations of H2S and SO2 a canister type mask maynot be worn, as this type is unreliable.

g) To prevent irritation of the eyes full goggles with water dams arerecommended. The water dams prevent fogging of the lenses, whichshould be made of safety glass.

h) When loading or unloading catalyst, wearing of masks is recommendedto prevent inhalation of catalyst dust.

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3. First Aid Measures

If a person has lost consciousness by inhalation of H2S or SO2 gas, thefollowing procedure is advised:

a) Remove the patient to fresh air or a well ventilated room and loosenany restrictive clothing.b) In conjunction with 1 above, contact the medical department, and call

immediately a doctor, stressing the nature of the accident.

c) Application of oxygen to a patient should only be carried out by aperson familiar with the use of oxygen inhalation apparatus. Anattempt to apply oxygen by a person not familiar with the use of theapparatus may result in the loss of valuable time and/or may harm thepatient.

d) Keep the patient comfortably warm, but not hot. If the patient regainsconsciousness during this period, keep him as calm as possible as hemight be in a state of shock.

e) If, however, respiration of the patient has stopped, commence artificialrespiration treatment at once and continue until professional assistancearrives.

f) It should not be attempted to give anything to eat or to drink to anunconscious patient.

WARNING:WARNING:WARNING:WARNING:

Do not attempt to enter a gaseous area to render assistance before putting onDo not attempt to enter a gaseous area to render assistance before putting onDo not attempt to enter a gaseous area to render assistance before putting onDo not attempt to enter a gaseous area to render assistance before putting ona compresseda compresseda compresseda compressed airairairair

breathing apparatus or air hose mask.breathing apparatus or air hose mask.breathing apparatus or air hose mask.breathing apparatus or air hose mask.

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11116.6.6.6.14.14.14.14.3333 Toxicological DataToxicological DataToxicological DataToxicological Data

Tables of H2S and SO2 effects are given below, followed by a summary ofsome of their properties.

1. Physiological Effects Of H2S

SL.NO

.

DESCRIPTION PPM1 VOL. %

1. Limit for odour detection 0.14

2. Weak odour hardly noticeable 0.77

3 Noticeable odour 4.6

4 Obnoxious odour 7.0

5 MAC2 10 0.0.1

6 Slight signs of inflammation of the eyes after onehour

50 - 100 0.05 - 0.01

7 Limit that can be stood for six hours withoutadverse effects

78 - 128 0.008 -0.013

8 Limit that can be stood for one hours withoutconsequences effects

170 - 255 0.017 -0.026

9 Odour no longer disagreeable 198 - 283 0.02 -0.028

10 Distinct signs of inflammation of the eyes afterone hour

200 - 300 0.02 -0.03

11 Danger to life within thirty to sixty minutes 355 - 496 0.036 -

0.05012 Fatal within thirty to sixty minutes 425 - 580 0.043 -

0.058

13 Fatal after half an hour 500 - 700 0.05 -0.07

14 Causing immediate fainting 700 - 1000 0.07 - 0.1

15 Immediately fatal 850 - 1980 0.085 - 0.2

1) PPM = volume parts of H2S per million parts of air1 PPM = 1 cm3/m3

2) MAC = Maximum allowable concentration for an eighthours working day

2. Physiological Effects of SO2

SLNO.

DESCRIPTION PPM1 VOL. VOL. %

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1. Limit for odour detection 3 - 5

2. MAC2 2

3 Smallest amount causing immediateirritation of the eyes and through

20 0.002

4 Maximum Allowable concentration for 30

- 60 minutes

50 - 100 0.005 -

0.015 Danger even with short exposure more than 400 0.04

1) PPM = volume parts of H2S per million parts of air1 PPM = 1 cm3/ m3

2) MAC = Maximum allowable concentration for an eighthours working day

3. H2S Properties and Toxic Effects

H2S is a colourless, inflammable and very toxic gas having an offensive odour

and sweetish taste. It has a specific gravity 1.17 times that of air.

The offensive odour, like that of rotten eggs, is not reliable as a warning ofdangerous concentrations, as persons differ greatly in the ability to detectsmells, and furthermore the sense of smell deteriorates and is of little help innoting higher increased concentrations.

H2S is almost as toxic as hydrogen cyanide and six times as toxic as carbonmonoxide. The toxic effects vary considerably with the concentration andalso to some extent with individual susceptibility.

At low concentrations, it has an irritant action on the respiratory tract, whichcould result in sickness, vomiting and a feeling of pressure on the chest.Simultaneously it affects the nervous system.

At high concentrations, H2S paralyses the nervous system. Consequently therespiration fails and death will follow immediately by suffocation. Even at lowconcentrations H2S affects the cornea of the eye.

4. SO2 Properties and Toxic Effects

Sulphur dioxide is a colourless gas, with a specific gravity 2.2 times that of air.

In the presence of mist or water this gas forms sulphurous acid. The gas hasa sour taste. It irritates the respiratory tracts because it forms, with the waterpresent, sulphurous acid and further sulphuric acid. This acid etches thehuman tissue.

At low concentrations, it irritates the mucous membranes. Inhalation ofhigher concentrations causes hoarseness, pain and a feeling of pressure on the

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chest and bronchitis. It is sometimes impossible to speak or to swallow.Very high concentrations cause acute bronchitis, tightness of the chest, and aquick start of perturbance of consciousness. Instant death by poisoningseldom occurs. Suffocation, however, can cause death quickly. SO2 alsocauses an increase of haemoglobin in the blood. The toxic effects vary to

some extent with individual susceptibility.A certain immunisation to SO2 is possible, to a maximum of 30 to 50 PPM.Human beings can withstand a maximum of 20 PPM without adverse effects.Higher concentrations can give the victim a pale appearance, cause anunpleasant taste in the mouth and can even make the gustatory nervesinsensitive. Additional effects are loss of appetite and constipation.

5. Sulphur Dust

Sulphur dust in the atmosphere has a highly Irritating effect upon the humaneye. Therefore, it is advisable to wear safety goggles when working in an

atmosphere where dust contaminates the air. This cannot be overemphasised.

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11116666.14..14..14..14.4444 Fire AnFire AnFire AnFire And Explosivity Datad Explosivity Datad Explosivity Datad Explosivity Data

a. H2S

The lower and upper limits for inflammability in a gas air mixture are 4.3 and

45.5 vol. %, respectively. In the stoichiometric ratio with oxygen, it explodesviolently when ignited. It is therefore necessary to handle hydrogen sulphideby excluding all sources of ignition, open flames, sparks (including staticdischarges) and heat producing equipment from contact with this gas whenmixed with air.

The auto-ignition of H2S in air will occur at a temperature of approximately

260 C.

b. SO2

This is not an inflammable gas.

c. Sulphur liquid

At a temperature of approximately 230 C, auto ignition of liquid sulphur willoccur when in contact with air. Therefore attention must be paid to ensurethat the liquid sulphur temperature is maintained below the above mentionedvalue. Ignition of the sulphur will also occur when exposed in the area of anopen flame, resulting in the formation of SO2.

d. Sulphur Dust

As stated above, liquid sulphur has a relatively low ignition point, 230 C;however, sulphur dust clouds

will already ignite at a temperature of approximately 190 C.

e. Hydrogen sulfide released from liquid sulfur

Some hydrogen sulfide (as both monosulfide and polysulfide) is dissolved inClaus sulfur. The total sulfide solubility decreases as temperature decreases.Reported equilibrium compositions for molten sulfur in contact with H2S at

atmospheric pressure ar given below:

Temperature H2S H2Sx TotalOC oF wt% (as H2S), wt% (as H2S) wt%

125 257.0 0.0450 0.00940.0544132 269.6 0.0441 0.0149 0.0590

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148 298.4 0.0432 0.0418 0.0850156 312.8 0.0423 0.0718 0.114162 323.6 0.0414 0.0838 0.125181 357.8 0.0405 0.1045 0.145

11116666.14..14..14..14.5555 MATERIAL SAFETY DATA SHEETMATERIAL SAFETY DATA SHEETMATERIAL SAFETY DATA SHEETMATERIAL SAFETY DATA SHEET SULPHURSULPHURSULPHURSULPHUR

Section 1. Chemical Product

Product Name : Sulphur, Commercially formed solid elemental

Synonym : Elemental sulphur, solid sulphur

Chemical name : Sulphur

Chemical Family : Inorganic sulphur

Chemical formulae: S8

Material uses : Elemental sulphur is used as a raw material in themanufacture

of sulphuric acid, as a soil conditioner, in pesticides andin

rubber vulcanising.

Section 2: Hazards identification

Potential acute health effects:Sulphur dust can cause irritation of the skin, eyes, gastro intestinal orrespiratory tract, characterised by burning, chapping, redness of theeyes, abdominal discomfort, diarrhea, sneezing, coughing, and difficultyin breathing. Contact with molten sulphur may cause severe burns.Molten sulphur may contain hydrogen sulphide gas which is extremelytoxic and flammable. At low concentrations, hydrogen sulphide gas isirritating to the respiratory tract and has a rotten egg odor. Odor

cannot be relied on as a means of detectin because at higherconcentratinos, H2S causes olfactory paralysis. Even short termexposure of a concentration of 500 to 1000 ppm. Of H2S may lead tounconsciousness, respiratory paralysis and death.

Potential chronicle health effects.Sulphur can irritate the respiratory tract in concentrations above 5mg./M3. Possible, but not proven, effect on lung and airway function.

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H2S may cause irritation, breathing failure, comma, and death withoutany warning odor being sensed. Prolonged or repeated skin contactmay cause mild irritation. Can be irritating to eyes and may causeconjectivitis. Possible skin sensitisation. Susceptible individuals mayhave increased sensitivity to exposure.

Section 3: First Aid measures

Eye contactCheck for and remove any contact lenses. IMMEDIATELY flush eyeswith running water for at least 15 minutes, keeping eye lids open. DONOT use an eye ointment. Seek medical attention if irritation persists.

Skin contact:Remove contaminated clothing launder before reuse. Wash gentlyand thoroughly the contaminated skin with running water and non-

abrasive soap. Get medical attention if redness or irritation occurs.

Inhalation

Evacuate the victim to a safe area as soon as possible. If the victim isnot breathing, perform artificial respiration. Administer Oxygen ifavailable. Allow the victim to rest in a well ventilated area. Seekmedical attention.

IngestionDo not induce vomiting because of danger of aspirating liquid into

lungs. Get immediate medical attention. If victim is conscious and gastricdecontamination is required, give activated charcoal tablets or mixture of charcoalwith saline cathartic or sorbitol. Immediately transfer the victim to a forewarnedhospital for medical assessment.

Section 4 ; Fire fighting measures

The product is : Readily ignitable, combustible solid.

Auto ignition temperature : Ignites in air above 261 oC, in oxygen below 260oC. (190 oC for sulphur dust)

Flash points: Closed Cup 207 oC (405 oF) (NFPA)

Flammable limits: Lower 35 g/m3 ; Upper 1400 g/m3 (dust)

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Product of combustion: Releases of Sox, sulphur compounds, smoke andirritating fumes when heated to decomposition.

Fire Hazards in presence of various substances : Do not cut, weld, heat, drill

or pressurise empty container. Contain is may explode in heat of fire.Dust forms explosive mixtures with air, or in contact with oxidisingmaterials. Molten sulphur can accumulate static charge. Vapourexplosion hazard indoors, outdoors, or in sewers.

Fire fighting media and instructions: SMALL FIRE: Use DRY chemicals,CO2, water spray or foam. LARGE FIRE: Use water spray, fog orfoam. Do not use water jet. If tank, rail car or tank truck is involvedin a fire, isolate for 800 meters in all directions. Also consider initialevacuation for 800 meters in all directions. Cool containing vesselswith water spray in order to prevent pressure build up, auto ignition

or explosion. If this is impossible, withdraw, from area and let fireburn out under controlled conditions. Withdraw immediately in caseof rising sound from venting safety device or any discolouration oftank due to fire. Avoid flushing spilled material into sewers, streams orother bodies of water. Self contained breathing apparatus (SCBA) willbe required.

Special remarks on fire hazards: Small fires are virtually invisible. Largerfires will have pale blue flame. Fire may restart after it has beenextinguished.

Section 5: Accidental release measures:

Small spill: Avoid contact and inhalation. Elminate all ignition sources; noflares, smoking or flames in hazard area. Stop leak if without risk.Contain spill. Purge with CO2 or other inert has to exclude air (avoidpossible asphyxiation hazard). Recover or clean up spill solid sulphurby vacuum or a wet method to reduce dust formation. Collect andmix with 4 times weight of lime stone for land filling. DO not flush tosewers, streams or other bodies of water. Check with applicablejurisdictions for specific disposal requirements and clean up of

contaminated materials and empty containers.

Section 6: Handling & Storage

Handing: Due to the possible release of hydrogen sulphide gas, care mustbe taken when handling or working with the solid elemental sulphurabove its melting temprature (112 oC). Manipulate in a well ventilatedarea. Handle carefully to avoid spills and dust accumulation. In case of

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insufficient ventilation, wear suitable respiratory equipment. Avoidcontact with skin and eyes. Keep away from sources of heat andignition. Use spark proof electrical equipment. Protect equipmentagainst wet elemental sulphur erosion. Exposed clothing to sulphurdust should be removed before leaving the operating site. Wash hands

after handling and before eating. Launder work clothes frequently ordiscard after use.

Storage: Store in a closed containers in cool, dry, isolated, well ventilatedarea, away from heat, sparks, open flame, or any other ignition sourceand strong oxidising agents (such as chlorates, Nitrates).

Section 7: Exposure controls for personnel protection.

Engineering controls: General and local exhaust ventilation to maintain airborne dust concentration below 5 mg / m3. Use explosion proof

mechanical ventilation suitable for group D atmospheres. Generalventilation in storage is essential to avoid accumulations of undesirablelevels of evolved hydrogen sulphide gas. Make up air should always besupplied to balance air removed by exhaust ventilation. Ensure that eyewash station and safety shower are close to the work station location.

Personal protection: Chemicals splash goggles in case of splashing. From 5-50 mg/m3, wear full face mask with approved filters in areas withsufficient oxygen. Above 50 mg/m3, wear self contained or airsupplied breathing apparatus. Wear protective gloves impervious tothe passage of sulphur dust. Modest chemical protection (glove)required against acidity. Exposure of hair should be minimised. Wearloose, dust impervious full body coverage with modest protection fromshort term chemical resistance. Fire retardant fabrics recommendedwhen handling solid sulphur.

Exposure limit: Elemental sulphur may contain trace amount ofhydrogen sulphide and / or sulphur dioxide. Release of hydrogensulphide and sulphur dioxide is not a significant hazard with solidsulphur. However, release may occur on remelting the sulphur. It isrecommended as 8 hour allowable exposure of 5 mg/m3 for respirable

dust and 10 mg/m3 for total dust when handling dry solid sulphur; 14mg/m3 (10 ppm) for hydrogen sulphide and handling molten sulphur.

Section 8: Physical & Chemical properties

Physical state and appearance: Loose crystaline solid, which may be inbulk, prilled or slated form.

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Boiling point: 445 oC

Melting point : 113 120 oC

Specific gravity : 1.96 (water 1)

Vapour pressure : 5.28 x 10-6 kPa @30.4 oC

Vapour density : 0.00005 lb/ft3 @32oC

Volatility: Non volatile

Solibility : Insoluble in water, very slightly soluble in alcohol, ether,chlorofom and benzene

Odor : Odorless or rotten egg odor when residual hydrogen sulphide

is present.

Taste: : Disagreeable

Colour : Yellow

Section 9 : Stability & Reactivity

Stability: The product is stable

Conditions to avoid: Will form explosive mixture with an oxidising agent orcarbon: moist sulphur becomes extremely corrosive to metals.

Incompatibility with various substances: Strong oxidising agents (Oxygen,peroxides, chlorine, permanganates, perchlorates), reducing agents,metals, acids and moisture.

Decomposition products: Sulphur dioxide, H2S and smoke generated oncombustion.

Corrosivity; Not applicable for soild, dry sulphur. Hydrogen sulphide gas

may readily cause pipes and valves to corrode or become brittle.Atmospheric sulphur compounds, ( SO2, SO3 and Ammoniumsulphate) react with the carbonate in lime stone and solomites,calcareous sand stone and mortars to form calcium sulfate (gypsum).This cause blistering, scaling, and loss of cohesion of the surfaces, andinduces similar effects in neighbouring materials not themselvessusceptible to direct attack.

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Special remarks on reactivity: Highly reactive with halogens, carbides,zinc, tin, sodium, nical, phospersous, pottasium, calcium, aluminium,ammonia, ammonium nitrate, pottassium permanganage, ammoniumperchlorate, barrium halites, bromates, calcium chlorate, calcium hypochlorite, calcium iodate, charcoal, chlorates, chlorine oxides, chromic

unhydride, flourine, hydrocarbons, iodates, lead halikes, lead dioxide,lithium, magnesium halides, mercury oxides,perchlorats, potassiiumhalides, pottassium perchlorates, silver halides, sodium halides,sodiumnitrates, and zinc halides.

Section 10 : Toxicological information

Routes of entry: Inhalation, skin contact, eye contact and ingestion.

Toxicity to animals: Sulphur accute oral toxicity (LD 50): 12 g (human).Hydrogen Sulphide (H2S) LC 50: 600-1000 ppm with the upper

value being immediately lethal.

Chronic Effects on Humans: Sulphur can irritate the respiratory tract inconcentrations above 5 mg/m3. Possible, but not proven, effect onlung on airway function. H2S may cause irritation, breathing failure,coma, and death without any warning order being sensed. Prolongedor repeated skin contact may cause mild irritation. Can be irritating toeyes and may cause conjunctivitis. Possible skin sensitization .Susceptible individuals may have increased sensitivity to exposure.

Other toxic effects on humans:Sulphur dust can cause irritation of the skin, eyes, gastro intestinal orrespiratory tract, characterised by burning, chapping, redness of theeyes, abdominal discomfort, diarrhea, sneezing, coughing, and difficultyin breathing. Contact with molten sulphur may cause severe burns.Molten sulphur may contain hydrogen sulphide gas which is extremelytoxic and flammable. At low concentrations, hydrogen sulphide gas isirritating to the respiratory tract and has a rotten egg odor. Odorcannot be relied on as a means of detection because at higherconcentratinos, H2S causes olfactory paralysis. Even short termexposure of a concentration of 500 to 1000 ppm. Of H2S may lead to

unconsciousness, respiratory paralysis and death.

Special remarks on chronic effects on Humans:

Pre-existing bronchitis or asthma conditions may be aggravated byexposure to this product.

Section 11: Ecological information

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Eco-toxicity. Harmful to aquatic life in high concentrations. 10000ppm / 96h/mosquito fish/TLm/fresh water; 16000 ppm/5h/goldfish/LC100/frsh water (colloidal suspension); 2 100ppm,/1h/goldfish/LC100/fresh water.

Section 12: Disposal considerations:

Waste disposal: Landfill at licenced waste reclaimer facility approvedfor receipt of elemental sulphur, after mixing with lime stone.Reclamation of sulphur rich wastes is preferred over solid wastedisposal. Consult your local or regional authorities.

Section 13: Transport Information

TDG classification: Shipping name: Sulphur, solid; class 4.1; UN 1350;

Packing group III. Label required; Flammable solid.

Special provisions for transport: Acceptable modes of transportation: air,rail, road and water.

mit

10101010....

WORK PERMIT SYSTEMWORK PERMIT SYSTEMWORK PERMIT SYSTEMWORK PERMIT SYSTEMINTRODUCTIONThe Work Permit System is an important tool for safety in hydrocarbon processing/handling installation. The basic purpose of the work permit system is to ensure thatwork is carried out in the safest possible manner to prevent injuries to personnel,protect property from damage, avoid fire etc. The recommended Work PermitSystem is described covering various aspects like when a work permit is required,types of permits, responsibilities, check lists, validity etc. The success of a WorkPermit System depends upon the training, motivation and participation of allindividuals concerned with its implementation. Since several maintenance/

construction jobs are often carried out with assistance from contractors, it is essentialto provide sufficient exposure to contractors and his/ their employees as well.The work permit system of BPCL Kochi Refinery has been formulated in line with the

recommendations laid down by the Oil Industry Safety Directorate (OISD) StandardSTD-105 Revision-I, September 2004 and STD-137, August 1990.

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Work permit is a written authorization for performing any job within the Refinery,Jetty facilities, Water Quarries, Water treatment facilities at Chullichira, Water PumpHouse at Aluva, or on any facility belonging to the Refinery.

GUIDELINES GOVERNING THE WORK PERMITGUIDELINES GOVERNING THE WORK PERMITGUIDELINES GOVERNING THE WORK PERMITGUIDELINES GOVERNING THE WORK PERMIT

If a work has to be performed in Kochi Refineries by any person other than theowner personnel of that area, a duly authorised written permit shall be obtained bythe person/ agency executing the work from the Owner of the area beforecommencement of the work. However, even for operating personnel, when work hasto be performed outside their normal routine, an exclusive permit to that effect by

the authorized person shall be obtained. It is the policy of the company to ensure thesafety of people, equipment and materials when performing any work within theRefinery premises, Jetty Facilities, Water Quarries, Water treatment plant atChullichira, Water pump house Aluva, any other facility belonging to the company.The Work Permit System shall always operate on "Owner-In-Charge" concept. The

concerned Departments shall issue the appropriate authority limits for variousinstallations and type of permits based on this concept.Separate forms shall be used for Cold Work, Electrical work, Hot Work includingconfined space entry permit and Radiography, Electrical Isolation & Energisation andEarth Work Permit.All jobs shall be performed only after obtaining the stipulated permits fromconcerned authorities. The permit forms in book form are printed serially and issuedby Safety Section.All permits shall be issued/ renewed and received only by the personnel designatedfor the same and are to be signed by the issuing/ renewing and receiving personnel.The permit shall be signed and issued by the authorized person from the concernedowner department/ section. The permit shall be signed and received by theauthorized person from the executing department. Where no such independentauthorised person exists, the Owner-In-Charge can issue the permit to thecontractors supervisor directly and obtain his signature.The concerned department shall issue the appropriate authority by name for variousunits as well as sections for issue/ renewal/ acceptance of permits. The list ofauthorised persons of each department for issuing/ renewing and receiving of variouspermits duly approved by the General Manager of respective departments shall beupdated on yearly basis and forwarded to Safety section. The list shall be revisedwhenever there is a transfer/ new appointment to the department.All necessary checks and tests shall be conducted by issuing personnel to ensuresafety of the job to be performed prior to issue of permits. All precautionarymeasures required to be taken shall be clearly indicated in the permit and theircompliance ensured both by the issuing/receiving personnel.

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Critical jobs are to be carried out under specific written procedure and reference ofthe same shall be noted down clearly in the permit so issued. The procedures forthese critical jobs have to be prepared by the section heads of the owner department,Safety section and the executing department and to be concurred by the ownerdepartment head. Owner department shall initiate the preparation of such procedures.

Permits shall be worded clearly so as to limit the work to the designated area/equipment/ facilities, agencies and time. The work permit shall be filled up carefullyand accurately in clear writing ensuring that detailed and complete information isprovided in all the sections/ sub sections. Sketches should be attached whereverpossible to avoid miscommunication. Additions and alterations on the original shall

also be endorsed on all the copies.

Should any of the conditions vary during the course of the work, which may affectthe safety of human beings and equipments, the job shall be stopped, the permitwithdrawn and given back to the issuer. Reasons for withdrawing the permit to be

mentioned in the permit.If a permit is withdrawn, the work should be restarted only after safe conditions areestablished back and clearance obtained from the issuing/ renewing authority.Permits shall be readily made available at the work site for verification by concernedpersonnel. Failure to present the permit on demand shall result in stoppage of work.Permits are valid only for the time period specified in the permit. Normally thepermits will be issued for the shift timings of the issuing authority.The site of hot work jobs should be indicated in the plot plans available in the controlrooms and fire station with red pins. This helps the incoming supervisor/s (both inFire and Operating departments) to get a quick idea of the hot jobs being undertakenand help in identifying the areas which require inspection/ attention, depending uponthe criticality of the area and the job. A display board shall also be maintained in thecontrol rooms and fire station furnishing details such as the area of hot work,equipment/ facility involved, executing agency (Department/ Contractors namewherever applicable), permit number and validity. The Shift-in-Charge/ Concernedpersons of owner department will ensure that the display board is updated on issue/renewal/ closing of the hot work permit.If the job is to be continued beyond the time limit specified in the permit, it has tobe renewed at the beginning of the next shift. Jobs can continue on expiry of theshift after obtaining the signature of the authorized person from the ownerdepartment/ authorised personnel from the executing department in the original ofthe permit. The issuing authority subsequently can renew the permit after making asignature in both original and triplicate in the case of hot work permits/ electricalisolation and energisation permit and original and duplicate in the case of cold workpermits. The authorised personnel of the executing department shall make his

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signature in the copy available in the control room as early as possible as but notlater than the expiry of the shift or before completion of the job whichever is early.Permits once issued shall be renewed up to a maximum 7 calendar days. Theendorsement for renewal is to be done only in the space provided for the purpose. Incase the job has to be continued even after the above period, a fresh permit has to be

issued/ obtained for the same. The serial number of the old permit shall bementioned in the new permit.During shutdown of a plant, deviation of the procedures laid down in the ROS, if anyrequired, shall be made with the specific approval from a committee consisting ofowner department DGMs, executing department DGMs (DGM- Maintenance, DGM-

P&U, DGM- E&C, DGM- Projects) and Chief Manager (Safety & Fire)While renewing a permit that has already been issued by authorized person of theconcerned department, the issuing/receiving persons are in no way relieved of theduties and responsibilities specified for issuing/ renewing permits.

At the time of renewal of a permit or when the job is in progress, if the issuing orrenewing authority, feels that some additional conditions or precautious are to bestipulated or are not necessary based on the prevailing conditions, a new permit hasto be issued incorporating the changes and the previous permit will remain cancelled.If the owner/ executing departments require any clarifications on the precautions tobe followed for critical jobs, the same shall be consulted with Safety & Fire sectionand to be incorporated in the permits.All permits must be closed on completion of the job with signature for closure bythe designated person of the executing department/ section as well as the ownerdepartment. Permits once closed cannot be renewed.No hot work shall be allowed to be included in the hot work permit already issuedfor other jobs. The work permit should be issued for one job only. Separate permitsto be issued for performing separate work on same equipment.

All the permits stands cancelled on declaration of emergency. Fresh permits/Revalidation shall be taken on clearance of emergency.DUTIES AND RESPONSIBILITIES UNDER WORK PERMIT SYSTEMDUTIES AND RESPONSIBILITIES UNDER WORK PERMIT SYSTEMDUTIES AND RESPONSIBILITIES UNDER WORK PERMIT SYSTEMDUTIES AND RESPONSIBILITIES UNDER WORK PERMIT SYSTEMBefore issuing any permit the authorized issuing authority shall give proper briefing

of the work situation, including the possible hazards and the precautions to be taken,to the authorized executing authority or receiver of the permit and a noting to thiseffect should be made in the permit, at the space provided for special instructions.ISSUING/ RENEWING AUTHORITYISSUING/ RENEWING AUTHORITYISSUING/ RENEWING AUTHORITYISSUING/ RENEWING AUTHORITYThe issuing/ renewing authority is primarily responsible for the safe execution of thejob covered under the permit and as such is to perform the following duties.Analyse and determine the condition of the facility and the area involved andstipulate necessary precautionary measures to be taken to ensure safe execution of

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the work. He shall ensure that all the columns of the permit forms are filled up. NR(Not required) shall be marked wherever that particular item is not required. He shallput his full signature along with name and badge number marked in the permit.

Stipulate precautionary measures such as area preparation, blinding/ isolation/

tagging, provision of safety and fire protection equipment, standby personal etc. orspecial procedures required (in case of critical jobs) in the permits and ensure theircompliance.Conduct preparatory, preventive and precautionary measures to be carried out bypersonnel of his department and ensure compliance of the same.

Co-ordinate with other departments/ sections wherever precautions are necessary tobe taken from their end also and counter signature to be obtained wherever neededbefore commencing the jobEnsure verification and certification of installation and removal of blinds/ isolationsand their tagging.

Perform necessary gas and other required tests. As a pre-requisite to issue permit,particularly in the case of hot work/ vessel entry permit, gas test forhydrocarbons/ oxygen deficiency/ toxic gases shall be conducted as applicable.Ensure that the facilities and the area in and around the place where the permit isissued/ renewed are made safe prior to commencement and during the progress ofthe job.Follow up periodically the progress of the job permitted and stop the job ifconditions become unsafe.Ensure that while hot work is in progress no other work likely to result in hazardousconditions are permitted in the vicinity (e.g. repairs to oil or gas lines, bleeding orsampling of flammable materials, draining of hydrocarbon, venting of gas, removal ofblind from hydrocarbon lines etc.). Where gas-free conditions are not fully ensuredfor the duration of hot work, a system of monitoring either by automatic or bymanual periodic verification shall be resorted to depending upon the prevalentconditions of the operating area.Ensure that all personal protective equipment/ clothing are available at site beforecommencement of work and the same is used by personnel while performing thework.The issuing authority shall inform the Chief Manager (Shift Administration) if a hotwork permit is issued/ renewed beyond the normal office working hours.The issuing authority shall inform the fire station, of all the new as well as renewedhot work permits and get the token number before issuing a new hot work permit.The token number shall be written on the hot work permit in the column for tokennumber.

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After completion or stoppage of the job, the person to whom the permit was issued,should thoroughly check the area for clearing of debris, ensure safe workingcondition and then shall close the work permit.The issuer on receiving back the original permit duly closed by the receiver wouldsatisfy himself regarding completion of the job and that the area has been cleared.

Then he shall also sign the permit and hand over original permit to the receiver(except in the case of Energisation / Isolation permit in which the duplicate copy ofthe permit to be returned to the receiver and original permit to be retained by theissuer). Returned closed permits are to be preserved by the owner department for aminimum of 90 days.

RECEIVING AUTHORITY/ EXECUTING PERSONNELRECEIVING AUTHORITY/ EXECUTING PERSONNELRECEIVING AUTHORITY/ EXECUTING PERSONNELRECEIVING AUTHORITY/ EXECUTING PERSONNELThe fact that permits has been issued for performing a certain job in no way relievesthe authorized person of the executing department or the personnel executing thework of their responsibility for safe execution and completion of the job. Thereceiving authority/ executing personnel is/ are responsible for the compliance of the

precautions/ conditions prescribed in the permit. Their duties include the following:Secure necessary permit from the concerned department before commencement ofthe job. He shall put his full signature along with name and badge number marked inthe permit.Provide for and comply with all necessary precautionary measures stipulated in thepermits. Ensure that all safety equipment are in good working condition and availableat site prior to commencement of the work.Take extra care when commencing the work, especially while breaking flange joints,cutting through lines, striking an arc for the first time etc.Ensure vigil and work diligently for safe completion of the job. When in doubt, stopthe job and obtain clarification from concerned personnel.Ensure safe working practices throughout the job by continuous supervision (eitherby executing personnel or contractor personnel).

Ensure the availability of all personal protective equipment/ clothing are available atsite before commencement of work and also ensure that the same are used duringthe work.Stop the job if conditions become unsafe and report to the issuing/ renewingauthority. Restart the job only after getting the clearance from the issuing/ renewingauthority.Ensure that the permit is readily available at the work site for verification.Ensure that no blinds or other isolations, specified for the work are removed ordisturbed during the work.Ensure that the grade area is barricaded by red & white colour tape to coverexcavated area or in case of material handling at overhead.Ensure that 24 V (AC) hand lamps are used in the confined space.

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Upon completion of the job, clear the area of all construction materials& scrap,removal of temporary electrical isolation and replace in its original location thefacilities/ equipments used for the execution of the job. Maintain good housekeeping.All permits must be closed on completion of the job and after clearing the area by

the authorized person of the executing departments/ section. The receiver will signfor closure after specifying the job status at space provided at the back of the permitand return the original permit to issuer for signing. Permits once closed cannot berenewed.FIRE STATION PERSONNELFIRE STATION PERSONNELFIRE STATION PERSONNELFIRE STATION PERSONNEL

Fire station personnel has to register the exact location of the hot work, issue thetoken number for the work and to provide necessary additional/ special fire fightingfacilities at the request of the issuing/ executing authority or as desired by themdepending upon the nature of hot work and hazardous nature of the area.SAFETY OFFICERSAFETY OFFICERSAFETY OFFICERSAFETY OFFICER

The Safety Officer/ Fire Officer authorised will make periodic check of the work sitesand see that the work is being carried out as per conditions laid down in the permit.At any point of time, if he considers that the conditions are not safe enough for thework, he may bring to the attention of the issuing authority or suspend the workand inform the permit issuing authority as the case may be, to restore the safeconditions so that the work can be re-started. If the job has to be stopped and permitwithdrawn, the permit to be given back to the issuer with reasons for withdrawingthe permit mentioned in the same.TYPES OF PERMITSTYPES OF PERMITSTYPES OF PERMITSTYPES OF PERMITS

Depending on the nature of jobs to be performed, permits issued for carrying outjobs in the Refinery are of fivetypes. They are:1) Cold Work Permit/Clearance Certificate for Hot work.2) Electrical Permit3) Hot Work Permit4) Electrical Isolation & Energisation permit.

5) Earth Work Permit