Enhancing HSE Performance through “Operational Excellence” · 8. JSA in critical activities...

“ Kalinga Safety Excellence Award- 2018”

Paradip Refinery & Petrochemical Complex

PO : Jhimani, Dist: Jagatsinghpur, Odisha-754141

Enhancing HSE Performance through

“Operational Excellence”

2

Safety Management System of Paradip Refinery Safety Management Systems of Paradip Refinery is in line with:

Guidelines on Safety, Health and Environment Management System of Indian Oil.

OISD Guidelines on Safety Management System in Petroleum Industry (OISD-GDN-206).

Process Safety Management of Occupational Safety and Health Administration (OSHAS)

3

E

lemen

ts of S

afety

Ma

na

gem

ent S

ystem

of P

DR

Co

mm

it To P

roce

ss

Sa

fety

Un

de

rstan

d

Ha

zard

& R

isk

Ma

na

ge

Risk

Le

arn

from

Exp

erie

nce

Process Safety Culture

Compliance With Standards

Process Safety Competency

Workplace Involvement

Stake holder engagement

Process Safety Information

Hazard identification & Risk Analysis

Operating Procedures

Safe work practices

Asset integrity & reliability

Contractor Management

Training

Management of Change

Operational readiness

Conduct of Operation

Emergency Management

Incident Investigation

Measurement & Metrics

Auditing

Management Review

Pro

cess S

afe

ty m

an

ag

em

en

t Sy

stem

4

SAFETY THROUGH LEADERSHIP & COMMITMENT Corporate Safety, Health and Environment

Policy : Issued by The Corporate Office . Displayed at all important locations Made available to all the employees, contractors, business associates.

Unit Level Occupational Health & Safety and Environment Policy : Signed by the Unit Head. Published in Hindi, English & Local Language. Prominently displayed at conspicuous locations. Made available to all Stake Holders.

5

Objectives of Safety Management System

To prevent any unsafe condition and eliminate or mitigate their probable

consequences.

To control loss to personnel, equipment, material and environment.

To standardize the procedures which should continue to be followed by one and all

unless a change in the system is duly authorized by a competent person.

Year 2015 Year 2016 Year 2017

Objective

6

SAFETY

• Zero Accident.

• Zero Fire.

• Increasing Near miss Incident Reporting.

• Improve Housekeeping.

• Raise safety awareness through safety education & Training.

HEALTH

• Monitor & maintain for hygiene at work place.

• Carry out pre-employment, & periodic medical health check up of employees.

• Conduct surveys & investigations on potential health hazards.

• Train employees in First-Aid, Occupational Health & hygiene.

ENVIRONMENT

• Carry out continuous Stack monitoring & ensure emission is within the stipulated norms.

• Reduce CO2 emission from the plant.

• Reduce consumption of fresh water .

• Increase the re-use of treated water.

7

8

EMERGENCY RESPONSE & DISASTER MANAGEMENT PLAN ERDMP as per PNGRB Notification established

9

TPM Implementation of TPM at Paradip Refinery.

Total Productive Maintenance (TPM) in Paradip Refinery implemented in 2019 at Sulphur Block as Pilot Unit. Subsequently 5-S (pre TPM

activity) kick off was done.

Total productive maintenance (TPM) implemented to maintain and improve the integrity of production, safety and quality systems

through machines, equipment, processes, and employees. Focus to avoid breakdowns.

The main objective of TPM is to increase the Overall Equipment Effectiveness (OEE) of plant equipment. TPM addresses the causes for

accelerated deterioration while creating the correct environment between operators and equipment to create ownership.

OBJECTIVE

AIM

PILOT

PLANT

10

HSE Statistics

Fire Free Days:- 708

Accident Free Days:- 729 MMH-30.29(as on 31.10.2019)

HSE Statistics

System improvement techniques

The Energy Gateway to Eastern India … Paradip Refinery

1. Henry Ford (1920) : Assembly line production

2. Alfred Solan (GM) : Cost centre and Revenue Centre

3. DELL, SW Air line : Profit Centre

4. Toyota Motor Corporation , Japan (1950) : Lean manufacturing/ “The Toyota Way”/TPS

5. Motorola, USA (1980) : Six Sigma

6. “The Goal” by Dr. Eliyahu Goldratt (1984) : Theory of Constraints (TOC)

7. Xerox, GE, Johnson & Johnson : Lean Six Sigma

8. Dr Shigeo Shingo, Japan : The Shingo Principles of OE

9. Chevron : The Chevron OE Management System (OEMS)

10.DuPont : DuPont Operational Excellence Model

11.Exxonmobil : Operation integrity management system

Mousom Some 11

Paradip Refinery - The Energy Gateway to Eastern India Mousom Some 11th Sep’19 12

Operational Excellence

Operational Excellence framework of Indian Oil

The Energy Gateway to Eastern India … Paradip Refinery 13

Paradip Refinery Marching

towards excellence

in Safety & Operational Risk

Management

14

Elements of Safety Management System of PDR

Elements

Safety in Operation

and Maint.

Efficient and Reliable

Operation

Security of Facility

Facility Design

Training and Development

Contractor Management

Elements

Environment Management

Incident Investigation

Relationship with

Neighbour Industries

Emergency Preparedness

Compliance Guarantee

Information Communicati

on

Element- 0 :Safety in Operation & maintenance


Action points:

1. Implementation of Process Safety Management System

2. Implementation of New Technologies

3. Alarms KPI MIS generation

Overall frequency report, Process safety escalation, FDAS actuation

4. Daily discussion and action on deviations of alarms

5. Monthly Safety Day

6. Compliance on interlock system protocol, SOP

7. Introduction of Risk Perception in SOP

8. JSA in critical activities like hot work, dechoking activity etc.

9. Skill development of panel engineers and field operators on case study

disasters pertaining to process safety

10. Revising the existing Safety audit checklist

11. Apps for Safety audit observation entry and close out

12. Identifying critical operation/task for each units

13. Recognition of Safety Ambassadors 15

Aim: Operate & maintain all facilities to prevent incidents/accident, damage to asset, environment & company reputation.

Chevron’s Principles

- Do it safely or not at all

- There is always time to do it right

Exxonmobil’s Principles

- Safety is a Culture, Not a Priority

- Nobody Gets Hurt



Block layout of Paradip Refinery as per OISD-STD-118 maintaining safe separation distance between the facilities

Reduction of the amount of hazardous substances – e.g. Hot feed routing to Secondary units

Leak-tight containment of dangerous substances- e.g. Double seal in light hydrocarbon storage tanks & double seal for LPG

pumps.

Avoidance of opportunities for error with automation – e.g. Safety Instrumented System with highest SIS & SIL rating.

Multiple level Safety Alarm, Interlock & Trip Logic with provision of emergency shut down (ESD) in all Process Units.

Designing of fail safe equipment - Instrumentation for fail safe control valves, Pressure Safety valves, Closed blow down

etc.

Risk Analysis & EIA study by reputed International Agencies with full compliance of recommendations

System to carry out OISD PCSA of all facilities before commissioning

Quantitative Risk Assessment, HAZAOP/ HAZAN Studies etc.

e-MOC for any Process modification

Approved procedure for Interlock by pass

Aim: Operate & maintain all facilities to prevent incidents/accident, damage to asset, environment & company reputation.



Safe equipment handing over for maintenance and enforcement / adherence to Work permit System

1. Cold work

2. Hot Work

3. Work at Height

4. Confined space Entry

5. Excavation

6. Vehicle entry

7. Radio graphy

8. Road block/ Road

Cutting

9. Dyke Cutting

10. Electrical isolation



Safety during Hot Tapping activities for Process Modification

Any Job through Process

Modification Scheme

HAZOP

Engg. Drawing/

Design

JSA

TBT prior to

execution of job

MOC

Work Permit /

Clearance



Structure Safety Committee meeting are being organized for 16 sections inside Refinery and issue raised

during meeting being recorded. Review of compliance of SSCM points being done during RSM & MSCM.



Celebration of theme based Monthly Safety Day programs every month at 18 zones inside Refinery with involvement of senior management personnel (CGMs/GMs). ED attend program at any one location with Surprise

Visit.


The Energy Gateway to Eastern India …

Paradip Refinery

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Winner- Process Units

FCCU

Runners : Process Units

AVU & SR-LPG

Runner Plant & Non Plant

Buildings –

QC Laboratory

Winner BOO,BOOT & Project

sites –

M/s Praxair

Winner Plant & Non Plant

Buildings –

Central Store & Warehouses

Runner BOO,BOOT & Project

sites –

PP Project (LSTK-1)

Inter-unit Safety & Good Housekeeping Competition-2019 organized and Trophies distributed amongst

winners during Independence Day Celebrations.

Element-1: Efficient & Reliable operation


Aim: Efficiently design, Operate and maintain plant and installation to ensure asset integrity and prevent

untoward occurrences and conserve natural resources. Action points:

1. Implementation of RTF recommendation in totality.

RTF/Reliability review meeting for monitoring the status

of implementation.

2. Preparation of operating window for equipment and

review of existing operating range. Based on above

finding deviation if any of operating parameters to be

reviewed every month and the report shall be circulated

to HODs.

3. RCM, RBI implementation

4. Bad Actor tool

5. Online health monitoring systems such as System-1, RV-100,

PROGNOST are installed in critical machines.

6. Implementation of RCA, Why why



Implementation of Online Monitoring software

23



Implementation of Online Monitoring software

24

Element 2- Security of Facilities, Resources and Personnel


Aim: Ensure a secured atmosphere for the facilities, resources and personnel for proficient business

Lighting arrangement

along with perimeter

wall

Scanning of

suspicious movement of people

outside perimeter

wall by CCTV.

Security audit in

nights in every week

Strict control on

detention of truck/tanker

overnight.

Conducting security mock

drill

Security managem

ent plan implemen

tation

Security awareness

programs including

Cyber

Security

Cyber security

audit by IS

Vehicle movement

through Battery

limit gate

Element-3: Facilities design, engineering & project management


Aim: Design, Engineering and construction of projects to prevent incidents and to operate assets in safe,

consistently efficient and environment friendly manner

Action points:

1. Developed a multi disciplinary checklist for pre-start up of new units/existing unit start-up after shutdown

2. Develop a consolidated checklist for all statutory approvals.

3. Creating Unit wise database for “lesson learnt”

4. Incorporate OEMS requirement in design and construction of new facilities

5. Design addresses the HSE risk, impact of environment

Element-4: Management of Change


Aim: Ensured a secured atmosphere for the facilities, resources, personnel for proficient business

Strengthening of existing

MOC system

Bringing all the

modifications under MOC

Development of HAZOP

trained Engineers.

Periodic audit of MOC System

Updation and distribution of

P&ID

Review of MOC by OEM (for

equipment) and Licensor (plants/Units)

Element-5: Training & Development


Aim: Appropriate selection and placement, continual assessment of employees, creation of functional expert

groups and proper training and development

Action points:

1. Competency development in key areas Operation, Reliability, Safety

2. Experience sharing session by the persons who attend outside training

3. Behavioural based, motivational program percolated to employees and contractor.

4. Mentoring new officers/fresh joinees

5. Training module for new joiners

6. Regular skill test of shift officers and maintenance personnel

7. Operation mock drill for emergency SOPs.

8. System of handover note during transfers

9. Succession planning and development of subordinate

10. Quarterly brainstorming session on building OE culture at all levels.



2018

Type of HSE training Program No. of Program No. of Participants

Mass Tool Box Talk 33 4437

Classroom training 258 5286

On-the-job training 92 2357

Driver/helper training 52 1258

Shutdown Induction 129 5193

TOTAL 564 18,531



Mandatory safety induction training to all new entrants and conducting periodic refresher training

including distribution of Booklet for workers with job related safety precaution



Safety corner developed by Paradip refinery in house resources



“Swadhyaya” a self learning website and mobile application developed by corporate IS for self learning.



Structured Skill Development and Specialized training programs by Senior & Experienced personnel



System of imparting daily Tool Box Talk in small groups prior to start of job is in place. Weekly Mass TBT by

F&S.



Electrical Safety Training Working at Height Training

Glimpses of Class Room Training at Project Site

Behavior Based Safety Training Safety Training for Operators

of Hydra , Crane & Excavator



Glimpses of Hands On training and Demonstrations on Safety While Working at Height.



Commissioning Safety – Training Program for Fire Crew



Structured F&S Training for CISF Personnel



Special training program on “Shutdown Safety” organised for 3 days taking faculty support fromGM(MN),

GM(P&U) , GM(PN) & DGM(F&S) clarifying roles & responsibilities of Operation , Maintenance & Safety

departments during Shutdown. Persons from PN, MN, EL, CL, P&U departments as well as from BOO-BOOT Agencies, Contractors & other ARC agencies covered in the programme.



Glimpse of Hands on training



Glimpses of Traffic Safety Awareness program for Contract workers at Refinery Main Gate & Main Road



Publication and circulation of Special e- Safety Bulletin on Monthly Safety Theme

Element-6: Contractor Management System


Aim: Drive to improve contractor overall performance wrt safety, job quality, output, timeline through OE

Action points:

1. Compulsory Medical examination certificate for contractor workers

before deployment at work site introduced. Modification in SCC.

2. Mandatory Safety training of all contract labours and linking with

gate pass .

3. Job specific training to contract workers

4. Incorporation of use 3 and carry 3 in usage of PPEs

5. Development of certified contractor safety supervisors.

6. Safety gift to the contractor workers

7. Contractor field safety audit

8. System of near miss submission by contract workers

9. Periodic evaluation of contractor HSE performance and assessment

of the contractor HSE system.

10. Separate helmet color to contractor employees for easy

identifications.

11. inclusion of contractor employees in SSCM at field level.

12. Direct interactions by top management with contractors in MSCM.

Giving awards to the contractor for best safety practices



Issue of Job competency cards for workers engaged for critical Tasks at Project Sites. e.g. System of Issue of

Height Pass after Physical test at Site.



Training & Demonstration

Medical Checkup

Safety Audit & Inspection

Inspection- Lifting tools & tackles Inspection- ELCB/ RCCB



Glimpses of Demonstration on importance of PPEs while working at Height and Rescue from Confined

Space Faculty Support: M/s 3M India



Glimpses of Class Room, Demonstrations and Hands On training on Safety While Working at

Height.



Monthly Sensitization Program on Electrical Safety is being conducted for Electrical Engineers, Supervisors,

Technicians & Helpers working under Maintenance & Project Agencies.



Regular Mock drills at Project construction site.



Monthly Meeting chaired by CGM(HSE) with the RCMs of PMCs & LSTK agencies working under BS-VI & MEG-

ERU Projects.



Safety training through Virtual Reality Headset.

Delay Start Unit in vehicle, the vehicle would not start & instead horn will start buzzing for 20 seconds to alert



Mandatory Health Check up of all contract workers at site

Element-7: Environment Management


Aim: Continuous endeavor for improvement of compliance with environmental norms and minimize impacts

to the environment from our operation

Liquidation of hazardous Waste inventory

Accounting of emissions

Provision of emissions limits for each pollutant in DCS panel with High Level Alarm.

Identifying list of potential environment risk by developing a Risk register and mitigation plan.

EIA/QRA/ISA, 3rd party audit to identify, asses and mitigate significant risk.

PSM implementation for identification and control of process hazards

Waste disposal system

Fugitive emission by LDAR

e-waste disposed off under buy-back policy

Waste paper recycling

Online Connectivity with OSPCB and CPCB.

Element-7: Environment Management


• Ambient Air quality –Real time data display in

OSPCB portal

• Effluent Discharge quality–Real time data display in

OSPCB portal

Element-8: Incident Investigation, Root Cause Analysis & Mitigation Plan


Aim: Prevention, Elimination and reduction of incidents by proper investigation and carrying out RCA (root

causes analysis).

Accident Reporting/inve

stigation

Near miss reporting and

closing system

HIPO near miss reporting

system and identifying RCA

Investing steps for RCA

Availability of Investigation

Report for access



Guidelines to Incident Categorization, Reporting & Investigation

Fire not extinguished in 15 minutes

Incident causing Shut down of operation due to Fire/explosion/Leak

Financial Loss above 20Lakh

Fatality

Major loss of containment & adverse effect outside plant

Road Accident during Transportation of Petroleum –Fire/Explosion/Fatality

Incident gets reported in National Media within 24hrs of occurrence

Permanent Loss of body parts/Permanent disability

Cumulative loss of Man Hours more than 500

Major Reportable Incidents




Fire of duration less than 15 minutes

Injury to employees /Contractor Workmen/Security Guard/TT crew/Visitors etc.

Lost Time Accident – Absenteeism More than 48hrs & less than 500 hrs.

Collapse of Roof or Boundary Wall

Collapse of High Mast Tower/Shed/Structure etc.

Natural Calamities leading to Fire/Minor injury/property loss less than 20 Lakh

Incident at residential Colonies involving employees & Contractor worker

Other incident required to report as per Statutory Guidelines

Minor Reportable Incidents


Paradip Refinery

INVESTIGATION TEAM

At least One Person from

Operation/Maintenance/Project/ES etc.

At least One Person from F&S/HSE

At least One Person from HR/Medical etc.

if necessary

At least One Person from Other Unit/Location

At least One Person from HO

One Person from Corporate HSE

Committee should not have less than 03 members.

Office Order for formation committee to be issued within 24hrs by Competent authority.

Competent Authority

Minor incident – Unit Head/Major incident – Respective HSE head at HO

Committee to Submit Report within 4 days.




Online Near miss Reporting system for employees

The Reported Hazard/Near Miss goes to concerned Area In charge for action, if required Area in charge may

forward same near miss to concerned department for taking action, the Department after job completion

returned the Near miss with status to Area in charge and Area in charge finally close the Hazard/Near Miss.

ENTRY OF HAZARD/NEARMISS (Including UA & UC)

AREA IN CHARGE

HAZARD/NEARMISS CLOSED

ACTION TAKEN BY

AREA IN CHARGE

SERVICE MAINT DEPARTMENTS (CIVIL,ELECTRICAL,MECH,HR,F&S,INSTRUMENT,IS,INSP)

RETURNED FORWARD

Automatic e-Mail Generated and sent to concern for each steps



Near miss Reporting system for Contract Employees

Near miss Box with format in local language to report safety Observations/Near miss/suggestion by contract

employees installed at 20 strategic locations inside refinery and Administrative building.



Reporting of High Potential Near miss and its RCA.



Accident investigation report of accident happened across Indian oil can be accessed through intranet site.

Element-9: Relationship with Neighborhood & Stakeholders


Aim: Trust & long term relationship is to be built by engaging in healthy dialogues with the stakeholders & the

community.

Action points:

1. Mutual aid Scheme

2. Contractors Meet

3. Meeting with Sarpanch

4. Community Awareness Program

5. Interaction with School heads/ Villagers

6. Regulatory and Statutory authorities

7. CSR activities

8. Community Awarness leaflets

9. Swachh Bharat Mission



IFFCO

PPL

PDR, IOCL

PHBPL, IOCL

Members

Paradip Refinery has Mutual Aid with neighborhood industries

PPT



IOCL, Paradip has adopt M/s Paradeep Calciner Ltd. Udayabhatta as a Safety Buddy.

IOCL is also in the process of adopting few more safety buddies in Paradip region engaged in handling of

Hydrocarbons so that Paradip Refinery can play the role of mentor and guide for improvement in the safety

standards of the Factories.



Contractor Meet are being organized regularly.



Community Awareness Programme on 23 October 2019 on Safety, Environment & CSR involving the elected

representatives of Gram Panchayats of four adjoining villages Paradipgarh, Fatehpur, Gandakipur and

Mangrajpur along with volunteers from these villages was conducted.



Safety Awareness program conducted at nearby village schools



Oil & Gas Conservation” was organized at Raghunath High School, Kothi which is located nearby Paradip

Refinery on 07th Feb’2019



Participated in District Crisis Group meeting chaired by ADM on 30.10.2019



Community Awareness Leaflets



Special Bulletin Published road safety developed and circulated.



A dedicated Mobile medical check up van deployed to give basic medical treatment to near by villagers.



Free Medical Check up camps for Near-by Villagers.



Swachha bharat mission programme at nearby School.

Element-10: Emergency & disaster preparedness


Aim: Even though prevention of any incident is the top priority, workforce should be prepared for effective &

immediate response to any emergency related to our assets. Action points:

1. ERDMP

2. Ensure that all credible and significant risks and impact consideration pertaining to specific site are addressed in the ERP.

3. Emergency response plans Communicated to employees & contractor employees. Communication on Emergency Response plans to be

strengthen by

a) Various Emergency Scenarios & Dos & Don’ts included in the training

b) ERDMP inclusion in monthly safety day theme.

c) Leaflets distributed during safety induction training.

4. Routine mock drills – onsite and offsite

5. Linking outstation with ERDMP organogram



Off-site Disaster Drill for the year 2018-19 on 18.03.2019 at Tank Truck Parking Area the scenario envisaged for

the exercise was “Leakage of Propylene gas from the Tank Truck Pressure Gauge Point near TTL Gate”.



The On-site Disaster Drill at PP unit conducted on 25.06.2019 and scenario was “Leakage of propylene from

Propylene feed pump No. 73-P-301B due to seal failure followed by ignition of vapor”



The Odd Hour On-site Disaster Drill conducted on 18.09.2019 at HGU and scenario was “Leakage of Naphtha

from HGU feed pump no. P-0031 B due to Seal Failure followed by Fire”



Paradip location is prone to natural calamities like flood, cyclone and Earthquake. All facilities of Paradip

Refinery have been designed considering the risks involved due to above natural calamities :

Site altitude : 4.36 m above Indian mean sea level (IMSL)- highest recorded flood level of 3.91 m

Design Wind velocity - 265 km/Hr. (73 m/sec)

Seismic Design : Zone- 3 (as per IS 1893 )

Designed considerations for Natural Calamities



Developed software application with the help of IS for real time availability display of ERDMP coordinators list of PDR



Attended a district level mock drill conducted at collectorate ground, Jagatsinghpur for disaster preparedness on 19.06.2019.



Disaster Awareness Programme on the day of Odisha Disaster Preparedness day 29.10.2019.

Element-11: Compliance Guarantee


Action points:

1. In-House training Programs for EIC’s and HoDs for Implementation of Contract Labour Act

2. Communication to all the stake holders – apprise the significance/dos-don’ts of each policy

• On-line Document system development which will cover all statutory provisions, Acts, Forms, Reports & Returns

formats etc.

3. To develop Portal on “Statutory Compliance” which will cover:

• All major Statutes , acts and forms Centrally Monitored / Audited

• In-built triggers for time bound compliance.

4. For each policy, feed back mechanism being developed through workshops

5. RCA being done for violation of company policy

Aim: Company policy & applicable regulations should conform to the OE guidelines & the employees should

be trained on the OE guidelines.

Element-12: Information, communication & documentation


Aim: Relevant information related to operation, maintenance, regulatory issue, to be made available to all

concerned through proper communication systems. All documents should be properly archived and

made readily available.

Action points:

1. Identified Document controller from each unit/discipline

2. Unit related important documents placed in server

3. Operating manuals, SOPs, SMPs, MSDS (English/Hindi/Odia) made available in intranet. Operating Manuals and MSDS

of chemicals uploaded on Document Management System.

4. SOP pertaining to activities related to service department (HR/Finance/Materials/Store/Contract cell/Purchase) also

made available

5. System of communicating the message of Chairman, Directors and Unit Head to all the target levels

6. System of communicating the message of Section in charge, Plant in charge to all the target levels

7. System of placing all the structured review presentations (as per the meeting schedule) in intranet

8. Implementation of e-MOM system

9. Structure communication channel to all the stake holder



Availability of Operating Manual/SOP on intranet for easy access to all.



Availability of e-Notice board to circulate all important messages



Availability of standards on corporate HSE website.

5’T of Odisha Government


5’T principle of Odisha Government at Paradip Refinery

Technology Transparency Team Work Time Transformation

1. Annual Safety Calendar

The Annual Safety Calendar of Paradip Refinery includes the Divisional & Corporate level programmes

scheduled for the Refinery units of IOCL including national as well as mandatory programmes of the external

agencies

Priority Action points for prevention of Accidents in Factories


2. AAINA

Facilities being showcased as a "Model Work Place" for other Refining Industries to replicate are:

a) Main Process Control Room (MCR)

b) Material Warehouse in the Refinery Stores.

c) Quality Control laboratory

d) Mechanical Workshop

e) Hydrogen Plant

State of the Art- MCR Tracing of Material through

Barcoding at Main warehouse Display of Refinery Product



3. Safety Buddies

IOCL, Paradip has adopt M/s Paradeep Calciner Ltd. Udayabhatta as a Safety Buddy.

IOCL is also in the process of adopting few more safety buddies in Paradip region engaged in handling of

Hydrocarbons so that Paradip Refinery can play the role of mentor and guide for improvement in the safety

standards of the Factories.



4. Nearmiss Boxes

Paradip Refinery has provided “Near miss” incident reporting facility using computer based online application

and the system is working to the satisfaction of all the employees.

Near miss Reporting boxes put up in outdoor 20 locations for contract workers



5. Safety Gatherings

Operational and project areas observe Daily Tool Box Talks, Weekly Mass Tool Box Talks, and Monthly Safety

Day administering ‘Safety Pledge”. Discussion on a different safety themes is done during safety gatherings. The

Safety gatherings are attended by large number of workers.



6. Safety Touch

At Paradip Refinery 16 Sectional Safety Committees( SSC) have been constituted for conducting monthly

meeting at 16 different shop floor locations with participation of Interdepartmental employees involved in the

concerned area (Both executive & non-executives). Unsafe conditions are brought out and same are

attended on time bound manner.



7. Safety Hot Spots

A total of 356 CCTV cameras are installed in the Refinery out of which 144 nos. are installed in the process

units and the rest in offsite areas and peripheral roads of the Refinery

Inter Unit Housekeeping contests including BOO, BOOT, LSTK and PMC agencies have been organized every

year and the units adjudged as "BEST" and "RUNNER UP" are rewarded during Independence Day

Celebrations by Unit Head to promote a clean and safe work place



8. Use of Technology

F&S officials along with Traffic Marshals & Security personnel carry out surprise checking using hand held

Speed Guns and violators are penalised. Drivers of Heavy Vehicles are imparted on the spot trainings on safe

driving practices twice in every week.



9. Safety Compliance by Contractors

OISD Guidelines - OISD GDN- 207 on Contractor Safety and GDN-192 on Safety practices during

construction are strictly adhered to. Any job carried out in the Refinery premises is done after issuing

work permits as per OISD-Std-105.

Monthly Safety Day administering of Safety Pledge - in Hindi and Odia, Tool Box Talks are conducted

involving all Contract Workers.



10. Mock Drills

Quarterly Disaster Drills is a mandatory requirement for each of the IOCL’s Refineries as per

Divisional guidelines.



Best Safety Practices


Assembly Point Route marker and Manual Call Point (MCP) Flag



In house Hydrocarbon Detector installed on Foam Tender to alert Fire Crew.



Display of HSE statistics & Star Performer at South Fire Station & at Main entrance Gate of Refinery .



Display of Safety Triangle & Safety 1st Message



Electronic plot plan installed at south fire station to display the live Hot work, Excavation, Radiography and Road closure



Developed software application with the help of IS for real time display of live hot permit on intranet page of Paradip Refinery.

106

Award & Recognition

Paradip Refinery adjudged as 2nd Runner up of “Shri A. V. Ogale” Award for the year 2018-19 :

Paradip Refinery Received “Kalinga Safety Award” consecutively for the last 3 years

Year 2015 Year 2016 Year 2017

107

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