Safety Training. WHY SAFETY? PROTECTION OF PERSONNEL FROM SUFFERING PROTECTION OF PLANT AND PROPERTY UNINTERRUPTED PRODUCTION STATUTORY REQUIREMENT WELFARE.

Safety TrainingSafety Training

WHY SAFETY?•PROTECTION OF PERSONNEL FROM SUFFERING

•PROTECTION OF PLANT AND PROPERTY

•UNINTERRUPTED PRODUCTION

•STATUTORY REQUIREMENT

•WELFARE OF THE COMMUNITY BY AVOIDING POLLUTION

•REPUTATION AND SELF RESPECT.

10 CAUSES OF ACCIDENT.1.VIOLATION OF PROCEDURES / RULES.

2.LACK OF PROPER INSPECTION AND MAINTENANCE.

3.PROTECTIVE EQUIPMENT NOT USED.

4.LACK OF COMMUNICATION.

5.HOUSEKEEPING.

6.UNSAFE CONDITIONS.

7.UNSAFE ACTS.

8. IMPROPER TOOLS AND EQUIPMENT.

9. INATTENTION / NEGLIGENCE.

10.POOR JUDGMENT.

Why OISD ?• The Oil Industry in India is 100 years old.

• Because of various collaboration agreements, a variety of international codes, standards and practices have been in vogue.

• Standardisation in design philosophies and operating & maintenance practices at a national level was hardly in existence.

• This, coupled with feed back from some serious accidents that occurred in the recent past in India eg. Bhopal Gas Tragedy and abroad, emphasised the need for the industry to review the existing state of art in designing, operating and maintaining oil and gas installations.

Why OISD ?• With this in view, the Ministry of Petroleum and

Natural Gas in 1986 constituted a Safety Council assisted by the Oil Industry Safety Directorate (OISD)

• Staffed from within the industry.

• For formulating and implementing a series of self regulatory measures aimed at removing obsolescence, standardising and upgrading the existing standards to ensure safe operations.

• Accordingly, OISD constituted a number of functional committees of experts nominated from the industry to draw up standards and guidelines on various subjects.

OISD-105• The Work Permit System is an important tool for

safety in hydrocarbon processing / handling. • The recommended Work Permit System is described

covering various aspects:When a work permit is required ?Types of permits & responsibilities.Check lists.Validity.• The success of a Work Permit System depends upon

the training, motivation and participation of all individuals concerned with its implementation.

• Since several maintenance/ construction jobs are often carried out with assistance from contractors, it is essential to provide sufficient exposure to contractor and his employees as well.

OISD-105

When a work permit is required ?

• If the work has to be performed by any person other than the operating personnel of that area, a duly authorised written permit shall be obtained by the person/agency executing the work before commencement of the work.

• However, even for operating personnel, when work has to be performed outside their normal routine, an exclusive permit to that effect by the authorised person shall be obtained.

OISD-105

• a) Hot Work : Hot Work is an activity which may produce enough heat to ignite a flammable air - hydrocarbon mixture or a flammable substance.

• b) Cold Work : Cold Work is an activity which does not produce sufficient heat to ignite a flammable air- hydrocarbon mixture or a flammable substance.

OISD-105 Type of Work Permits

• Based on the nature, the work shall be undertaken either Hot Work Permit or Cold Work Permit to be issued.

PROCEDURE FOR WORK PERMIT SYSTEM• The Work Permit System shall always operate

on "Owner - In-charge" concept. (Example: Process Unit-Shift In-charge; Laboratory-Chief Chemist; Depot-Depot Manager; Pipelines Installation- Shift In-charge).

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OISD-105• The permit shall be in printed form.• Separate forms shall be used for Hot Work and

Cold Work.• A system of colour coding is recommended to

identify two types of permits. The recommended colours are pink for Hot Work Permit and yellow for Cold Work Permit.

• All permits shall be serially numbered.• Hot Work Permit shall be in four copies. The

original shall be in pink colour and other copies shall have the word "COPY" printed in large pink letters.

• Cold Work Permit shall be in two copies. The Original shall be in yellow colour and the copy shall have the word "COPY" printed in large yellow letters.

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OISD-105• Both Hot Work Permit as well as Cold Work

Permit be made in the form of books with tear-off facility.

• Distribution of copies :– Hot Work Permit,

• Original copy to the receiver• Duplicate to the Fire Section• Triplicate to Safety Section • Quadruplicate retained in the book.

– Cold Work Permit,• Original shall be issued to the receiver,

retaining the Duplicate in the book.• For simplification of procedure, Hot Work Permit

also covers permission for vessel entry, vessel boxing-up and excavation. All activities outside the scope of Hot Work Permit shall be covered by Cold Work Permit.

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OISD-105• No hot/cold work shall be undertaken without a work

permit except in the areas pre-determined and designated by the owner-in-charge.

• All work permits shall be issued by the person who is designated as responsible person for the operation of the area where work is to be carried out.

• The work may be planned to be done either departmentally or through a contractor. In either case, the work permit should be received and signed by the maintenance / project /construction supervisor of the company as he is responsible for the work of the contractor also.

OISD-105

• Permit should be issued only for a single shift and its validity should expire at the termination of the shift.

• However, where the work has to be continued, the same permit may be revalidated in the succeeding shift, by authorized person after satisfying the normal checks.

• Blanket Hot Work Permit could be given if the owner-in-charge is fully satisfied that the conditions are totally safe for the multiple jobs to be performed.

• As a pre-requisite to issue permit, particularly in the case of hot work/vessel entry permit, gas test for hydrocarbons / oxygen deficiency / toxic gases shall be conducted as applicable.

OISD-105• Where gas-free conditions are not fully ensured for

the duration of hot work, a system of monitoring either by automatic or by manual periodic verification shall be resorted to depending upon the prevalent conditions of the operating area.

• Where gas-free conditions are not fully ensured for the duration of hot work, a system of monitoring either by automatic or by manual periodic verification shall be resorted to depending upon the prevalent conditions of the operating area.

• The issuer on receiving back the permit would satisfy himself regarding completion of the job and that the area has been cleaned. Then he shall also sign the permit and keep the records for one month.

OISD-105• EXPLANATORY NOTES TO WORK PERMIT

FORMS:• Equipment / Area inspected• Surrounding area checked / cleaned • Sewers, Manholes, CBD etc. and Hot Surfaces

covered• Considered hazard from other routine / non-

routine operations and persons alerted• Equipment electrically isolated and tagged• Running water hose/Portable extinguisher

provided• Fire water system checked for readiness• Equipment blinded / dis-connected / closed /

isolated / wedge opened • Equipment properly drained / depressurized

OISD-105– Equipment properly steamed / purged– Equipment water flushed– Gas / Oxygen deficiency test done and found

OK– Gas test includes measurement of :

• Hydrocarbons by Explosimeter• Oxygen Deficiency by Oxygen Meter• Use of Calibrated Meters

– Shield against sparks provided– Proper ventilation and lighting provided– Proper means of exit provided– Precautionary tags / boards provided– Portable equipment / Hose nozzles properly

grounded

OISD-105• Standby person provided for vessel entry• Area cordoned off• Precaution against public traffic taken• Clearance obtained for excavation from

Technical/ concerned departments• Checked Flame / Spark arrestor on mobile

equipment• Checked Flame / Spark arrestor on mobile

equipment• Checked Flame / Spark arrestor on mobile

equipment• Oxygen and Acetylene cylinders kept outside the

vessel / tank

FIRE PROTECTION SYSTEM(OISD-117)

• THE FOLLOWING FIRE PROTECTION FACILITIES SHALL BE PROVIDED DEPENDING UPON NATURE OF RISK IN THE INSTALLATION.

– FIRE WATER SYSTEM.

– FOAM SYSTEM.

– FIRST AID FIRE FIGHTING EQUIPMENT.

– MOBILE FIRE FIGHTING EQUIPMENT.

– FIRE ALARM / COMMUNICATION SYSTEM.

FIRE PROTECTION SYSTEM(OISD-117)• DESIGN CRITERIA.DESIGN CRITERIA.• FACILITIES SHOULD BE DESIGNED ON THE

BASIS THAT CITY FIRE WATER SUPPLY IS NOT AVAILABLE CLOSE TO INSTALLATION.

• ONE SINGLE LARGEST RISK SHALL BE CONSIDERED FOR PROVIDING FACILITIES.

• FIRE WATER DEMAND AND STORAGE SHALL BE DESIGNED TO CATER TO THE WATER DEMAND OF FOLLOWING SYSTEM, AS PROVIDED FOR VARIOUS RISKS:– HYDRANT MONITOR SYSTEM.– WATER SPRAY SYSTEM.– FOAM SYSTEM.– SUPPLEMENTARY HOSE STREAM .


• FIRE WATER SYSTEMFIRE WATER SYSTEM

– THE INSTALLATION HAVING AGGREGATE A/G STORAGE CAPACITY >1000 KL (CLASS A + B + C) AND PIPELINE INSTALLATIONS SHALL BE FULLY COVERED BY HYDRANT SYSTEM.

– CLASS 'A' A/G STORAGE SHALL HAVE FIXED WATER SPRAY SYSTEM FOR DIA > 9 M. HOWEVER, FOR SMALL INSTALLATION ( A/G STORAGE CAPACITY OF CLASS 'A' AND 'B'< 5000 KL AND DIA OF TANK STORING CLASS 'A' PRODUCT < 9 MTRS) ARE EXEMPTED FROM FIXED WATER SPRAY SYSTEM.


• CLASS 'B' A/G PETROLEUM STORAGE TANKS OF DIAMETER LARGER THAN 30 MTRS. SHALL BE PROVIDED WITH FIXED WATER SPRAY SYSTEM.

• WHEN CLASS 'A' & 'B' A/G STORAGE TANKS ARE PLACED IN A COMMON DYKE, THE FIXED WATER SPRAY SYSTEM SHALL BE PROVIDED ON ALL TANKS EXCEPT AS MENTIONED FOR SMALL INSTALLATIONS.

• DESIGN FLOW RATE:DESIGN FLOW RATE:

• A) FIRE WATER FLOW RATE FOR’ A ‘TANK FARM SHALL BE AGGREGATE OF THE FOLLOWING:

• COOLING OF TK. ON FIRE - 3 LPM /M2.

• EXPOSURE PROTECTION FOR TANK WITHIN (R+30) MTR. - 3 LPM / M2.


• EXPOSURE PROTECTION FOR TANKS OUTSIDE (R+30) MTR. - 1 LPM / M2.

• FIRE FLOW REQUIRED FOR APPLYING FOAM ON A SINGLE LARGEST TANK BY WAY OF FIXED FOAM SYSTEM, WHERE PROVIDED, OR BY USE OF WATER / FOAM MONITORS.

• CONE ROOF : 5 LPM / M2

• F/R TANK : 12 LPM / M2 OF SEAL AREA WITH FOAM DAM HT. 600MM

: 8.1 LPM / M2 OF LIQUID SURFACE AREA IN CASE OF SINKING CASE

• DURATION FOR 65 MIN. IN CASE OF CLASS ''A'&'B''

• 30 MIN. FOR SPILL FIRE. WATER : 97% TO 94%


• VARIOUS COMBINATIONS SHALL BE CONSIDERED IN THE TANK FARM FOR ARRIVING AT DIFFERENT FIRE WATER FLOW RATE AND THE LARGEST RATE TO BE CONSIDERED FOR DESIGN.

• B) FIRE WATER FLOW RATE FOR SUPPLEMENTARY STREAMS SHALL BE BASED ON USING 4 SINGLE HYDRANT OUTLETS + 1 MONITOR SIMULTANEOUSLY. CAPACITY OF EACH HYDRANT OUTLET IS 36 CU.M. / HOUR AND EACH MONITOR IS 144 CU.M. / HOUR.

• C) TANK WAGON LOADING GANTRY - 10 LPM /M2.

• THE DESIGN FIRE WATER RATE SHALL BE THE LARGEST OF A / B / C.


• STORAGE SHOULD BE EFFECTIVELY FOR MINIMUM 4 HRS. WHERE MAKE UP WATER SUPPLY SOURCE IS 50% OR MORE OF DESIGN FLOW RATE, THE STORAGE CAPACITY MAY BE REDUCED TO 3 HOURS.

• MIN. PR. SHOULD BE 7 KG / CM2.• FIRE WATER SUPPLY SHALL BE PREFERABLY

FROM FRESH WATER SOURCE.

• THE INSTALLATION SHALL HAVE FACILITIES FOR RECEIVING AND DIVERTING ALL THE WATER COMING TO THE INSTALLATION TO FIRE WATER STORAGE TANKS.

• STORAGE SHALL BE IN TWO EQUAL INTERCONNECTED COMPARTMENTS.


• FIRE WATER PUMPS:

• SHALL BE INSTALLED TO MEET THE DESIGN FIRE WATER FLOW RATE. SHOULD HAVE FLOODED SUCTION.

• A MINIMUM OF 50% STANDBY PUMPS OF THE SAME TYPE AND CAPACITY AS THE MAIN PUMPS SHALL BE PROVIDED.

• SHALL BE DIESEL ENGINE DRIVEN TYPE WITH QUICK STARTING TYPE WITH THE HELP OF PUSH BUTTONS.

• EACH ENGINE SHOULD HAVE INDEPENDENT FUEL TANK ADEQUATELY SIZED FOR 6 HOURS RUNNING.


• FIRE WATER AND PUMP SHALL BE EXCLUSIVELY USED FOR THE FIRE FIGHTING PURPOSE ONLY.

• FIRE WATER NETWORK SHALL BE KEPT PRESSURISED BY A STATIC TANK OR JOCKEY PUMPS.


• FIRE WATER DISTRIBUTION NETWORK:FIRE WATER DISTRIBUTION NETWORK:

• LOOPING - SHALL BE LAID IN CLOSED LOOPS.

• THE ABOVE / UNDERGROUND NETWORK - SHALL BE LAID AT A HEIGHT OF 300 MM TO 400 MM WITH SUPPORTS NOT EXCEEDING 6 MTRS. APART FOR ABOVE GROUND AND SUITABLE COATING / WRAPPING WITH 1 MTR. EARTH CUSHION TO BE PROVIDED IN CASE OF UNDERGROUND.

• FIRE WATER MAINS SHALL NOT PASS THROUGH BUILDINGS OR DYKED AREAS.


• HYDRANT AND MONITORS:HYDRANT AND MONITORS:

• AT LEAST ONE HYDRANT POST SHALL BE PROVIDED FOR EVERY 30 MTRS. OF EXTERNAL WALL MEASUREMENT OR PERIMETER FOR HAZARDOUS AREAS. FOR NONHAZARDOUS AREAS- 45 MTRS.

• HYDRANTS SHALL BE LOCATED AT A MIN. DISTANCE OF 15 MTRS. FROM THE PERIPHERY OF STORAGE TANK., IN CASE OF BUILDINGS, THIS DISTANCE SHALL NOT BE LESS THAN 2 METERS.


FOAM SYSTEM:FOAM SYSTEM:– THERE ARE THREE TYPES OF FOAM SYSTEMS:

• FIXED SYSTEM.• SEMI-FIXED SYSTEM.• MOBILE SYSTEM.

• FIXED / SEMI FIXED FOAM SYSTEM WITH FOAM TENDER SHALL BE PROVIDED ON BOTH FIXED &F/R TANKS HAVING DIA>18 MTRS.

• AUTOMATIC ACTUATED FOAM FLOODING SYSTEM MAY BE CONSIDERED FOR F/R TANKS HAVING DIA. >60 MTRS.


• FLOATING ROOF TANK PROTECTION

– SYSTEM TO BE DESIGNED TO CREATE FOAM IN A SHORT SPAN OF TIME.

– CONTINUOUS APPLICATION AT A HIGH RATE.

– FOAM MAKERS / POURERS SHALL BE LOCATED NOT MORE THAN 24 MTRS. APART ON THE SHELL PERIMETER


• FIXED ROOF TANK PROTECTIONFIXED ROOF TANK PROTECTION– VAPOUR SEAL CHAMBER SHALL BE PROVIDED

WITH AN EFFECTIVE AND DURABLE SEAL, TO PREVENT ENTRANCE OF VAPOUR INTO THE FOAM CONVEYING PIPING SYSTEM.

– TANKS SHOULD BE PROVIDED WITH FOAM DISCHARGE OUTLETS / POURERS AS BELOW:

• TANK DIA.(M) MINIM. OUTLETS• >18 UP TO 20 2• >20 UP TO 25 3• >25 UP TO 30 4


• PROTECTION FOR DYKE AREA / SPILL AREAPROTECTION FOR DYKE AREA / SPILL AREA:– PORTABLE MONITORS / FOAM HOSE STREAMS

SHALL BE CONSIDERED FOR FIGHTING FIRES IN DYKED AREA AND SPILLS

• FOAM QUANTITY REQUIREMENTFOAM QUANTITY REQUIREMENT– QUANTITY OF FOAM WILL BE MAXIMUM OF

THE FOLLOWING 'A', 'B' AND 'C' CRITERIA.

• A) 5 LPM/M2 FOR CONE ROOF. • 12 LPM/M2 FOR F/R TANKS,8.1

LPM/M2 IN SINKING, FOR 65 MIN.


• B) WHEELED PORTABLE WATER/FOAM MONITORS.• INSTALLATIONS NO CAPACITY

– 1000 KL NIL– UP TO 10, 000 KL 1 1600

LPM– UP TO 25,000 KL 1 2400

LPM– >25,000 KL 2 2400 LPM

• C) TWO HOSE STREAMS OF FOAM EACH WITH CAPACITY OF 1140 LPM OF SOLUTION.

• FOAM REQUIREMENT WILL BE 3% TO 6% OF FOAM SOLUTION


FIRST AID F/F EQUIPMENT:FIRST AID F/F EQUIPMENT:• PORTABLE FIRE EXTINGUISHERS:• SHOULD BE LOCATED AT A CONVENIENT

LOCATION AND SHALL BE READILY ACCESSIBLE AND CLEARLY VISIBLE AT ALL TIMES. THE MAXIMUM RUNNING DISTANCE SHOULD NOT EXCEED 15 MTRS. AND TOP OF EXTINGUISHER SHOULD NOT BE MORE THAN 1.5 MTRS. ABOVE THE FLOOR LEVEL

FIRE PROTECTION SYSTEM(OISD-117)• WHEELED F/F EQUIPMENTWHEELED F/F EQUIPMENT

– INST. CAPACITY 1000 KL NIL– INST. CAPACITY 10,000 KL 1X1600 LPM– INST. CAPACITY 25,000 KL 1X2400 LPM– INST. CAP. > 25,000 KL 2X2400 LPM

• FOAM COMPOUND TROLLEY 200 / 210 LTRSFOAM COMPOUND TROLLEY 200 / 210 LTRS– 1 NO. UPTO 24 MTRS. DIA– 2 NOS. FOR 24-30 MTRS. DIA.– 3 NOS. FOR 30-40 MTRS. DIA.

FIRE PROTECTION SYSTEM(OISD-117)• HOSES

THE NUMBER OF HOSES STORED IN AN OIL INSTALLATION SHALL BE 30% OF THE NUMBER OF HYDRANT OUTLETS. THE MINIMUM NUMBER OF HOSES SHALL NOT BE LESS THAN 10.

• NOZZLES • MINIMUM QUANTITY OF NOZZLES SHALL BE

STORED AS FOLLOWS:• JET NOZZLES WITH BRANCH PIPE - 4 • FOG NOZZLES - 4• UNIVERSAL NOZZLES - 4• FOAM BRANCH PIPE - 4

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Hoses, Nozzles & Accessories1.Reinforced rubber lined hoses (63 mm) confirming to

IS:636 (Type A or B) shall be provided.

2.The hoses shall be of 15 Mtrs. Standard length and shall be provided with gun metal/ aluminum alloy male and female couplings of instantaneous pattern.

3.50% spare hoses shall be stored in the LPG plant.

4. In addition to the nozzles provided in the hose boxes there shall be at least 2 nos. spare nozzles in each category viz. Jet nozzles with branch pipes, Fog nozzles, Universal nozzles, Water curtain nozzles, Spray nozzles and Triple purpose nozzles in LPG plant.

FIRE PROTECTION SYSTEM(OISD-117)ACCESSORIESFOLLOWING MIN.ACCES. TO BE PROVIDED.SAND SCOOPS.SAFETY HELMETS.WATER CURTAIN NOZZLES.STRETCHER.FIRST AID BOX.RUBBER HAND GLOVES.EXPLOSIMETER.FIRE PROXIMITY SUIT.ELECTRICAL SIREN - 3 KM.HAND OPERATED SIREN.RED / GREEN FLAGS.

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First Aid Fire Fighting EquipmentWheeled/Mobile Fire Fighting equipment

1.1 no mobile 75kg DCP fire extinguishers shall be provided in filling shed, LPG storage vessel/LPG pump house area, Tank Truck loading/unloading gantry & Tank wagon loading/unloading gantry area.

2.Considering the large area and no of operations involved in MEGA LPG plants, special fire fighting facilities like DCP fire tenders should preferably be provided.

3.A trolley with suitable first aid fire protective accessories shall be readily available in the LPG plant.

First Aid Fire Fighting Equipment Portable Fire Extinguishers1.Portable fire extinguishers shall be located at

convenient locations and shall at all times be readily accessible and clearly visible.

2.The maximum running distance to locate an extinguisher in working areas shall not exceed 15 Mtr.

3.The top surface of extinguishers shall not be more than 1.5 Mtr.

4.The fire extinguishers shall be provided at various locations as stipulated in OISD std.117 & 144.

5.100% spare cartridges and 50% (Min.) spare DCP powders (As per total fire extinguishers capacity) shall be stored in a location.

FIRE PROTECTION SYSTEM(OISD-117)ALARM SYSTEM:ALARM SYSTEM:

1. SMALL FIRE: NO SIREN.

2. MAJOR FIRE: A WAILING SIREN FOR TWO MINUTES. SIRENS

WILL BE UNDED 3 TIMES FOR 30 SEC. WITH AN INTERVAL OF 15 SEC.

3. DISASTER: SAME TYPE OF SIREN AS ABOVE AT AN INTERVAL

OF 2 MINUTES.

4. ALL CLEAR: STRAIGHT RUN FOR 2 MNTS.

5. TEST: STRAIGHT RUN FOR 2 MNTS.

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COMMUNICATION SYSTEM:

• ADEQUATE COMMUNICATION SYSTEM LIKE TELEPHONE / PUBLIC ADDRESS SYSTEM / PAGING SYSTEM / INTRINSICALLY SAFE WALKIE TALKIE SYSTEM SHOULD BE CONSIDERED.

LAYOUT AND DESIGN(OISD-118)

LAYOUT.LAYOUT.• PLANT LAYOUT PHILOSOPHY.• BASIC INFORMATION.• BLOCKS.• ROADS.• LOCATION.• ERECTION AND MAINTENANCE.• FUTURE EXPANSION.


LAYOUT OF STORAGE TANKS.LAYOUT OF STORAGE TANKS.• DYKED ENCLOSURES.• GROUPING.• FIRE WALLS.• GENERAL.• INTERDISTANCES FOR TANKS / OFF-SITE

FACILITIES.


BASIC INFORMATION:• PROCESS FLOW DIAGRAM INDICATING FLOW

SEQUENCE.• UTILITY REQUIREMENTS, STORAGE TANKS LIST.• MODE OF TRANSPORT.• WAREHOUSE AND OPEN STORAGE AREA.• ENVIRON. CONSIDERATIONS & SURROUNDING

RISKS.• FIRE STATION.• PREVAILING WIND DIRECTION.• TOPOGRAPHY CONTOUR MAP, HIGH FLOOD

LEVEL .


BASIC INFORMATION:• SOURCE OF WATER SUPPLY & LIKELY ENTRY

POINT.• ELECTRIC SUPPLY SOURCE & DIRECTION OF

ENTRY POINT.• STORM WATER / EFFLUENT DISPOSAL POINT.• RAILWAY ENTRY POINT.• APPROACH ROADS.

LAYOUT AND DESIGN(OISD-118)BLOCKS:BLOCKS:• BLOCK LAY OUT SHOULD BE ADOPTED .• ENTIRE AREA SHOULD BE SUB DIVIDED INTO

BLOCKS.• MAX. SIZE OF BLOCK SHOULD BE ESTABLISHED

ON TANK FARM LAYOUT• PLANT LAY OUT ARRANGEMENT SHOULD

FOLLOW RECEIPT STORAGE AND DISPATCH MODE.

LOCATION:LOCATION:• SHOULD BE ON HIGH GROUND• IGNITION SOURCE SHALL ALWAYS BE BEYOND

BOUNDARY WALL.• ORIENTATION OF THE LOCATION SHOULD BE

DECIDED ON PREVAILING WIND DIRECTION.


ROADS:ROADS:• ROADS TO BE PROVIDED ALL AROUND THE

BLOCKED FACILITIES.• ALTERNATE ACCESS TO BE PROVIDED FOR

EACH FACILITY• ROAD WIDTH AND TURNING RADII SHALL BE

DESIGNED TO FACILITATE FIRE FIGHTING VEHICLE.

• MINIMUM TRUCK TRAFFIC.• TWO ROAD APPROACH SHOULD BE PROVIDED


ERECTION AND MAINTENANCEERECTION AND MAINTENANCE:• TOWERS, REACTORS, ETC. SHOULD BE

LOCATED AWAY FROM CONGESTED AREAS TO FACILITATE ERECTION AT ANY STAGE.

• MAINTENANCE METHODS FOR EACH EQUIPMENT SHOULD BE KEPT IN MIND WHILE CONSIDERING THE LAYOUT.

FIRE PROTECTION SYSTEM(OISD-117)FUTURE EXPANSION:FUTURE EXPANSION:• SPACE PROVISION FOR KNOWN AND

UNFORESEEN NEEDS SHALL BE MADE. ORDERLY FUTURE EXPANSION SHALL BE EFFECTED BY PROVIDING SPACE ADJACENT TO SIMILAR TYPE OF FACILITIES. EXTENSION OF PIPE SLIPPERS AND PIPE WAY ROAD CROSSINGS SHALL BE GIVEN DUE CONSIDERATION. CARE SHALL BE TAKEN TO FACILITATE FUTURE EXPANSION WITHOUT ANY INTERFERENCE TO OPERATION IN THE EXISTING FACILITIES.

FIRE PROTECTION SYSTEM(OISD-117)DYKED ENCLOSURES:DYKED ENCLOSURES:• AGGREGATE CAPACITY OF TANKS LOCATED IN

ONE DYKED ENCLOSURE SHALL BE AS BELOW:• FOR A GROUP OF FLOATING

ROOF TANKS: 1,20,000 CU.M.

• FOR A GROUP OF FIXED

ROOF TANKS 60,000 CU.M.

• IF A GROUP OF TANKS CONTAIN BOTH FIXED AND F / R TANKS, THEN IT SHALL BE TREATED AS A GROUP OF FIXED ROOF TANKS.

FIRE PROTECTION SYSTEM(OISD-117)• DYKED ENCLOSURES SHOULD BE ABLE TO

CONTAIN THE CONTENTS OF THE LARGEST TANK , IN CASE OF ANY EMERGENCY. ENCLOSURE CAPACITY SHALL BE CALCULATED AFTER DEDUCTING THE VOLUME OF TANKS (OTHER THAN THE LARGEST TANK) UP TO THE HEIGHT OF THE ENCLOSURE. A FREEBOARD OF 200 MM SHALL BE CONSIDERED FOR FIXING THE HT. OF THE DYKE.

• THE HEIGHT OF TANK ENCLOSURE DYKE SHALL BE AT LEAST 1 M. AND SHALL NOT BE MORE THAN 2.0 M

• THE TOP FLAT SURFACE OF DYKES SHALL BE AT LEAST 0.6 M WIDE.

FIRE PROTECTION SYSTEM(OISD-117)• INTERDISTANCE BETWEEN THE NEAREST TANKS

LOCATED IN TWO DYKES SHALL BE EQUIVALENT TO THE LARGEST TANK DIAMETER OR 30 M, WHICHEVER IS MORE.

• PUMP STATIONS SHOULD BE LOCATED OUTSIDE DYKE AREAS BY THE SIDE OF ROADS.

GROUPING:GROUPING:• TANKS SHALL BE ARRANGED IN MAXIMUM TWO

ROWS SO THAT EACH TANK IS APPROACHABLE FROM THE ROAD SURROUNDING THE ENCLOSURE. HOWEVER, TANKS HAVING CAPACITY 50,000 CU.M. AND ABOVE SHALL BE LAID IN SINGLE ROW.

FIRE PROTECTION SYSTEM(OISD-117)GROUPING:GROUPING:

• CLASS 'A' AND / OR CLASS 'B' PETROLEUM CAN BE STORED IN THE SAME DYKED ENCLOSURE. CLASS 'C' PETROLEUM SHOULD PREFERABLY BE STORED IN SEPARATE ENCLOSURE. HOWEVER, WHERE CLASS 'C' PETROLEUM IS STORED IN A COMMON DYKE ALONG WITH CLASS 'A' AND / OR CLASS 'B' PETROLEUM, ALL SAFETY STIPULATIONS APPLICABLE FOR CLASS 'A' AND / OR CLASS 'B' RESPECTIVELY SHALL APPLY.

FIRE PROTECTION SYSTEM(OISD-117)FIRE WALLS:FIRE WALLS:• IN A DYKED ENCLOSURE WHERE MORE THAN ONE

TANK IS LOCATED, FIRE WALLS OF 600 MM SHOULD BE PROVIDED AS EXPLAINED BELOW:

– A) ANY TANK HAVING A DIAMETER MORE THAN 30 M SHOULD BE SEPARATED WITH FIRE WALLS FROM OTHER TANK.

– B) FIRE WALLS SHOULD BE PROVIDED BY LIMITING THE AGGREGATE CAPACITY OF EACH GROUP OF TANKS WITHIN, TO 20,000 CU.M.

FIRE PROTECTION SYSTEM(OISD-117)GENERAL:GENERAL:• THE TANK HT. SHALL NOT EXCEED 1&1/2 TIMES

THE DIA. OF THE TANK OR 20 M, WHICHEVER IS LESS.

• PIPING FROM / TO ANY TANK LOCATED IN A SINGLE DYKED ENCLOSURE SHOULD NOT PASS THROUGH ANY OTHER DYKED ENCLOSURE. PIPINGTO BE MINIMISED.

• NO FIRE WATER / FOAM RING MAIN SHALL PASS THROUGH DYKED ENCLOSURE.

• THE MINIMUM DISTANCE BETWEEN A TANK SHELL AND THE INSIDE TOE OF THE DYKE WALL SHALL NOT BE LESS THAN ONE HALF THE HEIGHT OF THE TANK.

FIRE PROTECTION SYSTEM(OISD-117)INTERDISTANCES:INTERDISTANCES:• TABLE NO 3 OF OISD 118 FOR TANKS STORING

CLASS 'C' PETROLEUM; OR CLASS 'A' AND 'B' PETROLEUM PRODUCTS WITH TOTAL STORAGE CAPACITY NOT EXCEEDING 5000 CU.M. ATONE INSTALLATION. CHART IS IN THE FOLLOWING SLIDE.

• INTERDISTANCES SHALL BE AS GIVEN IN TABLE 4 OF OISD 118 FOR TANKS STORING CLASS 'A' AND CLASS 'B' PETROLEUM PRODUCTS WITH TOTAL STORAGE CAPACITY EXCEEDING 5000 CU.M.

FIRE PROTECTION SYSTEM(OISD-117)INTERDISTANCES:INTERDISTANCES:• INTERDISTANCES FOR TANKS AND FENCING

SHALL BE AS GIVEN IN TABLE 6 FOR TANKS STORING CLASS 'A', CLASS 'B' AND CLASS 'C' PETROLEUM PRODUCTS WITH TOTAL STORAGE CAPACITY OF CLASS 'A' AND CLASS 'B' PETROLEUM STORED EXCEEDING 5000 CU.M.

STATIC ELECTRICITY• WHAT IS STATIC ELECTRICITY ?• Static Electricity is a phenomenon of electrifi-cation of

materials through physical contact and separation and the various effects that result from the positive and negative charges so formed.

• In general, static electricity results form removal of electrons from the atoms of one material (leaving it with positive charge) and absorption of these electrons on the second material (negative charge) during physical separation of the two materials.

• Both materials remain charged if they are well insulated electrically.

STATIC ELECTRICITYSPECIFIC GUIDELINES FOR CONTROL OF STATIC SPECIFIC GUIDELINES FOR CONTROL OF STATIC

ELECTRICITYELECTRICITY • Storage Tanks :Storage Tanks :

– Ensure earthing of tanks Ensure earthing of tanks

– Ensure no metal objects/appurtenances projecting Ensure no metal objects/appurtenances projecting from roof/shell plates which will attract highly from roof/shell plates which will attract highly charged spots in fuel for dissipation.charged spots in fuel for dissipation.

– Ensure reduced rate of flow initially into tank/vessel Ensure reduced rate of flow initially into tank/vessel until fill point/nozzle is completely submerged in until fill point/nozzle is completely submerged in fluid (filling rate initially restricted to 1 mtr. per fluid (filling rate initially restricted to 1 mtr. per second).second).

STATIC ELECTRICITY• Storage Tanks :Storage Tanks :

– Ensure that all tanks are provided with Dip pipes Ensure that all tanks are provided with Dip pipes extending to tank bottom. If Dip pipes are not extending to tank bottom. If Dip pipes are not provided, give a relaxation time of 30 minutes provided, give a relaxation time of 30 minutes before sampling/gauging.before sampling/gauging.

– Ensure that only gauge tapes with earthing Ensure that only gauge tapes with earthing provision are used for gauging.provision are used for gauging.

– Ensure periodic checking and recording of earthing Ensure periodic checking and recording of earthing test for tanks and piping systems are maintained.test for tanks and piping systems are maintained.

– Avoid high velocity or splash filling, in all types of Avoid high velocity or splash filling, in all types of products.products.

STATIC ELECTRICITY• Sampling of Products :Sampling of Products :– Ensure nylon rope/cord is not used for sampling

/gauging which is to be lowered into product tanks.

– Ensure no personnel is allowed on tank roof for gauging / sampling during product transfer unless Dip pipes extend to bottom of tanks. Use only mechanical gauges for ascertaining product transferred during transfer operations otherwise.

– Ensure gauging/sampling of tank after product transfer is done only after relaxation time of 30 min. unless Dip pipes extend to bottom of tank.

STATIC ELECTRICITY• Loading/unloading operations in Tank Wagon Loading/unloading operations in Tank Wagon

Gantries :Gantries :– Ensure proper grounding of gantry structure.Ensure proper grounding of gantry structure.

– Ensure tank wagons are electrically bonded to Ensure tank wagons are electrically bonded to gantry structure.gantry structure.

– Ensure that the tank cars are fully bonded with the Ensure that the tank cars are fully bonded with the chassis for electrical continuity.chassis for electrical continuity.

– Ensure rails on which tank wagons stand are Ensure rails on which tank wagons stand are effectively earthed.effectively earthed.

– Ensure rail siding is insulated/ isolated from main Ensure rail siding is insulated/ isolated from main running track.running track.


Gantries :Gantries :– Ensure piping / header systems are effectively Ensure piping / header systems are effectively

bonded and in the case of rake, unloading hose bonded and in the case of rake, unloading hose point.point.

– Ensure use of continuous electrically bonded Ensure use of continuous electrically bonded decanting hoses.decanting hoses.

– For tankwagon loading, ensure loading hose is For tankwagon loading, ensure loading hose is electrically bonded with tank wagon manhole cover.electrically bonded with tank wagon manhole cover.

– Ensure splash filling is avoided for all white oil Ensure splash filling is avoided for all white oil products, LDO and low intermediate and high products, LDO and low intermediate and high vapour pressure products by filling only wagons vapour pressure products by filling only wagons fitted with fill pipes.fitted with fill pipes.


Gantries :Gantries :– Ensure gauging/sampling of tank trucks, tank cars Ensure gauging/sampling of tank trucks, tank cars

or fuders after product transfer is done only after or fuders after product transfer is done only after relaxation time of 10 minutes for ATF or 5 minutes relaxation time of 10 minutes for ATF or 5 minutes for others, unless Dip pipes extend to bottom of the for others, unless Dip pipes extend to bottom of the tank trucks or tank cars.tank trucks or tank cars.

– Continuity tests for bonding across the piping shall Continuity tests for bonding across the piping shall be carried out.be carried out.

STATIC ELECTRICITY• Loading/Unloading Operations In Tanktruck Loading/Unloading Operations In Tanktruck

Gantries :Gantries :– Ensure use of electrically continuous hoses having Ensure use of electrically continuous hoses having

jumper wire between flanges coiled around hose.jumper wire between flanges coiled around hose.

– Ensure proper earthing and bonding of tank truck.Ensure proper earthing and bonding of tank truck.

– Ensure electrical bonding of wagon with under Ensure electrical bonding of wagon with under carriage for electrical continuity.carriage for electrical continuity.

– For transfer mixing operations, ensure pumping For transfer mixing operations, ensure pumping rates are reduced to 0.5 metre per second until fill rates are reduced to 0.5 metre per second until fill lines/nozzles is completely submerged in product. lines/nozzles is completely submerged in product. This is particularly important when mixing gasoline/ This is particularly important when mixing gasoline/ kerosene/ HSD/ATF.kerosene/ HSD/ATF.

STATIC ELECTRICITY• Loading/Unloading Operations In Tanktruck Loading/Unloading Operations In Tanktruck

Gantries :Gantries :

– Switch loading (Low flash to High flash ) operation Switch loading (Low flash to High flash ) operation to be avoided. to be avoided.

– Ensure gauging/sampling of tank trucks after Ensure gauging/sampling of tank trucks after product transfer is done only after relaxation time product transfer is done only after relaxation time of 10 mins for ATF or 5 min for others; unless Dip of 10 mins for ATF or 5 min for others; unless Dip pipes extend to bottom of the tank truck.pipes extend to bottom of the tank truck.

STATIC ELECTRICITY• SMALL CONTAINERS (DRUMS, CANS)SMALL CONTAINERS (DRUMS, CANS)– Protective bonding is not required if containers are Protective bonding is not required if containers are

filled through a closed system.filled through a closed system.

– Protective bonding is required when fill open Protective bonding is required when fill open containers where the product to be handled has a containers where the product to be handled has a flash point below 54.5 Deg.C (130 Deg.F) or, in the flash point below 54.5 Deg.C (130 Deg.F) or, in the case of a higher flash point product, when it is case of a higher flash point product, when it is heated to within 6.0 Deg. C (15 Deg.F) of its flash heated to within 6.0 Deg. C (15 Deg.F) of its flash point. The purpose is to keep the nozzle and point. The purpose is to keep the nozzle and container at the same electrical potential, thus container at the same electrical potential, thus avoiding a possible static spark in the area of a avoiding a possible static spark in the area of a flammable mixture.flammable mixture.

STATIC ELECTRICITY• SMALL CONTAINERS (DRUMS, CANS)SMALL CONTAINERS (DRUMS, CANS)– Provide 30 seconds relaxation between a filter and Provide 30 seconds relaxation between a filter and

a container where a container where ‘‘intermediate vapour pressure intermediate vapour pressure products are handled.products are handled.

– Small containers made up of plastic or other non-Small containers made up of plastic or other non-conductive materials should not be used for filling conductive materials should not be used for filling of MS, Naphtha, Kerosene, Diesel etc.]of MS, Naphtha, Kerosene, Diesel etc.]

• TANK CLEANINGTANK CLEANING– Introduction of steam into gassy tanks should be Introduction of steam into gassy tanks should be

avoided. avoided. – Washing gassy tanks by means of gas oil, or other Washing gassy tanks by means of gas oil, or other

hydrocarbons using tank cleaning jets should be hydrocarbons using tank cleaning jets should be avoided.avoided.

– Water washing is safe from a static electricity stand-Water washing is safe from a static electricity stand-point. point.

STATIC ELECTRICITYEFFECTIVE BONDING / EARTHING SYSTEMS:EFFECTIVE BONDING / EARTHING SYSTEMS:

• FOR TANKWAGON LOADING / UNLOADING GANTRY:

– Continuity between rail and gantry shall be ensured by checking at a suitable frequency.

– The gantry structure to be suitably earthed in earthing pits of standard specifications (as per electrical installations and number of earthlings also to be as per standards IS-3043 and OISD-108.

– Tankwagon siding to be insulated from main running track.

STATIC ELECTRICITY• TANKTRUCK LOADING AND UNLOADING

GANTRY :– For the gantry 6 mm Sq. braided copper wire with

one end firmly bolted to the gantry and the other end provided with G.I crocodile clips are to be used, the crocodile clips being attached to the tank-truck under loading or discharging.

– The gantry to be suitably earthed as indicated for tankwagon gantry.

– During tanktruck discharge at retail outlets, 6 mm Sq. braided copper wire of suitable length with crocodile clips on either side are to be used for bonding between tank truck under discharge and receiving tank pipeline.

STATIC ELECTRICITY• BARGE/TANKER JETTY OPERATIONS :– 6 mm Sq. braided copper wire with crocodile clips

on either side are to be used for bonding between barges/tankers under loading/discharge at jetty.

– Jetty pipeline to be suitably earthed as indicted for tanktruck gantry.

• PIPELINES/PUMPS :– Running pipelines are to be bonded with loading

gantries by running copper strip jumpers suitably bolted to the flanges.

– The gantry structure to be suitably earthed in earthing pits of standard specifications (as per electrical installations and number of earthings also to be as per Standards IS-3043 and OISD-STD-108).

STATIC ELECTRICITY• STORAGE TANKS:

– All storage tanks are to be earthed separately as per electrical specifications "IS-3043-1966, 1994 and OISD-STD-108.

• SAMPLING /GAUGING :– For sampling jars to be inserted into product tanks,

use only manila ropes.

– When the filling nozzle is in electrical contact with the container and will remain so throughout the filling operation, no special bond is required.

Safety Training. WHY SAFETY? PROTECTION OF PERSONNEL FROM SUFFERING PROTECTION OF PLANT AND PROPERTY UNINTERRUPTED PRODUCTION STATUTORY REQUIREMENT WELFARE.

Documents

cold work permit

hot work permit

recommended work permit

b cold work

safety training slide

exclusive permit

written permit

operating personnel