9112 000 Hse 006 00048 - 01 PDF

·1
[UNCONTROLLED COPY] Printed from TDMS dated: 25-September-2019, 12:21:34 PM By Siddiqui MD Ghazunfer Ali (10000065)
®
/ HM EL
HPCL·Mittal Energy Limited

Guru Gobind Singh Refinery, Bathinda
Emergency Response and Disaster Management Plan
9112·000·HSE·006·00048
Issued for
01 27 -FEB-201 B IFI
Implementation
Issued for Aman Chopra Ramesh Nandanwar Ian Thorpe
00 05-SEP-2016 IFI
Implementation (Oy. Mgr Safety) (AGM-Fire & Safety) (VP-Health & Safety)
REV DATE STATUS REVISION LIST PREPARED CHECKED APPROVED
'l hls document is confidential. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of HPCL-MITIAL ENERGY
LTD. The copyright of this document is vested in HPCL-MITIAL ENERGY LTD. All rights reserved . Neither the whole nor any part of this document may be reproduced, stored in
any retrieval system or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of the copyright
owner.
Fo rmat No. 9111-000-PCT-007-00006 Rev-OO
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Revision 01
HPCL·Mittal Energy Ltd.
)
Issue Date I 27-FEB·2018
Next Review
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)
REV DATE REV DETAILS

)
) ERDMP document prepared based on regulations called The Petroleum and Natural
07/01/2015 Gas regulatory board ( codes of practice for emergency response and disaster
) management plan (ERDMP) regulations 2010 ).
00
) Revised ERDMP document with added Mock Drill repOli (conducted in presence of
05/09/2016
technical expert from DMI Bhopal)
) Cha~ter-1 5.2 Description of Facilities

( Revised ERDMP document with added facilities in LCEP)
) 5.2.17 Process Drescription ARU/SWS
5.2.18 BBU Project Details
) 5.2.19 RFG Feed to HGU Project I
I
5.2.20 CFBC Boiler I

)
Cha~ter-3 Satutory Requirements
) (Renewal date of Factory License - updated)
) Cha~ter-4 Pre Emergency Planning

4.2 Risk Analysis and risk assessment
) (updated as per QRA report issed on 2016)
) Cha~ter-5
5.1 Fire Protection Facilities at HMEL Refinery
) (Total number of Fire alarm and detection system)
01 27/02/2018
) 5.2 Health Safety Environment and Quality (HSEQ) Policy
(Old HSE policy replaced by the new HSE&Q policy dated .19th Sept'15)
)
Cha~ter-8 Emergency Organization & Responsibilities
) (Consideration the casualities of the FS/RSS as an Incident Controller)
) 8.2 Key Roles & Responsibilities (Level-1)

(Inclusion in details of the mode of communications to all concerned persaonnel,
) whose names are already defined as per the level of emergency)
) 8.3 Key Roles & Responsibilities (Level-2)

(Clarification added on role of CIC for outside GGSR incidents)
)
8,4 Communication Service
) (Siren code corrected)
)
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) Form at No. 9111-000-~CT-FRM-00006 Rev-OO
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Chapter-23
) Annexure-4 Important Emergency Contact Numberes
(updated Contact number list )
Annexure-6 List of Pre Incident Plans (new PIP are included in the list)
) Annexure-7 List of Hazardsous Hydrocarbons & Chemicals in Refinery (list updated)
Annexure-7 Process Flow Diagram (revised flow diagram for Fuel Gas Treating Unit
) - post LCEP)
) Chapter- 6
Emergency Preparedness Measures
) (Level-1 Mock Drill Report)
Chapter - 6
) ) Integration of the ERDMP with the National Disaster Management Plan (NDMP)
Annexure - 4
Impotant Emergency Contact Numbers
(updated Contact number list for a.lnternal no. b.External no.)
Mutual Aid Numbers
Annexure - 6
)
List of Pre-Incide nt Plan (PIP)
(updated PIP list)
) Anneuure - 8
Material Safety Data Sheets
)
(updated MSDS list)
) Chapter - 21
ERDMP for road transportation - Risk Assesment report for Petcoke/Poly
) Propylene/Sulphur transpo ration
) The Owner of this proced ure is department H&S Dept. at HMEL. Please contact VP-H&S for any clarifications, updates or
revisions.
)
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) Format No. 9111-000-PCT- FRM -00006 Rev-DO
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Revision I 01
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ABBREVIATION S
)
0 AFS - Auxiliary Fire Services NCC - National cadet corps
0 ARU - Amine Regeneration Unit .." NCDM - National committee on disaster management
0 BGU - Break Glass Unit 0 NDMA - National disaster management authority
) 0 BEDP -Basic Design and Engineering Package 0 NDRF - National disaster response force
CCTV -Closed Circuit Television ., OEMP - Onsite Emergency Management Plan
".,
) CDU -Crude Distillation Unit • OHC - Occupational Health Centre
CEO - Chief Executive Officer OISD - Oil Industries Safety Directorate
)
" 0
CIC - Chief Incident Controller PA System- Public Address System

0
"..
CMO - Chief Medical Officer PIP - Pre Incident Plan
) COO - Chief Operating Officer .. PESO - Petroleum & Explosive Safety Organisation
0 CPP - Captive Power Plant 0 PPCB - Punjab Pollution Control Board
) 0 CFBC - Circulating Fluidized Bed combustion 0 PPE - Personal Protective Equipment
)
CRT - Crude Receipt Terminal 0 PPU - Poly Propylene Unit
) "
0 DCC - Data Control Centre 0 PRO - Public Relationship Officer
• DCP - Dry Chemical Powder QRT - Quick Response Team
) "
• DCS . - Distributed Control System
" RSS - Refinery Shift Superintendent
)
. DCU - Delayed Coke Unit • RWTP - Raw Water Treatment Plant
DGFAP - Data gathering Fire Alarm Panel • SCCC (SC3)- Security Command & Control Centre
)
0 DG Set - Diesel Generator Set • SMS - Short Mail Service
• DMCR - Disaster Management Control Room • SRU - Sulphur Recovery Unit
• DM - Disaster management • SS - Sub Station
• EMCR - Emergency Management Control Room • UHF - Ultra High Frequency
) • ERT - Emergency Response Team • UVCE - unconfined vapour cloud explosion
• ETP - Effluent Treatment Plant
" VDU - Vacuum Distillation Unit
0 FCCU - Fluidized Catalytic Cracking Unit • VGO - Vacuum Gas Oil
• FWPH - Fire Water Pump House e VP - Vice President
) 0 GGSR - Guru Gobind Singh Refinery
• H&S - Health & Safety
) • HGU - Hydrogen Generating Unit
.. HL - Human Leadership
) ) HMEL - HPCL Mittal Energy Limited
"
0 HOD - Head of Department
) • HPCL - Hindustan Petroleum Corporation Limited
0 HRO - Head of Refinery operations
) • HSE - Health, Safety, Environment
• HVWSS - High Velocity Water Spray System
) 0 IC - Incident Controller
IFI - Issued For Implementation
) 0 IDLH - immediate danger to life and health
• IDLH - immediate danger to life and health
) . LCEP - Low Cost Expansion Project
0 LPG - Liquified Petroleum Gas
)
., MCR - Main Control Room
) 0 MVWSS - Medium Velocity Water Spray System
) Format No. 91 11-000-PCT-FR M-00006 Rev-OO
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) TABLE OF CONTENT
Chapter No. Page No.
(Reference: Section 5 of PNGRB (ERDMP) Regulation, 2010)
1
Chapter 1 General Information About the Refinery and ERDMP 8
)
Chapter 2 Cagtegorisation of Emrgencies 22
)
Chapter 3 Statutory Requirements 24
)
Chapter 4 Pre Emergency Planning 26
)
Chapter 5 Emergency Mitigation Measures 49
) ) Chapter 6 Emergency Prepardness Measures 60
) Chapter 7 Response Procedures and Measures 70
Chapter 8 Emergency Organisation and Responsibilities 74

)
Chapter 9 Infrastructu re 91
)
Chapter 10 Declaration of Onsite and Offsite Emergencies 94
)
Chapter 11 Resource for Controlling Emergency 96
)
Chapter 12 Demographic Information 104
) Chapter 13 Medical Facilities 115
Chapter 14 Evacuation 118
) Chapter 15 Information to Public 123
Chapter 16 Roles and Responsibilities of External Agencies 126

)
Chapter 17 Reporting of Incident 135
) )
Chapter 18 Termination of Emergency 139
)
Chapter 19 Emergency Recovery Procedures 141
~.
) Chapter 20 ERDMP for pipelines carrying petroleum products and retail outlets " 146
) Chapter 21 ERDMP for road transportation 149
) Chapter 22 Security threat plan 156
Chapter 23 Integration of the ERDMP with the national disaster management plan (NDMP) 159
)
Annexure 1 List of neighbouring industries 163
)
Annexure 2 List of Hospitals in Bathinda 164
)
Annexure 3 List of Ambu lances and their Contact Numbers 166
) Annexure 4 Important Emergency Contact Numbers 167
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) Fo rm at No . 911 1-000·PCT-FRM-000 06 Rev·OO
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Annexure 5 Address and Telephone Number of Mutual Aid Numbers 172
)
Annexure 6 Add ress and Telephone Number of Emergency Material Supplier·s 173
J Annexure 7 List of Pre Incident Plans 174
) Annexure 8 List of Hazardous Hydrocarbons and Chemicals in the Refinery 180
) Annexure 9 Material Safety Data Sheets 183
) Annexure 10 Contours for th e Affected Zones 204
Annexure 11 Process Flow Diagrams 208

)
Annexure 12 Block Flow Diagram of Refinery 222
) ) Annexure 13 Overall Plot Plan 223
)
Annexure 14 Emergency Evacuation Plan & Assembly Points 224
) Annexure 15 Fire Water Network Layout 225
) Annexure 16 Layout with process units & storage 226
) )
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) Format No. 9111-000-PCT-FRM-00006 Rev-OO
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FOREWARD
)
-) The Emergency Response Plan of GGSR Refinery named as Emergency Response and Disaster Management Plan (ERDMP)
has been prepared to mitigate different types of catastrophic situations arising out in the facility. This manual is revised as per
guidelines of Petroleum and Natural Gas Regulatory Board (Codes of Practices for Emergency Response and Disaster
)
Management Plan (ERDMP)) Regulations 2010. In this plan, the probable scenarios have been developed based on ORA
study of refinery. The functions of all the coordinators are given in detail. This manual is now revised (Revision 01) and updated
)
to include Low Cost Expansion Project (LCEP).Some minor additions have been done in the roles and responsibilities of CIC
and in the communication system. .
)
ERDMP of GGSR Refinery shall be available in company's document management system.
)
PLACE:
) GURU GOBIND SINGH REFINERY,BATHINDA . H,M - L. 4-u.M. ;:_' L.. fJ 1

Ec oument of MIs .. ........i;; ........';:f...........L'1ptJl.Nf
i;;;;;~g;: 'c~;;i!,ft:":tff;:' j; ~G*r:t:;i

)
)
Practices for Emergency Resp~1'
)
1_
MlllIg8IMnt Plan (ERDMP) J Hl':,lU:i!:IC
No . .:;!.3;1£t.f."I:!Hf::118 i E II.D
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.. p.!.!. ~.&~ /. .~ .. ,..r). .1.s.:: .I. ~"j'~' .~r\ .1)j .
)
0IIId...9.?'.~..9..~.:.;'.9.J." ~ p vJ~
(Dr. Rakesh Dubey) .
Director
) Disaster Management Institute. Bhopal
\~
)
)
(PtJ£ ~)
)
(flp 1f. Ceo
)
) Format No . 9111-000-PCT-FRM-00006 Rev-OO
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CHAPTER 1
) Genaral Information about the refinery and
) ERD MP
)
) )
)
)
)
) Format No . 9111-000·PCT·FRM·00006 Rev·OO
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Chapter 1
GENERAL INFORMATION ABOUT THE REFINERY AND ERDMP

I
Introduction
)
The Guru Gobind Singh Refinery is located in southern part of Punjab at a distance of approximately 40 km from Bathinda,
near Phulokhari Village in Punjab, at an elevation of 203.4M above Mean Sea Level and spread over an area of 632 Ha,
Green Belt Area 120 Ha and Water Block of 175Ha. It is accessible from N.H .64 directly by link road of 17km distance.
) GGSR is a newly commissioned grass-root refinery and has refining capacity of 9 MMTPA and includes a captive power
plant. polypropylene production and delayed Coker unit.
) ,
)
)
Best practice industrial safety standards have been implemented in both design and operation of the refinery however
) accidents are still possible. This document covers the key hazards present and the mitigation measures in place to
respond with any emergency or disaster which may occur.
)
ADDRESS OF THE REFINERY
)
GURU GOBIND SINGH REFINERY
HPCL MITTAL ENERGY LTD.
Phulokhari Village,Taluka·Talwandi Sabo,Distt.
Bathinda
Punjab·151301
)
2 Objective:
)
The overall objectives of Emergency Plan are summarized as follows :
) • To contain and control emergency incidents.
• To prevent loss of life and minimize the risk of bodily injury to employees and neighbouring population.
• To minimize damage to company installations.
• To minimize impact on environment.
• To provide maximum possible safety for the emergency response personnel.
)
To ensure compliance with relevant legislation and guidelines including Petroleum and Natural Gas Regulatory Board
(Codes of Practices for Emergency Response and Disaster Management Plan (ERDMP) Regulations, 2010, The
)
Factories Act, Manufacture, storage and Import of Hazardous Chemicals Rules, Environmental Protection Act and OISD
regulations
)
Format No. 9111-000-PCT-FRM-00006 Rev-OO
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3 Definitions
)
a, "Act" means the Petroleum and Natural Gas RegulatOly Board Act, 2006;
b, "Board" means the Petroleum and Natural Gas Regulatory Board established under sub-section (1) of section 3 of
the Act; )
c, "boiling liquid expanding vapour explosion (BLEVE)" means the violent rupture of a pressure vessel containing )
saturated liquid or vapour at a temperature well above its atmospheric boiling point and the resulting flash evaporation
of a large fraction of the superheated liquid which produces a large vapour cloud which burns in the form of a large )
rising fireball due to ignition ;
)
d, "chief incident controller" means the person who assumes absolute control of the unit and determines action
necessary to control the emergency;
)
e, "codes of practice" means the codes of practice for emergency response and disaster management plan notified by
)
the Board;
.,
f, "disaster" means an occurrence of such magnitude as to create a situation in which the normal patterns of life within
an industrial complex are suddenly disrupted and in certain cases affecting the neighborhood seriously with the result
that the people are plunged into helplessness and suffering and may need food, shelter, clothing, medical attention
,
protection and other life sustaining requirements;
)
g, "disaster management plan" means a well coordinated, comprehensive response plan to contain loss of life, property,
environment and provide speedy and effective recovery by making the most effective use of available resources in ,)
case of a disaster;
)
h, "emergency" means a situation or scenario which has the potential to cause serious danger to persons, environment
or damage to property and which tends to cause disruption inside or outside the premises and may require the help )
of outside resources;
)
i. "hazard" means an event related to the property of substance or chemicals with a potential for human injury, damage
to property, damage to the environment,or some combination thereof; , )
j, "incident" means an unplanned or unintended or intended event having potential to cause damage to life, property )
and environment;
)
k, "installation" means facilities , namely, gaseous product pipeline, liquid Product pipeline, hydrocarbons processing
installation, oil and natural gas terminals and commercial storage and transportation, hydrocarbons gas bottling )
Installations including eNG, city gas distribution facilities and retail outlets;
I. "leak" means release or discharge of a dangerous chemicals or substances or material into the environment;"mutual
aid association" means an industrial mutual aid association in which participating industries as a community shall )
assist each other in case of emergency,
)
m, "occupier" of an installation means the person who has ultimate control over the affairs of the installation;
)
n, "off site emergency" means an emergency that takes place in an installation and the effects of emergency extends
beyond the premises or the emergency created due to an incident , catastrophic incidents, natural calamities, etc, It .>
no longer remains the concern of the installation management alone but also becomes a concern for the general
public living outside and to deal with such eventualities shall be the responsibilities of district administration; )
Form at No, 9111-000-PCT-FRM -00005 Rev-OO )
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3.1 Applicability
These regulations shall apply to:

)
o Hydrocarbon processing units inside the refinery.
• Storage of petroleum products inside the refinery.
• Transportaion of petroleum products by road.
)
4 Scope & Intent

)
4.1 Scope;
)
) This document is applicable for any emergency occurring inside the boundary of the HMEL GGSR refinery which includes
) all process areas/ units, buildings, tank farms, rail & road gantries, ROOM, RWTP, crude receiving terminal and assisting
with emergencies at the HPCL pumping station located within the site of refinery.
The document also cover the consequences of emergencies which may go outside the boundary of the site.
J
Thescope of this document covers the following:
• Identification of emergencies;
• Mitigation measures that attempt to reduce and eliminate the risk or disaster;
) • Responses that mobilize the necessary emergency seNices including
• Responders (primary, secondary and tertiary) like fire seNice, police seNice,medical seNice including ambulance,
government as well as non-governmental agencies;
• Post disaster recovery with aim to restore the affected area to its original conditions;
4.2 Intent;
)
It is intended to apply this emergency plan -
) • to manage an emergency and not to use EROMP just as reference material for training and shall be made
applicable ;
• to prevent casualties - both on-site and off-site;
• to reduce damage to property, machinery, public and environment;
) • to develop a state of readiness for a prompt and orderly response to an emergency and to establish a high order
of preparedness (equipment, personnel) commensurate with the risk;
) • to provide an incident management organogram with clear roles and responsibility.
• To maintain good public relations.
)
) Format No. 9111-000-PCT-FRM-00006 Rev-DO

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)
5 Location And Description Of Facilities
)
5.1 Site Location
Guru Gobind Singh Refinery is located at a distance of approximately 35 km from Bhatinda in Punjab. While most of the
tank-farms are located to the south and south-east of the process-facilities, the Crude Oil tank farm is situated to the )
north-west, while both the road and rail-loading gantries are situated along the eastern perimeter of the facility.
)
5.2 Description Of Facilities
)
5.2.1 Crude and Vacuum Di stillation Unit
)
The unit is designed to process Arabian Medium and 90%Arabian Heavy + 10% Doba, crudes to produce transport fuels
of EURO IV specifications. The unit is also designed to handle 70%Arabian Heavy +30% Maya and Bombay High crude
at reduced throughput. Facilities provided in the unit battery limit are: )
)
1) Heat integrated Crude & Vacuum Distillation Units
2) Naphtha Stabilisation section
)
3) Naphtha caustic wash
The products are Fuel Gas, LPG, Stabilised Naphtha, Swing/Heavy Naphtha, Light Kerosene, Heavy Kerosene, Light
and Heavy Gas Oils, Atmospheric Residue, Hot-we ll Gases, Hot-we ll Slop' Oil, Vacuum Diesel, Light Vacuum Gas Oil, )
Heavy Vacuum Gas Oil, Vacuum Slops and Vacuum Residue.
)
Guru Gobind Singh Refinery (GGSR) set up by HPCL-Mittal Energy Limited (HMEL) is currently operating at crude
processing capacity of 9.0 MMTPA of high sulphur crudes. Revamp of the crude processing capacity of GGSR from 9.0 )
MMTPA to 11.5 MMTPA via low cost expansion project (LCEP) .
)
The CDU / VDU and Naphtha Stabilizer are designed to produce Liquefied Petroleum Gas, Stabilized Naphtha,
Swing/heavy naphtha,Lt. Kerosene, Heavy kerosene, Light Gas Oil (LGO) & Heavy Gas Oil (HGO), Reduced Crude Oil )
(RCO) ,Hot well gases,Hot well slop oil ,Vacuum diesel, Light vacuum gas oil (LVGO),Heavy vacuum gas oil
(HVGO),Vacu um Slops ,Vacuum residue. )
)
Major modificatio ns are to be carried are as under:
)
a. Columns (Modification and replacement of Valve trayes / Packing)
b. Vessel'(Modification and installation of new vessels) )
c. Filters (replacement)
d. Heat Exchangers )
e. Vacuum Ejector Package (new facility installation)
f. Desalter (internal replacement)
g. Pumps
h. Air Coolers :01 New Air cooler addition and Replacement of 01 existing cooler. )
i. Associated Piping , civil , elect , Inst installation added/ modified
)
Format No. 9111-000-PCT- FRM-00006 Rev-OO )
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5.2.2 Naphtha Hydro·Treater Unit
The Naphtha Hydro-treater unit protects the Reforming and Isomerisation catalysts by eliminating or reducing to
acceptable levels, the impurities present in naphtha. Impurities, detrimental to catalyst activity, such as, sulphur, nitrogen,
water, halogens, di-olefins, olefins, mercury, arsenic and other metals. The naphtha is treated by passing it over a fi xed
bimetallic catalyst bed in adiabatic reactors,in the presence of hydrogen . There are two fundamental reactions occurring
in the unit - hydrorefining and hydrogenation. In hydro-refining , sulphides, di-sulphides and mercaptans are reacted with
hydrogen to convert them to the corresponding alkanes and arenes, with the release of hydrogen sulphide. With
hydrogenation, alkenes and di-alkenes are converted to alkanes. The reactions take place in two reactors employing
bimetallic catalysts, followed by a stripper column . While the overhead vapours produced are routed either to the Fuel
gas Treating Unit or to the VGO Hydro-Treater, while the bottoms product is sent to a splitter column where three cuts
are obtained - light naphtha, hexane and heavy naphtha
5.2.3 Naphtha Isomerisation Unit
Isomerisation of light hydro-treated naphtha is carried out in two fixed bed reactors in series. The CS/C6 Isomerisation
Section converts normal CS/C6 paraffins to their isomers, i. e. to a higher octane branched arrangement, over a
proprietary platinum catalyst, in the presence of hydrogen. The conversion of normal paraffins to their isomers in each
pass is etermined by the equilibrium conditions of the reaction under the operating conditions of the reactor.
A stabilizer column is used to remove the light ends from the reactor effluent, before routing the effluent to the De-iso-
hexanizer column .
A De-iso-hexanizer tower is used for recovering and recycling the low octane methyl-pentanes and the unconverted n-
hexane from the reactor effluent. The De-iso-hexanizer distillate and the bottoms streams are combined to produce the
final isomer product.
The stabiliser reflux drum vent gas contains hydrogen and chloride, which are removed by neutralization with caustic
soda in a Caustic Scrubber.
5.2.4 Catalytic Cracking Unit
Conversion of paraffins and naphthenes to high-octane aromatics is achieved by passing the naphtha over a slow moving
bimetallic catalyst bed in four adiabatic reactors, in the presence of hydrogen at a relatively high temperature and low
pressure. Operating under these conditions, the rate of coke lay-down on the catalyst is comparatively high. A semi-
regenerative type process is impractical, rendering a continuous catalytic regeneration unit necessary. In this process,
catalyst is withdrawn from the reaction section at a fixed rate, regenerated in the continuous catalytic regeneration unit
and returned afresh to the reaction section.
5.2.5 Diesel Hydro·Treater Unit
The processing objective of the Diesel Hydrotreating Unit is to hydrotreat diesel pool streams produced from various
processing units & Coker Naphtha to produce treated diesel meeting Euro IV specifications. The treated diesel produced
in the unit will have a minimum CI of 46 .5. The unit will also produce the required quantity of ATF and MTO products in
blocked out mode.
5.2.6 Delayed Coker Unit
The purpose of the Delayed Coker Unit is to upgrade high sulphur residue from the Vacuum Distillation Unit. The Delayed
Coker Unit is designed to produce Coker Fuel Gas, Coker LPG, LCGO and Naphtha, Heavy Coker Gas Oil (HCGO) and
Green Coke. The feed to the DCU is either hot vacuum residue (240°C) from both the CDU and the VDU, or a cold (140°C)
Format No. 9111-000-PCT-FRM-00006 Rev-Oo
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vacuum residue from storage. The process scheme for the Delayed Coker Unit includes two Coker Heaters, two pairs of
Coke Drums, a Coker Fractionator with Side Strippers, Coker Fractionator Overhead System and a Vapour Recovery )
Section. The Vapou r Recovery Section consists of a Wet Gas Compressor, Absorber, Stripper, Sponge Absorber,
Debutanizer and LPG Amine Contactor. Coker Unit also features Decoking System, Blow-down System, and ISBL Coke
Handling System.
)
5.2.7 VGO Hydro·Treater Unit
)
The purpose of the unit is to produce VGO with a maximum content of 200 ppm (wt) of Sulphur. The VGO HOT Unit
processes a mix of Straight run VGO feedstock from the CDUNDU and Heavy Coker Gas Oil from the DCU . The main
)
objective of the unit is to produce 2.22 MMTPA of hydrotreated VGO having the desired level of hydrogen, low sulphur
and low nitrogen .
)
5.2.8 FCC·PC Unit, FCC Naphtha Splitter and Propylene Recovery Unit
) )
The FCC complex unit is designed to produce Polymer grade Propy lenel LPG and high octane gasoline yields . The
design objective of the 2.22 MMTPA complex is to maximize Propylene Recovery. The minimum target yield of the PRU )
will be 433,000 TPA.
)
5.2.9 Hydrogen Generation Unit )
The Hydrogen Generation Unit comprises two parallel lines of 2 x 44,000 TP A capacity with a common Pre- )
Desulphurisation section and a Pressure Swing Adsorption Unit. The plant is designed for operation with SR Naphtha
and DHDT Naphtha as feedstock. Continuous operation with a mixture of SR Naphtha and DHDT Naphtha has also been )
envisaged . The PDS Unit desulphurises the raw naphtha feed, while the desulphurisation and reforming unit produces
syngas and the PSA unit purified the syngas, to arrive at the hydrogen product. As an alternative to naphtha, refinery fuel )
gas may also be used. In addition to hydrogen, the unit also generates superheated high pressure steam at 38 kg/cm2.
)
5.2.10 Polypropylene Unit
)
The Polypropylene Polymerization Plant and its support facilities have a total capacity of 440,000 MTPA of polypropylene.
The plant comprises one production line. The line will have an annual production capacity of 440KT A based on 8,000 )
operating hours per year. )
)
5.2.11 SR LPG Treating Unit
)
The treatment process is designed to remove H2S and mercaptans from LPG. The LPG coming from the CDUIVDU and
the VGO-HDT is first treated in the Amine Absorption section, where the bulk of the H2S is removed, followed by the )
Continuous Film Contactor (CFC) unit, where the remaining H2S and mercaptans are removed using caustic, to meet
product specifications. )
5.2.12 Cracked LPG Treating Unit )
This unit is identical to the SR LPG Treating Unit, except that the LPG stream comes from the Delayed Coker Unit. )
Format No. 9111-000-PCT-FRM -00006 Rev-OO )
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)
5.2.13 Storage Facilities
)
Tankages·
-, HMEL plans to revamp its offsite facilities under Low Cost Expansion Project (LCEP),
This description is intended to provide process design basis/description of the storage tanks and associated pumping
)
facilities for Additional Tankages under LCEP, HMEL, and Bathinda, No, of Tanks, Storage & Pumping -philosophy is
decided by HMEL based on process requirement.
)
Following tanks have been included-
)
1- New Naphtha Tank (554-T-01 D) (Capacity: 9500 m3 ; 1 no, ; Dome Roof Type)
)
2- VGO Tank (552-T-07B) (Capacity: 34,410 m3 ; 1 no; Cone RoofType Tank)
3 - MS-IV STORAGE- No new MS tank is considered under this project. Existing HSD Tank (554-T-09A) in Tank Farm 19 will
)
) be converted for the storage of MS,
4 - Hexane Tank ( 554-T-06 A/B) will be converted to Sweet Naphtha Tank,
)
5 - ATF Tank 554-T-06A converted to Hexane Tank
6 - HSD -III STORAGE- New HSD Tank (554-T-09C) of floating Roof Type (Capacity: 30000 m3) -1 no,
)
7 - Bitumen Storage Tank (Capacity: 2838 m3 each) - Total 7 no ,
) 8 - BBU Feed Tank (Capacity: 22,300 m3) -1 no,
g - BBU Slop oil tank (Capacity: 9,217 m3) -1 no,
)
) The storage facilities envisaged are as indicated in the table below:
) CRUDE STORAGE TANKS
No of Type of Capacity
) Service Class
tanks Roof (m3 each)
CRUDE 4 FR A 60000
)
CRUDE WATER
1 CR A 3758
) DRAIN TANK
SURGE RELIEF
) TANK
1 CR A 425
)
) INTERMEDIATE FEED TANKS
) Service
tanks Roof
Class
(m3 each)
) NHT FEED 2 IFR A 29865
HGU FEED 1 IFR A 10565

)
VGO HDT FEED 1+1 * CR C 34410
)
DHDT FEED 3 IFR B 19990
) DHDT
1 IFR B 19990
FEED/PRODUCT
DCU FEED 3 CR C 24420
)
)
)
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)
FCC-PC FEED 2 CR C 29980
)
DRY SLOP(HEAVY) 2 CR C 3300
DRY SLOP(LlGHT) 2 FR A 4560
HEAY NAPTHA 1 CR C 5330 )
REFORMATE 1 FR - 5860 )
ISOMERATE 1 DR - 4230
)
CPP FUEL LCO 2 CR A 8200
)
IFO /RFO 2 CR C 5330
SWEET NAPTHA 1 IFR .A 1800

) )
HCGO STORAGE )
1 CR C 6300
TANK
)
FUEL OIL TANK 1 CR B 1200
BBU Feed Tank 1* CR - 22300 )
BBU Slop Oil 1* CR - 9217 )
)
* New Tank
)
FINISHED PRODUCT STORAGE TANKS
)
Servi ce Class
)
SWEET NAPHTHA 2** IFR A 565
)
MS - III 5 FR A 9150
)
MS - IV 5 FR A 9150 )
NAPTHA 3 FR A 9150 )
SKO 5 FR B 4545 )
ATF 2 IFR B 9190
)
HEXANE 1** IFR B 9190
ATF 2 IFR B 8900

)
MTO 2 FR B 1100
HSD-III 5 FR B 56070 )
HSD-IV 1 FR B 56070 )
MS -IV 1** FR B 56070 )
Fo rmat No. 9111-000-PCT-FRM-00006 Rev-OO )
)
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)
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)
SWEET SKO 1 FR B 4545
I
I
Naphtha 1* DR A 9500
J HSD 1* FR B 30000
) Bitumen 7* CR - 2838
- - - -- - .. _.
) ** Converted
* New Tank
)
)
PRESSURISED STORAGE (c apaci t y in m 3 each)
) )
HYDROGEN 2 BULLET 100
) MOUNDED
PROPYLENE 3 2900
BULLET
) MOUNDED
LPG 8 2900
BULLET
) - - - -
)
5.2.14 LPG and Auto-LPG:
)
LPG and Auto-LPG will be loaded directly from the refinery's offsite bullets with no separate storage for rail loading.
) The LPG gantry will be capable of loading one full rake comprising 72 fourwheeler wagons or 32 eight-wheeler
wagons, with a carrying capacity of 1200 MT. There will be two shift operations amounting to 16 hours per day with
) 3.5 hours filling time and 2.5 hrs for connection and disconnection. A total of 76 loading arms are provided to handle
72 four-wheeler wagons or 32 eight-wheeler wagons. .
)
5.2.15 Road Loading Facilities
)
) Road Tanker Loading will be carried out for ATF, MTO .and Hexane on a regular basis, and for MSIII ,MS-IV (Premium) ,
) HSD, SKO and Naphtha on the basis of demand . The tanker capacity considered is 20 KL for ATF and 12 KL for other
W.O. products . Arrangements will be made for top as well as bottom loading of all white oil products except MS and
) Naphtha, for which only bottom loading arrangements will be made .
)
5.2.16 Process Description Sulphur Recovery Unit (SRU)
)
Feed to SRU comprises of acid gas from ARU and sour gas from SWSU . Gas from ARU or SWSU passes through
) gas knock out drum, to remove any liquid carryover before feeding to the main burner. The air to main burner is exactly
sufficient to accomplish the complete oxidation of all hydrocarbons and ammonia present in the feed gas and to burn
) as much H2S as required to obtain desired concentration . Process gas is introduced into condenser where sulphur
vapour is condensed and is separated from gas. Sulphur condensed in condensers is routed via sulphur locks to
) sulphur cooler and drained into sulphur degasification vessel. The H2S/S02 gas from the claus unit is then treated in
a tail gas treatment unit to obtain an overall recovery of 99.95% sulphur from the feed. The effluent from the tail gas
) is incinerated.
) SRU is divided into two identical trains. SRU includes four main sections:
) Form at No . 9111-000-PCT-FRM-00006 Rev-OO
)
)
)
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)
- Claus section (one section per unit)
- Sultimate section (one absorption section per unit and one common regeneration section) , )
- Incineration section (one section per unit),
- Degassing section (common for both train).
As part of capacity expansion new feed stream will be processed to existing SRU with oxygen enriched air technology.
High purity oxygen stream (90% vol. minimum) shall be supplied from a new oxygen production plant. (VPSA type)
)
An SRU modified for oxygen enriched air operation can easily change between air-based and oxygen enriched air , )
(oxygen-based) operating modes. Generally, air-based operation is used unless unit capacity reaches a limit: oxygen-
based operation is then used only as needed to achieve the desired SRU operating capacity.
)
Operation with oxygen enriched combustion air (oxyge n-based operation) will start when the feed gases throughput
)
approaches the hydraulic limits of the unit in air-based operation.
A Low Level Oxygen Enrichment (LLE) technology, with approximately 26-27% vol. oxygen in the mixed combustion ) )
air/pure oxygen stream, will allow achieving the capacity increase from 600 TPD to 750 TPD minimum.
)
The basic SRU process flow scheme is not altered by implementation of the Low Level Oxygen Enrichment (LLE)
technology: the only addition consists in one common Oxygen package and one Quench Water Trim Cooler for each )
SRU train.
)
5.2.17 Process Description ARU SWS )
The purpose of the Amine Regeneration Unit (ARU) is to regenerate the rich amine streams received from Amine )
absorbers of other refinery processing units. Lean amine (MDEA 40 wt%) is used to recover H2S from refinery units .
The lean amine is returned back to the refinery absorbers while the H2S-rich overhead stream is sent to the Sulfur )
Recovery Unit (SRU) . The lean amine is supplied from ARU (U522) with an amine loading of less than 0.015 mol
H2S / mol MDEA. The ARU comprises of two parallel trains each of 440TPH design capacity. )
The purpose of Sour Water Stripper Unit (SWS) is to treat sour water streams generated in various processing units )
of the refinery for removal of hydrogen sulphide (H2S) and ammonia (NH3). The stripped sour water from the unit is
then either recycled back to process units or routed to Effluent Treatment Plant for further treatment / disposal. Sour )
water stripper facility will have two independent sour water stripping units namely Refinery Sour water stripper
(SWS-I) & Hydroprocessing sour water stripper (SWS-II). Segregated treatment of sour water from Hydroprocessing )
units of the refinery is proposed to avoid contamination of recycle stripped sour water to hydroprocessing units by
phenols which is present in the sour water from non-Hydroprocessing units. Refinery Sour Water Stripper (SWS-I) )
shall be single stage and Hydroprocessing Sour Water Stripper (SWS-II) shall be two stage.
Project Description ARU -SWS

-. )
)
Guru Gobind Singh Refinery (GGSR) set up by HPCL-Mittal Energy Limited (HMEL) is currently operating at crude
processing capacity of 9.0 MMTPA of high sulphur crudes. Revamp of the crude processing capacity of GGSR from )
9.0 MMTPA to 11.25 MMTPA via low cost expansion project (LCEP).
The scope for the project is EPCM services for Revamp of ARU, SWS & Associated Offsites & Utilities at HMEL )
Bhatinda.
Major modifications to be carried are as Under: )
i. Heat Exchangers )
ii. Filters (Sour water package)
iii. Air Cooler )
iv. Caustic Injection Package'
)
)
)
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v. Pumps (Additional New pump on new and existing foundations, Old pumps modification)
vi. Column Internal Replacement (Modification/Replacement of Valve Trays/Packing is to be carried out for 6
Nos. Columns for Capacity Enhancement)
-, vii. Nozzle modification / addition
) 5.2.18 88U Project Details .

HPCL-Mittal Energy Ltd. (HMEL) plans to produce 62.5 TPH (500,000 TPA) of different grades of Bitumen at Guru
Gobind Singh Refinery, Bathinda by mid of year 2017. Bechtel Engineering & Construction India (BECI) Private
Limited has been appointed to prepare Basic Design and Engineering Package for OSBL facilities.
)
• Basic Design of the OSBL facilities , all required tie-ins, a new air compressor (identical to the existing
machines), steam condensate recovery system comprising a flash drum & pumps;
)
• Detail Engineering & Procurement services for the aforementioned OSBL facilities and the BBU ISBL Unit.
)
I The BBU project does not include utilities generation. All required utilities will be sourced from existing refinery headers
and distributed to BBU ISBL & OSBL users . For all BBU project incoming streams, the piping downstream of the tie-
)
ins and distribution to the BBU ISBL & OSBL users is included within the BBU project. Existing facilities upstream of
the tie-ins are not part of the project.
)
All effluents / slops / drains etc. generated from the BBU ISBL & OSBL facilities will tie-in to existing refinery headers.
) The project does not include waste / effluent / slops treatment. For all BBU project outgoing streams, the piping
upstream of the tie-ins and collection within BBU ISBL & OSBL is included within the BBU project. Existing facilities
) downstream of the tie-ins are not part of the project. Adequacy check of existing refinery facilities is also not part of
the BBU project.
) Basic Design of BBU ISBL Unit has been provided to Bechtel by HMEL from the HMEL appointed Licensor. BBU unit
is designed to produce three different grades of bitumen viz., VG1 0, VG30 and VG40. These grades differ in viscosity,
) softening point and penetration index. Feed to BBU unit is a blend of Vacuum Residue (VR), Heavy Vacuum Gas Oil
(HVGO) and Heavy Coker Gas Oil (HCGO). The proportions of individual feed stock in the feed mixture varies based
on required grade of bitumen to be produced.
) Vacuum Residue (VR) is sourced from existing VR rundown line that feeds to DCU Feed Storage tank (552-T-
01A1B/C). VR feed from tie-in point is routed via new 20inch piping to BBU Feed Tank, 552-T-101 located in Unit 552
) and serves as storage of VR. 552-P-1 01 A/B transfers VR from 552-T-101 to ISBL facilities (BBU) to produce Bitumen.
) BBU Slop Oil tank (552-T-102) is located in Unit 552. Refinery heavy slops generated from various Process Units,
) slops from ISBL facilities (includes flushing oil return, off-spec Bitumen, Blown Distillate, Closed Blowdown Drum
contents) and slops from OSBL facilities are routed to tank 552-T-102. BBU Slop Oil Pump (552-P-102A/B) shall
) transfer heavy slops to DCU tanks / Crude tanks.
Bitumen product from BBU (Unit 530) is stored in Bitumen Storage Tanks (565-T-101 - 107) located in Unit 565. In
J current phase of project 7 Nos. , tanks will be installed to store three grades of product Bitumen . Necessary provisions
are made for integration of future Bitumen storage tanks (565-T-108/109/110) and associated·future piping.
)
Bitumen Tank Vent Air Cooler (565-A-101) cools hot vapours being discharge from Bitumen storage tanks during
) pump-in operation . The cooled vapours are routed to both SRU incinerators of Unit 524 and Unit 525 or stack (Unit
524/525) via Bitumen Tank Vent Blower (565-K-1 01 AlB) for final disposal.
) Bitumen product will be loaded to road truck through Bitumen Loading Arm (566-LZ-101 to 110) located in Unit 566.
There are 10 loading bays with individual loading arm per loading bay. The design of loading facilities permits
) simultaneous loading of 3 Bitumen grades at different loading bays . Truck loading operation will be done in 2 work
shifts i.e., 14hr per day. Batch controller is provided to control bitumen loading operations.
)
) Format No. 9111-000-PCT-F RM-00006 Rev-OO
I
)
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)
)
5.2.19 Process Description for RFG Feed to HGU Project:
The existing 2 trains of 88KTPA (44x2) capacity HGU at GGSR are designed by MIs Haldor Topsoe. The common )
Hydrogen purification, PSA unit is licensed by MIs UOP. At present, HMEL is going ahead with the installation of two
pet coke fired CFBC boilers each with steam generation capacity of 300 TPH .
With a view to optimise utilisation of the CFBCs, the CFBC project also considers utilisation of surplus Refinery Fuel )
gas as feed to HGU. Post commissioning of CFBC boilers in Sept 2016 and their subsequent operation at a load of
370 MTIhr, around 13 MTIhr of surplus refinery fuel gas in combination with naphtha is planned to be used for )
Hydrogen production as feed to one train of the HGU.
)
The modifications required for this feedstock changeover in HGU would include modifications in outside battery limit
(OSBL) area as well as the inside battery limit (ISBL) area of the HGU.
)
The OSBL area includes Fuel gas preparation and compression to meet ISBL condition (battery limit conditions at
)
HGU).
5.2.20 CFBC BOILER Project Details·

)
HPCL-Mittal Energy Ltd (HMEL) owns and operates 9 MTPA Guru Gobind Singh (GGS) Refinery in Bathinda district
of Punjab. The power and process steam required for the refinery process is being met from its captive cogeneration )
power plant. In order to minimize the fuel oil consumption and to reduce the operating cost, HMEL is under the process
of installation 2x300 TPH capacity pet coke and coal fired CFBC boilers . )
Brief project .information: )

• Project: 2x300 TPH CFBC project at GGS Refinery, Bathinda, Punjab.
• Owner : HPCL-MiUal Energy Ltd (HMEL). )
• EPCM : Tata Consulting Engineers Limited.
• Boiler package supplier : Isgec Heavy Engineering Ltd. )
• Civil & Structural and Chimney works: Larsen & Toubro Ltd.
• Material handling system package supplier: Larsen & Toubro Ltd. )
Ash handling system package supplier: Macawber Beekay Private Limited.
• Balance of plant packages like compressed air system, OM water system, Potable water system, Fire Fighting system etc. )
are being extended from existing system through various contractors.
)
In view of the flexibility for multi fuel firing with wide variation in fuel properties and high Sulphur content in Pet coke Circulating
Fluidized Bed Combustion (CFBC) technology has been adopted for this project.
)
The main fuel for CFBC boilers is pet coke, the byproduct of the refinery and will be used as main fuel. During non-availability of
pet for any reason the CFBC boiler will be operated using coal from the coal stock at silo. The boilers have provision of LCO/RFG )
firing upto 50 % load and for startup purpose.The pet coke is having high Sulphur content. To restrict the SOX emission as per
MOEF guideline Limestone will be injected in the boiler from the lime stone silo. )
The coal and Lime stone shall be brought to plant mainly by railway. A wagon tippler has been installed for the purpose. However,
provision has been made for the supply of Coal/Lime stone through trucks also. The coal/pet coke/Lime stone will be crushed to
the desired grain size within the plant and will be supplied either directly to boilers or to the silos. Crusher and Lime stone grinding
mill has been installed for the purpose. )
In order to minimize the operational cost, the existing oil fired boilers would be replaced by the CFBC boilers except one oil fired )
boiler will run at lower capacity for emergency requirement.
)
The ash generated in the CFBC boilers will be evacuated as dry ash and will be directly disposed at nearby cement plants or for
other use. )
The project would be brought into operation from mid of 2017 and would meet the total steam and power requirement of the
turned around petro-chemical units.
)
The present status of the project completion is around 81.2 % overall progress.
Format No . 9111·000· PCT-FRM·00006 Rev·OO )
)
\ )
, )
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)
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)
The CFBC boilers are already installed and pre-commissioning activities are in progress. The pre-commissioning and commission
the other equipment shall be commenced from March 2017.
)
6.0 Content of the regulation
The ERDMP includes:
a) Classification of emergencies .
)
b) Implementation schedule.
c) Consequences of defaults or non-compliance .
)
d) Statutory requirements.
) e) Pre-emergency planning.
f) Emergency mitigation measures.
) g) Emergency preparedness measures.
)
h) Emergency response measures and procedures.
i) Emergency organization and responsibilities.
j) Infrastructure requirement.
k) Declaration of Onsite & Offsite emergencies
) I) Resources for controlling emergency.
m) Demographic information .
) n) Medical facilities.
0) Evacuation
) p) Public relations and information to public
q) Reporting of the incident.
)
r) Emergency recovery procedures.
) s) ERDMP for tank trucks and pipelines carrying petroleum products
t) Security threat plan and action plan to meet eventualities .
)
)
)
)
Form at No. 9111-000-PCT- FRM-00006 Rev- OO
)
)
)
HPCL·Mittal Energy Ltd. Revision 01 I
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)
Chapter 2 )
CATEGORIZATION OF EMERGENCIES
)
) )
)
Format No. 9111-000-PCT-FRM-00006 Rev-OO )
)
)
)
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)
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Chapter 2
) CATEGORIZATION OF EMERGENCIES
-,
Emergencies can be categorized into three broad levels on the basis of seriousness and response requirements, namely:-
Level 1 : This is an emergency situation such as Fire, Toxic release, oil spill arising in any equipment of section/unit of
) plant or an incident which
• can be effectively and safely managed, and contained within the site, location or installation by the available
resources;
• has no impact outside the site, location or installation.
Level 2 : This is an emergency arising in any equipment! unit! section of one particular plant / area or an incident which -
• cannot be effectively and safely managed or contained at the location or installation by available resource and
) additional support is alerted or required;
• is having or has the potential to have an effect beyond the site, location or installation and where external
support of mutual aid partner may be involved;
) • is likely to be danger to life, the environment or to industrial assets or reputation.
) Level 3: This is an emergency or an incident with off-site impact which could be catastrophic and is likely to affect the
population, property and environment inside and outside the installation, and management and control is done
) by district administration.
Note: Level-I and Level-II shall normally be grouped as onsite emergency and Level-III as off-site emergency.
)
SCHEDULE - I
Schedule of implementation of Code of Practice for ERDMP
)
Implementation Time
(from the notification date
) S. No. Activity Status
of Codes of Practices for
ERDMP)
) 1. On-site Emergency Plan 3 months • Implemented
Off-site Emergency Plan • Updated ar)p
) '-
2. (Submission of information to District 3 months submitted to District
Authority) Authority in Mar 2014 . .
) 3, Resources in position 6 months • Com~ied
Accredited Third Party Certification of • In progress
) 4. 1 year
ERDMP
)
• Conducted regularly
5. Testing and Mock Drills (On-site) 3 months once in a month. Last
on 27th Dec'14
)
• Information submitted
6. Testing and Mock Drills (Off-site) 12 months to District authorities to
)
conduct Offsite drill.
) Format No. 9111-000-PCT- FRM·00006 Rev·OO
)
)

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)
Chapter 3 )
STATUTORY REQUIREMENTS
)
)
)
)
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)
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)
Chapter 3
)
STATUTORY REQUIREMENTS
)
The ERDMP is prepared for statutory compliance of th e following statutory regulations

)
(Reference: Section 9 of PNGRB (ERDMP) Regulation, 2010) .
) Relevant Statutes on management of Hazardous substances Compliance of HMEL refinery .
) Environment (Protection) Act, 1986 and rules thereunder Complied
) The Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989

(amended, 1994 and 2004) Complied ·
)
) The Hazardous Wastes (Management and Handling) Rules, 2008. Complied
) Authorization valid upto: 31 st Mar 2019
Complied.
Bio-medical Wastes (Management and Handling) Rules. 1989 Authorization valid up to: 31 st Dec 2017
) The Factories Act, 1948 (amended 1987) Complied .

Factory Licence No.: Bathinda/G-
)
• State Factory Rules- Punjab Factories Rules, 1952 186/1443, valid upto: 31 st Dec 2020.
) The Petroleum Act, 1934

Complied
The Petroleum Rules, 2002
)
) Gas cylinder rules 2004 Complied

- - - - -- - --------
JlcenceJor chlorine storage
}
These regulations are not intended to override the requirement of other statutory bodies or any other guidelines issued by the
) Central Government in respect of formulation of ERDMP.
)
)
)
)
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)
Chapter 4 )
PRE EMERGENCY PLANNING

)
) )
Format No. 9111·000·PCT-FRM ·00005 Rev·OO )
)
)
)
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)
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)
Chapter 4
) PRE EMERGENCY PLANNING
) (Reference: Section 10 of PNGRB (ERDMP) Regulation, 2010)
)
4·1 Hazard Identification
)
Hazard identification and risk assessment has been carried out to identify and assess the possible accidents. Based on
this Pre Incident Plans (PIP's) detailing the key hazards, emergency equipment present and incident control plans have
)
been prepared for each unit of the refinery. The plans are available as separate documents however a full list of the
available plans is contained in Appendix . All emergency and unit based staff are trained on the plans relevant to them.
)
) EMERGENCY SCENARIOS (FIRE, EXPLOSION, TOXIC RELEASE & HYDROCARBON LEAKAGE)

)
). Accidents in refinery can occur due to human errors, leaks, failure of vessels/ equipment or pipelines, lack of safety
measure etc. In addition, natural hazards pose an additional risk for industrial accidents.
The accidents of the following types can occur inside the refinery:
)
a) Major Fires in tank farm, process units& building fires.
) b) Major toxic gas release like H2S, S02, Chlorine, etc,
c) Different types of explosions
) d) Major hydrocarbon leakage from process units, pipelines or from storage tcmks.
e) Any emergency incident which may impact with the environment.
) D Security threats- bombs.
) The following techniques have been used to identify the Hazards;

o HAZOPs
)
o Quantitative Risk assessment study.
)
) 4.1.1 Hazards in Offsite tankage area:
)
Crude oil tanks;
)
A rim seal fire can ensue from lightning or an electrostatic spark. Were this to escalate, it could result in a tank on fire,
A radiation level of 8 kW/m2 arising from a tank fire , on anyone of the tanks, can approach the tanks adjacent to it.
)
However, all the crude oil tanks are provided fixed water-sprinkler systems for cooling the shell, should an adjacent
tank be on fire. In case a tank fire occurs on the southern tank in Tank Farm 1, it can affect the Crude Pump House
)
with 8 kW/m2 radiation. Nevertheless the radiation levels would not affect the process facilities or tanks in that area
)
NHT Feed Storage Tanks/MS IIIIIV Tanks/HSD III Tanks/Naphtha Day·Tanks;
)
Radiation of intensity 8 kW/m2 from a tank fire on either one of the Naphtha Day-Tanks (Case No. 18.1) can affect
) other adjacent tanks in the same tank farm, In line with OISD guidelines, the adjacent tanks are provided with fixed
water-sprinkler systems to obviate failure of the adjacent tanks,
)
) Format No, 9111-000-PCT-FRM-00006 Rev-OO
)
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)
Propylene Bullet
Before being sent to the Polypropylene Unit, propylene is stored in three mounded bullets, 84 m in length and 7 m in
diameter, with a stored capacity of 2,900 m3 . Although the likelihood of a major failure is significantly reduced, by
virtue of the bullets being mounded, there is a possibility of a small failure in the connected pipeline system. In general,
failures in pipeline systems are due to corrosion. Since propylene, which is handled here, is not corrosive, the
likelihood of such an event is low. Nevertheless, as a representative case, a large hole in the outlet line with an )
equivalent diameter of 1" (25 mm) has been cons idered, for evaluating the hazards. The effects of a flash fire, a jet
fire and an Unconfined Vapour Cloud Explosion (UVCE) have been studied.
Flash Fire Hazard Distances due to 50 mm hole in Propylene Bullet Outlet Line. The flash fire is primarily restricted to )
within the Battery Limits.
)
Propylene and LPG Pumps:
A flash fire arising from a pump seal failure is entirely restricted to the LPG and Propylene Pump House, with little
likelihood of affecting even the Mounded Bullets nearby. Almost no hazard is posed to units outside the Pump House, ) )
from a jet fire.
The Propylene Pumps are located in the LPG and Propylene Pump House within the Mounded Bullets Area and are
)
used to pump Propylene to the Polypropylene Unit. Therefore, a failure occurring with one of them, has the potential
to escalate taking into account the nature of the units right beside. Hence, the scenarios arising from the failure of the
)
seal of one of the pumps have been considered , since such a fai lure is not very uncommon.
)
Hydrogen Bullets:
The effects of all events considered will be entirely confined to the Bullet area,with a very low likelihood of effects upon
the roads to the south and to the north.
)
Loading Gantries )
LPG Loading Arm Failure: )

A flash fire from a full-bore rupture will be, primarily, restricted to the LPG Rail Loading Gantry area. The possibility of
any effect upon the White Oil Rail Loading Gantries immediately to the West is low, since the wind generally blows )
from the North-West to the South-East. Radiation of intensity 37.5 kW/m2 from a jet fire, can affect the White Oil Rail
Loading Gantry to the west, as can a UVCE. Since the gantry is provided with sprinkler systems to cool the tankers
should they be subject to an increase in temperature, the likelihood of escalation is lowered.
) )
LPG Headers
LPG is being transferred to marleting terminal through transfer pumps (553-P-01 AlBIC). Two headers 12"-P-553- )
1207-B1A & 12"-P-553-1212-B1A are provided for auto LPG and LPG services respectively. Marketing terminal is
located outside the refinery complex and both the headers are passing under the culvert. These headers are studied )
to assess the impact of loss of containment of LPG as LPG is highly flammable gas.
Chlorine tonners
Chlorine is being stored in tonners in the refinery at the following locations: )
Upto 15 tonners at raw water treatment plant.
Upto 36 tonners at cooling tower area. )
Each tonner has a capacity of storing 900 kg of ch lorine gas.
Following scenarios have been considered for ch lorine tonners; )
• Leak from chlorine tonner rupture case .
• Leak from chlorine manifold. )
After studying the process description, operating conditions, substance handledetc, unit equipment including storage )
tanks are selected for identifying those which can, in case of accidental release lead to major accidenrt hazards.
Format No . 9111· 000·PCT·FRM·00006 Rev·OO
)
)
)
Revision 01
)
Next Review
) 9112·000·HSE·006·00048 Page 29 of 226
)
Process unit failure cases.
Listing of failure case helps eliminate failure case of small magnitude as well as case with a very low probability of
) occurrence. The failure cases considered for consequence analysis are listed in the Table below.
Released Incident
SI.No Unit Name Equipment Failure
quantity Classification
Pre-flashed Crude Discharge line
)
Pumps instrument tapping 6084 Kg Levei 1
CDUIVDU (501 -P-1 04) failure
)
Crude Heater 50 mm Hole in outlet
16914 Kg Level 1
(501-F-101) line
) 1.
Crude column Reflex Pump Seal failure
Pump 1097 Kg Level 1
)
) (501-P-105)
Stabiliser Reflux drum Catastrophic Failure
19943 Kg Level 2
(501-V-104)
Second Hydro-treating 20 mm hole in the
)
reactor feed line 2196 Kg Level 1
(502-R-002)
HDT Recycle Discharge line
compressor instrument tapping 2500 Kg . Level 1
2. NHT
(502-K-001 ) failure
Stripper Reflux Drum Catastrophic Rapture
) 3348 Kg Level 1
(502-V-004)
Heavy Naphtha Pumps Pump Seal failure
) 1146 Kg Level 1
(502-P-005)
Hydrogen Make-up Discharge line
)
Compressors instrument tapping 1572 kg Level 1
(503-K-001 ) fai lure
)
Second Stage Feed line flange
isomerisation reactor. gasket failure 1674 Kg Level 1
)
(503-R-002)
) Naphtha
DIH Recycle Drum Catastrophic Failure
) 3. isomerization 3670 Kg Level 2
(503-V-008)
Unit
Heavy Isomerate Pump Seal Failure
)
Pumps 1026 Kg Level 1
(503-P-004 )
)
Dryer regeneration Shell- side outlet
super- heater Instrument Tapping 500 kg Level 1
)
(503-E-013) Failure
LPG Absorber Pumps Discharge line
)
(504-P-002) instrument tapping 12276 Kg Level 1
failure
) Sabiliser Reflux Drum Catastrophic Rupture
2301 Kg Level 2
(504-V-009)
) 4. CCR
De-ethaniser column 50 mm hole in the
35274 Kg Level 1
(504-C-002) feed line
)
De-ethainiser Reflux Pump seal Failure
Pumps 1332 Kg Level 1
(504-P-006)
) Form at No. 9111-000-PCT-FRM-0 0006 Rev-OO
)
)
)
Revision 01
Issue Date I 27-FEB-2018
Next Review
9112·000· HSE·006·00048 Page 30 of 226
)
Feed pumps Pump seal failure
3096 Kg Level 1
(507-P-001)
Hot HP separator Catastrophic
56947 Kg Level 2
Diesel (507-V-003) Rapture,
Hydrotreater HP Amine Absorber 50 mm Hole in top
5160 Kg Level 1
(507-C-001) DischarQe line )
Stripper Reflux Pump Pump Seal Failure
5, 1380 Kg Level 1
(507-P-004) )
Fractionator Reflux Bottom Nozzle
Drum Failure 186600 Kg Level 2 )
(507-V-011)
Cold HP separator 20 mm Hole in feed )
drum line 25740 Kg Level 1
(507-V-004)
Fractionator overhead Pump Seal failure
) )
Liquid pump 1254 Kg Level 1,
(508-P-010)
Delayed Stripper Feed Pump Discharge Line )
6,
Coker (508-P-013) instrument tapping 10896 Kg Level 1
failure , )
Debutaniser overhead Catastrophic
8557 Kg Level 2
Receiver (508-V-012) Rapture )
De-ethaniser feed drum Large Hole In The
(509-V-017) Bottom Discharge 8820 Kg Level 1 )
Line
Hydrogen Compressors Feed Line )
(509-K-002) Instrument Tapping 1800 Kg Level 1
7, VGO-HDT
Failure )
Stripper reflux Drum Bottom Nozzle
253200 Kg Level 2
(509-V-013) Failure . )
Debutaniser Reflux Catastrophic
5800 Kg Level 2
Drum(509-V-016) Rapture )
Reactor 50 mm Hole in feed \
(51 O-R-001) line 23100 Kg Level 1 ) )
Main Fractionator Catastrophic )

FCC-PC,
Distillate Drum Rapture 175103 Kg Level 2
FCC
8, (510-V-102) )
Naphtha
Stripper Feed Pumps Pump Seal Failure
Splitter 1302 Kg Level 1
(510-P-203) )
Absorber Bottom Discharge line
Pumps Flange gasket failure 1374 Kg Level 1 )
(510-P-207)
Naphtha surge Drum Catastrophic Failure )
Hydrogen 14926 Kg Level 2
(511-V-104)
9, Generation MT Shift Convertor Feed line Instrument )
Unit 1200 Kg Level 1
(511 -R-104) Tapping Failure
Propylene C3 Splitter Transfer Pump Seal Failure )
10, Recovery Pumps 1350 Kg Level 1
(512-P-101) )
Format No , 9111-000· PCT-FRM· 00006 Rev-OO )
)
)
)
Revision 01
)
Issue Date I 27·FEB·2018 I
Next Review .
) HMEL 9112·000·HSE·006·00048 Page 31 of 226
)
C3 Rectifier Drum Catastrophic 71057
Level 2
) (512-V-102) Rapture
Polypropylen Polimarisation Reactor Feed line instrument 4380 Kg
Level 1
) e Unit (513-R-310) . lapping failure
8" Nozzle Failure 313800 Kg Level 1
11.
Carrier Gas Instrument tapping 2958 Kg
Compressor 3rd stage failure Level 1
) (513-K-600X)
SR LPG LPG Amine Absorber Top Discharge line 11220 Kg
) 12. Level 2
Treating (515-C-101) 20mm hole
) Amine Amine Regenerator Top Discharge line 140 kg
Regeneration Reflux Drum Instrument tapping
13. Level 1
Unit (522-V-102) Failure
)
) 1 &2
Plant cooling Chlorine Tonner %" Line Rapture 495 Kg
)
14. Water Level 2
system
)
Raw water Chlorine Tonner %" Line Rapture 495 Kg
15. treatment Level 2
)
plant
Raw water Chlorine Tonner Rupture of chlorine 900 Kg
) Level 2
16. treatment tanner
plant
)
)
)
) Format No. 9111·000·PCT·FRM·00006 Rev·OO
)
)
)
() HPCL·Mittal Energy Ltd.
Revision 01
)
Issue Date 27-FEB·2018
~'V~ Emergency Response and Disaster Management Plan
9112·000·HSE·OO6·00048
Next Review
HMEL Page 32 of 226 )
)
Offsite area (Inside the refinery premises) Failure cases.
)
SI.No UNIT Equipment Failure Mode Consequence Emergency
1. Crude storage Crude storage Tank RIM seal Fire Tank Fire Level 2
NHT Feed Tank Over pressure lOver Tank Fire Level 2
filling
)
Propylene Mounted Bullet 50 mm Hole in Bullet Flash Fire Level 1
outlet line Jet Fire Level 1
Intermediate )
UVCE Level 2
2. storage
Flash Fire Level 1 )
Propylene Pumps Seal Failure Jet fire Level 1 !
Hydrogen Bullets Instrument Tapping Flash Fire Level 2 )

Failure Jet fire Level 2
UVCE Level 2
MS-3 Tank RIM Seal Fire Tank fire Level 2 ) )
HSD -3 Tank RIM Seal Fire Tank fire Level 2 )
3. Finished LPG Mounted Bullet 50mm Hole In Bullet Flash Fire Level 2
Product Outlet Line Jet fire Level 1 )
storage UVCE Level 2
ATF Tank RIM Seal Failure Tank Fire Level 2 )
Level 2
Naphtha Rail Day tank Rim Seal Fire Tank Fire )
Level 2
4. Day Tanks Naphtha Road Day tank Rim Seal Failure Tank Fire )
Level 2
Hexane Road Day tank Rim Seal Failure Tank Fire
LPG Rail Full-bore Rapture Flash Fire Level 2
Loading Jet Fire Level 1 )
Gantry
UVCE Level 2 )
Loading Arm
Swivel Joint Leak Flash Fire Level 1
5. Jet Fire Level 1 )
UVCE Level 2
Seal Failure Flash Fire Level 1
) )
LPG Rail Loading Pumps Jet Fire Level 1
UVCE Level 2
White Oil Naphtha Loading Pumps Discharge Line Flash Fire Level 1
Road Loading Flange Leak Jet Fire Level 1 )
gantry UVCE Level 2
6. )
Full- Bore Rupture Flash Fire Level 1
Loading Arm Late Pool fire Level 1
UVCE Level 2 )
White Oil Rail Loading Arm Full-Bore Rupture Flash Fire Level 2
7. Loading Jet Fire Level 2 )
Gantry UVCE Level 2
LPG storage LPG transfer pumps 553-P-01 Seal failure Vapour cloud Level 2 )
8.
area AlBIC Jet fire
9. LPG header 12" LPG header Rupture case Fire ball Level 2
)
Form at No. 9111-000-PCT-FRM -00006 Rev-OO )
)
)
)
Revision 01
)
Next Review
) HMEL 9112·000·HSE·006·00048 Page 33 of 226
)
Cases affecting off·site facilities (outside refinery premises) (Level·3) and its impact.
)
After co nducting analysis using (PHAST Softw<;lre of DNV) based on operating and ambient conditions the following of
) accidents that affect offsite facilities and population is prepared. The list also shows the hazardous event (toxic, flash
fire etc.)And affected distance from the source of leak.
)
SI.No Hazard Event Hazard Distance at 2.50 Contour drawings RisklAvg year
Weather Condition
)
Escaped H2S vapours Toxic ERPG 3(100 ppm) Refer Annexure 9 4.96E-06
from Middle Inlet of H2S level reaches up to
) 1
Rich gas KOD 524-V- approximately 435.57 m
002 (SRU) from leak source
) Chlorine tonner in Toxic gas release due to Refer Annexure 9
cooling tower area. 25mm hole.
(Chlorine storage) Contour of 20 ppm of
2
chlorine will travel upto
)
633.9 m from the leak
source.
) Escaped LPG Vapours Flash Fire, LFL Refer Annexure 9
From LPG Transfer Concentration Level
) 3 Pump 553-P-01A/B/C reaches Up to
(LPG Storage) Approximately 433 m from
) Leak source
Jet firefFrom LPG Contour of jet fire radiation Refer Annexure 9 4.22 E-6
) Transfer Pump 553-P- showing 4kW/m2,
4
01A/B/C (LPG Storage) 12.5kW/m2 & 37.5 kW/m2
) impact area.
) )
)
) Format No. 911 1-000-PCT- FRM -00006 Rev-OO
)
)
)
Revision 01
HPCL-Mittal Energy Ltd. )
Next Review
9112-000-HSE-006-00048 Page 34 of 226 )
)
CONSEQUENCE ANALYSIS OF THE SELECTED FAILURE CASES
This section discusses the consequences of the selected failure scenarios listed above. The hazard distances are reported
for the prevalent weather conditions. The effect zones for incidents are plotted on the plot plan , and provided in Annexure.
For detailed plots, refer the Risk analysis report.
)
Flash
Jet Fire Late Explosion
Fire
)
Case Radiation
51. No Unit Equipment Failure Weather Overpressure(psi)
No. Effect Levels(kW 1m2) )
Distances in mtrs.
Zone(M) Distances in mtrs.
)
4 12.5 37.5 1 2 5
u.
Discharge
,.; 50 77 60.41 50.7 87.1 73.38
63.26 ) )
Pre flashed
,.; line u 49 72 55 .24 52.04 72 .28 60.35
rl crude pumps
instrument
f'J
51.53 )
(501-P-104 )
tapping 0
rYl 48 51 45.65 42.41 72.24 60 .32 )
Failure 51.52
u.
,.; 11 27 20.68 16 .14 19 .35 15.89
)
13 .34
f'J Crude Heater 50 mm hole u
,.; f'J 10 27 21.18 16.65 18.82 15.56
(501 -F-101 ) in outlet lin e 13.15 )
0
rYl 10 27 21.44 17.12 - -
-
,.;
~
0
)
u u.
,.; 24 27 21.1 17.7 37 .11 30.78
26.11
Crude co lumn
)
Pump sea l u 17 25 19 .34 15.9 21.3 17.12
rYl f'J
,.; reflux Pumps 14.04
Fail.ure )
(501 -P-105 )
0
rYl 13 24 18.16 14.73 20 .75 16.78
13.84 )
u.
,.; 93 - - - 367 246
157 )
5tabiliser Reflux
<:J: Catastrophic u
,.; Drums (501-V- f'J 138 - - - 370 252
failure 178
104) )
0 - -
rYl 181 - 379 260
218
)
Format No. 9111-000·PCT·FRM·OOO06 Rev·OO )
)
)
)
Revision 01
) HPCL·Mittal Energy Ltd.
Emergency Response and Disaster Management Plan Issue Date I 27-FEB·2018
Next Review
) HMEL 9112·000·HSE·006·00048
Page 35 of 226
)
LL
rl 29 55 36.47 NR 39.38 32.21
) 26 .92
Second Hydro
rl 20m m ho le u
N Treating Reactor N 29 54 36.55 NR 38 .67 31.77
in Feed line 26 .67
) (502-R-00 2)
0
en 28 54 36.74 NR 38.51 31 .66
26.61
LL
rl 24 19 13.65 NR 35.57 29 .82
Discharge 20.86
) HDT Recycle gas
N li ne u
N com presso r( 502- N 20 19 14.12 NR 20.97 16.91
inst rume nt 16.84
) K-001)
t apping 0
I- en 18 19 14.4 NR 20.86 13 .92
N I Fail ure 13.88
) z
LL
rl 26 - - - 206.9 13 7.77
St ripper Ref lux 86.76
) 'i
""! Drum(502-V-
Catastrop hic u
) N
Ruptu re
N 28 - - - 203.2 135.4 4
85.44
004)
) 0
29 - - 197.3
en - 131.71
83.32
) LL
rl 19 34 26.54 22 .37 21.74 17.40
Hea vy Naphth a 14.20
<:J: Pum p sea l u
N Pumps(502-P- N 17 31 24.31 20.13 . 21.19 17.06
Failu re 14.00
005
0
) m 16 30 22 .9 18.68 21.07 16.97
13.95
LL
rl 27 21 15 .15 NR 38.02 31.36
) Discharge 26.44
Hyd rogen M ake-
rl line u
rYi up co m presso r N 23 22 15.77 NR 36.53 30.42
) instru me nt 25.90
(503-K-001)
tap ping 0
en 21 22 16.09 NR 35 .94 30.05
) Fa ilu re 25.69
LL
rl 41 47 - - 72.24 60.32
) Second st age 51 .52
Feed lin e
N iso merisati on u
rYi f lange gas ket N 39 46 - - 58 .5 8 48 .01
Reactor (503-R- 40.21
) Fai lure
002 ) 0
38 43 -
)
) en - 57.5 7 47.37
39.85
LL
rl 149 - - - 285.4 23 1.13
DIH recycl e 191.65
) en E Catastrop hic
0 ""! Drum (503- u 188 -
::! en N - - 315 263. 04
fail ure 22 7.07
V-008)
) 0
en 192 - - - 320.8 268. 76
23 0.32
) LL
19 32 25.46 21.47 21.42
rl 17.20
Hea vy Iso merat e 14.08
<:J: Pum p sea l u
) en Pum ps N 16 30 23 .31 19.31 20.84 16.83
Failure 13.87
(503-P-004)
0
) en 5 29 21.94 17.92 20.7 16.74
13 .82
Dryer Shell Sid e LL
rl 33 60 47.64 40.31 54.24 45.28
) Regeneration 38.66
Outer
lI) u
en Super- Instrume nt N 32 56 43.37 36.19 52.27 44.03
) Heate r( 503 -E- 37.95
Tap ing
013 ) Fai lure 31 53 40. 71 33 .53 52.06 43.9
37.88
)
)
)
.)
Revision 01
Emergency Response and Disaster Management Plan Issue Date I 27 -FEB-2018 )
Next Review
9112·000·HSE·006·00048 )
Page 36 of 226
)
LL
rl 62 65 42.96 21.06 105.5 88.65
Discharge 76.24
LPG Absorber )
rl lin e u 48
.,j- Pumps (504- N 59 44 .87 30.6 76.78 63.18
instrument 53.14
P-002)
tapping 0
41
"1
m 57 49 .36 43.66 74.61 61.81
Failure 52.37
LL
)
rl 91 - - - 179.1 146.2
Stabiliser Reflux 121.84
"! Drums (509-V-
Catastrophic u )
.q N 94 - - - 185 149.6
Rupture 123.79
009)
a:
0
m 86 - - - 180.1 142
)
.q U 115.16
u
LL
rl 191 176 137.2 114.2 339 .7 284.4 )
De-etha n iser 243.49
m 50 mm hole u
.,j- Column (504-
C-002)
in Feed lin e
N 205 165 125.9 103.1 321.9 276.8
243.54 ) )
0
232 158 118.9 95.98 355.8 309 .3
m
274.96 )
LL
De-ethaniser rl 14 31 25.41 21.82 19.64 16.08
13.45 )
.q Reflux Pump sea l u
.,j- N 13 29 23.01 19.49 19.17 15.78
Drum(504-P- Fai lure 13.28 )
006) 0
m 12 27 21.48 17.97 19.06 15.71
13.24
)
LL
rl 22 43 33 .99 28.57 36.86 30.63
26 .03
rl Feed Pumps Pump sea l u )
LI) N 21 40 31 .03 25 .69 35.49 29.76
(507-P-001) Failure 25.54
0
20
)
m 38 29.19 23.84 35.22 29.59
25.44
LL
rl 32 - - - 261.4 175 .8 )
Hot HP 112.67
N Catastroph ic u
LI) Separator (507- N 33 - - - 262 .9 176.8 )
Rupture 178.88
V-003)
0
m 35 - - - 112.7 113.2 )
114.39
HP amine
50 Mm hole
LL
rl 63 53 NR NR 108.1 90 .29
77.17 ) )
m in top u
f- LI) Absorber (507- N 60 53 NR NR 105.4 88.64
0 Discharge 76.23 )
LI)
I C-001)
0 line 0
m 61 53 NR NR 103.7 87 .5.,6
75.62
)
LL
rl 35 37 28.54 23 .77 54.8 45 .63
Stripper Reflux 38 .86
~ Pump sea l u
)
LI) pumps (507- N 30 34 26.3 21.49 38.34 31.56
Failure 26.55
P-004)
0 )
m 26 33 24.86 20 37 .82 . 31.23
26 .37
LL
rl 525 341 263.2 214 .8 609 .1 574.9
551.1
Fractionator u
Bottom N 350 335 256.4 208.3 498 .1 443.4 )
LI) Reflux 402.91
<Ii Nozzle
Drum(507-V- 0
failure m 273 324 246 .2 198.8 458.5 388 .8 )
011) 337 .32
u 22 NR NR NR
N 33.13 28.27 )
24 .69
Format No . 9111-000-PCT- FRM-00006 Rev-DO )
)
)
)
Revision 01
)
Next Review
r ) HMEL 9112·000·HSE·006·00048 Page 37 of 226
)
Fract ionator LL
r-l 21 37 30.33 25.93 35.54 29.79
25.55
Separator Drum
r-l Pump seal u
Overhead Li qu id N 18 35 27.6 23.2 20.64 16.71
\D
Failure 13.8
I Pump (508-P-
0
010} M 16 33 25.84 21.42 20.52 16.63
13 .76
) discharge LL
r-l 80 73 56 47 142 119
102
Stripper Feed line
::J
) \D U
N
\D
Pump(508-P- instrument u
N 76 69 52 42 116 99
0 86
OB} tapping
) Failure
0
M 80 66 49 40 126 109
97
LL
) r-l 40 - - - 295 .8 197.5
Debutaniser 124.95
M Overhead Catastrophic u
N 48 - - - 315.9 213.9
) ")
\D
Receiver(508-V- Rupture 216.94
012} 0
M 62 - - - 320 .8 216 .9
141.9
LL
r-l 147 143 106.6 84.46 252 .8 211.1
Large Hole in 180.3
)
r-l De-ethaniser Bottom u
r-- N 148 135 98.84 76.69 233.7 199
Feed Drum Discharge 173.46
) Line 0
M 143 127 91.89 70 .3 1 227.4 195.3
171.32
) LL
r-l 33 31 22.65 15.91 58.67 48.07
Feed lin e 40.24
) N Hydrogen Instrument u
r-- N 30 31 23 .69 17.2 43.33 34.71
Compressor Tapping 34.51
I- Failure
) 0 0
M 28 32 24.72 19.08 43.03 34.51
:r:, 28 .23
r--
0 LL
) 19
> r-l 25 57 43.72 NR 42.08 33.92
27 .89
Stripper reflux Bottom
M
Drum(509-V- Nozzle u 23 53 39 .15 NR 40.59 32.97
) r-- N
27 .35
013) failure
0
M 24 50 36.27 NR 39.83 32.5
) 27.08
)
) Debutaniser
LL
r-l 42 - - - 273.4 183.4
116.95
~ Reflux Catastrophic u
r-- N 59 - - - 275.4 188.4
Drum(509-V- Rupture 124.11
016 - ' 0
M 82 - - - 290.7 198
129.55
)
)
)
Revision 01
Next Review
H MEL 9112·000·HSE·006·00048 Page 38 of 226 )
)
LL
rl 18 38 29 22 22 18
141
.. rl Reactor(510-R- 50mm Hole u 16 39 30 22 22 17
)
C() N
001) in Feed line 141
0
16 39 30 23 22 17
I
J
(Y)
14
L main LL
109 - - - 806 .2 541.4
)
rl
(lJ
345.84
+-'
+-' Fractionator
N Catastrophic u )
0.
Vl C() Distillate N 114 - - - 800 .2 537.9
m Rupture 348 .19
..c Drum(510-V-
+-'
..c
0.
102)
0
(Y) 144 - - - 831.8 561.2
361.44
)
C() m
z LL
u rl 32 36 27 .95 23.29 52.59 44 .3 )
u 38 .11
LL Stripper Feed
u' "! Pump seal u
D- Pumps(501-P- 26 34 25.74 21.05 37.56 31.07
U
u
C()
203)
Failure
N
26 .27 ))
LL 0
(Y) , 24 32 24.34 19.59 37.01 30 .72
26.08 )
LL
discharge rl 84 72 55 46 144 120
Absorber 103
lin e )
<:J: Bottom u
C() instrument N 81 68 51 41 128 110
Pumps(510-P- 97
207)
tapp in g
0
)
Failu re (Y) 83 65 49 39 127 110
97
LL
)
rl 336 - - - 588 .6 493
422 .37
Naphtha Surge
rl Catastroph ic u )
m Drum(511-V- N 281 -. - - 509.9 419.8
354 .93
Rupture
004)
::::J
0
(Y) 240 - - - 476.4 38 1.6
315 .85
.)
m \.9
I LL
Feed Lin e rl 20 - - - 20 .67 16.73
13 .81 )
Mt shift
~ instrument u
Converter(511 - 18 - - - 20.15 16 .39
m
Tapping
N
13.63 )
R-104)
Failu re 0
(Y) 18 - - - 19.89 16 .23
13.53 )
LL
15 34 27 .83 24.02 19.92 16 .25
C3 Splitter rl
13.54 ) )
rl transformer Pump sea l u
0 N 14 31 25.15 21.43 19.54 16.01
rl Pumps(5 12-P- Failure 13.41
)
101) 0
(Y) 13 30 23.43 19.73 19.43 15 .95
0 ::::J
'. 13 .37
rl cr: )
D-
LL
rl 90 - - - 648.7 438.4
283 .15
C3 rect ifi er
N
0 Drum(512-V-
Catastrophic u 97 - - - 655 442.4
)
N
rl Rupture 455 .6
102)
0
(Y) 122 - - - 283 .2 285.4 )
'----- -
297.24
Format No. 9111-000-PCT- FRM-00006 Rev-DO )
)
)
)
Revision 01
Next Review
)
H MEL 9112·000·HSE·006·00048 Page 39 of 226
LL
rl 39 75 58 .9 NR 55 .9 46.33
Feed Lin e 39 .25
rl instrum ent u
rl N 35 69 53 .09 40 .87 54.73 45.58
rl Tapping 38 .83
-l
Polymerisation Failure 0
(Y) 36 65 49.44 37 .56 54.55 45.47
38 .77
) - Re actor(513-R-
LL
310) rl 232 418 334.4 283.9 399 .8 337
290 .66
) rl :::J N
rl
8" nozz le u 222 382 253.1 377 .9 319.5
rl
(L
N 301.6
(L rl Failure 276.42
) 0
(Y) 216 36 1 281.5 233.4 366.1 308.4
265.76
) ca rrier gas
LL
rl 13 26 20.9 16.63 19.5 15.99
13.39
Instrument
<Y! Compressor 3rd u
) rl Tapping N 13 26.5 21 .29 17.07 19.1 15.74
rl Stage (5 13-K- 13.25
) 600X)
failure
0
12 26.4 21.42 17.36 19 .02 15.68
) (Y)
13.22
LL
Top rl 34 61 NR NR 54 45
) 19 LPG Am in e 39
N
(L Discharge
rl -' Ab so rb er(515-C- u 32 56 NR NR 53 45
cr: Line 20mm N
38
) V)
101)
Hol e 0
(Y) 34 53 NR NR 53 44 38
)
) Failure Frequencies
) Equipment Type of Failure Connection Pipe Dia.(mm) Failure Frequency

(per Year)
Catastrophic Failure - 1x10·6to 1.51 x10·4
) >25 3x10· 5
40 1x10-5
) Pressure Vessels
50 7.5 x10-6
)
)
80 5x10-6
100 4x 10-6
)
>150 3x10-6
) Pipe Work Failure Catastrophic <50 8x 10-7to 1x10-6
) 50<Dia.<150 9x1 0-8 to 3x10-7

>150 3x10-8to 1x10-7
} Small Bore Rapture 20 5x10-4 toO.01
Connection
) Centrifugal Pump Seal Leak 0.09
Storage Tank Atmospheric Tank catastrophic 6x10-6 t03 x10-5
) Pressurized Sphere/Bullet catastrophic 1x10-6to 1.51 x10-4
Atmospheric Tank Fire 1.2x10-3
)
Loadinq Arm Catastrophic 2.4x10-3
Hoses Rapture (heavy Stressed) 0.32
- -- - _.
)
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)
4·1(a) Check points for hazard identification are given as per the checklist
(Reference: Section 10.1 (d) of PNGRB (ERDMP) Regulation, 2010)
Checklist-1
Hazard Identification )
Which of the following procedures or techniques for hazard identification has

been used in terminal/installation )
)
• Hazo /Hazan )
• Incident consequences & analysis )
• Event tree analysis
• Fault tree anal sis )
• Failure modes, Effects, and Criticality analysis
)
• Risk Assessment ,j
)
• What if Analysis
• Other accredited practices )
Hazard identification
2 Is the terminal/installation covered under the definition of "Major incident )
Hazard Installation" as per the Manufacture Storage & Impart of Hazardous ,j
Chemical Rules 1989 (Amended 1994 and 2004. If yes, please specify the site )
notification and Safet Re orts
3 If yes, whether major incident hazards identified and steps taken for their ,j )
prevention
4 Whether design deficiencies, failures or errors which can contribute to hazards )
and cause abnormalities leading to an incident are identified. ,j
) )
5 What are the measures undertaken to counter above deficiencies or, errors The countermeasures as suggested by
the Hazop analysis are implemented to )
counter the deficiencies
)
6 Consequences of a major incident on the workers, people on the ,j
nei hbourhood and the environment are considered )
7 Steps envisaged for mitigation of the consequences of such incident i. Warning
ii. Impact evaluation )
iii. Rescue
iv. Relief )
v. Rehabilitation
)
8 Does the installtion produce /handle/ use/ import! store any hazardous Yes
chemicals as defined under MSIHC Rules 1989(Amended 1994 & 2004) )
9 If Yes, whether a list of these chemicals, preferably in alphabetical order with Annexure 07 )
their maximum licensed stora e quantities dis la ed .
)
)
)
)
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10 Are material safety data sheet (MSDS) of these chemicals are prepared Yes
lobtained in the prescribed format as per MSIHC rules and State Factory rules.
11 Whether a system for disseminating information about these MSDS to Displayed at the site and available with
---j concerned are existing the unit teams .
12 Are there a system of labeling of containers I storage tanks for the chemicals Yes
) I hazardous substances
13 Whether estimation of maximum possible quantity of each hazardous Yes
) substances are considered including any vehicle (TTnW) on site or within 500
mtrs of the site.
) 14 Whether locations, configuration and condition under which the hazardous Yes
substances are stored and handled are clearly declared
Vulnerability Analysis
15 Whether zones of influence or vulnerable zones are estimated by considering Yes
) the maximum single storage of hazardous substance and maximum loss
) scenario
16 Whether effects of influence on the vulnerable zones are made after Yes
considering the population , facilities and environment encompassed inside
) that zone.
Risk Analysis
) 17 Whether a relative measure of probability and consequences of various Yes
possible hazardous events including worst case scenario are taken into
) account.
18 Whether risks are calculated by multiplying the probability of occurrence of Yes
each event by the consequences of that event and then summing up the
results.
) 19 Whether all types of events possible in petroleum installations are considered Yes
including i) Storage tanks on fire ii) pool fire [burning pool of liquid fuel] iii)
Flange joint leakages in pipeline iv) Fire in TTnW gantry and v) Rupture of
hoses
Risk reduction measures
20 Whether measures for reduction of identified high risks are included by Yes
reducing the consequences through hazard mitigation measures
21 Whether steps have been considered to reduce risks to the exposed Yes
) ) population by increasing safe distances by acquiring property around the
facility
) Hazop Study
22 Whether the above method is applied if the location handles more than Yes
)
23
specified storage and! or critical operations
Whether the study systematically identify all possible deviations from normal Yes
'-
) operations
24 Whether risk levels are established for each deviation after considering the Yes
) probability and consequences of each such events
25 Whether potential means for detection of such events and preventive Yes
) measures are recommended by the study
4·2 Risk analysis and risk assessment

)
Risk concept
)
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)
The hazard associated with an industrial activity may pose risk to people, In the context of this study release of hazardous
material due to loss of containment is considered as source of risk, Risk is estimated as combined effect of severity of )
consequences due to accidental releases and the probability/frequency of occurrence of the release,
Frequency analysis
Failure rate is estimated for each failure case identified for the hazard analysis, Leak frequencies play an important role in )
determining risk levels for hazardous events involving release of hydrocarbons,it is important for risk analysis to understand
how often leaks of hydrocarbons can occur from various process systems and equipment.equally important is having an
understanding of the variance of release size with equipment tyoe, which gauges the magnitude of an intial event and its
escalation potential. )
To estimate the failure frequency of components of HMEL refinery, database published by Exploration and production forum
database is used, )
The base frequencies provided by E and P forum are as under,
S,OOE-04
) )
4.50E-04 )
4,OOE-04
3.50E-04 )
3,OOE-04
2.50E-04
)
2.00E-04
)
1.50E-04
1.00E-04 )
• •
S,OOE-OS
O,OOE+OO
,,:$ ~
':Y'" /.-~
•'" •1
,, :>- ~
'" ~~Q," 1
" :>- '1 n"
,~'(}
~
~Q,"'?
)
,,~ )
. "Q, , '1
<;1'"
I>< . ~Q, Q," I>< ,,'1
~Q,
~~Q," ~
~¢{, ~~Q,
,,0 ""
,,"~" . "Q,
~''< ~?J. ~¢{,
Q,"
~?J.<:-
~?J.
~?J.
~?J. 0,Q,
,,'?
.::,<..Q,
~
<.,Q,
,," ~,o <.,Q,
<.,Q, ~?J. ~~
<$'?J. ~
"Q, )
,,0
~
" )
Basic failure frequency from E & P forum
) )
Format No, 9111-000-PCT- FRM-00006 Rev-DO

)
)
)
)
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)
H MEL 9112·000·HSE·006·00048 Page 43 of 226
)
0.018
)
0.016 l,---------------------l
) I 0.014 L---------~----l
) 0 .012 +1- - - - - - - - - - - - - - - - - - - - - 1
0.01 +1- - - - - - - - - - - - - - - - - - - - - - - 1
0.008
)
0.006
0 .004
) 0.002
)
o - - -
process pipe flanges valves small bore pressure centrifugal centrifugal
fittings vessel pump compressor
)
Base frequencies from E & P forum with pumps & compressors
) )
)
Format No. 9111-000-PCT-FRM-00006 Rev-DO
)
)
Revision 01 I )
Issue Dale 27·FEB·2018 I
. Emergency Response and Disaster Management Plan
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HMEL Page 44 of 226 I
)
Risk acceptance criteria
)
The criteria for tolerability of individual risk and societal risk. Three risk levels are specified as follows;
1. An in-tolerable region, within which the risk is generally intolerable, whatever the benefit may be. Risk reduction
measures or design changes are considered essential.
2. A middle band (or ALARP region) where the risk is considered to be tolerable only when it has been made as low as )
reasonably practicable, as evaluated by cost-benefit analysis.
3. A negligible risk region, within which the risk is generally tolerable and no further risk reduction measures are )
imposed.
UK-HSE has issued the following guidelines for individual risk tolerability criteria. )
1. Maximum tolerable risk for worker is 1E-3 per year.
2. Maximum tolerable risk for member of the public is 1E-4 per year.
3. Broadly acceptable risk is below 1E-06 per ye~r .
)
Employo public
iIU1\''lccep l;1b,le Re;ion I )
1£ ·00 p er yearl )
)
e
)
)
Risk estimation
After estimation of failure frequency and consequence analysis, the risk has been calculated using PHAST risk software. The
)
location specific individual risk is superimposed on the overall layout and presented below.
)
Format No. 9111-000-PCT- FRM-00006 Rev-OO
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)
(~;- :: ~ .~;'l .: ~
!"!"" " 70;;::·

)
~
)
)
)
..... £#..-...._8:0. ........

) ~
.:...~~.
I ~.!:,;.
) I
! . "" : I~ ' , - ,'kl,; '!;.. i 1'-1
1,
)
I
!
~............
11: ~"-
,,:.~~"==.___"'.!~~"'~:.:. ..:!_.~~-~·c
r. -:::: :.
I . , ~.. ~~
~I
..
~
B' ?~-
··dfZ~~~·n( ';: i:~
tI ~rn ~ . ".~"
) "
) Risk Level
)
•
I r ~·.O~1!~~3 t
1 ) f
I I ~ :~Fl ~-:=. .,
)
) ) •
)
• I I 1.0ElO-5
f
)
) •
Sa I 1.0ElO-6
) This risk is within ALARP zone.

Risk conntour is presentation of risk by joining equal risk points generated by consequence analysis multi pied by frequency
) of failure.this is done by taking into account probability of ignition, wind direction probabilities and the resultant fatalities .
In the above risk counter the risk is for the offsite facilities.
)
The equipment contributing for risk level of 1E-3/avg year are as under:
)
1. LPG pipeline
2. HP amine absorber 509-C-001
3. Stripper 506-C-003
)
)
)
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)
4. Hexane pump S06-P-OSA/B
S. Hexane column S06-C-002 )
4·3 Causes of disasters
The common causes for the events are tabulated below for reference and the ERDMP is prepared to deal with the
following emergencies: )
Man made Natural calamities* Extraneous )
• Heavy leakage • Flood • Riots/ Mob attack
• Fire • Earth quake • Sabotage )
• Explosion • Cyclone • Bomb threat
• Failure of critical control system • War/ hit by missiles. )
• Design deficiency
• Unsafe acts ) )
• In-adequate maintenance
)
*Note: Floods and cyclones are not prevalent in this region.
)
4.4 Consequences
)
The consequences of an Incident may be confined within the premises or may spill off-site triggering cascading
effects. )
The consequences of an Incident are fire explosion, deflagration, blast waves, fast spreading flames, BLEVE, UVCE )
resulting in direct effects like damage to buildings/property, burns, fatalities . However, an Incident in the neighborhood
may sometimes cascade into an on-site emergency. It should be prevented or managed to avoid major emergency. )
4.5 Hazardous Chemicals and Properties )
4.5.1 Hazards Associated With Liquefied Hydrocarbons )
Liquefied Petroleum Gas (LPG) is one of the most hazardous of hydrocarbon products, on account of its highly )
inflammable nature. A mixture of C3 and C4 hydrocarbons, which is gaseous under atmospheric pressure and )
temperature, it is liquefied under 8-12 kglcm2 at ambient temperatures. )
Propylene is an almost equally hazardous hydrocarbon product, also on account of its flammability .
It remains in the gaseous state under atmospheric pressure and temperature and is liquefied under pressures of 16- )
19 kglcm2 at ambient temperatures.
When a liquefied hydrocarbon is suddenly released from a storage drum or vessel on account of a mechanical failure,
a substantial fraction of it flashes to vapour almost instantaneously, entraining much of the remaining liquid as droplets. )
The flammable cloud formed by pressurised gas is normally denser than air and forms a thin layer over the surface )
whose movement is influenced even by slight breezes in the area of a spill. The cloud could also flow into depressions
and trenches, and can , thus, travel considerable distances. Upon ignition, it would constitute a flash fire spreading
)
over the area covered by the cloud .
)
A jet fire may ensue, if the liquefied substance is emitted under sufficient pressure as a continuous stream. The flames
of a jet fire are normally of greater intensity near the source while the radiation decreases rapidly farther away. While
)
the flame is normally in the direction of the jet, the wind can bend the flame , if it blows with sufficient force and from
such a quarter as to do so.
)
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)
) A hazard that liquefied hydrocarbons are particularly more susceptible to is the Boiling Liquid Expanding Vapour
Explosion (BLEVE). A BLEVE occurs when a pressurised storage vessel containing a liquid or liquefied hydrocarbon
---:1 is exposed to an external fire. The liquid, absorbing heat through the shell of the vessel, vaporises, thereby increasing
the pressure in the vapour space up to its level, the liquid absorbs heat from the shell, thus cooling the metal and
preventing its weakening, above it the heat accumulates, weakening the sheiL Once the pressure in the vapour space
increases beyond the threshold of the weakened shell , it fails in a catastrophic rupture, releasing all its contents.
") Thereafter, whether a fireball or a veE ensues with the remaining material, depends entirely upon the conditions
prevalent. While blast, overpressures are of concern, the most serious consequence of a BLEVE arises from the
) pieces of the fragmented shell, which, as missiles, can cause secondary failures, thus setting in train domino effects.
) Here the BLEVE hazard is negated in the design stage since both LPG and propylene are stored in the mounded
bullets.
)
) Hazardous properties of LPG
S.No Properties Values

) 1 LFL(%v/v) 1.7
2 UFL (%v/v) 9.0
) 3 Auto Ignition Temp. (0C) 432
4 Heat of combustion (kcal/kg) 10,960
) 5 Normal boiling point (0C) -27
) Hazardous properties of Propylene
) S.No Properties Values I
1 LFL (%v/v) 2.0 I
) 2 UFL (%v/v) 11.0

3 Auto Ignition Temp. (0C) 455
) 4 Heat of combustion (kcal/kg) 11,000
~- Normal boiling point (0C) -47
)
4.5.2 Hazards Associated With Hydrogen
)
The primary hazard associated with hydrogen is the formation of a flammable or detonable mixture. As with all other
) inflammable substances, it is necessary for hydrogen to be mixed with an oxidant, for the mixture to be within
flammability limits, and an appropriate ignition source to be present for it to burn.
)
The ignition of a hydrogen-air mixture usually results in a deflagration, with less significant hazards than with
) detonation. However, in a confined or partially confined enclosure a deflagration can evolve into a detonation.
Nevertheless, hydrogen is much lighter than air and rises rapidly by turbulent diffusion when released. This results in
) a rapid reduction of its concentration below the lower flammability limit, thus making it virtually impossible for hydrogen
to explode in an unconfined area.
)
Exposure to hydrogen fires can result in significant damage from thermal radiation. A hydrogen fire must be allowed
) to bum under control until the hydrogen flow can be stopped. A combustible mixture forms if a hydrogen fire is
extinguished without the hydrogen flow being stopped, making it possible for the mixture to ignite, with an explosion,
causing more damage and re-starting the fire .
)
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4.5.3 HAZARDS ASSOCIATED WITH CRUDE
)
The major hazards resulting from crude oil are fires and the thermal radiation from them. A spillage or loss of
containment will result in a highly flammable pool of liquid; partiCUlarly so, when large inventories are involved .
Such a pool can catch fire, on encountering a source of ignition, and result in a: confiagration releasing large
amounts of heat radiation, detrimental to surrounding facilities . )
Pool fires of crude oil are difficult to extinguish on account of the tendency of the material to not vaporise and thus
remain un-dispersed. )
4.5.4 NAPHTHA AND OTHER HEAVIER HYDROCARBONS: )
Heavier hydrocarbons, stored in an atmospheric cone roof tank, can generate enough vapours to produce an )
explosive mixture in the space between the tank roof and the liquid surface. Such a hazard, though lower in a floating-
roof tank, does exist in case the tank-seal ruptures, causing a high concentration of vapours in the space above the
roof. Under such circumstances, lightning or static electricity can cause a fire . Fires in floating roof tanks generally ) )
start from the rim due to the higher concentration of vapours in the roof seal area and are triggered upon encountering
)
a source of ignition.
)
A spillage or loss of containment will result in a highly flammable pool of liquid.Such a pool can catch fire, on
encountering a source of ignition.
)
4.5.5 CHLORINE
)
Chlorine, though not flammable is highly toxic in nature. Its routes of entry into the human system are the respiratory
and digestive tracts, the skin and eyes . Exposure to a low concentration of chlorine can cause eye irritation, sneezing
)
and restlessness, whereas higher concentrations of chlorine can cause respiratory distress and violent coughing .
Lethal effects ensue depending not only upon the concentration. of the gas to which an individual is exposed,.but also J
upon the duration of exposure. The toxic effects of chlorine is listed as:
)
ISTEL
IDLH
11 ppm
fTc
LJ.9...pQm )
4.5.6 HYDROGEN SULPHIDE )
Exposure to hydrogen sulphide causes irritation to the eyes, which can escalate to conjunctivitis, eye pain, lacrimation,
photophobia and corneal vesiculisation, depending on the duration and concentration of the individual is exposed to,
and to the respiratory system, where it can lead to apnoea. It can also result in dizziness, headache and convulsions, )
and even lead to coma, if exposure is prolonged . H2S is also flammable and can cause substantial damage if it is
exposed to a source of ignition. The toxic properties of H2S are listed in the table; )
I STEL 115 ppm )

I I
IDLH I )
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)
Chapter 5
~ EMERGENCY MITIGATION MEASURES
)
)
)
)
)
)

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Chapter 5
EMERGENCY MITIGATION MEASURES
The following resouces are available for dealing with the emergencies and the actions required are detailed as:
5.1 Fire equipment details:
Fire Protection system of Refinery is designed to fight two major fires simultaneously anywhere in the Refinery at a flow
of approx. 7000W/Hr.
FIRE PROTECTION FACILITIES AT HMEL REFINERY I
Fixed Fire Protection Facilities I

!
SN Fire Protection Facility Scope Remarks
1 Fire Water Reservoir 50,000 m3 Two compartment each of 25,000 m3
2 Fire Water Pumps 15 no's 11 main (06 diesel + 05 electrical) + 04 jockey
3 Double Hydrants on single stand post Entire Site Distributed in all Refinery Complex based on hazard
4 Monitors Entire Site Distributed in all Refinery Complex based on hazard
5 Hose Boxes Entire Site Distributed at every alternate hydrant point
All along pipe rack and all plant & non-plant building
6 Hose Reels Entire Site
having more than one floor
Pumps, Un-insulated vessel, Columns, Air fin-fan
Automatic/Manual Fire water spray system
7 Entire Site coolers, Atmospheric storage tanks, , Road and Rail
(MVWS)
loading gantries, bullets etc.
8 Automatic Fire water spray system(HVWS) Substations High capacity transformers
9 Semi Fixed Foam Pourer System Tank Farms Floating and Fixed Roof Tanks
10 Rim Seal Foam Package System Tank Farms All four crude oil storage tanks
Main Control Room, SRR, OMS C/R, CPP & Admn.

11 Clean Agent System Entire Site
building.
12 Fire Proofing Entire Site As per 01SD-164
As per Electrical "Operation Philosophy of Fire
13 Fire alarm and detection system 4530
Alarm System"
As per Electrical "Operation Philosophy of
14 Communication and Public address system Entire Site
Communication and Public address system"
Mobile/First Aid Fire Protection Equipments/ Appliances
15 Foam Tender 4 Nos. Entire Site
16 Water Tender 01 No Entire Site
17 Foam Nurser 2 Nos. Entire Site
18 DCP Tender 3 Nos Entire Site
19 Emergency Rescue Tender 1 No Entire Site
Vehicle mounted oil suction unit (Gulley
20 2 Nos. Entire Site
Sucker unit) ---
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5.2 Incident preventing measure and procedures;
)
Refinery is having a Health & Safety management system certified to OHSAS-18001 (2007) standards . This
--1 safety management system has been written to conform to the requirements of the international standard for
safety management systems - OHSAS 18001 :2007 and OISD 206 - guidelines on safety management
systems in the petroleum industry.Health, Safety & Environment policy is available. Health & safety policy is
available.
)
)
HEALTH, SAFETY, ENVIRON M ENTAL AND QUALITY (HSEQ) POLICY
) HPCL-Mittal Energy Limited and its subsidiaries (HMEl Group) are commi:ted, as part
of its core values, to conduct all business activities in a socially responsib le manner to
) protect hea lth, well-being and safety of our employees, the communities around,
environment and assets, and exceed stakeholders and customers expectation. HMEL
Group requ ires active commitment to and accountability for HSE·:::t from all
)
employees, contractors, and business associates. The line management has a
leadership role In the communication and Implementation of, and ensuring
) compliance with, HSEQ pol/cles an d standards.
) We are comm itted to:
./ Integrate HSEQ aspects and sustai nable development principles in our Injury,
)
unsafe practices, occupational illness, environmental and quality business plans
../ Assess and minimize risks from our activities w ith the aim of pr;vention of
) injury, III health and environmental damage
../ Educate, train, motivate and empower employees to conduct their activities in
) a safe, environmentally responsible and quality oriented manner at all the
times during their employment
) ./ Efficiently use energy and resources, minim ze waste, and prevent pollution
../ Wor k with our suppliers, partners and customers to mutua lly Improve HSEQ
) performance
../ Foster openness, dialogue and consultation with our employees and
) stakeholders
../ Strive to continually improve health, saf ety, environmenta l and quality
management systems and performances to herp achieve the company goal of
)
business excellence .
../' Provide quality products that meet or exceed customer requirement
) ,/ Comply with or exceed all applicable lega l and other requ irements
) (17tuf;;; 1Iruo/_ *~ :.~~

~- -- -
Martin HawlOns- COO I Prabh' Oas - MD & CEO
)
th
19 September 2015
)
) Format No. 9111-000-PCT- FRM-00006 Rev-OO
)
)
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)
)
5.2.1 Safety committees:
• Central Health & Safety committee .

• Local area Health & Safety committees. )
The roles of these committees are defined as: )

o Ensure review committee decisions are put in place
• Review local area incident and trends )
• Review site audits
)
• Review training & initiatives
• Discuss site issues / suggestions related to safety.
• Action list from the incident reportins.
) )
)
Central safety committee
The central Safety Committee has been constituted to review the Health and safety management system. The )
meeting is done monthly and chaired by Head refinery operations. This meeting is attended by the chairpersons
from the local safety committee and one shop floor member from each area. The following are the roles: )
• Ensure review committee decisions are put in place )

• Review progress against targets
• Review incident trends )
• Review major incidents
• Review site audits )
• Review training & initiatives
• Discuss site issues / issues not resolved by local teams )
• Review effectiveness of local committees.
• Review learning from incident, suggest and agree improvement. )
) )
)

)
)
)
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L....-- ---- ---
~-
)
iVleeting No. 20 15/04 Da te & T ime : 15th Jul : 1200 Hrs.
Agenda of iVleetin g: - Review on Health & Safety.
Incide nt statisti cs. perfo rm ance aga inst ta rgets. Key fi nd ings from audi ts. Safety. Occupati onal health &
hyg ie ne updates. Review workin g o f local sa fety committees. Rev iew o f Nea r rvlisses.
C hairman : A.S.Basu Lo cation : MC R; Meetin g Room N o. 1
Secretary : Aman Cho pra

)
Attendance Details :
)
Member Present Depa rtm e nt M embe r Prese nt Department
A.S.Basu COO office Harpreet Singh Opns./JE
) Krishan T uteja VP-Opns. Vij ay Katkar Opns.
Martin Hawkins COO N itin Mittal RSS
) B .C. Doley Opns. Ratnesh Kumar Maintenance
) R.S.Nandanwar Health & Safety Jayes h Opns./JE
) Sanjib Chaudhary Maintenance Ajit Maity Technical Services
Anshu Sharma Opns. Neeraj Jain Opns.
) S.C.Das Projects Pratik Sharma PSM
Arun K umar Maintenance Aman Chopra Health & Safety
) Mohit Sabharwal Maintenance Ashwan i Bansal Opns./JE
Bikash Garodia Opns. Daljit Singh Civil maint.
Kamlesh Shah RSS Abhishek Haldar COO office
)
Napa Satish Opns./JE Harish K um ar Opns./JE
B.K.Singh Opns. Pravin Bodkhe Risk Assurance
)
(Copy for the safety committee members)
)
5.2.2 Audits: External & Internal
)
• External safety audits are carried out once every 02 years.
)
• OHSAS-18001 continuous surveilence audits every 06 months. (Last in Nov'14)
• Internal audits for implementation of OHSAS-18001 , once every year for an area/unit.
)
• Work permit audits every 03 months.
) ) • Housekeeping inspections monthly.
• Contractor safety audits once a year.
) • Last external safety audit was carried out in Jan'14.
) 5.2.3 Work permit system:
)
System in place in line with the 01SD-105 guidelines. Maintenance jobs are controlled through work permit system .
Entry insise the process units for doing the maintenance jobs is cotrolled through work permit system. Hazards
identification and control measures using Job safety analysis is an integral part of the work permit system. Various
)
permits are as:
) • Hot jobs.
• Cold work permit.
) • Confined space entry.
• Vehicle entry inside plant areas.
) • Excavation jobs.
• Electrical jobs.
• Blinding and De-blinding
• Work on equipment in service.
)
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HMEL 9112·000·HSE·006·00048 Page 54 of 226
)
)
THIS PERMIT COPY MUST REMAIN AT JOB SITE IN CASE OF EMERGENCY DIAL 0165527222218054923515
Permit No: )
~
GURU GOBINO SINGH REFINERY
c- ...,
HMEL COLD WORK PERMIT
L To be compltltd by Pennk Requestor D COLD WORK D BUNDJDEBllND D ELECTRICAL WORK D EXCAVATION WORK (MAHUAL ONLy) )
Plant :________ .__ ._____ .__..._.UnItfArta .________._____._.Equlpment NamelTag No. :____________ .__
Work DualpOOn :... ___. _____ ._______.____________________.__.. _ _ _ _ _ _ _.______ ._ )
Oat, : _ _ ._______ ...____ . at : ________.____ ..Hrs. )

Penni! Is requUltd on
peCi~::;;~e-ci~rc;:~;;:-~;·Dtplrtmtnl--·--CJ";~~~ N~·;;~=~~;~=:=--:.-..:.-=--=-~.~~ I! )
lI
No. of PtI$OllS : _._. __ Name 01 Contractor's Supervllor & Agency NItnI __ .__ .__.______ _ I
i )
II. To be completed by Permit Issuer : (Following conditions shall be checked before Issuing the permit) I
I
A. Other Work In D YES location ' .___ ._____ .Typt of Permit : .. _____ .___ .__ .P'rmIlNo.: .________ .
I
vlcinkyCritlcalto
this work
D NO
I
i )
B. EltcbicaillOlatlon ' Enervlsetlon Form No ___._____ . __ .. _ .. Lockout I Tagout No.: ...... _... ___ .. i
I
C. Exc.vetlon ClNnnce Ctrtlflcalt No.. _ .._. ____ .__ ._.___ ... I
; )
~ ~ ~ ~
~ , .it
D. Operetlonal Considerlllon , Precautions
I V_I : Iron Sulfldt ..
..." . ...
, kIPt ~,
DeprtUurlZlllon System I Lint
lsotetlon of System I lint I VeSMt Add! 1
CI)
"~lnspected
Overrldt interlock (Req, NO_. _________ 1 , Cit dwilh.. _ _ _ )
Instd BllndlFllllIJts/SpadH E en
Disconnect Lints , ~c ' 0
' . ScaftA ,~ FOR USE" Tag No: . ___ ._ _ ._
Requlrn wwning bairds I signs ' Barricede Arta
E.Addltional P.... onntl Prottctlvt Equipment (PPE) :,:~ ,~::,
. .,... .
i
)
(Minimum requirement : Saftly Helmet. safely Goggltl. Safely Shots, NOIIIIIIICD.verall &'1I'I!'u.F"S) i
CJ FaCt Shield CJ Filter Muk CJ Hearing Prottcti~ c:r !il!uit ~ CJ Rubber Boots CJ Heat·rnblant Gloves ! )
CJ ChtmlcalSuk CJSlfely Hlmtss CJ Full FactMISj. , "C!I ~eratus CJ RubberGlovtl t::J H,5DtttctorC]Othtn !
F. Preeautlons "lIled 10 control system (If requi"dJ : ' .~ ': , i
Syllem By-pass "qulled 1 t::J YES • \'" t , \CwtfrolielS In Manual? t::J YES i )
D~ D~ I
.
Consolt SupervilOr : NImt _ .• _. ___. __....,_""_'"iD ~-~ .r..-.--.-Sign..--------Date-.------_.runt________
.5;
!
)
G. SpecJalPrecautlonL.__...._, __.. _ _ _ .. _" ..-..:.,.'l;......-- '_' --.-.--..--------------.-.--.-... - .. -.-.-...-,--------- ~
lVways Koep WorII atea free from IP..h~ _cessary malOflals etc. Pay allentlon 10 wind drocioMYi:ld socks. n CITlOfgOOcy 5"00 Is Z
adJvated STOP ALL WORKS, Pl9Ciiitto I ~1Y point. Pennit Requestor Is slticly r~ired to comply WIth 31 HMEL safely prooecbes. )
III. Gas Tests:
Conduc:""" ~
HC's('4LEL) : ..... __ ._ -.'
_ ..,...~
.," .".::, HtS._._. __ ..... ppm 0._..._____'4 OIherGu : _ _ _ ..ppm
Gu Test .;,_,;,::, /wOo ~Gu Safely Tuter(Naml) : .__________ Sigrutu" .._______ runt : _ _ _ _ _
)
IV, Ptrrnk~. nM:.- thatlll "qulrtmtnts oltht penni! have been COrrtttly compltttd. physlelily checked and verifitd by III partlts ) )
conetmed arid.......,"" lii~uItd In. latisfactory manner.
Worlt Period : ,~.... ',' DatI 01 Issut : ____ ._._ .. __ .. __ Validity : From._....__ ._._ ... _._. __ Ib. To_. ___ •...HIS.
)
Permit Requestor : Name Signature Date TIml_ _ _ __
Permillssuerl Field Supervisor: Name Signatu" Date TIml, _ _ __ )

Approver 1 : Name
-- - -- Signatu" ._-_. Date TImt _ _ _ _ I~
)
Approver 2 : Name Signature . _ _ _ _ _ Date TIm. 0
V. Permit extension :
Permit Requestor Permit Issuer Field Engineer Appro_·\ Approver·2 Approver·3 "
)
Namt & 591111... tI
B· Shlft )
Ezttndtd upto (TlIlt) ~
Homo & Si\J1111... c(
C·Shlft
Ezttndtd upto (TInt) ~ )
VI . Permit Close Out:
Belore the close out 01 the permit : Has the area been deaned up and aI the waste materials seperaled and cJsposod dI i1 corred c:oriaJler JOB STATUS
D YH D No If No, Why 1._.___._.. _. __.• Job Complelt D )
Ptrmlt Requestor : Name : __ ..._._ .. _ _ Signature : _....._.____ Dale & TIme : _. ___ ._ ..._ •._ Job Incomplete D
Field EnglnHr : Name : ____.... ___ Signature : _ .. __.._._._... Oat, & TIme : ----.-,-.-- Remarlts : .___. __ •
Permit Issuer : Name : Signature : __ ... _. ____ .__ . Date & TIme : _...__ , . .. .. _ )
In case 01 any emergency, PERMIT SHALL STAND CANCELLED. New Permit must be Issued lor renewal 01 Work.
Format No . 9111::Cllro-=-p-Cr=-FRM::WO·06-Rev·OO )
)
)
)
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)
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)
THIS PERMIT COPY MUST REMAIN AT JOB SITE IN CASE OF EMERGENCY DIAL 0165527222218054923515
PennltNo:
-, ~,~e GURU GOBIND SINGH REFINERY

HOT WORK PERMIT
H·
HMEL
) HotWorIl
Radiation Source Work
P1.1lI :....................................................UnItlAre ...... ........................... _ ................ Equlpment N. llIIITag No. :........................... _................_.
) Work Dncripllon :....................................................... _.. _ ..................................... _ .... ......................... _••• _ .................. _ ............... .. _ .......... _._.
Tooll & Equlpments

to be used : 0theI1 ••• _.•• _.
Permit II reqUHled on Dale: • .__ .... _•••• _ ........ _.. 81 : _. ... .. _ • •••• __ ..... __ ... .Hr•.
) PermllRequaslor : Nam ....... ....... _ ............. __ •• _...... Dtplrtmenl. ................... _..... __........SlgnalUrt._ ..................... _... ___ . . . . .. __
CJ HMEL Empl. CJ
Outsotrced/"O&M" only CJ
ColJ1lllny Nam. (Outsourcedf'O&M}_ .. __ ______ .. _. ___ ____ ._._._
Endorsed by : HMEL Malnl8nancel Optlllilans Supervisor
) (required If work 1.10 be don. by contraclor) NIIIIt.... ____ .. ________ _ _.. __ .... __ ___ .5lgn.Ift.___ • __. .. __.. _ ... _... __.. _.. _ ... _.
NI/IIII of Contractor's
)
Location: -.. - .... -.. --.. --.. --•• -...."JYPI
)
B. Operellon. 1ConsldereUon I Precaution. :
Dtp,...urlDllon By.ltm , Lint' Vas ..1
Elec:lrlcallsolaUonl Energ1satlon Form No ... _ ..... _ .....
Lockoutl T.goul No_... _.. _ . .. __.__... _... _ .. ___ .___ •• __
i
UI
ElIC.vIUan Clearanc. ClrIlllcalt No. _ •• _............ _... __

) Work.1 htl~L - .... - .. - ..... - ..... ----.... - .. --... -.----..
P"lII With : ... __..._... _ .. __ ... __ ... _.. __... __.__.... _ .. _..._.
CI .....~ Flushed wfth __ .. _ .. __ ..... _.. _.... _ .. _........ __ .. _
OvelTlde Int.rtock IRaq. NO ... ____ .... _ ............. _ .. __ •.)
Orelns, Manholes, CBD & Hotsurfacea nelrby covered
R.qulres werning bo.rd" signs' berrlcld. area
8h1l1d provided eg.lnslspalll Ing Wa~d fire txtln~lah.
) dad. Fino WIl8ravalablt.
..... "SAFE FOR USE" Tag No. _... _.• __ .. ___ _
E::l E::l
C. Manlto~ng
)
St ...dbymanl Sof. lyWltch :
Fire Witch
D. Specl.1 Equlpmelll
N..... : ... _.. _........ _.. __ ..I~
NIIIIt : ... _.. _.... _•.••• _... II
8 Arta Monllorlng StaUon
Running WII., Hose
L1fe Lint
Rlle_ Tripod 8
Non-Sperldng Tool.
Spllle Arreslors
Softly Ntl
Olh ...
8 8 ~,
) E. Additional Pnonal PrOllclvt E",1II1 (PPEI IIyHllrnel,lIfeIy Gqj~, SaI~ 8IoeI, ~I H,S Oeleclor& HInd Gbvet) ~f
8 Fact Shltld
R..,b., BoOli
HNI-reslsllnl Glov.
HaaJtng Protection 8 Fun Flct Milk
Others
8 I
) ~
)
DyES DNO
I
)
)
)
Work Period: D.la olin... : ..... __.. __ ... _.... _... _.... __ VaUdlly : Frarn._. .... _.... _.... __ __ .. _.. .Hr.. To_._ .. __ __ .. ___ .__.. __.. Hr•.
) RadlaUon Source WoIII eN/A eVES Soun:e Strtngth_ _ _Call mator used_ _(YeslNo) Cordoned Dlslince requirld. ... _ .. _IIn MIra.)
RadIIICII Sillily Olllcer (ConlrlClor\ NIIM Signal ...t Olle TIme,_ _ __
Ptnnl! Rtqueslor: Name Signal... Dale TIme,_ _ __ ;!
) Ptrmllluut~ FIeld S~""'or:
Approvtrl:
AppIovtr2:
Name
NIIM
NIIIIt
Signal...
Signal..e
Signal ...e
D.le
Dale
Olle
TImt,_ _ __
TImt,_ _ __
TImt. _ _ __
o
AppIovtr3 : Nam. Signal ...t 011. Time
) 9pln19'lY1la1:"IIqJ_.d .. '*"'llIM beancxrrdt~.~clUtdnl...r.lby . . . pa1.aramedlld .. l lle'lllJ'kcanbte_~ fI.IIIIlIdaySlfe ...mtI. 1:
V. PERMIT EXTENSION : ~
)
Perml RIQUHlar Perml Issu., I Field Engln • ., Approv.,·1 Approv.r·2 Approv.r-3 8
BoShlfl Name & SIaNN.. I ~
~~~~II I ~
)
permit : Haa III ... belli dllll1td!!l!.!...OO aille WI.el!llleNls sepnItd aOO dispo_ d 01 iI correct
DYII DNo IINo,Why? ____ .. __ ..............
cart.,.JobCompltlt 0
JOB STATUS
Field EngintGr (Namo) ... _.. _. ... _.... _.... _.... _..... ... Signature : ....... _.... _.... _....._. Dale & lime _.. _.. __ .. __ .... _.. Job Incomplele 0
Permll Requeslor IName) ...... _.......... ___._ .. _ .... _... Signature : ......... _.. ..... _....._. Dale & lime ... _.. __ .. __ .... _.. Rtmarkl : ... _... ___ .. _.. __ .. .
Permlll .....r (NIIMI .. _.. __ •• _....... __.. _ .... _... SlanalUre: __... ____.. _....__. Dale & lime _... ____ ___ ._ ..
)
) Format No. 9 111· 000· PCT· FRM -00005 Rev·OO
)
)
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)
5.2.4 Early warning systems:
• F & G system: Gas detection system includes hydrocarbon & H2S detectors in the process areas including at )
Heaters FD Fan suction and cooling towers
• Smoke & heat detectors for the building areas including sub-stations.
• Flame detectors for TEAL handling area.
• Low and high pressure alarm for the processes. )
• CCTV are installed in Process units and Rail/Road loading gantries.
• High & low level alarms. )
• High & low pressure alarms.
• High/low temperature alarms. )
5.2.5 Safety through Design (In Built Facilities And Other Emergency Safety Interlock Systems) )
• Safety is the topmost priority in GGSR refinery operation and is one of our core values. Our focus on health &
safety has ensured that potential problems are dealt with proactively before they occur. Highest safety standards )' )
are followed during the operation of GGS Refinery.
• To meet the International standards in safety, Refinery Process Safety Design is complying with various OISO )
and other international Standards.
• 0ISO-STD-116 (for Fire Protection) , )
• 0ISO-STD-118 (for Plant Lay Out)
• 0ISO-STD-150 (for LPG Mounded Storage Facility) )
• Other Non-mandatory standards being complied are OISO Std-11 0, 113, 115, 119, 120, 149, 163, 164, 173, 180
and OISO RP 122, 123 in addition to relevant API standards. .)
• Design of Flare and relief system is an optimum blend of 0ISO-STD-106 and API-RP-520/521 and safety valves
connected to closed flare system )
• Storage tanks design follows API-620/650 based on the applicability.
• All the centrifugal pumps within the process battery limit conform to API-610. )
• Design of Compressors comply with API-617 (centrifugal compressor), API-618 (Reciprocating Compressor)
and API-619 (Screw Compressor) )
• PSVs designed for Fire case with HC service have provision of installed spare.
• High Pressure compressor circuit in VGO-HOT is complying to SIL 3 level of Safety system )
• HC, H2S and H2 gas detectors are provided in various process units including at Heaters FD Fan suction and
)
cooling towers
• Refinery Control room and Satellite Rack rooms are blast resistant buildings
• Operators are sitting in blast resistant Satellite Rack rooms
) )
• Provision of 6 MW OG Set for emergency back-up power in case of total black-out
)
• CCTV are installed in Process units and Rail/Road loading gantries.
• Control room outside Hazardous area -blast proof co nstruction .
)
• LPG storage in mounded bullets at the extremity of the site.
• Space provision for future expansion )
• Fuel station , occupational Health Center, Admin Block and field maintenance office well away from Hazardous
Area. )
• Storage (Crude & Product tanks)
• Layout as per 01SO-118 guidelines. )
• Oyked storage to take care of Loss of containment.
• Class-A petroleum products stored in Floating roof tanks . )
• Double seal protection for all floating roof tanks.
• Rim seal fire protection system for crude storage tanks. )
• Water spray protection for all storage tanks .
• Semi-fixed foam storage for all storage tanks. )
• High volume long range fire water/foam monitors around the dyke areas.
)
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( ')
Safety management system
Safety management system is a key element for managing Health &safety at site. Safety management system
) is accredited to OHSAS-18001 standard. This gives the foundation of how health and safety is managed.
We have a robust system of procedures with a total of more than 1,500 procedures covering safety, operations
and maintenance activities. These procedures takes care for the personal and process safety.We have a defined
standard for writing procedures to ensure safety aspects are fully covered.
) Risk assessments are carried out for routine tasks and for non-routine tasks done under the permit to work
system wherein a job safety analysis is mandatory before the work can start.
Process Safety management

Process safety management was adopted in 2013. The implementation is based around 4 pillars as;
)
Pillar-1: Commit to process safety.
')
Pillar-2: Understand Hazards and Risks
) Pillar-3: Manage Risk
Pillar-4: Learn from experience.
)
All the 14 elements from the USA OSHA process safety regulations are in place.
)
Control of ignition sources
)
Refinery site is marked for hazardous area classification. According to the area classification, flame proof
) equipment is used .
Whole refinery is a No smoking area.

•
) Vehicle entry inside the units is controlled through a hot work permit system.
Fire Fighting Facilities in Refinery Process Units

)
) • All Fire Fighting facilities in the Refinery are designed as per OISO -116 guidelines.
)
• Following are the key features in Fire protection systems in refinery:
) • Fire-Water system designed to fight two simultaneous major fires.
• Hydrocarbon storage facilities has manually operated water spray system
) • Semi fixed foam system is installed for hydrocarbon storage facilities
• Rim seal protection with foam flooding system for floating roof tanks storing class 'A' hydrocarbons for tank
) diameter more than 60 m
• Automatic fixed spray system for pressurized storages
) • Automatic water spray system on Rail wagon/road loading gantries
• Manually operated spray system on columns, Vessels, Pumps, Fin-Fan Air coolers in process units.
) • Long range monitors for protection of inaccessible equipment around process units.
• Clean agent fire extinguishing systems for Main Control Room and Satellite Rack Rooms
) • Fire protection systems for cable cellars, transformers etc.
• First aid equipment, mobile fire-fighting equipments, communication and PA system, personnel protective
) clothing, fire-training ground etc.
• Overhead Foam Storage Facility of 40KL at Fire Station and 40KL at Satellite Fire Station.
)
) Format No. 9111·000-PCT· FRM-00006 Rev-OO
)
)

Revision 01 I
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9112·000·HSE·006·00048 )
)
Fire System
)
• Fire Water Reservoirs:
a. No of Compartments in Fire Water Reservoir: 2 nos
b. Capacity of Fire Water Reservoir 50,000 m3 (2 x 25000 m3)
o Replenishing of Fire Water Reservoir through:
)
• Raw Water Reservoir of capacity 11,00,000 m3
• Fire Water Storage can meet the requirement of 6 hrs. Continuous fire fighting
)
• Fixed Installations
• Fire Water Network of length 51 km
)
• Total nos of Hydrants 1030 Nos
• Total nos of Water Monitors 135 Nos )
• Total nos of Water cum Foam Monitors 60 Nos
• Total nos of Long Range Monitors 65 Nos
) )
For the protection of process equipment water monitors are provided at ground level. Elevated monitors are also )
provided for protection of elevated structures. Fixed type water monitors are located around Process Area.
)
Communication System
Emergency Management Control Room has the following facilities for communication in case of any )
emergency:
• Emergency phone numbers: )
• 2 phones, 2525/2222(lntercom .)
• Mobile phone back-up 08054923515 )
• Tetra handheld radio communication Facility, having additional ability to interphase with VOIP phones.
• PA System consisting of a total of 94 speakers configured as follows: )
• 38 External High power speaker stations placed at strategic locations for optimum auditability, in addition 10
strobe warning lights to enable audible and visual warning ir1' process units )
• 56 Internal speakers for all buildings
• Automated pre re-corded warnings integrated with the Central Fire Panel )
• 65" LVD display from Central Fire Alarm Panel and detection system.
• 3 number of Multi tone Sirens capable of 5km aerial audible range ensuring full coverage )
• Bulk SMS and e-mail facility to notify the emergency message to all internal stake holders.
) )
Safety MIS system
Safety dashboard is created which is giving daily information to the top management on the following details: )
This gives an overview for the leading and lagging indicators for safety. )
• Any reported incidents including FACs-first aid cases. )

• Reported near misses.
)
• Near miss closing status .
• Near miss trends. )
• Health check up data.
• Incident frequency and severity rate. )
Standby equipment )
Standby safety equipment is tested periodically. )
Form at No. 9111-000-PCT-FRM-00006 Rev-OO

)
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HMEL 9112·000·HSE·006·00048 Page 59 of 226
CHECK LIST ·2
Refer regulation 11 .3(12)
\ Incident Prevention Measures
) SI.No Check·Point Yes or No Remarks

Whether safety Health and Environmental Policy of the location is
1. Yes
.) displayed
Whether the safety Policy is documented and duly approved by the
2. Yes
top management
Whether the safety Policy is well structured to cover all elements of
3. Yes
safety<Health and Environment Protection
Whether the layout is convenient from operation and safety
4. Yes
) aspects and meets minimum distance norms as per OS10-118
) Whether a duly constituted Safety Committee is functioning in the
5. Yes
) location with representation from workmen/staff
Whether all unsafe developments and likely risks are deliberated in
) 6. the meetings and appropriate steps are recommended for Yes
eliminating such risk
) Whether compliance status of recommendations of earlier safety
7. Yes
committee meetings are discussed before taking up new issues.
Whether Performance and short comings observed during recent
8. MOCK disaster Drills forms part of the discussions in safety Yes
committee meetinQs.
Is the safety Committee Minutes are recorded and signed by all the
9. Yes
) attending members?
Whether periodical safety audits and inspections by internal and
10. Yes
) external audit teams are conducted in defined intervals
Whether a system of regular monitoring of such Audit compliances
11. Yes
) by controlling offices/HO are in place
What is the composition of External Audit teams to ensure
12. External team
) impartiality of Audit Findings?
Whether work permit system in line with OS10-105 Have been
) 13.
implemented
Yes
}
Whether work permits are issued for hot work, cold work, electrical
14. Yes
) work and vessel entry jobs.
Whether the location -incharge or his authorized nominee remain
.
) 15. the issuer for the all hot work and vessel entry permits for enhance Yes
safety and control.
) Whether work permits are duly closed at completion of the
16. Yes
stipulated jobs ,duly certified by the supervising officer.
) Whether heat detectors in tank sprinkler systems high level alarms
17. of tank farm management system are provided and checked for NA
)
regular functioning
Whether in-built safety interlocks provided in the design of the
) 19. terminal are adequately specified and checked for regular Yes
functioning .
)
) Form at No. 9111-000 -PCT-FRM -00006 Rev-OO
,\
)
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HMEL 9112·000·HSE·006·00048 Page 6001226
)
Chapter 6
EMERGENCY PREPAREDNESS MEASURES
)
)
)
) )
.l
)
)
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) 9112·000·HSE·006·00048 Page 61 of 226
')
Chapter 6
)
EMERGENCY PREPAREDNESS MEASURES
- ) This sections details the emeregcny handling preparedness and measures.
6.1 Emergency Mock drills

)
a. Emergency Mock drills are carried out on a monthly basis for level-1 category. For level-2 category, the drills are
carried out once in six months. Drills are done to reherse the scenarios and to check the preparedness of all the
agencies.
b. Table top exercises are also carried out.
)
c. For level-2 drills the external agencies are also invited viz; city fire brigade, district medical officials, information to
The Factory department to witness the exercise .
), ) d. For level-3 drills, we have already submitted the required data to the District Authorities
e. Observers:
) Observers shall be appointed prior to the mock drill. The observers shall be well experienced and knowledgeable
persons of the field. They shall be briefed about the scenario of mock drill and objectives of the mock drill. They will
) be deputed at different locations. After completion of mock drill they will submit their observations.
6.2 Training and rehersals:
) The training of emergency planning is imparted during induction phase of all the employees / workers in HMEL. Refresher
training for all the employees is being imparted every two years to all non-operational personnel & every year to
) operational employees. The emergency groups will be imparted training on emergency planning once in every six months.
)
The training program for handling such emergency shall be regularly conducted for the employees, to make them aware
about the following .
)
) • Emergency plan.
• Categorization of emergency.
) • Roles & responsibilities of each individual and all functionaries.
• Emergency handling resources available at site.
) • Emergency exercise & drills.
)
) The employees and health facilities are integrated in plan that is exercised and evaluated at least once every 06 months.
When all of the agencies that will be called upon to respond to an emergency have participated in the plan's development,
) they are more likely to ensure that the full needs of the system can be met and that emergency groups are not
overburdened due to poor planning.
)
An emergency plan can be exercised in one of the two ways.
)
The first involves desktop simulation exercises, often called "Table Top Exercises," using paper, verbal, or computer-
) based scenarios designed to improve coordination, to share information, and to practice decision making. Paper drills are
often done to demonstrate how "response functions" work and communication together as part of the OEMP. Table top
) exercises include CIC and all other coordinators.
The second method, "field exercise drills," is effective because responders get to know each other and each other's roles,
gain experience working with the emergency plan, and understand what must be done -- thus enhancing their ability to
rely on each other's activities. Field exercises take place in real time as they test the mobilization, including the activation
)
)
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e Next Review
HMEL 9112·000·HSE·OO6·00048 Page 62 of 226 )
)
of OEMP of all or as many as possible of the response components, In full-scale exercises, the participants include the
different agencies, incident controller, observer team and victims, )
All these mock drills shall be based on pre-incident planning scenarios documents prepared for handling various types of
emergencies in all the units,
)
Frequency:
)
As per OISo 116, a mock drill is to be conducted once every month in different process units, As per facto ry act 1948, an
on -site mock drill is to be conducted twice in a year, As per ERoMP, L1/L2 drills will be conducted at a frequency of 3 )
months and L3 once a year,
)
6.3 Pre Incident plans
Unit wise pre incident plans are available in which the credible scenarios are considered, Mock drills are conducted based
on these scenarios, (List of Pre incident plans are available in the Annexure 6)
) )
)
6.4 Training
)
a, Training sessions for the sectional heads on their roles and responsibility during an Onsite emergency,
b, Training session for Emergency management system is a part of Fire and safety induction training, )
6.5 Mutual Aid )
Refinery location is situated around 40 kms away from Bathinda city, Near to refinery HPCL- LPG bottling plant is
Available, Within the refinery complex, HPCL pipeline terminal is sited having the fire tender and emergency staff, Mutual )
aid agreement exists between HMEL and Talwandi Sabo Power Ltd,
)
)
6.6 Schedule of Checking & calibration
)
S. No. Activities Reference Frequency Status ! )
DETECTORS : ) )
1 OISo Done as per
Once in 6 month
Calibration of detectors by using STD-116 schedule )
test gas
)
Communication system:
2 OISo Daily Done as per
1, Testing of fire siren STo,-116 schedule )
2, Testing of walkie-talkie
)
Format No. 9111-000-PCT-FRM -00006 Rev-DO )
)
)
)
Revision 01
)
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NexlReview
9112·000·HSE·006·00048 Page 63 of 226
CHECK LIST - 3
) (Refer Regulation 12.1 (1))
-, MUTUAL AID/MOCK DRILLS.

SI.No Check-Point Yes or No Remarks
1. Whether mock fire/ Emergency response drills are held Yes
2. If yes ,Periodicity of Emergency response drills Monthly
) 3. Mock Drills cover all type of probable emergencies yes
4. Does the location have Mutual Aid plan NA
If Yes, the details of other members including names and contact
5. NA
nos. of concerned officials
) List of firefighting equipment's available with each Mutual Aid
6 NA
members including District Fire service
Compatibility of safety Equipment's of all Mutual Aid Members
7. including District Fire service with said location has been tested NA
) and documented in DMP.
Details of water storage available with Mutual Aid Member
8. including District Fire Service And mechanism to utilize the same NA
in the said location well documented in the DMP
) Details of firefighting foam concentrate/chemicals available with
9. Mutual Aid Members Including Nearest fire service have been NA
) incorporated.
Details of Lead time of response of mutual Aid Members Including
10. NA
District Fire service have been Documented in DMP.
Periodicity of safety training for officers ,staff, contractor workers,
11. yes
) TT crew, and security personnel mentioned in the ERDMP
Mutual Aid Plans
12. NA
Does the location have established Mutual Aid plans,
Which are the Mutual Aid Plan Team Members and the Assistance
13, NA
) Offered
Does the plan clearly indicate type of possible hazards and fir
14, Yes
fighting measures required?
15, Does the plan include expected assistance from each members? NA
) Does the plan spell out the communication protocol and the
16, Yes
channels in time of emergency
) Periodic Joint and meeting for practice, familiarization and identify
17, NA
and resolving compatibility issues ,
)
) Form at No . 9 111-000-PCT-F RM-00005 Rev-OO
)
)
.f~•
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HMEL 9112-000-HSE-006-00048 Page 64 of 226
- - - -- -- -~
~~-
~
HMEL
I )
)
HPCl MITTAl ENERGY LIMITED
(Guru Gobind Singh Refinery) )
) )
)
LEVEL-1 MOCK DRILL AT GURU GOBIND )
SINGH REFINERY, BATHINDA, ON 17.11.2017 )
Format No . 9111-000-PCT-FRM-00006 Rev-OO )
)
)
)
Revision 01
)
Issue Date I 27 -FEB-1018
Next Review
) I HMEL 9112·000·HSE·006·00048 Page 65 of 226
Abbreviations
) AFS - Auxiliary Fire Services
) BGU Break Glass Unit (Manu al Call Point)

CIC - Chief Incident Controller
)
DMCR - Disaster Management Control Room
DMI - Disaster Management Institute
EMCR - Emergency Management Control Room (Fire Control Room)
)
ERDMP - Emergency Response and Disaster management Plan
)
ERT - Emergency Response Team
) ESD - Emergency Shut Down
H&S - Health & Safety
)
Hl - Human leadership
)
HPCL - Hindustan Petroleum Corporation Limited
) IC - Incident Controller
IOTl - Indian Oil Tankage Limited
)
lEl - lower Explosive Limit
) LPG - Liquified Petroleum Gas
) MAH - Major Accident Hazard

MVWS - Medium Velocity Water Spray
O&M - Operation & Maintenance
) OHC - Occupational Health Centre
) PA - Public Address
) RCR - Rail Control Room

)
RSS - Refinery Shift Superintendent
) SCBA - Self Contained Breathing Apparatus
SCR - Security Control Room
)
SIC - Shift In-charge
)
SMS - Short Mail Service
) TBT - Tool Box Talk
) Format No. 9111-000-PCT- FRM -00006 Rev-OO
)
)
.s
HMEL
~
9112·000·HSE·OO6·00048
Revision
Issue Date
Next Rev iew
Page
01
2HEB·2018 I
l
66 of 226 1
I
)
)
)
DATE: 17.11.2017 TIME: 1402 Hrs.
UNIT : CDUNDU LOCATION: Bottom flange of Pre Flash drum 501 V·101
)
1. OBJECTIVE:
To check the preparedness of Emergency Response team along with associated
response teams . Level-1 Mock drill as per ERDMP was conducted at CDUIVDU. The
observers were deployed at different locations and all the emergency activities were
observed by them . Representatives of Disaster Management Institute were also
present to witness the drill.
2. SCENARIO:
During normal plant round, Field engineer observed heavy leakage of crude oil along
with H2S from the bottom flange of pre flash drum 501 V-101 subsequently fire
occurred due to unknown source.
3. RESPONSE ACTIVITIES:
On receiving the information about leak following activities were performed by various
agencies to control and arrest the leakage . The FS communicated to console engineer
who in turn informed EMCR and RSS about the incident. He then broke the glass of
Manual Call Point. The EMCR operator on receiving the message over Fire Alarm
Panel initiated turn out procedure. The field engineer after informing the console
evacuated all the people working to the safe assembly point. Fire team after reaching
the site searched for casualties and initiated rescue operation. Extinguishment process
then started with cooling around process pipe lines by operating the portable monitors
using hydrants . RSS arrived at incident spot and took the charge as incident
commander. The Security team barricaded the roads to prevent unauthorized vehicle
entry. After the arrival of the RSS at site, looking at the quantum of leakage & fire , he
declared level 1 and asked EMCR to actuate siren for level 1 emergency. After the
extinguishment of fire foam flooded on the spilled crude oil to prevent the re-ignition.
Mechanical maintenance and civil maintenance arrived at site for leak arresting and
cleaning of area . After ensuring everything safe and getting headcount details from the
field and assembly point, "All Clear" was declared by the IC .
Format No. 9111-000-PCT-FRM -00006 Rev-OO

)
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)
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) HMEL 9112·000·HSE·006·00048 Page 67 of 226
)
4. Observer Team:
Sr. No Observer Location

)
1. Ms Swati Mishra - Tech. Expert, oMI, & Site
Mr. Anilsinh Chauhan
2. Mr. Jayant Raushan - Tech. Expert, oMI & MCR CoUIVoU Console
Mr. Vikas Mehta
) 3. Mr. Rahul Mathur - Tech. Expert, oMI & EMCR
Mr. Preetpal Singh Kahlon
)
4. Mr. Venkata oavuluri OHC
)
)
5. Persons! Agencies Responded:
)
1. Fire Team
) 2. RSS
3. Operations team
) 4. Maintenance team
5. Security team
) 6. Level Of Exercise: Level-1 Mock Drill (as per ERoMP)
)
7. Elements Of Exercise:
)
:}$tr..Jm0·,', .;
--
C>J~§ crlpjl~,I'l·. : . _ -, .
-
..- --. jRt~tm1ank
- .
A Pre informed exercise No
)
B Secret/Surprise exercise Yes
C Public announcement system used during the exercise Yes

)
) 0 Siren used during the exercise Yes
)
8. Incident Was Assumed During:
)
.s.r,~~'0,
~
. .; .jlll~~~P;tlolil , !R~lima"k
-- • =~
) A Shift changeover time NO
B Past mid-night time NO

)
C Early hours in morning NO
)
0 During lunch time NO
)
E During general shift duty hour YES
)
) Format No. 91 11-000 -PCT-FRM -00006 Rev-OO
)
)
)
Revision 01
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H M EL 9112·000·HSE·006·00048 Page 68 of 226 )
9. Chronological Order Of Key Events
r -- , - - '.
mllmtl~ (~lJil1 IHflls.)]
.. ~'1leTrilt
J
- - --- - i
1402 Initiation of drill by breaking the glass of MCP after observing the heavy crude
oil leakage from the bottom flange of pre flash drum. )
1404 First turn out reached the site. )
Went ahead with search operations and laying of hoses for extinguishment of
fire. )
1405 )
2nd turn out reached the site and started supporting the first team .
Fire commander reached site and established communication with FS. ) )

1406 )
Information received that Console supervisor had isolated the line and slow
down the process.
)
1407 RSS arrived at site and took charge as the incident controller.
)
1408 One casualty found near pipe rack and shifted to ambulance for transporting
)
to OHC. He was exposed to H2S.
Spraying of foam started for the extinguishment of fire and portable monitor )
1410 arranged for cooling of nearby process line.
)
RSS declared level-1 emergency
)
1411 AFS team reached the site and started barricading roads and reported to Fire
commander. )
Extinguishment of fire completed and stopped the spraying of water. )

1425 Meantime one more casualty observed. He sustained burn injury on his right
arm during fire fighting process. ) )
1427 Application of foam started on the spilled crude oil to prevent re-ignition as )
per the direction of fire commander.
)
1429 IC discussed with Fire Commander and FS and declared All Clear after
taking head count )
10. Debriefing: )
A debriefing session was chaired by Sh. Ramesh Nandanwar at MeR Meeting Room )
# 1. Key observations points from the drill are recorded for action list. )
)
Submitted by
Pankaj Ankush Hingnekar )
AM (H & S)
)
- -
NCONTROLLED COPY] Printed from TDMS dated: 25-September-2019, 12:21:34 PM By Siddiqui MD Ghazunfer Ali (1000006
~ ~ ~ ~ ~ ~
i
~ ~ ~ ~ ~ ~ '-" '-" )
'-" '-" '-" '-" '-' '-" -../ J -.-/ --.,) -' -.-/ -.-/ --'
Revision 01
HPCL·Mittal ~rgy Ltd.
Issue Date 27.FEB.2018
Next Review
9112·000·HSE·006·00048 Page 69 of 226
Observations and Actions
The observers appreciated response of the ERT and control actions of the responders. However there are some improvement opportunities which are given below:
Siren was not heard inside MCR. Check and rectify Sunil Goel Completed
It was observed that the non-emergency vehicles

Give TBT to all the drivers irrespective of HMEL operated
were found parked without drivers inside the
2 or contractor owned to shift their vehicle immediately Rajnish Mathur Completed
barricaded road. Vehicles were there during the entire
from the road which has barricaded during emergency
mock drill period.
Mechanical maintenance and Civil maintenance team

Ensure personal detector whenever anyone arrive at the Oaljit Singh I Narendra TBT given
3 arrived at incident location without their personal
incident spot during an emergency. . Kirar Completed
detector.

)
)
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)
Chapter 7
RESPONSE PROCEDURES AND MEASURES )
) )
Format No . 9111-000-PCT-FRM -00006 Rev-OO )
)
I )
)
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)
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Chapter 7
RESPONSE PROCEDURES AND MEASURES
--,
1.1 Zoning and maps.
)
The zones and maps have been prepared highlighting the Incident prone areas of the unit so that in case of an
)
emergency it serves as a basis for taking the action . This indicates the size of the area within which human life
is seriously endangered by the consequences of incident. This also indicate the location of assembly points
Different zones as per the risk scenarios based on the risk analysis are already mentioned in Chapter 4 and also
)
refer Quantitative Risk Analysis Report of the refinery.
) Location of assembly point is shown in the figure below:
) • I·_n•.~ I
.....:,.. rco.l ...' .. ~
PGoIU II W
--. ruw]
)
)
1.2 Manpower data:
) Shift Name Shift time(hrs.) manpower
I
. Evening 1500 - 2300 266

General 0830 -1700 1932
)
Morning 0700 -1500 300
Night 2300 - 0700 168
) Format No. 9111-000-PCT- FRM -00006 Rev- OO
)
)
)
Revision 01
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HMEL 9112·000·HSE·006·00048 Page 72 of 226 )
)
7.3 Emergency Evacuation Plan
)
The evacuation procedures are limited to on-site emergencies, which are caused by emergencies taking place within
the plant boundaries. Personnel safety and accounting of all employees at the site, is of paramount importance. Map
of Emergency Evacuation of whole refinery is enclosed in appendix 15.9.
)
The evacuation depends on:
)
• The assembly points in refinery.
• Primary and alternative escape routes. )
• Estimated time required for escape and evacuation.
)
Refinery wide, there are 30 assembly points located at strategic locations near every process units & buildings. The
assembly points are meant for assembling all the people from the area to a safe location. In case of further escalation
of emergency situation, they can be moved to other safe location or outside the refinery. ) )
)
)
Steps to be followed for evacuation from affected area:
)
• On hearing the Fire Alarm, emergency siren & PA system announcement, all the persons working in the affected
area shall proceed to the assembly point accept the persons who are supposed to deal with the emergency
)
handling.
• Affected or rescued victims shall be transported to OHC for necessary medical aid by ambulance and/or by ORT
)
vehicle.
• The incident controller shall coordinate with security & HR for further mobilization from assembly point to other )
safe location or outside the refinery, if required.
• Security shall perform the headcount and shall inform to incident controller. )
• Incident controller will evaluate the incident, and give strategic direction to the Security for evacuation, if the
situation further worsens. )
• All the evacuated persons will return to their work location only after hearing the ALL CLEAR siren &
announcement on PA system. )
) )
Head Count
)
A "Plant Entry Register" is kept near the plant entrance / SRR / Operation Porta cabin for entry of names of the visitors
entering the plant areas. All the visitors except the plant field personnel on duty, are required to make an entry. During
an emergency, these visitors are required to assemble at the emergency assembly point. The security guard, who is
assigned the responsibility for head count at the specified assembly point will tally the entries with those present at
- j
)
the assembly point. Some of the visiting personnel who has entered their names in the register may be required to
take part in the emergency control activities. They will inform their presence to the Security Officer so that they are
accounted for. )
)
)
)
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CHECK L1ST·4
(Refer Regulation 13.0)
) ERDMP Response Measuresllnfrastructures
) SI,No Check-Point Yes or No Remarks

Zones, Maps and Layouts
) Does the location have Emergency Zones Clearly Identified for Yes
1.
Incident Prone Areas
) Do the maps indicate location of Emergency Assembly points and Yes
2. Emergency Control Rooms
) 3. Is the process Lay-Out Prominently Displayed . Yes
Does the piping and instrument Diagram include emergency Yes
) 4. control valves ,shutdown system, isolation valves, important
control valves etc.
5. Does the fire Hydrant Lay- Layout conspicuously Displayed. Yes
Man Power
) 1. Is the ERDMP Organogram Clearly displayed? Yes
Does the organogram include all duties to be attended in Yes
2.
) connection with an emergency?
Is the organogram includes key personnel by their names or work Yes, by position
3.
) position
Does it have alternate coverage to take care of the absence of a Yes, alternate
) 4. particular persons(incase organogram is developed basis Names) persons are
identified
) Does it include assignment of all key coordinators viz. the Incident Yes
5. controller, Administration and communication controller and safety
) coordinator.
Emergency Control Centers
) 1. Is the ECC well defined and clearly marked on the displayed layout Yes
Is it strategically positioned to be outside the periphery of Yes, it is in
) 2.
immediate affected area. OSBL
) Is the center have adequate communication channels including Yes
) 3. internal and external telephone connections, PA, Paging, VHF
systems.
) Is list of key Personnel and essential telephone nos. are Yes
4.
prominently displayed.
) The layout of the firefighting system, different hazardous zones, Yes
5.
and Assembly points are prominently displayed.
)
SI,No Check-Point Yes or No Remarks
) Emergency Assembly Points
Are the EAPs well-defined and clearly marked on the displayed
) 1. Yes
layout?
The EAPs have pre-Defined in -charges including emergencies
) that who keep in touch with the Emergency Control Centre and
2. Yes
administrative controllers and updated on the roll calion peoples
) reporting.
)
)
)
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9112·000·HSE·006·00048 Page 7401226 )
)
Chapter 8
EMERGENCY ORGANIZATION &
RESPONSIBILITIES )
) )

)
)
)
)
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)
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Chapter 8
EMERGENCY ORGANIZATION & RESPONSIBILITIES
---,
When an emergency situation is identified it can be difficult to initially judge the level and if not controlled quickly the incident
may escalate. The procedures have therefore been set using a single response structure which can be maintained and
expended as an incident develops and more people / resources become involved.
)
For any emergency requiring assistance of the fire team the initial communication will normally come to the emergency
)
management control room. They will mobilize resources and ensure appropriate communication via radio, PA system,
telephone, mobile, mass e-mails, mass SMSs or siren. The initial response will involve the following groups of people:
• Incident controller - this will initially be the field supervisor or most senior operation person immediately available in at the
) unit / area where the incident happens. As soon as RSS reaches to incident spot, he will take over the role of Incident
controller. If in an unfortunate circumstances, IC becomes a casualty, the seniormost person available at the incident site
) will assume the role of IC with all th e roles and responsibilities associated with the IC. He will then arrange to call the other
RSS from either the Refinery site or the township, who ever is available. He will handover the charge of IC onces such a
) person (RSS) arrives at site.
) • Fire Commander - this will initially be the fire engineer or leading fireman arriving with the first turnout fire tender. As more
senior people arrive this role can be handed over to a more senior person e.g. fire engineer or chief fire officer.
)
The two above people will establish a forward control location close to the incident scene and will stay together to lead the
emergency response. They will co-ordinate the response of the teams below and call additional support as required .
) The other groups who will attend in the initial response are:
) • Security team - Their initial key role will be to cordon off the area around the incident and assist with roll call of evacuated
people.
• Ambulance - The ambulance from the OHC will attend all emergency call outs attended by the fire team
)
) • Plant maintenance in charge - The person in charge of the maintenance like mechanical, electrical, instrument of the unit
) will attend the incident scene and take instructions from the plant manager / incident controller.
) The following other groups will also playa role in the initial response:
) • Emergency management control room - Will co-ordinate emergency communications and additional emergency team
support at the incident.
)
• Main control room / console supervisor - Will co-ordinate plant related activities including safe plant shutdown.
)
• Occupational Health Centre - Will diagnose and treat injured persons
• Security control room - Will co-ordinate the security response on site. They will also provide information as appropriate
)
from the CCTV cameras around the incident location.
)
• Fire Water Pump House - Will ensure adequate pressure is maintained in the fire water main to cope with the fire fighting
activities.
) Format No. 911 1-000-PCT-FRM-00006 Rev-OO
)
)
)
Revision 01
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HMEL 9112·000·HSE·006·00048 Page 76 of 226
)
Additional groups may be called as required e.g. technical services, Plant manager, HL, Admin, laboratory, warehouse etc.
)
If incident is of a serious or prolonged nature the RSS can declare a level-2 emergency where the disaster management control
room will be activated at SC3.
8.1 Emergency Organisation )
)
L10rganisation
)
In t id en t Contro ll e r il e)
- .. ._-- )
RSS
I )
)
t
FiT.. Se~urit v Plan.t I II nit-
Shift Fire In S hift Security Fie ld S up e.rY'i ~or )
ch<lrge Offi c .. r
)
Se eurit y Gu a rd s ] J
I )
l Fi ..ld Exe<:utive J PI.. nt M aint en .. n ee

<-entr.3J
( Con~l e
S up '!lv~or
1 )
M .. int en<lnce C r~...,
)
1 I I (
\
F'. 'lPH 1 )
l I
EM CR Ambul anc@
AFS
Memb ers
) [ Op erator ) l l Pump Operato r
J
)
)
) )
)
NOTE:
If the emergency escalates beyond Level-1, IC will assess the situation and decide to declare L2 emergency. He may
seek the guidance of HRO if required before declaring L2 emergency. Once a level 2 emergency has been declared
the relevant team will assemble in the Security Command and Control Centre to assist in emergency control and take
)
care of the wider more strategic issues. The structure will be as shown below:-
In case of non-operational areas like administration block, warehouse, ect., the safety district head will act as the plant
manager. )
Format No. 9111·000·PCT-FRM·00006 Rev·OO )
)
)
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)
)
L2/ L3 Organization
---..J
[ CEO/CO D 1_ __
) ~. --:---"'.,
)
Heads
) Procurement
) Plant Manager Field Supervisor
Fire Shift Incharge
)
Plant Maintenance I
1--'----------1r Conso le
--:==-----T--------,---------,r------=~~- =upervisor
Fire Operators
) AFS
~
) ~Ob;le
)
)
Note
) The term Head of H & S, Head Operations etc is used in the diagram above. This will be the most senior person
available at the time of the incident from that department. If the HR manager is not available then the Adim manager
) ) will take his place and if the Procurement manager is not available the Finance manger will take his place.
In silent hours, DCC operator will be called to DCC in case of need.
)
) 8.2 Key Roles & Responsibilities (Level·1) -'-

) In any incident there are two key roles at the incident site .
) i) Incident Controller:
) IC will initially be the field supervisor or most senior operation person immediately available in at the unit / area
where the incident happens. As soon as RSS reaches to incident spot, he will take over the role of Incident
controller. .
)
) The Incident Controller will be identified by Fluorescent Orange colored jacket with identification mark as "Incident
Controller".
j
Form at No . 9111-000-PCT- FRM-00006 Rev-OO
)
)
HPCL·Mittal Energy Ltd. Revision 01 I )

Issue Date 27.FEB.2018 I
Next Review I
9112·000·HSE·006·00048 )
Page 78 01226 I
)
Roles of Incident Controller:
1) On receiving the emergency message immediately rush to the spot of emergency and assess the situation
in consultation with Shift Field Supervisor of the affected plant.
2) Take the initial information from the person who has operated the BGU or has given the emergency message
or has witnessed the incident. )
3) Ensure safety of the personnel and evacuate them, if required , to assembly points or nearby safe location
and arrange for head count. Head count will be done by security personnel & data will be matched with data,
if available, with incident controller / plant manager.
4) . Initiate emergency control actions from the available resources of the plant. )
5) Manage all plant related activities in consultation with shift field supervisor / plant manager
6) Get additional operation and maintenance support. )
7) If situation warrants for shut down of the affected section / plant, ensure the safe shut down to control the
emergency. )
8) Advise Shift fire engineer for fire control and rescue measures . )
9) Arrange for maintenance team for maintenanc.e related activities . During silent hours and holidays mobilize . )
shift technician from maintenance group available at site. The team will be identified beforehand by the
Maintenance Manager.
10) Instruct security to barricade the affected areas.
11) If the situation is controlled, terminate the Level-2 emergency and declare "All CLEAR" in consultation with )
Shift Field Supervisor and Shift Fire Engineer.
12) After ALL CLEAR, ensure conditions are safe for restart-up. )
13) After the emergency is controlled take necessary steps for Environment Control and mitigation measures
for removal, segregation and disposal. )
ii) Fire Commander: )

Leading Fireman or Shift Fire Engineer will be Fire Commander. He will be identified by Red fluorescent jacket )
with identification mark as "Fire Commander". If level of emergency demands, Chief Fire Officer will reach to the
incident site & will take charge as Fire Commander.
)
Roles of Fire Commander:
)
1) Respond to the emergency call with Emergency Response Team in first turn out.
2) Report to Incident Controller at site of emergency.
'\ )
3) Decide line of control actions in consultation with Incident Controller / Shift Field Supervisor / Pre Incident
Planning for firefighting and other control actions including evacuation of the trapped personnel, search and
)
rescue.
4) Decide need of additional Fire tender, Rescue tender or additional firemen & instruct EMCR to do so. )
5) Arrange for rescue and transporting of casualties to OHC, if any.
6) After getting clear instruction from Incident Controller, instruct EMCR operator to sound emergency siren. )
7) In consultation with EMCR, keep track of all Fire personnel responding to the scene of emergency, who will
report first to Fire Commander at the scene of emergency. )
8) Coordinate with ambulance and medical team
9) Coordinating with security for road blockage activities. )
10) If deemed necessary ask Security to deploy additional Auxiliary Fire Services (AFS) for assisting ERT.
11) Keep track of Fire water network pressure & fire water pond level. If required coordinate with Shift Incharge )
- Utility for pumping in additional water through raw water pond to fire water pond for make-up.
12) Lead and guide the ERT and AFS members. )
13) Ensure safety of the ERT and AFS members.
14) Ensure the necessary equipment, firefighting appliances and consumables at incident site . )
15) Assess severity of the incident and if required, seek for second turn out / additional help.
)
Fo rm at No. 9111·000-PCT- FRM-00006 Rev-DO
)
)
Revision 01
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9112·000·HSE·006·00048 Page 79 of 226
)
16) Keep constant contact with Incident Controller /Shift Field Supervisor/Emergency Management control room/
) FWPH
---.J Note: The incident Controller & Fire Commander will be available at Forward Control Point (normally location of
first turnout fire tender)
)
iii) Additional roles:
)
a) Shift Security Supervisor / Officer
)
• Instruct and deploy security personnel at security posts / gates and around the affected area.
) • Mobilize the Auxiliary Fire Squad members to emergency site immediately on receiving emergency call by
QRT vehicle.
) • Keep track of all Security personnel and AFS members responding to the scene of emergency.
• Cordon off the area and guide traffic / emergency vehicles and control unnecessary gathering of persons
) around.
• Arrange for head count at assembly point and report to Incident Controller.
) • Ensure that assembly point is manned by security guard .
• Ensure that all person(s) gathered in the assembly point are lined up in discipline.
) • Ensure vigilance at security posts / gates and be in constant contact with and other members connected with
firefighting or rescue operation .
) • Mobilize for evacuation of personnel from assembly points to safe locations.
b) Maintenance in charge (Mechanical/Electrical/Instrumentation)
) • On receiving emergency message, report to Field Supervisor and be prepared for necessary actions at the
spot of emergency.
• Mobilize the resources required for controlling the emergency.
• Make available special equipment like crane, hydra, JCB, fork lift, gas cutters, etc. with operators, upon
) • Instruction from Incident Controller/ Shift Field Supervisor.
• Keep constant contact with Shift Field Supervisor and carry out required emergency control activities to
} terminate the cause of emergency.
• Record all actions and necessary blinding / isolation / bypass / closures etc. Also provide relevant labels /
) tagging / warning or other instructions for streamlining the emergency actions.
• If Maintenance manager arrives at the site, brief him and follow the instructions.
)
c) Shift EMCR Operator (Main Fire Station)
• On receiving an emergency message either by Console supervisor or through Fire Alarm Panel system,
) Walkie-Talkie, the EMCR operator will:
Activate turn out bell & inform to ERT about incident location.
) Inform to RSS
Inform to Medical
Inform to Security.
• After confirming about L2/3 emergency from Fire engineer; the EMCR Operator will
Inform to Chief Fire Officer
Send Mass SMS to all the concerned personnel mapped for receiving information during L2/3 emergency.
) Announce through Public Address system
Send emergency Email to all key personnel, whose names are defined as per the level of emergency .
• Guide turn out crew and vehicles for safe and shortest approach route from up-wind direction.
• Inform to Fire Water Pump House Operator and Auxiliary fire Squad (Security) .
)
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)
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)
• Keep in constant touch with Shift Fire Engineer for receiving instructions from time to time and act accordingly.
• Activate the emergency siren, as per the instruction of Fire Commander (Level-1 : Continuous wailing sound )
siren for two minutes, Level-2 siren: continuous siren of 8 minutes as 02 minutes RUN-01 minute STOP-02
minutes RUN-01 minute STOP- 02 minutes RUN &ALL CLEAR siren: straight siren for two minutes)
• After termination of emergency, activate ALL CLEAR siren / PA announcement after getting instructions from
Fire Commander& send ALL CLEAR message by Email / sms to all concerned personnel, whose names are )
already defined as per the level of emergency.
• Keep log of all activities performed with time. )
)
d) Field Supervisor
• Give priority to rescue of personnel before the arrival of fire team. )
• Start emergency control measures like cooling / fire extinguishment, before the arrival of the fire team
• Take stock of the Process conditions and actions needed to control the emergency. )
• Act in close liaison with the IC and initiate process control actions, including plant shut down
)
• Coordinate with the maintenance team for emergency maintenance related role .
• Direct the console supervisor for process control from the console.
)
• Apprise the console supervisor from time to time about the actions being taken to control the emergency.
• Ensure the plant area is safe before advising the Incident controller for ALL CLEAR. )
e) Console Supervisor )
• On receiving message from field or from Fire Alarm system, DCS, immediately inform Refinery Shift )
Superintendent, Shift Field Supervisor, Shift Field Engineer, Emergency management control room, Plant
Manager and other concerned parties to mobilize resources .
)
• Take necessary steps isolation/shut down of the area/unit through DCS.
• The designate console supervisor upon instruction from Shift Field Supervisor shall communicate to
)
maintenance in charge. During silent hours and holidays mobilize shift technician from running maintenance
group.
)
• Keep in touch with Field Supervisor and receive necessary instructions for control actions.
)
f) Occupational Health Centre - CMO or Duty Doctor
• Ensure ambulances immediately attend scene of incident
) )
• Organize medical staff to receive casualties and provide necessary medical treatment. )
• Treat and stabilize casualties
• In cases of multiple casualties prioritize them for further treatment )
• Ensure casualties are transferred to hospitals for further treatment as required
• Call in additional medical support as required )
• Keep in touch with fire commander and ambulance drivers for information on further casualties
)
g) Fire Water Pump House Operator
)
• Ensure all pumps operate as required to maintain fire water line pressure and take appropriate action on any
problems )
• Call for maintenance support in case of any problems
• Keep in touch with emergency control room for information on fire water usage )
)
Fo rm at No. 9111-000-PCT- FRM·00006 Rev-OO
)
)
)
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)
8.3 Key Roles & Responsibilities (Level·2 & 3)
In consultation with Plant manager & Fire Commander, IC will assess the emergency situation & if appropriate will
declare L2 emergency. He may consult the COO (or Head of Refinery) for seeking guidance, if required. Once this is
~
declared the following additional roles will come into operation
a) Chief Incident Controller (CIC) - HRO (VP·Operation if HRO is not available)

)
• Take command of Disaster Management Control Room at Security Command and Control Centre (SC3).
• Provide leadership and guidance to the major emergency management team.
) • Inform and appraise at regular intervals regarding the situation to CEO & COO.
• Take strategic and technical decisions in line with the incident scenario to mitigate the emergency.
)
• Ensure that all necessary support services are activated.
• Asses the effect of incident outside the GGSR premises.
) • Liaise with Railway establishment to stop the train movement in the areas outside the Refinery which are in
the likely affected zone.
)
• Liaise with the senior officials of Police, Fire Brigade, Medical and Factory Inspectorate, external technical
) agencies for help and provide information on possible effects to the surrounding areas outside the factory
) premises and necessity of evacuating the area and moving the people to safe places.
• Direct PRO through HL coordinator to deal with press and media about the emergency status.
)
• Declaration of termination of emergency & withdrawal of Onsite Emergency Management Plan.
• Initiate post-rehabilitation of the affected area.
)
b) Head of Operations
) • He shall report to DMCR.
) ) • Organize operational change, isolation of process equipmenUsystems.

• Identify the danger zone and inform to Incident controller through plant manager.
)
• Keep informing CIC on the progress of mitigation measures.
)
• Mobilization of additional man power for operation requirements.
)
c) Head of Technical Services
)
• On hearing of emergency siren or declaration on Public Address system he will report to Disaster
) Management Control Room
• Will give necessary technical back-up to CIC
)
• Will assist CIC / Manager HL in conducting press meeting.
)
• Will arrange for necessary additional documents and drawing at DMCR. He will be helped by the DCC
) operator
)
)
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)
.. Will assess the pollution to the environment due to the incident and ensure air monitoring of the affected
)
area is initiated if required .
• Liaison with PPCB Officials as per the instructions of CIC
o Will advise any additional precaution, to contain any emergency in Refinery. )
)
d) Head of Maintenance
• Report to Disaster Management Control Room and appraise to CIC the situation at site. )
• Provide expertise and engineering assistance to the Emergency Management Team. )
• Provide guidance to the Maintenance Chief Manager and Manager for necessary isolation of electrical
)
equipment etc.
• Arrange for emergency D.G. sets, light masts special tools and tackles, dewatering pumps, sand bags,
) )
heavy automotive equipment like crane, lifting machines and get them installed at strategic locations )
wherever required.
)
• Ensure additional facility and equipment that will be available all the time for mitigation of emergency is kept
ready. )
)
e) Head of Security
)
• Report to Disaster Management Control Room.
• Take charge of all security functions like mobilization of security personnel, threat analysis, and traffic )
control, evacuation of personnel and manning of gates. )

• Depute additional Auxiliary Fire Services members and track their reporting to emergency site to report to
)
the Fire Commander
• Ensure easy access to all key members' vehicles without hindrance/delay at the gates. ) )
• Ensure that all non-emergency vehicles plying on the road are parked at the road side, to make unobstructed )
way for emergency vehicles.
)
• Transport casualties in security vehicles, (if ambulance is not available) under the instructions from Medical
Officer / Incident Controller / Fire Commander )
• Ensure security personnel at main gate to escort mutual aid scheme vehicles to emergency site. )
• Guide evacuation of persons as per guidance of the incident controller and Chief Fire Officer.
)
• Ensure assembly point is manned by guard and head count of all personnel evacuated from affected area.
• Ensure orderly evacuation from assembly point to Safe place. )
• Liaise with local police under instruction from CIC and mobilize additional security force , if required. )
• Ensure assistance of Executive assistant to CIC by deputing a Security Officer to act as Radio Officer in the
)
DMCR to log all the incoming and outgoing messages and important emergency actions.
)
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)
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• Cordon-off Avenues and Streets around the incident site and establish alternate routes.
J
-.-J f) Head of H&S
• Report to Disaster Management Control Room.
• Carryout the strategic orders of CIC in line with firefighting, rescue , spill control and toxic release .
)
• Ensure healthiness of Fire water pumps at Fire Water Pump House.
) • Ensure the operability, facility, documents of DMCR to be ready for emergency
) • Advice CIC on issues related to safety, health and fire .

• Provide leadership and guidance to safety, health and fire team.
)
) • Liaison with OISD / PESO Officials as per the instructions of CIC
• Seek the support of Mutual aid under the guidance from the CIC.
) • Ensure that adequate safety and fire equipment are made available until the completion of emergency
operations.
)
• Arrange to mobilize PPE and other safety appliances from unaffected plants.
)
• Organize documentation of emergency scenarios using photography, video, etc., if instructed by CIC.
) g) Head of HL
• Report to Disaster Management Control Room and carryout the strategic orders of CIC.
)
e Depute responsible person to record names and dept. of the persons assembled during major evacuation
)
and assist in head count.
) . He will get the information from HMEL Security and Time office coordinator and ensure the head count at
assembly point.
)
• Coordinate to inform next of kin of the affected persons.
) } • Manage any press enquires and assist in providing press information once approved by CIC
) • Depute HL Representatives to the affected site for extending necessary help for emergency teams at site.
• Assign officials at various hospitals / clinics to look after the needs of victims admitted there.
)
• Liaison with the statutory authorities (Factory Inspector, Labor Dept., Etc.) as per the instruction of the CIC
)
• Arrange for blood donors from employees/ their relatives on the advice of Medical Coordinator as per the
) records available with HL Coordinator.
) • Provide leadership to the administration, welfare, transport and Public Relations in line with statutory
obligations.
)
• Arrange for transpo(l for shifting evacuees from assembly points to safe place.
) • Mobilize all the available company vehicles along with the drivers for emergency use.
) • Coordinate with neighboring industry/transport agency for additional vehicles/ambulances as may be

required .
)
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)
., Arrange alternate accommodation/temporary shelters for evacuated persons · with necessary food ,
refreshment, bed/blankets as per requirement.
• Arrange necessary food , soft drinks and other refreshments for the personnel engaged in the emergency
operation and ensure sufficient stock is made available. )
• Arrange refueling of various vehicles used in emergency.
h) Head of Procurement
• Report to Disaster Management Control Room. )
• Carryout the strategic orders from the CIC for supplying all emergency materials, equjpment, and other )
supplies as applicable.
)
• Liaise with heads of finance marketing and warehouse as may be needed
)
• Arrange for issue of materials from the Warehouse round the clock.
• Arrange transportation of material from the Warehouse to incident site. )

• Arrange emergency procurement from local dealers / vendors or from neighboring industries. Liaison with
)
Financial Coordinator for any approval or concu·rrence.
)
• Arrange emergency procurement from national/international vendors / suppliers if required. Liaison with
Financial Coordinator for any approval or concurrence. )
• Organize air lifting of above emergency equipment if required in concurrence with CIC.
)
• Ensure availability of materials. Liaison with all key vendors and arrange supplies like Safety equipment,
firefighting equipment, foam compound, medical equipment, medicines and other materials / consumable )
required for emergency control. )
i) Plant Manager
)
• Act in close liaison with the IC and review process control actions, including plant shut down.
• Coordinate with the maintenance team for emergency maintenance related role. ) )
• Ensure the plant area is safe before advising the Incident controller for ALL CLEAR. )
j) O'CC Operator
)
• Will be available at DCC and inform the HOD - Technical services over mobile about his presence at DCC
• Will make the required document available to the HOD - Technical services on his demand.
k) Recorder )
The Recorder responsibility will be to maintain a record of key information received from the incident or emergency
location and to record the actions initiated by the CIC and for implementing the emergency response actions )
below:
)
(a) To record key incident events/actions on incident status board/display.
(b) To ensure all status and information is up to date and correctly displayed. )
Display boards are provided at DMCR for Health & Safety, Technical services and Operations. Respective co- )
ordinators at DMCR will update their boards for the key information.
)
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)
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8.4 Communication Service
The alert is a first request for assistance, in principle, using alarms which are inside or outside the establishment. Any
~ witness to the beginning of an incident or of an anomaly which might lead to an incident should give the alert and act
with available means within the limit of his ability.
)
) The emergency message is communicated in any of the following manners:

• Call to EMCR on Tetra UHF system, phone or breaking the glass of nearby BGU (Manual Call Point).
)
• Reporting by Walkie Talkie after switching over its channel to Fire & Safety channel.
)
Caller to confirm the accuracy of the message (location of emergency) as repeated by EMCR personnel, wait for
)
acknowledgement from EMCR personnel and inform shift Console Supervisorl plant shift Incharge I Shift
)
) Superintendent at main control room.
)
Emergency siren & PA Announcement:
After getting a clear instruction from Incident Controller, Fire Commander will inform EMCR to sound the Refinery siren.
)
As per level of emergency siren coding is done as follows:
Level-01 Continuous wailing sound siren for two minutes .
) Level-02/03 Continuous wailing siren for 08 minutes as:
i) Sound the fire siren continuously for 2 minutes.
)
ii) Stop the fire siren for 1 minute.
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.
. )
ALL CLEAR siren: Continuous sound siren for 02 minutes.
) ) Test Siren Continuous sound siren for 01 minute (at 08:30 hrs . each morning).
' NOTE: Once Level-02 siren is sounded, Level-03 siren will not be sounded further even if the emergency escalates
to Level-03.
)
Township Siren:
) EMCR will inform township security (24 x 7 available) for sounding the siren.
Township Security will sound the siren (2 minutes wailing).
) Township security will write the incident description on white board and display at the township security gate
for the residents to see.
) On declaration of all clear, EMCR will inform township Security.
Township Security will sound the siren (2 minutes continuous).
) Township Security will then write "ALL CLEAR" on the white board and rub off everything after an hour
Test Siren: Continuous sound siren for 01 minute (at 08:30 hrs.' every Monday).
)
PA system: is available to make announcements refinery wide or as per zones as required during an emergency.
)
)
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Page 86 of 226
)
CHECK LlST·5
(Refer Regulation 14.2.1 (a)) )
Review and updation of ERDMP
SI.No Check-Point Yes or No Remarks )

1. Frequency of MOCK-Drills for practices, refinement and Updation Monthly drill
Are the records for periodic Mock Drills Maintained in a well Actions are tracked. )
2. Yes
Defined Format
After each drill whether assembly meetings involving all staff and Post drill the debriefing )
contract personnel are conducted to share experience to share the sessions are conducted to
3. event as also to identify the shortcomings and scope for further Yes share the learnings. )
improvement in procedures. Whether the issues are discussed and
the plan modified suitably. )
4.
Does the review ensures efficiency of the plan particularly w.r.t
Yes
)
response for refinement of the plan. )
Do the mutual Aid Members participate in the drills and based on District authorities
No Mutual aid
5. the actual response and difficulties experienced, corrective actions members participates. )
members
initiated for refinement of the plan
Does a procedure exist in incorporating the findings/leanings of the )
6. actual disaster management handling, if any so that the plan con Yes
revised accordingly. )
) )
)
)
Format No. 9111·000· PCT· FRM-00006 Rev-OO
)
)
Revision 01
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9112-000-HSE-006-00048 Page 87 of 226
Details on Mutual Aid
)
A formal Mutual aid agreement is there with "Talwandi Saba Power Ltd . & HMEL.
-)
)
)
) HM
)
) ) Unur::K03
)
OVIDIN
)
)
Format No . 9111· 000· PCT· FRM·00006 Rev·OO
)
)

Issue Dale 27-FEB-2018 I
9112·000·HSE·006·00048
NexlReview J )
Page 88 of 226 I
)
UNDERSTANDING BETWEEN ~El &TSPl

FORPf!OWIINOMIITIW.AUlSTAHCEIfFIREElllERGENCI
~
The IIl1IIersI3ndi1 IS exaeu!ed. by all
Inca!poraled IIlder )
)
ll\el be deemed 10 mI!M end 1~ their Idrrlniltta 011
Art. (TSf\~ ha.q b • cum )
OCCJlS IWII
)
OlHERPAAT.
)
\he ".ty~ )
IDr IllIl'q ) )
audI oil II1d Pft)CIudl
)
AocI ~ 1980 WI (6a0J3 ~ Thermal powtf BarIiMIIII, 0i;I ••
)
in )
II1d
)
)
NOWTH lHOERSTANOOfG WlTHi AS FOLLOWS:
1. )
_h ~'"1n
)
2. The
)
3
) )
)
)
)
)
)
Revision 01
)
HMEL • 9112-000-HSE-006-00048
Next Review
Page 89 of 226
)
~
)
---.J
/
) 4, 'J'ho Panes agree and ~ lhallhe ob9lIoo IllI1UUaIly cooperale IA'IdW IliI Unde~ "" be
OCClJrrence 01 51 IwnI 01 foIt$ . . .. The PaI1es urdmtJnl Ihal the pI'!Iformn:e undI!l
IdIjeI;t III
) ng may be pnI'/Mt!1d or dIII)'ld because 0'
~ epId-. ~. flood OIbeca.1se o/lIfIY Iat, ocder, ~
)
) lid Of delayed
) Nethor~. nor • ditedrn 01 repmen!8lJws ' " be il.I1yda;

~ at the OIhar PiIIfy cbI1g !Nt pa1I:rmaIU or 8I1Y of
) Undel1ta "tdiIO
) This ume..tlidiil\l WI! be \IC1IJd b' 8 periOd Of line Howewr,

e/IIler Pav rMIf try gIW1g • IIIItt!n IlOICe 0( 3() dIIys can
)
7. This ,liI'lding shall be made in two CIIIIt Ioreac/l Pili)'
)
s.
)
!his lJnIImla
~"
9; Comdelllldlty: e.:h PlIIy slid IllB'ItoIin In eooIdeIa In ~

that ~ uL.~ ill I'I'IIinIaiIilg b own confickntlal il/omIIcIcrt
)
WotmaIim Sl4lPhd 01
)
10. Amendment No ~ <II OI~ 10 any orlh8 ns cf this lbIemanding thai! be elIecM \I1I;I$S ,
) it Yltiling SId IIvned by or on bINI or
l ) WHEREOF. boCh the PaI1IeIIwet> hav& At lllelrhnl.and seal II)
)
II~
AGM (F$S). GGSR
)
Ian 'IlIorpe
)
,
VP{H4S). GGSR
) I} & FIdIIIy ~V. GGSR
)
Format No. 9111-000-PCT- FRM -00006 Rev-DO
)
)

Revision 01 I )
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)
)
Instructions to visitors Do's & Don'ts
)
Visitors are required to go through the security &safety video briefing at the Gate pass section. They will be handed over the
Visitors booklet at the gate. HMEL Host will accompany the visitor inside the refinery area and also on his/her return at the
main gate.
)
.. Donal ........ prMl.u....-.criNdb)' ... ~

)
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)
, =--e:~..::-,~::;,,'!!"~ GURU GOSINO SINGH REFINERY
SATHINOA
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)
)
)
Revis ion 01
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) 9112·000·HSE·006·00048
HMEL Page 91 of 226
) Chapter 9
~ INFRASTRUCTURE
)
)
)
Fo rmat No. 91 11·000·PCT-FRM-00005 Rev-OO
)
)
I
Revision 01
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9112·000·HSE·006·00048 )
)
Chapter 9
INFRASTRUCTURE )
9.1 DMCR· disaster management control room

Refinery is having a dedicated disaster management control room. This is a separate building at SC3 away from the )
plant area.This is of RCC construction . .
Following are the facilities at DMCR: )
• Base station walkie/talkie arrangement.
• Copy of ERDMP. )
• Layout of fire water network.
• Important telephone numbers of district authorities. )
• Refinery layout plan with areas in the vicinity.
• Telephones. )
• Dedicated computer to have an access to the SOPs, P&IDs through TOM S. ) )
• Refinery Plot Plan
• White boards to record the happenings.
)
• Electronic board to log on the events and send as a file.
This DMCR serves as the Emergency control centre both for the Onsite & Offsite emergencies. )
9.2 EMCR - Emergency Management Control Room )

Refinery is having a dedicated Emergency Managementg control room set up in the main fire station building. It is
manned 24 x 7 by a control room operator. )
Following are the facitities at EMCR
• Walkie Talkie base station )
• Telephones (2525, 2222)
• Mobile (8054923515)
)
• Plot plan
)
• PA system Control
• Fire Alarm system panel
)
• Siren control
• Important contact number list ,
)
9.3 Assembly Points )

Total 30 nos. of emergency assembly points are identified throughout the refinery comlex for the employees to
assemble in case of an emergency. Each assembly point is coordinated by an identified assembly point coordinator.
Following is the list of Assembly Points along with the assembly point coordinator.
)
Name of Assembly Point
Sr. No. Plant/Unit/Areal Location of Assembly Point Coordinator during
)
Building emergency
)
1 Site Office Building Security
Near Construction Sub-Station
2 TraininQ Centre In front of raining Centre entrance in green area. Security )
Main Administrative Security
3
Building Main Entrance-Near Security cabin-Left )
4 Laboratory In front of Lab Building entrance open area . Security
5 CDUIVDU East side of Caustic Tank T-1 01/De-Salter Security )
6 DHDT S-W Corner of DHDT Plant-Near Scarp Bin area Security
)
Format No . 9111-000-PCT-FRM-00006 Rev-OO
)
)
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)
Hydrogen & VGO Security
West side of SRR-03
7 Unit
8 VGO S-W corner of VGO Plant Security
~ 9 CPP 1.S-W corner of CPP near utility boiler. Security
2.CPP main entrance ,near GT-01 road Security
10 CPP
entrance.
11 MS-Block NW corner of the plant. Security
) 12 MS-Block Near SRR8 on road side Security
13 FCCU North side of plant. Near Entrance. Security
) 14 FCCU East Side entrance Security
15 Polypropylene Unit North of. PP Plant near blending silo-H Security
) 16 PP Ware House 1.N-E corner of PP ware house in open area. Security
17 Crude Tank Farm Nera CRT Office / Outside Control room Security
Road Tanker Security
18 Loading North side near barrier
) GantrylTank Farm
NW corner of OCU plant in open area. Near the Security
) 19 Delayed Coker Unit
future expansion area.
Sulphur Recovery N-W corner of the plant near plant entrance Security
) 20
Unit road .
Sulphur Recovery Security
) 21
Unit South side of plant
West side of the SS-27 open area opposite side Security
) 22 ETP
of the road
23 OMS Control Room North of OMS C/R Security
24 ROOM/CPU Unit East side of SS-28 in Open area Security
LPG/FG/Naptha Security
)
25 Treater & ATF SouthWest Corner of the plant in front of CT
Merox Unit
)
26 Air & N2 Plant West Side of the Plant below the Light Mast Security
27 Workshop S-E corner Security
)
28 Warehouse In front of MMC Bays Security
29 CRT Near SRR -1 /Crude Tank -551 0 Security
) 30 Rail Road Gantry East side of Rail, Road Gantry Security
)
9.4 Evacuation Of People
The evacuation of people shall be decided by incident coordinator based on situation at site. This may include
) partial evacuation or total evacuation from the site of incident or from the nearby areas of the Refinery.
The communication about evacuation shall be announced on Central P.A. System or P. A. System of Process Unit
) area or through hand held Megaphones.
Route of evacuation will be through main roads across the wind and specifically depending upon the individual
case.
) No short cut will be adopted unless communicated so by Fire Chief depending upon the situation.
)
All available modes at site shall be used for evacuation of persons from the site of incident to assembly/ Muster
points at safe location. .
)
)
)
)
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Chapter 10 )
DECLARATION OF ONSITE AND OFF-SITE ~
)
EMERGENCIES
)
)
) )
) )
)
)
)
)
)
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I HMEL Page 95 of 226
)
Chapter 10
) DECLARATION OF ONSITE AND OFF· SITE EMERGENCIES
.-)
Once the emergency call is received at either of the control rooms (EMCR or MCR), an emergency response is initiated and
emergency respondants reach the site of emergency. Shift Field Supervisor is the incident controller till the arrival of RSS
) RSS is informated, both by the EMCR as well as MCR. He becomes the Incident Controller when he reaches the emergency
site. He shall assess the situation and depending on his assessment, or on advise of the Fire Commander or Plant / Unit
Manager, declare L2 emergency. He may directly declare L3 emergency as per the demand of the situation. Since RSS is
available 24 x 7, the plan applies even during silent hours as well as holidays.
)
On declaration of L2 emergency, DMCR will come into effect and all the designated personnel will occupy the DMCR. Further
) decisions regarding the handling of the emergency will be taken by the CIC, who is based in DMCR.
)
When the emergency becomes catastrophic and the incidents starts affecting outside the refinery (L3) , the chief incident
) controller will inform the district authorities for implementing the offsite emergency plan.
)
)
)
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)
Chapter 11 )
,
RESOURCE FOR CONTROLLING ---;
)
EMERGENCY
)
) )
) )
)
Format No . 9111-000-PCT-FRM-00006 Rev-DO
)
)
)
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NexlReview
)
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)
Chapter 11
) RESOURCE FOR CONTROLLING EMERGENCY
--.J 11.1 Details Of Fire Fighting And Other Facilities Available
Fire Protection system of Refinery is designed to fight two major fires simultaneously anywhere in the Refinery at a flow of
approx. 7000W/Hr.
)
FIRE PROTECTION FACILITIES AT HMEL REFINERY
) Fixed Fire Protection Facilities
SN Fire Protection Facility Scope Remarks
) I
1 Fire Water Reservoir 50,000 m3 Two compartment each of 25,000 m3
2 Fire Water Pumps 15 no's 11 main (06 diesel + 05 electrical) + 04 jockey
) ) Distributed in all Refinery Complex based on
3 Double Hydrants on single standpost Entire Site
) hazard
Distributed in all Refinery Complex based on
4 Monitors Entire Site
hazard
5 Hose Boxes Entire Site Distributed at every alternate hydrant point
)
All along pipe rack and all plant & non-plant
6 Hose Reels Entire Site
building having more than one floor
)
Pumps, Un-insulated vessel, Columns, Air fin-fan
') Automatic/Manual Fire water spray system
7 Entire Site coolers, Atmospheric storage tanks, , Road and
(MVWS)
Rail loading gantries, bullets etc.
)
8 Automatic Fire water spray system(HVWS) Substations High capacity transformers
)
9 Semi Fixed Foam Pourer System Tank Farms Floating and Fixed Roof Tanks
)
10 Rim Seal Foam Package System Tank Farms All four crude oil storage tanks
)
Main Control Room, SRR, OMS C/R, CPP &
11 Clean Agent System Entire Site
Admn. building.
12 Fire Proofing Entire Site As perOISD-164
)
As per Electrical "Operation Philosophy of Fire
13 Fire alarm and detection system 4530
) Alarm System"
As per Electrical "Operation Philosophy of
) 14 Communication and Public address system Entire Site
Communication and Public address system"
I )
Mobile/First Aid Fire Protection Equipments/ Appliances
15 Foam Tender 4 Nos. Entire Site
) 16 Water Tender 01 No Entire Site
17 Foam Nurser 2 Nos. Entire Site
)
18 DCP Tender 3 Nos Entire Site
) 19 Emergency Rescue Tender 1 No Entire Site
Vehicle mounted oil suction unit (Gulley
20 2 Nos. Entire Site
) Sucker unit)
)
Format No. 9111-000· PCT-FRM·00006 Rev·OO
)
)
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HMEL Page 98of226 J
)
)
11.2 Details Of First Aid And Medical Facilities
Refinery is having well established Occupational Health Centre, with stabilization facility and 2 nos. of highly
sophisticated Ambulance. Doctor, nurse, helper and ambulance driver will be available round the clock at refinery.
)
)
After stabilization, the victim will be send to hospital at Bathinda where HMEL will be having an agreement to attend
)
for further treatments . For more than one victim, HR shall make arrangement for shifting the victim to Bathinda in
consultation with CIC. )
))
Medical facilities;Ambulances and Occupational health centre details are in the Annexure 02/03. Ambulances are
)
available in-house .
)
)
11.3 Emergency Communication Plan
)
Communication system is the back bone of emergency management system, which allows the un-interrupted
dissipation of information among the concerned groups dealing with the emergency situation . )
The following means of communication are available at refinery site:
)
i) Multi sensing intelligence detection system: refinery wide multi sensing detectors, ·about 5600 nos., have )
been installed covering all buildings, process buildings, SRRs, Electrical substations, warehouses. This system
works on automatic operation mode and raises the alarm in respective area panel & in EMCR on detection of )
ii)
any fire in these areas.
Break glass units (Manual call points) : total of about 560 BGUs are strategically installed all over the refinery
,
process areas & outside the buildings. Whenever an emergency situation is noticed, any person will break the \ )
glass of BGU , which will result in alarm in DGFAP of respective area as well in DGFAP of EMCR.
)
iii) Hydrocarbon detectors: hydrocarbon detectors, gas detectors are installed at strategic locations in the process
areas, which will sense the abnormal concentration of leaked gas or hydrocarbon & will give alarm in panel of )
respective SRR and MCR.
)
iv) Close Circuit TV cameras: CCTVs are also installed all along the periphery of refinery, on internal roads and
in process areas as well. These cameras will capture any abnormality and will give its image in SC3. Apart from )
Security cameras, we also have process cameras installed for process purpose whose images can be viewed
from MCR. )
v) UHF sets: All the key personnel are provided with UHF setsl Walkie-Talkie sets. Different groups 1channels )
are assigned for internal communication . In case of any emergency any person shall switch over to Fire & Safety
Chanel and can communicate the emergency message to EMCR. However, he should switch over to his )
assigned channel once the communication with EMCR is over.
)
)
Form at No . 9111·000· PCT- FRM -00006 Rev·OO
)
Revision 01
)
. Issue Date I 27·FEB·2018
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) 9112·000·HSE·006·00048 Page 99 of 226
)
vi) PA System: Pre- recorded messages as well as manual messages related to various emergencies like toxic
gas release, fire, etc. will be announced through PA system unit wise & whole refinery depending upon the
situation & necessity from EMCR Or from Main control room. This system also has the facility of beacons (visual
-; strobes indications) to alert people working in high noise areas where audibility is not good.
vii) IP Phones: LAN based IP nos. are installed in all buildings, SRRs, Substations, etc for communicating any
emergency message to EMCR .
.l
viii) Intrinsically safe (IS) Mobile Phones: Key personnel are equipped with intrinsically safe mobile phones for
) communicating the emergency to any concerned person or agency or dept.
) ix) Emergency Siren: Four nos. of emergency sirens, at Fire Station, at SS-28 (ROOM), at SS-24 (near OMS C/R)
and at Township are installed, which will be sounded as per the requirement of level of emergency.
)
) 11.4 Communiciton Matrix
11.4.1 InitiaL Communication Matrix in case of L1 Emergency

)
)
or messenger
)
}
- -~
) Plant Manager (_. Plant Maintenance •

. .. - - ~ .-
Security Control Room

)
)
FWPH Operator
H & SHead
\ AFS (Security)
Central
Maintenance
Crew
)
Note: Eledrical & Instrumentation Head will ensure the availability of the communication system in healthy condition during
) an emergency.
)
) Format No. 9111-000-PCT-FRM -00006 Rev-OO
)
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I
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)
11.4.2 Initial Communication Matrix in case of L2 Emergencies
Message from RSS

}'erbal
Shift Fire In charge
'l
\
)
)
Security Control Room
)
FWPH Operator I
)
AFS (Security)
Chief Fire Officer
)
H&S Head
)
DMCR Members )
11.5 Safety Equipments )
The following safety equipment is available; ) )
• Safety showers in the plant areas. )

• Portable and fixed detectors for monitoring H2S, Hydrocarbons, 0 2and CO levels.
• PPEs are available in the unit PPE cabinets. Back up stock is available in the warehouse. )
• Emergency handling SCBA sets are available in the units and Fire station store.
• Fire proximity suits. )
• Chemical protection suits. )
)
)
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)
CHECK LIST ·6
(Refer Regulation 17.0(5))
Availability of Resources (Internal/External)
}
) Details of firefighting Equipment of the location incorporated in the
1. Yes
DMP
Information on critical resources like no. of fire hydrants, water
2. monitors, f ire fighting pumps, static water storage, portable Yes
) firefighting equipment's and foam systems are included
3. Available resources as per Schedule -4 Yes
) Location has storage of water for hours firefighting .incase water
4. Yes As per OISD-116
availability is less ,plan for replacement from nearby sources
) ) Details of drainage system including oil water separator is
5. Yes
available in DMP, wherever applicable.
6. Requirement and availability of personal protective equipment's. Yes
Whether manpower available during regular as well as idle shift
7. Yes
hours including security personnel clearly indicated.
)
External and internal Resources for combating Emergency
)
Does the plan enumerate the following resources available
) internally with the location as also from external agencies including
Mutual aid Members and Gov!. agencies like fire brigade, police,
) Municipal authorities etc.
1.water Foam Static reservoir as also mobile water tankers
2.Fire Hoses
3.Specialized nozzles e.g .. Fog, jet, triple purpose
) 8. 4.Mobile water Monitors Yes
4.Fire Extinguisher type and capacity
) 6.water Gel blanket
7.Foam compounds
) 8. First Aid material. Medicines, stretchers
J 9.Mobile or fixed ladders
10.Vehicle available
)
Trained Man power for combating emergency.
9. Any other resources considered necessary No
J
)
) Format No. 9111-000·PCT-FRM-00005 Rev-OO
)
)
)
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)
SCHEDULE -IV
(Refer regulation I 1.2)
)
Resource Mobilisation (Men and Eqnipment)
S.N Total Requirement Available with Neighbouring Civil

Installation Units Authorities )
1 MAN POWER
Regular employees -shift wise 12 (Emergency
res ponse team)
Security staff 65 in General shift )
45 in each shift
Personnel trained in first aid 200 )
Others (Techni cians /Helpers) 02
2
FIRE FIGHTING ) )
APPLIANCES/EQUIPMENT/CHEMICALS
Fire tenders /Fire fi ghting engines II Nos. 02 03 )
Water Storage Capacity 50,000 m3
)
Fire Hoses 900 200 100
Jet/Fog/Spray Nozzles 400 )
Foam Branch 30
Jumbo Jet Nozzles - )
Foam Compound (kl ) 75000 Ltrs.
)
3 SAFETY EQUIPMENTS
PV C Suit 20 )
Compressed air B.A set 70
Refill cy linders for B.A set 100 ->
Cascade B.A Set IS
)
Fire proximity Suit 20
4 COMMUNICA TION )
Walkie -Talkie II Nos. with Fire and
sa fety ))
Public Address System Installed
Megaphone 06 )
5 TRANSPORT
Jeeps 02 )
Cars Ava il able
)
Ambulance 02
Trucks N il )
Buses 08
)
Tractors Available
Boats N il
)
Mobil e cranes 02
6 MISCELLANEOUS )
Rop es(Meters) 10
E mpty drum s 50
)
Forma t No. 9111-000-PCT-FRM-00006 Rev-OO )
)
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)
Buckets 10
) Sand bags 50
Dewaterin g pump 05
) Pneumatic pump 05
Photo camera I
)
Video camera I
) 7 EQUIPlYIENTS FOR CORPS DISPOSAL
Light metal stretch ers 2
Tarpauline 12" X 12" 2
Rop es fibre 3/8" 2
)
Bucket 10
) Rubber g loves 50
)
L~TOFElYIERGENCYDRUGSAND MAX hospital
8
APPLIANCES
Canvas Stretcher ROHC-2,TMC-I Avai labl e Available
) Oxygen Cy linders ROHC-4,TMC-2,IN Avai lab le Ava ilable
AJvfBULANCE-2
Steril e Bandages 60 PACKETS Avai lab le Availabl e
Cotton Steri lised 85 Avai lab le Ava il able
) Antibiotics AVAILABLE Ava ilab le Ava ilable
Analgesties AVAILABLE Ava il ab le Avai lab le
)
Sedatives AVAILABLE Ava il able Available
) Tetanus Toxoid AVAILABLE Avai lab le Ava ilab le
Dressing Instrum e nts AVAILABLE Available Avail ab le
) Steri Iisers ROHC-I ,TMC- I Ava il ab le Ava ilabl e
A utoclave fo r sterilis ing Instruments, dress ing ROHC-2,TMC-l Avai lab le Avai lab le
)
B.P. Apparatus ROHC-6,TMC-2 Avai lab le Ava il ab le
LV Set 60 Avai lab le Available
) Antishock drugs AVAILABLE Availab le Avai lab le
) Avai lab le Avai lab le
Gluco saline set 60
Gluco saline Bottle I SO Ava il ab le Ava ilable
) - -
) Fo rm at No. 9111-000-PG-FRM·00006 Rev·OO
)
)
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,
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).
Chapter 12 )
DEMOGRAPHIC INFORMATION
)
)
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)
Chapter 12
DEMOGRAPHIC INFORMATION
-,
)
12.1 Metereological And Baseline Data Baseline Status
In Environment Impact Assessment (EIA) studies, it is important to know the baseline status of environment. Only
)
when the baseline status is known , it is possible to superimpose the projection of impacts to assess the overall
)
environmental impacts.
)
Collection of baseline data is a collective effort. Considering the nature of the project and its sensitivity to the area, a
)
) scientifically arranged baseline survey is required for establishing the actual baseline environmental status of the area.
Understanding this, a baseline data collection agency, MIs. Mantec Consultants Ltd ., an approved laboratory for
) analytical analysis by MOEF, was entrusted to collect baseline environmental data. Spatial distribution of the study
area of 10 km radius with project at centre has been considered for the purpose. The study has been done over three
)
(non-monsoon) Seasons to cover the Temporal variation . The three seasons during which the baseline environmental
) data has been considered are;
) 1st Season June-July, October & November 2007

(Post Monsoon Season)
)
2nd Season December 2007 to February 2008 and
(Winter Season)
) 3rd Season March to May 2008

(Summer Season)
)
I )
) This data was supplemented by specialized environmental studies carried out for different purpose at various stages
of the refinery and governmental records.
)
)
The following subsections describe the existing environmental status around the Refinery Complex of GGSRP.
)
12.1.1 Climate and Meteorology
)
The climate of India can be broadly divided the four climatic phases namely summer, post monsoon, winter and
) monsoon . However, for all air pollution applications, the seasons are restricted to all non-monsoon seasons.
) An automatic continuous meteorological data logger was installed near the project site. Hourly ambient temperature
at Tow heights, wind speed, wind direction, Relative Humidity and Rainfall was monitored for the whole study period .
)
The temperature was recorded at 2 m and 10m level.
) The brief details of instruments, parameter and freq uency are presented in Table below.
Format No. 9111-000-PCT- FRM -00006 Rev-DO
)
)
)
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)
Instruments, Parameters and Frequency of Meteorological Monitoring at Site
Parameters Instruments Frequency

)
)
1 Wind Speed
Automatic Weather Continuous
2 Wind Direction )
Station Automatic,Hourly
Ambient Temperature at Two )
3 (Envirotech WM 251) average
Heights 2 m & 10 m
Daily at 08:30 & 17:30
) )
4 Max. & Min Temperature Wet & Dry Bulb Thermometer
1ST )
Daily at 08:30 & 17:30 )
5 Humidity Hygrometer
1ST
)
6 Rainfall Rain Gauge Daily
)
The summarized observations for the three seasons are as follows )
)
1st Season June· July, October & November 2007
The results and analysis of the field observations based on the Data collected for the various parameters are as )
follows: )
Ambient Temperature
)
The observed annual minimum, maximum and average temperature was 8.20C, 41.800C and 250C respectively.
Relative Humidity
) )
The annual minimum, maximum and average relative humidity is recorded at 25.9%,69.10% & 47.5% respectively. )
Wind Speed
)
Analysis of hourly wind speed shows that the winds are generally light to moderate in this area. The annual mean
wind speed varies from 0.00 to 17.0 Km/hr. )
Wind Pattern
)
The wind rose diagram for seasonal has been drawn on the basis of hourly wind speed and direction data. During the
post monsoon season the wind direction were NW (15.25%), W (14.2%), WNW (11.40%) and in pre-monsoon season )
the wind direction were WSW (12.37%), SW (11 .9%). The seasonal wind rose diagrams are presented in Figure. )
Cloud Cover
)
Analysis of hourly cloud cover shows that the maximum cloud cover is in the months of June and July.
)
')
)
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) 9112-000·HSE·006·00048 Page 107 of 226
Summary of Meteorological Data Recorded at Site
(June 2007; Oct. to Nov. 2007)
Temperature, Relative
J Rainfall, mm Wind Speed, Km/Hr
°C Humidity, %
.c Vl
C >- (I) >-
0 - b.O ro c
) 2
Min Max
..c
-+oJ
ro
"- Min Max
C
ro Cl rnrn
-+oJ .....
c x
ro ro
(I)
C (I) (I)
>- o .~ ~ ~
o > ~ C I- ro ~
) ~. « ro
c::
c::
June 25.0 41.8 33.4 35.1 69 .1 52.1 - - 0.0 7.9 4.0
)
Oct. 25.6 41.3 33.5 35.1 55.0 45.1 - - 1.6 3.9 2.7
)
) Nov. 8.2 29.5 18.9 25.9 66.1 46.0 - - 0.0 17.0 8.5
) Figure: Wind-Rose Diagram for Post-Monsoon
)
LOCATION·BHATINDA WINDROSE-DIACRAM START, 01/ 1012007 00,00
SCALE: 03.0 % per em. END , 0111112007 24,00
-
Speed
Ranges
) <KM/Hr)
.1..8
) 7.2
~
) .1.4.4
) Irmr::rrrmm
28.8
I
)
ALL STABILITIES
) CALlIl(% ),68.0
DIRECTION, FROM
<c> -ENUI-ROTE-CH Inst:YUMents (P) Ltd ... New Delhi.

)
) Format No. 9111·000· PCT· FR M ·00006 Rev·OO
)
)
)
Revision 01 I
I
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9112·000·HSE·006·00048 Page 108 of 226
)
Figure: Wind-Rose Diagram for Pre-Monsoon
)
ILOCATION-BHATINDA WINDROSEROSE DIACRAlII STRAT:0810612007 . 00:00
=s CALE: 03.0 % per em END: 081071'2007 24:00
Speed )
-
Ranges
(KMI'Hr)
1..8 )
7 .2 ) )
~ )
1.4.4
If ::::::::::::::::::::::::! )
28.8
I I )
)
~ STABILlTES
ICALl'tI(%);62.2
IDIRECTION:FROIII
)
(c) ENVIROTECH InstruMents (P) Ltd, New Delhi.
)
)
2nd Season December 2007 to February 2008
Table: Summary of Meteorological Data Recorded at Site )
(Dec 2007; Jan to Feb 2008)
)
Rainf Wind I
Temperature, Relative ) )
ali, Speed,
°C Humidity, %
mm Km/Hr )
.c
III
C > >
0 <ll
ro )
~
-
..s::
.p.o
b.O
ro
....
I:
ro 0 roro
.p.o ....
I: X
ro
I:
ro
Min Max I: <ll Min Max <ll > o .~ ~
<ll
o > ~ I: I- ro ~ ~ )
~<! ro c:::
c:::
Dec 6.0 29.0 17.5 36.5 79 .5 58 - - 0.0 9 .9 4.9 )
Jan 6.0 27.5 16.7 62.0 32.0 47 - - 0.0 11.0 5.5 )

Feb 8.9 30.9 19.9 40.8 99.0 69.9 - - 0 .0 8.0 4
- - - ._ - -
)
Format No. 9111-000-PCT- FR M-00006 Rev-OO )
)
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)
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')
The analysis of the field observations based on the Data collected for the various parameters is as follows:
) Ambient Temperature
---; The observed annual minimum, maximum and average temperature was 6.0 OC, 30.9 OC and 18.450C, respectively.
Relative Humidity
)
The annual minimum, maximum and average relative humidity is 36.5%, 99.0 % & 67.75% respectively.
) Wind Speed
)
wind speed varies from 0.00 to 11.0 Km/hr.
)
Wind Pattern
) , The wind rose diagram for seasonal has been drawn on the basis of hourly data on wind speed and direction. During
)
the winter season, the wind direction were NNW (12.87%), N (11.40%) and S(6.9%). The seasonal wind rose
)
diagrams are Presented in Figure No. 3.3.
) Cloud Cover
) Analysis of hourly cloud cover shows that the minimum cloud cover is in the months of January and February.
3rd Season March to May 2008
)
.)
Figure: Wind-Rose diagram for December 2007 to February 2008
~
)
-
Speed
Ranges
) (K,.,/Hr)
1..8
) 3 .6
)
) 7 .2
~
~4 . 4
)
Fliii1
29.9
) c=J
) Locat ion: Bhatinda
All Stabl 1 i ties. Scale : 05 . 0 X
Direct ion: Fron

) (e) ENUIROTECH InstrUMents (P) Ltd~ Ne~ Delhi.
)
)
Revision 01
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HMEL 9112·000·HSE·006·00048 Page I 110 of 226 )
)
The analysis of the field observations based on the Data collected for the various parameters is as follows:
Ambient Temperature
The observed annual minimum, maximum and average temperature was 20.0 OC, 44.4 OC and 32.20C, respectively.
Relative Humidity
)
The annual minimum, maximum and average relative humidity is 14.0%, 99.0% & 56.5% respectively.
Wind Speed )
)
wind speed varies from 0.1 to 15.0 Km/hr.
Wind Pattern
The wind rose diagram for seasonal has been drawn on the basis of hourly wind speed and direction data. During the ) )
pre-monsoon season, the wind direction were NNE (12.8%), SW (12.2%) and WSW (11.19%).The seasonal wind
)
rose diagrams are presented in Figure No. 1.4
Cloud Cover )
Analysis of hourly cloud cover shows that the cloud covers are maximum March month. )
)
Figure: Wind Rose Diagram for the Third Season
~~I) l ,l(l~~, Q!(III)O

)
'1VIND ROSE DIAGRAM liAoIl;3l.(O ~i2 'fn. ~~lOO
)
)
Sp.-d )
Roliifi1JYa
(t{IV"H t' )
~ ~~w~_ A I-I )
)
)'
)
20.0
lhr.ation ; Dh~ )
S IDe ~OO"'l1. pf:l'cm
Al I St.ob i I H : lc=.
C D IM( X )~ 3<:.9 )
h ' l!!c; 1; 19n : F r_
c) II n!rt t-UM c n't:!:i ow
)
Form at No . 9111-000-PCT- FRM-0 0006 Rev-DO )
)
!. )
Revision 01
)
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) H MEL 9112·000·HSE·006·00048 Page 111 of 226
( )
12.2 Details Of HMEL Bathinda Refinery And Its Surroundings
Site Location
1
Guru Gobind Singh Refinery is located in southern part of Punjab at a distance of approximately 40 km from Bathinda,
( ) near Phulokhari Village in Punjab. The site is located about 400 kms from Delhi between 29 11 33' and 30 11 36' North
Latitude, 74113S' and 75 11 46' East Longitude is at an elevation of 203.4M above Mean Sea Level and spread over an
( )
Refinery Area of 632 Ha, Green Belt Area 120 Ha and Water Block of 175Ha. It is accessible from N.H .64 directly by
)
link road of 17km distance. While most of the tank-farms are located to the south and south-east of the process-
) facilities , the Crude Oil tank farm is situated to the north-west, while both the road and rail-loading gantries are situated
along the eastern perimeter of the facility .
)/ )
Mean Wind Speed during post monsoon season (June 07-Nov 07) is S.5km/hr (0.0 to 17.0) ,Winter season(Oec 07-
) Feb OS) is 5.5 km/hr(O.O to 11) and in Summer Season (March OS to May OS) is 7.55km/hr (0.1 to 15).
) General Wind Pattern during post monsoon season is NW, W & WNW, Winter Season is NNW, N & S and Summer
season is NNE,SW & WSW.
RAMAMANDI
) LOCAL PLANNING .AREA
EXISTING LAND USE PLAN·2010
)
..--_---.
1=...._..
--
_-.-~
-- I _~-
)
)
)
)
I- -
) ...-
I'-.--rai, a.uc... .
~
) 1
---
_ --,
.... --
.-...-
1-
-_.
)
J-
)
)
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9112·000·HSE·006·00048 Page 112 of 226 )
)
Layout of Bathinda Refinery and its Surrounding Villages )
ijleaoa Qj)
)
Se~h u
Talwa'nBiSa
KAm~lu
)
J~jj81 )
cp
,dna G
Ph~lIo
Ram"ra
6 \ ) )
M,lkana
Guru Gobind )
Nsurall{j 0
Singh Oil Rennery
Khokhar
cp HaUl!
51
)
)
Gians
Jogiwaia
Asir
)
Panna
Oesu·Malkan.
II )
Knokhar Kewal
Pipli )
)
Nearby Villages (In the vicinity of the refinery)
) )
1. Ramsara
2. Raman )
3. Phullokhari
4. Kanakwal )
5. Hassu
6. Naurang )
)
)
)
Revision 01
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) Issue Date 27-FEB-2018
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) Villages near Guru Gobind Singh Refinery (Punjab)
(Records as per Census 2011)
Village Name Bagha Chak Hira Singh Giana Jajal Kanakwal
Population 2105 2160 4367 3229 2918
')
Male 1095 1116 2336 1684 2066
Female 1010 1044 2031 1545 852
)
Number of 618 417 853 586 679
Families
Literacy 589 972 1730 1556 1693
) Area (In hal 1153 869 1875 838 1189

Development Talwandi Saba Sangat Talwandi Saba Talwandi Saba Talwandi Saba
) Block
Sikh/Hindu Sikh/Hindu/Muslim Sikh/Hindu/Mu slim Sikh/Hindu Sikh/Hindu/Mu
Major Religion
) slim
) Occupation Pottery Work/ Cloth/ Tool s for
other Carpenter/ Cultivation/Service/ Shops/Service Shops/Service Shops/Service
)
then Agriculture Service/ Shops Black Smith/Shops
Distance from
)
Refinery 6 15 3 10 3
(approx. in kms)
Main Road Bathinda - Bathinda
Bathinda Dabwali:6 Bathinda -Dabwali :5 Bathinda-Rauri :8
(Nearest in Kms) Sardulgarh :l0 Sardulgarh:12
)
Railway Station
Raman Mandi:2 Raman Mandi 12 Kilanwali Raman Mandi 5 Kanakwal
(Nearest In kms)
)
Villages near Guru Gobind Singh Refinery (Punjab)
(Records as per Census 2011)
)
Village Name Phulo Khari Raman Ram Sara Sekhu Sukh Laddi
Population 2308 . 21643 16526 5000 2656
)
Male 1201 11556 14930 2629 1410
Female 1107 10087 1596 · 2371 1246
> 1.08:1 1.15:1 9.35:1 1.11:1 1.13:1
Ratio
) Number of
555 N/A 5089 950 517
) Families
Literacy 974 13231 3708 2407 1108
Male 564 7280 3457 1428 747
) Female 410 5951 251 979 361
Ratio 1.36:1 1.22:1 13.78:1 1.46:1 2.07:1
Area (In hal 1192 N/A 576 1919 800
) Development
Talwandi Saba N/A Talwandi Saba Sangat Talwandi Saba
Block
) Major Religion Sikh/Hindu Sikh/Hindu/Muslim Sikh/Hindu/Muslim Sikh/Hindu Sikh/Hindu
Wheat/Cotton Wheat/Cotton Wheat/Cotton Wheat/Cotton/Rice Wheat/Cotton/Ri
Major Corps
) Rice/Maize Rice/Maize Rice/Maize ce
Pottery Work/
Occupation other
Shops/Service Shops/Service Shops/Service Carpenter/ Black Shops/Service
) then Agriculture
Smith Service
Format No. 9111-000-PCT-F RM -000 06 Rev-DO

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Distance from
Ref:(approx.in 5 7 3 11
kms)
Main Road Bathinda Bathinda Bathinda Bathinda Dabwali:9 Bathinda

(nearest in kms) Sardu lgarh:8 Dabwali:23 Sardulgarh:4 Dabwali:17
Railway Station Kilanwa li: 3 Raman Mandi :7 Raman Mandi:3 Raman Mandi:l0 Raman Mandi:6
(Nearest In Kms)
)
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Chapter 13
J MEDICAL FACILITIES
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Chapter 13
MEDICAL FACILITIES
Details for the medical facilities at refinery OHC and Bathinda city is as under;
)
We have three beds in OHC and extending three more beds with all lifesaving medical equipment like ECG, Oxygen
concentrator, cardiac monitor, suction machine, ventilator with defibrillator, crash cart and all emergency medicines to meet
)
demand in any emergency situation in refinery .We have two ACL8 ambulances fitted with all lifesaving equipment to transport
critical patients to the nearby tertiary care hospital in Bhatinda .
)
Doctor and paramedical staff on duty will send the ambulance at the scene site and immediately call to CMO, other medical &
paramedical staff and ambulance drivers to reach to OHC as soon as incident notification has been received. Doctor and
)
paramedical staff on duty will prepare for all emergency equipment and medicines and prepare for casualties.
) )
Transportation of casualities
The ambulance will be called as per attached list of ambulances from hospitals and from private institutions .As we have a tie )
up with different major hospitals a proper agreement has been made with the hospitals to treat the patient on priority basis.
The proper training for transportation of the patients to ambulance and treatment en route has been given to all doctors, )
paramedical, fire team and ambulance drivers.
)
Trained first Aiders
Emergency response team and other refinery employees from operations and maintenance are trained in First Aid. Their list )
with contact details are available with the refinery OHC .
)
Details of thte nearby Medical facilities like hospitals, Ambulances, Clinics, are available in the Annexure 2 & 3
)
First aid box details: )
SRR-1 crude tanks MCR HGU S8-16 Nitrogen cooling tower )
CRT warehouse 88-19 ground floor DHDT porta cabin Mounded bullet 8S-14 )
CRT Main area DCU VGO-HDT porta cabin OM8 control room ) )
Paid canteen DCU SRR-5 Cooling tower 8S-23 Offsites 8S-24 )
CDUIVDU 8RR-2 FCCU porta cabin FCCU S8-22 Tankfarm 8RR-7B
CDUIVDU 88-15 S8-18 for DCU FCCU SRR-6 Tankfarm 8RR-7A
M8 Block 8RR-8 HGU 8RR-3 Nitrogen plant Offsites 88-21 )

VGO DHDT S8-20 8ecurity Kanakwal gate SRU SS-26 8RU 8RR-9 )
Rail control room CPP 8RR 10A/B CPP Porta cabin CPP S8-10
)
CPP control room RODM 8S-28 Security Phulokhari Gate Fire Station )
QRT% 8ecurity main gate Material gate Training centre

)
- - - - - - - L- _ _ -_ . -
Fo rm at No. 9111-000-PCT-FR M-00006 Rev-DO )
)
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Laboratory Admin building (02) Security Car (03) Main canteen
Warehouse (04) Workshop (02) Security product gate PPU SS-17

)
PPU SRR-4 PPU warehouse PPU Extruder
These first aid boxes are checked on a monthly basis.
Emergency medicines and antidotes are available with the OHC.
)
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Chapter 14
EVACUATON )
) )
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)
Format No . 9111-000-PCT- FRM-00006 Rev-DO )
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Chapter 14
EVACUATON
)
In a major accidents / disaster, it may become necessary to evacuate people from and around the area likely to be
affected by accident. Sometimes, the evacuation may have to be made to safe places within the complex area itself,
)
At other times, however specially in cases of catastrophic disaster, it will be necessary to shift the entire population
, ) outside the complex area to certain pre-designated places in Bathinda, fixed in advance, The task may be difficult, as
there will be no notice or very short notice of a calamity, there may be failure of electricity, and there may be shortage
of manpower resources.
)
14.1 Evacuation Of People
)
The evacuation of people shall be decided by incident coordinator based on situation at site. This may include partial
) ) evacuation or total evacuation from the site of incident or from the nearby areas of the Refinery.
) The communication about evacuation shall be announced on Central PA System or through hand held Megaphones .
Route of evacuation will be through main roads across the wind and specifically depending upon the individual case.
)
No short cut will be adopted unless communicated so by Fire Chief depending upon the situation .
) All available modes at site shall be used for evacuation of persons from the site of incident to assembly/ Muster points
at safe location .
)
14.2 Search and rescue plan
)
Overallincharge is the Site incident controller in consultation with fire commander.
) Control of Non-Essential Personnel during Search & Rescue Operation
In order to ensure smooth and effective search and rescue operation during emergency control of non-essential
)
personnel also plays a vital part.
) Security will ensure removal of non-essential personnel from the site for the above job.
)
) Search and Rescue Operation During Off Site Emergency
) During off site disaster, rescue and search operation will be carried out under the guidance of Dy. Superintendent of
Police, Bathinda as per off site emergency plan approved by DM.
)
)
14.3 Requisitioning Of Buses/Trucks: -
)
The Deputy SP, Bathinda will act as the commander-in-charge of evacuation, He will determine in consultation with the
) COEC the extent of evacuation necessary in view of the likely hazards of disasters. Once this is decided, the next job
would be to effect necessary evacuation as soon as possible. For this evacuation commander will requisition all
) available buses and trucks. A list of such vehicles should be prepared in advance and kept ready. For this purpose he
may also requisition buses from PSRTC. For ordering evacuation it will be necessary to fix pick up points in different
) areas in advance so that the residents wil l know where exactly to board the buses. The buses/trucks will be lined up at
these points for shifting to safe places .
)
The entire area to be evacuated should be divided into convenient sectors and each sector should be placed in charge
) of a senior officer, whose duty would be to ensure that all persons in this sector are compulsorily shifted . Help of security
police staff should also be taken in achieving this task, if considered necessary.
) Format No. 9111-000-PCT-FRM-00006 Rev·OO
)
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Repeated announcements should be made over mobile vans, fitted with mikes, directing people to evacuate immediately
)
and board buses/trucks at pick-up points, which should be earmarked in advance. The routes by which evacuation will
be made from different areas to Bathinda will be fixed in advance. The drivers of buses/trucks will be informed about
their role and also about their destinations, where the residents have to be off-loaded . In the case of shifting to Bathinda,
the Chairman of Bathinda Municipality should be informed for keeping the places of accommodation ready to receive
)
evacuated persons and also to make other arrangements. Sheltering of shifted people will be taken care of by the
Bathinda municipality, which will also make arrangement for their food, drinking water, sanitation etc. After completing
)
one trip, buses/truck will go back immediately, without losing time, to make another trip for picking up other persons.
This process will be continuous till the entire work is completed. Quick and timely evacuation will save lot of lives and
therefore, the Evacuation commander will have to plan this job very meticulously. Nothing should be left to chance or )
last minute decision, everything having been already firmed up leading to an almost automatic action.
)
In case of power failure, which is not unlikely, the evacuation work, will be totally disorganized unless battery or diesel
operated flood lights are fixed at strategic points to enable people to move from their houses to pick up points. A large ) )
number of lamps, torches etc. will also be necessary to reduce confusion.
)
In addition, the following requirements will also be taken care of:
)
Monitoring the shelter camps and villages till such a time that normalcy is restored .
)
Ensure proper care of the evacuated people in shelter relief camps and provide them adequate facilities such as food ,
drinking water and medical services. )
Ensure security arrangement for protection of the evacuated people's property in their areas till such time they are safely )
brought back to their villages from the shelter camps.
)
14.4 Control of visitors and contractors
)
During major emergency / disaster refinery, main gate will be kept closed and entry will be controlled by security.
No visitors will be allowed to enter in the refinery during the emergency time. Only the mutual aid partners / govt. )
agencies will be allowed to come inside for rendering assistance.
On hearing disaster sirens all visitors and contractors workers will come out of the affected areas and will assemble at
the Assembly point for evacuation. ) )
Pay attention to the announcements through the PA system. )
14.5 Evacuation & Rehabilitation )
• If a major industrial accident does occur, the general public in surrounding areas will have very little time to react )
and save themselves. The local population will have to be warned in a very short period .
• Time available to population for a safe escape and threatened by the accident will depend on the nature of )
accident.
• A fire will give more time to escape and generally area affected will be small. Effects of a fire on population will )
be injuries due to thermal radiation.
• An explosion will give little time to warn population and area affected may be much larger than that in case of a )
fire. Effects of an explosion on the population will be injuries caused by shock wave, flying debris collapsing
structures as well as exposure to thermal radiation . )
• A toxic gas release will generally threaten a much larger area and people will be exposed to drifting cloud of toxic
gas / vapours. Time available for warning population will depend on the point of release, air direction and air )
velocity.
)
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14.6 Communication System:-
The following communication system should be made available connecting the DMCR with the Refinery & Emergency
,) Services:
• Radios
The different user groups are operating at different frequency channels allotted to them for ease in operation in
respective groups . However during an emergency situation the following key members will tune to channel for all
emergency communication. All other user groups will continue to operate on their respective channels . All the key
) members operating from incident site are provided with hand held radios to communicate amongst them.
Key Members to tune their radio on emergency channel are Emergency Response Team, Fire department, Incident
Controller, Medical Coordinator and Head refinery operations (Base station at DMCR) .
) )
) • Telephones
Telephones are provided allover the complex. In hazardous area, the telephones are Intrinsically safe. Telephones
)
may be used by the plant personnel to communicate internally and to avoid congestion of Radio Communication.
)
14.7 Alternate Communication System
)
There could be a situation when all the communication facilities and systems may come to halt. In the event of such a
failure, following alternate systems shall be made available based on the seriousness of the situation:
Messengers
) Use of messengers as a last resort to carry the hand written messages to persons concerned in dealing with the
emergency.
A dedicated vehicle with necessary permits to enter the battery limits shall be made available by the Transport
Coordinator / Travel desk upon request from the concerned Plant Manager during such situations.
)
)
14.8 Actions By General Population
) On being warned of a major industrial accident of gas leak general public should take the following actions:
) • Immediately go indoors
• Shut all doors, windows, and ventilators. Block all the gaps with wet cloth and draw curtains.
)
. • Switch off fans, exhaust fans , air conditioners
) • Extinguish all flames
) • Keep torches handy. Store water for emergency use

• Do not jam emergency phone lines by calling emergency services.
)
• Covering nose / mouth with wet cloth will help.
• Wait for further instructions from emergency services before moving out.
)
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14.9 EDUCATION )
• Educating general public about the potential hazards associated with refinery and actions to be taken in case of
accident, will one of the key areas of disaster management plan. For this purpose, the following actions are
1
proposed: )
• Pamphlets / booklets regarding industrial hazards will be prepared and distributed to general public of the
concerned area. . )
• Notice boards will be put up in strategic places giving the above information.
)
• Help of voluntary organizations and local schools will be taken to conduct educational sessions to make people
aware of the actions that the general public should take in case of any major emergency. )
• Periodic meetings with the village heads to educate them.
))
)
)
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Chapter 15
---; INFORMATION TO PUBLIC
)
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) Format No. 9111·000· PCT- FRM -00006 Rev-DO
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Chapter 15
INFORMATION TO PUBLIC
The police dept. will inform about the emergency to the public whioch is likely to be affected .
)
DO's and DON'Ts In Emergency Situations
General guidelines for the people residing in areas surrounding the refinery in case of Emergency situation at
Bathinda refinery
)
DO'S
)
Don't panic, keep cool.
)
2 If any gas leakage is reported, move either side perpendicular to wind direction towards a safe place.
3 Keep wet cloth on the nose and breathe normally.
4 Immediately extinguish the fire in kitchen, sigri, chulha or bhatti with water in and around the house. )
5 Immediately put off any open flame like candle, lantern, heater etc.
)
6 If evacuation is called for, lock the house and be ready.
7 Free the domestic animals. )
8 Help fire fighting team and emergency staff to keep the situation under control. )
9 Listen carefully to the Announcements in your area and follow the instructions.
)
)
DON'Ts
)
1 Do not put "ON" or "OFF" any electric switch. If any electric switch is "ON" keep it in "ON" position only.
2 Do not smoke and do not allow anybody to smoke . )
3 Do not pay attention to rumors and do no spread any rumors. ) )
4 Do not use any personal vehicle
)
5 Do not block any public area
6 During any emergency situation, do not unnecessarily talk on phone. )
Form at No. 9111-000-PCT-FRM-00006 Rev-OO )
.>
)
)
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')
') Chapter 16
} ROLES AND RESPONSIBILITIES OF
)
EXTERNAL AGENCIES
)
) )
) )
)
) Format No. 9111·000· PCT-FRM-OOOo6 Rev-DO
)
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Chapter 16
ROLES AND RESPONSIBILITIES OF EXTERNAL AGENCIES )
)
16.1 Off·Site Disaster Management Plan
16.1.1 Role And Organogram

)
16.1.1.1 Chief Off·Site Emergency Coordinator (C.O.E.C.):·
)
The District Collector/Deputy Commissioner, Bathinda will be the Chief Off-site Emergency Coordinator (COEC) for
operating the Off-site Emergency Plan . Additional Deputy Commissioner, Bathinda will be the Deputy Off-site ) )
Emergency Coordinator (DOEC) . The COEC will be the overall In-charge of all Off-site Emergency activities. He will )
coordinate various activities with the Chief Operating Officer, Bathinda Refinery) who is the Chief coo.rdinator for the
)
on-site emergency plan. The COEC will also be the authority to activate the Off-site Emergency Plan and order
evacuation if necessary. He will coordinate with various service agencies such as the police, Fire Brigade, Medical, )
Railways, Civil Defence, NDRF, Army (as and when required), Factory Inspectorate, and Pollution Control Board etc.
)
The role of COEC/ DCOEC will be: )
i) Establishing the Disaster Management Control Room at Refinery or any premises of the locations )
feasible in the order of priority.
ii) Establishing communication linkage at the Control Room.

)
iii) Requisitioning fire fighting services from Municipal Fire Services, Bathinda if the situation demands.
) )
iv) Coordinating the rescue operations with ERT, NDRF, and Police. )
v) Arrangement for announcement through PA system to the affected population about action to be taken by )
them and advising for evacuation, if required. .
)
vi) Identify places of safe shelters where the evacuated population has to be lodged .
)
vii) Requisitioning all possible modes of transport for shifting them to predetermined shelters, if required.
)
viii) Organise tents etc. if the shelter places are open grounds.
)
ix) Organise necessary medical aid through district health authorities and other voluntary institutions.
)
x) Ensure supply of food , drinking water and proper sanitation to the evacuated persons kept in various shelter
locations. )
xi) Arrange protection of property of the evacuated villagers during their absence.
)
)
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xii) Coordination with District Administration , Bathinda/Punjab State Govt.
)
xiii) Coordination I assistance to Refinery management for their On-site Emergency Management.
I
xiv) Monitoring public announcements from time to time in the villages, shelter camps and in the city and
) coordination with media persons.
xv) Transportation of the villagers back to the villages after emergency has been controlled.
16.1.1.2 Chief Incident Controller (CIC) - Head Refinery Operations (VP·operations if HRO is not available)
)
• On escalation of level-2 emergency, take command of disaster management control room till arrival of COEC.
) • Coordinate with district administration, Bathinda/Punjab Gov!.
) • Coordinationl assistance to refinery management for their own ONSITE emergency management plan.
)
• Inform and appraise at regular intervals regarding the situation to CEO & MD.
• Ensure that all the necessary support services are activated .
) • Liase with the senior officials of police, fire brigade, medical and factory inspectorate, external technical
) agencies for help and provide information on possible effects to the surrounding areas outside the factory
premises and necessity of evacuating the area and moving the people to safe places.
)
• Will direct PRO through HL coordinator to deal with press and media about the emergency status.
• Declaration of termination of emergency & withdrwal of Offsite emergency management plan.
) • Initiate post-rehabilitation of the affected area.
16.1.2 Establishment Of Disaster Management Control Room (DMCR):-
The COECI DOEC will coordinate the activities from the Disaster Management Control Room established for the
) purpose in Bathinda Refinery or Township.
)
Fire Station Emergency Management Control Room No. 01655272222 I 2525.
)
16.1.3 Communication System:-
)
The following communication system should be made available connecting the DMCR with the Refinery &
Emergency Services:
• Radios
The different user groups are operating at different frequency channels allotted to them for ease in operation
)
in respective groups. However during an emergency situation the following key members will tune
to channel for all emergency communication. All other user groups will continue to operate on their respective
) channels. All the key members operating from incident site are provided with hand held radios to communicate
amongst them.
) Fo rm at No . 9111-000-PCT-FRM-00006 Rev-OO
)
)
)
Revision 01
HPCL·Mittal Energy Ltd,
Next Review
9112·000·HSE·006·00048 Page I 128 of 226 )
)
Key Members to tune their radio on emergency channel are Emergency Response Team, Fire department,
Incident Controller, Medical Coordinator and Chief Operating Officer.
• Telephones
)
Telephones are provided allover the complex. In hazardous area, the telephones are fiameproof. Telephones
may be used by the plant personnel to communicate internally and to avoid congestion of Radio )
Communication.
)
)
• Alternate Communication System
There could be a situation when all the communication facilities and systems may come to halt. In the event ) )
of such a failure, following alternate systems shall be made available based on the seriousness of the situation:
)
Messengers )
Use of messengers as a last resort to carry the hand written messages to persons concerned in dealing with )
the emergency.
)
A dedicated vehicle with necessary permits to enter the battery limits shall be made available by the Transport
CoordinatorrTravel desk'upon request from the concerned Plant Manager during such situations. )
)
16.1.4 Other Items:-
)
In addition to the communication system, the following items should be readily available:-
)
i) Checklist of actions to be taken
ii) A complete list of people to be evacuated if required, pick up points for evacuation. )
iii) A copy of the Emergency Plan
iv) Personal protective equipment (PPE), such as respiratory Safety equipments (self-contained breathing ) )
apparatus, industrial gas mask, non-respiratory safety equipments, such as PVC suits, PVC hand gloves,
safety goggles, safety helmets, PVC gum boots etc.) )
v) Emergency Power supply and lights
vi) An updated list of resources available to avoid the emergency
)
vii) Manpower with various emergency services .
viii) Equipments required for tackling the emergency
)
ix) List of organizations and persons with specialized knowledge to handle the emergency.
Head Refinery Operation (HRO) is the overall In-charge of all a,ctivities in the Refinery. He will act according to the
)
On-site Disaster management Plan. He is also responsible to inform COEC/DM/SSP/DMCR in case of a major )
emergency/declaration of a disaster.
)
COEC, in turn, will activate the Off-site Emergency plan as per established procedure. HRO will also provide to COEC )
full details, nature and magnitude of the Emergency and the area likely to be affected, etc.HRO is authorized for
)
enforcement and withdrawal of Onsite Disaster Management Plan .
)
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ORGA NI SAT IO N CHART FOR OFF-S ITE D ISASTER M A NAGE M ENT
J
COEC
DISTRICT COLLECTOR/DEPUTY COMISSIONER
BATHINDA
) \.
I
) I
HEAD OF REFINERY OPERATION /
)
VP-OPERATIONS
)
DY.COEC
) ADDITIONAL DEPUTY COMMISSIONER
BATHINDA
)
)
l EMERGENCY SERVICES
J
)
) I I ~
I J I
POLICE MEDICAL DEPT. TRANSPORT CIVIL DEFENCE DGM DOT PHONES
FIRE BRIGADE
) (SP, BATHINDA) (CMO-CIVIL (GM - PUNJAB (CDO) PHONES BHATINDA
(FIRE STATION
HOSPITAL, ROADWAYS}
OFFICER) ~
) -4
, BATH INDA)
~
)
)
)
)
POLLUTION
CONTROL BOARD
" Dept. OF FACTORIES
ASSISTANT
"\
STATION SUPERINTENDENT
BHATINDA/RAMANDI
" ARMY
SUB AREA
" COMMANDING
OFFICER-NDRF
(RO, PUNJAB) DIRECTOR (I&SH) RAILWAY STATION COMMANDER BATHINDA
) \. ~
\.-
BATHINDA
J
J
, BATHINDA
.tJ
)
) Format No . 9111-000-PCT-FRM -00006 Rev-OO
)
)
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Issue Dale I 27·FEB·2018 )
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9112-000-HSE-006-00048 Page 130 of 226 )
16.2 Organisation coordinators during offsite emergency
Once a level-2 emergency has been declared, the relevant team will assemble in the DMCR to assist in emergency
control and take care of the wider more strategic issues .The structure will continue functioning during OFFSITE
)
emergency mitigation as shown below:
)
)
HRO
)
Additional expertise Key contacts )

Corporate office
as required
External aaencies )
J I I I I -' )
Head Head Head Head
Head H&S Head security Technical )
operations maintenance procurement
services
)
Key contacts with following groups )
)
EMCR II
•
MCR
• • Process
••
••
OHC Plant Procuremp"
Safety management II
Maintenance
Contractors •• SC3
•
engg . Admin .
Finance )
• Fire
• Incident
• projects
Police Process
safety
HR
team •• Marketing
commander controller
• Env.
warehouse
)
Format No. 9111-000-PCT-FRM-0 0006 Rev-DO )
)
)
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16.3 Role Of Different Agencies
16.3.1 Police Department· Security & Evacuation:·

-,
Deputy Superintendent of police, Bathinda will be the overall authority for security, evacuation, and rescue operations,
law and order and road traffic control in times of emergency.
Evacuation of population may not be required in all disasters. It is, at times, advisable to make people stay indoors
and close their windows and doors. Evacuation of population is a very difficult task requiring massive resources at a
very short notice. It is therefore, essential that evacuation be done on a very selective basis in consultation with Head
Refinery operations (HRO).
)
) Police department will have detailed plans for rescue operations and evacuation of different locations for all incidents
and wind direction. These plans must be based on realistic assumption of resources available and time required
gathering these resources. The role of Police will include the following :
)
) a) Information to Public, COEC/DyCOEC, emergency services as identified in the organization structure.

b) Rail & road traffic will have to be diverted to safeguard people and keep escape route clear. Stopping the traffic
)
to the link road may be considered.
) c) Mobilizing Highway patrol party, cordoning off affected areas assisting Fire fighting personnel, assisting
) medical services, evacuation of population, maintaining law and order.
) Equipment to be carried by the police personnel:
) Apart from normal police equipments, it is necessary that police force should also be equipped with personnel
) protective equipments for respiratory and body protection . This may include steel helmets, gas masks, water bottles,
earplug etc.
)
16.3.2 Fire Services:
)
Chief Fire Officer, HMEL will be the overall in charge for the services.Chief fire officer from municipal Fire Brigade,
Bathinda will assist the CFO, HMEL. During the Off-site emergency, the main role of fire services will be:
) • Fire Fighting
• Spraying water to knock down toxic gases/ vapours
• Washing away spilled chemicals
• Rescue of people trapped in fire
Fire services must be aware of the properties and behavior of various industrial chemicals. While fighting they
themselves should not get affected by the toxic gases or any other harmful chemicals. Proper protective equipment
should be used for this purpose.
)
All other fire brigade, belonging to different organizations, in Bathinda will work under the Fire Commander.
Format No. 9111-000·PCT·FRM-00005 Rev-OO
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Equipment To Be Carried By The Fire Fighting Personnel:- )
Fire services should have adequate number of following items :
• Fire tenders
• Portable fire pumps )
• All other items / materials required for fighting and rescue operations,
)
The fire services should also be equipped with adequate supply of protective equipments, This will include:
• Protective PVC suits and fire suits )
• Self-contained breathing sets and compressor for refilling the compressed air bottles,
• Canister type gas mask etc, )
16.3.3 Medical Services )
)
The Chief Medical Officer, Bathinda District will be overall in charge of medical services to be rendered to the affected
population both at site of the incident and at the location where evacuated population is sheltered )
)
First aid posts:
These can be located near the affected locality and provide immediate aid, They will also assist in evacuating people )
on priority for medical treatment.
)
Hospital:
)
Local Hospitals will treat patients in emergency wards , For the purpose a complete list of hospitals with resources
available and beds earmarked for taking care of off-site emergency will be kept available with the OHC, Bathinda )
Refinery, List of Hospitals and medical facilities in Bathinda is given Annexure 1
)
)
16.3.4 Railways
) )
a) , Railways will have their own task force to tackle the emergency as soon as the same is declared,
)
b) To move out loaded railway rakes from Marketing Terminal if the situation so warrants ,
)
c) To get in touch with OM/concerned officials of District Administration.
)
16.3.5 Water Supply And Sanitation Department )
a) They will point out the existing water sources in nearby area. )
b) They will arrange for water tankers and bleaching powder stock in case of emergency at required location,
c) They will arrange for technical workers and equipments to install hand pump during emergency if required. )
)
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16.3.6 Public Works Department (PWD)
In case of natural calamity viz flood road and bridge to be repaired so that manpower and
)
material should be organized as quickly as possible.
) 16.3.7 Food And Supply Department

They will insure the supply of food and necessary material such as food packets, petrol, Kerosene, etc in case of
emergency.
)
16.3.8 Electricity Department
)
) a) They will insure the supply of electricity, arrange for electrical insulation and damage recovery arrangement in
) case of emergency.
b) Punjab electricity department should liase with Deputy Commissioner so that necessary
guidelineslinstruction to be given .
) c) They will provide the necessary manpower and electrical installation or equipment in case of emergency.
) 16.3.9 Transport Department
) a) They will provide transport vehicles such as buses, truck, mini bus etc and manpower in case of emergency.
b) They will provide uninterrupted transport services to supply food items, drinking water etc to relief camps at
) emergency sites, injured persons to hospitals and wherever required.
) 16.3.10 Irrigation Department
)
a) Deputy Commissioner and other officers will do the necessary inspection or visit for the flood affected area in
) rainy season or in case of emergency arising due to flood according to the flood relief manual.
b) In case of emergency all irrigation officer will be alerted and do the co-ordination with Deputy
) Commissioner.
c) Accordingly, they will setup control rooms in the affected area and do the repair and relief work to bring back
)
) the situation to normal
16.4 Evacuation & Rehabilitation

)
) Safeguarding General Public:-
If a major industrial accident does occur, the general public in surrounding areas will have very little time to act and
save themselves. The local population will have to be warned in a very short period.
)
Time available to population for a safe escape will depend on the nature of accident.
)
• A fire will give more time to escape and generally area affected will be small. Effects of a fire on population
) will be injuries due to thermal radiation .
)
Format No. 9111-000-PCT- FRM-00006 Rev-DO
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• An explosion will give little time to warn population and the area affected may be much larger than that in case
of a fire . Effects of an explosion on the population will be injuries caused by shock wave, flying debris,
collapsing structures as well as exposure to thermal radiation.
• A Toxic release will generally threaten a much larger area and people will be exposed to drifting cloud of toxic
gas/vapour. Time available for warning population will depend on the point of release, wind direction and
velocity.
)
Actions By General Population:-
)
On being warned of a major industrial accident, general public should take the following actions immediately:
• Immediately go indoors.
)
• Shut all doors, windows, and ventilators. Block all the gaps with wet cloth and wet curtains.
)
• Switch off fans, air conditioners
• Extinguish all fiames. )
• Keep torches handy. Store water for emergency seNices.

J
• Do not jam emergency phone lines by calling emergency seNices .
)
• Covering nose/mouth with wet cloth will help.
• Wait for further instructions from emergency seNices before moving out. )
)
)
Format No. 911 1-000-PCT-FRM-00006 Rev-OO )
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)
) Chapter 17
) REPORTING OF THE INCIDENT
)
)
)
)
)
)
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)
Chapter 17
REPORTING OF THE INCIDENT
All the incidents , whether minor (L 1) or major (L2 & L3) will be reported and investigated . All th e nearmisses will be also be
reported and investigated.
)
All the L2 / L3 incident report will be submitted to the Board (PNGRB) within 48 hours from its occurance in the format prescribed
)
in the Schedule VI of the Code of Practice for Emergency Response and Disaster Management Plan Regulation 2010.
)
SCHEDULE - VI
(Reference: Section 23 of PNGRB (EROMP) Regulation, 2010) )
INCIDENT REPORTING FORMAT ) .,
1. Organization 2. Sector )
3. Location 4. Incident Sr. No.
)
5. Date of Incident 6. Time of Incident
7. Major / Minor / Near 8. Report- )
miss Preliminary/ Final
9. Fire / Incident 10. Duration of fire - )
Hrs / Min
11. Type of Incident with loss of life / injury, Fire, Explosion , Blowout, )
Electrocution , Fall from Height, Inhalation of Gas, Driving, Slip / Trip, Others ,
NA )
12. Location of Incident ( Name of Plant / Unit / Area / Facility / Tank farm /
Gantry / Road / Parking area etc) )
13. Whether plant shutdown / caused outage of the facility? Yes / No
14. Fatalities nos. a) Employees = b) Contractor = c) Others = )
15. Injuries nos. a) Employees = b) Contractor = c) Others =
16. Man - hours Lost a) Employees = b) Contractor = c) Others = )
17. Direct Loss due to the incident (Rs. In Lac) . Loss to equipment / Machinery ) )
as per Insurance claim etc.
18. Indirect Losses: Through put! Production Loss, etc.
)
19. Status of the Facility: Construction / Commissioning / Operation / Shutting
down / Turn around, Maintenance / Start up / Arl'{ other. )
20. Brief Description of the Incident including post
incident measures . )
( Attach details in separate sheet)
21 . Whether similar Incident has occurred in past at the )
same location, If yes, give brief description of the
incident and attach details in separate sheet. )
22. Whether Internal Investigation has been ~
completed. If no, likely date by which it will be )

completed.
23. Whether internal investigation report (Major )
Incident) has been submitted to PNGRB. If no, likely
date by which it will be submitted . )
24. Cause of the Incident ( Tick the most relevant cause preferably one, maximum two)
Forma t No . 9111-000-PCT-FR M -00006 Rev-OO )
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A) Deviation from Procedure I) Not using the PPE
B) Lack of Job Knowledge J) Equipment failure
C) Lack of supervision K) Poor design / Layout etc.
--, D) Improper Inspection L) Inadequate facility
E) Improper Maintenance. ( Mech. / Elec. / Inst ) M) Poor House Keeping
F) Improper material handling N) Natural Calamity
( ) G) Negligent Driving 0) Pilferage / Sabotage
H) Careless walking / climbing etc. P) Any other (give details)
) 25. Cause of leakage - Oil, Gas or Chemical ( Tick one only)
A) Weld leak from equipment / lines E) Leakage due to improper
I )
operation
B) Leak from flange, gland etc. F) Leak due to improper
) maintenance
)
C) Leak from rotary equipment G) Normal operation - Venting /
draining
D) Metallurgical failure H) Any other
) 26. Cause of Ignition leading to fire ( Tick only one cause)
A) Near to hot work F) Static Electricity
)
B) Near to Furnace / Flare etc. G) Hammering / Fall of object
) C) Auto - ignition H) Heat due to Friction
D) Loose electrical connection I) Lightning
) E) Near to hot surface J) Any other ( pyrophoric etc)
27 . Was the incident Avoidable? (Yes/No)
)
28. The incident could have been avoided by the use of / or by ;
( Tick the most relevant point preferably one, maximum two)
A) Better supervision F) Personal Protective
Equipment
B) Adhering to specified operating procedure G) Better equipment
C) Imparting Training H) Management Control
) D) Giving adequate time to do the activity through proper I) Adhering to specified
) planninq. maintenance procedure
E) Adhering to the work permit system J) Adhering to specified
Inspection / Testing
procedures.
K) Any other information;
) Form at No. 9111-000-PCT- FRM -00006 Rev-OO
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)
Guidelines for Filling the Incident Report )
1. All Major, Minor and Near miss incidents shall be reported in the quarterly report.
2. Incident Reporting form shall be filled up for all Major, Minor and Near miss Incidents.
)
3. Summary report shall be enclosed with every quarterly report.
4. Investigations shall be carried out for all Major, Minor and Near miss Incidents. )
5. Investigation report of all Major incidents shall be submitted to PNGRB. An incident shall be treated as Major if any of the )
following occurs;
- Fire for more than 15 minutes )
· Explosion / Blowout
· Fatal Incident.
) )
- Loss above Rs. 10.0 Lac. )
· Cumulative man hours lost more than 500 hrs. )
- Plant Shutdown / Outage due to the incident
)
6. Loss time Incident shall be monitored till the affected person joins duty. In case the affected person is yet to join the duty,
then the status of report submitted will be preliminary. Final report against the same incident shall be sent once he joins )
duty and the man - hours lost are known.
7. All columns must be filled up. )
8. For any additional information use separate sheets as required. )
9. Quarterly report shall be sent to PNGRB within 15 to 30 days of end of quarter.
)
10. Immediate reporting of incident through fax/telephone shall continue as per the prevailing system.
)
)
Signature & Name )
Designation of the Occupier/Manager ' )
Format No . 9111-000-PCT- FRM-00006 Rev-OO )
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)
Chapter 18
J TERMINATION OF EMERGENCY
)
) )
)
)
)
) Format No. 9111-000·PCT-FRM·00006 Rev·OO
)
)
)
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Chapter 18
TERMINATION OF EMERGENCY
)
After assessing the situation as normal, CIC in case of Level-2 and Incident controller in case of Level-1 shall declare the
termination of emergency. All employees I workers will be informed by operating continuous siren for two minutes (straight
run) as well as making refinery wide announcements of ALL CLEAR through PA system by EMCR operator. In addition,
bulk SMS and e-mails will be sent from EMCR to the internal stake holders. A debriefing session shall be held immediately
)
after the emergency termination for any incident related feedback.
For level-3, termination of emergency shall be declared by CoEC.

)
Reporting of the incident )
All the level-1/2/3 incidents are reported internally in the HSE-SAP reporting system and investigations are carried out to ) )
find out the root cause and implementation of the recommendations to prevent the recurrence .
)
All Level-2/3 incidences are reported in the prescribed format (As per Schedule-VI).
)
Form at No. 9111-000-PCT-FRM-00006 Rev-OO )
)
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)
Chapter 19
J EMERGENCY RECOVERY PROCEDURES
)
) )
)
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)
Chapter 19
EMERGENCY RECOVERY PROCEDURES )
19.1 Information to Statutory Authorities

)
For any major emergency the reporting is carried out to the statutory authorities;
• Factory inspector. )
• PESO
• OISO )
• State pollution control board .
• PNGRB )
19.2 Investigation
) )
A detailed investigation will be carried out by the team of members formed in a committee nominated by the refinery )
head .The team will carry out the detailed investigation to find out the root causes for the incident and give their
recommendations to prevent the recurrence for such incident. )
A detailed report will be prepared which shall include the damage estimation, lessons learnt and learnings.
)
19.3 Post emergency recovery
)
• Check for OWS and storm water drainage network for any accumulated product.
• Check that the affected area is now cleaned and dried. )
• Check that all the drains are now dried .
• Check that the interlock systems for tanks/ gantries has been normalized . )
• If required carry out the soil testing to check the soil contamination as per the requirement of the SPCB/CPCB norms.
)
19.4 Affected manpower
)
• Head count of the manpower to be done by the security team as per their role.
• Carry out the medical check up for the affected employees at the OHC. )
• Records for the reporting personnel are maintained as WIR-work injury report at the refinery OHC.
) )
19.5 Addressing Media
)
As per the company's policy any media addressing will be done by the corporate communications department.
)
19.6 Clean up and restoration
• Restoration job to be carried out for the affected area.

J
• All the safety systems will be checked after restoration prior to starting the facility. )
• A detailed PSSR-pre start up safety review is carried out for a cross functional team to ensure the start up
preparedness and to check all the essentials are in place for safe start up to normal operations. )
Form at No. 9111-000-PCT- FRM-00006 Rev-DO )
)
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)
CHECK LIST·?
(Reference: Section 26(2) of PNGRB (fROMP) Regulation, 2010)
J
ERDMP • Recovery Measures
Sr.No. I Check· point I Yes I Nol Remarks

Post Emergency Recovery
)
Salvage of product
)
1 Check that spilled / accumulated product contents are transferred to the OWS
') or collected in drums.
)
) 2 Check whether the quality and quantity estimation of the product extracted from
OWS has been done for further disposal in line with standing QC guidelines by
) either transferring to service tanks or to nearest refinery for blending /
reprocessing or not.
)
3 Check that correct stock accounting of spilled product as loss has been
) completed in accounting system.
) 4 Check that affected area has been completely cleaned and dried after
evacuation of spilled product.
)
5 Declare that affected area after salvage operations is fully clean and safe for
) movement of the working personnel.
) 6 Check that all drains are not having any residual oil and are thoroughly cleaned
and dried.
)
7 Check that all control valves on product lines and OWS lines outside dyke area
) and drains are completely closed after removal of the spilled product.
)
) 8 Check that interlocking system of tanks / gantry has been re-activated for
normal operations.
)
9 Check whether the soil testing of the affected area, if required, has been done
) to assess the soil contamination level to meet the Environmental- SPCB norms
/ requirements.
)
Taking care of affected manpower
)
10 Whether physical accounting of all personnel on duty during and after the
) incident are ascertained by the Site Incident Controller and reconciled
immediately
)
11 Whether the first-aid treatment and post-incident health check of the affected
)
personnel has been undertaken in time
) Format No . 9111-000-PCT- FRM-00005 Rev-DO
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)
12 Whether these personnel are declared fully physically fit before allowing them
to resume their normal duties )
13 Whether the records for such first aid and treatment of the affected personnel
are maintained in a well defined format
)
Addressing media and outside bodies
)
17 Whether the incident was appropriately informed to the local media in line with
the respective company's Press and Media Policy )
18 Whether the role of neighbouring population during the drill{ disaster is suitably )
informed to the population during subsequent meetings with local
administration { panchayat etc. for necessary improvements ) )
19 Whether the awareness and preparedness on disaster is regularly assimilated )
{shared with nearby public {societies and stake holders.
)
Reporting
)
20 Check whether that disaster incident report was communicated to respective
controlling office { HQ promptly in a standard format. )
21 Whether the incident reports are also sent to concerned State Level Industry )
Coordinator on time.
)
22 Check that detailed report on disaster in proper format was communicated to i
PNGRB{ Factory inspector { Labour inspector { SPCB { District Magistrate )

{PESO . .
)
Investigation
)
23 Whether investigation teams are constituted as per respective company
policies ) )
24 Whether RCA (Root Cause Analysis) of the disaster is conducted by the )

investigating team
)
25 Whether detailed investigation into effective functioning of interlocks, detection
devices, automation controls and applicable norms are carried out to find out )
possible improvements in design { construction { operations {maintenance and
training aspects etc. )
26 Whether a system of initiating appropriate corrective measures including )

suitable revisions to the Disaster Management Plan are adopted based on
findings of the investigation )
Damage Assessment - Monetary and Physical )
)
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)
27 Check the valuation / cost of product loss / down gradation on account of
contamination, if any / Property / Structures / damaged assets - equipments.
I 28 Whether repairs and maintenance cost of property, assets and equipment are
assessed .
)
29 Whether any penalty by statutory authorities like SPCS / Factory Inspector and
Labour Commissioner are assessed.
30 Whether possible impact on environment are also assessed and appropriate I
measures are taken

)
31 Whether damage assessment also include potential erosion of reputation -
) from company, industry and national perspectives
)
) Clean up and Restoration
-32 Whether the affected area has been fully cleaned and cleared after due
clearance from investigation team
)
33 Check whether heat detectors, high level alarms, in built safety systems (NRV,
) TSV etc.) are fully functional after the disaster incident.
) 34 Check whether all fire fighting equipments like - hoses / nozzles / Fire
Extinguishers etc. have been put back at designated places and are fully ready
) for reuse
) 35 Whether clear procedures are in place to allow resumption of normal operations
)
)
)
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)
Chapter 20
ERDMP FOR PIPELINES CARRYING )
PETROLEUM PRODUCTS AND RETAIL

)
OUTLETS )
) )
)
)
) ,
)
.>
)
Format No. 9111-000-PCT- FRM-00006 Rev-DO )
)
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Chapter 20
ERDMP FOR PIPELINES CARRYING PETROLEUM PRODUCTS AND RETAIL OUTLETS

}
)
(Reference: Section 27 of PNGRB (ERDMP) Regulation, 2010) Not Applicable to Refineries
1) ERDMP for pipelines carrying petroleum products should follow modern methods of surveillance of Pipeline and take
guidance from all the aspects of Disaster Management Plan mentioned in the ERDMP . Schedule-VII should be referred, .
) which is in line with Chemical Disaster by National Disaster Management Authority.
2) ERDMP for retail outlets should take care of all aspects mentioned in ERDMP and shall also refer to OISD STO- 225 .
)
) Schedule -VII
) (Reference: Section 26 of PNGRB (ERDMP) Regulation, 2010)
ERDMP for pipelines carrying petroleum products
) Pipelines are assuming importance as a means of transport of hazardous substances. Crude oil, its derivatives and natural
gas are among the main substances transported by pipelines.
)
The Guidelines, therefore, comprise:
i) Creation and maintaining an administrative framework to facilitate the development of a safe and environmentally sound
) transportation infrastructure, including pipelines for hazardous substances .
ii) The pipeline operator has the primary responsibility for the safety of the systems and for taking measures to prevent
)
incident s and to limit their consequences for human health and the environment.
iii) Pipelines for the transport of hazardous substances will be designed and operated so as to prevent any uncontrolled
release into the environment.
) iv) Risk assessment methods should be used in evaluating pipeline integrity and impact on human health and the
) environment.
v) Land-use planning considerations will be taken into account both in the routing of new pipelines (e.g. to limit proximity
) to populated areas and water catchment areas to the extent possible), and in decisions concerning proposals for new
developments/building in the vicinity of existing pipelines.
) vi) Pipeline operators and tbe authorities responsible for pipelines shall review and, if necessary, develop and implement
systems to reduce third-party interference, which is a cause of incident including their effects.
)
vii) National legislation shall be clear, enforceable and consistent to facilitate safe transport and international cooperation.
) viii) Competent authorities should ensure that pipeline operators:
(a) Draw up emergency plans.
)
(b) Provide the authorities designated for that purpose with the necessary information to enable them to draw up Off-
) Site emergency plans.
(c) Emergency plans shall be coordinated between pipeline operators and competent authorities, as well as with fire
brigades and other disaster control units.
ix) Pipelines shall be designed, constructed and operated in accordance with recognized national and international codes,
standards and guidelines, notified by the Board.
) Format No . 9111: 000· PCT·FRM·00006 Rev·OO
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)
x) Consideration will be given to the impact on the safety of a pipeline such as design and stress factors , quality of material,
wall thickness, and depth of burial, external impact protection, markings, route selection and monitoring.
xi) The safety of the pipelines shall be demonstrated through a suitable risk assessment procedure including the worst case
scenario and including breakdowns and external additional loads.
xii) The pipeline operator shall draw up a Pipeline Management System (PMS) to ensure that it is properly implemented. )
The PMS shall be designed to guarantee a high level of protection of human health and the environment. The following
issues shall be addressed by the safety management system. )
)
(a) The pipeline will be inspected and maintained regularly. Only reliable trained staff or qualified contractors may
carry our maintenance work on a pipeline. Third party conformatory assessment bodies should inspect the
)
pipeline at regular intervals as far as required by the Board . These inspections are to cover in particular the proper
condition of the pipeline and the functioning of the equipment ensuring pipeline safety.
(b) Organization ability, roles and responsibilities, identification and evaluation of hazards, operational control, and
) )
management of change, planning for emergencies, monitoring performance, audit and review shall be duly )
addressed in the Pipeline Management System.
)
Note:
)
ERDMP for pipeline is not applicable to Guru Gobind Singh Refinery as refinery is not in the business of the pipeline
transportation of Petroleum' products. )
) )
Format No. 9111·000· PCT· FRM·00006 Rev·OO )
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Chapter 21
) ERDMP FOR ROAD TRANSPORTATION
)
)
)
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Chapter 21
ERDMP FOR ROAD TRANSPORTATION
)
The road transport of Petroleum product has significant presence and needs special attention . Complete details of treatment
for handling emergency arising out of road transportations have been provided below: )
22.1. Resource Mobilization for Road Transport Emergency )

(Reference: Section 28.1 of PNGRB (EROMP) Regulation, 2010)
)
Resource mobilization for road transport emergency shall be as per the Schedule-VIII as given below.
) )
(a) In order to handle Emergencies, which may arise due to incident involving Petroleum Product Transportation, it is
required that a comprehensive Emergency Management Plan is readily available with the industry as well as with )
other related authorities all along the routes. The ERDMP should be clearly understood by its users so that the
emergencies can be handled in a systematic manner with minimum response time in accordance with the prescribed )
procedure . .
)
(b) Copies of the ERDMP shall be made available by the Industry to all the field locations i.e . Installations, POL Depots,
Terminals I Installations, Refineries, Gas Processing Plants, Dispatch units of etc., the concerned District
Administration, Police Stations and Fire Brigades en-route and within vicinity of specified tank truck routes, oil industry )
sales personnel of concerned area as may be required.
)
(c) Location specific availability of Emergency Response Vehicle shall be mentioned in the ERDMP.
)
)
Note:
)
ERDMP for Road Transportation is not applicable to Guru Gobind Singh Refinery as Refinery is not in the business
of the road transport of Petroleum products (Liquid and Gasses). However solids are transported by road (Sulphur I ) )
PP I Petcoke). These are low hazardous substances. Risk assessment is carried out for these transportation.
)
)
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Risk Assessment
Risk Assesment for Coke Transportation

--j Section 1: Information
) Date: 12/02/2018
Area 1Location: Marketing
Task:
Coke transportation from Refinery to Customer end
)
Assessment Number: 9112/MARKETTING/RA/01
Reason for Assessment: To minimize the environmental impact for coke dust
)
Task Carried out by: Transport of Coke is being monitored by the marketing team.
)
Frequency task carried out 1
Truck driver and Khalasi
number of people involved:
) Equipment used:
Truck
)
Method Used to carry out task I
) Loaded Coke trucks are transported to the customer site.
Relevant procedures:
History of incidents or changes

Nil
) to improve safety I operability:
) Section 2: Assessment
Who Might be Further Actions

Hazard Harmed and How Existing Controls Required
(Note - none means residual
) (Type of Injury I Loss)
risks are considered acceptable)
) All the trucks are covered by the Tarpaulin sheets

Impact on
before leaving the Refinery.
Coke Dust Environment.
Water sprinklers are used at loading site for dust Nil
Inhalation of coke
suppression .
dust.
Dust Masks are,used by the operators.
)
) Spillage due to No significant Hazard

Road Accident because of property N/A Nil
) of solid coke
)
Fire/Smoke
(Inflammable Truck Driver and Sh.ould not dry (Moisture content is maintained)
) Nil
Substance) helper Use water if ignited
'-------
) Format No. 9111-000-PCT-FRM -00006 Rev-DO
)
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Risk Assesment for Sulphur Transportation
Section 1: Information )
Date: 12/02/2018
)
Area I Location: Marketing
Task:
Sulphur transportation from Refinery to Customer end
Assessment Number: 9112/MARKETTING/RA/02 )

Reason for Assessment: To ensure the safe transporation of Sulphur to the customer end. )
Task Carried out by: Transport of Sulphur is being monitored by the marketing team .
Frequency task carried out I
Transporation activity is carried out daily 1Truck driver and Khalasi
) )
)
Equipment used:
Truck
)
Method Used to carry out task I Loaded Sulphur trucks are transported to the customer site. )
Relevant procedures: SOP for Loading 1Unloading
)
History of incidents or changes )
Nil
to improve safety I operability: -
Section 2: Assessment
)
)
Who Might be Harmed Further Actions Required
Hazard and How Existing Controls (Note - none means residual risks are )
(Type of Injury I Loss) considered acceptable)
All the trucks are covered by the Tarpaulin )
sheets before leaving the Refinery.
Sulphur Dust Impact on Environment.
Inhalation of Sulphur dust.
Water sprinklers are used at loading site for
dust suppression.
Nil ) )
Dust Masks are used by the operators.
)
It is the responsibility of the driver to
keep all information provided to him )
in writing i.e., in the form TREM
Fire may happen because of sulphur self- CARD (Transport Emergency Card). )
ignition, or, fire may cause by the surface This is to be kept in the drivers cabin
Fire hazard
damage of the cover resulting from thefts or and should be available at all times. )
(It is inflammable solid
attempting thefts the cover. Driver will also ensure that parked
Spillage due to substance able to ignite
vehicle is safe from fire, explosion or
Road Accident from a match flame, spark, )
Work location to be barricaded . any other risk. As per Rule the driver
and burn extensively in an
should have the ability to read and
open truck forming toxic )
Spraying water to keep Sulphur in wet write at least one Indian language
oxides)
condition. specified in the Constitution and
English language. The driver should )
have successfully passed.a course
connected with the transport of )
hazardous goods.
Format No. 9111·000· PCT-FRM-00006 Rev-OO )
)
)
)
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The driver of a goods carriage
transporting soild sulphur shall, on
Fire/Smoke the occurrence of an accident
Should not dry (Moisture content is
(Inflammable transported by his truck, report
) Truck Driver and helper maintained)
Substance) forthwith to the nearest police station
Use water if ignited
and also inform the owner of the
) goods carriage or the transporter
regardin~ the accident.
Risk Assesment for Poly Propylene (PP) Transportation

Section 1: Information
)
Date: 12/02/2018
)
) Area 1Location: Marketing
) Task:
Poly Propylene (PP) transportation from Refinery to Customer end
Assessment Number: 9112/MARKETTING/RA/03

) Reason for Assessment: To ensure the safe transporation to the customer end.
Task Carried out by: Transport of PP is being monitored by the marketing team.
) ,
Frequency task carried out I
Truck driver and Khalasi
Equipment used:
) Truck
)
Method Used to carry out task I
.> Loaded PP trucks are transported to the customer site .
Relevant procedures:
)
History of incidents or changes
) Nil
) to improve safety I operability:
) . Section 2: Assessment
) Who Might be Further Actions

Hazard Harmed and How Existing Controls Required
(Note - none means residual
) (Type of Injury I Loss)
risks are considered acceptable)
) Spillage due to No significant Hazard

Road Accident because of property Not applicable
) of solid PP
)
Fire/Smoke
(Inflammable
) Substance) Truck Driver and helper Not applicable
)
)
)
)
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)
Schedule - VII
(Reference: Section 28.1 of PNGRB (ERDMP) Regulation, 2010) )
Resource Mobilization for Road Transportation Emergencies
A. In-Plant Resources )
Following items should be available at the Plant in adequate quantity / nos,
)
Mechanical Equipment:
)
1. Gaskets (Carbon Asbestos Filled)
)
2. Studs and bolts .
3. Teflon tapes.
4.
5.
6.
1,h" / ~" crowbar (1 m long)
Spade / blind flange
Rope (Manila I Jute)
) ~
7. Spark arrestors.
8. 1" tapered wooden pegs. )
9. Chopper
10. Spare fan belt for tank lorry with P.T.O. unit )
11. Wind sock
12. M-Seal / epoxy-base cold-welding compound . )
13. Wooden slippers
14. Teflon-taped spanners, wrenches )
15. Spark-proof wrenches, hammer and tools.
16. Barricading masts and ropes / tapes )
17. hoses
' 18. Chain pulley blocks and stay pipes )
19. Small valve keys for operating valves in the tank truck
)
Electrical Equipment:
)
1. Gas Explosi-meter
2. Flame-proof torches ) )
3. Earthing wires (10m long) with crocodile clips
)
)
Personnel Protective Equipment:
)
1. Gloves:
i) Rubber gloves )
ii) Low Temperature Gloves
iii) Industrial gloves (with leather lining) )
iv) Canvas gloves
)
2. Face shields
3. Ear muff / ear plugs )
Forma t No. 9111-000·PCT·FRM-00006 Rev-OO )
)
)
)
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)
Other Safety Items:
')
1. 1 roll of gunny / hessian cloth (about 10 mts. long)
---, 2. First aid box (containing water gel compounds)
3. Soap
4. Blanket.
5. Water Gel Blanket
)
6. Breathing Apparatus (With spare filled cylinder and Canister gas masks)
7. Fire proximity suit
Fire Fighting Equipment:

)
1. Portable Dry Chemical Powder Fire Extinguishers
)
) 2. Fire-water Hoses
3. Triple Purpose diffuser nozzle for use with fire hoses.
Communication Equipment:
)
1. Hand operated sirens
) 2. Whistles
3. Megaphone, Mobile Phones, VHF sets.
)
Traffic Control Equipment:
)
1. Red lights (Battery operated) - for traffic diversion
) 2. Area maps
3. Diversion Boards
)
) )
) Format No. 9111-000·PCT·FRM-00006 Rev-OO
)
)
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)
Chapter 22 )
SECURITY THREAT PLAN

)
) )
)
) )
)
)
)
)
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)
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)
Chapter 22
SECURITY THREAT PLAN
---l There is a detailed document available as: Security Crisis Management Plan with document number·9111·000·SEC·
704·00038
Bomb Threat
) A bomb threat may be received on telephone or through a written message. Experience shows that most of the threats
received on telephones are hoaxes. However, till experts carry out detailed search and come to that conclusion, the situation
)
has to be taken seriously by the Security department. Periodically key members of the HMEL Security shall be trained by
Bomb Disposal Squad to handle such threats.
)
) When a call is received , it is important to compile as much information as possible in order to determine the location(s) to
) be searched and/or evacuated. Each threat must be handled as if it is genuine. Following procedure must be followed on
receipt of a call:
) • Do not panic
) • Be calm and composed
• Be courteous
)
• Speak softly
)
• Do not lose patience
)
• Note down time of the call
)
• Do not interrupt the caller
)
• Do not spread the message
) • Try to find out the purpose or the real mission of the caller.
)
) • Try to find out the reason of the grievance for placing a bomb
) • Try to secure as much specific information as possible, e.g . Location of the bomb (Name of the building, floor,
room), time of detonation, or any other descriptive information
) • Pay attention to the telephone display and record the number shown
) • Pay attention to any background noise and distinctive sounds such as traffic, other voices, television, music,
machinery, etc.
• Note the characteristics of the caller's voice such as gender, age, education, and accent
) • Immediately after the call has ended contact SC3
)
• If the threat was leflon voice mail, do not erase it
• HMEL Fire tender and ambulance must be alerted immediately after call
)
• Upon receipt of the bomb threat, Security must alert the Bomb Disposal Squad . They may be required to move
) on short notice.
• Also inform the police and the fire department.
) Form at No. 9111-000-PCT-FRM-00006 Rev-DO
)
)
)
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9112·000·HSE·006·00048 Page 158 of 226 I )
)
Additional actions in case of bomb threat )

.. ORT to cordon off the area .
o Security staff to redirect traffic and control crowd.
)
• Assist fire crew in evacuation.
• Render help and support as per instruction of bombdisposal squad commander. )
)
Search by trained security personnel:
)
Security shall search the building/facility immediately after the receipt of information. They shall look for:
• Foreign objects
) )
• Typical objects like transistors, Tiffin box, toys, etc. )
• Bundles, parcels, handbags )

• Inflammable material, chemical or gas storage rooms
• Bottom of tables )
• Below cupboards
• Hissing or ticking sound
)
TECHNICAL ALERTS: strengthening security measures by security gadgets. )
The Security Command & Control Centre (SC3) is an integrated control room is having electronic feeds from various )
sources. It receives the feeds of electro-fence, intrusion detection system, boom barriers, video analytics supported
surveillance system, access control system, ORT GPS trackers, thermal imaging camera at Mundra, similar feeds of the )
system at COT, all the SVs & pumping stations.
)
The feeds normally are of the functional state of a particular system. In case of any anomaly in the functions of the system, ) )
an alarm will be generated at the SC3 to warn about malfunction of that particular system. These alarms shall be deemed
an emergency till the cause is established and supplernentary controls are put in place. )
Format No. 9 111-000-PCT-FRM -0000 6 Rev-OO

)
)
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{ } Issue Date 27·FEB·2018
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HMEL 9112·000·HSE·006·00048 Page 159 of 226
Chapter 23
~) INTEGRATION OF THE ERDMP WITH THE
NATIONAL DISASTER MANAGEMENT
PLAN (NDMP)
" )
)
)
)
)
J
)
)
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~
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I' HPCL·Mittal Energy Ltd.
9112·000·HSE·OO6·00048
Issue Date
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Page
27-FEB·2018
160 of 226
Chapter 23
INTEGRATION OF THE ERDMP WITH THE NATIONAL DISASTER MANAGEMENT PLAN (NDMP)
-}
21.1 NATIONAL DISASTER MANAGEMENT PLAN (NDMP) )

(1) On 23 December 2005, the Government of India took a definite step towards NDMP by enacting the NDMP ACT,
2005. The NDMP Act, 2005 is a Paradigm Shift from a response and relief-centric approach to a proactive and )
comprehensive mindset towards NDMP covering all aspects from prevention , mitigation, preparedness to
rehabilitation, reconstruction and recovery, ) .>
(2) Similar to National Authority at the Centre, the State Government is to establish a State Disaster Management ')
Authority for the State. The State Authority is to be headed by the Chief Minister of the State as the Chairperson.
Every State Government, in turn, is to establish a District Disaster Management Authority for every district in the
State with the District Collector as the Chairperson .
)
(3) The Central Government is empowered to take further measures as it deems fit for the purpose of disaster
management like deployment of naval , military and air forces, other armed forces of the Union or any other civilian )
personnel as may be required for the purposes of this NDMP Act. Government of India is empowered to establish
institutions for research , training, and developmental programmes in the field of disaster management as per this )
Act.
)
(4) The national vision is to build a safer and disaster resilient India by developing a holistic, proactive, multi-disaster
and technology driven strategy for NDMP. This will be achieved through a culture of prevention, mitigation and )
preparedness to reduce the impact of disasters on people. The entire process will centre stage the community and
will be provided momentum and sustenance through the collective efforts of all government agencies supported )
by Non-Governmental Organisations (NGOs).
)
(5) National Disaster management Structure showing the interactive linkage among various agencies for synergised
management of disaster is given below; )
\ .1
\ )
\ )
( )
Fo rmat No. 9 111-000-PCT-FRM-00006 Rev-OO
t )
)
')
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')
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NATIONAL DISASTER MANAGEMENT STRUCTURE
)
NDMA
), NEC
)
t.IIIS1RES &
DEPMTUEIITS OF
GOVT OF IImlA
) ARMED FORCES
) STATl:POLEE
)
STATE DISASTER
RESPONSE FORCE
NCe, NSS& FIRE

NYKS SERVICES
)
ACAOBHc 1t1S'TTTl/TOtIS p ~ FESSotl AL E)) DIES
)
SCIENTIFI:OIl:lANISATDNS l eo M M U NIT Y co RPO RATE Sl'ClO RS
)
TEC HNCAL ItISTrruIDN S n:;OB
Ndes: 1. . llis liaglClll ralects irteractive linkages for synergised managemert cllisasters
CIld nd a lierarclical structll'e. .
)
2_ ~clward andfooNard lilkages, esPecially ~tl:le flIlctim~ level, are with a vilWto
qiimise·!fli:iency.
)
3. PClticipation of the can mumy is a crucial factor.
)
Note: Since PNGRB has been constituted by PNGRB Act, 2006, it should be identified under Ministries I
) Departments of Govt. of India.
) Format No. 9111-000-PCT-FRM -00006 Rev-OO
)
)
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21.2 Abbreviations for NDMA:
NDMA National Disaster Management Authority

NEC National Executive Committee
DM Disaster Management
NCC National Cadet Corps
NCDM National Committee on Disaster Management
NDMRCs National Disaster Mitigation Resource Centres
NDRF National Disaster Response Force
NSS National Service Scheme
)
NYK Nehru Yuva Kendra
NGOs Non·Governmental Organisations
)
SDMA State Disaster Management Authority
SEC State Executive Committee
DDMA District Disaster Management Authority
)
21.3 Integration of ERDMP with NDMP )
This ERDMP document has been developed taking into account all possible inputs on the subjects from various )
stake holders. Efforts have also been made to synergize this with the document on National Disaster
Management Guide (Chemical Disasters) Industrial brought out by National Disaster Management Authority )
~ )
Fo rm at No. 9111·000·PCT·FRM ·00006 Rev·OO )
)
)
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Annexure 1 LIST OF NEIGHBOURING INDUSTRY
SN NAME DESIGNATION DEPARTMENT CONTACT NO.

---l
9463420272,
) 1 R K MALHOTRA Sr. MANAGER SAFETY NFL Email :-
rkmahotra@nfl.co.in I
2 KULBHUSHAN VERMA EXECUTIVE DIRECTOR NFL 9478401830
ASSISTANT
3 PRASUN KUMAR SINHA NFL 9478001407
COMMANDANT (FIRE)
) CHIEF REGIONAL BATHINDA RETAIL

4 PKUPPAL 9501048850
) MANAGER REGION
) SR. INSTALLATION
5 P K SHRIVASTAVA BPCL, POL DEPOT 2430061,9876777450
MANAGER
)
6 KHAIRWAL MANAGER BPCL, POL DEPOT 2430241 , 9876045030
) 7 RAJ ORA OFFICER BPCL, POL DEPOT 2430303
8 BPCL, LPG PLANT 2430134
)
CHIEF INSTALLATION
10 NEGI IOCL,POL DEPOT 2430008,9417217955
MANAGER
)
11 PRASHANT MANAGER IOCL,POL DEPOT 9464655647
) 12 SANJAY NARANG OFFICER IOCL,POL DEPOT 9646008591,2430318
SR. OPERATIONS
13 A K SINGH IOCL, PIPELINE 2430263
MANAGER
) 14 BALDEV SINGH INCHARGE FIRE BRIGADE 101 , 9855023101
15 JASWINDER SINGH FIRE BRIGADE 2211101
) 16 ASHWANI KUMAR FIRE BRIGADE 2255101
) 17 RAJBIR SINGH SHO POLICE, KOTFATTA 9878421110
18 MANJIT SINGH MUNSHI POLICE, KOTFATTA 9878421310
) 19 SSP Office SSP OFFICE POLICE, BATHINDA 2219100,2219300
)
20 Ambulance AMBULANCE 2212221
21 Civil Hospital CIVIL HOSPITAL 2212501
) 22 DC Office DC,BATHINDA 2212594
23 KATAR SINGH WALA RL Y. STATION 2430474

-
)
) Format No . 9111·000·PCT·FRM·00006 Rev·OO
)
)
)
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Issue Date I 27-FEB·2018 )
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)
Annexure 2
List of Hospitals in Bathinda )
For Cardiology
SN. Hospitals Doctor Clinic Mobile No.
1 Delhi Heart Institute ,Namdev Road (BTl). NareshGoyal 0164-2222102 9872403400 )
2 Pragma Hospital, Bhatti Road (BTl). Gursewak Singh Gill 0164-2215501 9876819922
)
3 Jindal Heart Hos.Power house Road (BTl) Rajesh Jindal 0164-2211111, 9855125505
2213111
)
For Eye Care !
)
1 Sethi eye clinic #155 Veer colony AmritSethi 2251500 9814032953
} )
2 Sodhi eye clinic G.T.road corner power H.Rd H.S.Sodhi 2215427 9888545245
)
3 Singla eye care centre near sport stadium N.K. Singla 2241247 9417105342
)
4 Surya eye Hospital G.T.road G.S.Khurana 2255716 9814226716
5 Kataria eye Hospital mall road Anil Kataria 2253174 9814783483 )
6 Sarwal eye &Maternity Hospital AryaSmajchowk VarinderSarwal 2236756 9717115218 )
7 Sra eye Hospital Opp. Omega centre G.T.Rd J.S. Sra 9814171718 9814171718
)
For Paediatrician
)
1 Ludhiana Children Hos.Mall Rd Ajay Gupta 2251657 9988010753 )
2 Bajaj Children Hos.Mall Rd KK Bajaj 2251059 9814135081 )
3 Nagpal Children Hos. GT Rd B K Nagpal 2235868 9814322341
)
4 Chandigarh Children Hos. GT Rd Jagjeet Singh 2224468 9814157952
5 NO Goyal Children Hos.Hospital Bazar
)
NO Goyal 2251880
6 Maheshwari Children Hos. Veer Colony RN Maheshwari 2250030 9876079975
For Dentist

)
1 Bansal Dental Care Centre Power House Road B.P. Bansal 2212323
2 GUPTA Orthodentic&Dental care Hanuman chowk Rajinder Gupta 2235996 )
3 AmnishOrthodentic&dental Care Mall Road Amnish Singh 2251642 )
4 Singla Dental Care Hanuman Chowk Munish Singla 2239596
)
5 Gopal dental care AryaSamajChowk R .Gopal 2250321
6 Naresh dental care AryaSamajchowk Naresh Gupta 2237003 )
7 Vermapshychatric&Dental care Bhatti Road Nidhiverma 2212780 )

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)
For Clinical Laboratory
) SN. Hospitals Doctor Clinic Mobile No.
I
1 Gee Ess Lab. G.T. Road BTl. Sharanpaul Singh 2250049 9855203300
)
2 Bikaner Lab. Birla Mill G.T. Road .BTI. S.R.Uttreja 2253498 9417325125
)
3 Pushpa Clinical Lab. Mall Road BTl. R.R. Jain 2255780
4 KKClinical Lab. Mall Road BTl. ChanderShekhar 2252779 9417094651
) 5 Kanwal Clinical Lab. Mall Road BTl. Kuldeep Singh 2238343 9814923822
6 monika Lab. GaneshaBasti G.T. Road BTl. Monika 2237024 9814744711
)
7 Mittal Lab.G.T.Road, BTl. Anita Mittal 2241226 9814526326
)
) For Gynaecologists
1 Sharma Maternity&Surgical centre mall Road Arvind Sharma 2253273 98727 -97075
)
2 Rajpaul Hospital G.T.road near GaneshaBasti Pritam Singh Rajpaul 2212774 98724-90328
) 3 Madan Nursing Home G.T.Road UshaMadan 2237500 98151-71511
) 4 Romana Maternity Hospital old bus stand Rupinderromana 2241270 98142-54072
5 Gagan N. Home near Bhanamal trust GaganLata 2255200 93562-20281
)
6 Chandigarh Children &Maternity Home G.T.Road Surinder Kour 2224468 98141-57952
) General Physician

1 GoyalHospital,Old Bus stand BTl Ashok Goyal 2218700 9356200900
)
2 Nohria Hospital ,near petrol pump, GT Rd KKNohria 2211 21 1 9814066760
3 Mohan Lal Nursing Home ,Mall Rd Mohan LalGarg 2252666 9814035179
) )
4 MohinderGen.Hosp. GT. Road BtL Mohinder Singh 2258820 9872635022
5 Mittal Chest & TB Hos.MaIiRd.Bti. R.K.Mittal 2237332 9417094654
) 6 KishoriLal Hos. VasantVih ar Vitul Gupta 2215400 9417020903
For Burns
)
) 1 Badyal Hospital # Opp DAV College ZafarAkeel ---
9814035411
2 Deol Bone and Joint Hospital # Opp Church Raman Goyal 9876640114 9872850433
) 3 Adesh Hospital Medical and Research Institute Varsha 0164-5055000 8872500682
4 Civil Hospital --- 0164-2212221 ---
)
5 Nagpal Hospital # Mall Road T S Nagpal --- 9914032355
6 Delhi Nursing Home # Bibiwala Road Sanjay Garg --- 9814099746
)
)
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Annexure 3
List of Ambulances & their contact numbers
No. Of
Sr. Name of agency Location Contact no. Service Type
Ambulances
BTl 9814074074,
1 Sahara club Bhatinda 12 Free
9876074474,9855133333,9872172072
2 WaheGuru welfare Society BTl 2 9814049037, 9814049037
3 Naujawan Welfare society BTl 6 9888760007,9872460007,9815687280 Free
4 Asra welfare society BTl 2 9815775239,9356368262,9855399158 Free
5 Hanuman welfare Society BTl 2 9779738750, 9779738751 Free
6 Sathi welfare society BTl 1 9914663001,9888043001 Free
7 Badial Hospital BTl 1 9478002411,1642216411 Paid
BTl 9815040203,1642222102,1642211302, Paid
8 Delhi Heart Institute 1
9888235182
9 Pragma Hospital BTl 1 9876819922,1642215501,9356115501 Paid
10 Nagpal Hospital BTl 1 9855211355,9914032355 Paid
11 Adesh medical college BTl 2 1645055000, 1645055100, 1645055015 . Paid
12 Bharat Brain Hospital BTl 2 9781804370, 1642224237,9814206579 Paid

13 Jindal Heart Hospital BTl 1 1642211111,1642213111 Paid
14 Sewak Singh BTl 9 9915855218 Paid
15 Tinku BTl 2 9815113293,9988378257 Paid )
16 Jagsir singh BTl 2 9855307980,8591310057 Paid
)
17 Sanjay BTl 1 9815685090,9914423620 Paid
18 Gurpreet BTl 2 9417322204,9779470014 Paid )
19 Jaswinder BTl 3 9888239319,9915109031 Paid
20 MAX Hospital BTl 1 1646601000 Paid
21 Civil Hospital BTl 3 1642212221 .Gov!.
Talwandi
22 Civil Hospital 2 1655220111 Gov!.
Sabo
23 Civil Hospital Raman 1 7837070028 Gov!.
24 Civil Hospital Sangat 1 9814807505 Gov!.
25 Helpline Welfare Society Raman 1 8699920000, 9653277777 Paid
26 Rotary club Raman 1 9780911200,9417040417 Paid
Total 53 Nos.
)
)
)
)
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)
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) •
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Annexure 4
) Important Emergency Contact Numbers
a) Internal Nos.
-,
S.N NAME DESIGNATION CONTACT NO. IP Number
) Nitin Mittal / Praviin Gangaram Dudle / Refinery Shift
1 8054018659 2618
Kamlesh Shah / Nimesh Kumar Trivedi Superintendent
') Shrikanth M, Vikrant Damodar Chaware, Firoj
2 Ramjan Sheikh, Pankaj Ankush Hingnekar, Shift Fire Engineer 8054018831 2217
Sunil Kumar Maurya
Fire Control Room
)
3 Emergency Management Control room 8054923515 2222/2525
Operator
4 Fire Water Pump House Fire Pump Operator 8054923516
) S.N .Hota, Thomas Varughese, Darshan 3333/3310
) 5 Security Executive 9216693402
Singh, M S Gill , Sukhpal Singh , Dinesh Joshi
) Dr Praveen Mudgal, Dr.Rakesh Bansal, 01655· 2206/2220/2200
6 Dr Sadhu Singh
OHC' Doctor
2206/2220/2200
) 01655·
7 Martin Hawkins Chief Operating Officer
272102/9463697078
2102
) Head of Refinery 01655·2721041
8 A.S. Basu 2104
Operations 9988833432
) 01655·
9 Krishan Tuteja Vice President-Operations
272501/9988819775
2501
) 01655·
10 Ian Thorpe Vice President-HSE
272201/9988881609
2201
01655·
11 Ramesh Kumar Chugh Vice President-Technical
272801/9988887570
2801
Dy. General Manager- 01655·
12 Bharat Chandra Ooley
272504/9988899308
2504
Operations
) 01655·
13 Yogesh Chaudhary AGM- Operations
272519/9988899837
2519
14 Arvind Kumar Vats
273301/9988803866
3301
) Security
) General Manager- 01655·
15 Sanjay Gangopadhyay
272502/9988602790
2502
Operations
16 Prasanta Saha
272904/9988887476
2904
Refinery EDC
) Dy. General Manager-
01655·
17 Arun Kumar Maintenance equipment
272704/9988899427
2704
) reliability
) 18 Rajib Kumar Roy
272441/9988887612
2441
Procurement
)
19 Satish Kumar Kalra 2905
Technical Services 27290519988865653
Ass!. General Manager - 01655·
) 20 Ajit Kumar Maiti
272802/8054100969
2802
Technical
Ass!. General Manager- 01655·
) 21 Pankaj Sharma
272250/9988881682
2250
Warehousing
Ass!. General Manager, 01655·
22 Charanjeet Singh 2302
Refinery HL 272302/9988807902
)
)
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)
23
01655· 2204
Ramesh Shioramji Nandanwar AGM- Fire &Safety
222204/9988805615 )
24 Dr. Praveen Mudgal
01655· 2202
Chief Medical Officer
272202/9988886218
25 Rajnish Mathur
01655·2723451 2345
Dy. Manager - Admin
~- -
9988881504 - --- - --
)
NOTE: )
The list is available at EMCR & any change shall be incorporated by EMCR operator, further it will be incorporated in )
this plan during its revision every year.
)
b) External Nos.
') )
)
IMPORTANT EMERGENCY CONTACT NUMBERS OF BATHINDA )
PESO & Labour Department )

SNo Designation and Address Office Phone
)
1 The Secretary, Ministry of Petroleum &Natural Gas, New Delhi 011-23383562(0)
011-23315542 (0) )
2 Executive Director, Oil Industry Safety Directorate(OISD), New Delhi-11 0001
26493115 (R)
)
3 Chief Controller of Explosives, Nagpur-440 006 (0712)2510103/2510389/2510579
)
Joint Chief Controller of Explosives,
A-1 &A-2 Wing, 5th Floor, C.G.O. (022)27564941 27575946 )
4
Complex, CBD Belapur, 27573881
Navi-Mumbai(Maharashtra) -400614 )
Deputy Chief Controller of Explosives ) )

5 S.C.O. 802, Second floor, NAC, Manimajra (0172)2731035 2731036
Chandigarh -160101 )
Chairman (Punjab Pollution Control Board), Vatavaran Bhawan, Nabha Road , )

6 Patiala, 147001, Punjab, India Phone: 91-175-2215793, 2215802
Zonal Office Bathinda, Punjab Pollution Control Board ,Street No. 12,Power 98789-50502 )
7 house road, Bathinda 98789-50608
)
Regional Office Bathinda
8 Punjab Pollution Control Board , 0164- 2212827 )
Gov!. Quality Marketing Centre, Near I.T.I., Bathinda
Addl., Director of Factories 0172 2700587 )
9
S.C.0-87-88 ,Sector- 170, Chandigarh 98145-03151 (Sh Sodhi Mal)
Joint, Director of Factories 0172 2728610
)
10 S.C.0-87-88 , Sector- 170, Chandigarh 98145-72070 (Sh M P Beri)
- )
)
)
)
Revision 01
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') 9112·000·HSE·006·00048 Page 169 of 226
)
Ass!. Director of Factories
11 9888·507737( Sh Sahil Goel )
221 E, First Floor Mini Secretariat, Bathinda ·151001
- )
12 Labour Enforcement Officer ( C) Chandigarh 9876555499 ( Sh Santosh Mahur )
13 Ass!. Labour Commissioner ( C) Karnal 9981164510 (Sh MS Meena)
14 Regional Labour Commissioner ( C) Chandiagrh 8146181505 ( Sh A K Goyal)
)
Administration Department
) SNo Designation and Address Office Phone
1 Deputy Commissioner, Bathinda 2210042
2 Commissioner, Municipal Corporation Bathinda 2252812
) 3 Additional Chief Administrator, PUDA 2212532
)
4 Assistant Commissioner (UT) 2212042
5 District Transport Officer 2216827
) 6 Sub Divisional Magistrate, Bathinda 2212525
7 Sub Divisional Magistrate, Talwandi Sabo 220241
8 Sub Divisional Magistrate, Rampura Phul 248225
) 9 District Revenue Officer 2219042
10 Tehsildar, Bathinda. 2212412
)
11 Tehsildar, Rampura Phul 248231
12 Tehsildar,Talwandi Sabo 220252
Police Department
)
SNo Designation Office Phone
) 1 DIG Faridkot Range, Bathinda 2219401
2 S.S·. P. Bathinda 2219100
3 S.P. (D) Bathinda 2217900
)
) 4 S.P. (H) Bathinda 2219500
5 D.S.P. (H) Bathinda
)
6 D.S.P. (Rural) Bathinda 2214021
- ~
) 7 D.S.P. (city) 2211125

8 D.S.P. Phul 248229
)
9 D.S.P. Talwandi sabo 220267
)
Format No. 9111-000-PCT- FRM-00006 Rev-DO
)
~
1° HPCL·Mittal Energy Ltd.
9112·000·HSE·OO6·00048
Revision
Issue Date
Next Review
01
2HEB·2018
HMEL -- -
Page 170 of 226 )
PWD B&R
SNo. Designation Office Phone
1 Superintending Engineer, B&R 2240582
6 Executive Engineer, Electrical PWD,B&R 2211615
)
Public Health
SNo. Designation Office Phone )
1 Superintending Engineer, Public Health 2211338
2 Executive Engineer, Public Health No.1 2212380
)
3 Executive Engineer, Public Health No.2 2211431 )
4 Executive Engineer, Public Health (Govt.Works) 2211165
5 S.D.O., Public Health (GW) 2220048 )
Sewerage Board )
)
.1 Superintending Engineer 2212898
2 Executive Engineer, Sewerage Board 2270284 )
Irrigation Department
)
1 Superintending Engineer, Canal Lining 2280410 )
2 Executive Engineer, Canals 2280158
3 Executive Engineer, Canals, Rampura Phul 220359 )
4 Executive Engineer, Jawaharke Divin. Mansa 233914 I
)
Development & Panchayat Department
)
1 D.D.P.O. 2221042 )
2 Secy. Zila Parish ad 2213246
3 Executive Engineer, Panchayati Raj 2210737
) )
4 B.D.P.O., Bathinda. 2211575
)
6 B.D.P.O., Rampura 226129
7 B.D.P.O., Phul 248227 )
8 BD.P.O., Talwandi Sabo 220226
)
9 S.D.O., Panchayati Raj 2210737
Local Government )
)
1 Commissioner, Municipal Corporation 2252812
2 E.O., Bathinda 2252811 )
3 M.E., Municipal Corporation, Bathinda. 2252810
)
4 Dy. Director, Local Bodies, Bathinda. 2272611
5 M.E., Municipal Corporation 2252810 )
)
)
)
Revision 01
)
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'\ HMEL 9112·000·HSE·006·00048 Page 171 of 226
Health Department
}
1 Civil Surgeon, Bathinda. 2212501
2 Emergency 2212221
)
District Officers
) SN o. Designation Office Phone
1 District Informatics Officer 2212080
2 D.P.R.O. 2212865
3 District Forest Officer 2271555
4 District Town Planner 2211230
5 District Social Security Office 2211480
)
) 6 District Welfare Officer 2211915
7 District Food & Supply Controller 2210812
) 8 Deputy Director, Horticulture 2211160
) 9 Deputy Registrar Cooperative Societies 2212409
) )
)
)
Revision 01
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HMEL 9112·000·HSE·006·00048 Page 172 of 226 )
)
Annexure 5
)
Address & Telephone numbers for Mutual Aid Numbers
EMERGENCY CONTACT NUMBERS AT HPCL

IP Number )
SN NAME DESIGNATION CONTACT NO.
(01659 24 ????)
1 Jaya Kumar Aind Sr. Manager - HPCI 97791-38101 3021 )
2 Rajesh Bariyar Manager Maintenance 84276-48772 3057 )
3 Arjun Kulshreshtha Operations Officer - F&S 90411-74711 -
4 Control Room Shift Engineers 92572-03668 3019 )
)
EMERGENCY CONTACT NUMBERS AT TSPL
IP Number )
SN NAME DESIGNATION CONTACT NO.
(0165924 ????)
1 Philip Chacko COO 9501191111 8001 )
2 Chetan Srivastav HEAD-O&M 9779100188 8004
3 Awinash Kumar GM-HSE 8146674456 8009 )
4 Ashwini Mittal Head Operations 8146628201 8042
)
5 Sameer Nayak Head - Maintenance 8146628220 8008
6 Fire Station Fire Station 9876760763 - )
7 Security Control Room Security Office 1659248080 8080
)
8 Operation Control Room Shift IIc Control Room 8283816873 8204
9 Pramod Ranjan AGM - Safety 7087020162 8050 )
) )
)
)
Revision 01
')
NexlReview
9112·000·HSE·006·00048 Page 173 of 226
Address & Telephone numbers of
Annexure 6
---,
Address & Telephone numbers of Emergency Material Suppliers
Environment
) Mis Detox Corporation Pvt. Ltd.
K.G. Chambers, Udhana Darwaja, Ring Road, Surat - 395002
P: +912612351248,2346181
)
Medical
)
) Mis Aviation medical services
) Medanta Air Ambulance services.
GM Marketing Mr Abhijeet Kumar [99100-38895]1 [99588-99479]
)
) Fire fighting checmical suppliers
) Mis KEMEX inrenational Pvt. Ltd. ,
) Regd. Office: BO, Bonanza Industrial Estate, Ashok Chakrawarti Road , Kandivali (E),
Mumbai - 400101. INDIA * Tel. : 91- 22-2887 1234/65703955 * Fax : 91 -22-28878570
Mis Fire Safety devices Pvt. Ltd.

)
8-4 , Rama Commercial Complex, Sector-20b , Nr. Ajronda Modh, Faridabad, Haryana - 121007, India
)
Phone Nos. 08042753560, 0129-2288196/2288197
) )
) Form at No . 91 11-000-PCT- FRM -00006 Rev-OO
)
)
)
Revision 01
Next Rev iew
9112-000-HSE-006-00048 Page 174 of 226 )
Annexure 7
List of Pre Incident Plans (PIP)
Sr. No PIP for Description HMEL Document ID
Crude/Vaccum PIP FOR HOT VR LEAK AND FIRE FROM 501-E- 113A
1 9112-501-HSE-006-00002
Distillation Unit OUTLET NOZZLE FLANGE
Crude/Vaccum PIP FOR HOT HVGO LEAK AND FIRE FROM 501-E-118A
2 9112-501-HSE-006-00003
Distillation Unit OUTLET NOZZLE FLANGE
Crude/Vaccum PIP FOR HGO CR PUMP 501-P-l11A/B SEAL LEAK AND
3 9112-501-HSE-006-00004
Distillation Unit FIRE
Crude/Vaccum PIP FOR PRE FLASH DRUM BOnOM FLANGE LEAK )
4 9112-501-HSE-006-00005
Distillation Unit AND FIRE
Crude/Vaccum )
5 PIP FOR FIN FAN A1011NLET FLANGE LEAK AND FIRE 9112-501-HSE-006-00006
Distillation Unit
Naphtha Hydro PIP FOR FLANGE LEAK AND FIRE FROM UV 8202 IN )
6 9112-502-HSE-006-00001
Treater Unit PSA FEED LINE IN MSB
)
Naphtha Hydro PIP FOR FLANGE LEAK AND FIRE FROM 502 UV 1672 IN
7 9112-502-HSE-006-00002
Treater Unit NHT HEATER FG LINE IN MSB
)
Naphtha Hydro PIP FOR FLANGE LEAK IN 502-R-02 BOnOM FLANGE
8 9112-502-HSE-006-00003
Treater Unit DUE NHT RGC (502-K001) TRIP
Naphtha Hydro PIP FOR NHT SEPARATOR V-02 OUTLET VALVE FV-1701
9 9112-502-HSE-006-00004
Treater Unit FLANGE LEAK(H2S LEAK)
Naphtha Hydro PIP FOR NHT REACTOR FIRE (502-R002 OUTLET
10 9112-502-HSE-006-00006
Treater Unit FLANGE LEAKAGE)
ISOMERISATION PIP FOR OUTLET FLANGE LEAK AND FIRE IN ISOM
11 9112-503-HSE-006-00001
UNIT REACTOR 503 -R002 IN MSB
ISOMERISATION PIP FOR 503-PV-1601 BY PASS VALVE GLAND LEAK
12 9112-503-HSE-006-00002 )
UNIT AND FIRE IN MSB
Continuous Catalytic )
PIP FOR OUTLET FLANGE LEAK DUE TO CCR RGC (504-
13 Reforming 9112-504-HSE-006-00001
K001) TRIP IN MSB
(Reactor Section) )
14
Continuous Catalytic
Reforming
(Reactor Section)
PIP FOR CCR STABILIZER BOnOM 504 UV-2701
FLANGE LEAK AND FIRE
9112-504-HSE-006-00002 ,
Continuous Catalytic ,)
PIP FOR CCR HEATER 504-F-Ol TUBE RUPTURE &
15 Reforming 9112-504-HSE -006-00003
HYDROCARBON FIRE INSIDE HEATER )
(Reactor Section)
PIP FOR OUTLET FLANGE LEAK DUE TO CCR RGC (504- }
16 Reforming 9112-504-HSE-006-00004
K001) TRIP IN MSB
(Reactor Section)
PIP FOR LPG LEAKAGE
17 Reforming 9112-504-HSE-006-00005
(DE-ETHANIZER REFLUX DRUM 504-V010 LEAKAGE) )
(Reactor Section)
Diesel Hydro Treater PROCEDURE FOR PIPA FOR HYDROCARBON LEAK )
18 9112-507-HSE-006-00002
Unit (DHTU) FROM THE OUTLET FLANGE OF ROO1IN DHDT PLANT
Fo rm at No. 9111·000·PCT·F RM·00005 Rev·OO )
)
)
)
Revision 01
) Issue Date I 27-FEB.2018
Next Review
HMEL 9112·000·HSE·006·00048 Page 175 of 226
)
Diesel Hydro Treater PIP FOR HYDROCARBON LEAK AND FIRE FROM THE
19 9112-507-HSE-006-00003
Unit (DHTU) OUTLET OF V-005 IN DHDT PLANT
Diesel Hydro Treater PIP FOR HYDROCARBON LEAK FROM THE OUTLET OF
20 9112-507 -HS E-006-00004
-) Unit (DHTU) V-Ol0 IN DHDT PLANT
PIP FOR HYDROCARBON LEAK AND FIRE FROM THE
) Diesel Hydro Treater
21 OUTLET OF V-012 IN DHDT 9112-507-HSE-006-00005
Unit (DHTU)
PLANT
) PIP FOR NAPHTHA LEAK FROM THE OUTLET OF C-003
Diesel Hydro Treater
22 9112-507-HSE-006-00006
Unit (DHTU) DHDT PLANT
)
Delayed Coker Unit
23 PIP FOR TUBE RUPTURE AND FIRE IN HEATER - DCU 9112-508-HSE-006-00002
) (DCU)
Delayed Coker Unit
24 PIP FOR LPG LEAK AND FIRE IN PUMP 508-P-028A-DCU 9112-508-HSE-006-00003
) (DCU)
l Delayed Coker Unit PIP FOR VR LEAK AND FIRE IN HEATER CHARGE PUMP
25 9112-508-HSE-006-00004
) (DCU) 508-P-002A - DCU
VGO Hydro Treater PIP FOR PIPA FOR LEAK FORM OUTLET FLANGE OF E-
) 26 9112-509-HSE-006-00002
Unit 001 G
VGO Hydro Treater PIP FOR HYDROCARBON LEAK AND FIRE FROM THE
) 27 9112-509-HS E-006-00003
Unit OUTLET OF V-004 IN VGO PLANT
) VGO Hydro Treater PIP FOR HYDROCARBON LEAK FROM THE OUTLET OF
28 9112-509-HSE-006-00004
Unit C-007 VGO PLANT
) VGO Hydro Treater PIP FOR HYDROCARBON LEAK FROM THE OUTLET OF
29 9112-509-HSE-006-00005
Unit C-007 IN VGO PLANT
) VGO Hydro Treater PIP FOR HYDROCARBON LEAK AND FIRE FROM THE
30 9112-509-HSE-006-00006
Unit OUTLET PIPELINE OF RGC-K-001IN VGO
)
FCC-PC Unit,FCC
31 Naphtha Splitter PROCEDURE FOR PIP FOR HEAVY CYCLE OIL (HCO) 9112-510-HS E-006-00002
)
(FCCU) PUMP, 510-P-l02A SEAL LEAK AND FIRE
) FCC-PC Unit,FCC
32 Naphtha Splitter PROCEDURE FOR PIP FOR PROPYLENE (PGP) PRODUCT 9112-510-HSE-006-00003
) ) (FCCU) PUMP, 512-P-l03A SEAL LEAK
FCC-PC Unit,FCC
) 33 Naphtha Splitter PROCEDURE FOR PIP FCC FEED PREHEATER, 510-F-002 9112-510-HSE-006-00004
(FCCU) OUTLET LINE LEAK AND FIRE
) FCC-PC Unit,FCC
34 Naphtha Splitter PROCEDURE FOR PIP FOR PROPANE-PROPYLENE (PP) 9112-510-HSE-006-00005
) (FCCU) MIX PUMP, 510-P-501A SEAL LEAK
FCC-PC Unit,FCC
) 35 Naphtha Splitter PROCEDURE FOR PIP FOR LPG PUMP, 510-P-301A 9112-510-HSE-006-00006
(FCCU) SEAL LEAK
)
FCC-PC Unit,FCC
36 Naphtha Splitter PROCEDURE FOR PIP DEPROPANIZER BOnOM (B-B 9112-510-HSE-006-00007
)
(FCCU) MIX) PUMP, 510-P-502A, SEAL LEAK
FCC-PC Unit,FCC
)
37 Naphtha Splitter PROCEDURE FOR PIP FOR LIGHT CYCLE OIL (LCO) 9112-510-HSE-006-00008
(FCCU) PUMP, 510-P-l04A, SEAL LEAK AND FIRE
)
)
Revision 01
Next Review
H M E L 9112-000-HSE-OOS·00048 Page 176 of 226 )
)
FCC-PC Unit, FCC
38 Naphth a Splitter PROCEDURE FOR PIP FOR SLURRY PUMP AROUND 911 2-510-HSE-006-00009
(FCCU) PUMP, 510-P-101A SEAL LEAK AND FIRE
FCC-PC Unit, FCC
39 Naphtha Splitter PROCEDURE FOR PIP FOR SLURRY PRODUCT PUMP, ·911 2-510-HSE-006-00010
(FCC U) 510-P-106A SEAL LEAK AND FIRE )
FCC-PC Unit,FCC
40 Naphtha Splitter PROCEDURE FOR PIP FOR C3 RECTIFIER REFLU X PUMP, 911 2-510-HSE-006-00011 )
(FCCU) 512-P-102A SEAL LEAK
FCC-PC Unit,FCC
41 Naphtha Splitter "PROCEURE FOR PIP FOR C3 SPLITTER TRAN SFER 9112-510-HSE-006-00012
(FCCU) PUMP (51 2-P-101A) SEAL LEAK" )
FCC-P C Unit, FCC
42 Naphth a Splitter PROCEDURE FOR PIP FOR 51 2-R-101A/B AND 51 2- R- 9112-510-HS E-006-0001?
)
(FCCU) 102A/B FLANGE LEAK
)
FCC-PC Unit,FCC
43 Naphtha Splitter PROCEDURE FOR PIP FOR WGC SECOND STAGE 9112-510-HSE-006-00014
)
(FCCU) DISCHARGE FLANGE LEAK
FCC-PC Unit,FCC )
44 Naphth a Splitter "PROCEDURE FOR PIP FOR REACTOR VAPOR LINE 9112-510-HS E-006-00015
(FCCU) FLANGE (VLB FLANGE) LEAK AND FIRE"
FCC-PC Unit,FCC
45 Naphtha Splitter PROECEDURE FOR PIP STRIPPER FEED PUMP, 510-P- 9112-510-HSE-006-00016
(FCCU) 203A, SEAL LEAKAGE
FCC-PC Unit,FCC
46 Naphth a Splitter PROCEDURE FOR PIP FOR LCN PRODUCT PUMP, 510- 9112-510-HS E-006-00017
(FCCU) P-304A, SEAL LEAK
Hydrogen
PIP FOR FLANGE LEAK AND FIRE FROM EMERGEN CY )
47 Generation Unit 9112-511-HSE-006-00003
HYDROGEN VESSEL V-401 - HGU
(HGU)
Hydrogen
PIP FOR METHANOL LEAKAGE AND FIRE FROM VESSEL
48 Gen eration Unit 9112-511-HSE-006-0000{
(511-V-411) HGU
(HGU)
Hydrogen
PIP FOR HYDROGEN LEAKAGE AND FIRE IN PSA BED - )
49 Generation Unit 9112-511-HSE-006-00005
HGU
(HGU)
Hydrog en
PIP FOR NAPHTHA LEAl< AND FIRE FROM KOD (511-V-
50 Generation Unit 911 2-511-HS E-006-00006
102) - HGU
(HGU)
Hydrog en
51 Generation Unit PIP FOR FLANGE LEAK AND FIRE IN REFORMER 911 2-511-HSE-006-00007
(HGU)
Hydrogen
52 Gen eration Unit PIP FOR LEAK AND FIRE IN MI XING POINT 911 2-511-HSE-006-00008 )
(HGU)
Hydrogen )
PIP FOR LEAK AND FIRE FROM OUTLET FLANGE OF
53 Gen eration Unit 9112-511-HSE-006-00009
2ND RECYCLE GAS COMPRESSOR 511-K-301A )
(HGU)
Format No . 9111-000-PCT-FRM-00006 Re v-OO )
)
)
Revision 01
)
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9112·000·HSE·006·00048 Page 177 of 226
Poly Propylene Unit PIP FOR TEAL FIRE DUE TO RELEASE FROM PUMP
54 9112-513-HSE-006-00002
(PPU) DISCHARGE FLANGE
Poly Propylene Unit PIP FOR FIRE IN PG TAPPING OF PROPYLENE CHARGE
55 9112-513-HSE-006-00003
-, (PPU) PUMP Pll0A/B
Poly Propylene Unit PIP FOR HYDROGEN LEAK FROM THE FILTER G150A/B
) 56 9112-513-HSE-006-00004
(PPU) OUTLET FLANGE AND FIRE
Poly Propylene Unit PIP FOR DUST EXPLOSION DUE TO PP POWDER
57 9112-513-HS'E-006-00005
(PPU) SPILLAGE FROM REACTOR POWDER DISCHARGE LINE
Poly Propylene Unit PIP FOR HYDROCARBON LEAK AND FIRE
58 9112-513-HSE-006-00006
(PPU) FROM JSW COMPRESSOR DISCHARGE FLANGE
PIP FOR H2S LEAKAGE FROM THE CONTROL VALVE OF
59 Treater Unit 9112-514-HS E-006-00001
RICH AMINE LINE OF FUEL GAS AMINE ABSORBER
) PIP FOR LPG LEAKAGE AND FIRE FROM CR (CRACKED
, ) 60 Treater Unit 9112-516-HSE-006-00001
RUN LPG) PREWASH COLUMN
)
PIP FOR LPG LEAKAGE AND FIRE FROM SR (STRAIGHT
61 Treater Unit 9112-516-HSE-006-00002
RUN LPG) PREWASH COLUMN
Sulphur Recovery
) 62 PIP FOR FIRE IN SULPHUR YARD 9112-524-HSE-006-00003
Unit (SRU)
) 63
Sulphur Recovery
PIP FOR FIRE IN SUB STATION-26 CABLE CELLAR 9112-524-HSE-006-00004
Unit (SRU)
Sulphur Recovery PIP FOR H2S LEAKAGE IN SOUR WATER STRORAGE
64 9112-524-HSE-006-00005
Unit (SRU) TANK (520-T-101)
Sulphur Recovery PIP FOR H2S GAS LEAK FROM ACID GAS KNOCK OUT
65 9112-524-HSE-006-00006
Unit (SRU) DRUM UPSTREAM FLANGE
)
Sulphur Recovery
66 PIP FIRE IN ACID GAS KNOCK OUT DRUM 522-V-108 9112-524-HSE-006-00007
) Unit (SRU)
Crude Oil Storage PIP FOR CDU FEED PUMP 551P01A, SEAL LEAK AND
67 9112-551-HSE-006-00002
) and Pumping FIRE
Crude Oil Storage
)
) 68
PIP FOR FULL SURFACE FIRE IN CRUDE TANK
9112-551-HSE-006-00003
and Pumping 551-T-01A
Intermediate Storage PIP FOR DOME ROOF RUPTURE & FIRE IN ISOMERATE
) 69 9112-552-HSE-006-00001
& Pumps TANK 552-T-06
Intermediate Storage
) 70 PIP FOR NHT FEED TANK 552-T-04 A PVRV FIRE 9112-552-HSE-006-00002
& Pumps
) Intermediate Storage PIP FOR PROPYLENE PUMP 552-P-17A SEAL LEAK AND
71 9112-552-HSE-006-00003
& Pumps FIRE
) Intermediate Storage PIP FOR VR TANK 552-T-01B BODY VALVE FLANGE
72 9112-552-HSE-006-00004
& Pumps LEAK
)
Intermediate Storage PIP FOR DCU FEED PUMP 552-P-01A SEAL LEAK & H2S
73 9112-552-HSE-006-00005
& Pumps RELEASE
)
PIP FOR LPG BULLET 553-MB-OlC BOnOM FLANGE
LPG Bullet /
74 LEAK AND FIRE 9112-553-HSE-006-00005
Propylene Bullet
(ALSO APPLICABLE FOR PROPYLENE BULLETS)
)
)
)
Revision 01
Issue Date I 27·FEB-2018 )
Next Review
HMEL 9112·000·HSE·006·00048 Page 178 of 226 )
)
Other Product
PIP FOR RIM SEAL FIRE IN NAPHTHA TANK
75 Storage & Transfer 9112-554-HSE-006-0000l
554-T-OlA
to Marketing
Other Product
76 Storage & Tran sfer PIP FOR RIM SEAL FIRE IN MS TANK (554-T-04B) 9112-554-HSE-006-00002
to Marketing )
Other Product
77 Storage & Transfer PIP FOR FIRE IN MS TANK DYKE 9112-554-HS E-006-00003 )
to Marketing
Other Product )
PIP FOR PRODUCT NAPHTHA PUMP 554-P-01A SEA L
78 Storage & Transfer 9112-554-HSE-006-00004
LEAK AND FIRE )
to Marketing
Other Product
PIP FOR FULL SURFACE FIRE IN MS TANK
79 . Storage & Transfer
554-T-04B
9112-554-HSE-006-0000: ,\. )
to Marketing
)
PROCEDURE FOR PIP FOR AMMONIUM
80 War ehouse 9112-557-HSE-006-0000l
POLYSULP HIDE LEAKAGE AT CHEM ICAL WAREHOUSE )
81 Warehouse PROCEDURE FOR PIP FOR FIRE IN ETHYL MERCAPTAN 9112-557 -HSE-006-00001
)
Effluent Treatment
82 PIP FOR LEAKAGE IN NAOH STORAGE TANK 558-T-14 A 9112-558-HSE-006-00002
Plant (ETP)
Effluent Treatment
83 PIP FOR LEAKAGE IN HCL STORAGE TANK 9112-558-HSE-006-00003
Plant (ETP)
Effluent Treatment
84 PIP FOR LEAKAGE IN H202 STORAGE TANK 9112-558- HSE-006-00004 )
Plant (ETP)
Marketing Terminal PIP FOR LPG LEAK AND FIRE AT
85 9112-562-HSE-006-00003
Connecting piping LPG RAIL LOADING GANTRY
Marketing Termin al PIP FOR FIRE IN OWS COLLECTION PIT ATTANK TRUCK
86 9112-562-HSE-006-00004
Connecting piping LOADING BAY
Marketing Terminal PIP FOR NAPHTHA LEAK AND FIRE AT )
87 9112-562-HSE-006-00005
Connecting piping WHITE OIL RAIL LOADING GANTRY
)
Captive Power Plant PIP FOR FIRE IN TRANSFORMER 10-TR-114 AT CPP
88 9112-575-HSE-006-00002
(CPP) TRANSFORMER YARD
)
Captive Power Plant PIP FOR FIRE IN LCO STORAGE TANK
87 9112-575-HSE-006-00003
(CPP) 575-T-00-509
Captive Power Plant
88 PIP FOR FIRE IN GAS TURBINE-01 9112-575-HSE-006-00004
(CPP)
Captive Power Plant
89 PIP FOR FIRE IN FUEL OIL PUMP HOUSE-CPP 9112-575-HSE-006-00005 )
(CPP)
Captive Power Plant
90 PIP FOR FIRE AT UTILITY BOILER-1 BURNER FLOOR 9112-575-HSE-006-00006
(CPP)
Raw Water )
91 PIP FOR CHLOR INE EMERGENCY IN RWTP 9112-578-HSE-006-00002
Treatment Plant
Cooling Water )
92 System - Refinery & PIP FOR CH LORINE EMERGENCY IN COOLING TOWER 9112-582-HS E-006-00001
Utility )
Format No . 9111-000-PCT-FRM -00006 Rev-DO )
)
)
Revision 01
)
Next Review
9112·000·HSE·006·00048 Page 179 of 226
)
Coolin g W at er
PIP FOR SULPHURIC ACID TANK WALL RUPTUR E IN
93 Syst em - Refin ery & 9112-58 2-HSE-006-00002
COOLING TOWER
Utili t y
---, Coolin g W at er
PIP FOR HYDRO CARBON INGRESS IN COOLING
94 Syst em - Refin ery & 9112-582-HSE-006-00003
TOWER RESULTING FIRE
Utility
Flare & Blowdown PIP FOR LEAKAGE FROM KOD PUMP SUCTION LINE
95 911 2-589-HSE-006-0000l
) System FLANGE AND FIRE
) 96 Laboratory PIP FOR FIRE DURING FLASH POINT TESTING 9112-702-HSE-006-00001
PIP FOR FIRE DURING DISTILLATION OF HSD SAMPLE

) 97 Laboratory 9112-702-HSE-006-00002
LABORATORY
) MCR Electrical PIP FOR FIRE IN ELECTRI CAL CABINET IN MCR
) 98
Cabinet
9112-704-HSE-006-00002
) CRUDE PIPELINE PIP FOR LEAKAGE OF CRUDE PIPELINE PARALLEL TO

99 PARALLEL TO AVENUE D 9112-801-HSE-006-00002
) AVENUE D
PRE INCIDENT PLANNING FOR CLORINE EMERGENCY
) 100 All Refinery Site 9112-000-HSE-006-00003
IN REFINERY
)
Note: All the pre incident plans are available internally at HMEL- TOM S-Technical document managenment system.
)
)
)
) (
Format No. 9111-000-PCT-F RM-00006 Rev-OO
)
)
Revision 01
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HMEL 9112·000·HSE·006·00048 Page 180 of 226 )
)
Annexure 8
List Of Offsite Facilities In Refinery
Following tanks have been included-
1- New Naphtha Tank (554-T-01 D) (Capacity: 9500 m3 ; 1 no. ; Dome Roof Type) )
2- VGO Tank (552-T-07B) (Capacity: 34,410 m3; 1 no ; Cone Roof Type Tank)
3- MS-IV STORAGE- No new MS tank is considered under this project. Existing HSD Tank (554-T-09A) in Tank Farm 19 will )
be converted for the storage of MS.
4 - Hexane Tank ( 554-T-06 AlB) will be converted to Sweet Naphtha Tank. )
5 - ATF Tank 554-T-06A converted to Hexane Tank
6- HSD -III STORAGE- New HSD Tank (554-T-09C) of floating Roof Type (Capacity: 30000 m3) -1 no. )
7- Bitumen Storage Tank (Capacity: 2838 m3 each) - Total 7 no.
8- BBU Feed Tank (Capacity: 22,300 m3) -1 no.
9- BBU Slop oil tank (Capacity: 9,217 m3) - 1 no. )
)
The storage facilities envisaged are as indicated in the table below:
)
CRUDE STORAGE TANKS )

Service Class
tank s Roof (m3 each) )
CRUDE 4 FR A 60000
CRUDE WATER )
1 CR A 3758
DRAIN TANK
SURGE RELIEF
1 CR 425
)
A
TANK
)
INTERMEDIATE FEED TANKS )

No of Type of Capa city
Service Class
tanks Roof (m3 each) )
NHT FEED 2 IFR A 29865
HGU FEED 1 IFR A 10565 ))
VGO HDT FEED 1+1 * CR C 34410
)
DHDT FEED 3 IFR B 19990
DHDT
1 IFR B 19990
FEED/PRODUCT
DCU FEED 3 CR C 24420
)
FCC-PC FEED 2 CR C 29980
DRY SLOP(HEAVY) 2 CR C 3300 )
DRY SLOP(L1GHT) 2 FR A 4560
HEAY NAPTHA 1 CR C 5330 )
REFORMATE 1 FR - 5860
ISOMERATE 1 DR - 4230
CPP FUEL LCO 2 CR A 8200 )
IFO /RFO 2 CR C 5330
SWEET NAPTHA 1 IFR A 1800 )
Format No. 9111-000-PCT-FR M -00005 Rev-OO )
)
)
)
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)
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) 9112·000·HSE·006·00048 Page 181 of 226
HCGO STORAGE
1 CR C 6300
TANK
FUEL OIL TANK 1 CR B 1200
-, BBU Feed Tank 1* CR - 22300
BBU Slop Oil 1* CR - 9217
)
* New Tank
)
FINISHED PRODUCT STORAGE TANKS
No of Type of Capa'city
Service Class
) SWEET NAPHTHA 2** IFR , A 565
MS -III 5 FR A 9150
) MS -IV 5 FR A 9150
NAPTHA 3 FR A 9150
SKO 5 FR B 4545
) ATF 2 IFR B 9190
HEXANE 1** IFR B 9190
) ATF 2 IFR B 8900
MTO 2 FR B 1100
)
HSD-III 5 FR B 56070
) HSD-IV 1 FR B 56070
MS - IV 1** FR B 56070
) SWEET SKO 1 FR B 4545
Naphtha 1* DR A 9500
) HSD 1* FR B 30000
Bitumen 7* CR - 2838
)
**Converted
)
* New Tank
)
) PRESSURISED STORAGE (capacity in m 3 each)
HYDROGEN 2 BULLET 100
) MOUNDED
PROPYLENE 3 2900
BULLET
) MOUNDED
LPG 8 2900
BULLET
)
) Format No, 9111·000·PCT-FRM·00006 Rev·OO
)
)
)
Revision 01
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9112·000·HSE·006·00048 Page 182 of 226
)
SOME IMPORTANT CHEMICALS

Sr. No. Chemical Name Quantity (Kg) Process location I Remark )
1 Chloriding agents 83900 MS Block, 06 months consumption
)
Various Process units, 45 days
2 Caustic Soda 750350 )
consumption
Various process units, 06 months )
3 Anti Foam agent 90000
consumption
MDEA Neat Amine SRU &,ARU; 06 months consumption
) )
4 356000
)
5 PPU additives 481600 06 months consumption
SRU & HGU, 06 months )
6 Ammonia 23920
consumption )
Lubricity improver DHDT; 06 months consumption
7 150000 )
8 Antioxidant & biocide 13700 FCC·PC; 06 months consumption
)
Neutralizing Amine CDU-VDU, annual consumption
9 33200
)
10 Hydrogen peroxide 51360 ETP, 06 months consumption
ETP, 03 months consumption )
11 Hydrochloric acid 90000
Ethyl Mercaptan Additive Offsite; 06 months consumption )
12 20000
Cooling water system & ROOM; )
13 Chlorine 40 tonners
03 months consumption
)
Cooling water system;
Sulphuric Acid 22 tonnes
14 )
03 months consumption
15
Dispersant, Biodispersant, -
82027 Cooling water system )
Microbiocide
Tri-sodium phosphate, )
16 Hydrazine hydrate, Vanadium 100013 CPP, 06 months consumption
Inhibitor, Ammonia Solution )
Oxidizing Biocide, Corrosion &
CPP CT chemicals, 06 months
Scale Inhibitor, Polymeric )
17 17432
Dispersant, Biodispersant, Non- consumption
oxidizing biocide )
)
)
)
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)
Annexure 9
)
Material Safety Data Sheets
---J 1. Crude Oil
1. Chemical Identity
Chemical Name Chemical Classification: Flammable
)
Synonyms: Crude Oil Trade Name
) Formula: CAS No. 80002-05-09 UN No.: 1267
Regulated Identification Shipping Name Hazchem No.:

)
) Codes/Label
) Haz. Waste 10 No.
) Hazardous Ingredients CAS No. Hazardous Ingredi ents CAS No.
1. Toluene 108-888-3 3. Hydrogen
)
2. Benzene 71 -43-2 4. Sulphur
) 2. PHYSICAL AND CHEMICAL DATA
) BOiling Range/Point >23 • C Physical State Appearance: Vi scous liquid Yellow to Black
)
Melting/Freezing Point: NA Vapour Pressure@ 3S ' C Odour: Mild
)
)
Vapour Oensity(Air): 1.7 Solubility in water @
30' C: 0.01 Soluble
Other .
Sp. Gravity(Water:l): 0.9 pH:
3. FIRE & EXPLOSION HAZARD DATA
)
Flammability: Ye s LEL: 1% Fla sh Point>3S'C
) ) TGO Flammability UEL: 5% Auto Ignition Temp :23S ' C

Explosion sensitivity to Impact: Ha zardous Combustion Products :
) Explosion Sensitivity to Static Electricity: Hazardous Polymerization NA
Hazardous Combustion Products
)
Combustible Liquid: Yes Explosive Material Corrosive Material
) Flammable Material: Yes Oxidizer: Others:

Pyrophoric Material: No Organic Peroxide
) 4. REACTIVITY DATA
) Chemical Stability: Stable Reactivity Nil

Incompatibility with Other Material Haz. Reaction Products: C0 2,H 2S, Co etc .
)
5. HEALTH HAZARDS DATA
e
) Routs of Entry: Inhalation, Irritating to Skin & Eyes
Effects of Exposure/Symptoms: Redness, Irritation, Dizziness on Exposure
)
) Format No . 911 1-000-PCT-FRM-00006 Rev-OO
)
)
)
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HMEL 9112·000·HSE·006·00048 Page 184 01226 I )
Emergency Treatment : Flush w ith plenty of water ,Ge l Medical Attention
I
TWA(ACGIH): N/A mg/m3 STEL: N/A

Permissible Exposure Li mit: Not Known Odour Threshold :Not Know n
LD SO(Oral- Rat)
NFPA Hazard Hea lt h= 1, Flammability= 3, Stability= 0, Special=NA
6.PREVENTIVE MEASURES
Personal Protective Equipment's: Goggles, Rubber Hand Gloves

Hand ling & Storage Precau tion s: W ear rubber gloves, Face Shi eld etc.
7.EMERGENCY & FIRST AID MEASURES
-
FIRE Fire Extinguishing Media: Wat er Fog, Foam, Dry Chemical
Special Procedure:
Unu sual Hazard: Non e
EXPOSURE First Aid M eas ures : Respiratory protection, Use plenty of water, Remove victims to Fresh Air
& Provide Oxygen If breathing is difficult
Antidotes/Dosages:
SPILLS Steps to be Take n: Confined Flows, Collect the spil led material
Wa ste Disposa l M ethod: Safe Disposable by burning in incin erator
8. ADDITIONAL INFORMATION /REFERENCES
Refer to published exposure limits-utilize effective control measures and PPE t o maintain worker exposure to co ncen tration s
that are below these limits . En sure th at eyewash stations and safety showers are proximal to the workstation loca ti on. Use non-
Sparking, grounded ventilation system separate from other exhaust systems.
9. MANUFACTURER/SUPPLIER DATA
Contact Person in Emergency

Nam e of Firm Mailing Address Tel epho ne/Tel ex Local Bodies Involved
no's.Telegraphic Address
Standard Packing
. Treamea rd Details/Ref.
Others
)
.. )
)
)
)
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)
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Next Rev iew
) 9112·000·HSE·006·00048 Page 185 of 226
)
2. Diesel
J Chemical Name: Diesel Oi l Chemical Classification: Fl ammable

Synonyms: Diesel Oil Trade Name: HSD
Formula :C13- C18 CAS No . 68476-30-2 UN No.: 1202
)
Regulated Identification Shipping Name Hazchem No .: 3
)
Codes/Label
Haz. Waste ID No .
Hazardous Ingredients CAS No. Hazardous Ingredients CAS No .
)
) 1. Diesel 68476-30-2 3. Naphtha Trace 91-20-3
) 2. Benzene 71-43-2 4. Sulphur Trace 7704-34-9
Diesel is complex mixture of HCs .its exact composition depends on the source of crude oil from which is produced and refining
) methods used.
2. PHYSICAL AND CHEMICAL DATA
) Boiling Range/Point >21S-376 • Physical State: Liquid Appearance: Y ellowish Bro wn
C
)
Melting/Freezing Point: NA Vapour Pressure@ 21 ·C Odour: Perceptible Odour
=2.12 to 26mm of Hg
Vapour Density(Air): 4@ Solubility in water @ Other: Pour Point 6-18 deg. C
) 101kPa 30· C: In- Soluble
Sp. Gravity(Water:l): 0.86- pH:
) 0.90@ 20· C
) Flammability : Yes LEL: 0.6% Flash Point>32 · C
TGD Flammability: Class 3 UEL: 6% Auto Ignition Temp :22S · C
)
Explosion sensitivity to Impact: Not sensitivity to Hazardous Combustion Products: CO, Nitro- oxides, aromatic- HCs
) ) Mechanical impact
Explosion Sensitivity to Static Electricity: For Vapour
etc .
Hazardous Polymerization NA
) sensitivity exist
) Combustible liquid: Yes Explosive Material: Yes Corrosive Material : No

Flammable Material : Yes Oxidizer: NA Oth,ers:
) Pyrophoric Material: NA Organic Peroxide: NA
4. REACTIVITY DATA
)
Chemical Stability: Stable Reactivity· Nil
) Incompatibility with Other Material :Oxidizers such as Hazardou s Reaction Products: CO,S02, N02 etc.
peroxides ,Nitric Acid and Perchlorates
) 5. HEALTH HAZARDS DATA
Routs of Entry: Inhalation, Skin absorption, Ingestion

)
Effects of Exposure/Symptoms: Excessive inhalation, Vapours cause rapid breathing, excitability, Staggering, headache, fatigue
,nausea and vomiting ,dizziness, drossiness, narcosis, convulsions ,coma
) - - -- -- - - - - - - - - --
)
)
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)
Emergency Treatment: Flush with plenty of water, Gel Medical Attention, Move to fresh air.
}
TWA(ACGIH): 800 ppm STEL:N/A
Permissible Exposure Limit: NA Odour Threshold :NA
LD 50(Oral - Rat): 5g/m3
NFPA Hazard I Health= 1, Flammability= 2, Stabi lity= 0, Specia l=NA )
6.PREVENTIVE MEASURES )
Personal Protective Equipment's: Goggles, Rubber Hand Gloves ,Canister type gas mask, safety shower )
Handling & Storage Precautions: Do not expose to heat and naked lights, Keep container and valves closed when not in use .
7.EMERGENCY & FIRST AID MEASURES )
FIRE Fire Extinguishing Media: Water, Foam, Dry Chemical Powder,C0 2
Special Procedure: Shut off leak, if safe to do, keep non -involved peo ple away from sp ill site.
J)
Remove so urces of ignition. )
Unusual Hazard : None
EXPOSURE First Aid Measures: For skin contact use plenty of water, Remove victims to Fresh Air & )
Provide Oxygen If breathing is difficult
Antidotes/Dosages: NA )
SPILLS Steps to be Tak en: Shut off leak, if safe to do so, keep non-Involved people away from spi ll
site .Eliminate all sources of ignition. Prevent spill 'entering into sewers .for major spi llage )
contact emergency serv ices .
Waste Disposal Method : NA )
)
Refer to published exposure limits-utilize effective control measures and PPE to maintain worker exposure to concentrations
that are below these lim its. Ensure that eyewash stations and sa fety showers are proximal to the workstation location. Use non-
)
9. MANUFACTURER/SUPPLIER DATA )
)
Nam e of Firm Mailing Address Telephone/Telex Local Bodies Involved
no's .Telegraphic Address ))
Standard Packing
Treameard Details/Ref. )
Others
)
Format No . 9111·000·PCT·FRM -00006 Rev-OO )
)
)
~
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) Issue Date 27·FEB·2018
Next Review
) HMEL 9112·000·HSE·OO6·00048 Page 187 of 226
J
3. Liquified Petroleum Gas (LPG)
Chemical Name :Liqufied Petroleum Gas Chemical Classification : Aromatic Mixture
I
Synonyms:LPG, Propane, Butane, Propylene, Trade Name: LPG
Purofax, Bottled Ga s
Formula: C3H6-C3H6-C4H10(Mix) CAS No: 68476-85=-7 UN No: 1075
)
Regulated Identification Shipping Name: Hazchem No: 2WE
) Petroleum Gases,
Liquefied
) Codes/Label:
Flammable, Cla ss 2
) Haz. Waste ID No: 5
) CAS No.
Hazardous Ingredients CAS No: Hazardous Ingredients
)
1. Propane- 74-98-6 3 Propylene 115 -07 -1
) 2. Butane 106-97-8
) Boiling Range/Point:>-40"C Appearance: Colourless
Physical State: Gas
)
Melting/Freezing Point: NP Vapour Pressure Odour: Nil
)
Vapour Den sity(Air-1): 1.5 Solubility in water- Other :
) Floats
Sp. Gravity(Water:1): 0.51-
) 0.58
)
Flammability: Yes LEL: 1.9% Flash Point: NA
) TGD Flammability: 2 UEL: 9.5% Auto Ignition Temp : 466 .1

Explosion sensitivity to Impact: NA Hazardou s Combustion Products: CO, C02, S02
J
) Explosion Sensitivity to Static Electricity: Yes Hazardous Polymerization:
)
Combustible: No Explosive Material: May Corrosive Material: No
) Flammable Material: Ye s Oxidizer: No Othe rs :

Pyrophoric Material : No Organic Peroxide: No
Chemical Stability: Stable Reactivity: No reaction with common materials but may react with
)
oxidizing material s
Incompatibility with Other Material: Strong Oxidizer
)
) Routes of Entry: Inhalation, Skin
) Effects of Exposure/Symptoms: Rednes s, I rritation, Dizziness on exposure
Emergency Treatm ent: Remove victim to the fresh air. Provide artificial respiration . Seek medical help . Flush with plenty of
water.
) Format No . 9111·000·PCT·FRM·00006 Rev·OO
)
)
)
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9112-000-HSE-006-00048 Page 188 of 226 )
)
TWA(ACGIH): 1000ppm STEL: Not Listed .
Perm issibl e Exposure Limit: Odour Threshold: 5000-20000
LD 50(Oral- Rat) : IDLH
NFPA Hazard Hea lth= l ,Fl ammabi lity=4 ,Sta bility=O ,S pecial= NA
Personal Protective Equipment: Avoid contact with liquid or gas. Use hand gloves, safety gogg les, gas mask, protective clothing
and shoes . )
Hand ling & Storage Precau ti ons: Keep in ti ghtly closed cylind ers in a coo l, ventilated area, away from heat, fl am e, sparks .
)
FIRE Fire Extinguishing Media : Water spray, DCP . CO 2
)
Special Procedure : keep the co ntain ers coo l by sp ray ing water if exposed to fire or heat.
Unu sual Ha zard: Containers may exp lode in fire. )
EXPOSURE First Aid Measures : Seek medical help. For proper ventilation move victim to the fresh air, J
Give artificial respiration. )
Antidotes/Dosages : Not specific antidote. Trea t symptomati ca lly .
SP ILLS Steps to be Taken : Shut-off leaks if without risk. Warn everybod y that air mixture is explosive .
)
Waste Disposal Method: All ow gas to burn und er contro l.
)
Refer to published expos ure limits- utilize effective contro l measures and PPE to maintain worker exposure to concentra ti ons )
that are below the se limits. Ensure that eyewas h stat ion s and safety showers are proximal to the workstation locat ion. Use non-
sparking, grounded ventilation systems separate from ot her exhaust systems. )
Contact Person in Emerge ncy )

Name of Firm M ai ling Address Telephone/Telex no's. Local Bodies Involved
Telegrap hic Add ress
Standard Packing
Treameard Details/R ef.
)
Oth ers
)
)
)
)
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)
4. Hydrogen Sulfide (H 2S)
Chemical Name: Hydrogen sul phide Chemical Classification: Flammable and Tox ic
J
Synonyms: Hydrosulfuric acid, Sewer gas, Sulphureted Trade Name:
) hydrogen
Formula : CAS No: 7783-06·4 UN No: 1053
) Regulated Id entification Shipping Name: Hazchem No:
Liquefied Compressed
) Gas
Codes/Label
) Haz. Wast e:
Hazardous Ingredients CAS No . Hazardous Ingredients CAS No.
)
) 1. H ydrogen Sulphide 7783-06-4

Boiling Range/Point : 195.8°C Physical State: Gas Appearance: Clear
)
Melting/Freezing Point: 210°C Vapour Pressure= 17.6 Odour: Strong Odour of rotten eggs
)
atm
) Vapour Density(Air-1): 1.25 Solubility in water: 0.4% Other: Mol.Wt. = 34.1
) Sp. Gravity(Water:1): 0.95
) 3. FIRE & EXPLOSION HAZARD DATA
Flammability: Yes LEL: 4% Flash Point : -82deg C

)
TGD Flammability: UEL: 44% Auto Ignition Temp: 260 deg. C
) Explosion sensitivity to Impact: Hazardous Combustion Products: Oxides of sulphur
Explosion Sensitivity to Static Electricity: Hazardous Polymerization: None
Combustible Liquid: Explosive Material : No. Corrosive Material: Yes
) Toxic as well as
flammable Material
Flammable Material: Yes Oxidizer: Yes Strong Others:
)
Pyrophoric Material : No Organic Peroxide: Not
Occur
)
4. REACTIVITY DATA
Chemical Stability: Stable
Incompatibility with Other Material: Strong nitric acid, metals
Routs of Entry : Inhalation, Skin and/or eye contact
)
Effects of Exposure/Symptoms : Irritation eyes, respiratory system; apnea, coma, convulsions; conjunctivitis, eye pain,
lacrimation (discharge of tears), photophobia (abnormal vi sual intolerance to light), corneal vesiculation; dizziness, headache,
)
la ssitude (weakness, exhaustion), irritability, insomnia; gastrointestinal disturbance; liquid: frostbite
)
Emergency Treatment : Symptomatically Treatment is necessary.
TWA(ACGIH): 10 molar ppm STEL:
) Format No . 9111·000·PCT·FRM·00006 Rev-DO
)
)
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)
Permissible Exposure Limit: C 20ppm SOppm [10-m inute Odour Th reshold: Not Known
maximum peak]
)
IDLH: 100p pm
NFPA Hazard Hea lth= 2, Flammability= 4, Stab il ity= 1, Special=NA
)
Personal Protective Eq ui pment: Full face piece resp irator or gas ma sk, gogg les
Hand lin g & Storage Precautions : Do not expose to heat, keep containers & valves closed when not in the use . )
FIR E Fire Extinguishing Media: Se lf breathing apparat us while fighting fire . Water fog and not so li d )
steam of water as it might generate dust & explode in confin ed space.
Special Procedure : Remove contami nated clothes. Provide f rostbite wash. )
Unusua l Hazard:
EXPOSURE First Aid Measures: Respiratory protection, Fresh air drawn if breathing is difficult. ) )
An tid ot es/Do sages : NA )
SP ILLS Steps to be Taken : Keep unauthorised persons awa y. Eli min ate so urces of ignition . Ventilate
area. Sto p leak if it ca n be done sa f ely. Prevent ent ry into sewe rs, waterways, confined )
spaces. Use clean, non-sparking too ls to transfer t o con t ainer.
Waste Di sposa l Method: Sa f e disposal by burning in in cin era tor. )
Refer to published exposure limits -utilize effective control measures and PPE to maintain worker expos ure to co ncentration s )
t hat are below t hese li mits. Ensure that eyewash stations and safety showers are proximal to the workstation location. Use no n-
Sparking, grounded ventilation system sepa rate from oth er exhaust syst ems. )
Co ntact Person in Emergency
)
Name of Firm Mail ing Addr ess Telephone/Telex Loca l Bodies Involved
no's .Telegrap hic Add ress
)
St andard Packing
Treamea rd Details/R ef. )
Others
)
.>
)
')
)
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)
Issue Date 27 ·FEB·2018
Next Review
9112·000·HSE·006·00048
,
) Page 191 of 226
5. Propylene
')
---=J
Chemical Name: Propene Chemical Classification: Flammable
) Synonyms : Methylethylene Trade Name:
Formula: CH2CHCH3 CAS No: 115-07-1 UN No:
)
. .
Regulated Identification Shipping Name: Hazchem No.:
)
Propylene
) Codes/Label
Haz. Waste 10 No.
) ) Hazardous Ingredients CAS No . Hazardous Ingredients CAS No .
) I. Propane 74-98-6
2. Propylene 115-07-1
)
) Boiling Range/Point: >23°C Physical State: Gas (Liq . Appearance: Coloress
Under pressure)
) Melting/Freezing Point: - Vapour Pressure@ 20° Odour: Mild Olefin
185°C C=10atm
)
Vapour Oensity= 1.4 Solubility in water: Other: Mol Wt .: 42 .08
) Slight
Vapour Pressure: 10atm@20°C pH:NA
(68° F)
)
) Flammabil ity: Yes LEL: 2.0% Flash Point: -108°C

TGO Flammability: UEL: 11.1% Auto Ignition Temp: 480°C
)
Explosion sensitivity to Impact: Not Occur Hazardous Combustion Products: CO, C02, small amounts of
J aromatic and aliphatic hydrocarbons .
Explosion Sensitivity to Static Electricity: Hazardous Polymerization: Not Occur
Hazardous Combustion Products: CO, C02, small amounts
of aromatic and aliphatic hydrocarbons.
) Combustible Liquid: Yes Explosive Material: No Corrosive Material:
Flammable Material: Yes Oxidizer: Others:
)
Pyrophoric Material : No Organic Peroxide:
4. REACTIVITY DATA
Chemical Stability: Stable Reactivity:
Incompatibility with Other Material: Keep away from open flames, oxygen and oxidizing materials. Reacts violently with oxides
of nitrogen (NO, Nz0 4 and N20). Oxid izers, mineral acids, halogenated compounds, nitrogen dioxide, molten sulphur.
) 5. HEALTH HAZARDS DATA .
( ) Routs of Entry : Inhalation, Irritating to Eyes, Ingestion

Effects of Exposure/Symptoms: dizziness, disorientation, in-coordination, narcosis, nausea or narcotic effects, vomiting,
prostration
( )
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Emergency Treatm en t : Flush with plenty of Water, seek Medical help, for difficu lti es in breathing provide artificial oxygen.
)
TWA(ACGIH): Simple Asphyxiant STEL:
Permissible Exposure Limit : None Established Odour Threshold :Not Known
LD SO(Oral- Rat): )
NFPA Hazard Health= 1, Flammability= 4, Stability= 1, Special=NA
)
Personal Protective Equipment's: Protective gloves, gogg les with face sh ield, air suppl ied respirator )
Handl ing & Storage Precautions: Do not breathe va pours. Use under well-ventilated conditions. Utilize good personal hygiene
practices, e.g. thoroughly washing after handling the product. Keep product away from heat, sparks, and op~n flames. Avoid )
skin, eye and clothing contact. Keep con tainer closed when not in use. Do not reuse container for any purpose until
commercia lly cleaned. Do not store in open, unlabelled or mislabelled conta in ers. All wiring and electrical equipment shou ld be )
Class 1, Group D. Outdoor or separate storage is preferred.
FIRE Fire Extinguishing Media: Use ABC dry chemical and Halons.
Special Procedure: Fire fight ers should wear a self-contained breathing apparatus (SCBA) )
under positive pressure and full protective gear to prevent all body contact.
Unusual Hazard: None )
EXPOSURE First Aid Measures: Respiratory Protection, Use Plenty Water, Remove Victims t o Fresh Air &
Provide Oxygen if Breathing is Difficult.
)
Antidotes/Dosages:
)
SPILLS Steps to be Taken : Extreme fire and exp losion danger. Eliminate all ignition sources . Shut off
leak if safe to do so. Wear NIOSH/MSHA approved self-contained breathing apparatus (SCBA)
)
to avoid an oxygen depleted atmosphere All unnecessary personnel and persons without
su itable respiratory protection must be escorted from the spill or release area. Do not flush
chemica l into a sewer or water system. Iso late the hazards area (b e prepared to evacuate
)
unnecessary people at least 2,000 feet if there is danger of exp loding containers. Ventil ate
enclosed area. Use explosion-proof fans to increase ventilation and to keep gas )
concentration s below explosive limits.
8. ADDITIONAL INFORMATION /REFERENCES )
Refer to published exposure limits-uti lize effective control measures and PPE to maintain worker exposure to concentrations
that are below these limits. Ensure that eyewash stations and safety showers are proximal to the workstation location . Use non- )
)
Name of Firm Mailing Address Telephone/Te lex Loca l Bodies Involved
no's.Telegraphic Address )
Standard Packing
Others
'------ - - - - -- - - - - -
)
Format No. 9111-000-PCT-FRM-00005 Rev-DO )
)
)
}
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9112·000·HSE·006·00048 Page 193 of 226
6. Hydrogen (H2)
---,
Chemical Name: Hydrogen Chemical Classification: Flammable and Toxic
Synonyms: Dihyd rogen, hydrogen liquid, hydrogen Trade Name:
compressed
) Formula: H2 CAS No: 1333-74-0 UN No.: 19502.1
Regulated Identification Shipping Name: Hazchem No. : 2SE

Liqu efied Compressed
Gas
Codes/Label
)
) Ha zardous Ingredie nts
Haz . Wa ste ID No.
CAS No. Hazardous Ingredie nts CAS No.
1. Hydrogen 1333-74-0
) Boiling Range/Point: -252°C Physical State: Gas Appea rance : Colourless
)
Melting/Freezing Point: -259°C Vapour Pressure=NA Odour: Odourless
)
Vapour Density(Air) : 0.069 Solubility in water: Other:
1.82%by volume @30
J deg.C
Sp . Gravity(Water:1): 0.95
)
)
Fl ammab ility: Yes LEL: 4% Flash Point : -20°C
) TGD Flammability UEL:74.2% Auto Ignition Temp : Product is not self-ignitab le

) Explosion sens itivity to Impact: Yes Ha zardous Combustion Produ cts:
Explosion Sensitivity to Static Electricity: NA Hazardo us Polym erization : None
)
Combusti bl e Material : Yes Explosive Materi al: No Corrosive Material : No
)
Flammable Material: Yes Oxidizer: No Others:
Pyrophoric Material: No Organic Peroxide : No
)
4. REACTIVITY DATA
) Chemical Stability: St ab le
Incompatibility with Other Material : React vigorously with oxidizing mate rials . No chemical reaction with co mmon mat erials but
) low temp causes most materials to become very brittl e.
)
Routes of Entry: Inhal ati on, skin and/or eye contact
) Effects of Exposure/Symptom s : Irritation eyes, respiratory syste m; apnea, coma, con vul sions; co njun ctiviti s, eye pain,
lac rimation (disc harge of tears), photophobia (abnormal vi sual intol eran ce to light), corneal vesiculation; dizziness, headache,
lassitud e (weakness, exhaustion), irrita bility, in somnia; gastroint estin al disturbance; liquid ; fro stb ite
Em ergency Trea tm en t : Symptomatically Tr eatment is necessary
) Format No . 9111-000·PCT-FRM-0 0006 Rev-OO
)
)
Rev ision
I
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HMEL 9112·000·HSE·OO6·00048 Page 194 of 226 - )
---
TWA(ACG IH):.NA STEL: NA
Permissible Exposure Limi t: Not Known Odour Threshold: Not Known
IDLH: NA
NFPA Haza rd Hea lth = 0, Flammab il ity=4, St abi lity=O, Specia l=N A
Perso nal Protective Equipme nt's: Use Goggles, Rubber Hand Gloves .
Hand ling & Storage Precautions: Use of Face shields, W ea r rubber gloves, etc. ! )
)
FIRE Fire Extingui shing Media: Hydrogen is easi ly ignited with low ign ition energy, inclu ding static
electricity . It is lighte r than air & can acc umul ate in the upper sections of enclosed spaces.
Burns with a blu e flame & difficult to see in a day li ght. Preferably wire mesh to be wrapped
around flang es to id entify leaky flan ges . Can exp lod e. Fires could be due t o fri ction, static )
electricity, hea t or flame . ~eep conta in ers cool & allow the gas to burn under contro l.
)
EXPOSURE First Aid Measures: Treat for frostbite. Get medical att ention . Soak skin in lukewarm water . )
Move vi ctim to fresh air.
Antidotes/Dosage s: NA )
SPI LLS Steps to be Taken: Shut off leaks without risk. Can explode.
Wast e Di sposa l M ethod : Do not use or st ore near hea t or open flame The product in liquid
)
form ca n ca use ski n burns.
8. ADDITIONAL INFORMATION /REFERENCES )
Refer to published exposure li mit s-uti lize effective control mea sures and PPE to maintain worker exposu re to concentrations
)
t hat are below these limits. Ensure t hat eyewash station s and safety showers are proxim al to th e workstation location. Use non -
Sparkin g, ground ed ventilation system separate from other exhaust systems .
)
)
)
Nam e of Firm Mailing Address Telephon e/Telex Loca l Bodies Involved )
no' s.Teleg raphi c Address
Sta nd ard Packing
)
Trea mea rd Details/Ref.
Oth ers )
-
Form at No. 9111·000-PCT-FRM-00006 Rev-OO )
)
)
)
Revision 01
) Issue Date I 27·FEB·2018
Next Review
) 9112·000·HSE·006·00048 Page 195 of 226
)
7. Aviation Turbine Fuel (ATF)
)
} Chemical Name : Aviation Turbin e Fuel Chemical Classification: Flammable

Synon ym s: ATF, Jet Fuel Trade Name:
Formula: CAS No: 8002-05-09 UN No: 1267
Regulated Id entification Shipping Name: Hazchem No :
)
Codes/Label
) Haz. Waste:
Ha zardous Ingred ients CAS No. Ha za rd ous Ingredients CAS No.
, I .Kerosene 8008-20-6 3. Napht halene 91-20-3
) 2.Kerosene, Hydro 64742-81-0 4.Ethyl Benzene 100-41-4

) Desulphurised
Boiling Range/Point : 160- Physical St at e: Liquid App eara nce: Col ourl ess to yellow
300 ·C
M elting/Freezin g Point: 40· C Vapour Pressure@ Odour: Petroleum

)
37 .8' C = 1kPa I
) Vapour Density(Air-1): 1.25 Solubility in water @ Other:

30' C: In so lubl e
) Sp . Gravity(Wat er: 1) : 0.81
Flammability: Yes LEL: 0.7% Flash Point: 38 deg C

)
TGD Fl ammability : UEL: 5% Auto Ign ition Temp: 210 deg . C
) Exp losion sensitivity t o Im pact: Ha za rdou s Combustion Products: COx ,SOx, NOx, smoke
Explosion Sensitivity to Static Electricity: Yes Hazardo us Polymerization: Not occur
)
Combustible Liquid : Yes Explosive M ate ri al: May Corrosive Material: No
)
) form ex plosive mixture
with air
Flammable Material: Yes Oxidizer: Oth ers
)
Pyrophoric M ateri al: No Organic Peroxide: NA
4. REACTIVITY DATA
)
Chemical Stability:
) Incompatibility with Oth er Material: With heat, spark oxidizer
Rout s of Entry: Inhalatio n, Irritating t o Skin and eyes
) Effects of Exposure/Symptoms: Irritation ,Redness, Dizziness on expos ure
Emergency Treatment: Flush with plenty of W ater; seek Medical help, move to fresh air
TWA(ACGIH) : NA STEL: NA
) Permissible Exposure Limit: Not Known Odour Threshold: Not Known
LD50 (rat 4hrs.):
NFPA Hazard Hea lth= 0, Flam mability=2, Stability= 0, Special=NA
--- --- -- - -
)
}
I~
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Personal Protective Equipment :Goggles, PVC hand gloves, Heavy Duty work shoes, chemical resistant apron, Respiratory
protection

FIRE Fire Extinguishing Media : Foam, Dry chemical powder, water, CO 2
)
Special Procedure:
)
Unusual Hazard:
EXPOSURE First Aid Measures: For skin contact ,u se plenty of water, remove victim to fresh air if
breathing is difficult, Remove contaminated clothes.
Antidotes/Dosages : NA )
SPILLS Steps to be Taken: Eliminate all sources of ignitions, prevent spill entering into sewers, for
major spillage contact emergency services, Avoid over stacking, Hot work must not be carried )
out near any container used for storage unless it mad e safe plugging or suitable means .
Wa ste Disposal Method : )
)
Refer to published exposure limits-utilize effective control measures and PPE to maintain worker exposure to concentrations
that are below these limits. Ensure that eyewash stations and safety showers are proximal to the workstation location. Use non-
Sparking, grounded ventilation system separate from other exhaust systems. )
)
Name of Firm Mailing Address Telephone/Telex Local Bodies Involved
no's .Telegraphic Addre ss )
Standard Packing
Others
)
Form at No. 9111~OOO - PCT- F R M -00006 Rev- OO )
)
)
)
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9112·000·HSE·006·00048 Page 197 of 226
8. Chlorine (Ch)
J
Chemical Name: Chlorine Chemical Classification :
Synonyms: Trade Name:
Formula: CL2 CAS No: 7782-50-5 UN No.: 1017
) Regulated Identification Shipping Name: Hazchem No .:

Liqu efied Compressed
) Gas
Codes/Label
) Haz. Waste ID No.
) Hazardous Ingredients CAS No. Hazardous Ingredients CAS No .
) 1. Hydrogen 1333-74-0
)
Boiling Range/Point: -34°C Physical State: Gas Appearance: Greenish- Yellow Gas
)
) Melting/Freezing Point: - Vapour Pressure=6.8 Odour: Pungent odour

101°C atm
) Vapour Density(Air-l} : 2.5 Solubility in water: Other:
0.7g/100ml at 20 deg. C
) Sp . Gravity(Water:l}: 1.41 at 20' C
)
Flammability: NA LEL: NA Flash Point:
)
TGD Flammability UEL: NA Auto Ignition Temp:
) Explosion sensitivity to Impact: Hazardous Combustion Products :
Explosion Sensitivity to Static Electricity: Hazardous Polymerization:
J
Combustible Material: Explosive Material: Corrosive Material:
) Flammable Material: Oxidizer: Others:

Pyrophoric Material: Organic Peroxide:
Chemica l Stabil ity: Stab le Reactivity:
)
Incompatibi lity with Other.Material:
Routes of Entry: Inhalation, skin, eye contact

)
Effects of Exposure/Symptoms: burns, chest pain, difficulty breathing, headache, dizziness, hyperactivity,
emotion al disturbances, bluish skin colour, lung damage, death
)
Emergency Treatment: Remove victim to fresh air. Give artificial respiration only if breathing ha s stopped. If breathing is
) difficu lt, give oxygen, in case of skin contact Remove contaminated clothing .
Wash affected area with soap and water., Wash eyes with plenty of water
) TWA(ACGIH}: 0.5ppm STEL: lppm
Permissible Exposure Limit: Not Known I Odour Threshold: Not Known
)
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HMEL 9112·000·HSE·006·00048 Page 198 of 226 )
)
LDSO (Ora l-Rat )
NFPA Hazard Hea lth = 4, Flammability=O, Stability=O, Special=NA
Persona l Protective Equipment's: Breat hing Protectio n. Closed system and venti lation, co ld insul atin g gloves, Protective clothing
Hand ling & Storage Precautions: No co ntact with combustible, acelyne, eth yl ene, hydroge n, ammon ia and finely divided metals
)
FIRE Fi re Extinguishing M edia: In case of fire in th e surro undings use appropriate extinguishing
media, Kee p cylin ders cool by spraying w ith wat er but NO di rect contact with water.
Specia l Procedure:
Unu sua l Hazard:
)
EXP OSURE First Aid Measures: Consult a doctor in all cases
)
Antidotes/Do sages: NA
SPILLS Steps to be Take n: Evacuate danger area, Consu lt an expert! Ventilation .NEVER direct water
jet on liquid . Remove gas with fine water pray. Perso nal Protection, Complete protective
clothing including SCBA, Do not let this chemical en t er the environment. )
Wa ste Disposa l Method :
Refer to published exposure li mits-uti lize effective control measures and PPE to maintain worker ex posu re to concentrations
th at are below th ese lim its . En sure that eyewash sta tions and sa f ety showers are proximal to th e workstation location . Use non- )
Sparkin g, grounded ventilation syste m se parate from other ex haust systems .
)
)
Contact Person in Em erge ncy
Name of Firm Mailing Address Telephone/Telex Local Bodies Involved )
no's .Telegraphic Address
Standard Packing )
Treameard Detail s/Ref.
)
Others
Format No. 9111-000-PCT-FR M-00006 Rev-OO )
)
)
')
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') Issue Date I 27-FEB·2018
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) 9112·000·HSE·006·00048 Page 199 of 226
9. Motor Spirit
---l 1. Chemical Identity

Chemical Name: Motor Spirit(Gasoline/ Petrol) Chemical Classification: Flammable
Synonyms: Motor Spirit(Gasoline/ Petrol) Trade Name :
') Formula: CAS No. 86290-81-5 UN No.: 1203
)
Regulated Identification Shipping Name: Motor Hazchem No.: 3YE
Spirit(Gasoline/
)
Petrol)
Codes/Label
)
) Haz. Waste ID No.
) Hazardous Ingredients CAS No. Hazardous Ingredients CAS No.
I .Ethyl Benzene 1000-41-4 5.C9Aromatics Mix
) 2. Benzene 7\-43-2 6.C6 Naphthenic Mix
3 .. Toluene 108-88-3 7.C5/C6 Paraffin Mix
)
4.Xylene 1330-20-7
) Boiling Range/Point: 46.5 -190 Physical State: Liquid Appearance: Green liquid with motor spirit Odour
•C
) Melting/Freezing Point: NA Vapour Pressure@ 21·C Odour: Motor spirit Odour

=46 -60 kPa
)
Vapour Density(Air-1) : 3-4 Solubility in water @ Other:
) 30· C: I n- Soluble
Sp. Gravity(Water:1): 0.7 ~
) 3. FIRE & EXPLOSION HAZARD DATA
}
) Flammability: Yes LEL: 1.4% Flash Point: -42.7"C
TGD Flammability: Class 3 UEL: 7.8% Auto Ignition Temp:280· C
) Explosion sensitivity to Impact: Not sensitivity to Hazardous Combustion Products: C02, CO,Aldehydes
Mechanical impact
) Explosion Sensitivity to Static Electricity: Yes Hazardous Polymerization NA
) Combustible Liquid : Yes Explosive Material : Yes Corrosive Material: No
Flammable Material: Yes Oxidizer: Yes Others:
)
Pyrophoric Material: NO Organic Peroxide: NA
4. REACTIVITY DATA
Chemical Stability: Stable Reactivity Nil
Incompatibility with Other Material: Hazardous Reaction Products:
) Format No . 9111-000-PCT- FRM-00006 Rev-OO
)
)
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9112·000·HSE·006·00048 Page 20001226 )
)
Routs of Entry: Inhalation, Skin absorption, Ingestion )

Effects of Exposure/Symptoms Redness, Irritation, Di zz iness on Exposure
Emergency Treatment: Flush with plenty of water, Gel Medical Attention, Move to fresh air. )
TWA(ACGIH): 300 ppm STEL: 500 ppm
Permissible Exposure Limit: Not Known Odour Threshold :Not Known )
LD 50(Oral- Rat): sOOOmg/kg
)
NFPA Hazard Health= 1, Flammability= 3, Stabi lity= 0, Special=NA
Personal Protective Equipment's : Goggles, Rubber Hand Gloves ,Can ister type gas mask, safety shower; Heavy duty work shoes )
Handling & Storage Precautions: Do not expose to heat and naked lights, Keep conta in er and valve s closed when not in use.
FIRE Fire Extinguishing Media: Water, Foam, Dry Chemical Powder,C02 )

Special Procedure: Shut off leak, if safe to do, keep non·involved people away from spill site .
Remove sources of ignition . )
Unusual Hazard : None
EXPOSURE First Aid Measures: For skin contact use plenty of water, Remove victims to Fresh Air &
)
Provide Oxygen If breathing is difficult
Antidotes/Dosages: NA
)
~P ILLS Steps to be Taken: Shut off leak, if safe to do so, keep non -Involved people away from spi ll
)
site .Eliminate all sources of ignition. Prevent sp ill entering into sewers .for major spil lage
contact emergency services., Hot work must not be carried out on or near any container used
for storage unless it made safe plugging or suitable means.
)
Waste Disposa l Method: NA
)
8. ADDITIONAL INFORMATION /REFERENC,ES
Refer to published exposure limits-uti lize effective control measures and PPE to maintain worker exposure to concentrations )
that are below these limits. Ensure that eyewash stations and safety showers are proximal to the workstation location. Use non-
Sparking, grounded ventilation system separate from other exhaust systems. )
)
- ,
)
Standard Packing )
Treameard Details/Ref.
)
Others
- - - -- - - -- - - --
Format No. 9111-000-PCT-FRM-00006 Rev-DO )
)
)
)
Revision 01
)
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9112·000·HSE·006·00048 Page 201 of 226
10. Triethyl Aluminium (TEAL)
J
Chemical Name : Triethyl Aluminium Chemica l Classification : Extremel y Flammable Liquid
Synonyms: Trade Name:
Formula: CAS No. UN No .: UN 3394
~
)
Regulated Id entification Shipp ing Name: Hazchem No .:
Codes/Label
) Haz. Waste 10 No .
) Hazardous Ingredients CAS No . 97-93 -8 Hazardous Ingredients CAS No. 97-93-8
)

)
Boiling Range/Point: Physical State: Appearance: liquid
) 186 °C (101.2 kPa)
) Melting/Freezing Point : Vapour Odour: clear, colourless

- 52 °C Pressure@
21' C "
Vapour Oensity(Air-1): Solubility in other:
) water@ 30'
C: In- Solubl e
Sp . Gravity(Water:1):
)
)J Flammability: LEL: not Flash Point: - not applicable
pyrophoric ( paper char test) applicable
) Reacts explosively with water
TGO Flammability : UEL: not Auto Ignition Temp: Spontaneous ly flammable in air
applicable
)
Explosion sens itivity to Impact: Hazardous Combustion Products:
) Explosion Se nsitivity to Static Electricity: Take Hazardous Polymerization

precautionary measures against static
discharges
)
Combustible liqui d: Explosive Corros ive Material:
)
Material:
Flammable Material: Oxidizer: others : Reacts violently with water
)
Pyrophoric ( paper char test) Spontaneously flammable in air
Reacts explosively with water Causes burns.
) Pyrophoric Material: Yes Organic
Peroxide:
Format No. 9111-000·PCT- FRM-00006 Rev-OO
)
)
)
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)
4. REACTIVITY DATA
Chemical Stability: Stable under recommended Reactivity : Avoid contact with moisture and water, alcohols, acids, organic )
storage and handling conditions halides,
ox en containin com ounds .
Incompatibility with Oth er Material: In order to Hazardous Reaction Products:
prevent thermal decomposition do not overheat ( Aluminium, hydrocarbons
T > 180°C exothermic }
5. HEALTH HAZARDS DATA )

Routs of Entry :
)
Inhalation - Always seek medical advice in case of significant exposure
Skin - Remove all contaminated clothing immediately. Wash off with plenty of soap and water. Always seek medical advice.
Launder clothes before reuse. )
Eye- Rinse immediately and as long as possible with plenty of water. Eyelids should be held away from the eyeball to ensure
thorough rinsing . Always seek medical advice.
Ingestion - Only when conscious, rinse mouth, give plenty of water to drink . DO NOT induce vomiting. Seek medical advice ) }
Emergency Tre atment:
)
TWA(ACG IH): OES-TWA 2,0 mg/m' (Aluminium al kyl STEL:
compounds)
Permissible Exposure Limit: Odour Threshold: )
LD SO(Oral- Rat): not determined
)
NFPA Hazard Health= , Flammability= ,Stability= ,Special=
)
~
HIGHLY FLAMMABLE (F)

• CORROSIVE (C)
6.PREVENTIVE MEASURES In all cases of doubt, or when symptoms persist, seek medical attention
~I
~'6>
--~
"\~~
Personal Protective Equipment's : Wear a standard aluminised firefighting suit, Wear self contained breathing apparatus.
)
Respiratory - In case of insufficient ventilation wear suitable respiratory equipment.( respirator with Filter Np2 ) )
Hand- impervious gloves
Eye- Safety glasses and a full face shield )
Skin and body- aluminised suit, protective boots
Handling & Storage Precautions : Handle only in closed system. During sampling , disconnecting lines or opening )
connections, an aluminised suit should be worn . Keep under dry nitrogen containing less than 10 ppm oxygen.
Keep container tightly closed in a cool place. Keep container dry .Keep container in a well-ventilated place.
7,EMERGENCY & FIRST AID MEASURES )
FIRE Extinguishing media dry chemical powder, pressurized with nitrogen, )

vermiculite
Unsuitable extinguishing media Never use water!!! )
CAUTION : reignition may occur
EXPOSURE Special exposure hazards CAUTION: reignition may occur )
)
SPILLS Hazardous decomposition/combustion products
Products of complete combustion are carbon dioxide , water and aluminum )
oxide.
Additionally , products of incomplete combustion may include carbon
monoxide, )
elemental carbon and hydrocarbons (alkanes and alkenes)
. Do not flush into public water courses . Isolate spill area . After fire has been
extin~uished or has been allowed to burn out completely, wait
)
)
)
)
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) 9112·000·HSE·006·00048 Page I 203 of 226
)
CONSIDERABLE TIME (until smoke is no longer observed). After that,
carefully wash spill area with a waterspray.
Protective equipment - Wear a standard aluminised firefighting suit, Wear self contained breathing apparatus
J
.

)
Standard Packing
Treameard Details/Ref.
Others
)
)
)
)
)
)
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Page 204 of 226 I
)
)
Annexure 10
Contours for the affected zones

)
) )
)
)
Toxic contour of leak in H2S rich sour gas KOD 524·V-002 for SRU Unit.
)
Scenario:
)
Large leak from middle inlet of H2S rich sour gas KOD
)
Area affected:
)
South East will travel 435.57 mtrs. from the leak source.
)
)
)
)
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9112·000·HSE·006·00048 Page I 205 of 226
J
)
')
')
)
)
)
)
Toxic contour of chlorine release due to leak of 25mm from chlorine tonner when one tonner is in operation
)
Scenario:
25mm leak in chlorine tonner when one tonner is in operation .
)
...
Contour interpretation:
Contour of 20 ppm (ERPG 3) of ch lorine (10 Minutes release duration) liberated from chlorine tonner when one tonner
) is in operation at time.
) Area Affected:
South east and will travel 633.9m from the leak source.
)
) Form at No . 9111·000-PCT- FRM·00006 Rev-OO
)
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HMEL 9112-000-HSE-006-00048 Page 206 of 226 I )
)
) )
)
)
LFL contour of large leak from LPG transfer pump 553·P·01 AlBIC )
Scenario:
)
Large leak of LPG due to release from LPG transfer pump 553-P-01 AlBIC
)
Area Affected:
East and will travel 433m from the leak source.
)
)
)
)
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9112·000·HSE·006·00048 Page 207 of 226
')
-)
) )
)
37.5kW/m2 _
) 4kW/m2 _
) 12kW/m2 _
) Jet fire contour of large leak from LPG transfer pump 553·P·01 AlBIC
) Scenario:
Large leak of LPG due to release from LPG transfer pump 553-P-01 AlBIC.
) Contour of jet fire radiation showing 4kW/m2 , 12.5 kW/m2 & 37 .5 kW/m2 radiation impact area .
'f Area Affected: 4 kW/m2

East and will travel 394m from the leak source.
)
Fo rm at No. 9111-000-PCT- FRM-00006 Rev-OO
J
)
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01
27·FEB·2018 )
HMEL 9112·000·HSE·OO6·00048 Page 208 of 226
)
)
Annexure 11
Process flow diagrams

)
I NHT UNIT 502
-.
ron
I:@ I )
)
t::::'-.:::.~
1'::.':"... _.,",
::n.:J:'_._ .....
)
,
)
Format No. 911 1-000-PCT-FRM-00006 Rev-OO

)
)
)
Revision 01
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9112·000·HSE·006·00048 Page I 209 of 226
CCR REACTION
.!.iNJilll4SECTION
r-@ I
-) _-.-
)
)
)
) T It ~ ..,:::- 1l . t & = &IP.
)
)
)
)
)
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9112·000·HSE·006·00048 Page 210 of 226 I )
)
CCR REGENERATION SECTION
~ )
e
)
) .)
J
)
Format No . 9111-000-PCT- FRM-00006 Rev-OO )
)
)
)
Revision 01
Issue Dale 27·FEB·2018
NexlReview
) 9112·000·HSE·006·00048 Page I 21 1 of 226
)
ISOMERIZATION
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Next Review
9112·000·HSE·006·00048 Page 21 2 of 226
)
ISOMERIZATION
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-- I---.J
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-
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)
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) )
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)
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-
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)
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') 9112·000·HSE·006·00048 Page 213 of 226
)
..... YUJaI ... c. . . ..,
.."".-."'--,.. ...,...,
)
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) *- HGU PROCESS FLOW DIAGRAM
)
)
)
)
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1* DHDT PROCESS flOW DIAGRAM

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Annexure 12
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Block flow diagram of refinery
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SLOCK FLOW DIAGRAM·GURU GOSIND SINGH REFINERY
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Ann exure 13 OVERALL PLOT PLAN
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Annexure 14 EMERGENCY EVACUATION PLAN AND ASSEMBLY POINTS
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Format No . 9111-000-PCT-FRM-00006 Rev-DO
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·1

HPCL·Mittal Energy Limited

Fo rmat No. 9111-000-PCT-007-00006 Rev-OO

REV DATE REV DETAILS

) Cha~ter-1 5.2 Description of Facilities

5.2.20 CFBC Boiler I

) Cha~ter-4 Pre Emergency Planning

) 8.2 Key Roles & Responsibilities (Level-1)

) 8.3 Key Roles & Responsibilities (Level-2)

) Form at No. 9111-000-~CT-FRM-00006 Rev-OO

) Format No. 9111-000-PCT- FRM -00006 Rev-DO

CIC - Chief Incident Controller PA System- Public Address System

) Format No. 91 11-000-PCT-FR M-00006 Rev-OO

) ) Chapter 6 Emergency Prepardness Measures 60

) Chapter 7 Response Procedures and Measures 70

Chapter 8 Emergency Organisation and Responsibilities 74

Chapter 14 Evacuation 118

) Chapter 15 Information to Public 123

Chapter 16 Roles and Responsibilities of External Agencies 126

) Chapter 21 ERDMP for road transportation 149

) Chapter 22 Security threat plan 156

) Fo rm at No . 911 1-000·PCT-FRM-000 06 Rev·OO

) Annexure 9 Material Safety Data Sheets 183

) Annexure 10 Contours for th e Affected Zones 204

Annexure 11 Process Flow Diagrams 208

) Annexure 16 Layout with process units & storage 226

) Format No. 9111-000-PCT-FRM-00006 Rev-OO

) GURU GOBIND SINGH REFINERY,BATHINDA . H,M - L. 4-u.M. ;:_' L.. fJ 1

i;;;;;~g;: 'c~;;i!,ft:":tff;:' j; ~G*r:t:;i

) Format No . 9111-000-PCT-FRM-00006 Rev-OO

) Format No . 9111-000·PCT·FRM·00006 Rev·OO

GENERAL INFORMATION ABOUT THE REFINERY AND ERDMP

Format No. 9111-000-PCT-FRM-00006 Rev-OO

Form at No, 9111-000-PCT-FRM -00005 Rev-OO )

These regulations shall apply to:

4 Scope & Intent

) Format No. 9111-000-PCT-FRM-00006 Rev-DO

Format No. 9111-000-PCT- FRM-00006 Rev-OO )

5.2.3 Naphtha Isomerisation Unit

5.2.4 Catalytic Cracking Unit

5.2.5 Diesel Hydro·Treater Unit

5.2.6 Delayed Coker Unit

5.2.9 Hydrogen Generation Unit )

5.2.12 Cracked LPG Treating Unit )

Format No. 9111-000-PCT-FRM -00006 Rev-OO )

) The storage facilities envisaged are as indicated in the table below:

) CRUDE STORAGE TANKS

) INTERMEDIATE FEED TANKS

) NHT FEED 2 IFR A 29865

HGU FEED 1 IFR A 10565

DCU FEED 3 CR C 24420

) Format No . 9111-000-PCT-FRM-00006 Rev-OO

DRY SLOP(LlGHT) 2 FR A 4560

HEAY NAPTHA 1 CR C 5330 )

SWEET NAPTHA 1 IFR .A 1800

BBU Feed Tank 1* CR - 22300 )

BBU Slop Oil 1* CR - 9217 )

ATF 2 IFR B 8900

MS -IV 1** FR B 56070 )

Fo rmat No. 9111-000-PCT-FRM-00006 Rev-OO )

) Form at No . 9111-000-PCT-FRM-00006 Rev-OO

5.2.17 Process Description ARU SWS )

Project Description ARU -SWS