Chennai Petroleum Corporation Limited (A Group Company of IndianOil)

1
Chennai Petroleum Corporation Limited ( A group
company of IndianOil )
EMERGENCY PREVENTION, PREPAREDNESS MITIGATION
28.02.2011
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National Vision
Build a Safer and Disaster Resilient India, by
developing a Holistic, Proactive, Multi-hazard
and Technology-Driven Strategy for Disaster
Management
Our Vision
A world class Energy company well respected and
consistently profitable with a dominant presence
in South India
Our Mission
Maximize profit through manufacturing and supply
of petroleum products and other related business
in a reliable, ethical and socially responsible
manner
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Contents

• About CPCL
• Pioneering Efforts in Technology Emergency
  Management
• Emergency Prevention, Preparedness and Mitigation
  Measures

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Inception

• CPCL (erstwhile MRL) was established as a JV -
  PSU with
• GOI - 74
• NIOC, Iran - 13
• AMOCO, USA - 13
• AMOCO disinvested in 1985. GOI disinvested to
  IOC in March, 2001

Now CPCL is a group company of IndianOil. IOC
51.9 NIOC
15.4 FI others 32.7
6th January, 1967
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Panorama of Growth
Year Capacity MMTPA Major secondary processing units
1969 Ref-I Initial Capacity 2.5 Lube, Cat Reforming, Diesel Desulphurisation, Vis Breaker
1980 Ref-I Debottlenecked 2.8
1984 New 2.8 MMTPA Ref-II 5.6 FCC, Wax
1985-88 Value added products Propylene, Food Grade Hexane
1993 Ref-II Debottlenecked 6.5
1993 CBR Refinery 7.0
2002 Debottlenecking-CBR 7.5
2004 New 3 MMTPA Ref-III 10.5 Hydro Cracker, Cat. Reforming, Soaker Visbreaker
2010 Ref-III revamped 11.5
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CPCL Refinery Locations
Manali 10.5 MMTPA
Nagapattinam 1.0 MMTPA
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CPCL Manali Refinery Location
No of MAH Units in Thiruvallur District 18 No
of MAH units in Manali-Ennore Industrial Belt 12
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Manali Refinery as Mother Industry
Kothari Petrochemicals (PBFS)
POLY BUTYLENE
Manali Petrochemicals (Propylene)
POLYOL PROPYLENE GLYCOL
CPCL
Tamil Nadu Petro-Products (LABFS)
LINEAR ALKYL BENZENE
FERTILISERS
Madras Fertilizers (Naphtha)
Cetex Petrochemicals (MEKFS)
MEK
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Chennai Petroleum Corporation Ltd.,
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Pioneering Efforts
CPCL has implemented the following that are
First of its kind in the Oil Industry

• Distributed Digital Control System (DDCS)
• Advanced Control Optimization Techniques
• City Sewage Reclamation Plant - 1992 Capacity
  increase - 2006
• Zero Discharge Plant - 2002 Capacity increase -
  2005
• RO Rejects Recovery Project - 2006
• Sea Water Desalination Project - 2008
• Renewable Energy Initiatives - 17.6 MW Windmill
  Farm - 2007

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Pioneering Efforts
Emergency Management - Plans

• Factories Act amended in 1987 mandating
  Industries to prepare Onsite Emergency Plans.
• State Level and District Level Co-ordination
  Committees constituted by Govt of TN in Nov 1987
  pursuant to a directive from MoEF in March 1987.
  
• District Authorities were required to prepare
  Offsite Emergency Plans as per the Manufacture,
  Storage and Import of Hazardous Chemicals Rules
  enacted in 1989.
• CPCL took initiative as early as Oct 1986 and was
  the First Industry to prepare Onsite Offsite
  Emergency Plan (released in May 1989)
• Recommended by TNPCB to all industries in TN to
  use as model Assistance provided by CPCL to
  other Industries
• Recommended by OISD to Oil Industries shared
  with them

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Pioneering Efforts
13
Pioneering Efforts
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Pioneering Efforts
Emergency Management - Mock Drills

• The Manufacture, Storage and Import of Hazardous
  Chemicals Rules amended in Oct 1994 mandating
  conducting of Onsite Offsite Mock Drills.
• First Industry to conduct Offsite Mock drill on
  22.06.1989 itself, in the presence of officials
  from OISD, DGFASLI, RLI-Chennai TNPCB.
• Table Top Exercise conducted for Onsite
  Coordinators in 2007 2010 Video placed in
  Intranet for benefit of employees.

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Pioneering Efforts
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Pioneering Efforts
Emergency Management Collective Efforts

• CPCL formed Manali-Ennore Emergency Preparedness
  Committee comprising members from industries in
  Oct 1988.
• Reconstituted as Manali Industries Association
  (MIA) in . CPCL MD is President of the
  Association.
• MIA has two sub-groups - Safety/ Environment and
  HR.
• Meetings every quarter
• Offsite mock drills by one of the member
  industries, as per decision of MIA.

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Pioneering Efforts
Emergency Management Health Emergency Medical
care
First amongst Oil Industries to set up an
in-plant Occupational Health Services Centre
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Pioneering Efforts
Emergency Management Health Emergency Medical
care

• Has been a precursor for the establishment of
  similar OHS systems in other oil industries in
  the country.
• Emergency Medical Care, Education Training,
  Health Promotional activities for employees
  their families and neighbouring villagers
• Resource Centre providing professional and
  technical assistance to other industries.
• Pioneered developing Guidelines for Occupational
  Health Monitoring in Oil Gas Industry OISD
  GDN 166 by OISD.

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Pioneering Efforts
Emergency Management Health Emergency Medical
care

• Community Health Centres in three nearby villages
  for promotion of Health and Hygiene
• Periodical health camps conducted by either
  individually by CPCL-OHS or along with well-known
  Hospitals in eye-care, BP/ Blood sugar, etc

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Pioneering Efforts
Emergency Management - Awareness

• First ever APELL Workshop in India organized thru
  UN in Oct 1992
• Awareness and Preparedness for Emergencies at
  Local Level (APELL) - a process launched by
  United Nations Environment Programmes Division
  of Technology, Industry Economics (UNEP DTIE)
  in 1988.
• One-day Seminar on Chemical Disaster Medical
  Emergency Response was organized thru World
  Environment Centre, USA in March 1993 for the
  benefit of medical professionals from Industries
  in Manali-Ennore, Private and Public Hospitals.
• 4-day seminar on Chemical Emergency
  Preparedness was organized thru MIA/NSC in Oct
  1993 for the benefit of officials from State
  Govt, District Admn, Chemical Industries, Trade
  Unions, Professional Institutions, Voluntary
  Organizations and the local community.

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Pioneering Efforts
Emergency Management - Awareness

• CPCL has established an ITI / Polytechnic in
  1984.
• The courses on Mechanical and Petroleum
  Engineering includes Industrial Safety.

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Emergency Management - Prevention

• Focus towards Mechanical Integrity
• Total Productivity Management Concept (Japan
  Institute of Plant Maintenance)
• Aim Zero Accidents, Zero Breakdowns, Excellent
  Quality, Zero Customer complaints, Low Cost
  Zero Wastages and Defects.
• TPM Excellence Award received
• CPCL-CBR in Dec 2009 (1st South Indian Refinery)
• CPCL-Manali in Jan 2011

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PLANT 14 E 38
AFTER
BEFORE
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PLANT 14 E 106
BEFORE
AFTER
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PLANT 14 K 1C
BEFORE
AFTER
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PLANT 71K01B Lube Oil Cooler
BEFORE
AFTER
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Emergency Management

• Focus towards Mechanical Integrity
• Shell Risk Based Inspection (S-RBI) is adopted in
  CPCL.
• RBI is a structured, multidisciplinary risk based
  decision support process based on API RP 581
  Identifies optimum inspection tasks and integrity
  operating windows and ensures reliability and
  availability of pressure containing equipment
  Helps in assessing the Criticality of failure by
  identifying the probability (likelihood) and
  consequences (Economics, Health Safety and
  Environmental) of failures and Confidence Rating.
• Fire Fighting Facilities as per OISD requirement
• Constantly reviewed and addressed

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Emergency Management

• Awareness
• Focus towards Process Safety than Personal Safety
• CPCL has applied for membership in Centre for
  Chemical Process Safety (CCPS) and is registering
  with their Process Safety Incident Database
  (PSID).
• Awareness lecture sessions on Process Safety
  arranged for employees
• Employees awareness on Significance of Near
  Misses sharing of findings
• Lecture sessions by experts in risk assessment
  organized
• Increase in NMIs reported by more than 100
  during 2010-11
• Focus is on Unsafe Events rather than Unsafe
  Conditions Process or Otherwise
• Employees encouraged to look out for Process
  near-misses
• Incentive scheme under revision to bring focus on
  Process near-misses

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Emergency Management

• Awareness
• New contract workers briefed on basic fire
  prevention requirements, communication facilities
  and their obligations in the event of emergency
• Monthly meeting with Contractors Safety Officers
  Good wrong practices discussed, videos shown
• Contractor Safety Steering Committee comprising
  Contractors Safety Officers constituted recently
  to promote safe working practices, cross-auditing
  of work spots
• Contractors also encouraged to report
  near-misses made mandatory recently
• Safety Film meant for visitors screened at entry
  gate

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Emergency Management

• Awareness
• Conducted in collaboration with MoEF a Training
  Programe on Chemical Accidents Emergency
  Planning Preparedness in July 2010.
• Seminar on Emergency Management for the benefit
  of MIA members, Onsite emergency coordinators
  employees of CPCL and Polytechnic students in Jan
  2011
• RLI presented on Chemical Disaster Management
• CLRI presented Risk Assessment Mitigation
  measures in Manali-Ennore area
• MAPS and IGCAR, Kalpakkam shared their experience
  in conducting offsite mock drills GIS based
  decision support system.

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Emergency Management

• Awareness
• Video Films on DOs and DONTs in the event of a
  chemical emergency taken periodically shown in
  schools and to the public.
• Humorous film by Cine Artists NEVER FEAR in
  2007
• One such film is scheduled for release thru
  District Authorities in March 2011
• Videos released by CSB, US placed in Intranet for
  benefit of employees and shown to MIA members
  during meetings
• Booklets on awareness / self protection in the
  event of emergency distributed to public and
  school children
• Posters on awareness / self protection exhibited
  at PHC, Schools, Hospitals, Police Station and
  other Public Places.

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Emergency Management

• Mutual Aid Scheme with MFL TPL.
• CPCL responds to emergencies in any Industrial
  Unit and transportation emergencies in the
  vicinity.

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Emergency Management Path Forward

• Pursue issuance of updated offsite emergency plan
• GIS based Emergency Management System Develop
  for Manali-Ennore area with support from IGCAR,
  Kalpakkam
• Conducting full fledged mock exercises
• Associate NDRF, Arakkonam (who are trained in
  handling CBRN disasters) other external
  agencies in future offsite mock drills
• Awareness programmes in nearby schools
  periodically, including live fire exercises

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Emergency Management
National Disaster Management Framework envisages
involvement of Corporate Sector in awareness
generation and disaster preparedness and
mitigation planning through sensitization,
training and co-opting of the corporate sector
and their nodal bodies in planning process and
response mechanisms. As a responsible
Corporate, CPCL will continue to play a major
role in the planning process, sensitizing the
public on the safety measures put in place at
CPCL to avoid disasters dos donts in the event
of emergency activating recovery mechanisms.
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Mother Terasa Award

• CPCL awarded the prestigious Mother Teresa Award
  on 23.3.09.
• For Corporate Citizen 2008 for its deep
  involvement in CSR
• By Loyola Instituted of Business Administration
  (LIBA), Chennai

Jury for the prestigious award Shri N.Vittal
Shri T.S.Krishnamurthy
MD receives the award from Dr.C.K.Prahalad,
Management Guru
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THANK YOU