Natref%20regrets%20the%20occurrence%20of%20recent%20accidents%20and%20the%20impact%20on%20those%20affected - PowerPoint PPT Presentation

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Natref%20regrets%20the%20occurrence%20of%20recent%20accidents%20and%20the%20impact%20on%20those%20affected

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Natref regrets the occurrence of recent accidents and the impact on those affected Recent incidents Despatch Incident HF Alkylation unit incident Also available ... – PowerPoint PPT presentation

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Title: Natref%20regrets%20the%20occurrence%20of%20recent%20accidents%20and%20the%20impact%20on%20those%20affected


1
Natref regrets the occurrence of recent accidents
and the impact on those affected
2
BRIEFING AGENDA
  • Recent incidents
  • Despatch Incident
  • HF Alkylation unit incident
  • Also available
  • Natref Background and Orientation
  • SHERQ Management systems
  • Business performance

3
DESPATCH INCIDENT
  • Accident description.
  • On Saturday October 30th a fire occurred in the
    Natref despatch area when a road tanker, whilst
    loading, overfilled. The spill occurred when
    approximately half the tanker compartment volume
    was loaded.
  • The fuel that spilled during the overfill
    ignited, fatally injuring the persons involved
    with the loading.

4
DESPATCH INCIDENTSchematic of scene of accident
Royale Energy Loaded Prem 3459 lt Loaded Diesel
7027 lt Express Fuel Loaded Diesel 7641
lt Henro Bulk Loaded Prem 45000 lt
Person 3 Mr Champion Moletsane Henro Bulk Person
4 Alex Mponda Express Fuel
West
Drain system Grid
BRJ 838 NC
3
Source of Spill
FFX 787 N
Island B
Island A
Henro Bulk
1
Express Fuel
Royale Energy
4
DGP 757 GP
Person 1 Mr Jan Smit Royale Energy Person 2 Mr
Chetty Gazelle Testing Service
Fire Damage
N o r t h
Drawing not to scale
5
(No Transcript)
6
DESPATCH INCIDENT
7
DESPATCH INCIDENT
  • Emergency handling
  • The spray water system was opened at 0112
  • Natref emergency services arrived on the scene at
    0115
  • The Natref emergency action plan was activated
    immediately
  • Mutual Aid assistance was obtained from
    surrounding industries
  • The fire was extinguished at 0210

8
DESPATCH INCIDENT
  • Injuries
  • Four persons were injured and hospitalised at
    0118
  • Two were transferred to Milpark hospital in
    Johannesburg
  • Two persons were treated in Sasolburg and
    discharged the same day
  • Mr R Chetty (surveyor) and Mr J Smit (the truck
    driver) passed away 12 hours and 10 days
    respectively after the accident in the Milpark
    hospital

9
DESPATCH INCIDENT
  • Investigation status
  • Incident was reported to SAPS and DOL - site
    visits on same day
  • Internal investigation held on 30 October -
    possible causes identified and revised procedures
    proposed
  • Results of further technical investigations by
    independent experts
  • Investigation was conducted by DOL with all
    relevant parties present on 26 November.
  • Dossier finalised on 18 February and to be handed
    to state prosecutor
  • Most probable cause of accident - mechanical
    defect on tanker truck
  • Mechanical defects on service provider road
    tanker caused by inadequate maintenance practices

10
DESPATCH INCIDENT
  • Corrective actions (1)
  • DOL Prohibition Notices were immediately
    implemented
  • Upgrade training by tanker service providers
  • No flood loading allowed
  • Vehicle not idling, lights switched off, battery
    isolated, earthed
  • Compartment hatches closed
  • Verify loading volume request versus compartment
    capacity
  • Supervision increased
  • Operating procedures were revised and implemented
    (including training)
  • New documentation (inspection check lists
    driver declarations)

11
DESPATCH INCIDENT
  • Corrective actions (2)
  • Prevention of product spillage is pro-actively
    managed by
  • Pressure testing of vehicle prior to loading
  • Stop loading in gantry if mechanical failure
    occurs
  • Transporter demerit system resulting in vehicle,
    driver or fleet suspensions
  • Root Cause Analysis of each spillage incident in
    co-operation with Transporter
  • Hardware installation to link the overfill
    protection system on vehicles to loading
    de-activation in progress

12
HF ALKYLATION UNIT INCIDENT
  • Process description (more than 250 units
    worldwide)
  • Production of high octane petrol from LPG
    (Butane, butylene)
  • The catalyst used in the process is Hydrofluoric
    acid (HF)
  • HF is a hazardous chemical which is a strong acid
    as well as toxic
  • Precautionary measures to handle HF acid
    (standard procedure)
  • Acid resistant metallurgy used to ensure
    containment
  • People protection through acid resistant
    protective clothing (PPE)
  • People protection through restricted access
  • Early warning systems to indicate loss of
    containment (leak detectors)
  • Training and re-training of personnel working in
    the unit

13
HF ALKYLATION UNIT INCIDENTIncident description
  • Shut down procedure of the Alkylation plant was
    started on 23/1/05
  • Shutdown procedure typically takes 7 days and
    entails the following
  • Separation of acid and hydrocarbons
  • Safe storage of acid
  • Evacuation of hydrocarbons to safe storage
  • Neutralisation of process equipment to allow safe
    entry for repairs
  • On 26/1/05, while the acid was being recovered
  • A gas leak was noticed by plant personnel and the
    alarm was raised
  • The leaking gas ignited and resulted in a fire
  • The site emergency plan was initiated
  • Site emergency personnel were deployed and
    combated the fire
  • Personnel not directly involved were evacuated to
    muster points

14
HF ALKYLATION UNIT INCIDENT
  • Emergency handling
  • Principles
  • Contain gas cloud with water
  • Identify source of gas leak
  • Evacuate personnel not involved (including other
    industries)
  • Emergency statistics
  • Alarm raised 1703
  • Natref emergency services on scene at 1715
  • Own and contractor personnel evacuated at 1715
  • Neighbouring industries were informed at 1720

15
HF ALKY INCIDENTIncident description (continued)
  • Plant personnel started with emergency shut down
    procedures At 1711 the released gas ignited
  • At this time the emergency fire team were already
    at the scene attempting to limit the gas cloud
    with water sprays
  • At 1715 the Natref fire team were at the scene
  • People were evacuated from the refinery at 1715
  • Neighbouring factories were notified of the
    incident
  • At 1740 the fire was extinguished
  • People with special PPE then isolated the last of
    the gas leaks

16
HF ALKYLATION UNIT INCIDENT
17
HF ALKYLATION UNIT INCIDENTHandling of those
affected
  • Principles
  • Be pro-active
  • Dont leave anything to chance
  • Rather over treat than under treat
  • Statistics
  • 17 people were taken to the local hospital
  • 12 were released after observation
  • 5 were kept overnight for further observation

18
HF ALKY INCIDENTInvestigation Process
  • The team was identified to include
  • 3 Trade Unions (Solidarity, SACWU, CEPPWAWU)
  • Natref SHE representatives
  • Natref experts
  • External experts (including Sasol and Total)
  • People involved in the incident
  • DOL site inspection on 28 January
  • All information required by DOL submitted

19
HF ALKY INCIDENTInvestigation Process (continued)
  • Technical experts did an initial evaluation of
    the information
  • The investigation team started their process and
    has completed its work
  • The pump will be investigated by the experts
    approved by DoL
  • Final analysis of the incident and root cause
    identification will then take place
  • Provisional conclusion has been made

20
QUESTIONS ?
21
Historical perspective of Natref
  • In operation for the past 34 years
  • Commissioned in 1971 (most recent in RSA)
  • Oldest operating Total refinery 50 years
  • Oldest operating refinery in South Africa 45
    years
  • Ownership
  • Sasol 63,64
  • Total 36,36
  • Employment
  • Direct jobs 560 persons (2x more than
    Europe/USA)
  • Indirect jobs 4000 jobs, services, contractors

22
Strategic perspective
  • Only inland crude oil refinery
  • Supplies 80 of JIA jet fuel requirement
  • Important supplier of Gauteng area
  • Cheaper to transport crude oil than refined
    products
  • Most efficient crude oil refinery in South Africa
  • Converts 15 more crude oil to petrol, diesel and
    jet
  • Removes twice as much sulphur from crude oil
  • Recovers 15 t/h CO2 (greenhouse gas) for Rand
    Water

23
BUSINESS ORIENTATION
Gauteng and surrounding market
10
Rail - export
600 km
Natcos
Shipping
Petronet pipeline
Tankfarm Durban
Road
30
Petronet Pipelines
Depots
  • Natref oil refinery
  • Sasolburg
  • petrol
  • diesel
  • jet fuel
  • bitumen

60
Crude oil typical from Middle East West African
Johannesburg International
24
Business results
  • Safety
  • Four fold reduction of own personnel injuries
    last 30 months
  • Four fold reduction of contractor injuries last
    24 months
  • Fourth lowest injury rate amongst 28 Total
    refineries
  • Reliability
  • Best reliability amongst 28 Total refineries for
    past 2 y
  • Lowest number of production interruptions in RSA
  • Independent international benchmarking results
  • First in 8 performance parameters
  • Second in 7 performance parameters
  • Third in 2 performance parameters (Profitability
    related)
  • Fourth in one performance parameter (Energy
    consumption)

25
Drivers of Natrefs business success
  • Clear vision and strategy shared by all personnel
  • Effective management systems
  • Demonstrated manpower competence
  • Demonstrated management commitment
  • Independently confirmed, DuPont, Total, Nosa
  • Recognised interdependence and need for networking

26
SHERQ Management
  • Corporate SHERQ support
  • Involvement of both Sasol and Total
  • Guidance via group policies, standards and
    guidelines
  • Industry benchmarking via Total
  • Lessons learnt and incident briefing from other
    sites
  • Subject specific advice
  • Sharing of best practices
  • Incident investigations
  • Corporate audits
  • Networking

27
SHERQ Management
  • Legal framework
  • OSHAct
  • Environmental Management Act
  • Major Hazardous Installations Act
  • Health and safety meeting structure
  • Representatives elected by employees
  • Divisional/Departmental committees
  • Central committee chaired by General Manager

28
SHERQ Management
  • Standards
  • OSH Act and regulations
  • SABS codes
  • Corporate standards (Total Sasol)
  • Management systems (Audited twice/year)
  • NOSA safety management system
  • Inspection management system
  • ISO 14001 (First integrated site system in 1996)
  • ISO 9000 (Since 1992)

29
SAFETY PERFORMANCERecordable Case Rate (12 month
rolling average)
2004
2003
2002
30
SAFETY PERFORMANCEContractor Recordable Case Rate
2004
2003
31
PERFORMANCEFires
32
PERFORMANCEReliability - on-line (12 month
average)
33
PERFORMANCE Utilisation (12 month rolling
average)
2004
2003
2002
34
PERFORMANCEReliability Pump MTBF (12 month
rolling average)
2004
2003
2002
35
Current FCC/Alkylation shutdown results
  • Planning
  • Budget R15m
  • Duration 30 days
  • Manpower
  • Own personnel assigned
  • Contractor personnel assigned
  • Total manhours worked
  • Injury statistics
  • Lost work day cases 4 of which 3 are contractors
  • Recordable cases 2 of which 0 are contractors
  • First aid cases 24 of which 16 are contractors

36
Conclusion
  • Natref is a well managed National asset
  • Recent incidents were caused by material failure
    due to
  • Improper maintenance practices
  • Improper management of change
  • Current management strategy in line with
    international practice
  • Benchmarking with Total
  • DuPont audit findings
  • Identified areas of improvement
  • Process safety management which includes
  • Management of change
  • Contractor management
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