Title: Natref%20regrets%20the%20occurrence%20of%20recent%20accidents%20and%20the%20impact%20on%20those%20affected
1Natref regrets the occurrence of recent accidents
and the impact on those affected
2BRIEFING AGENDA
- Recent incidents
- Despatch Incident
- HF Alkylation unit incident
- Also available
- Natref Background and Orientation
- SHERQ Management systems
- Business performance
3DESPATCH 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.
4DESPATCH 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)
6DESPATCH INCIDENT
7DESPATCH 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
8DESPATCH 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
9DESPATCH 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
10DESPATCH 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)
11DESPATCH 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
12HF 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
13HF 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
14HF 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
15HF 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
16HF ALKYLATION UNIT INCIDENT
17HF 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
18HF 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
19HF 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
20QUESTIONS ?
21Historical 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
22Strategic 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
23BUSINESS 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
24Business 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)
25Drivers 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
26SHERQ 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
27SHERQ 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
28SHERQ 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)
29SAFETY PERFORMANCERecordable Case Rate (12 month
rolling average)
2004
2003
2002
30SAFETY PERFORMANCEContractor Recordable Case Rate
2004
2003
31PERFORMANCEFires
32PERFORMANCEReliability - on-line (12 month
average)
33PERFORMANCE Utilisation (12 month rolling
average)
2004
2003
2002
34PERFORMANCEReliability Pump MTBF (12 month
rolling average)
2004
2003
2002
35Current 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
36Conclusion
- 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