28.02.2011

Chennai Petroleum Corporation Limited( A group company of IndianOil )

EMERGENCY

PREVENTION, PREPAREDNESS & MITIGATION

Build a Safer and Disaster Resilient India, by developing a Holistic, Proactive, Multi-hazard and Technology-Driven Strategy for Disaster Management

Maximize profit through manufacturing and supply of petroleum products and other related business in a reliable, ethical and socially responsible manner

Our Vision

Our Mission

National Vision

A world class Energy company well respected and consistently profitable with a dominant presence in South India

Contents

About CPCL

Pioneering Efforts in Technology & Emergency Management

Emergency Prevention, Preparedness and Mitigation Measures

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 %

Inception

6th January, 1967

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

Panorama of Growth

Manali10.5 MMTPA

Nagapattinam1.0 MMTPA

CPCL Refinery Locations

CPCL Manali Refinery Location

No of MAH Units in

Thiruvallur District = 18

No of MAH units in Manali-

Ennore Industrial Belt = 12

POLY BUTYLENE

POLYOL

PROPYLENE GLYCOL

LINEAR ALKYL

BENZENE

MEK

FERTILISERS

Manali Refinery as Mother Industry

CPCL

Kothari Petrochemicals

(PBFS)

Manali Petrochemicals

(Propylene)

Tamil Nadu Petro-Products(LABFS)

Madras Fertilizers(Naphtha)

Cetex Petrochemicals

(MEKFS)

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Chennai Petroleum Corporation Ltd.,

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

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

Pioneering Efforts

Pioneering Efforts

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.

Pioneering Efforts

Pioneering EffortsEmergency 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.

Pioneering Efforts

Emergency Management – Health & Emergency Medical careFirst amongst Oil Industries to set up an in-plant Occupational Health Services Centre

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.

• 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

Pioneering Efforts

Emergency Management – Health & Emergency Medical care

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

Programme’s 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.

Pioneering Efforts

Emergency Management - Awareness

CPCL has established an ITI / Polytechnic in 1984.

The courses on Mechanical and Petroleum Engineering includes

Industrial Safety.

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

AFTER

PLANT 14 E 38

BEFORE

BEFORE AFTER

PLANT 14 E 106

BEFORE AFTER

PLANT 14 K 1C

PLANT 71K01B Lube Oil Cooler

BEFORE AFTER

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

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

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

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.

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.

Emergency Management

Mutual Aid Scheme with MFL & TPL.

CPCL responds to emergencies in any Industrial Unit and

transportation emergencies in the vicinity.

Emergency Management

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

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.

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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