hsef report jan 2013
TRANSCRIPT
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Indorama Eleme Petrochemicals LimitedHSEF Monthly Report (January, 2013)
INDORAMA ELEME PETROCHEMICALS LTD.PORT HARCOURT, NIGERIA
HSEF
MONTHLY REPORT(IEPL-HSEF-4.400)
JANUARY 2013
Prepared by: HSE&F department
Record No. EPCL-HSEF-4.400
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Contents:
SectionNo.
Topics Page No
1 HIGHLIGHTS OF THE MONTH 31.1 Targets for February , 2013 4
1.2 Training highlights 5
2.0 HEALTH STATISTICS
2.1 PME Data 6
2.1 Work related illness 7 8
2.1 Non work related illness 7 - 8
3.0 SAFETY STATISTICS 8
3.1 HSE Committee meetings 83.2 incident / accident statistics: 9
3.3 Activity and area Radiation survey: 10 - 11
4.0 ENVIRONMENTAL STATISTICS :
4.1 Noise level monitoring 12
4.2 BT/VOC survey 13
4.3 Effluent Quality 14 - 15
4.4 Ambient air quality monitoring 16
4.5 Solid waste disposal 16
5.0 ANNEXURE
5.1 Annexure -1 Brief Description Incidents 17
5.2 Annexure 2 Pending compliance from Safety Audit / FARs /Near misses
17
List of abbreviations 18
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1.0 HIGHLIGHTS OF THE MONTH:
DPR (Department of Petroleum Resource) officials visited site for license renewal.
The complex completed 226 Man days free of Lost Time Accident (LTA).
HSE&F performance assessment for HSE&F performance award schemeconducted for last three months in all plants and departments.
Assessment for winner of near miss ward scheme done and winner declared.
One MTC (Medical Treatment Case) injury was recorded in the month of January
2013. (Please see Annexure I)
One fire incident reported in the month of January 2013 ( Please see Annexure I)
Safety meeting conducted in all the plants & departments
Training on Work permit conducted 15 persons participated.Facility for training to contractors employees made operational at gate A with
audio visual facility.
Routine ambient air quality monitoring conducted in IEPL and its host communities
Routine BT/VOC Survey
Routine TCLP Analysis carried out on polymer and sludge incinerator ash
Routine physiochemical and heavy metal analysis of waste water
Routine waste management.Quarterly stack monitoring conducted.
Quarterly servicing of fire trucks, Water Tender and UT- 2 truck done.
Servicing and maintenance of 6Kg / 9Kg portable fire extinguishers in PPU, Project
office and Fire station done.
Live firefighting training conducted for 28 nos. employees, 59 nos. Contractor
security guards.
Fire prevention training conducted for 28 nos. employees.B.A. Set training conducted for 34 nos. employee.
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1.1. TARGETS FOR FEBRUARY, 2013
S/N Activities Responsibility Areas Target Date
1.Process safety Management
coordinators trainingKPP All plants 28.02.2013
2.Internal process safety Management
audit.KPP All Plants 28.02.2013
3. Complex wide Signage up gradation KPP All Plants 28.02.2013
4.Servicing and maintenance of 6kg / 9
kg DCP extinguishers.HSS
Olefins, ETP,
MMD, PP
Warehouses, PE
Warehouses,
Chemical
Warehouse and
Barrie D.
28/02/13
5.
Flushing of underground fire water
mains
( Network )
HSS
All complex
28/02/13
6.Quarterly servicing of fire trucks,
Emergency truck and UT-1 truck.
HSSFire Station
28/02/13
7.Routine ambient air quality monitoring NAK
IEPL Complex and
host communities
28/02/2013
8. Routine TCLP AnalysisNAK ETP
28/02/13
9. Routine BT/VOC Survey JS Olefins plant 28/02/13
10.Physiochemical and heavy metal
analysis of waste waterNAK
Okulu Aleto and
ETP Final
discharge
28/02//13
11. Routine Noise Monitoring JS
Olefins plant,
PPU, PE Plant, PE
W/H and PP Plant.
28/02/13
12.Socializing for BSC 5 Star Audit for
EnvironmentNAK
for HOFs &
HODs28/02/13
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1.2 .TRAINING HIGHLIGHTS:
TrainingPrograms
Target for2012
(Nos. ofpersonnel)
YTD (%) Jan
First Aid Training 140 0 0
Live Fire Fighting747 13 87
Safety Training540 4 25
Safety Induction(Contractors / Visitors)
NA 330 330
2.0 HEALTH STATISTICS:
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PATIENTS TREATMENT CATEGORIES
Sr.No.
Description No. of persons
2.1 TOTAL NUMBER OF PERSONS / PME CHECKED 122
IEPL (Expats) 30IEPL (Local) 36
DEPENDANTS (Expats) 0
DEPENDENTS (Locals) 0
SECURITY 34
CONTRACTORS 22
2.2 WORK RELATED ILLNESS 0IEPL (Expats) 0
IEPL (Local) 0
DEPENDANTS (Expats) 0
DEPENDENTS (Locals) 0
SECURITY 0CONTRACTORS 0
2.3 NON WORK RELATED ILLNESS 121IEPL (Expats) 30
IEPL (Local) 36
DEPENDANTS (Expats) 0
DEPENDENTS (Locals) 0
SECURITY 34
CONTRACTORS 21
2.4 HOSPITALIZATION 22.5 PERIODIC MEDICAL EXAMINATION 22.6 REFERRAL 22.7 INDUSTRIAL ACCIDENT 12.8 MINOR SURGERY 02.9 EXCUSE DUTY 22.10 IMMUNIZATION 42.11 STAFF TRAINING 02.12 NURSES TRAINING 0
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3.0. SAFETY STATISTICS:
Month Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec
Frequencyrate 0
Severity rate0
Total LTA Free Days (As on 31.01.2013): - 266 Days.
Last Lost Time Incident was on : 20. 06. 2012 (Canteen)
3.1 HSE Committee meetings at Plant Levels were conducted as indicated below.
PLANT LEVEL SAFETY MEETING
Olefins PP PE PPUO QAQCLab
Workshop MMD Bagging
: Conducted. X : Not Conducted.
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3.2 INCIDENT / ACCIDENT STATISTICS:
Minor fire (Plant)
Minor fire (Nonplant)
Major fire (Plant)
Major fire (Nonplant)
Gas leakage
Minor Injury (NonPlant)
Minor injury(Plant)
Nearmiss (Plant)
Lost time (plant)
Lost Time (Nonplant)
Month Jan
Minor fire (Plant) 1
Minor fire (Non plant) 0
Major fire (Plant) 0
Major fire (Non plant) 0
Gas leakage 0
Minor Injury (Non Plant) 0
Minor injury (Plant) 1
Nearmiss (Plant) 10
Lost time (plant) 0
Lost Time (Non plant) 0
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3.3 ACTIVITY AND AREA RADIATION SURVEY:
3.3.1 POLYPROPYLENE (PP) PLANT
s/n Tag no. Source serialno.
Equipmentno.
Date of Manufacture Monthly Average (fortnightly)reading((Sv/hr)
1 LE-6012 M-8081 / 5888 06-D-601 1992 2.97
2 LE-6013 M-8163/8162 06-D-602/603 19922.14
3 LE-5007 / 5008 M-6994 06-D-501 1992 1.78
4 LSL-3107 M-6288 06-F-301 1992 1.44
5 LE-3005 M-6505 /6504 06-CY-301 1992 2.65
6 LE-3006 M-6880 06-CY-301 1992 2.28
7 LE-3108 M-6663 06-F-301 1992 0.18
8 LAHH-3109 M-6629 06-F-301 1992 0.42
9 AC-2401 M-6661 06-R-201 1992 0.14
10 AC-2501 M-6662 06-R-202 1992 0.16
3.2 POLYETHYLENE (PE) PLANT
s/n Tag no. Sourceserial no.
Equipmentno.
Date of Manufacture Monthly Average(fortnightly) reading
((Sv/hr
1 LT-1154 7383, 7384,7385, 7386
S-401 1991 3.22
2 LT-1158 M8062 S-402-1 1996 0.20
3 LT-1658 M8068 S-402-2 1996 0.14
4 LT-1163 9510GG S-403-1 (STRAIGHT) 1993 0.20
5 LT-1663 9503GG S-403-2 (STRAIGHT) 1993 0.22
6 LT-1162 9499GG S-403-1 (CONE) 1993 0.09
7 LT-1662 9504GG S-403-2 (CONE) 1993 0.08
8 REMOVEDFROM TAG LT-1162
9398GG OUTSIDE BUNKER 19930.07
9 REMOVEDFROM TAG LT-1662
9385GG OUTSIDE BUNKER 19930.08
TLVs
-Classified Personnel (Radiation worker)- 25 Sv/hr
-Unclassified Personnel (Members of the public)- 7.5 Sv/hr
Sv/hr microserviets per hour
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4.0 ENVIRONMENTAL STATISTICS :
4.1 NOISE LEVEL MONITORING
PLANT NAME SOURCE EQUIPMENT
NOISE LEVEL at Micro level
(dBA)At source 5 meter
OLEFINS BOILER Area 1-K-12A/1-P-
50A/B/C
91 82.1
1-K-12B 85.5 84.0
1-K-12C 88.0 85.5
Compressors K1 94.0 91.5
K2/K3 93.5 82.5
Caustic area Walkway 85.5 83.0
De-propanizer 81.5 78.1
PE PLANT Blender/Silo Grd
floor
North end 88.1 84.0
South end 92.1 89.0Extruder Train-2 91.1 82.5
Operators table
(inside cubicle)
74.0
--
PP PLANT Co-polymer reactor Reactor 401 90.0 85.5
Extruder house 6-D-801 92.1 86.0
Silo/compressor 85.5 81.0
PE Bagging Classifier 90.1 86.5
Bagging Machines Sewing m/c (on/off) 88.1/78.9 75.1
POWER PLANT GTG Inside 88.1 82.0
outside (stacks) 85.0 82.1
Purging air filter 98.5 86.5Nitrogen Plant Plant entrance. 84.2 82.0
Control Room 64.6 -
Compressors
25-K-1 F
90.1 84.8
TLV for Noise is 85db (A)Recommended to use ear protection above the TLV.
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4.2 BT/VOC SURVEY:LOCATION UOM BENZENE TOLUENE VOC
C-5 Hydrogenation Unit
Pumps 1P90A to 1P98B
walkway
ppm 1.1 0.0 0.1
1-P-42 ppm 1.0 0.0 0.0
Walkway by 1-D-80 ppm 0.0 0.0 0.0
C-9
Bottom ground Area 1P39A
to 1P37B
ppm 0.0 0.1 0.0
1-P-35B ppm 0.1 0.0 0.1
K-3 bottom area ppm 1.2 0.1 0.0
D-41 bottom area ppm 0.0 0.0 0.1
C-7
Bottom ground floor ppm 0.0 0.1 1.0
Re-boiler Platform ppm 0.0 1.0 0.0
C-5
Bottom ground floor ppm 0.0 1.0 0.0
Re-boiler Platform ppm 0.0 0.0 0.1
C-4
Bottom ground floor ppm 0.0 0.1 0.0
Driers DR-1/2 A/B & 1-F-1B ppm 0.0 1.2 0.0
DMFS Walkway by 1-D-47/E-
37
ppm 1.1 1.0 0.1
K-1
K1 floor/E25-E28-1E20A/B ppm 0.0 0.0 0.1
Note: Benzene TLV: TWA=0.5ppm, STEL=2.5ppm. Toluene TWA=50 ppm (ACGIH)
Reading taken between 5 m 10 m around emission source(s)
Use of full face with Organic cartridge recommended in area with reading >TLV
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4.3 EFFLUENT QUALITY :
i) pH
Month Jan.13
Nos. of off- spec. 0/31
iii) TSS
Month Jan.13
Nos. of off- spec. 0/31
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iii) BOD
Month Jan.13
Nos. of off- spec. 0/31
iv) COD
Month Jan.13
Nos. of off- spec. 0/31
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4.4AMBIENT AIR QUALITY MONITORING: (EXTERNAL AGENCY)
Parameters UOM
Standards. In side Stations Outside Stations
FMENV DPRNear
Gate.
Near
W/Bridge
Flare
Stack
(North)
Near
AGIP AKPAJO ALETO
SO2 g/m3 260 350 0.00 0.00 0.00 0.00 5.26 0.00
NO2 g/m3 75-113 400 6.31 4.89 12.75 4.34 4.59 2.33
CO g/m3 22.8 30 2.21 2.65 0.00 1.2 0.00 3.78
H2S g/m3
- -0.1
0.080.11 0.00 1.90 0.60
CxHy g/m3 3-160 - 0.00 1.54 0.00 0.00 1.20 0.00
VOC g/m3 6000 - 0.00 2.68 3.91 1.05 3.31 0.00
NH3 g/m3 0.5-1.0 0.5-1.0 0.03 0.00 0.13 0.00 0.38 0.18
TSPM g/m3 600 230 14.74 17.48 20.13 17.79 32.04 27.44
4.5FLUE GAS MONITORING: (EXTERNAL AGENCY)
Parameters UOMIFC
Standard
Stacks
PolymerIncine-rator
SludgeIncine-rator
GTG Stack OlefinsHeaterStack(1-H-1B)
Olefins Boiler Stack
GT-01
GT-04 A B C
SOxmg/Nm 500 1.58 ND 0.00 0.00 0.00 0.00 24.38 0.00
NOxmg/Nm 300
18.22 ND 94.53 100.22 91.11 151.93 158.53 184.96
COmg/Nm --
40.28 ND 0.00 0.00 0.00 0.00 0.00 0.00
H2Smg/Nm --
0.25 ND 0.00 0.00 0.00 0.00 0.00 0.00
CxHymg/Nm --
0.00 ND 0.00 0.00 0.00 0.00 4.32 0.00
VOCmg/Nm --
0.00 ND 0.00 0.00 0.00 0.00 0.00 0.00
ND: Not done (Unit was not running)
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4.6SOLID WASTE DISPOSAL:
Waste. Type. UOM.Quantity/
month
Quantity/
Year (2013)Disposal Method.
Metal Scrap. Scrap. Kg 1580 1580 Sale.Wooden Scrap. Scrap. Kg Nil Nil Sale.
Plastic Scrap.( Including torn
bags)Scrap.
Kg940 940 Sale.
Decontaminated
Containers.Scrap Nos. 566 566 Sale.
Spent Alumina.Solid
Waste.MT 132 132
Stored in designated
location within the
premises
Incinerated Waste. Hazardous Kg 2220 2220 Incinerated.
Waste Oil Scrap LTR 2800 2800Sale./incineration
Molecular Sieve Solid waste MT Nil. 17.5Stored in designated
location within the
premises
Medical waste Hazardous Kg 10.1 10.1 Incinerated.
5.0 ANNEXURE
5.1 Annexure -1 Incidents - FireType of incident : Minor fire
Date : 10-12-2012
Non-Plant : New IRC club (Bush bar)
Description: The straws laid on the roof of the bush bar ignited when a welding work was in progress. The flamingfire spread on 10 m x 8 m area of the roof.
Control measure to prevent recurrence:1. Bunch of highly combustible straw must be removed and then the welding job to be started.2. Fire extinguisher and buckets of water for fire fighting must never be forgotten before starting any hot
work like this.
Annexure -1 Incidents - Injury
Type of incident : medical Treatment case
Date : 08-01-2013
Plant : Chemical warehouse
Description: During unloading gas cylinder finger got caught in between cage and the cylinder.
Control measure to prevent recurrence:i. Proving handle at cage frame. Training the person for right method.
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5.2 Annexure -2 Pending compliance from Safety Audit / FARs / Near misses
Department Pending Responsibility Target Date / Remarks
All plants Training of Safe handling of GasCylinders.
KPP 28.02.2013
PPOU Construction of flange guard onacid pumps in ETP
A.K. Gupta / PhoolSingh/ M. Putta
31/03/2013(Installation going on.Material received earlier isfinished. New order made)
Olefins / PP /offsite
Facility of close loop for Lab.Sampling
Mr. Stoica Ichim / Mr.A Mohapatra / Mr.S.K. Dave.
Survey started.Job will be completed inTAM
General Traffic safety managementownership to be decided
HSS/ RB Discussion between HOF-HSE & Security headongoing
PE plant MOC of drain pit and drain dykearrangement to be executed.(Vaporizer fire FARrecommendation)
Mr. A.B. RAO
Will be completed duringTAM
All Plants All cases of short bolts, less boltsand use of dissimilar materials as
bolts and nuts to be corrected bymechanical group
All plants mechanicalsectional heads Will be completed during
TAM
Electrical/Polymer andchemicalwarehouse.
All 10 years old capacitors of theelectrical lamp fixtures to bereplaced with new metalliccapacitors.
Mr H. Sood31/03/2013Job is in progress
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List of Abbreviations:
ACGIH : American Confrence of Governmental Industrial Hygienist
BOD : Biological oxygen demand
BSC : British Safety CouncilBT/VOC : Benzene, Toluene & Volatile Organic compounds
COD : Chemical oxygen demand
DCP : Dry chemical powder
FMENV : Federal Ministry of Environment
HAZOP : Hazard operability studies
GIT : Gastro intestinal tract
HSE&F : Health, Safety, Environment & Fire
IFC : International Finance Corporation
INDSOP : Indorama Safety Observation Process
JSA : Job Safety Analysis
LEL : Lower Explosive Limit
LOTO : Lock out tag out
LPD : Low point drain
LTA : Lost Time Accident
NESREA : National Environmental Standards and RegulationsEnforcement Agency
ONSEM : Onsite emergency management
PME : Periodical \medical examination
PPE : Personal protective equipment
PTW : Permit to work
RTI : Respiratory Tract Infection.
STEL : Short term exposure limit
TAM : Turn around maintenance
TCLP : Toxic characteristics leachate procedure
TLV : Threshold limit value
TSPM : Total suspended particulate matter
TSS : Total suspended solids
TWA : Time weighted average
UOM : Unit of measure
UTI : Urinary Tract Infection
*** End of Report****