Dedication

Every challenging work needs self efforts

as well as guidance of elders especially

those who were very close to our heart.

My humble effort I dedicate to my sweet

and loving

Father & Mother,

Whose affection, love, encouragement

and prays of day and night make me able

to get such success and honor,

Along with all hard working and respected

Teachers

ABSTRACT

The study emphasis on the industrial health and safety, fire fighting techniques, work permits,

ppe’s, environmental conditions and health procedure of the organizations The industrial health and

safety is being adopted throughout the world because it is a cost saving option and providing shield

to the workers and this work has high magnitude and significance.

The study was carried on at National Refinery Limited (NRL) Karachi situated at Korangi

Industrial area near the Chorangi commonly known as Chamra Chorangi. National Refinery

Limited (NRL) was incorporated on august 19, 1963 as a public limited company. Government of

Pakistan took over the management of NRL under the economic reforms order. The refinery

complex comprises of three refineries, consisting of two lube refineries and a fuel refinery where as

products are grouped into three categories:

As a result of these products stack emission, waste water effluent, noise pollution health and safety

threats remain there, which is required to analyze and mitigate by HSE Engineers. These HSE

issues are caused to serious incidents and hazards if not managed/tackle properly.

We observe during the project study that Noise level is high near the machinery compare to the

other sounding areas and the stack gaseous emissions were found within the NEQs limits where as

the chances of incidents remain present in such a big complex and its happening as well but glad to

know that these were not the sever nature that can cause permanent disabability in spite of this they

focused on the health issue of their precious workers.

In short this organization established within an aims to facilitate and promote environmental,

healthcare and education awareness among the people and the visitors. Further improvement can be

achieved to adopt the required international standards and by drillings activities.

LIST FO ABRIVIATIONS

NRL = National Refinery Limited

NEQs = National Environmental Quality Standards

EPA = Environmental Protection Agency

PEPA = Pakistan Environmental Protection Agency

UAE = United Arab Emirates

API = American Institute of Petroleum

ISO = International Standardization Organization

OHSAS = Occupational Health & Safety Advisory Services

HSE = Health Safety & Environment

COD = Chemical Oxygen Demand

BOD = Biological Oxygen Demand

TSS = Total Suspended Solids

TDS = Total Dissolved Salt

pH = Percentage of Hydrogen Ions\

BTX = Benzene Toluene Xylene

LBO = Lube Base Oil

Mg/l = Milligram per liter

Kg = Kilogram

*C = Degree Centigrade

Cl = Chlorides

Pb = Lead

CO = Carbon Mono Oxide

CO2 = Carbon Dioxide

SOx = Oxides of Sulfur

NOx = Oxides of Nitrogen

H2O = Water (vapors)

LIST OF FIGURES

3.1 National Oil Refineries Limited (NRL) Karachi (00)

3.2 Policy Statement of NRL (00)

4.1 Personal Protective Equipments and their Use (00)

4.2 Eye Protector Safety Glass (00)

4.3 Ear Protector or Ear Plugs (00)

4.4 Multipurpose Head and Ear Protector (00)

4.5 Arms and Hand Protector Safety Gloves (00)

4.6 Protective Clothes and High Visible Safety Apparel (00)

4.7 Foot Protector or Safety Shoes (00)

4.8 Fire brigade vehicle uses during firing for water showering (00)

4.9 Fire fighters during operation (00)

4.10 Controlling equipments like nozzles to increase the velocity of water (00)

4.11 Workers work in Confined Space (00)

4.12 Hot work is doing in a Confined Space (00)

LIST OF TABLES

Table 5.1 High Noise Level of working area near the Machines (00)

Table 5.2 Low Noise Level in open area and working places away

from heavy machines (00)

Table 5.3 Time duration with Noise Level (00)

Table 5.4 Determination of Stacks gaseous emission in

National Oil Refineries (00)

Table 5.5 Determination of Stacks Particulate matters emission in NRL (00)

Table 5.6 Ambient Air Quality of different area of NRL (00)

Table 5.7 Ambient Particulates Matters Monitoring in NRL (00)

Table 5.8 Determination of amount of particles in waste effluent (00)

Table 5.9 Determination of VOCs and H2S inside the refinery (00)

Table 5.10 Month wise status of incidents and loss time injuries in NRL (00)

LIST OF GRAPHS

Figure 5.1 Graphical representation of Noise Variation and compared

with NEQ (00)

Figure 5.2 Graphical comparison of stacks Particulate matters emission

with NEQs (00)

Figure 5.3 Temperature value of NRL with compared with NEQs (00)

Figure 5.4 Amount of Total Dissolved solids of NRL compared with NEQs (00)

Figure 5.5 Values of COD, BOD and TDS in NRL compared with NEQs (00)

Figure 5.6 Value of Grease and Oil in NRL compared with NEQs (00)

Figure 5.7 Graphical Representation of monthly number of incidents in NRL (00)

ACKOWLEDGEMENT

No work would be completed without sacrifice, motivation and encouragement.

We are greatly thankful to almighty Allah who gave us such strength and enabled us to accomplish

this energy intensive and demanding work successfully.

To complete this work we are greatly thankful from core of our heart to our supervisor

Mr. Junaid Ahsan Arain

Lecturer Energy & Environment Engineering department QUEST Nawabshah for his valuable

cooperation, precious guidance, suggestion, constructive and comprehensive information along

with continuous encouragement during the whole work.

We are also the great thankful to the administration of National Refinery Limited. Deep thanks to

Engr: Hafiz Waseem our field supervisor and Mr. Abdul Rasheed Fire Fighter Specialist in

National Refinery Limited.

In Last we exchange our words of thankful to all of our friends and elders who boost us sprit to

work day and night to achieve our long standing desires and to complete this work.

Last but not least THANKS to all of you

Zakir Raza (G.L)

Atiqur Rehman (A.G.L)

Rao Babar (Member)

Suhail Younus (Member)

CHAPTER NO 1

INTRODUCTION

1.1 INTRODUCTION TO STUDY

Industrial health and safety has paramount importance because all the working process, products

and environmental conditions based on it.

For the auditing of any industry various activities related to health and safety issues are being

observed, that the organization either flowing in proper direction smoothly and safely or not, and

this analyze gives us the outcome which reflects the current scenario of the organization and

associated problems in the shape of Health injury, waste water (contaminated water), stack

emissions etc. to manipulate these issues different techniques are involved which contribute to

reduce the hazards which seems to associated by improper working and misuse of

equipments/devices etc.

1.1.2 INTRODUCTION TO OIL REFINERIES

An oil refinery is an industrial process plant where crude oil is processed and refined into more

useful petroleum products, such as Gasoline, Diesel fuel, Asphalt, Heating oil, and Liquid

petroleum gas (LPG). Different product of crude oil is obtained by distillation process where

different products are separated at different temperatures because of difference of boiling points.

Oil refineries are typically large sprawling industrial complexes with extensive piping running

throughout, carrying steam and fluids between large chemical processing units.

Raw crude oil is not useful in natural form as it comes out of the ground. For making it useful for

humans, the oil needs to be separated into parts and refined before its utilization as fuel and

lubricants. Some of the by products of crude oil can be used in petrochemical processes to form

other useful materials such as Plastic and Fiber. Oil refineries are large scale plants where several

hundred thousand barrels of crude oil is processed per day. This high capacity also makes process

optimization and advanced process control very desirable

1.1.3 ABOUT THESIS WORK

As we know that our thesis work is on “Occupational Health and Safety (HSE) in National Oil

Refineries Limited” (NRL). During working in oil refineries there is maximum chance of

unpleasant event or chance of accidents. So we visited and analyze the HSE standers, working

procedures, availability of personal protective equipments and their proper utilization in NRL.

During the whole month of June we studied and visited the industry with Hafiz Waseem. In our

thesis work we observe the working conditions in Oil refineries and also rate of accidents and

probability of accidents. In our case study of occupational health and safety we will provide

information about National Oil Refinery, Safety equipments, fire and fire fighting techniques,

nature of accidents, and cause of accidents, techniques to prevent accidents and proper equipments

for specific accidents.

1.1.4 SCOPE OF WORK

Industry means combination of machines, motors and workers. During work there will be chance of

accidents like explosion, broken of rotating parts of machine, problem of high level of noise that

cause of headache and fatigue etc. To minimize these factors study of occupational health and

safety is very necessary and best for providing safer work place to workers and mitigate the rate of

accidents. Human life is very precious and valuable for everyone and some accidents accurse

during work cause death and failure of body parts like legs or hands can be damage, for providing

information about safety equipments and their proper utilization, intensity of accidents and also

preventions. HSE is very important for any type of work in any industry to provide safer and

efficient work also to mitigate the rate of accidents.

Through ensuring that employees’ tasks are safe, meaningful and conducive to the development of

their personalities, We seeks to create a work environment that fosters creativity as well as

constructive and critical thinking, good learning environment by ensuring that courses, welfare

provisions and the physical environment are adapted to their needs. The work and learning

environment must support and promote its users’ capacity to work and learn, safeguard their health

and well-being, and protect them against work-related illnesses and accidents.

1.1.5 SIGNIFICANCE OF WORK

Study of Health and safety plays an important role in working place in any type of industries to

provide safer working place and safe the valuable life of workers and also provide basic

information about safety equipments.

The health, safety and environmental (HSE) work at NRL shall constitute continuous and

systematic efforts that are integrated into the primary activities. HSE-related problems should be

solved consecutively at the lowest possible level, in order to prevent employees from developing

work-related illnesses or suffering work-related accidents, and to prevent the activities from having

a negative impact on the environment and workers. We know that if there is unpleasant case accrue

like firing, destruction in moving part of machine and problem of chemical leakage etc causes

number of death and loss of valuable products, raw materials and effect the over all structure of

work and work efficiency, to avoid such type of accidents and loss HSE department is vary

essential and beneficial for plant.

HSE department or safety engineers provide us safer working place which is beneficial for worker

as well as industry and management to create awareness among employers and workers on the

importance of OH practices in industry to preserve and protect the health of workers from being

affected by hazards in the working environment. To investigate the effect of specific hazard on the

health of workers so that the short and long term measures can be taken to control the hazard.

1.1.6 PROBLEM STATEMENT

To ensure the health and safety of NRL’s employees which are engaged to perform their duties in

the field, confined space or somewhere else in the premises of NRL for them it remains a hot issue

as they work in the conducive environment than production will automatically increase. Once the

conducive environment is developed it remains for longer time period which not only give the

safety to the worker but also helps to build up their moral once invest in the side of Occupational

Health Safety it must give payback to the higher authorities in the shape of minimum chances to

happen accidents if not than may face injuries in the shape of temporary and/or permanent

disabilities, asthma, suffocation, skin burning, cardiovascular diseases, fatigue etc.

1.1.7 DESCRIPTION OF CHAPTERS:

For the partial requirement of bachelor degree this thesis comprises of several theoretical

aspects like health and safety issue, aims of HSE, Pakistan conditions of OSHAS, safety act,

personal protective equipments, fire fighting and techniques, work permit, risk assessment

regarding occupational health and safety each of these aspect give clean and crystal picture that

how much importance they exist in the completion of case study.

Chapter 1

Introduction

It contain those topic which are consider helpful for the

fulfillment of project area study, these are background, scope of

study, objectives and other terms.

Chapter 2

Literature Review

Work, References and publications of those who have been

worked on industrial health and safety.

Chapter 3

Project Area

General description of about those term which have significance

in the field of occupational health and safety like work permit,

PPE’s, fire fighting techniques at working area

Chapter 4

Importance of HS& E

Theoretical work related to HSE

Chapter 5

Experimental Work

Investigations, survey and questioner regarding to HSE in the

organization (NRL) and collection of data by utilizing

equipments.

Chapter 6Conclusion

Conclusion and recommendation towards the working conditions

and environment and final result.

. 1.1.8 OBJETIVES OF WORK The objectives of the work are:

To analyze the health hazards and potential of hazards during working in Oil Refineries.

To analyze the HSE standers and availability of safety equipments for prevention or

mitigation of the intensity of accidents.

To provide the basic information of PPE’s and proper use of PPE’s for specific hazards.

To analyze the accident rate and to collect the HSE reports of NRL.

CHAPTER NO 2

LITERATURE REVIEW

Various works have been carried out for the safety of the workers and also environmental safety to

protect precious life of the workers as well as working area. Many scholars worked and give their

valuable ideas related to Occupational Health and Safety. Their articles are briefly discussed below:

Chun-Chieh Chi, He researched on industrial health and safety and states that petrochemical and

petroleum industries are two of the main sources of industrial air pollution in Taiwan. Data used in

this study concern outdoor air pollution and the health of individuals living in communities in close

proximity to oil refinery plants. The prevalence of delivery of preterm birth infants was

significantly higher in mothers living near the oil refinery plants than in control mothers in Taiwan.

After controlling for several possible confounders (including maternal age, season, marital status,

maternal education, and infant sex), the adjusted odds ratio was 1.14 (95% CI=1.01–1.28) for

delivery of preterm infants for mothers living near oil refinery plants. These data provide further

support for the hypothesis that air pollution can affect the outcome of pregnancies [01].

Goldenhar, Linda M et al they studied often lacked a theoretical basis; they used small samples,

and tested interventions lacking the intensity to cause the desired change. Most designs were either

no experimental or quasi-experimental with uncontrolled sources of bias. Recommendations for

future research include methods of minimizing the problems and biases caused by these

weaknesses. No methodological issues such as the costs of implementing interventions and the

cultural and political dimensions of the workplace are also addressed. Although many

methodological issues associated with field-based research are not easily addressed, researchers

should make a stronger attempt to address these issues if the field of occupational health and safety

intervention research is to be productive [02].

Craig Zwerling MD, PhD, MPH, he searched on Occupational injuries continue to exact a great

toll on American workers and their employers—the physical and financial costs are enormous.

However, in the current political climate, few employers or regulatory agencies will implement

injury prevention interventions without specific evidence of their effectiveness. This paper reviews

the literature on the design, conduct, and evaluation of occupational injury interventions. Our

review suggests that randomized controlled trials are rare and also notes that the quasi-experimental

studies in the literature often use the weakest designs. We recommend a hierarchical approach to

evaluating occupational injury interventions—beginning with qualitative studies, following up with

simple quasi-experimental designs using historical controls, continuing with more elaborate quasi-

experimental designs comparing different firms' experience, and, when necessary, implementing

randomized controlled trials [03].

Chrysanthi Lekka, Caroline Sugden they worked and suggested that there are a number of

practices that organizations can adopt to achieve high levels of reliability and safety. These

practices are often discussed in the context of major incidents to highlight the safety standards that

high hazard organizations should try to emulate. However, previous research has predominantly

focused on non-profit organizations, and comparatively little research has examined whether high

reliability practices may be meaningfully applied to commercial contexts. This paper addresses this

gap by using a qualitative approach to explore the types of reliability-enhancing practices

implemented in a UK-based oil refinery in its attempt to achieve its ethos of ‘safe and reliable

operations’. The findings illustrate the successful application of reliability-enhancing practices in

several domains, including: hazard identification and control; emergency preparedness and

collection; and analysis of incidents and near misses. Management commitment to safety emerged

as an important factor underpinning the successful implementation of reliability-enhancing

practices, highlighting its potential significance in the context of commercial organizations.

However, promoting an open reporting culture and maintaining high levels of management

visibility may be some of the challenges encountered by organizations striving to implement

reliability-enhancing practices [04].

Tarja Ketola studied and stated that it regularly results in environmental shocks and stresses and in

public outrage. Strategic planning has become very complex in practice as the traditional political

and economic factors to be taken into account have now been accompanied by environmental

factors. This paper examines the strategic environmental planning process in two companies with

different approaches to change.

It seems that top-down sophisticated strategic environmental planning leaves room for power

struggles which may compromise the environmental behavior of a company. In addition, there is

often a gap between environmental scenarios and environmental policies which should be filled

with a vision. A bottom-up approach may lead to better environmental performance because there

is little room for political games and because the operating unit can respond directly to the

environmental pressure exerted by its interest-groups. Yet the lack of scenarios and visions in a

bottom-up approach reduces the operating unit's chances to make long-term plans, and allows it

only to react to changes in its business environment. In general, companies should enrich their

strategic environmental planning with visioning and link these two with rigorous strategic

environmental leadership [05].

Faisal I Khan and SA Abbasi studied and state that in their research article of Risk Assessment in

Chemical Process Industries the use of a new computer-automated tool TORAP (Tools for Rapid

risk Assessment in Petroleum refinery and Petrochemical industries) is demonstrated through a

rapid and quantitative risk assessment of a typical petroleum refinery. The package has been

applied for an appraisal of the risks of accidents (fires, explosions and toxic release) posed by

different units of the refinery, and to identify steps to prevent/manage accidents. The studies reveal

that TORAP enables a user to quickly focus on the accidents likely to occur, and enables

forecasting the nature and impacts of such accidents. This information is directly utilizable in

identifying 'soft' spots and in taking appropriate remedial measures to prevent or control accidents.

The special attributes of TORAP are: (a) wide range of applications — achieved by incorporating

models capable of handling all types of industrial fires and explosions, (b) sophistication —

brought about by including state-of-the-art models developed by these authors and others, (c) user-

friendliness — achieved by incorporating on-line help, graphics, carefully formatted output, and,

above all, an automatic module, with which even a lay user can conduct a risk assessment. The

entire package, especially its automatic module, is supported by an extensive knowledge-base built

into the software. [06].

Faisal I Khan et al studied in Journal of Loss Prevention in the Process Industries the term domino

effect denotes `chain of accidents', or situations when a fire-explosion-missile-toxic load generated

by an accident in one unit in an industry causes secondary and higher order accidents in other units.

Most of the past risk assessment studies deal with accident in a single industry, more so in one of

the units of an industry. But, often, accident in one unit can cause a secondary accident in a nearby

unit, which in turn may trigger a tertiary accident, and so on. The probability of occurrence and

adverse impacts of such `domino' or `cascading' effects are increasing due to increasing congestion

in industrial complexes and increasing density of human population around such complexes. The

multi-accident catastrophe which occurred in a refinery in India, on 14 September 1997, claiming

60 lives and causing loss of property worth over Rs 600 million, is the most recent example of the

damage potential of domino effect Lees F.P. Loss prevention in process industries, Major accidents

in process industries and an analysis of their causes and consequences in Journal of Loss

Prevention in Process Industries, A quantitative study. Process Safety Progress, 18, 135-145.

Recently, we have proposed a systematic methodology called `domino effect analysis' (DEA). The

paper makes a strong case for making DEA an integral part of all risk assessment initiatives [07].

Bo Johansson, et al worked and the purpose of this study was to carry out a broad survey and

analysis of relevant research articles about piece rate wages and their effects on health and safety

that were published internationally until the fall of 2008. The aim was to summarize and describe

the state of the art of the research in this field and if possible draw conclusions from the

accumulated research results. Although research is still sparse and fragmented, much of the

accumulated knowledge about the effects of piece rate work tells us that piece rates in many

situations have a negative effect on health and safety. The fact that 27 of the 31 studied articles

found negative effects of piece rates on different aspects of health and safety does not prove

causality, but together they give very strong support for the hypothesis that in most situations piece

rates have negative effects on health and safety. In order to achieve better knowledge about the

effects of piece rates in branches where piece rates are regarded problematic, further research is

needed and such research has to be designed to meet the specific questions that are to be answered

[08].

Sauter Steven L et al studied and describe about NIOSH recognizes psychological disorders as a

leading occupational health problem. This document, developed by a NIOSH working group led by

the present authors, represents a first attempt to fashion a comprehensive national strategy to

protect and promote the psychological health of workers. Roles are identified for industry, labor,

government, and academia. Key initiatives include (a) steps to improve working conditions and

employee mental health services and (b) increased research and surveillance to advance

understanding of the problem. Because work-related psychological disorders appear to be a rapidly

developing problem lacking complete definition in terms of scope and etiology, this strategy is not

to be considered a final statement of NIOSH policy [09].

G.Waddell, A.K Burton, studied about back pain during work that there is increasing demand for evidence‐based health care. Back pain is one of the most common and difficult occupational health problems, but there has been no readily available evidence base or guidance on management there are well‐established clinical guidelines for the management of low back pain, but these provide limited guidance on the occupational aspects. Occupational Health Guidelines for the Management of Low Back Pain at Work were launched by the Faculty of Occupational Medicine in March 2000. These are the first national occupational health guidelines in the UK and, as far as we are aware, the first truly evidence‐linked occupational health guidelines for back pain in the world. They were based on an extensive, systematic review of the scientific literature predominantly from occupational settings or concerning occupational outcomes. But a compact version is presented here to aid its dissemination [10]

Quick, James Campbell and Tetrick, Lois E. Declared about Occupational health psychology,

that it is a relatively young specialty within the science and practice of psychology. This handbook

is designed to consolidate and organize the rising knowledge in the field from the interdisciplinary

perspectives of an international group of scholars and researchers. Provide historical,

contemporary, and future-oriented perspectives on this emerging specialty after first discussing

prevention and public health in occupational settings. That addresses key causes of health and

safety at work as well as key risks to health and safety, focusing on factors both within the specific

workplace as well as broader occupational factors and factors from the personal life area.

Regardless of how effectively organizations design prevention and public health programs to

protect the health and safety of people at working place, some experience symptoms and health

disorders, and the specific primary, secondary, or tertiary interventions for health and safety, This

book addressing issues of epidemiology, program evaluation, and socioeconomic cost-benefit

analysis [11].

DEFRA (2002) and Hunt et al (2000) Both stated that the adverse health effects of exposure to

high concentration of chemicals such as Benzene, 1,3-butadiene, Carbon monoxide, Lead Nitrogen

oxides, Ozone, Particles and sulpher dioxide, range from mental impairment to cancer and with

excessive exposure death. Whilst Air quality has been improved in Urban and Rural areas during

the last 20 years, between 123000 and 24100 death are thought to be hastened annually due to air

pollution by ozone, Particulates and sulpher dioxide (ibid,:3; DEFRA, 2003:76). Poorer peoples

living in the disadvantaged areas are exposed to the highest level of air pollution [12].

L.H Vassie and W.R Lucas studied and states about health, safety and Environment that team can

be managed in different ways: using supervisor, team leaders, or self-managed. The management of

health and safety and other business risk is dependent on the way in which the team is managed.

Although the differences are not always significant, it is noticeable that within organization using

supervised work environment, there is a lack of communication of specific health and safety

information, little involvement and participation in safety activities, and a greater reliance on the

safety functions. However in organization using team leader and self-managed groups, there is

evidence of greater management involvement, more open communication, and greater employee

involvement in health and safety, Although empowerment in its true sense was still limited in these

organizations [13].

Hunt et al (2000) stated that the impact of the environment on the health is a complex and difficult

to disentangle; health within an environmental context must be considered as a Multiphase and

holistic Phenomenon, They recognize that identification of a link between environment and Public

is not a new and that Environmental Legislation targeted at protecting health through improved

housing and sanitation go back centuries (ibid.; See also Morris, 2003; Gesler, 1998). In past years,

there have been some reports (Meng et al., 1995; Meng and Zhang 1997) from many countries,

which showed significant excess of chromosomal aberration hazards of the employees of phosphate

fertilizers plant [14].

Shang hwa hsu, chun-chia lee, muh-cherng wu, these above listed professionals identify the

safety factors and their influence mechanism in Taiwan and Japan oil refinery. Taiwanese purely

emphasis on safety activities, higher devotion to supervision as well as quality of safety

performance, Where as Japanese engaged to work on systematic safety and efficient reporting

system of team work which can minimize the health safety threats. These perform task and script

provide safety improvement in emerging countries and developed countries respectively [15].

CHAPTER NO 3

PROJECT AREA

3.1 INTRODUCTION TO NATIONAL OIL REFINERIES (NRL).

A national oil refinery (NRL) is the largest petroleum refining complex in Pakistan. Comprises

of three refineries and a BTX plant located in the industrial zone of Korangi 1, Karachi

Metropolitan area 15 Km South East of Karachi.

National Refinery Limited (NRL) was incorporated on August 19, 1963 as a public limited

company. Government of Pakistan took over the management of NRL under the Economic

Reforms Order, 1972 under the Ministry of Production, which was exercising control through

its shareholding in State Petroleum Refining and Petrochemical Corporation (PERAC).

The Government of Pakistan had decided to place the National Refinery Limited under the

administrative control of Ministry of Petroleum & Natural Resources in November 1998.

In June 2003 the Government of Pakistan decided to include NRL in its privatizations

programmed.

The selling of 51% equity and transfer of management control to a strategic investor had been

proposed accordingly, the due diligence process for the privatization was initiated. After

competitive bidding NRL was acquired by Attock Oil Group in July 2005.

The Company has been privatized and the management handed over to the new owner (Attock

Oil Group) on July 7, 2005.

National Oil Refineries

Figure 3.1 National Oil Refineries Limited (NRL) Karachi

3.1.2 MAJOR PRODUCTS OF NRL

This classification of crude oil products is based on the way by which crude oil is distilled and

separated into fractions, and this process is called distillation process. Most products of oil

processing are usually grouped into three categories:

1) Light distillates (LPG, Gasoline and Naphtha).

2) Middle distillates (Kerosene, Diesel)

3) Heavy distillates and residuum (Fuel oil, Lubricating oil, wax and Tar).

3.1.3 COMMON PROCESS UUNITS FOUND IN NRL

Several number of process units in oil refineries are involved for making crude oil pure and

useable and removing of undesirable products from it.

Distillation Unit

Visbreaking Unit

Dehydration Unit

Alkyl nation Unit

De saltation Unit

Isomerization Unit

Amine Treating Unit

Catalytic Reformer Unit

Liquefied gas storage unit

Vacuum Distillation Unit

Fluid Catalytic Cracker Unit

Naphtha Hydro-treated Unit

Coking Units

3.1.4 PRODUCTION

The refinery complex of the Company comprises of three refineries, consisting of two lube

refineries and one fuel refinery.

First Lube Refinery commissioned in 1966 with designed capacity of 539,700 tons per annum

of Crude Processing and 76,200 tones per annum of Lube Base Oils. Second Lube Refinery

commissioned in 1985 with designed capacity of 100,000 tons per annum of Lube Base Oils.

In 1974, a turnkey agreement was signed between NRL and Industrial Export Import (IEI) of

Romania, to design and construct the 1.5 million tones per year of crude oil refining capacity.

The Fuel Refinery commissioned in 1977 with designed capacity of 1,500,800 tones per annum

of crude processing and after revamp the designed capacity comes to 2,170,800 tones per annum

of crude processing.

The BTX (Benzene, Toluene and Xylene) unit was commissioned in 1985 with design capacity of

25,000 tons per annum of BTX. It was the first petrochemical unit integrated with unit of fuel

refinery.

NRL enjoys a competitive edge, as it is the only refinery producing LBO (Lube Base Oil) in

Pakistan. This was export till 1986.

At present the production capacity of LBO is 1, 97,000 tones per year with two Lube Refineries.

3.1.5 DEVELOPMENT POLICY

To ensure that business policies and targets are in conformity with the national goals.

To Contribute in meeting the country's demand of petroleum and petrochemical products

Customer's satisfaction by providing best value and quality products.

Optimization of the value of barrel of crude oil and cost reduction through conservation

measures

To achieve and maintain a high standard of Occupational Health, Safety and Environment

Maintain modern management system conforming to international standards needed for an

efficient organization.

3.1.6 VISION

Our passion is to attain a distinctive leadership amongst the corporate success stories of tomorrow

we at NRL recognize that the realization of this passionless superior professional competencies,

continuous value addition an improvising, and development of Human capital and complete

commitment to safety, occupational health and Environment.

3.1.7 MISSION

To remain the premium and preferred supply source for various petroleum products and

petrochemicals.

Offer products that are not only viable in terms of desirability and price but most

Importantly give true and lasting value to our customers. Deliver strong returns on existing

and projected investments of our stakeholders by Use of specialized and high quality

corporate capabilities.

Business development by adoption of emerging technologies, growth in professional

Competence, support to innovation. Enrichment of human resource and performance

recognition.

Be a responsible corporate citizen by serving the community through a variety of socio-

economic acts and maintaining a high level of safety, occupational health and

environmental care.

Provide safer and high standers of lives and achieve the goals of NRL development policy

3.1.8 CORE VALUE

Following concepts and ideas guide the Management and Staff of National Refinery

Limited in conducting its business practices in most ethical ways

Ethical Conduct and Integrity We value lifestyle in our organization where ethics like truth,

honesty, integrity and fair play are basic ingredients while interacting within the

organization or dealing with the outside world.

Teamwork and Responsibility We share information and resources and step in to help out

other team members. Conflicts are worked out in spite of obstacles and difficulties. We

accept responsibility with “can do” attitude.

Customer Satisfaction We endeavor to provide quality products to our customers at

competitive prices. We value their satisfaction essential for continued growth of our

business. Core Values

Continuous Improvement We generates new ideas and creative approaches to upgrade and

update our refinery to best available technology and processes so that our products are at the

level of internationally accepted standards.

Profitability we believe in enhancing our profitability to the maximum so that Employees,

Shareholders and Government all benefits from it.

Corporate Citizenship As a good Corporate Citizen, we are more than willing and happy to

meet our social responsibilities towards the community around us. We are also committed

to meet requirements of health, safety and environment.

3.1.9 IMORTANCE

Energy conservation is vital for today’s refinery economics to reduce per unit cost of production

and to protect Natural Environment. NRL contributes to sustainable development management

through the integration of Environmental, Social and Economic considerations in its work.

The recent introduction of 90 RON unleaded motor gasoline is a further evidence of our

environment to concern towards good health and preservation of environment.

The primary function of the HSE Department is to explore opportunities for environment

improvement and energy conservation at Refinery Units, prepare and evaluate proposals and

implement them. NRL has an HSEQ policy which is the corner stone in its decision making

process to ensure compliance with the Environmental laws (NEQS) and achieve continuous

performance improvement.

Refinery consumes enormous quantity of thermal energy, supplied by combustion of fuel oils

and fuel gas at furnaces. Number of energy conservation projects has been implemented at

National Refinery, which has reduced energy consumption per barrel of crude oil. Large

quantities of liquid effluents and gaseous emissions are also encountered in petroleum

processing. Improvement programs are constantly undertaken at NRL to combat pollution in

respect of emissions and effluent waste water.

Regular monitoring of pollutants is carried out by testing of effluents and emissions samples to

measure environmental performance. In recognition to the reality that eventually sulphur will

have to be reduced in HSD to make it environment and health friendly, the management has

already initiated a preliminary feasibility study to put-up a hydro-desulphurization plant for

reduction of sulphur to limits set by the government.

3.1.10 OBJECTIVES OF HSE

The objectives of HSE are

To establish procedures and implement work instructions sufficient to avoid injury to

employees and others who may be affected by Company operations.

To establish standards and procedures to minimize harm to employees and others through

the Occupational health hazards and substance abuse.

To provide facilities, plant, and equipment and maintain them in safe condition.

To provide an effective system of communication throughout the management and with

workers to ensure active participation in all aspect of safety management.

Through investigation, follow up, and analysis of incident reports, strive to eliminate the

accidents and incidents within the Company operations

3.2 HSE POLICY OF NRL

Figure 3.2 Policy Statement of NRL

HSE POLICY OF NRL Energy conservation is vital for today’s refinery economics to reduce

per unit cost of production and to protect Environment. NRL contributes to sustainable

development management through the integration of Environmental Social and Economic

considerations in its work environment. The recent introduction of 90 RON unleaded motor

gasoline is a further evidence of our concern towards good health and preservation of

environment.

 The primary function of the HSE Department is to explore opportunities for environment

improvement and energy conservation at Refinery Units, prepare and evaluate proposals and

implement them. NRL has an HSEQ policy which is the corner stone in its decision making process

to ensure compliance with the Environmental laws (NEQS) and achieve continuous performance

improvement.

Refinery consumes enormous quantity of thermal energy, supplied by combustion of fuel oils and

fuel gas at furnaces. Number of energy conservation projects has been implemented at National

Refinery, which has reduced energy consumption per barrel of crude oil. Large quantities of liquid

effluents and gaseous emissions are also encountered in petroleum processing. Improvement

programs are constantly undertaken at NRL to combat pollution in respect of emissions and

effluent waste water. Regular monitoring of pollutants is carried out by testing of effluents and

emissions samples to measure environmental performance. In recognition to the reality that

eventually sulphur will have to be reduced in HSD to make it environment and health friendly, the

management has already initiated a preliminary feasibility study to put-up a hydro-desulphurization

plant for reduction of sulphur to limits set by the government.

3.2.1 ISO 9001, ISO - 14001 & OHSAS – 18001CERTIFICATION

In order that Quality Standards and Environment practices at NRL are according to world

standards, certification for Quality ISO 9001 Environment Management System ISO-14001

has been acquired. Likewise, for controlling of work related health and safety risks, OHSAS-

18001, certification has been acquired. Implementation of ISO 9001, ISO 14001 AND OHSAS

18001 has put NRL as the pioneer in the country in areas of Quality, Environment and

occupational health & safety certification.

3.2.2 NRL SAFETY BOARD

NRL Safety Board is updated by second week of every month. Safety Board shows the number of

Safe Man-hours worked by NRL MPT and Non MPT Staffs. By the Grace of Al Mighty Allah and

joint efforts by all of us, we have achieved 16.07 millions safe man-hours with out Lost Time

Injury as on October 31, 2011. Let us all give top priority towards safety, as there is no job, which

cannot be done in a safer way.

3.2.3 QUALITY CONTROL, RESEARCH & DEVELOPMENT AT NRL

Every product leaving the refinery has to conform to stringent international or national

specification requirements. In order to achieve the fine degree of control, extensive monitoring of

crude oil feed stock, intermediates and final products is conducted with the aid of modern

sophisticated analytical equipment in our Quality Control Laboratory. Usage of NRL produced

base oils by numerous national and international lubricating oil companies for producing world

class lubricants authenticates the supreme quality of our lube base oils. NRL strives to satisfy the

customers by providing best products within specifications.

The role of NRL Quality Control Laboratory is, however, not limited to Quality Control alone.

Research and Development work is carried out to give a basis for innovation in processes and

products.

NRL Quality Control Department, which was certified to ISO 9002 Quality Management System in

the year 2000. Currently entire Refinery is ISO 9001:2000 certified under Integrated Management

System (IMS), which include ISO 14001 and OHSAS 18001

3.2.4 HOT WORK PERMIT AT NRL

By the Grace of Al Mighty Allah and joint efforts of all concerned, all naked flame hot work

permits were performed safely.

During working days in the morning 6 to 7 Nos. of naked flame hot work permits were audited for

various jobs at different locations inside Refinery. Sr. Engineer & Engineer HSE / Fire Protection

Officers along with respective area custodians audit these permits before issuance. Total numbers

of naked flame hot work permits carried out during the month of October 2011 were 155 No in

Korangi Refinery.

3.2.5 PPE’S AT NRL

In NRL personal protective equipments are use for safety and to reduce the intensity of accidents.

There is number of PPE’s are available in NRL and latest equipments are present at NRL safety

department.

3.2.6 FIRE FIGHTING AT NRL

At NRL Korangi Refinery every Thursday at 1000 hrs sharp, fire drill is carried out at fire drill

ground. This drill helps in checking the fitness of fire fighting equipments & imparting training to

Fire Protection staffs and Auxiliary Staffs that come from Production, Security, Quality Control

and Oil movement departments to gain experience in fire fighting on live fires. HSE department

observes the response time during fire drill. The average response time of fire drill was about 4:20

to 7:37* minutes. This time includes reaching the fire tender at site, lying of water hoses / foam

hoses and the time when water showering starts. During the month of October 2011 04 No of live

fire drills were carried out at Korangi Refinery. Where as 04 Nos. of weekly fire drills were carried

out at K.T during the month of October 2011.

* Fire Tender # 3 & 5 participated in Fire Drill. Water Hose not fully unrolled, however it was

pressurized by Tender operator, which resulted in attainment of Response Time beyond benchmark.

3.3 IMS (HSEQ) Management System at NRL

This document defines the scope of NRL's Occupational Health & Safety, Environmental and

Quality Management Systems IMS (HSEQ) and provides linkages of system documents to the

elements of the ISO 9001:2008, ISO 14001:2004 and OH&SMS18001:2007 Standards.

NRL Integrated Management System IMS (HSEQ) provides a mechanism for Occupational Health

& Safety, Environment and Quality Management Systems throughout all areas, units and

departments of NRL Korangi Refinery, Kea Mari Terminal and Korangi- Kea Mari Pipeline.

Determine the processes needed for the IMS (HSEQ) Management System and their

applications throughout the organization,

Determine the sequence and interaction of these processes,

Determine criteria and methods required to ensure the effective operations and controls of

these processes,

Ensure the availability of resources and information's necessary to support the operations

and monitoring of these processes,

Monitor measure where applicable and analyzed these processes,

Implement actions necessary to achieve the planned results and continual improvement of

these processes.

3.3.1 IMS (HSEQ) POLICY

NRL has established its policy for Health, Safety, and Environment & Quality ensures that it:

Is appropriate to the purpose, nature and scale of the organization,

Includes a commitment to prevention of injury and ill health and continual improvement in

IMS (HSEQ) Management and performance.

Provides a framework for setting and reviewing IMS (HSEQ) objectives and targets.

Includes a commitment for prevention of pollution requirements.

Is communicated to all persons working under the control of the organization.

Is available to interested parties.

Is periodically reviewed for continuing suitability at appropriate level of the organization.

The IMS (HSEQ) Policy is communicated and enforced through management reviews, training,

displayed at appropriate locations.

3.3.2 MONITORING AT NRL

NRL applies suitable methods for monitoring and, where applicable, measurement of the IMS

(HSEQ) management system processes. These methods demonstrate the ability of the processes to

achieving planned results. When planned results are not achieved, correction and corrective actions

are taken, as appropriate.

Note: When determining suitable methods, it is advisable to consider the type and extent of

monitoring or measurement appropriate to each of its processes in relation to their impact on the

conformity to product unless otherwise approved by a relevant authority and, where applicable, by

the customer.

3.3.3 Waste Monitoring & Management

During Normal / Turnaround / Shutdown operations, Steering Committee identifying waste

generates causing Environmental Load with respect to the aspect like (Air emissions, Effluent

discharge, and solid waste). Environmental Load identification for normal / turnaround operation is

carried out on format (NRL-FAF-AIA-001). On the basis of the Environmental Load Summary for

Normal operation developed on (NRL-FAF-AIA-002) and Turnaround Operation (NRL-FAF-AIA-

003). Total Environmental load at NRL on the basis of above mentioned summaries is developed

by concerned department’s e.g.

Hot Air

API-I Effluent

Spent Caustic

Cotton Waste

Plastics

3.3.4 Drinking Water Monitoring

Three-Stage filter elements are installed at each drinking water cooler placed inside Refinery and

Kea Mari Terminal. Filter elements are changed by Maintenance-II department as per schedule.

HSE coordinates with Administration and Maintenance-II departments to send samples of drinking

water to laboratory for testing. Result of drinking water samples are found satisfactory for drinking

purpose.

3.3.5 Environmental Impact Assessment (EIA) and Initial Environmental Examination

(IEE) for New Projects

The framework for identifying and evaluating the environment and occupational health and safety

issues of new projects at NRL to ensure the appropriate consideration is given to Health, Safety,

Environment and Quality (HSEQ) issues prior to project approval and funding, to ensure aspects

and hazards generated by projects are identified & their significance evaluated, to secure approval

from regulatory agencies are well defined in the documented procedures (NRL-SPR-RIP-012) &

(NRL-SPR-RIP-019).

3.3.6 Initial Environmental Examination (IEE) Lube Refinery Revamp Project

An IEE of the proposed unit was carried out as part of the project to ascertain that said project will

not cause any possible adverse impact on the environment. The purpose of this IEE was to identify

potential source of impact due to operation of MEK-II and recommended measures for impact

mitigation and management.

3.4 RISK ASSESSMENT

Risk assessment is the process where you:

Identify hazards.

Analyze or evaluate the risk associated with that hazard.

Determine appropriate ways to eliminate or control the hazard.

In practical terms, a risk assessment is a thorough look at your workplace to identify those things,

situations, processes, etc that may cause harm, particularly to people. After identification is made,

you evaluate how likely and severe the risk is, and then decides what measures should be in place

to effectively prevent or control the harm from happening.

For definitions and more information about what hazards and risks are, please see the OSH

Answers document Hazard and Risk.

Risk assessments are very important as they form an integral part of a good occupational health and

safety management plan. They help to:

Create awareness of hazards and risks.

Identify who may be at risk (employees, cleaners, visitors, contractors, the public,

Determine if existing control measures are adequate or if more should be done.

Prevent injuries or illnesses when done at the design or planning stage.

Prioritize hazards and control measures.

3.4.1 Hazards, Evaluation and Risk Assessment Frame Work at NRL

OH&S hazards of Normal Operation

OH&S Turnaround / Shutdown Operation

Routine activities

Non Routine activities

Access to the work place

Facilities at work place

Absence of control measures

3.4.2 Hazards Categories

Ergonomics Hazards

Mechanical hazards

Electrical hazards

Pressure hazards

Pneumatic hazards

Falling hazards

Biological hazards

Noise hazards

Vibration hazards

Toxic hazards

Radiation hazards

Explosion hazards

Chemical hazards

Fire hazards

3.4.3 OH&S Hazards Impacts Categories

Injury / Illness

Disability / Death

Production delays and interruption

Asset Loss

Property damage

Tools and equipment damage

Product and material damage

Evaluation of Risks Assessment for

3.4.4 Identified Hazard

Legislative and regulatory requirements

Identification of the OH&S Risks face by NRL

Review OH&S practices, process and procedures

Evaluation of feed back from the investigation

Audit results & Recommendations

Direct inspection and measurement

3.4.5 Risks Control

Residential hazard identified, even after current control measures, will be assessed for risk and

classified under tolerable risks and un-tolerable risks.

Measure taken with the principal of ERIC-P

E-Eliminate

R-Reduce,

I-Improve,

C-Control,

P-Protect

If risk can not be converted into tolerable risk than PPE's used to reduce the impact

3.4.6 Emergency Preparedness & Response Planning and Risk Management

The Fire Protection Manager and HSE Manager are responsible for developing and implementing

an emergency prevention, mitigation and response plan.

Emergency situation may be of any one or combination of two or more included Flood / Territorial

Rains / Typhoons or Cyclone, Terrorist Attacks, Fire, Earth Quake, Oil Leakage / Spills, Chemical

Leakage / Spills, LPG Emergencies, Flammable / toxic gas release, Explosion, Loss of utility

services, Epidemic, Failure of Fire Alarm and monitoring devices, Serious injuries & Traffic

Accidents

Roles and responsibilities for communications with-in the facility and for obtaining outside support

services established, maintained and addressed in the departmental emergency preparedness and

response procedures.

Environmental, health and safety emergency methods and communications tested at least

biannually basis if practicable or whenever required and maintain records of these drills.

3.4.7 Environmental Objectives

NRL has established, implemented and maintained a system procedure (NRL-SPR-EOT-016) for

environmental objectives and targets at relevant function and level.

The Environmental objective consistent with the IMS (HSEQ) Policy, including commitment to

prevention of pollution, shall be measurable (where practicable) to compliance with applicable

legal and other requirements, which organization subscribes for continual improvement.

SAFETY LABELLING

For the attention and prevention of workers for any unwanted events different safety labeling are

mention at different places like near machinery “NO SMOKING” label is mentioned.

Some safety labels are shown

Safety sign at the entrance gate of NRL

Safety sign at different exit areas

Safety sign near oil Storage

Safety sign near Storage

Safety board at different places

CHAPTER NO 4

OCCUPATIONAL HEALTH AND SAFETY

4.1 Health and Safety

Health and Safety are the two vital factors that can immensely contribute towards your performance

at different situations like workplace, sports, and so on. Often, people neglect issues pertaining to

health & safety, eventually landing in trouble. So, what is it that drives these two factors? Why are

they essential? The answers to these recurrent questions lie ahead.

Especially in workplaces, employee productivity is of core essence to build on the companies as

well as the employees’ prospect. This prospect highly rests on the performance delivery, which

further is supported by accurate health and safety. For instance, a sales officer can neither travel

comfortably nor perform effectively in an unhealthy and unsafe condition. This would only lead to

a lackluster performance, further causing a stoop in sales.

Health and Safety also have a solid impact on your personality. A charming personality can work

for you tremendously not only at work, but also in general lifestyle. While health reflects your

personality, safety acts as the solution to obtaining a perfect heath. Saying so, safety has a lot to do

with the application of appropriate techniques at the right time.

The positive characteristic of Health & Safety is its widespread practice. Even if you are unable to

recognize the adequate and exact techniques, there are scores of health and safety training

consultants, available all over the world, to provide assistance. A health & safety consultant

specializes in sophisticated related equipments, and provides exclusive training programs, in a

professional manner. With certified skills, he provides an ideal opportunity to get things right for

you within a span of just few days.

Besides a health & safety consultant, you too can work towards attaining enhanced health & safety.

Maintaining cleanliness and hygiene, intake of suitable diet, regular exercising, etc. are some of the

most prominent techniques in achieving health and safety. In this case, consistency is the key.

These activities have to be done persistently for lifetime, in order to ensure better longevity.

There are other intangible factors as well that can influence your health. For example, several

people go through stress and depression regarding their work-life and relationships. These factors

can hamper your health to a great extent, forcing you to live a miserable life. Hence, to overcome

these barriers, a health and safety consultant offers special yoga and stress management practices,

as safety techniques. However, it all depends on the individual how he follows them. If one is

honest to himself, he is bound to achieve quicker results and lead an improved life.

4.1.2 Aims of the HSE

The main aims of the HSE are to:

Protect the health, safety and welfare of people at work

Safeguard others, including members of the public, who may be exposed to risks from the

way work is carried out

Carry out enforcement of health & safety law to promote a thriving local economy & a fair

and safe trading environment

As a minimum, adhere to all requirements of the Occupational Health and Safety Act

(2000) and OHS Regulation (2001),

Increase the awareness of its staff of the provisions and requirements of Occupational

Health and Safety Act,

Develop and maintain regular workplace inspections and reporting procedures,

Assess and control risks as they are identified,

Encourage staff and students to take an active role in the development of safe working

practices,

Implement appropriate drills for evacuation of the workplace in the event of a dangerous

situation,

Continue the consultative process between staff, and management,

Train appropriate staff to assist in the implementation of occupational health and safety

policies of the organization

Provide adequate occupational health and first aid services.

4.1.3 Occupational Health & Protecting employees from Occupational Hazards

The work-related accidents accounted for:

103,000 deaths in the USA,

122,000 in the European Union,

90,500 in China and

40,000 in India during 2005.

In case of developing countries, where the rate of such deaths is higher, the relevant data is

either unavailable or unreliable.

4.1.4 Pakistan, Conditions of OHSAS

Most of the 47.57 million employed workforces, including females and children, are poor,

illiterate and semi-trained.

Thus exposed to various occupational hazards.

The working conditions and environment in most of the workplaces are sub-standard.

There is no concept of taking preventive and control measures to safeguarding the health of

workers.

There is no record keeping and data collection of accidents and incidents that also go mostly

unreported.

The range and scope of occupational safety and health covers all the industrial, commercial,

agricultural and service sectors, utilities, manufacturing, transport/ communications,

hotels/restaurants, mining/quarrying, and construction, the SMEs etc.

There is no Proper reporting of accidents

At local level or in small industries there is lake of skilled persons

Shortage of Personal Protective Equipments no proper equipments are available in many

industries.

Textile is our single largest industry. It uses a variety of chemicals for various processes

particularly spinning, weaving, knitting, scouring, printing, dyeing and finishing, which

generate noise, dust and emissions of toxic chemicals which--- all injurious to health.

4.1.5 Safety and Act

Under the provision of the labour 2002, national occupational safety and health council was to be

established to provide safety at work place, ensure compensation to the employees, and frame,

review and update regularly the requisite standards. Five years thereon there is no headway even

towards formation of the proposed triparite council

The list of legislation includes:

Factories Act of 1934,

Factories Rules 1975,

Mines Act of 1923,

Consolidated Mining Rules 1952,

Oil & Gas (Safety in Drilling and Production) Rules 1974,

Dock Laborers Act 1934,

Punjab Factories Rules 1978,

Sindh Factories Rules 1975,

Coal Mines Regulations 1926 (NWFP),

Hazardous Occupational Rules 1978,

Explosives Act 1884,

Boilers & Pressure Vessels Act 2002, to name only a few.

Safety is the state of being safe

S Spot the hazard

A Assess the risk

F Fined a safe way

E Every moment

For safety of the workers and to mitigate the industrial accidents there are many safety equipments

are used for safety like safety glasses, gloves, and ear muff etc

4.2 Personal Protective Equipment

Definition: Devices used to protect an employee from injury or illness resulting from contact with

chemical, biological, physical, electrical, mechanical, or other workplace hazard.

The need for PPE and the type of PPE used is based on hazard present.

These equipments are widely used in industries to save the life of a workers and minimized health

hazards. Personal protective equipment, or PPE, is designed to protect workers from serious

Workplace injuries or illnesses resulting from contact with workplace hazard.

There are different types of personal protective equipments are used according to the nature of

work. Some of these are discuss below which are generally used in oil refineries like

Eye and Face protection

Hearing protection

Head protection

Arm and Hand protection

Protective Clothing

Foot and Leg protection

Figure 4.1 Personal Protective Equipments and their Use

4.2.1 Eye and Face protection

These equipments are used to protect eyes and face from dust and harmful particles flying at the

work place. Sometimes these small particles cause hazardous for worker and as well as workplace.

To protect unwanted and danger worker should use these Protection Equipments

The Canadian Standards Association (CSA)-certified safety glasses have plastic polycarbonate

lenses. They are stronger than regular lenses, are impact-resistant, and come in prescription and

non-prescription (Plano or zero-power lens) forms

Lenses and Frames:

Safety frames are stronger than street-wear frames and are often heat resistant. They are also

designed to prevent lenses from being pushed into the eyes. Ensure your safety glasses fit properly.

Eye size, bridge size and temple length all vary. Safety glasses should be individually assigned and

fitted. Wear safety glasses so that the temples fit comfortably over the ears. The frame should be as

close to the face as possible and adequately supported by the bridge of the nose. Clean your safety

glasses daily. Follow the manufacturer's instructions. Avoid rough handling that can scratch lenses.

Scratches impair vision and can weaken lenses.

Figure 4.2 Eye Protector Safety Glass

4.2.2 Hearing protection:

In any industry there should be noise pollution because heavy machinery produces heavy noise that

is harmful for human ears and also causing fatigue and problems for worker.

Noise induced hearing loss can occur with exposures >90 dBA

Servation program becomes a requirement at exposures >85dBA

To control the level of noise and to prevent the noise pollution ear protection equipment are used

like Ear muff, Ear plugs etc

Ear plugs:

These are less expensive, disposable, good ones sometimes difficult to tell if employees are

wearing them and these are inserted to block the ear canal. They may be remolded (preformed) or

moldable (foam ear plugs). Ear plugs are sold as disposable products or reusable plugs. Custom

molded ear plugs are also available.

Ear muffs:

These are more expensive, more durable, and more obvious that Can be used together in very high

noise areas consist of sound-attenuating material and soft ear cushions that fit around the ear and

hard outer cups. They are held together by a head band.

Figure 4.3 Ear Protector or Ear Plugs

4.2.3 Head protection

In many industries numbers of people die because of falling of metallic equipments on the head of

the workers. Head is very sensitive part of the body. To protect head from injuries same hard cap or

helmet are use which consist of hard substance and these safety helmets and head protector are

useful and safer.

Figure 4.4 Multipurpose Head and Ear Protector

4.2.4 Arm and Hand protection

For the safety of hand from harmful chemicals, electric current, oil and other biological diseases

safety gloves are use. Generally they are made up of plastic for physical and chemical injury but for

the prevention of biological diseases disposable gloves are use.

Figure 4.5 Arms and Hand Protector Safety Gloves

4.2.5 Protective Clothing

Protective clothing is used to protect dress from oil and grease these are used to protect street

clothes from hazards in the workplace often hazard specific protective clothing can be considered

effective, protective clothing must prevent the contaminant from reaching the clothing or skin of

the wearer High-visibility safety apparel (HVSA) is clothing that workers can wear to improve how

well other people "see" them (their visibility). Most often, high-visibility clothing is worn to alert

drivers and other vehicle operators of a worker's presence, especially in low light and dark

conditions.

Figure 4.6 Protective Clothes and High Visible Safety Apparel

4.2.6 Foot and Leg protection

As the old saying goes, "When your feet hurt, you hurt all over."There are two major categories of

work-related foot injuries. The first category includes foot injuries from punctures, crushing,

sprains, and lacerations.

They account for 10 percent of all reported disabling injuries. The second group of injuries includes

those resulting from slips, trips and falls. They account for 15 percent of all reported disabling

injuries.

Slips and falls do not always result in a foot injury but lack of attention to foot safety plays an

important role in their occurrence. Steel-toed footwear, preferably with metatarsal guards, is used to

protect feet from crushing injuries caused by heavy objects Rubber boots are often used to protect

feet from exposure to liquids.

Figure 4.7 Foot Protector or Safety Shoes

4.3 FIRE FIGHTING AND TECHNIQUES

Fire is considered as uncontrollable and rapidly expanded cause of accident and, the biggest loss of

raw material and other valuable product are because of fire, accident in any industry always loss of

Infrastructure.

4.3.1 Fire and Causes of Firing:

Fire is considering as most dangerous and uncontrolled accident in every industry and especially in

oil refineries. A fire usually has a well-defined edge and can burn very slowly or very fast

depending on conditions. Industrial fires result not only in economic lost but in much human

suffering as well. Damage to Infrastructure and Loss of valuable things

4.3.2 The factors that cause fire

Fuel: Paper, wood, oil, solvents, gas, etc.

Heat: The degree necessary to vaporize, fuel according to its nature.

Oxygen: Normally at least 15% of oxygen in the air is required to sustain a fire. The

greater the concentration of oxygen, the brighter the blaze and the more rapid the

combustion

4.3.3 Types of Fires

Fires are classified into four types:

Class A: Fires generally combustible e.g. wood, paper, cloth or rubbish is usually controlled by

cooling e.g. using water to cool the material.

Class B: Fires generally liquids e.g. gasoline, oil, grease, paint are usually smothered by oxygen

control – using foam, carbon dioxide, or dry chemical.

Class C: Fires due to gases such as Methane, Ethane, LPG, Acetylene, are usually smothered by

dry powder & CO2.

Class D: Fires erupt due to combustible elements such as magnesium, lithium or sodium and

require special extinguishers and techniques.

4.3.4 How to Prevent Fire

Know where fire extinguishers are kept?

What each is for and how to use them?

Maintain a neat, clean work area and prevent accumulation of rubbish?

Put oil-soaked and paint-soaked rags in covered metal containers.

Observe all “no-smoking” signs.

Keep fire doors, exits, stairs, aisles, fire lanes and fire fighting equipment clear of

obstruction.

Keep all flammable materials away from furnaces and other sources of ignition.

Report any fire hazards that are beyond your control, especially electrical hazards, which is

the source of many fires.

Store combustible materials in safe area.

Remove combustible materials and fumes from paint, solvents and other flammables.

If you should have to burn waste paper, make sure it doesn’t contain explosive materials

such as aerosol or paint cans.

Proper maintenance procedures are important to fire safety.

Keep mechanical equipment properly lubricated to avoid excessive friction.

Ensure heater used in the workplace is away from flammable materials and cannot be tipped

over.

Figure 4.8 Fire brigade vehicle uses during firing for water showering

4.3.5 Leading Causes of Industrial Fires

Electrical failure

Friction

Foreign substances

Open flames

Smoking Matches

4.3.6 How to React the Fires

Set off the alarm

Leave the area if the fire is too big to handle

Deal with a small fire

Know your fire exits

When leaving, crawl on your hands and knees to the exits

Fire fighter specialist person

Proper use of fire fighting equipments

Proper use of safety equipments

Use non combust able clothes and face protection sheets

Figure 4.9 Fire fighters during operation

4.3.7 FIREFIGHTING TECHNIQUES

Generally we use water which has the primary effect of cooling the fuel.

This describes techniques used when water is scarce, and use of water is not possible.

Track crews also work on the other two sides of the fire triangle, removing air (smother) or fuel

(clearing) to control fire.

Effectiveness depends greatly on hard work, diligence and experience.

4.3.8 Fire fighting tools

Equipments that are use in fire fighting techniques are:

Shovel: Beating, Digging, Scraping, Throwing soil.

Slasher: Cutting light fuels for tracks.

Fire rake: Scraping tools with serrated cutting edge used for removing surface fuels.

Safe Handling of Tools: Carry tools at waist level, blade forward Keep 3 meters apart

when carrying or using pass tools handle first

Water showering pump: Use to control the intensity of fire by water

Fire brigade vehicle: for transfer of water quickly to the affected area

Figure 4.10 Fire Controlling equipments like nozzles to increase the velocity of water

4.4 WORK PERMIT

Work Permit Analyzing of work place and possible hazards during work and taking safety

measures and to describe procedures and guidelines on work permit system to carry out jobs of

inspection, testing, maintenance, alternation, repair, construction in safest possible manner. The

implementation of this system will help in bring down the risks at work sites to acceptable level,

thereby reducing possibility of any accident, fire, explosion, property damage and adverse effect on

environment.

4.4.1 Work That Requires Permit:

Normally all maintenance, repair, construction work shall be carried out with a proper work permit.

Jobs where work permit is required include but not limited to followings:

Major and minor maintenance work

Inspection

Construction

Any hot work (including use of normal battery driven equipment in operating areas)

Cleaning activities of process equipment

Entry into confined space

Excavation

Vehicle entry into process areas

Work at height

Handling of materials using mechanized means in operating areas • Isolation of electric

equipment/ facilities.

4.4.2 Types of work permit

There are so many types of work require Permit some of them are describing below:

4.4.2.1 Hot Work:

An activity that can produce a spark or flame or other source of ignition having sufficient energy to

cause ignition, where the potential for flammable vapors, gases, or dust exists This includes all

works, which produces spark, running of IC engine, breaking of concrete, use of ordinary torches,

use of battery operated devices etc are considered as hot work permit

4.4.2.2 Confined Space:

It is an enclosure with known potential hazards and restricted means of entrance and exit. It is not

meant for normal occupancy of people and is usually not well ventilated such as vessels, boilers,

storage tanks, large diameter piping etc. The excavation more than 1.2 m deep, entry into floating

roof tanks, when roof is more than 3m down from the top, space located below ground level such as

pits, drain channels etc shall also be considered as confined space. Proper ventilation and lighting

provided: Where natural ventilation is not available, fans / air educators are provided. These are

also required for speedy dispersal of fumes generated by welding job. Only approved reduced

voltage extension lights (not exceeding 24 volts) are to be allowed for work inside confined space

from consideration of personal safety.

Figure 4.11 Workers work in Confined Space

4.4.2.3 Hot work / Entry in to Confined Space Permit and clearances:

Hot Work Permit is required for carrying out any activity, which produces sufficient heat to cause

fire in a inflammable air- vapor mixture. Entry to Confined Space Permit is required for entry into

any confined space.

Shield against sparks provided: Hot works like welding, grinding etc generates sparks, which can

provide source of ignition to the surroundings. In order to protect operating area from the hazards

of sparks generated, shields are to be provided to contain the sparks generated. The shield material

shall be non-flammable and should be kept wet with water.

Proper means of exit provided: Proper means of exit is required in case of emergencies developed

on account of the work or otherwise. Availability of an alternate route of escape should be

considered. r. Area cordoned off and caution boards provided: To prevent any unwarranted entry in

the work area and also to caution other personnel taking actions which may endanger people

working on the permit job, precautionary tags / boards are to be provided to display like "No Entry"

sign on roads or "Caution - Men at Work Inside" on the manhole of a vessel, "Danger -

Radiography in progress" etc.

Figure 4.12 Hot work is doing in a Confined Space

4.4.2.4 Cold Work:

Cold Work is an activity that does not produce sufficient heat to ignite a flammable air-

hydrocarbon mixture or a flammable substance. Or cold work permit is an activity of doing work

on non combust able materials like wood work cleaning activities.

4.4.2.5 Working at Height:

Any activity that is carried out at 2.meters & above on temporary structure, scaffolds or on a

structure not meant to do particular job safely. The erection of any tubular scaffold shall not begin

before the checking of scaffold material at site (w.r.t quality and quantity), preparations at site,

availability of PPE, and availability of trained personnel for erection etc. in prescribed format on

“Pre Erection Checklist for Scaffold”. The requirements of checklist must be complied before start

of erection of scaffold at site. This check-list shall be filled up in duplicate. The original shall be

retained by executer and 1st copy with issuer (area in-charge).

All scaffolds after erection must be checked and certified in prescribed form by scaffold

supervisor and Officer of executing Dept.

Precautions during work at height

All roof-work operations should be pre-planned and properly supervised.

Roof work shall only be undertaken by workers who are physically and psychologically fit

and have the necessary knowledge and experience for such work.

Work on roofs shall not be carried on in weather conditions that threaten the safety of

workers. .

Where it is necessary for a person to kneel or crouch near the edge of the roof, necessary

precautions shall be taken.

On a large roof where works have to be carried out at or near the edge, a simple barrier

consisting of crossed scaffold tubes supporting a tubing guardrail may be provided. For

detail refer Standard on “Working at Height”.

All covers for openings in roofs shall be of substantial construction and be secured in

4.4.2.6 CONDITIONS FOR HOT AND COLD WORK

YES

Ensure the availability of valid work permit before start of work.

Ensure that work permit conditions are fully complied at site.

Ensure that walkways and passages are free from all slip/ trip and fall hazard.

Ensure proper illumination of work place while working in dark.

Executor should ensure the quality of hand tools and their health.

Always first wedge open the flanges.

Use of proper PPE must be ensured during

NO

Never stand or work under suspended loads.

Never enter work area without safety helmet and shoe.

Do not wear loose/ synthetic cloths while on work

Do not use short cuts on work

Do not use lamp of more than 24 V while working in confined space.

Do not run a machine without putting back the guard on its exposed moving part.

Do not use short cuts on work

Do not give any other responsibility to stand by person, which may cause his absence at

many ways

4.5 INDUSTRIAL ACCIDENTS

Industrial accidents are an accident which appears suddenly during working in industries and cause

Unexpected & unwanted event and Occurrence of incident causing bodily injury to a person

making unfit for further work

4.5.1 Nature of Accidents:

Nature of accidents vary from industry to industry

An employee may be caught by machine

An employee may fall against a machine

An employee may fall from height

An employee may expose to an explosive

All these may lead to Disablement or Death

Disablement

Loss of Ability to work or move

This situation may be temporary or permanent

Temporary disablement is of temporary nature

Permanent Disablement is of permanent nature

Certain accidents may result in permanent disablement like:

Loss of both hands

Loss of a hand and a foot

Loss of Eyes

Very severe face disfigurement

Absolute deafness

4.5.2 OCCUPATIONAL HAZARD:

Occupational hazards are Source or situation with a potential for harm in terms of injury or ill

health, damage to property, damage to the workplace environment, or a combination of these all

unwanted events are known as occupational hazards.

4.5.3 TYPES OF OCCUPATIONAL HEALTH HAZARDS

1. Physical

2. Chemical

3. Biological

4. Mechanical

5. Psychosocial

4.5.3.1 PHYSICAL HAZARDS

Physical hazards Are accurse because of physical disturbance Surrounding conditions like:

Heat: Heat Exhaustion, Heat Cramps, burns, Prickly heat.

Cold: Frost bite,

Light: Occupational Cataract, High intensity of light can damage the eyes

Noise: Occupational deafness,

Radiation: Cancer, Leukemia, anemia, Electricity - Burns, Shocks,

4.5.3.2 CHEMICAL HAZARDS

Chemical hazards are those hazards which accurse due to Chemicals and Environmental pollution

the main source of chemical hazard are Routes of entry Inhalation, Ingestion, skin absorption.

(Inhalation is the main route of entry)

Chemical agents can be classified into:

Metals: Lead, TEL, As, Hg, Cd, Ni, Co etc.

Aromatic: Hydrocarbons - Benzene, Toluene, phenol etc.

Gases: N2, CH4, CO2, CO, H2S, HCN

Dust: Inorganic Dust: Coal, Dust, Silica, Asbestos

Organic Dusts: Cane Fiber, Cotton dust (In Textile industries),

Tobacco and Grain Dust

4.5.3.3 BIOLOGICAL HAZARDS

Biological hazard are those types of hazards which cause by the inhalation of poisonous air or by

the affect of biological bacteria or viruses.

Bacteria

Virus

Protozoa & Parasitic

Fungi

4.5.3.4 MECHANICAL HAZARDS

Mechanical hazards are those types of hazards which cause due to mechanical injuries or falling,

striking like

Injuries: Falls, cuts, abrasions, concussions, contusions, etc.

Ergonomic: Disorders-Musculo-skeletal, disorders (MSDs), Cumulative-trauma-

Disorders (CTDs) Ergonomics: ``Adjustment of Man & Machine``

Application of human biological sciences with engineering science to achieve optimum

mutual adjustment of man & his work, the benefit being measured in terms of human

efficiency and well being

Back Injuries due to Manual Handling:

All forces which come down the spine compresses discs and as a result of Continuous

squeezing they can rupture and bulge causing severe pain. Most back injuries are built over

along period of time by repetitive pounding on discs caused by improper methods. After

sometime some minor lift can produce such rupture

4.5.3.5 PSYCHOSOCIAL HAZARDS

Lack of job satisfaction

Insecurity

Poor interpersonal relations

Work pressure

behavioral changes (aggressiveness, depression)

Psychosomatic disorders (Hypertension, headache, body-ache )

4.6 SAFELY WORK WITH FALAMMABLE AND COMBUSTIBLE

In oil refineries there is maximum chance combustion because oil is very combustible material.

This topic describes general safe work practices to use where flammable and combustible liquids

are used or stored. The document "Flammable and Combustible Liquids and their Hazards"

describes the hazards of these liquids more fully. Another document deals with safety issues related

to static electricity, bonding and grounding containers.

4.6.1 Ignition Sources

For a flammable or combustible liquid fire to start, a mixture of vapors and air must be ignited.

There are many possible ignition sources:

Sparks from electrical tools and equipment.

Sparks, arcs and hot metal surfaces from welding and cutting.

Tobacco smoking.

Sparks from grinding and crushing operations.

Sparks caused by static electricity from rotating belts, mixing operations or improper

transfer of flammable or hot combustible liquids.

4.6.2 Eliminate Ignition source

You can eliminate many of these ignition sources by:

Removing open flames and spark-producing equipment.

Not smoking around these liquids.

Using approved explosion-proof equipment in hazardous areas.

4.6.3 What is spontaneous combustion?

Spontaneous combustion occurs when a material in contact with air can heat up sufficiently

(without an outside heat source) to burn. The oils in some wastes and rubbish can slowly react with

oxygen in the air. This reaction creates heat that can build up over time if the wastes are left

undisturbed.

When the heat level in a "self-heating material" is high enough when the temperature reaches the

auto ignition temperature a fire may start.

4.6.4 Why Is Good Ventilation Important?

Well-designed and maintained ventilation systems remove flammable vapors’ from the workplace

and reduce the risk of fire and health problems.

The amount and type of ventilation needed to minimize the hazards of flammable and combustible

liquid vapors’ depend on such things as the kind of job, the kind and amount of materials used, and

the size and layout of the work area.

4.6.5 Flammable and Combustible Liquid Containers Storage

Store flammable and combustible liquids according to the laws, including building, fire, and

electrical codes, that apply to your particular workplace. These laws specify the kinds of storage

areas, such as storage rooms and cabinets, allowed for these liquids. They also specify how to

construct these storage areas and the amounts of flammable and combustible liquids in different

types of containers that you can store in each kind of storage area. There may also be restrictions

about the volume (how much) of product that can be stored. Never use plastic or glass containers

for storing flammable liquids unless storage in metal containers would affect the required liquid

purity or if the liquid would cause excessive corrosion of the metal container.

In all cases, allow only trained, authorized people into storage areas. Before storing, inspect all

incoming containers to ensure that they are not damaged and are properly labeled. Do not accept

delivery of defective containers. Keep containers closed when not in use.

4.6.6 Good Storage Area

Storage of flammable and combustible liquids can be stores in specific areas that are:

Well ventilated to reduce vapors concentrations.

Free of ignition sources.

Cool (temperature controlled) and dry.

Supplied with adequate firefighting and spill clean-up equipment.

Away from elevators, building and room exits, or main aisles leading to exits.

Accessible by firefighters.

Labeled with suitable warning signs. For example: "No Smoking".

4.6.7 Proper Deal with Combustible Fuel

Avoid storing flammable and combustible liquids in basements. Ground floor storage is usually

preferred as it provides easier access for emergency situations. Inspect storage areas regularly for

any deficiencies such as damaged or leaking containers, poor ventilation or non-approved

equipment. Unapproved modifications or damage to approve or explosion-proof equipment or

systems could result in unintended hazardous conditions. Correct all deficiencies as soon as

possible.

Many workplaces receive flammable liquids in large metal drums or barrels, and then fill smaller

containers from them. Moving full drums weighing hundreds of pounds by hand can be difficult

and hazardous. Specially designed drum cradles are available for moving drums around and can

also be used as individual drum storage racks. Check all containers used for flammable and

combustible liquids regularly to make sure that they are not damaged, that spring-operated

mechanisms are working properly and that flame arresters are not broken. Safety container

manufacturers will provide detailed ways to inspect their equipment for safe operation

Following these basic safe practices will help protect you from the hazards of flammable and

combustible liquids:

Obtain and read the Material Safety Data Sheets (MSDSs) for all of the materials you work

with.

Be aware of all of the hazards (fire/explosion, health, chemical reactivity) of the materials

you work with.

Know which of the materials that you work with flammable or combustible liquids are.

Eliminate ignition sources (sparks, smoking, flames, hot surfaces) when working with

flammable and combustible liquids.

Use the smallest amount of flammable liquid necessary in the work area.

Keep storage areas cool and dry.

Store flammable and combustible liquids away from incompatible materials

CHAPTER NO 5

EXPERIMENTAL WORK AND DISDUSSION ON REDULTS

5.1 SURVEY OF NATIONAL OIL REFINERIES

Before conducting experimental analyzing program our group of students visit at National Oil

Refineries with our field supervisor Engr: Hafiz Waseem Sahib. During survey we observe that

NRL is very clean and less pollutant than other plants like Thermal power station Jamshoro. Their

security management is very active, In NRL workers and Engineers are well qualified and

responsible person. Engr Majid Chemical engineer and Mr.Rasheed sahib Fire fighter specialist

gave brief lecture about their specific field. We observe that there are many Safety Signs and

symbols are displayed on every where for the awareness of common peoples. Good alarm system

and proper maintained Personal protective equipment shows that there is a proper management of

Occupational health and safety system.

5.1.1 RESEARCH METHODOLOGY In NRL we went through the various methods, which were beneficial for us in sense of maintaining

the data in the proper manners, by conducting surveys interviews and question answers.

We have observe various types of activities which were happening in NRL for the betterment of the

employees as well as for proper working and maintains of the machineries and we also conduct the

interview of HSE department person named Mr. Rasheed, who have gives us knowledge about the

HSE department and how they over come on the accidents cause due the operations.

During the survey of the environment of the HSE department of NRL we discuss about the

different quires of the operations, which help us to compile the data. We observe the different types

of barications in different colors, about which we ask quires from the employees of HSE

department. We also get information from about the different PPE being used according to the

nature of work.

5.1.2 RESEARCH PLANE

Six-month work was planed for this study in which our respectable teacher support us from the core

of heart and work trough out the half our year our occupational health and safety. Monday was

declared as the thesis day and enhance the work this option was the great opportunity the all the

members of group get together and discuss regarding to the academic as well as the assigned thesis

topic. Digital lab was specially kept maintain for the final year students that they can sort out

problems and then reserve them after regular classes and at Monday from 9am to 3pm.

5.1.3 LIMITATION

In order to compile these case studies we have faced no of stages during those days where we

engaged to analyze the situation regarding to occupational health and safety and were maintaining

the data, we find the concerned peoples frank, intellectual and technically sound. The time assigned

us by NRL was not the bed of roses because at that time thee was the worst law and order condition

in Karachi, which become the headache for us and we were considering us safe and séance.

Sometime it happens that we have to sacrifice our previous day that was fixed for the visit/survey

and the auditing in those days was cause interruption and barriers for us but we try our level best to

the make the most of our time and finally get the fruit of efforts.

5.1.4 Instruments Used to Analyzing HSE Parameters

For the quantification and measurement, various types of instrument used to get HSE data. Which

were reliable, durable and easy to operate. Instruments play vital role in HSE in expects of reducing

the over all ratio of the accidents. By using instruments over all efficiency of the plant is improved

and any type of the query which comes in the way of operations will be control through by using

instruments. If any type of big accidence occur it will definitely directly effects on the people as

well as on industry and also effect on the over all production of the functions.

Following are the main instruments use in the HSE department of NRL.

Flow gas analyzer

COD meter

BOD meter

PH meter

Leak detector

Lux meter, Etc.

5.1.5 TESTING PARAMETERS

During testing we analyze different parameters at NRL that are

NOISE LEVEL

STACKS GASOUS EMISSION

WASTE WATER EFFLUENT

VOLATILE ORGANIC COMPOUNDS

AMBIENT AIR

ACCIDENTS/INCIDENTS IN

5.2.1 NOISE LEVEL

In National Oil Refineries we determine the noise level from different places like lube 1 refinery,

Lube 2 refinery, fuel refinery, near to boiler R.O plant and open area of NRL by using Noise meter

and observe that noise level varies from place to place. The highest level of noise is in turbine hall,

where due to rotation of moving parts of turbine high level of noise is produced that shown in table

4.1, it is also observe that the open area of NRL is less noisy than the area near to machine.

According to NEQS standers the noise level does not exceed from 85 d BA and near the machines

the noise level is greater than 85 dBA and open area and workshops are less noisy the level of noise

is less then 85 dBA. The noise can be reduced by proper covering of machines and proper

lubrication of machine. We classified table of noise level into two categories one is high noise level

and other is less noise level table. The noise level is shown in table 4.1 and 4.2.

Table 5.1 High Noise Level of working area near the Machines

S.NO Area and Equipments Noise Level

01 LUBE 1 REFINERY 88.9 to 98.3

02 FUEL REFINERY 80.1 to 98.5

03 LUBE 2 REFINERY 90.4 to 93.5

04 BOILER IV 89.6

05 BOILER VNOT IN OPERATION

06 BOILER VI 90.3

07 BOILER VII 92.1

08 TUBBINE HALL 102.2

09 182 WHITE PRODUCT PUMP 90.3

Table 5.2 Low Noise Level in open area and working places away from heavy machines

S.NO Area and Equipments Noise Level

01 R.O PLANT 77.5

02 FABRICATION YARD 69.2

03 WORK SHOP HALL 78.5

04 MAIN OPEN AREA 61.4

05 OPEN AREA LUBE 2 63.6

06 LAB HALL 76.4

07 FLASH ROOM 65.1

08 DISTILLATION ROOM 68.3

09 MAIN GATE NRL 76.1

10 GATE C, NRL 79.4

11 SHIPPING II OFFICE 62.0

5.2.1.1 Time Duration and Noise Level

The time duration of work depend on the noise level if the noise level is increase than the time

exposure will decrease and we know that ear protectors or noise level reduction equipments are not

able to control 100% noise, they just reduce the noise level according to their capability so at highly

noisy working place the time duration of work must be lesser than normal working place. Noise

level with time duration table is shown below:

Table 5.3 Time duration with Noise Level

Sound Level (dBA) Exposure (hours)

90 8

92 6

95 4

100 2

105 1

110 0.5

115 0.25

Figure 5.1 Graphical representation of Noise Variation and compared with NEQs

5.2.2 STACKS GASOUS EMISSION

In National Oil Refinery we observe there is good control mechanism of flu gas emission because

the Level of stack gases are not exceed the NEQs standers that shown in table 4.4 and 4.5 The

amounts of Particulate matters are less and under NEQs limits. The overall environment of NRL is

safer and clean we can observe in observation table. In NRL the amount of stacks gaseous emission

is lower then the NEQs limits that show that the environment of the working area of NRL is non

pollutant safe. In figure 4.2 the difference between NEQs limits and stacks particulates emissions is

clearly show the amount of PM is controllable. The results of gaseous emission and stacks

particulate matters are as under:

Table 5.4 Determination of Stacks gaseous emission in National Oil Refineries

S NO. Reference PointSO2

mg / nm²CO

mg / nm²NOx

mg / nm²H2S

mg / nm²

NEQS Limits 1700 800 400 10

01 BOILER IV 0 14 230 0

02 BOILER V NOT IN OPERATION

03 BOILER VI 0 11 264 0

04 BOILER VII 0 26 39 0

05 POWER GENERATION 0 713 314 0

06 FUEL REFINERY 0 02 127 0

07 103F -05 0 03 199 0

08 LUBE 1 108 220 111 7

09 LUBE 2 0 91 65 0

Table 5.6 Determination of Stacks Particulate matters emission in NRL

S NO. Reference PointPM

mg / nm²NEQS Limits

mg / nm²

01 BOILER IV 03

300

02 BOILER V 05

03 BOILER VI 05

04 BOILER VII 09

05 POWER GENERATION 43

06 FUEL REFINERY 03

07 103F -05 02

08 LUBE 1 08

09 LUBE 2 06

Figure 5.2 Graphical comparison of stacks Particulate matters emission with NEQs

Table 5.7 Ambient Air Quality of different area of National Oil Refineries

S. No REFERENCE POINTCO

mg /Nm3

SO2

mg / Nm3

NOx mg / Nm3

H2O mg /N m3

01BETWEEN TURBINE AND OFFICE

- 0.5 1.3 0

02 NEAR WARE HOUSE - 0.2 4.3 0

03 RECYCLE MEMBRANE - - 3.1 0

04 INSIDE THE PLANT - - 3.9 0

05 NEAR MAIN GATE - - 4.2 0

Table 5.8 Ambient Particulates Matters Monitoring in National Oil Refineries

S. No REFERENCE POINT P Mmg /N m3

01 BETWEEN TURBINE AND OFFICE 17.7

02 NEAR WARE HOUSE 22.1

03 RECYCLE MEMBRANE 24.8

04 INSIDE THE PLANT 18.2

05 NEAR MAIN GATE 62.8

5.2.3 WASTE WATER EFFLUENT

All analytical or experimental work was done in National Oil Refineries lab and sample of waste

water was taken from waste effluent from National oil Refineries. In waste water effluent the

amount of pH is under NEQs standers Total dissolved solids are also in limited amount, other

parameters like COD, BOD, and TSS are also less than the amount/value that is given by NEQs.

The proper values of Biological Oxygen Demand (BOD) and Chemical Oxygen Demand (COD)

and other parameters are determined and shown in table 4.8 that table shoes that the quality of

waste water is under control and that is not too much pollutant and harmful for workers as well as

environment. The result of waste water effluent shows that the amount of impurities is under the

limits of NEQs.

Table 5.9 Determination of amount of particles in waste effluent

S.No. ParameterLab Test

ResultNEQS Limiting

Value

1 TEMPRETURE℃ 32 ≤ 3℃2 PH@ 25

8.1 6-9

3 Total Dissolved Solid (TDS) mg/l2725 3500

4 Chemical Oxygen Demand (COD) mg/l 322.7 400

5 Biochemical Oxygen Demand (BOD) mg/l 88.4 200

6 Total Suspended Solids (TSS)mg/l 54 200

7 Lead mg/l 0 0.5

8 Oil & Grease mg/l 8.5 10

9 Phenolic Compounds as Phenol mg/l 0.05 0.3

Figure 5.3 Temperature value of NRL with compared with NEQs

Figure 5.4 Amount of Total Dissolved solids of NRL compared with NEQs

Figure 5.5 Values of COD, BOD and TDS in NRL compared with NEQs

Figure 5.6 Value of Grease and Oil in NRL compared with NEQs

5.2.4 VOLATILE ORGANIC COMPOUNDS

Volatile organic compounds are toxic in nature and harmful for human being, the amount of

hydrogen sulphide and volatile organic compounds, they are found in negligible amount in NRL at

one or two places but overall condition of Volatile Organic Compounds are sustainable and do not

create pollution. In NRL the amount of VOCs are not in abundant that cause illness or nay be

harmful for human beings. The amount of VOCs and the area where they are present are shown in

table 4.9

Table 5.10 Determination of VOCs and H2S inside the refinery

5.2.5 ACCIDENTS/INCIDENTS IN NRL

After analyzing different parameters related to Health and Safety finally we collect the information

about accidents/incidents occur in National Oil Refineries. The overall Health Safety conditions are

satisfactory ands the management of NRL is sincere to provide a safer work place to workers and to

minimize the accidents and losses. According to NRL monthly accidents/incident report about 24

incidents have been accrued and there is no loss time injury that shows that the magnitudes of

incidents are not much higher that causes injuries. Table 4.10 shows the number of incidents in

NRL month

Table 5.11 Month wise status of incidents and loss time injuries in National Oil Refineries

MONTH INCIDENTS LOSS TIME INJURY

JANUARY 2011 NIL NIL

FEBRUARY 2011 01 NIL

MARCH 2011 07 NIL

APRIL 2011 NIL NIL

MAY 2011 02 NIL

JUNE 2011 03 NIL

JULY 2011 07* NIL

AUGUST 2011 04 NIL

YEAR TO DATE

TOTAL

24 NIL

*LUBE 1 Refinery

Figure 5.7 Graphical Representation of monthly number of incidents in NRL

*INCIDENT:

An incident is an unplanned, undesired event that adversely affects of tasks.

*ACCIDENT:

An Accident is an undesired event that results in personal injury or property damage

*LOSS TIME INJURY:

If any NRL employee on duty an on the job accident, which render the employee

medically unfit to resume hid duty during next 24 hours is considered as to be loss time

injury

CHAPTER NO 6

CONCLUSION

It is concluded that the design of facility is intrinsically safe and it conforms all standard

requirements like OSHA, ASME etc. once the safe design requirement are met, the safe operating

mechanism is made safer by imparting the required information to the concerned people and

continual trainings etc. The implementations of all the safe work practices ensure accident

prevention.

The cause of accidents can be divided in two main types immediate and indirect, immediate can be

due to unsafe act and unsafe conditions where as example of indirect causes of accidents include:

lack of policies and procedures, lack of training/supervision, lack of resources.

In NRL when carrying out the exercise it was found that the noise level was satisfactory except of

the working area near the machine and relative gas emission from the stack found under the NEQ

standards and waste water effluent reflects that the water parameters are not exceeding the NEQs

limit. As we know that the NRL is huge industry equipped with heavy and complex machines

which towards the happening of accidents it was observed that monthly 3 incidents are happening

which needs to control, when looking for the indirect cause of accidents it is important to accept

that that every one can make mistakes and management system need to take this in account.

Attempt must be made to develop system which reduces the likelihood of human error. This can be

done either following an accident, or preferably during the risk the risk assessment process before

an accident happens. Studying accident figures can give a good indication of where control is

lacking. The realization that accidents and waterborne/airborne disease have causes, those steps can

be taken to avoid them and that alack of action to avoid them will result in more accidents will

ultimately result in a safer working environment and eradication of the blame culture.

It is concluded that Noise level near the machinery is greater then 85 dBA and at other

places noise level is under limit according to NEQ Standers.

It is concluded that the values of CO, NOx and Sox are also controllable.

It is concluded that the amount of PM are under NEQs limit.

It is concluded that the value of pH of effluent is near NEQs standers.

It is concluded that the temperature of NRL’s is comfortable during work.

It is concluded that according to “accident report” the work place is very safer during 8

months in 2011 there is no accident is occur but 24 incidents are reported.

It is concluded that the value of COD, BOD and TDS are under NEQs limit.

It is concluded that in NRL, PPE’s are also easily available and also PPE’s are very

maintained.

The alarm system of NRL is very good.

It is also concluded that in NRL safety signs and symbols are placed at different places to

avoid any accident

It is concluded that over all HSE department in NRL is active and maintain...

RECOMMENDATIONS

It is recommended that advanced wastewater treatment method must be adopted for the

treatment of refinery effluents.

It is also recommended that the fire fighting equipments and fire brigade must be upgraded

and must increase the number of vehicle for fire fighting

It is also recommended that there should be proper control on flue gases and filtration

system in chimney.

It is also recommended that there should be proper control of dust at the area of NRL

It is also recommended that there should be proper system of training of emergencies.

It is also recommended that in NRL there is no drinking water for other peoples because we

observe that there is no easy availability of drinking water in NRL.

It is also recommended that there the number special PPE’s for poison gases should be

increase.

It is also recommended that in NRL the parking system of oil tanker should be properly

controlled by management of NRL

It is also recommended that there should be proper control of steam traps.

It is also recommended that HSE department should maintain a proper system of fire

fighting training.

.