L.A.D. College

INTRODUCTION

SAFETY AND PREVENTION MEASURES

Safety is the state of being “safe” the condition of being protected against physical,

social, financial, political, emotional, damage or event which could be considered as non-

desirable, The numbers of workers being exposed should be reduced to a minimum

Employers are obliged to provide workers with information on the risks posed by

hazardous substances

Where the risks to workers are not prevented, control measures should be applied to

remove or reduce the risks to workers' health. The following control hierarchy should be

followed:

1. Design work processes and controls, and use adequate equipment and materials to

reduce the release of dangerous substances.

2. Apply collective protection measures at the source of the risk, such as ventilation

and appropriate organizational measures.

3. Apply individual protection measures including using personal protective

equipment (PPE). By law this is the last resort, and should only occur where

exposure cannot be adequately controlled by other means. Where PPE is given to

workers, they must be trained in its use.

The number of workers being exposed should be reduced to a minimum, along with

duration and intensity of exposure and the amount of dangerous substances used.

Appropriate hygiene measures should also be adopted. Employers are also obliged to

provide workers with information on the risks posed by hazardous substances, and

training in how to use them safely. Regulations apply both to marketed products and to

the waste and by-products resulting from production processes. For many, but not all

chemical products, legislation also establishes standards on classification and labeling, so

that users can understand the substances they are dealing with. law covers the provision

of clear, standardized safety labels, risk symbols, and Safety Data Sheets(SDS) (which

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chemical manufacturers and suppliers must provide, giving information on the properties

of substances, the hazards associated with them, and guidance on storage, handling,

protection etc).

 

For some products, such as pharmaceuticals (e.g. cytostatic drugs) or cosmetics (e.g.

hairdressing products), safety data sheets do not have to be provided by suppliers.

 Even where SDS are available, more information might be needed in some cases. It is

then necessary to:

Use other sources (technical documentation, instructions for use, technical and

scientific reference papers and journals);

consult preventive services;

seek advice from professional organizations (trade associations, chambers of

commerce, trade unions, social security and others);

Contact the relevant authorities.

Most companies have some type of safety injury prevention measures in place designed

to keep employees safe and free from injury and danger while they are performing their

jobs. There are a number of prevention measures that can be utilized to help workers

remain injury and accident-free. A company can post injury prevention procedures on the

wall or inside each employee's cubicle. This information can be posted in the cafeteria

and the warehouse as well.

Safety Meeting

In order for a company to prevent injury on the job, a safety meeting must take place.

Attendance is required for all employees so that all the safety rules and procedures can be

explained. A meeting of this sort emphasizes the importance of injury prevention along

with some of the challenges a company is facing. This meeting provides employees with

an opportunity to have their suggestions and ideas about methods to improve safety and

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prevent injuries heard by all. Employees can make recommendations about safety

procedures designed to prevent injury.

Total Involvement

A company that is serious about preventing injury and providing safety will make sure

everyone is totally committed and involved in this process. Instruct each employee to

examine the work space and make an effort to correct any situation that could lead to an

injury, such as wires or cords lying in the aisle or on the floor. Instruct employees to

report all potential hazards that cannot be corrected or fixed to management immediately.

This helps to ensure that a workplace is safe and injury-free. Recognize and reward those

who make substantial contributions to safety and injury prevention with their ideas and

suggestions.

Written Policy

A written policy in the form of a procedures manual is a good tool for providing

employees with proper instruction about workplace safety and how to remain free of

hazards. This is the place to instruct employees on the proper use and operation of

equipment, as well as the methods needed to prevent injury. The proper procedure for

lifting heavy objects can also be included, if applicable.

Evaluation

Make workers aware of how they are doing in terms of preventing injuries. If some

statistics and measurements are in place which shows how a company is doing with

safety goals and objectives, it may motivate employees to adhere to the policies and

procedures. Negative results can motivate employees to improve and positive results can

motivate employees to keep doing what they are doing. Make a comparison between the

goals and the actual results for everyone to review, and put a plan of action in place to

eliminate any negative variances.

Equipment/Gear

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All employees that operate equipment and tools or supervise those who do can be

provided with a thorough overview of operation. Instruct everyone to wear the

appropriate safety gear such as gloves, hard hat, goggles, aprons, boots, steel toe shoes

and masks and shields. It is necessary that employees know that entry is not allowed in

certain areas without protective gear.

Pump Safety Tips

Some theories suggest that more electronics in cars contribute to gas pump accidents, so

always turn off your car.

Static electricity causes most of the sparks that ignite gas pump fires. Touching metal will

discharge static electricity, so always touch metal whenever you exit your car

It is not just the fuel liquid that is flammable. Fumes are also highly flammable, hence

never smoke, light a match, or use lighters when refueling

Some states now require you to hold the nozzle while pumping instead of locking the

nozzle to auto-fuel, always stay close to the fuel area. Never return to your car while

fueling

If your children pump gas, they should be educated on the safety tips. If there is a fire, it

is easier to get an unrestrained infant out of the vehicle. Better, not to let children pump

gas and don’t leave restrained infants in the vehicle.

Gasoline needs room to expand. Filling anything full of fuel can increase chances of

accidents from fumes: - Don’t top off tank; only fill fuel containers 95% full.

Some of the major injuries and damage from gas pump fires occurred when people

instinctively removed the nozzle from the vehicle after a fire started. A flaming nozzle

can further ignite fumes in the air, fuel spills on clothes and people, and fuel spills on the

ground. Keep the nozzle in contact with the container. That is, leave the nozzle in the car

if a spark ignites the fuel; ask attendant to cut off gas with emergency switch.

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Never refuel a hot lawn mower, 4-wheeler, go-cart, chain saw, weed eater, or other gas

powered equipment.

Never mix gasoline with kerosene or diesel. Use new or separate approved containers

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INDUSTRY PROFILE

The first oil refinery in the world was built in 1851 at Bathgate, Scotland, by Scottish

chemist James Young  but they were initially small as there was no real demand for

refined fuel. As kerosene lamp gained popularity, the refining industry grew in the area.

The world's first large refinery opened at Ploiesti, Romania, in 1856-1857, with United

States investment. After being taken over by Nazi Germany, the Ploiesti refineries were

bombed in Operation Tidal Wave by the Allies during the Oil Campaign of World War

II. Another early large refinery is Olean, Sweden (1875) (Swedish name means The

Petroleum Isle point, the refinery in Saudi Arabia owned by Saudi Aram co was claimed

to be the largest oil refinery in the world. For most of the 20th century, the largest

refinery was the Abadan Refinery in Iran. This refinery suffered extensive damage during

theIran-Iraq war..

An oil refinery or petroleum refinery is an industrial process plant where crude oil is

processed and refined into more useful products such as petroleum

naphtha, gasoline, diesel fuel, asphalt base, heating oil, kerosene, and liquefied petroleum

gas. Oil refineries are typically large, sprawling industrial complexes with

extensive piping running throughout, carrying streams of fluids between large chemical

processing units. In many ways, oil refineries use much of the technology of, and can be

thought of, as types of chemical plants. The crude oil feedstock has typically been

processed by an oil production plant. There is usually an oil depot (tank farm) at or near

an oil refinery for the storage of incoming crude oil feedstock as well as bulk liquid

products.

Petroleum products are usually grouped into three categories: light distillates (LPG,

gasoline, and naphtha), middle distillates (kerosene, diesel), heavy distillates and

residuum (heavy fuel oil, lubricating oils, wax, asphalt). This classification is based on

the way crude oil is distilled and separated into fractions (called distillates and residuum)

as shown in fig 1.

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An oil refinery in Mina-Al-Ahmadi, Kuwait

Petroleum or crude oil is a naturally occurring flammable liquid consisting of a complex

mixture of hydrocarbons of various molecular weights and other liquid organic, that are

found in geologic formationsbeneath the Earth's surface. A fossil fuel, it is formed when

large quantities of dead organisms, usually zooplankton and algae, are buried

underneath sedimentary rock and undergo intense heat and pressure.

Petroleum is recovered mostly through oil drilling. This comes after the studies of

structural geology (at the reservoir scale), sedimentary basin analysis, and reservoir

characterization (mainly in terms of porosity and permeable structures). It is refined and

separated, most easily by boiling point, into a large number of consumer products,

from petrol (or gasoline) and kerosene to asphalt and chemical reagents used to

make plastics and pharmaceuticals Petroleum is used in manufacturing a wide variety of

materials, and it is estimated that the world consumes about 88 million barrels each day.

.The crude oil distillation unit

The crude oil distillation unit (CDU) is the first processing unit in virtually all petroleum

refineries. The CDU distills the incoming crude oil into various fractions of different

boiling ranges, each of which are then processed further in the other refinery processing

units. The CDU is often referred to as the atmospheric distillation unit because it operates

at slightly above atmospheric pressure.

Below is a schematic flow diagram of a typical crude oil distillation unit. The incoming

crude oil is preheated by exchanging heat with some of the hot, distilled fractions and

other streams. It is then desalted to remove inorganic salts (primarily sodium chloride).

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Following the desalted, the crude oil is further heated by exchanging heat with some of

the hot, distilled fractions and other streams. It is then heated in a fuel-fired furnace (fired

heater) to a temperature of about 398 °C and routed into the bottom of the distillation

unit.

The cooling and condensing of the distillation tower overhead is provided partially by

exchanging heat with the incoming crude oil and partially by either an air-cooled or

water-cooled condenser. Additional heat is removed from the distillation column by a

pump around system as shown in the diagram below.

Fig 1Schematic flow diagram of a typical crude oil distillation unit as used in petroleum

crude oil refineries.

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COMPANY PROFILE

INDIAN OIL CORPORATION LIMITED(IOCL)

Company- Indian Oil Corporation limited

Founded- 1964

Headquarters- New Delhi

Products- Fuels, Lubricants, Petrochemicals.

Owners- Government of India

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Key

people-R.S.Butola, Chairman

Revenue- US$ 86.01 billion (2012)

Profit- US$ 0882 million (2012)

Total

assetsUS$ 43.15 billion (2012)[1]

Total

equityUS$ 11.85 billion (2012)

Website http://www.iocl.com/

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It is an Indian State owned oil and Gas Corporation with its headquarters in New Delhi,

India. the company was established in 1964.The Company is the world’s 83 rd largest

public corporation, according to the fortune global 500 list, and the largest public

corporation in India when ranked by revenue Indian oil and its subsidiaries account for a

49% share in the petroleum products market, 31% share in the refining capacity of 65.7

million metric India per year. Indian oil operates the largest and the widest network of

fuel stations in the country, numbering about 20575, it has started auto LPG dispensing

stations it supplies cooking gas to over 66.8 million households. It operates the largest

network of fuel stations in country. It includes diesel, petrol LPG, aviation turbine fuels,

lubricants, bitumen, paraffin kerosene etc.To promote all side development of the society,

Indian Oil also offers sports scholarships to upcoming players and potential/ talented

players.

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.

Digboi Refinery, in Assam, is India's oldest refinery and was commissioned in 1901.

Originally a part of Assam Oil Company, it became part of IndianOil in 1981. Its original

refining capacity had been 0.5 ONE MILLION METRIC TONNES PER ANNUM

(MMTPA) since 1901. Modernization project of this refinery was completed by 1996 and

the refinery now has an enhanced capacity of 0.65. UOP licensed the technology for the

Coking process in this refinery.

Guwahati Refinery, the first public sector refinery of the country, was built with

Romanian collaboration and was inaugurated by Late Pt. Jawaharlal Nehru, the first

Prime Minister of India, on 1 January 1962.

Bongaigaon Refinery became the eighth refinery of Indian Oil after merger of

Bongaigaon Refinery & Petrochemicals Limited. 25 March 2009. It is located at

Dhaligaon in Chirang district of Assam, 200 km west of Guwahati.

Barauni Refinery, in Bihar, was built in collaboration with Russia and Romania. It was

commissioned in 1964 with a capacity of 1 MMTPA

Gujarat Refinery, at Koyali (near Vadodara) in Gujarat in Western India, is Indian Oil’s

second largest refinery. The refinery was commissioned in 1965. It also houses the first

hydro cracking unit of the country. Its present capacity is 13.70MMTPA

Haldia Refinery is the only coastal refinery of the Corporation, situated 136 km

downstream of Kolkata in the Purba Medinipur (East Midnapore) district. It was

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commissioned in 1975 with a capacity of 2.5 MMTPA, which has since been increased to

7.5 MMTPA

Mathura Refinery was commissioned in 1982 as the sixth refinery in the fold of IndianOil

and with an original capacity of 6.0 MMTPA. Located strategically between the historic

cities of Delhi and Agra, the capacity of Mathura refinery was increased to 8.8 MMTPA.

Panipat Refinery is the seventh and largest refinery of Indian Oil. The original refinery

with 6 MMTPA capacities was built and commissioned in 1998. Panipat Refinery has

since expanded its refining capacity to 15 MMTPA.

Paradip Refinery- The commissioning of 15 million tones per annum refinery in

November 2012 has been delayed and is now expected to be operational only in

September 2013.

Subsidiary refineries – Chennai Petroleum

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SCOPE

Safety of employees is primarily important at any workplace irrespective of the fact

whether it is an office, factory or a construction site. But at the same time, proper

protection of the office property is essential. All the employees should be identified by

proper photo identity card that is required to be shown as one enters the office premises.

1) A photo ID card helps in identifying its holder with the name and photograph. This

helps in avoiding impersonation and reduces chances of theft, robbery and pilferage in

factories.

2)Each equipment should be properly labeled and a proper record should be maintained.

Safety is of utmost importance in warehouses. All the stocks should be labeled with the

help of a bin card and should be kept under strict vigilance of the storekeeper. The stock

chart should be maintained regularly so that any deficit in stock can be brought to notice.

3) It is important to buy insurance cover for all the workers as well as the working

equipments. But at the same time it is necessary to take proper safety steps. All insurance

claims are liable to rejections if the safety requirements are not being complied with.

4) A list of all adopted safety measures should be displayed at a prominent place so as to

attract attention of workers, special care should be taken with regards to preceding,

helmets, shoes and belts should be given and first aid kits should be given.

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OBJECTIVES

1. To find out the safety measures provided by INDIAN OIL CORPORATION

LIMITED.

2. To evaluate the safety measures used by the INDIAN OIL CORPORATION

outlets in Nagpur.

3. To find out the preventive measures provided IOCL in case of accidents/

emergency.

4. Safety and preventive training programmes are provided by various outlets to

their employers.

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RESEARCH METHODOLOGY

Research and experimental development is creative work undertaken systematically to

increase the stock of knowledge, including knowledge of humanity, culture and society,

and the use of this stock of knowledge to devise new applications proposed standard

practice for surveys on research and experimental development, 6th edition. It is used to

establish or confirm facts, reaffirm the results of previous work, solve new or existing

problems, support theorems, or develop new theories. A research project may also be an

expansion on past work in the field. To test the validity of instruments, procedures, or

experiments, research may replicate elements of prior projects, or the project as a whole.

The primary purposes of basic research (as opposed to applied research) are

documentation, discovery, interpretation, or the research and development of methods

and systems for the advancement of human knowledge. Approaches to research depend

on epistemologies, which vary considerably both within and between humanities and

sciences; there are several forms of research: scientific, humanities, artistic, economic,

social, business, etc.

Research is an academic activity and as such the term should be used in a technical sense.

According to Clifford Woody research comprises defining and redefining problems,

formulating

Hypothesis or suggested solutions; collecting, organizing and evaluating data; making

deductions and reaching conclusions; and at last carefully testing the conclusions to

determine whether they fit the formulating hypothesis. D.Slesinger and M. Stephenson in

the Encyclopedia of Social Sciences define research as “the manipulation of things,

concepts or symbols for the purpose of generalizing to extend, correct or verify

knowledge, whether that knowledge aids in construction of theory or in the practice of an

art. Research is, thus, an original contribution to the existing stock of knowledge making

for its advancement. It is the pursuit of truth with the help of study, observation,

comparison and experiment. In short, the search for knowledge through objective and

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systematic method of finding solution to a problem is research. The systematic approach

concerning generalization and the formulation of a theory is also research. As such the

term ‘research’ refers to the systematic method

Research Methodology

Consisting of enunciating the problem, formulating a hypothesis, collecting the facts or

data, analyzing the facts and reaching certain conclusions either in the form of solutions

towards the concernedProblem or in certain generalizations for some theoretical

formulation.

PRIMARY DATA–Primary sources are original materials. Information for which the

writer has no personal knowledge is not primary, although it may be used by historians in

the absence of a primary source. In the study of history as an academic discipline, a

primary source (also called original source or evidence) is an artifact, a document, a

recording, or other source of information that was created at the time under study. It

serves as an original source of information about the topic. Similar definitions are used

in library science, and other areas of scholarship. In journalism, a primary source can be a

person with direct knowledge of a situation, or a document created by such a person, data

observed or collected directly from first hand experiences are primary data .

SECONDARY DATA -Secondary data is the data that have been already collected by

and readily available from other sources. Such data are cheaper and more quickly

obtainable than the primary data and also may be available when primary data cannot be

obtained at all.Secondary data, is data collected by someone other than the user. Common

sources of secondary data for social science include censuses, organizational records and

data collected through qualitative methodologies or qualitative research. Primary data, by

contrast, are collected by the Secondary data analysis saves time that would otherwise be

spent collecting data and, particularly in the case of quantitative data, provides larger and

higher-quality databases that would be unfeasible for any individual researcher to collect

on their own. In addition, analysts of social and economic change consider secondary

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data essential, since it isimpossible to conduct a new survey that can adequately capture

past change and/or developments.

All methods of data collection can supply quantitative data (numbers, statistics, or

financial contents) or qualitative data. Quantitative data may often be presented in tabular

or graphical form. Secondary data are those which are collected by others, when it is not

possible to collect data in primary form. They are collected for serving the objectives

other than what the researcher might have in mind.

For this project these two sources of data are used in following forms:

PRIMARY SOURCE:

1. Direct interview with a Safety manager

2. Data collected from a interview with a General manager

SECONDARY SOURCE:

1. INTERNET

2. BOOKS

3. WEBSITES

1. SAMPLE SIZE

10 Respondents have been taken for convenience; hence workers are selected

randomly and interviewed.

2. SAMPLE AREA- Nagpur.

3. SAMPLE TECHNIQUE-

The sample size has been taken by simply random sampling method.

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DATA ANALYSIS AND INTERPRETATION

1. All the Dispensing Units externally & internally clean

Category 1 Category 20

10

20

30

40

50

60

70

80

90

NOYES

YES- 90%

NO- 10%

Inference- 90% of workers agree and rest 10% don’t.

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2. Dispensing units there is no Spillage of product and inflammable waste

Category 1 Category 20

10

20

30

40

50

60

70

80

YES- 80%

NO- 20%

Inference-80% of workers hasn’texperienced spillage and inflammable waste and 20% had.

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3. All the piping connections of Dispensing units & tank farm are leak free & there is

no sweating in the joints

RESPONSE

YES NO

YES- 70%

NO- 30%

Inference -70% of workers agree that of Dispensing units & tank farm are leak free &

there is no sweating in the joints and rest 30% disagree.

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4. Fire Extinguishers are in place and are valid for use as on date?

YES0

20

40

60

80

100

120

RESPONSE

YES- 100%

Inference -100% of workers agree.

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5. Road& pathways are clear of any obstructions

Category 10

20

40

60

80

100

120

Series 3Series 2

79 YES

21 NO

Inference- 79% of workers agree and rest 21% workers don’t.

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6. Safety signs are in place. (No smoking, Mobile Phone Switch Off)

RESPONSE

YES- 100%

Inference- 100% of workers agree.

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7. Tank farm is clean and free of dry vegetation.

AGREE- 62%DISAGREE- 27%NEUTRAL- 11%

Inference- 62% agree, 27% disagree with this statement and 11% of workers are neutral.

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8. The sand in the fire bucket is dry and without any lumps

YES- 87%

NO-13%

Inference-87% workers agree that the sand in the fire bucket is dry and without any lumps and rest 13% don’t.

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9. All the light fixtures at the periphery, canopy and the Sales rooms are in working

condition.

RESPONSE

YES

YES- 100%

Inference-100% workers agree.

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10. Daily briefing [Dos and Don’ts] on Safety before startingof shift has been carried out.

RESPONSE

YESNO NO RESPONSE

YES- 75%

NO-20%

NO RESPONSE- 5%

Inference- 75% workers agree and 20% workers don’t and rest 5% didn’t responded.

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A DETAILED STUDY OF SAFETY AND PREVENTION MEASURES IN INDIAN

OIL CORPORATION LIMITED, NAGPUR

Meanings

Safety is the condition of a “steady state” of an organization or place doing what it is

supposed to do. “What it is supposed to do” is defined in terms of public codes and

standards, associated architectural and engineering designs, corporate vision and

mission statements, and operational plans and personnel policies. For any organization,

place, or function, large or small, safety is a normative concept. It complies with

situation-specific definitions of what is expected and acceptable

Types of safety

It is important to distinguish between products that meet standards, that are safe, and

those that merely feel safe. The highway safety community uses these terms:

Normative safety

Normative safety is a term used to describe products or designs that meet applicable

design standards and protection.

Substantive safety

Substantive or objective safety means that the real-world safety history is favorable,

whether or not standards are met.

Perceived safety

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Perceived or subjective safety refers to the level of comfort of users. For example, traffic

signals are perceived as safe, yet under some circumstances, they can increase traffic

crashes at an intersection. Traffic roundabouts have a generally favorable safety record

yet often make drivers nervous.Low perceived safety can have costs. For example, after

the 9/11/2001 attacks, many people chose to drive rather than fly, despite the fact that,

even counting terrorist attacks, flying is safer than driving. Perceived risk discourages

people from walking and bicycling for transportation, enjoyment or exercise, even though

the health benefits outweigh the risk of injury

SAFETY GUIDELINES IN THE RETAIL OUTLETS OF PETROL PUMP

Lay-out and facilities

The space chosen for a petroleum retail outlet shall be sufficiently spacious to allow it to

minimize the risk from the petroleum fuels to any person likely to be at or near the retail

station. The layout should ensure unobstructed movement of all vehicles together with

adequate provision for entry and exit of tank trucks. Location of the facilities, equipment,

entrance, exit & paving shall be arranged in a manner to avoid the risk of any collision

amongst the motor vehicles. Access for mobile firefighting equipment to all the Retail

Outlet facilities shall be ensured.

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Storage tanks

Petroleum shall be stored only in underground tanks in single / double walled

[membrane] and its installation shall be outside any public risk. These shall be placed in

an earthen or masonry or concrete pit and shall be packed with sand/earth/gravel without

leaving any space between the tank and concrete/masonry wall. No part of the space over

the buried tanks shall be used for any purpose other thaninstalling equipment specifically

meant for the withdrawal/ monitoring of contents of the tank.

Fill Points

The fill points for the tank/tanks, whether off set or direct fill shall be located insuch a

manner so that any spillage of petroleum and its subsequent ignition does not pose any

immediate threat to members of the public or fore court or delivery staff. Fill points shall

be located in the open air such that any flammable concentrations of vapors resulting

from normal filling operations or spillage does not reach potentially ignition sources, or

accumulates in either building or outdoor locations so as to pose a danger. The fill points

shall maintain a minimum safety distance of 3meters, all around including property

boundaries or any other structure where a source of ignition is likely to be present. This

distance of 3 m may be reduced if a fire – resistant wall 4is constructed, e.g. of brick or

concrete, which is at least 2 m high and extends sideways or parallel to the boundary. If

the wall is a part of a building which houses a sensitive population, such as a school,

hospital or residential dwelling, this distance should be increased to 12 m.. Fill pipes shall

have minimum 1:200 slopes towards the storage tank to ensure easy flow due to gravity

and also to avoid any product retention within the fill pipe. Fill pipe shall be carried down

nearly to the bottom of the tank to prevent fire hazard due to generation of static charge

arising out of free fall of product. Proper identification of fill points for various types of

fuels shall be provided to avoid wrong decantation. .An “ear thing bus” shall be provided

in the close vicinity of fill points. Hose connections shall be properly tightened using

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screwed / cam lock couplings. . Fill pipe caps shall be made of softer material like brass

or aluminum. . Fill cap shall have a proper locking system and key shall be kept under the

Custody of the authorized person..Fill points shall be so located that the tank lorry when

under decantation is in drive out position.

Pipelines

Pipelines from tanks to dispensing points and vent pipes shall be routed below the

ground surface. It shall not be under a building or other features which prevent access to

the pipelines after installation. Fuel Pipes should be sloped towards Underground Storage

Tank. Provision shall be made in the piping including connection to the bulk storage

vessel to compensate for expansion, contraction, jarring and vibration Pipe lines shall be

earthed and to maintain electrical continuity suitable “Jumpers” to be provided at the

flanged joints to ensure dissipation of static charge developed due to product flow in pipe

line. The pipelines shall be protected against corrosion by suitable coating strapping and

where necessary by cathode protection.

Vent pipes

Each tank shall be provided with independent vent pipe(s) of adequate capacity unless

vapor recovery system is installed. Vent point shall never be located under any shade

/cover. The vent pipe shall be protected against damage by inadvertent collision with

vehicles. The outlet (opening) of the vent pipe shall be covered with two layers of non

corrosive metal wire mesh. Vent pipe shall be gradually sloped towards the tank to avoid

chocking of vent pipe due to any water ingress or due to product in the event of tank

overflow. The vertical portion of the vent pipe shall not be provided with any

intermediate thread joint. Dispensing equipmentDispensers shall be located in the open

space where they will be adequately ventilated. The dispensers shall maintain a minimum

distance of 6 meters. From any aboveground structure / property boundary. The dispenser

shall be installed on a firm foundation and protected against physical damage from

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vehicles. A shear valve to be provided in dispensers in a pressurized system. . The length

of the hose connected to the dispenser shall be kept minimum keeping in view the

Operational requirement and shall not in any case exceed 4 m. Breakaway coupling shall

be installed in Dispensing Hose / nozzle;the dispensing hose shall be electrically and

mechanically continuous and earthed. Necessary provisions shall be available in

Dispenser to earth the receptacles other than fuel tank of vehicles while dispensing.

Decantation locations the road tanker delivery locations for unloading into storage tanks

shall be in the open, away from the sales building, dispensing activities and emergency

escape routes.

.

Hose length shall not be more than 5.5 m. The location chosen shall allow the road

tanker to gain access without the need to reverse on to the site. The discharge area also

needs to be substantially leveled but should also incorporate drainage arrangements to

intercept largest possible likely spillage.

Sales room

. Any building or room intended to serve as a control point for a retail outlet shall

preferably be so located that an attendant in the sales room can see the forecourt and the

dispensing area clearly.

Canopy

The canopy, if provided, for weather protection shall not adversely effect the ventilation

or access to the equipment. .Canopy heights installed at fuel fore court shall have at least

300mm clearance from the maximum permitted height. Wind and seismic load for the

canopy design shall be considered as per IS: 875 and IS: 1893 respectively. Canopy

structure shall be properly earthed as per IS: 3043.7

.Electrical Power Distribution System

The following elements / components shall be considered in designing the Electrical

Power Distribution system in a Retail Outlet. Total electrical load for the entire Retail

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Outlet Availability, Suitability & Reliability of the relevant agencies grid.In case of

power failure, back-up arrangements.

Elements of Protection

Protection shall be provided to guard against sudden failures viz. neutral disconnection

and against overload, short-circuit & earth fault..The motors shall be protected against

short circuit and overload..Protection shall be provided for variation in voltage, frequency

and phase unbalance. The Retail Outlet operating after sunset, emergency lighting with

battery backup shall be provided near the dispenser, sales room and electrical room.

Earthling System

The earthen system shall be designed as per IS 3043 and following procedures

Shall be followed:-

All metallic structure, pipe fittings and enclosures of electrical equipments shall be

connected to earth. All earthen pits except DG neutral and instrument / IT earthen shall

be connected through grid In lightning prone areas, a risk assessment shall be carried out

for need of lightning protection and guidelines given in IS 2309 shall be followed.

Emergency Stop System

Emergency stop system shall be provided to cut off the power supply to all metering

pumps/ dispensing equipment and associated equipment, other than certified intrinsically

safe equipment at Sales Building. On actuating any of these push buttons, electrical

power supply to entire system shall be isolated instantaneously.

Operating Procedures

Operating personnel of retail outlet shall possess adequate knowledge and experience of

handling Motor Spirit (MS), High Speed Diesel(HSD) to ensure functioning of the station

in a safe and efficient manner. During unloading of the product from the tank

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truck to the bulk storage vessels, the tank truck shall be parked in the space marked for

the purpose. Operation of dispensing fuel to motor vehicles shall be suspended during the

period of unloading of fuel from tank truck to the storage tanks. All operations at Retail

Outlet shall be suspended during the period of evacuation of the storage tank for

maintenance and testing. MS/HSD shall not be filled in the fuel tank of motor vehicle

while the engine of the vehicle is running. The operating procedures shall be displayed at

relevant locations for the unloading of tank truck. Do’s and Don’ts shall be prominently

displayed in Retail Outlet.

Action in the event of emergency shall be clearly established and understood by all

concerned and displayed prominently. The following are the critical activities:-

a. Decantation

b. Management of the Forecourt / Fuelling area

c. Sampling

9. Decantation of Tank Lorries

On receipt of Tank lorry from the supply point, Dealer or authorized representatives shall

check seals; match the numbers with the supply point documents, number of

compartments and quantity/ product contained therein. The unloading operations shall be

done in presence of the authorizedperson at Retail

Outlet & Tank Truck Crew.

After decanting the product into the tank, at least 50 liters of product should bedispensed

through the pump before taking sample from the pump nozzle for ascertaining the density

of the product in the storage tank after receipt. The density at 150C thus ascertained

should be recorded in the density register.

Forecourt Management

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Guide the vehicle to the position at the designated area of the retail outlet facing the

direction of exit. Do not leave the vehicle unattended during refueling operation. Ensure

that sources of ignition, such as pilot lights, electrical ignition devices, electrical

appliances/ gadgets, and engines located on the vehicle being refueled are turned off

before dispensing of fuel to a vehicle. Delivery Sales Person must show zero setting to

the motorist before commencing delivery. Deliver product to customer as required. After

completion of delivery, remove nozzle and place it on the Pump boot.. Position the next

vehicle and repeat all steps as above..

At the end of the day’s work, ensure that valves are closed, hoses are properly stowed

and electrical equipment is switched off. Always guide all vehicles entering into the retail

outlets to designated area for refueling. Important operational activities shall be logged

and records of such activities highlighting receipt, inventory, level, pressure, temperature,

equipment running etc shall be maintained. A two-wheeler shall be re-fueled only after

the Riders have dismounted.

Sampling

The samples shall be taken in approved containers duly earthed/ bonded in line with the

industry guidelines. The samples shall be stored at designated approved place. The

samples shall not be poured back directly to the storage tank. The samples shall be

collected in a separate receptacle for each product and transfer to storage tank through a

container fitted with hose. The retail outlet operations shall be suspended during this

transfer.

Inspection

A well designed system of periodic inspection of all facilities of retail outlet shall be

formulated to maintain it in safe operable condition all the time. Safety audit of the retail

outlet shall be undertaken& certificate of fitness declaring integrity with respect to

equipment, facilities, operations & safety procedures shall be accordingly issued. All

recommendations of the safety audit/ inspections shall be complied in a time bound

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Manner and records maintained thereof. The system of permit to work shall be

established for non-routine works with and such works shall be undertaken with full

knowledge and approval by authorized person. Checklist shall cover conformity with the

design intention, operating and maintenance procedures, preventive measure & protection

systems and safety practices. The resistance shall be checked at least once a year and

records maintained thereof.

Safety inspections / Audit

The safety inspections / audit of Petroleum Retail Outlet shall be carried out as given

below:

Type frequency agency

Safety Inspection Daily operating personnelSafety Audit Once in 6 months Company

authorized Person / Agency

Electrical Audit Once a year Company authorized Person / Agency

Maintenance

A comprehensive maintenance system of all facilities of retail outlet shall be formulated

to maintain it in safe operable condition at all times. Preventive maintenance schedules

shall be drawn for all equipment in accordance with manufacturer’s recommendations

and established mandatory / recommendatory standards. Records of all preventive

maintenance undertaken shall be maintained and updated from time-to time.

Safety equipment

Each dispensing unit shall be covered by at least two ISI marked 10 kg DCP Fire

Extinguishers, placed at a safe location within 3m radius. Minimum one 4.5 kg CO2 fire

extinguisher conforming to IS: 2878 shall be available in each electrical meter room.

Minimum four sand buckets filled with dry sand should be available at the premises. All

employees working in the premises must be conversant with the safe handling of

petroleum

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Products and firsthand knowledge of the fire fighting & emergency handling..Insulated

pliers, screw driver, non-sparking tools, flameproof torch shall be available in the

premises. All periodic tests shall be carried out by competent / authorized persons, as

applicable and records shall be maintained. Fire extinguishers are to be periodically tested

and maintained.

The fire extinguishers are to be checked as per the following schedule:

1. Visual check of the extinguisher: Daily

2. Condition of DCP, Hose, Nozzle and safety clip: Every month

3. Weight checking of CO2 Cartridge: Every Quarter

4. Performance Testing & DCP Extinguisher: Every Year

5. Pressure Testing of Extinguisher: Every Three years

Emergency plan and procedure.

Each Retail Outlet shall be provided with at least 2 points for

Emergencyshutdown. The Operating Company having control over the Retail Outlet shall

Draw an operational emergency plan keeping in view the following:

1. Major failure of fittings resulting in spillage

2. Accidents or other emergencies, which can affect the Retail outlet.

3. Electrical Emergencies.

4. Civil emergencies.

Any other risks arising from the existence or operation of the Retail Outletthe above

emergency plan shall be disseminated amongst all personnel involved and ensure that

they understand their roles and responsibilities in the event of anemergency. The in-

charge of the Retail Outlet shall maintain close liaison withFire Service, Police, District

Authorities and marketing company.

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1. Important telephone numbers for emergency use shall be displayed prominently in the

Retail Outlet.

2. Means of communication shall be always at the disposal of the in charge of the Retail

Outlet.

3. Emergency Action Plan should be tested with mock drill at least once a year.

Training

The objective of training is to provide good understanding of all the facets of operations

at the Retail Outlet. Training shall ensure that the jobs are performed in accordance with

the laid down procedures and practices. Each POL dealer in collaboration with their

principle oil company shall develop training module of their own which should include,

inter-alia, the following:

a) Hazardous characteristics of product handled.

b) Familiarization with operational procedures & practices.

c) Hands on experience on operation of equipment.

d) Knowledge of emergency and manual shut down systems.

e) Immediate and effective isolation of any spill

f) Safety features and accident prevention.

g) Fire fighting facilities, its upkeep and operation.

h) Evacuation and safe egress of the vehicles in an emergency.

i) Housekeeping

j) Decantation.

k) Do’s & Don’ts

l) Emergency plan./drills,

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Additionally, people shall be trained for specific job / activity.

Customer safety and awareness

Display of important information:

At Retail Outlet, the particulars of license, emergency telephone numbers of local fire

service, police, marketing company and emergency instructions shall be conspicuously

displayed. Caution boards shall be displayed near the dispenser for customer awareness

as below:

a. Stop the engine before refueling

b. No smoking

c. Non-use of Mobile phone

DO’S& DON’Ts on the dispenser

DOs

I. Switch off the mobile phone.

ii. Switch off the engine before commencement of refueling.

Iii. Ensure a 10 kg DCP Fire Extinguisher is available near the Dispenser.

iv. In case of any spill / fire observed, press the “EMERGENCY STOP” button

on the Dispenser.

DON’Ts

Do not start the engine / drive away the vehicle till the filling nozzle has been

disconnected from the filler cap of the vehicle.

i. Do not refuel the vehicle during the period MS/HSD is being decanted to the tank.

ii. Do not Smoke

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iii. Do not use naked flame

Objectives of Fire Safety

The main objectives of fire safety are

• To minimize both the probability and the consequences of postulated fires.

• To detect and suppress fire with particular emphasis on passive and active fire

protection system and adequate capacity for the systems necessary to achieve and

maintain safe plant shut down with or without off-site power.

• To ensure that a failure, rupture or an inadvertent operation does not significantly

impair the safety capability of the structures, systems and components.

• To address not only the direct effects of flame, radiant heat and explosion but also to the

potential for the release of hazardous materials and hazardous combustion products in the

event of fire and the potential for the release of water and other fire fighting media

contaminated during fire fighting.

To meet these objectives, there are Passive Fire Safety Systems (PFSS)- The Passive Fire

Safety Systems are those systems, where no moving components are involved and which

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are provided to detect, prevent spread, or suppress fire. The examples are fire barriers,

fire seals, fire detectors, fire retardant paint etc. Active Fire Safety Systems (AFSS) -

The Active Fire Safety Systems are those systems where moving components are

involved and which are provided to protect against fire. The examples are fire pumps, fire

hydrants, sprinklers, extinguishers, etc.

Defense in Depth Concept

With respect to the fire protection programmer in all facilities, the defense-in-depth

principle shall be applied to achieve an adequate balance in:

a) Preventing fire from starting,

b) Detecting fires quickly, suppressing those fires that occur, putting them out quickly,

and limiting the damage and

c) Designing plant safety systems, so that a fire that starts in spite of prevention functions

shall not prevent essential plant safety functions from being performed. The first

objective requires that the design and operation of the plant be such that the probability of

a fire starting is minimized. The second objective concerns the early detection and

extinguishment of fires by a combination of automatic and/or manual fire fighting

techniques and therefore relies upon active fire safety systems. For the implementation of

third objective, particular emphasis shall be given to the use of passive fire barriers,

which would be the last line of defense, if the first two objectives were not effective.

Nuclear facilities use the concept of defense-in-depth to achieve the required high degree

of safety. In case of Nuclear Power Plants (NPPs), the nuclear safety is achieved by

performing three essential safety functions namely, safe reactor shutdown, core cooling

and confinement. It should be possible to achieve, maintain and monitor these three

safety functions in the event of fire anywhere in the nuclear power plant. This can be

achieved by building in fail-safe feature, redundancy, independence and physical

separation in the design of the equipment, instrumentation and support system provided

for carrying out these three safety functions.

Fire Hazard Analysis

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A detailed fire hazard analysis should be carried out during initial plant design to reflect

the proposed construction arrangements, materials and facilities. The fire hazard analysis

should be a systematic study of (a) all elements of the fire protection function being

proposed to ensure that the plant design has included adequate identification and analysis

of potential fire hazards (b) the effect of postulated fires relative to maintaining the ability

to perform safe shutdown functions and minimizing toxic and radioactive releases to the

environment and suggest remedial measures. The fire risk can be quantified for the

process industries based on the indices like Dow index the indices are comprehensive and

give a realistic value to the risk of individual process unit due to potential fires and

explosion. Facilities handling and storing flammable liquids are exposed to a potential

fire risk. The fires due to flammable liquid may be a Pool Fire, Jet Fire, Flash Fire or a

Boiling Liquid Expanding Vapor Explosion (BLEVE) depending on the containment,

type of release and source of ignition. Computer models are available to simulate the fire

conditions and estimate the potential consequences. The fire hazard analysis should

separately identify hazards and provide appropriate protection in locations where safety

related losses could occur as a result of:

a) Concentrations of combustible materials, including transient fire loads due to

combustibles expected to be used in normal operations;

b) Configuration of combustible contents, furnishings, building materials, or

combinations thereof conducive to fire spread

c) Exposure to fire, heat, smoke, steam that may necessitate evacuation from areas that

are required to be attended for safety functions;

d) Fire in control rooms or other locations having critical safety related functions;

e) Lack of adequate access or of smoke removal facilities that impede fire extinguishment

in safety related areas;

f) Lack of explosion prevention measures;

g) Loss of electric power and

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h) Inadvertent operation of fire suppression systems , The possibility of a fire spreading

from one unit to the other unit should be taken into account in the fire hazard analysis .i.e.

The analysis of consequences of the postulated fire on safety of the plant should be

conducted by the persons trained and experienced in the principles of industrial fire

prevention & control and in fire phenomena from fire initiation through its propagation

into adjoining spaces and it should be done in consultation with the Fire Protection

Engineer. The Fire Hazard Analysis report is reviewed by the regulatory body prior to the

commissioning of the facility. Any changes emerged from review are appropriately

incorporated by the facility.

PREVENTION

The following five steps provide a systematic approach to identifying hazards and

managing risks at petrol stations:

STEPS 1 IDENTIFY - Take a fresh look at your site and identify where fire and

explosion hazards may exist.

STEPS 2 CONSIDER - Think about what could go wrong and who could be affected.

STEP 3 EVALUATE - Look at your findings and decide if the precautions which have

already taken are enough to prevent anything going wrong or to reduce the consequences

if something does happen..

STEP 4 RECORD - Make a note of findings.

STEP 5 REVIEW - Consider when the next need to review the assessment will arise

STEPS ONE – Look for the areas where a fire or explosion hazard may occur. To

identify hazards know about our site, how it operates, its surroundings, and the age, make

and type of equipment installed. Employees or safety representatives may be able to help

fill in any gaps in r knowledge. A site plan may also prove useful when carrying out the

risk assessment. Looking for areas where petrol vapor may accumulate is a way of

determining where vapors may occur and is a legal requirement.

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STEP TWO - Think about what could go wrong and who might be harmed. For each

activity, decide whether and how petrol could escape. Think about how much could spill

or leak, what route it might take and where it would collect. Look for possible sources of

ignition. Take account of human error and the fact that people do not always follow

instructions or behave in a responsible way. For example, customers may park badly and

obstruct delivery tankers or emergency escape routes. They may also attempt to fill

unsuitable containers with petrol, or smoke when filling their cars. Consider all activities

including cleaning, maintenance etc, and those, which only take place infrequently. Think

about the greatest number of people who could be affected by a fire or explosion. Include

those who: work at the petrol station; come to the site to buy petrol; visit the site for other

reasons, such as contractors or customers using a forecourt shop or car wash; occupy

adjacent property; and share and/or operate another business on site. In each case, think

about what could happen or what could go wrong and include the most and least likely

events to occur. Include the worst events that could happen and those where may have no

visible sign or warning. Make a written note of findings and the measures already have in

place to deal with the hazard. This will help later in the assessment.

STEP THREE – Evaluate the findings and decide whether further precautions are

necessary.Andalready have in place. Although the probability of a particular occurrence

may be small, this will need to consider the consequences, if something does go wrong. If

the risks are already low enough andshould not have to introduce any further measures.

But if you conclude that y should do more, and must explore other options for controlling

or minimizing the risk. No two sites are the same, so it is not possible to provide a

straightforward list of what should do. Seek advice if necessary, and remember that you

are responsible for seeing that the risk assessment is adequately done. Some changes,

such as relocating vent pipes, may take time to achieve and require interim steps to be

taken to minimize the risk. When it is decided what to do and taken the appropriate

action, it need to check that the measures work. Howdoes this will vary according to the

nature of the changes made?

STEP FOUR – Recording the findings record significant findings of the risk assessment.

The type of information recorded should include: the significant hazards, i.e. those which

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pose a serious risk to workers or the public whose safety might be affected if something

goes wrong, the people who may be affected; and existing control measures and the

extent to which they control the risk – this need not replicate details more fully described

in documents such as manufacturers‟ instructions, health and safety policy statement or

procedures, company rules etc but you should refer to them if you intend to rely on them.

STEP FIVE – Review your assessment. Risk assessment is not a once and for all activity.

. Any change to the site or the operating procedures could affect the level of risk, so the

effect should be assessed and understood. Although individual or small changes may not

in themselves affect the assessment, a number of changes together may have a cumulative

and significant effect.

CONCLUSION

From this Project one can conclude that in Indian Oil Corporation all the safety

equipments are provided in the retail outlets there are many safety programmes which are

held every year in the outlets for awareness of safety, In this programmes various

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prevention measures are told so that in the case of an emergency the accident can be

avoided. There are various equipments like fire extinguisher, safety jackets, masks are

provided. For working at height, there is provision of safe access to the work site and

there is provision of ladder/ platform/ scaffold for safe execution of work. Check those

scaffolds provided are with green tags. Safety shoes are provided so that they can be

prevented from fire, Fire foam system is providing protection to fire vulnerable areas

(tanks loading rack, etc.).No smoking and no cell phone usage signs is significantly

displayed in the forecourt.Proper facilities for storage and disposal of used and waste oil

and gas are provided. Hence, Indian oil provides all the facilities regarding safety.

SUGGESTIONS

1. Safety Training programmes should be given to the workers who are working in

the retail outlet of a petrol pump.

2. Providing adequate ventilation, including local exhaust ventilation, to eliminate

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Flammable or harmful atmospheres.

3. Automating processes to eliminate human exposure and error.

4. Fitting safety critical control devices, alarms and critical condition shut-down

devices.

5. Installing lighting which provides ample illumination for the tasks to be

performed .

LIMITATIONS

1. Time was less to collect the primary data and complete the project.

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2. Due to busy schedule of manager it was difficult to interact.

3. Employees feared to reveal the negative aspects related to company

4. Results of the Project are limited to Sample size of 10.

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