Hsef Report Jan 2013

7/29/2019 Hsef Report Jan 2013

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Indorama Eleme Petrochemicals LimitedHSEF Monthly Report (January, 2013)

INDORAMA ELEME PETROCHEMICALS LTD.PORT HARCOURT, NIGERIA

HSEF

MONTHLY REPORT(IEPL-HSEF-4.400)

JANUARY 2013

Prepared by: HSE&F department

Record No. EPCL-HSEF-4.400


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IEPL/HSE/MR/01/13Monthly HSEF Report

( for internal circulation only)2 of 18


Contents:

SectionNo.

Topics Page No

1 HIGHLIGHTS OF THE MONTH 31.1 Targets for February , 2013 4

1.2 Training highlights 5

2.0 HEALTH STATISTICS

2.1 PME Data 6

2.1 Work related illness 7 8

2.1 Non work related illness 7 - 8

3.0 SAFETY STATISTICS 8

3.1 HSE Committee meetings 83.2 incident / accident statistics: 9

3.3 Activity and area Radiation survey: 10 - 11

4.0 ENVIRONMENTAL STATISTICS :

4.1 Noise level monitoring 12

4.2 BT/VOC survey 13

4.3 Effluent Quality 14 - 15

4.4 Ambient air quality monitoring 16

4.5 Solid waste disposal 16

5.0 ANNEXURE

5.1 Annexure -1 Brief Description Incidents 17

5.2 Annexure 2 Pending compliance from Safety Audit / FARs /Near misses

17

List of abbreviations 18


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1.0 HIGHLIGHTS OF THE MONTH:

DPR (Department of Petroleum Resource) officials visited site for license renewal.

The complex completed 226 Man days free of Lost Time Accident (LTA).

HSE&F performance assessment for HSE&F performance award schemeconducted for last three months in all plants and departments.

Assessment for winner of near miss ward scheme done and winner declared.

One MTC (Medical Treatment Case) injury was recorded in the month of January

2013. (Please see Annexure I)

One fire incident reported in the month of January 2013 ( Please see Annexure I)

Safety meeting conducted in all the plants & departments

Training on Work permit conducted 15 persons participated.Facility for training to contractors employees made operational at gate A with

audio visual facility.

Routine ambient air quality monitoring conducted in IEPL and its host communities

Routine BT/VOC Survey

Routine TCLP Analysis carried out on polymer and sludge incinerator ash

Routine physiochemical and heavy metal analysis of waste water

Routine waste management.Quarterly stack monitoring conducted.

Quarterly servicing of fire trucks, Water Tender and UT- 2 truck done.

Servicing and maintenance of 6Kg / 9Kg portable fire extinguishers in PPU, Project

office and Fire station done.

Live firefighting training conducted for 28 nos. employees, 59 nos. Contractor

security guards.

Fire prevention training conducted for 28 nos. employees.B.A. Set training conducted for 34 nos. employee.


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1.1. TARGETS FOR FEBRUARY, 2013

S/N Activities Responsibility Areas Target Date

1.Process safety Management

coordinators trainingKPP All plants 28.02.2013

2.Internal process safety Management

audit.KPP All Plants 28.02.2013

3. Complex wide Signage up gradation KPP All Plants 28.02.2013

4.Servicing and maintenance of 6kg / 9

kg DCP extinguishers.HSS

Olefins, ETP,

MMD, PP

Warehouses, PE

Warehouses,

Chemical

Warehouse and

Barrie D.

28/02/13

5.

Flushing of underground fire water

mains

( Network )

HSS

All complex

28/02/13

6.Quarterly servicing of fire trucks,

Emergency truck and UT-1 truck.

HSSFire Station

28/02/13

7.Routine ambient air quality monitoring NAK

IEPL Complex and

host communities

28/02/2013

8. Routine TCLP AnalysisNAK ETP

28/02/13

9. Routine BT/VOC Survey JS Olefins plant 28/02/13

10.Physiochemical and heavy metal

analysis of waste waterNAK

Okulu Aleto and

ETP Final

discharge

28/02//13

11. Routine Noise Monitoring JS

Olefins plant,

PPU, PE Plant, PE

W/H and PP Plant.

28/02/13

12.Socializing for BSC 5 Star Audit for

EnvironmentNAK

for HOFs &

HODs28/02/13


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1.2 .TRAINING HIGHLIGHTS:

TrainingPrograms

Target for2012

(Nos. ofpersonnel)

YTD (%) Jan

First Aid Training 140 0 0

Live Fire Fighting747 13 87

Safety Training540 4 25

Safety Induction(Contractors / Visitors)

NA 330 330

2.0 HEALTH STATISTICS:


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PATIENTS TREATMENT CATEGORIES

Sr.No.

Description No. of persons

2.1 TOTAL NUMBER OF PERSONS / PME CHECKED 122

IEPL (Expats) 30IEPL (Local) 36

DEPENDANTS (Expats) 0

DEPENDENTS (Locals) 0

SECURITY 34

CONTRACTORS 22

2.2 WORK RELATED ILLNESS 0IEPL (Expats) 0

IEPL (Local) 0



SECURITY 0CONTRACTORS 0

2.3 NON WORK RELATED ILLNESS 121IEPL (Expats) 30

IEPL (Local) 36



SECURITY 34

CONTRACTORS 21

2.4 HOSPITALIZATION 22.5 PERIODIC MEDICAL EXAMINATION 22.6 REFERRAL 22.7 INDUSTRIAL ACCIDENT 12.8 MINOR SURGERY 02.9 EXCUSE DUTY 22.10 IMMUNIZATION 42.11 STAFF TRAINING 02.12 NURSES TRAINING 0


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3.0. SAFETY STATISTICS:

Month Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec

Frequencyrate 0

Severity rate0

Total LTA Free Days (As on 31.01.2013): - 266 Days.

Last Lost Time Incident was on : 20. 06. 2012 (Canteen)

3.1 HSE Committee meetings at Plant Levels were conducted as indicated below.

PLANT LEVEL SAFETY MEETING

Olefins PP PE PPUO QAQCLab

Workshop MMD Bagging

: Conducted. X : Not Conducted.


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3.2 INCIDENT / ACCIDENT STATISTICS:

Minor fire (Plant)

Minor fire (Nonplant)

Major fire (Plant)

Major fire (Nonplant)

Gas leakage

Minor Injury (NonPlant)

Minor injury(Plant)

Nearmiss (Plant)

Lost time (plant)

Lost Time (Nonplant)

Month Jan

Minor fire (Plant) 1

Minor fire (Non plant) 0

Major fire (Plant) 0

Major fire (Non plant) 0

Gas leakage 0

Minor Injury (Non Plant) 0

Minor injury (Plant) 1

Nearmiss (Plant) 10

Lost time (plant) 0

Lost Time (Non plant) 0


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3.3 ACTIVITY AND AREA RADIATION SURVEY:

3.3.1 POLYPROPYLENE (PP) PLANT

s/n Tag no. Source serialno.

Equipmentno.

Date of Manufacture Monthly Average (fortnightly)reading((Sv/hr)

1 LE-6012 M-8081 / 5888 06-D-601 1992 2.97

2 LE-6013 M-8163/8162 06-D-602/603 19922.14

3 LE-5007 / 5008 M-6994 06-D-501 1992 1.78

4 LSL-3107 M-6288 06-F-301 1992 1.44

5 LE-3005 M-6505 /6504 06-CY-301 1992 2.65

6 LE-3006 M-6880 06-CY-301 1992 2.28

7 LE-3108 M-6663 06-F-301 1992 0.18

8 LAHH-3109 M-6629 06-F-301 1992 0.42

9 AC-2401 M-6661 06-R-201 1992 0.14

10 AC-2501 M-6662 06-R-202 1992 0.16

3.2 POLYETHYLENE (PE) PLANT

s/n Tag no. Sourceserial no.

Equipmentno.

Date of Manufacture Monthly Average(fortnightly) reading

((Sv/hr

1 LT-1154 7383, 7384,7385, 7386

S-401 1991 3.22

2 LT-1158 M8062 S-402-1 1996 0.20

3 LT-1658 M8068 S-402-2 1996 0.14

4 LT-1163 9510GG S-403-1 (STRAIGHT) 1993 0.20

5 LT-1663 9503GG S-403-2 (STRAIGHT) 1993 0.22

6 LT-1162 9499GG S-403-1 (CONE) 1993 0.09

7 LT-1662 9504GG S-403-2 (CONE) 1993 0.08

8 REMOVEDFROM TAG LT-1162

9398GG OUTSIDE BUNKER 19930.07

9 REMOVEDFROM TAG LT-1662

9385GG OUTSIDE BUNKER 19930.08

TLVs

-Classified Personnel (Radiation worker)- 25 Sv/hr

-Unclassified Personnel (Members of the public)- 7.5 Sv/hr

Sv/hr microserviets per hour


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4.0 ENVIRONMENTAL STATISTICS :

4.1 NOISE LEVEL MONITORING

PLANT NAME SOURCE EQUIPMENT

NOISE LEVEL at Micro level

(dBA)At source 5 meter

OLEFINS BOILER Area 1-K-12A/1-P-

50A/B/C

91 82.1

1-K-12B 85.5 84.0

1-K-12C 88.0 85.5

Compressors K1 94.0 91.5

K2/K3 93.5 82.5

Caustic area Walkway 85.5 83.0

De-propanizer 81.5 78.1

PE PLANT Blender/Silo Grd

floor

North end 88.1 84.0

South end 92.1 89.0Extruder Train-2 91.1 82.5

Operators table

(inside cubicle)

74.0

--

PP PLANT Co-polymer reactor Reactor 401 90.0 85.5

Extruder house 6-D-801 92.1 86.0

Silo/compressor 85.5 81.0

PE Bagging Classifier 90.1 86.5

Bagging Machines Sewing m/c (on/off) 88.1/78.9 75.1

POWER PLANT GTG Inside 88.1 82.0

outside (stacks) 85.0 82.1

Purging air filter 98.5 86.5Nitrogen Plant Plant entrance. 84.2 82.0

Control Room 64.6 -

Compressors

25-K-1 F

90.1 84.8

TLV for Noise is 85db (A)Recommended to use ear protection above the TLV.


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4.2 BT/VOC SURVEY:LOCATION UOM BENZENE TOLUENE VOC

C-5 Hydrogenation Unit

Pumps 1P90A to 1P98B

walkway

ppm 1.1 0.0 0.1

1-P-42 ppm 1.0 0.0 0.0

Walkway by 1-D-80 ppm 0.0 0.0 0.0

C-9

Bottom ground Area 1P39A

to 1P37B

ppm 0.0 0.1 0.0

1-P-35B ppm 0.1 0.0 0.1

K-3 bottom area ppm 1.2 0.1 0.0

D-41 bottom area ppm 0.0 0.0 0.1

C-7

Bottom ground floor ppm 0.0 0.1 1.0

Re-boiler Platform ppm 0.0 1.0 0.0

C-5


Re-boiler Platform ppm 0.0 0.0 0.1

C-4


Driers DR-1/2 A/B & 1-F-1B ppm 0.0 1.2 0.0

DMFS Walkway by 1-D-47/E-

37

ppm 1.1 1.0 0.1

K-1

K1 floor/E25-E28-1E20A/B ppm 0.0 0.0 0.1

Note: Benzene TLV: TWA=0.5ppm, STEL=2.5ppm. Toluene TWA=50 ppm (ACGIH)

Reading taken between 5 m 10 m around emission source(s)

Use of full face with Organic cartridge recommended in area with reading >TLV


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4.3 EFFLUENT QUALITY :

i) pH

Month Jan.13

Nos. of off- spec. 0/31

iii) TSS

Month Jan.13



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iii) BOD

Month Jan.13


iv) COD

Month Jan.13



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4.4AMBIENT AIR QUALITY MONITORING: (EXTERNAL AGENCY)

Parameters UOM

Standards. In side Stations Outside Stations

FMENV DPRNear

Gate.

Near

W/Bridge

Flare

Stack

(North)

Near

AGIP AKPAJO ALETO

SO2 g/m3 260 350 0.00 0.00 0.00 0.00 5.26 0.00

NO2 g/m3 75-113 400 6.31 4.89 12.75 4.34 4.59 2.33

CO g/m3 22.8 30 2.21 2.65 0.00 1.2 0.00 3.78

H2S g/m3

- -0.1

0.080.11 0.00 1.90 0.60

CxHy g/m3 3-160 - 0.00 1.54 0.00 0.00 1.20 0.00

VOC g/m3 6000 - 0.00 2.68 3.91 1.05 3.31 0.00

NH3 g/m3 0.5-1.0 0.5-1.0 0.03 0.00 0.13 0.00 0.38 0.18

TSPM g/m3 600 230 14.74 17.48 20.13 17.79 32.04 27.44

4.5FLUE GAS MONITORING: (EXTERNAL AGENCY)

Parameters UOMIFC

Standard

Stacks

PolymerIncine-rator

SludgeIncine-rator

GTG Stack OlefinsHeaterStack(1-H-1B)

Olefins Boiler Stack

GT-01

GT-04 A B C

SOxmg/Nm 500 1.58 ND 0.00 0.00 0.00 0.00 24.38 0.00

NOxmg/Nm 300

18.22 ND 94.53 100.22 91.11 151.93 158.53 184.96

COmg/Nm --

40.28 ND 0.00 0.00 0.00 0.00 0.00 0.00

H2Smg/Nm --

0.25 ND 0.00 0.00 0.00 0.00 0.00 0.00

CxHymg/Nm --

0.00 ND 0.00 0.00 0.00 0.00 4.32 0.00

VOCmg/Nm --

0.00 ND 0.00 0.00 0.00 0.00 0.00 0.00

ND: Not done (Unit was not running)


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4.6SOLID WASTE DISPOSAL:

Waste. Type. UOM.Quantity/

month

Quantity/

Year (2013)Disposal Method.

Metal Scrap. Scrap. Kg 1580 1580 Sale.Wooden Scrap. Scrap. Kg Nil Nil Sale.

Plastic Scrap.( Including torn

bags)Scrap.

Kg940 940 Sale.

Decontaminated

Containers.Scrap Nos. 566 566 Sale.

Spent Alumina.Solid

Waste.MT 132 132

Stored in designated

location within the

premises

Incinerated Waste. Hazardous Kg 2220 2220 Incinerated.

Waste Oil Scrap LTR 2800 2800Sale./incineration

Molecular Sieve Solid waste MT Nil. 17.5Stored in designated

location within the

premises

Medical waste Hazardous Kg 10.1 10.1 Incinerated.

5.0 ANNEXURE

5.1 Annexure -1 Incidents - FireType of incident : Minor fire

Date : 10-12-2012

Non-Plant : New IRC club (Bush bar)

Description: The straws laid on the roof of the bush bar ignited when a welding work was in progress. The flamingfire spread on 10 m x 8 m area of the roof.

Control measure to prevent recurrence:1. Bunch of highly combustible straw must be removed and then the welding job to be started.2. Fire extinguisher and buckets of water for fire fighting must never be forgotten before starting any hot

work like this.

Annexure -1 Incidents - Injury

Type of incident : medical Treatment case

Date : 08-01-2013

Plant : Chemical warehouse

Description: During unloading gas cylinder finger got caught in between cage and the cylinder.

Control measure to prevent recurrence:i. Proving handle at cage frame. Training the person for right method.


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5.2 Annexure -2 Pending compliance from Safety Audit / FARs / Near misses

Department Pending Responsibility Target Date / Remarks

All plants Training of Safe handling of GasCylinders.

KPP 28.02.2013

PPOU Construction of flange guard onacid pumps in ETP

A.K. Gupta / PhoolSingh/ M. Putta

31/03/2013(Installation going on.Material received earlier isfinished. New order made)

Olefins / PP /offsite

Facility of close loop for Lab.Sampling

Mr. Stoica Ichim / Mr.A Mohapatra / Mr.S.K. Dave.

Survey started.Job will be completed inTAM

General Traffic safety managementownership to be decided

HSS/ RB Discussion between HOF-HSE & Security headongoing

PE plant MOC of drain pit and drain dykearrangement to be executed.(Vaporizer fire FARrecommendation)

Mr. A.B. RAO

Will be completed duringTAM

All Plants All cases of short bolts, less boltsand use of dissimilar materials as

bolts and nuts to be corrected bymechanical group

All plants mechanicalsectional heads Will be completed during

TAM

Electrical/Polymer andchemicalwarehouse.

All 10 years old capacitors of theelectrical lamp fixtures to bereplaced with new metalliccapacitors.

Mr H. Sood31/03/2013Job is in progress


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List of Abbreviations:

ACGIH : American Confrence of Governmental Industrial Hygienist

BOD : Biological oxygen demand

BSC : British Safety CouncilBT/VOC : Benzene, Toluene & Volatile Organic compounds

COD : Chemical oxygen demand

DCP : Dry chemical powder

FMENV : Federal Ministry of Environment

HAZOP : Hazard operability studies

GIT : Gastro intestinal tract

HSE&F : Health, Safety, Environment & Fire

IFC : International Finance Corporation

INDSOP : Indorama Safety Observation Process

JSA : Job Safety Analysis

LEL : Lower Explosive Limit

LOTO : Lock out tag out

LPD : Low point drain

LTA : Lost Time Accident

NESREA : National Environmental Standards and RegulationsEnforcement Agency

ONSEM : Onsite emergency management

PME : Periodical \medical examination

PPE : Personal protective equipment

PTW : Permit to work

RTI : Respiratory Tract Infection.

STEL : Short term exposure limit

TAM : Turn around maintenance

TCLP : Toxic characteristics leachate procedure

TLV : Threshold limit value

TSPM : Total suspended particulate matter

TSS : Total suspended solids

TWA : Time weighted average

UOM : Unit of measure

UTI : Urinary Tract Infection

*** End of Report****

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Hsef Report Jan 2013