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Plant Inspection and Conducting Safety Audit of Various Facilities under MSIHC Rule 1989" at ISPRL

India, the world’s third largest crude oil importer, has decided to set up 5 million metric tons (MMT) of strategic crude oil storages at three locations namely, VISAKHAPATNAM, MANGALORE and PADUR, to ensure energy security. These strategic storages are typically state-funded and would be in addition to the existing storages of crude oil and petroleum products with the oil companies that would serve as a cushion during any supply disruptions.

The crude oil storages are constructed in underground rock caverns and are located on the East and West coasts of India. Crude oil from these caverns can be supplied to the Indian Refineries either through pipelines or through a combination of pipelines and coastal movement. These underground rock caverns are considered to be the safest means of storing hydrocarbons.  

 “Indian Strategic Petroleum Reserve Limited (ISPRL)”, a wholly owned subsidiary company of Oil Industry Development Board (OIDB) under the Ministry of Petroleum & Natural Gas (MOP&NG), has been entrusted with the implementation of these strategic storages of crude oil along with the operation & maintenance of these facilities. The strategic crude oil reserves at Visakhapatnam have a capacity of 1.33MMT for meeting the requirements of Indian Refineries such as M/s HPCL Visakhapatnam, Indian Oil Corporation Limited (IOCL) at HALDIA, BARAUNI, BONGAIGAON Refineries and Petrochemicals Limited (BRPL) at BONGAIGAON. This capacity was contributed by two caverns, VUA (1.03 MMT) and VUB (0.3 MMT)

  1. Annual Safety Audit as per Factories Act
  2. Submitting the Safety Report as per Schedule – 8 of Factories Act
  3. Updating the On-Site Emergency Plan (revision of ERDMP) with the scenarios
    1.  Leakage of crude / vapors giving raise to Fire / explosion
    2.  Leakage of crude causing Marine pollution during ship unloading
    3.  Leakage of HSD / vapors causing Fire / explosion
    4.  Leakage of LPG causing Fire / explosion.
    5.  Explosion / Bursting of boiler combustion chamber
    6.  Bursting of steam drum
    7.  Bursting of Nitrogen storage vessel and other pressure vessels.
    8.  Bush Fire on the hill top
  1. Areas Of Coverage
  2. Compliance with Statutory Requirements
  3. Accident Reporting & Analysis
  4. Contractors safety systems
  5. Education & training
  6. Electrical and Personal Safe Guarding
  7. Emergency Preparedness Plans (On-site / Off-site) Vulnerable area identification
  8. Employees participation in Safety & Health Management
  9. Fire Prevention, Protection and Fighting Systems
  10. First Aid facilities & Occupational Health Centre
  11.  Health & Safety improvement plan / targets
  12. Housekeeping Schedules & Procedures
  13.  Machine and General Area Guarding
  14.  Material Handling Equipment
  15.  New equipment review & inspection
  16.  Personal Protective Equipment
  17.  Periodical medical examinations
  18.  Process / plant modification procedures
  19.  Risk Assessment including Hazard Identification
  20.  Safe Operating Procedures
  21.  Safety & Health Policy
  22.  Safety Committees & Minutes
  23.  Safety for Customers
  24.  Safety in Storage and Warehousing
  25.  Safety Inspections
  26.  Safety Manuals & Rules
  27.  Safety Organizational Setup
  28.  Self-Discipline & Safety Practices
  29.  Transportation of Hazardous Substances
  30.  Ventilation, Illumination and Noise
  31.  Work Environment Monitoring System
  32.  Work Permit Systems
  33.  Engineering & Process

The evaluation process is carried out in a structured manner with an exhaustive Audit Checklist (as per IS 14489) being used. During the audit, the existing compliance and effectiveness of the Safety Management System has been evaluated.

The brief scope of work comprises of the following:

  • Field visits by Different streams of engineering (Chemical, Mechanical & Electrical) Team of Four people.
  • Reviewed Safety Management Systems
  • Reviewed documents and records
  • Preparation of onsite emergency plans for the new scenarios as mentioned above
  • Review of existing ERDMP considering the new scenarios
  • Debriefing of audit observations (Good observations and Recommendations) with ISPRL management
  • Draft report preparation
  • Final report submission 1. Safety Audit Report, covering the aspects in line with the various Statutory requirements of Factories Act, Petroleum Rules, Boiler Act, Explosives Rules, SMPV rules, IEC, ICR, Air and Water Act in line with APPCB, Environmental Protection Act,
  • 2. Safety Report, 3.Revision of ERDMP.
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