WELCOME Mr BOB WALLACE, BRITISH SAFETY COUNCIL

HSE&F Management in EPCL

Port Harcourt

Indorama

Global Footprint
18 Manufacturing Sites, 11 Countries, 4 Continents
Lithuania: Rotterdam: PTA/PET UK: PET PET Resins

Turkey: Spun Yarns

USA:

PET Resins

Egypt: Spun Yarns, Ammonia

Thailand: PTA, Polyester Yarns & Fibers, PET Resins Wool Yarns, Furfural Sri Lanka: Spun Yarns Indonesia: Polyester Yarns & Fibers, PET Resins, Spun Yarns, Fabrics, Medical Gloves, Real Estate

Nigeria: Olefins, PE & PP

- IVL

EPCL location

The EPCLs petrochemicals complex is located nearby the town of Eleme, about 15 minutes from Port Harcourt, capital city of Rivers state, Nigeria.

Key Plants - Description

IFP

Fuel Gas 145 KT/Y

ETHYLENE

BUTENE-1 22 K T/Y
(September 1995) Kobe Steel Ltd.

PRF PHRC
88 K T/Y NGL AGIP 583 K T/Y FUEL GAS AGIP Kellogg Brown & Root Ethylene 300,000 MT/Y

Nova Chemicals

OLEFINS 671 K T/Y

(May 1995)

ETHYLENE

POLYETHYLENE 270 K T/Y

(September 1995) Kobe Steel Ltd.

PE RESINS
HDPE 162 K T/Y LLDPE 108 K T/Y

Chiyoda

Propylene 126,000 MT/Y

Basell PROPYLENE POLYPROPYLENE 80 K T/Y

(August 1995) Cracking Naphtha / Virgin C5 Technimont & JGC

PP RESINS
80 K T/Y

PPU
(1994)
PHRC

120 K T/Y

CRACKED C5+
40 K T/Y

OLEFINS PLANT
KBR Technology Designed to Produce 300 KT/Y of Ethylene 126 KT/Y of Propylene (Both Polymer Grade) Also 120 KT/Y of V/C C5+ Feed: NGL (Natural Gas Liquids) from Agip Other by-products: Fuel gas Hydrogen Light/Heavy Oil

VC5+ / Light Naphta

PRF (Propylene Rich Feed) from PHRC

POLYETHYLENE PLANT
SclairtechTM Technology NOVA Chemicals Designed to Produce 270 KT/Y of Polyethylene HDPE 162 K T/Y LLDPE 108 K T/Y Solution Process More than 140 different polymer grades

Feed: Ethylene from Olefins Plant

Butene-1 from Butene-1 Plant

POLYPROPYLENE PLANT

Spheriphol Technology Basell

Designed to Produce 80 KT/Y of Polypropylene Homopolymer Co-Polymer (Ethylene)

Feed: Propylene from Olefins Plant Ethylene from Olefins Plant

BUTENE-1 PLANT
Alfa-Butol Technology IFP - AXENS
Designed to Produce 22 KT/Y of Butene-1 Other by-products: Hexenes+ (C6+)

Feed: Ethylene from Olefins Plant

ORGANOGRAM HSE&F

OCCUPATIONAL HEALTH

ENVIRONMENT

FIRE SERVICES

HEALTH SECTION ORGANOGRAM

HEAD HSEF

HEAD DOCTOR

DOCTOR

NURSES & PARAMEDICAL STAFFS

OCCUPATIONAL HEALTH MANAGEMENT

The section caters to the need of First aid to the employees General medical diagnosis & treatment Handling of medical emergency, if any occurs. Periodic medical check up Monitoring general hygiene Monitoring all occupational health risks within.

 Formulate HSE policy and general safety rules and ensure its implementation .

Key Responsibilities of Safety Department

Develop HSE procedures based on standards and ensure implementation.

Formation of HSE committees (top level/ Departmental) and ensure effective functioning of these committees. Co ordinate periodic internal safety audits and observation compliance follow up. Procedure compliance audit and work place inspections. Safety information sharing and publicity. PPE- Selection, inventory , training and use enforcement.

Investigation and Analysis of Near Miss/Injury incidents.

Key Responsibilities of Safety Department

Co-ordination for risk assessment and participating in Task bases risk assessments.

Making need based safety training modules and conducting safety trainings to company and contractors employees.
Safety promotional activities Safety contests/ incentives.

Management MIS on HSE&F and statutory compliance.

Ensuring HAZOP and PSUSR of selected MOCs. Development of Safety Intranet- loading of safety films, safety bulletins, MSDS, HSE&F report etc.

SAFETY MANAGEMENT (Procedures)

1. HSE Policy and Organization 2. Safety Guidelines 3. Safety Districts

4. Safety Ambassadors 5. Entry Pass for restricted areas and gate passes 6. Work Permit System 7. Management of Change 8. Gas Testing 9. Accident reporting & Investigation 10. Line Breaking 11. Positive Isolation 12. Excavation and Cordoning 13. Confined Space entry 14. Vehicle Entry Permit 15. Electrical Work Permit 16. Safety Aspects in Nitrogen Distribution

SAFETY MANAGEMENT (procedures contd.)

17. Changing of Instrumentation pre alarms / alarms/trips 18. Personal Protective Equipment (PPE) 19. Guidelines for Handling Flammable Hydrocarbon 20. Classification of Hazardous Area 21. Selection of Electrical Apparatus for Hazardous Areas 22. Job Safety Analysis (JSA) 23. HSE suggestion scheme 24. Contractors Safety 25. Safety Relief Valve 25. Procedure for risk assessment 26. Procedure for scaffolding

27. Procedure work permit for non plant building and areas.

SAFETY DEPARTMENTS ROUTINE ACTIVITIES

All Hot job preparation certification including LEL monitoring Scaffold inspection and certification Confined space entry Gas test and certification. Hazardous chemical loading unloading safety audit.

Monthly noise level monitoring

Monthly Radiation sources surrounding exposure monitoring. Contractors employee training and validation (Daily Basis) PTW audits Safety talk on critical jobs Supplying special safety equipment to plant on need base.

INCIDENT/ACCIDENT TREND FOR LAST 5 YEARS

Fire Minor Injury

2006 Fire Minor Injury Nearmiss Lost time 3 10 2 0 2007 8 26 19 1 2008 8 16 31 1 2009 5 15 19 1 2010 11 5 22 4

Nearmiss Lost time

INCIDENT/ACCIDENT TREND FOR LAST 5 YEARS

35 30 25 20 15 10 5 0 10 3 2 0 2006 8 1 2007 26 22 19 16 8 5 1 2008 1 2009 2010 5 4 19 15 11 Fire Minor Injury Nearmiss Lost time 31

SEVERITY RATE VS YEARS

7

6 5.79

3.86

2 1.5 1 1.5

0 2007 2008 YEARS 2009 2010

In 2010 there were three LTI which are non plant related incidents & happened out side the plant battery limit.

Severity Rate

FREQUENCY RATE VS YEAR

8 7.3 7

3 2.3 2 2.3 2.3

0 2007 2008 YEARS 2009 2010

In 2010 there were three LTI which are non plant related incidents & happened out side the plant battery limit.

SAFETY SECTION ORGANOGRAM

HEAD HSEF

HEAD Safety

Safety Officer

Safety officer Shift

Safety officer Shift

Safety officer Shift

Safety officer Shift

INCIDENT/ACCIDENT TREND
YEAR-2010

Incident Fire Minor Injury Near miss Lost time

2009 5 15 19 1

2010 11 5 22 4

JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC Fire Minor Injury Near Miss Lost tim e 1 0 1 1 2 1 1 0 1 2 2 0 0 0 0 0 2 0 3 0 0 1 7 0 0 0 3 0 3 0 1 0 1 1 0 2 1 0 1 1 0 0 3 0 -

Fire

Minor Injury

Near Miss

Lost time

Injury accident analysis Type wise.

TYPEWISE 2009

TYPEWISE 2010

ELECTRICAL CONTACT 8%

FALL 8% FALL

HIT AGAINST 11% FALL 34%

CHEMICAL CONTACT 31% STRUCK BY 45% HIT AGAINST 8%

STRUCK BY HIT AGAINST CHEMICAL CONTACT ELECTRICAL CONTACT

CAUGHT IN BETWEEN 22%

FALL STRUCK BY CAUGHT IN BETWEEN HIT AGAINST

STRUCK BY 33%

Injury accident analysis Injury wise

INJURYWISE 2009

INJURYWISE 2010

IRRITATION 15% FRACTURE 0%

FATALITY 0%

FATALITY 22% CUT BURN FRACTURE CUT 62% IRRITATION FATALITY CUT BURN FRACTURE IRRITATION CUT 67% FATALITY

IRRITATION 0% FRACTURE 11% BURN 0%

BURN 23%

Injury accident analysis Body part wise.

BODY PART - 2009

BODY PART - 2010

EYE & BODY 8%

HEAD 8% LEG 15% HEAD LEG FACE EYE SHOULDER

FACE 11% HEAD 33% HEAD FINGER LEG FACE LEG 45% FINGER 11%

FACE & BODY 23%

SHOULDER 8% EYE 15%

FACE 23%

FACE & BODY EYE & BODY

HSE&F Objectives and Targets 2011

Sr. No. Element. Key Performance Indicators
First aid Injury Lost time injury 2 Reduction in Fire Minor fire Major Fire 3 Environment emission norms Number of deviations

Department objectives

UOM

Base Level (FY 10)

5 4 14
1

Target (FY-11)
3 0
7

Reduction in accidents

Reduce First aid injuries by 50 % Zero lost time injury Reduction in Fire by 50% Reduction in Fire to zero Zero deviation from norms

Nos Nos Nos Nos Nos

Smoke Control 4 5 Occupational Health Risk Management Occupational disease % of MOC'S HAZOP %PSUSR of completed MOCs

Soot less burning of Plant Spent oil. Zero occupational disease HAZOP of all necessary MOC'S to be done % PSUSR done of all MOC completed before commissioning

% Nos %

100 0 100

100 0 100

100

100

HSE&F Objectives and Targets 2011

6 Safety AuditsExternal Safety AuditsInternal Audit by M/s British safety Council Audit frequency / weekly / Plant Complete audit of Five star safety Management system By M/s BSC Work permit procedure compliance audit Nos 0 1

Nos

30

40

Audit frequency/yearly Audit frequency/yearly Audit frequency/yearly Audit frequency/yearly Nos of Audits / Six monthly Nos of Audits / Six monthly

Trip/interlock bypass for complex PSV audit for complex Tools & tackles audit Tank farm (Offsite) Non plant building audit Canteen Hygiene audit

Nos Nos Nos Nos Nos Nos

1 1 1 1 1 0

1 1 1 1 2 2

HSE&F Objectives and Targets 2011

8 Procedures for Safety Nos of procedures To prepare & add the Safety Procedures for plant Nos 30 30+4

Participation in trainings

Training modules

Number of training Modules prepared

Nos

Nos of participants Nos of participants Nos of participants Nos of participants

Live Fire Fighting training

Nos

518

540

Induction training to contactors/ visitors FSE Refresher training First aid training

Nos Nos Nos

1285 60 150

2500 100 200

HSE&F Objectives and Targets 2011

10 Safety meetings Nos of meetings/ Quarterly Nos of meetings/ Monthly 11 Safety Promotion Statutory compliance Nos of program/ Six monthly License renewal / biyearly License renewal/Yearly Compliance to Environment related government norms Compliance to Factory Act related government norms Apex HOD/ HOF level meeting Nos 2 4

Plant/ Department level meetings Safety Competition- complex level Factory license renewal

Nos

90

96

Nos

12

Nos

NNRA license renewal

Nos

Complete all government norms

100

100

Complete all government norms

100

100

HSEF (ENVIRONMENT SECTION)

ENVIRONMENT MANAGEMENT

ENVIRONMENT SECTION ORGANOGRAM

HEAD HSEF

HEAD ENVIRONMENT

ENV.ENGINEER

WASTE EVACUATION STAFF

MONITORING STAFF

ENVIRONMENT
The function of Environmental Section is to ensure that 1. Control of all emission. 2. Proper treatment of all waste. 3. Compliance of all Statutory norms.

4. Monitoring all emissions. 5.Resource Optimisation. 6. Involvement of employees in conservation of the environment 7. Keeping a cleaner ambience

CHRONOLOGY OF ACTIONS Environmental Evaluation Report EER (EIA) was done to establish the baseline conditions and identify the action point areas. EER covered water environment, air environment, receiving water body environment, soil environment, noise study. Soil environment condition study was done as presence of hydrocarbon was Observed in some location. Reports submitted to FMENV, DPR, IFC and River State Ministry of Environment

CHRONOLOGY OF ACTIONS

Received initial provisional consent in 2007 from Federal

Ministry of Environment on following areas

Operation of ETP and discharge of effluent Operation of sludge incinerator

Operation of polymer incinerator Third party environmental audit was conducted and its was approved by above regulatory authority. Received final consent for discharge in 2008, renewed by FMEnv. upto 2012.

ENVIRONMENTAL

MONITORING

Daily monitoring of treated effluent discharged Regular monitoring of storm water drains Monthly monitoring of ambient air quality at four locations around complex periphery and recently started two outside station of the complex ( AKPAJO and ALETO) Monthly monitoring of stacks ( Sludge incinerator, polymer incinerator, olefins heater, Boiler and GTG stacks) Monthly analysis of ash from incinerators. Regular physiochemical analysis of waste water at recipient water body.

WASTE MANAGEMENT
The system is based upon following hierarchy:

Reduce

Reuse

Recover/Recycle
Disposal

WASTE MANAGEMENT STEPS

Identification Characterization Collection Transportation Disposal including Reuse, Recycle

FIRE SECTION

Prevent Fire

FIRE SECTION ORGANOGRAM

HEAD HSEF

HEAD FIRE

SR.FIRE OFFICER

FIRE MEN 1st shift

FIRE MEN 2nd shift

FIRE MEN 3rd shift

FIRE SERVICES

The section handles following activities Response for any emergency call for 24 hours and 365 days Mitigate & fight fire or any gas leakage and save people, property & environment. Prevent and reduce fire risks through fire fighting training Oversee the fire prevention while any hot work is being performed Keep all fire fighting equipment in working condition Conduct ONSEM and surprise mock drill

ACTIVE FIRE PROTECTION SYSTEMS

FIRE DETECTION SYSYTEM: Manual call points Gas & Smoke alarm FIRE FIGHTING SYSTEM: Extinguisher : DCP,CO2 and Foam Pressurised network with 4 main pumps of capacity 900m/hr each 3nos Multipurpose trucks 1no emergency truck 1 no water tender 1 no Hydraulic lift platform 2 nos utility trucks 2nos Mobile foam trailer 1 no DCP trailer

Thank you