Initiatives

in Indian Oil Refineries

 Safety Management System at IndianOil
HSE Leadership and Facilities Design and Process Safety, Risk Training & Personnel
Commitment Construction Analysis, Reliability Safety
o H,S&E Policy o Statutory Licenses o PHA/ HAZOP/ QRA o Use of PPEs
o Safety Committee o OISD Standards o Process Safety interlocks o IFR Coveralls
meetings o PNGRB Regulations o Emergency Shutdown o Training as per OISD-
o Employee o International Standards System STD-154
participation like NFPA, API, DIN etc. o Condition Monitoring o Live Fire Fighting
o Review & o Dedicated fire fighting o Predictive/ Preventive Training
Monitoring system Maint. o Training on specialized
o Apprising the Board topics
Procedural System Disaster Management Audits Incident Investigation
o Work Permit System o ERDMP for all locations o Internal Safety Audits by o Investigation
o Standard Operating o Mock Drills Multi-Disciplinary Teams Committee
Procedures o Onsite/ Off-site Disaster o System Audit o Implementation of
o Job Safety Analysis Drills o External Safety Audit recommendations
o Toolbox Talks o Mutual Aid Agreement o Surprise Safety Audit o Sharing of lessons
o Management of o Pre fire fighting plans o Pre-Commissioning Audit learnt
Change o Electrical Audit o Animated films
o Identified Fire Permit o Hygiene index Audit o Near Miss Reporting
Signatories HSE Department, Corporate Office o Penal Action
 New Initiatives being taken to curb incidents – by all Divisions

Implementation of issuing of Work Permit in SAP

E-learning modules on various safety related topics - Swadhyaya -

190 courses
Corporate guidelines have been developed on use of PPEs,
covering 57 critical activities across Divisions and PPEs to be used
during these activities.

Periodical review of SOPs of various activities at locations and

approval by Competent Authority.

Policy on FPR-Building Safety formulated and FPRs identified for

all Admin buildings, Training Centers and Residential Colonies
Implementation of Electrical Safety Audit Scheme for buildings,

HSE Department, Corporate Office

 New Initiatives being taken to curb incidents – by all Divisions

Safety
Awareness
Program Fire Fighting &
Rescue Drill
Competition
Safety Awareness &
Training Program
For Workers and
PPE Training/ Employees
Wearing
Competition
On-line/Offline
Safety Quiz
Magazines/
Safety Movies/ Safety Park
Street Play on
Safety
Monthly Safety Day/
National Safety Week

HSE Department, Corporate Office

 New Initiatives being taken to curb incidents – by all Divisions
Safety Park
Safety parks are designed as an area designated for reinforcement of safety knowledge of our work force through
visual display of safety related aspects.
In some of the refineries the safety park has various sections. Each section is dedicated to a specific hazard
present in the Refinery. These sections have both reading material and still models of various activities/ process &
related hazards in the Refinery.

HSE Department, Corporate Office

 New Initiatives being taken to curb incidents – Refineries Division

Video Lessons
o OPVLs are developed in house without any cost to the
organization. These are short 1-2 min video clips on PPEs,
Near miss etc.
o Preparation of In-house Safety Videos, around 30 nos. of such
videos are created based on real incident/near miss/unsafe
act/condition.
o Created In-house Video on Safety Induction for contract
workers for safety briefing.
o Videos are uploaded on Refinery portal for easy access to all
employees.

HSE Department, Corporate Office

 New Initiatives being taken to curb incidents – by all Divisions
Sharing of lessons learnt
Learning from incident/ accident is shared among the employees/
contract workers through measures like:
• One pagers circulated to all employees indicating major lapses/
improvement actions required.
• Questions on lessons learnt included in online safety quiz conducted on
All India basis.
• Sharing of accident details in safety committee meeting/ monthly safety
day program etc.
• E-learning modules based on incident, for use by all.

• Safety films on few major accidents being prepared by Refinery

Division.

HSE Department, Corporate Office

 New Initiatives being taken to curb incidents – Refineries Division

PPE Monitoring system

Artificial Intelligence (AI) based PPE monitoring system implemented in some of the refineries and under
implementation at remaining locations.

HSE Department, Corporate Office

 New Initiatives being taken to curb incidents – Refineries Division

“Automatic Vehicle Over speed Detection System” is made functional for speed safety monitoring
inside refineries.

HSE Department, Corporate Office

 New Initiatives being taken to curb incidents – Refineries Division

New Innovations – Helmet testing

Available System Innovation
For a crucial life saving PPE (helmet) , there Helmet Penetration Resistance Testing
is no testing mechanism or facilities available Bench was designed first at GR F&S) (As per
at industry level to test robustness of safety IS 2925) at very low cost utilizing available
helmet. resources and is being used for testing
safety helmets of working agencies.

Benefits:
• Identification and replacement of low-quality helmet
• Cost saved in terms of saving human life by using good
quality safety helmets

Value Addition:
• Enhancement of safety culture among the contract
workers.
• Sense of satisfaction and positivity among workers.

HSE Department, Corporate Office

 New Initiatives being taken to curb incidents – Refineries Division
New Innovations - Vertigo testing facility
Available System Innovation
• Workers have general medical fitness issued by Endurance test of worker’s fitness for VERTIGO thru’
“Vertigo Test Model”
OHC Doctors
• Mandatory safety training for working at height
and issue of Specialized Training Card.
• Model based training at safety park.
Major features:
✔Examination and recording of blood pressure & pulse of the person by
medical team (First Aid Doctor).
✔Person wears full body safety harness before climbing on vertigo
structure.
✔Person has to walk on the walkway to other end of the platform & return
back to the starting point.
✔BP & pulse of the person is again examined & recorded by medical team.
✔After the test, fitness of the person is decided by First Aid Doctor.
HSE Department, Corporate Office
 New Initiatives being taken to curb incidents – Refineries Division

1. Continuous Monitoring.
2. Ease of Monitoring at top of the Technical Structures/Columns.
3. Workers are more alert to follow safety norms.
4. Large area can be monitored.
5. TV displaying drone monitoring videos at site

HSE Department, Corporate Office

 New Initiatives being taken to curb incidents – Refineries Division

Imparting induction training by IOCL front line officers to the workers before the commencement of
the job.
Benefits:
1. First hand experience on safety training to newly joined IOCL officers.
2. Improvement in training quality
3. 18 safety topics identified by RHQ-HSE covering critical aspects.

HSE Department, Corporate Office

New Initiatives being taken to curb incidents – Refineries Division

HSE Department, Corporate Office

 New Initiatives being taken to curb incidents – Refineries Division

New Innovations/ Policies/ Guidelines

Revised guidelines on interlock bypassing and testing issued
Control procedure for impairment of fire protection system issued.
IFR coverall made mandatory PPE for all personnel entering battery area of Refineries irrespective of job
they are involved in. Inherent Flame Retardant (IFR) coverall provided in Refinery (32,463 nos).
Guidelines on Working on Fragile roof issued for ensuring safety .

HSE Department, Corporate Office

 New Initiatives being taken to curb incidents – Refineries Division

Safety thoughts broadcasted among employees on regular basis on

different topic

HSE Department, Corporate Office

 New Initiatives being taken to curb incidents – Refineries Division

Actions being taken by locations to ensure strict adherence of SOP

Existing Standard Operating Procedure (SOP)/ Standard Maintenance Procedure (SMP) are supplemented with
checklist specifying hazards, risks, and mitigation strategies for each step with provision of signature on
the checklist

⮚ Identification of violations of SOP during regular monitoring/ supervision of actual job

⮚ Counselling of violators and disciplinary action if required

⮚ Conducting Process Mock Drills & Skill Development Programs in all units with an external observer
⮚ Identification of deviations of the steps
⮚ Counselling of the concerned person followed by repetition of the mock drill to ensure compliance

Ensuring preparation/ modification of SOP with adequate training to all concerned employees
before commissioning of the approved MOC scheme

Interaction of senior and middle management with frontline officers and staff so that they can have a
better understanding of their duties and responsibilities including SOP compliances

HSE Department, Corporate Office

 THANKS

HSE Department, Corporate Office