Indorama Eleme Petrochemicals Limited HSEF 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

Contents:
Section No. 1 1.1 1.2 2.0 2.1 2.1 2.1 3.0 3.1 3.2 3.3 4.0 4.1 4.2 4.3 4.4 4.5 5.0 5.1 5.2 Topics HIGHLIGHTS OF THE MONTH
Targets for February , 2013 Training highlights HEALTH STATISTICS PME Data Work related illness Non work related illness SAFETY STATISTICS HSE Committee meetings incident / accident statistics: Activity and area Radiation survey: ENVIRONMENTAL STATISTICS : Noise level monitoring BT/VOC survey Effluent Quality Ambient air quality monitoring Solid waste disposal ANNEXURE Annexure -1 Brief Description Incidents Annexure 2 Pending compliance from Safety Audit / FARs / Near misses

Page No 3 4 5 6 78 7-8 8 8 9 10 - 11 12 13 14 - 15 16 16 17 17 18

List of abbreviations

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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 scheme conducted 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 1. 2. 3. Activities Responsibility Areas All plants All Plants All Plants Olefins, MMD, Servicing and maintenance of 6kg / 9 4. kg DCP extinguishers. Warehouses, HSS Warehouses, Chemical Warehouse Barrie D. 5. 6. 7. Flushing of underground fire water HSS mains ( Network ) Quarterly servicing of fire trucks, HSS Emergency truck and UT-1 truck. Routine ambient air quality monitoring NAK NAK JS heavy metal 28/02/13 All complex Fire Station IEPL Complex and host communities ETP Olefins plant Okulu Aleto and NAK ETP discharge Olefins 11. Routine Noise Monitoring JS plant, Final 28/02//13 28/02/13 28/02/13 28/02/13 28/02/2013 and ETP, PP PE 28/02/13 Target Date 28.02.2013 28.02.2013 28.02.2013

Process safety Management KPP coordinators training Internal process safety Management KPP audit. Complex wide Signage up gradation KPP

8. 9.

Routine TCLP Analysis Routine BT/VOC Survey Physiochemical and

10.

analysis of waste water

PPU, PE Plant, PE 28/02/13 W/H and PP Plant. for HODs HOFs & 28/02/13

12.

Socializing for BSC 5 Star Audit for Environment

NAK

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1.2 .TRAINING HIGHLIGHTS: Training Programs First Aid Training Live Fire Fighting Safety Training Safety Induction (Contractors / Visitors) Target for 2012 (Nos. of personnel) 140 747 540 NA

YTD (%) 0 13 4 330

Jan 0 87 25 330

2.0

HEALTH STATISTICS:

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PATIENTS TREATMENT CATEGORIES Sr. No. 2.1 Description TOTAL NUMBER OF PERSONS / PME CHECKED
IEPL (Expats) IEPL (Local) DEPENDANTS (Expats) DEPENDENTS (Locals) SECURITY CONTRACTORS WORK RELATED ILLNESS IEPL (Expats) IEPL (Local) DEPENDANTS (Expats) DEPENDENTS (Locals) SECURITY CONTRACTORS NON WORK RELATED ILLNESS IEPL (Expats) IEPL (Local) DEPENDANTS (Expats) DEPENDENTS (Locals) SECURITY CONTRACTORS HOSPITALIZATION PERIODIC MEDICAL EXAMINATION REFERRAL INDUSTRIAL ACCIDENT MINOR SURGERY EXCUSE DUTY IMMUNIZATION STAFF TRAINING NURSES TRAINING

No. of persons 122

30 36 0 0 34 22 0 0 0 0 0 0 0 121 30 36 0 0 34 21 2 2 2 1 0 2 4 0 0

2.2

2.3

2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12

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3.0. SAFETY STATISTICS:

Month Frequency rate Severity rate

Jan 0

Feb

Mar

Apr

May

Jun

Jul

Aug

Sept

Oct

Nov

Dec

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

QAQC Lab

Workshop

MMD

Bagging

: Conducted.

: Not Conducted.

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3.2

INCIDENT / ACCIDENT STATISTICS:

Minor fire (Plant)

Minor fire (Non plant)

Major fire (Plant)

Major fire (Non plant)

Gas leakage

Minor Injury (Non Plant)

Minor injury (Plant)

Nearmiss (Plant)

Lost time (plant)

Month Minor fire (Plant) Minor fire (Non plant) Major fire (Plant) Major fire (Non plant) Gas leakage Minor injury (Plant) Nearmiss (Plant) Lost time (plant) Lost Time (Non plant)

Jan 1 0 0 0 0 1 10 0 0

Lost Time (Non plant)

Minor Injury (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 serial no. M-8081 / 5888 M-8163/8162 M-6994 M-6288 M-6505 /6504 M-6880 M-6663 M-6629 M-6661 M-6662 Equipment no. 06-D-601 06-D-602/603 06-D-501 06-F-301 06-CY-301 06-CY-301 06-F-301 06-F-301 06-R-201 06-R-202 Date of Manufacture Monthly Average (fortnightly) reading ((Sv/hr) 2.97

1 2 3 4 5 6 7 8 9 10

LE-6012 LE-6013 LE-5007 / 5008 LSL-3107 LE-3005 LE-3006 LE-3108 LAHH-3109 AC-2401 AC-2501

1992 1992 1992 1992 1992 1992 1992 1992 1992 1992

2.14 1.78 1.44 2.65 2.28 0.18 0.42 0.14 0.16

3.2 POLYETHYLENE (PE) PLANT

s/n Tag no. Source serial no. 7383, 7384, 7385, 7386 M8062 M8068 9510GG 9503GG 9499GG 9504GG S-401 S-402-1 S-402-2 S-403-1 (STRAIGHT) S-403-2 (STRAIGHT) S-403-1 (CONE) S-403-2 (CONE) Equipment no. Date of Manufacture Monthly Average (fortnightly) reading ((Sv/hr 3.22 0.20 0.14 0.20 0.22 0.09 0.08 0.07 9398GG 9385GG OUTSIDE BUNKER OUTSIDE BUNKER 1993 1993 0.08

1 2 3 4 5 6 7 8

LT-1154 LT-1158 LT-1658 LT-1163 LT-1663 LT-1162 LT-1662 REMOVED FROM TAG LT1162 REMOVED FROM TAG LT1662 TLVs

1991 1996 1996 1993 1993 1993 1993

-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 OLEFINS SOURCE BOILER Area EQUIPMENT 1-K-12A/1-P50A/B/C 1-K-12B 1-K-12C K1 K2/K3 Walkway North end South end Train-2 Operators table (inside cubicle) Reactor 401 6-D-801 NOISE LEVEL at Micro level (dBA) At source 5 meter 91 82.1 85.5 88.0 94.0 93.5 85.5 81.5 88.1 92.1 91.1 74.0 90.0 92.1 85.5 90.1 88.1/78.9 88.1 85.0 98.5 84.2 64.6 90.1 84.0 85.5 91.5 82.5 83.0 78.1 84.0 89.0 82.5 -85.5 86.0 81.0 86.5 75.1 82.0 82.1 86.5 82.0 84.8

Compressors Caustic area De-propanizer PE PLANT Blender/Silo Grd floor Extruder

PP PLANT

PE Bagging POWER PLANT

Co-polymer reactor Extruder house Silo/compressor Classifier Bagging Machines GTG

Nitrogen Plant

Sewing m/c (on/off) Inside outside (stacks) Purging air filter Plant entrance. Control Room Compressors 25-K-1 F

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 1-P-42 Walkway by 1-D-80 C-9 Bottom ground Area 1P39A to 1P37B 1-P-35B K-3 bottom area D-41 bottom area C-7 Bottom ground floor Re-boiler Platform C-5 Bottom ground floor Re-boiler Platform C-4 Bottom ground floor Driers DR-1/2 A/B & 1-F-1B DMFS Walkway by 1-D-47/E37 K-1 K1 floor/E25-E28-1E20A/B

ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm

1.1 1.0 0.0 0.0 0.1 1.2 0.0 0.0 0.0 0.0 0.0 0.0 0.0 1.1

0.0 0.0 0.0 0.1 0.0 0.1 0.0 0.1 1.0 1.0 0.0 0.1 1.2 1.0

0.1 0.0 0.0 0.0 0.1 0.0 0.1 1.0 0.0 0.0 0.1 0.0 0.0 0.1

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 Nos. of off- spec.

Jan.13 0/31

iii) TSS

Month Nos. of off- spec.

Jan.13 0/31

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iii) BOD

Month Nos. of off- spec.

Jan.13 0/31

iv) COD

Month Nos. of off- spec.

Jan.13 0/31

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4.4 AMBIENT AIR QUALITY MONITORING: (EXTERNAL AGENCY) Standards. Parameters UOM In side Stations
Near Gate. 0.00 6.31 2.21 0.1 0.00 0.00 0.03 14.74 Near W/Bridge 0.00 Flare Stack (North) 0.00 12.75 0.00 0.11 0.00 3.91 0.13 20.13 Near AGIP 0.00 4.34 1.2 0.00 0.00 1.05 0.00 17.79

Outside Stations
AKPAJO ALETO

FMENV
SO2 NO2 CO H2S CxHy VOC NH3 TSPM g/m3 g/m3 g/m3 g/m3 g/m3 g/m3 g/m3 g/m3 260 75-113 22.8 3-160 6000 0.5-1.0 600

DPR
350 400 30 0.5-1.0 230

5.26 4.59 0.00 1.90 1.20 3.31 0.38 32.04

0.00 2.33 3.78 0.60 0.00 0.00 0.18 27.44

4.89 2.65 0.08

1.54 2.68 0.00 17.48

4.5 FLUE GAS MONITORING: (EXTERNAL AGENCY)

Stacks GTG Stack Parameters UOM IFC Standard Polymer Incinerator Sludge Incinerator Olefins Heater Stack (1-H1B) 0.00 91.11 0.00 0.00 0.00 0.00 Olefins Boiler Stack

GT01 0.00 94.53 0.00 0.00 0.00 0.00

GT-04 0.00 100.22 0.00 0.00 0.00 0.00

A 0.00 151.93 0.00 0.00 0.00 0.00

B 24.38 158.53 0.00 0.00 4.32 0.00

C 0.00 184.96 0.00 0.00 0.00 0.00

mg/Nm

500 300 --

SOx
mg/Nm
3

1.58 18.22 40.28

ND ND ND ND ND ND

NOx
mg/Nm
3

CO
mg/Nm
3

-0.25 --0.00

H2S
mg/Nm
3

CxHy
mg/Nm
3

0.00

VOC

ND:

Not done (Unit was not running)

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4.6 SOLID WASTE DISPOSAL: Waste. Metal Scrap. Wooden Scrap. Plastic Scrap. ( Including torn bags) Decontaminated Containers. Spent Alumina. Incinerated Waste. Waste Oil Molecular Sieve Medical waste Type. Scrap. Scrap. Scrap. Scrap Solid Waste. Hazardous Scrap Solid waste Hazardous UOM. Kg Kg Kg Quantity/ month 1580 Nil 940 566 132 2220 2800 Nil. 10.1 Quantity/ Year (2013)
1580 Nil 940

Disposal Method.
Sale. Sale. Sale.

Nos. MT Kg LTR MT Kg

566

Sale. Stored in designated location within the premises Incinerated. Sale./incineration Stored in designated location within the premises Incinerated.

132 2220 2800 17.5 10.1

5.0 ANNEXURE 5.1 Annexure -1

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 flaming fire 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.

Incidents - Fire

Type of incident : Minor fire

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 Department All plants

Pending compliance from Safety Audit / FARs / Near misses Pending Responsibility Target Date / Remarks 28.02.2013

Training of Safe handling of Gas KPP Cylinders. Construction of flange guard on acid pumps in ETP

PPOU

31/03/2013 (Installation going on. A.K. Gupta / Phool Material received earlier is Singh/ M. Putta finished. New order made)

Olefins / PP / Facility of close loop for Lab. Mr. Stoica Ichim / Mr. Survey started. offsite Sampling A Mohapatra / Mr. Job will be completed in S.K. Dave. TAM General Traffic safety management HSS/ RB ownership to be decided Discussion between HOFHSE & Security head ongoing

PE plant

MOC of drain pit and drain dyke Mr. A.B. RAO arrangement to be executed. (Vaporizer fire FAR recommendation)

Will be completed during TAM

All Plants

All cases of short bolts, less bolts All plants mechanical and use of dissimilar materials as sectional heads Will be completed during bolts and nuts to be corrected by TAM mechanical group

Electrical/ All 10 years old capacitors of the Polymer and electrical lamp fixtures to be chemical replaced with new metallic Mr H. Sood warehouse. capacitors.

31/03/2013 Job is in progress

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List of Abbreviations: ACGIH BOD BSC BT/VOC COD DCP FMENV HAZOP : GIT HSE&F IFC INDSOP JSA LEL LOTO LPD LTA NESREA : : : : : : : : : : : : : : : : : American Confrence of Governmental Industrial Hygienist Biological oxygen demand British Safety Council Benzene, Toluene & Volatile Organic compounds Chemical oxygen demand Dry chemical powder Federal Ministry of Environment Hazard operability studies Gastro intestinal tract Health, Safety, Environment & Fire International Finance Corporation Indorama Safety Observation Process Job Safety Analysis Lower Explosive Limit Lock out tag out Low point drain Lost Time Accident

National Environmental Standards and Regulations Enforcement Agency

Onsite emergency management Periodical \medical examination Personal protective equipment Permit to work Respiratory Tract Infection. Short term exposure limit Turn around maintenance Toxic characteristics leachate procedure Threshold limit value Total suspended particulate matter Total suspended solids Time weighted average Unit of measure Urinary Tract Infection *** End of Report****

ONSEM PME PPE PTW RTI STEL TAM TCLP TLV TSPM TSS TWA UOM UTI

: : : : : : : : : : : : : :

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