Tuesday, 7th May 2019

13.00p.m. Start of the Survey

Indian Oiltanking Paradip
Orissa
Phone: XXXXXX?

Operations Manager
Maintenance & Inspection Manager
HSSE Manager
Engineering Manager
Until Introduction by (Insurance/HSSE/Reg), Safety Briefing by IOTPT
13:30
13:30 - Business-Presentation IOTPT, overview by IOTPT
14:00
14:00 – Q&A - Discussion with Ops, M&I, HSSE, Eng. (45 mins max each = 4 x 45= 3
17.00 hours
All may attend or each slot 14.00, 14.45, 15.30, 16.15 pm if busy (can re-
order if required)

Close
T Tuesday,
Wednesday, 8th May 2019

7th May 2019 Tuesday, 7th May 2019uesday, 7th May 2019
09:00- Begin in CR - see current work permits, isolation certificates,
10:00 protections such as F&G, Bypass Register
See computer control system including tank HHL, alarms, manning
levels (night and day and weekends) – alarm management
ESD push buttons, Emergency Operations Guides

10:00- Walk through Crude Site - to each group of tanks, pump stations,
truck loading, rail loading, utilities, go inside one electrical substation
12.00

12.00- Lunch
13.00

13.00- Walk through Products Site - to each group of tanks, pump stations,
truck loading, rail loading, utilities, go inside one electrical substation
15.00

15.00- Visit Fire water pumps, Run water deluge test on one tank (live) and
16.00 one monitor (jetty?).
16.00-
Feedback on visit
16.45

C
T Tuesday,
Thursday, 9th May 2019

09.30- Obtain the following data:-

10.30 One copy of Work Permit
One example of a recent internal tank inspection (contractor report)
The main points in the Emergency Response Plan such as
- How major firefighting would be carried out
- How a major spill at the jetty is dealt with (boom?)

10.30-
11.00 Joerg, RTC will generate any
recommendations/observations.

11.00- Wrap-up Meeting (with attendees as per IOTPT manager's request.

12.00
RTC will present this and then we will discuss the findings
and recommendations to collect OTT input).

12.00- Lunch
13.00
Opportunity to collect any outstanding data.
13.00-
14.00 Close = leave for airport
Questions

Operations

1. Have site ever overfilled a tank, railcar, truck – if so please describe.

2. Any spillage at jetty or collision
3. What will company do if berthing slot is not available – if ship sinks or blocks access ?
4. What is max number of alarms in any 10 minute period ?
5. Rejection rate for Work Permits ?
6. How many board men per shift – day/night?
7. Any LPG/Propylene leaks?
8. Control system redundancy, back up UPS?
9. What happens on utility failure – to ESD valves, control systems?
10. What happens in cyclone ? will a tank always have liquid level during cyclone
window?

Maintenance & Inspection

1. Who does maintenance work – if contractor – how is this checked?

2. How many permits per day hot & cold
3. How is bolting maintained at 100%?
4. What equipment failures have occurred?
5. Is Mean Time Between Failure recorded and trended – what is KPI?
6. What are seals for LPG pumps - double?
7. Any line leaks or repairs ?
8. What is Tank Inspection schedule – for internal inspection ?
9. What is used for Positive Material Identification?
10. How will corrosion be dealt with?
11. Any Cathodic Protection ?
12. Any Lightning protection ?
13. What is maintenance backlog in weeks ? How is it measured?
14. What is the name of the Maintenance system e.g. SAP?

Please show frequency of inspections:

a. Jetty Annual Visual Inspection - by ??;

b. Monthly Transmitter & Instrumentation Calibration/Testing;
c. Pipelines Atmospheric Corrosion Inspection (annual);
d. Smoke Alarm Testing (every 2 months);
e. Thermography (annual test on major items);
f. Transformer Oils (1-3 years);
g. Function Test Instrumentation (annual) - SAAB/Rosemount;
h. Electrical Field Switches (4-12 months);
i. Substation switches (12 months);
 j. Tank Overfill Alarm (alarm annually);
k. Annual PFE service;
l. Spill Response Equipment Inspection (quarterly);
m. Pump Inspections (visual monthly, service annually, greasing every 3 months);
n. Filters (six months cleaning);
o. Tank Inspections (visual monthly), Internal as required (5-8 years average).
p. Floating Roof & Seals (10-15 years);
q. Tank Vents (visual monthly, removal 25% annually);
r. Product Hoses (annual);
s. PRV,TRV Calibration (annual);
t. Packing Rings on Valves (quarterly);
u. Insulation Flanges (annual);
v. Drain water Valves (quarterly);
w. Fire Water System (rotational by pump - 3 months);
x. Fire Valves (six months);
y. Foam System (3 months);
z. Hand wheels (6-12 months);
aa. Storm Drain Valves (3 months);
bb. Earthing (12 months);
cc. Fire Alarm (monthly);
dd. Lifting Equipment (annual);
ee. Lighting Poles (6 months);
ff. Resistance Test (annual)

HSSE
1. What is responsibility of HSSE with respect to work permit sign off, operating
firewater system, alerting refinery brigade?
2. What audits are carried out ?
Please provide ‘Near Miss’ Numbers – including number of unsafe acts, compliance
issues, Loss of Containment, Product Mixing issues, other incidents, material
deviations and personal injury.
3. Describe how Management of Change is enacted safely
4. Describe Firewater Performance Tests (head v flow confirmation)
5. Are firewater block valves locked open in site?
6. What fire cases have been studied, fire pre-plans produced – such as crude tank rim
seal fire, LPG release from storage, etc.
7. What is frequency of training for all shifts e.g. a tank fire training exercise id
repeated every xx months by the same shift?
8. Are incidents investigated – by whom? External ?
9. What actions are taken if there is a major incident inside the refinery?

Engineering
1. Who does all the updating of documents ? Are they up-to-date?
2. What does Engineering do in Management of Change Procedure?
3. What is Hazop Frequency (5 year cycle?)
4. What design aspects were used for cyclone, earthquake , flooding resistance? Are
tank annuli rings bolted to ground
5. What piling depth was used and for which items of equipment (tanks?)
 6. What is design rating of Control Room (blast resistance in psi?)
7. What is done to ensure safe air in Control Room, offices (gas detection in VAC
system, dampers?)
8. Describe SIL assessment

Security
1. What security is provided at site? How many per day and night
2. Fencing design?
3. If site was attacked what would be response?
4. Theft rate?
5. Any intrusions?
6. How are staff, contractors checked?