INTRODUCTION TO THE STUDY

Who are we?

HPCL is a Government of India Enterprise with a Navratna Status, and a Forbes 2000
and Global Fortune 500 company. It had originally been incorporated as a company under
the Indian Companies Act 1913. It is listed on the Bombay STOCK exchange (BSE) and
National Stock Exchange (NSE), India.
HPCL owns & operates 2 major refineries producing a wide variety of petroleum fuels &
specialties, one in Mumbai (West Coast) of 6.5 Million Metric Tonnes Per Annum
(MMTPA) capacity and the other in Visakhapatnam, (East Coast) with a capacity
of 8.3 MMTPA. HPCL also owns and operates the largest Lube Refinery in the country
producing Lube Base Oils of international standards, with a capacity of 428 TMT. This Lube
Refinery accounts for over 40% of the India's total Lube Base OIL production. Presently
HPCL produces over 300+ grades of Lubes, Specialties and Greases. HPCL in collaboration
with M/s Mittal Energy Investments Pte. Ltd.. is operating a 9 MMTPA capacity Refinery
at Bathinda in Punjab and also holds an equity of about 16.95% in the 15 MMTPA
Mangalore Refinery and Petrochemicals Ltd. (MRPL).
HPCL has the second largest share of product pipelines in India with a pipeline
network of more than 2,500 kms for transportation of petroleum products and a vast
MARKETING network consisting of 13 Zonal offices in major cities and 101 Regional
Offices facilitated by a Supply & Distribution infrastructure comprising Terminals, Pipeline

networks, Aviation Service Stations, LPG Bottling Plants, Inland Relay Depots & Retail
Outlets, Lube and LPG Distributor ships .Consistent excellent performance has been made
possible by highly motivated workforce of over 11,000 employees working all over India at
its various refining and MARKETING locations. View Past Annual Reports to know more
about HPCL. The RTI Information Manual provides various details about the operation of
the Corporation.
HPCL is committed to achieve the economic, ecological & social responsibility objectives of
sustainable development consistently through varied operations and activities. HPCLs focus
areas are in the fields of Child Care, Education, Health Care, Skill Development &
Community Development, touching lives of weaker section of society.

Registered Office & Corporate Headquarters

Hindustan Petroleum Corporation Limited.
Petroleum House,
17, Jamshedji Tata Road,
Mumbai 400020.
Maharastra, India.
Email: corphqo (at) hpcl [dot] in

Mission & HSE Policy

Mission.

To have safe, healthy and pollution free environment in and around all our refineries, plants,
facilities and other premises at all times; instill awareness in these areas, including relevant
laws, in all employees, their families and the communities in which we carry out our
activities.

ENVIRONMENT POLICY
The Corporation is committed to conduct its operation in such a manner as compatible with
environment and economic development of the community. Its aim is to create an awareness
and respect for the environment, stressing on every employees involvement in
environmental improvement by ensuring healthy operating practices, philosophy and
training.

HEALTH POLICY
To provide a structured program to look after and promote the health of vital Human
Resource, essential for productivity and effectiveness of the Corporation.

SAFTY POLICY
As an integral part of its business, HPCL believes that no work or service or activity is so
important or urgent that safety be overlooked or compromised. Safety of the employees and

public, protection of their as well as Corporations assets shall be paramount. Corporation

considers that safety is one of the important tools to enhance productivity and to reduce
national losses. The Corporation will constantly Endeavour to achieve and maintain high
standards of Safety in its operations.

Safety & Environment

General SAFETY, HEALTH & ENVIRONMENT

In HP GAS SAFETY, HEALTH & ENVIRONMENT have continued to gain increasing
importance, and rightly so, in view of the ecological imbalance that the world is facing at
large. HPCL as a responsible Corporate Citizen has always strived to strike a right balance
between operating its business and maintaining a sense of harmony with its surroundings.
It is the PEOPLE who make their working environment safe by adopting safe work practices
and it is these work practices that form a part of any Environment, Health & Safety(Sh&e)
Policy. the Objective of SH&E Policy is not only to bring about awareness, but to also
promote a pollution free environment; and create a healthy surrounding and safe working
conditions by constantly guiding all our actions within a consciously recognized and adopted
set of standards.

The SH&E Policy is atestimony to HP GAS's Commitment towards protection of

environment as we have a great responsibility to not only protect the health & safety of our
colleagues but also hand over a safe word to the future generation to come. we follow the
SH&E Policy, not only in word but in spirit, and actively contribute towards achieving its
objectives.
Safety
HP GAS committed to conduct it's business in the way that protects the safety of personnel
involved in the business including the customers and the public. It's our goal to have our
business 100% free from accidents, injuries and occupational illness through the active
participation of every one involved in our business.

To meet goal of 100% accident free operation HP Gas carry out following:

Design, Install, implement and maintain facilities which control safety risks.

Comply with statutory regulations and standards for controlling the risks.

Train the personnel working at work place for safety aspects, safe behaviour and
effective use of equipment's to avoid any incident/accident.

Undertake reviews, analyze, evaluate and install optimum value available

safety/operational equipment's for achieving the accident free operations economically.

Comply with satutory regulations & regulation of OISD OIL Industry Safety
Directorate), Ministry of Petroleum and Natural Gas ,New Delhi (india) for safe
operation of plants.

R A & DMP(Risk Analysis)-RA studies being conducted as and when required at

Plants/Import facilities to analyze the risk involved and how to manage the risk.
Necessary measures taken to minimize the risk at work places.
DMP ( Disaster Management Plan)- On site & off site DMP has been prepared in
consultation with local administration and other concerned statutory authorities to control on
any emergency/exigency situation. Monitoring for improvement and well control for safe
working. SH&E Department carry out internal safety audits and coordinate for 100%
compliance of internal & external safety audits recommendations.

Following are key activities of SAFETY, HEALTH & ENVIRONMENT:

Security of property and Personnel

Operational Safety

Safety Audit Programs

Product Knowledge

Incident /Accident / Near Misses investigation for root cause analysis

Emergency Response and File Protection.

Environmental protection

Safety, Training, Health records.

Health

HP GAS is committed to create a healthy working atmosphere and to overcome on any kind
of Occupational Health hazard associated with LPG at work place. HP Gas have plans to
evaluate health risk is any at work place, and take appropriate measure to overcome on such
risks.

HP GAS has engaged CDP (Company Designated Physicians) and ( or ) made

arrangement with near by hospital for regular medical check up /monitoring health &
handling of medical emergency of the employees. In addition company has got medical
centers at our main controlling offices at metros. In addition our employees are medically
insured as per HPCL Policy. we comply with statutory regulations on "HEALTH".
Few plants have carried out Occupational Health Survey and implemented the
recommendations of survey report. HP GAS plans to carry out occupational health survey at
all the plans and implement recommendations of surveyor.
Training on Occupational Health and Environment are regularly imparted to employees to
encourage them to be concerned and respect the environment and make them understand that
every one is responsible for maintain healthy environment and adopt appropriate working
practices.

Environment

HP GAS is committed to conduct it's business in the healthy and environmental friendly. HP
GAS plans to carry out study on environmental risks at all the plants and implement
recommendations of survey Various Environment Programs are done for betterment of
environment in and around work place. Training on Occupational Health and Environment
are regularly imparted to employees to encourage them to be concerned and respect the
environment and make them understand that every one is responsible for maintaining healthy
environment and adopt appropriate working practices.
We comply with environment standards and statutory regulations/requirements on
environment

Air & Water pollution prevention, Waste management procedure etc.

Given below values to Environment Eco Friendly:

Regularly promoting to convert OIL Fuel Vehicles in to Auto LPG so that pollution
is reduced and becoming more environments friendly

Plants/import facilities of HP GAS are ISO 9001:2000 Certified Plants

MLIF(Mangalore Import Facilities) is ISO 14001:2004 Certified Plants

Plants have taken initiative for obtaining ISO 14001:2004 certification. work in
progress

Availability of Management system for any sludge/Solid waste disposal. We plan to

have ETP(Effluent Treatment Plants) at our major plants to ensure that no pollution go
out of plants through waste

Water harvesting plant has been installed at few plants. MLIF has planned to install
shortly second harvesting plant

Regular plantation and maintaining green belts

Under ISO 9000 Certifications:

Plants/Import Facilities of HP GAS are ISO 9001:2000 Certified Plants

MLIF(Mangalore Import Facilities) is ISO 14001:2004 Certified Plants

Plants/Import Facilities has taken initiative for obtaining ISO 14001:2004

certification

Mangalore LPG Import Facilities (MLIF) is ISRS (International Safety Rating

System) Level 7 Certified location. It's the First MARKETING Location in Oil
Industry in India who has got ISRS level certification.

Major Fire Fighting Facilities:

Sufficient capacity Fire Fighting Engines

Automatic Fire Fighting System - Quarzoid Bulb heat detection system for detection
of any fire and actuate for Auto fire fighting system and operating water sprinklers for
extinguish fire. Also push buttons Auto fire fighting system is provided

Sufficient water storage as required for 4 HRs fire fighting are provided

GAA Monitoring System to detect any leakage of LPG and giving alarm for Fire
fighting

Pressure Vessels are provided with over filling alarm system and actuate auto shut off
pumps/compressors system

Safety Equipment's/PPE's/Safe Clothes for safe working

Effective COMMUNICATIONS systems

Electrical tripping systems to trip off VCB/OCB/other electrical circuits in case of

any leakage/short circuit

Under Safety Activities

Mock Drill Considering LPG locations are very risky, every one working at such location
needs to be trained to manage any exigency situation. They are given training by way of
Mock drills. HP GAS carry out 2 mock drills in a month at each plant so that personnel
working at place are enough trained to meet exigency situation.
Mock Drill Involving External Agencies A goal of 2 mock drills in a year is set by HP
GAS, so that personnel working at place are well trained and active to meet any kind of
exigency.

Training

The utmost care is given to import training to company employees, Contractor workmen,
security personnel, Trucks crew, Cylinder Delivery Men and Mechanics. Several training
programs covering several peoples have been organized and is a continuous process.
In current year as of Feb.2005, over 20000 personnel have been covered under training
programs by HP GAS.

training

project UTSAH for

organizing

Behaviour

and

Functional

Training programs. HP GAS has covered various locations under this program and programs
are continued till all LPG Plants are covered.

Responsibility of CONTRACTORs SM/SE/SO .

The CONTRACTOR / SUB-CONTRACTOR as a minimum requirement shall designate /

deploy following safety personnel to the SITE whose primary responsibility shall be to
ensure that a works carried out at the SITE shall meet PMCs safety standard. Total no. of
workers deployed up to 250 Designate One Safety Supervisor / Steward Above 250 & Up to
500 Deploy one qualified and experienced SE / SO Above 500 (for every 500 or less) One
additional SE/SO, as above + One SM

The CONTRACTOR shall have a SM/SE/SO responsible to the SITE whose primary
responsibility shall be to ensure that a works carried out at the SITE shall meet PMCs safety
standard. The CONTRACTORs SM/SE/SO shall establish close working ties with all other
SM/SE/SOs and shall lend assistance or advice as required, to maintain a safe working
environment. The CONTRACTORs SM/SE/SO shall conduct regular safety meetings with
all their employees to prevent any incident at the SITE.

The CONTRACTORs SM/SE/SO shall establish and maintain close ties with hospitals and
clinics nearby the SITE. The CONTRACTORs SM/SE/SO shall be responsible for Health,

Safety & Environmental Protection of their employees on the project SITE and correct any
deficiencies in these matters.

Every CONTRACTOR shall posses First Aid Box. The CONTRACTORs SM/SE/SO shall
be responsible for upkeep their First aid boxes.

Responsibility of SUB-CONTRACTORs SM/SE/SO

The SUB-CONTRACTOR as a minimum requirement shall designate/ deploy following

safety personnel to the SITE whose primary responsibility shall be to ensure that a works
carried out at the SITE shall meet PMCs safety standard.

Each SUB-CONTRACTOR shall employ at the SITE, a suitably qualified and experienced
SM/SE/SO and whose primary responsibility shall be to ensure that all works are carried out
in the manner meeting CONTRACTOR and HPCLs Safety requirements. Each SUBCONTRACTORs SM/SE/SO shall have basic training matters related to first aid.

The SUB-CONTRACTOR SM/SE/SO shall be responsible for educating their workforce in

safe working practices and shall constantly monitor such practices at the SITE taking any
and all remedial steps to eliminate Hazards. Each SUB-CONTRACTOR SM/SE/SO shall
organize and hold regular safety meetings which shall be attended by all supervisory staff
including foreman. At such meetings the safety requirements of the SITE and the working
environment at the SITE changing day to day shall be fully explained in order that all
personnel are aware of the standards to be achieved and maintained.

SUB-CONTRACTOR SM/SE/SO shall attend weekly safety patrol conducted by respective

CONTRACTORs. At occurrence of accident of a SUB-CONTRACTORs workforce the
concerned SUBCONTRACTORs SM/SE/SO shall investigate and report to the
CONTRACTORs SM/SE/SO. The SUB-CONTRACTORs SM/SE/SO shall establish and
maintain close ties with hospitals and clinics nearby the SITE.

SITE Engineer

Engineers shall be fully responsible for implementation safety norms at the workplace level.
Be aware of all HSE requirements and safe working practices. Organize all work activities to
comply with the established safety rules, regulations and procedures as well as safe working
practices.

Instruct foremen and workers precise on their task & responsibility for safe and correct
working methods. Instruct new employees on safe working practices as well as existing
employees assigned to and performing new work task(s). Make sure Personal Protective
Equipment have been provided and are properly used at SITE.

Organize and maintain clean and tidy workplace(s). Carry out Safety observation/inspection
round of the workplace(s) and report in writing the findings to Management. Correct all
hazards, including unsafe acts & conditions and report to Management. Conduct "toolbox
meeting" daily before start of work with the workers during which safety requirements and
unsafe acts are being highlighted, discussed and clarified. Secure prompt medical attention to
any employee accidentally injured.

Report in writing and investigate all accidents and pay particular attention to those having
caused injury to an employee.

Workers

Report to work in good mental & physical condition to carry out work safely. Work safely in
such a manner as to ensure your own safety as well as that of fellow workers and others.
Avail yourself of the safety rules, regulations and procedures established in this HSE plan
and follow these continuously. Use and properly maintain all Personal Protective Equipment
provided. Be aware of safety devices for all tools under his control, properly use and
maintain all of them and report to Supervisor any deficiency thereof. Correct unsafe acts or
conditions within the scope of the immediate work. Request help when unsure about how to
perform any task safely and/or provide fellow workers with assistance in safety
requirements. Report any un-corrected, unsafe condition or act to Supervisor.

Suppliers

Abide by all Safety Standards and Codes attributable to the materials/ products/ goods (to be)
delivered onto the project SITE. Be aware of the Safety Rules, Regulations and Procedures
in effect on the project SITE as prescribed in this HSE Manual. Comply with the established
safety rules, regulations and procedures as well as safe working practices during operations

on and visits to the project SITE. Be responsible for notifying in writing any adverse impact
on Health, Safety & Environment of their materials/ products/goods delivered at the project
SITE. Deliver a Material Safety Data Sheet (MSDS) together with each chemical material or
product.

SAFETY CONTROL

Training Programme

orientation /Induction course Each (group of) employee(s) of CONTRACTOR/SUBCONTRACTOR will be given an orientation/induction course under direction of their
SM/SE/SO prior to start of any work. The CONTRACTOR/SUB-CONTRACTOR shall not
be deployed on the job unless introductory briefing from PMCs SM/SE/SO so as to locate
project facilities, channels of communication relating to accident prevention & reporting, fire
prevention & fire fighting, personal responsibilities, etc is given.

Toolbox talk Tool box talk will be conducted daily in a group of workers of
CONTRACTOR/SUB-CONTRACTOR by their respective SM/SE/SOs for specific work as
required to reach the required level of competencies. During this meeting the hazards
involved in the activity and preventive measures will be highlighted. All topics in connection
with SITE activities will be covered in the meeting to create awareness among the workers
regarding safe practices. It will be done as per job/specific SITE requirement.

Training

CONTRACTOR/ SUB-CONTRACTOR shall arrange training program for their employees

to reach the required level of competency in :-

HSE requirements

Use of PPEs Permit System Heavy plant & equipment operations Fire Fighting & Control
Emergency Procedures In addition to the above, training in Electrical Safety, Scaffolding,
First Aid, Material handling etc will also be given to the employees.

HOUSE KEEPING

Good house keeping must be practiced by CONTRACTOR/ SUB-CONTRACTOR

personnel at all times while within the PLANT. During and after completion of the work,
they are to ensure that their work area is kept clean and tidy.

Rags, paper, wood shaving and other flammable materials shall not be scattered over and
shall be collected and disposed of in sufficient frequency

Wooden planks with protruding nails, sharp object rising above ground should be removed
immediately from the Work area where people are likely to step on them.

Temporary electrical cables shall be so installed as not to cause a tripping hazard to

personnel, nor be liable to Mechanical damage by equipment.

Elevated cables shall be installed at such height as to allow unrestricted movement of

construction, equipments and Vehicles.

Particular emphasis shall be placed on maintaining platforms, scaffolding, stairways or other

elevated places free of Construction debris.

Shuttering materials, platforms or scaffolding segments should be kept in orderly manner

before use as well as after dismantling so that they do not cause hindrance to the movement
of man and materials.

Equipments or materials stored at SITE shall not obstruct to essential facilities and / or
equipments such as fire Extinguisher, fire hydrants, valves gauges, emergency exits etc.
Separate manpower shall be provided by CONTRACTOR and SUB-CONTRACTOR for
daily housekeeping at SITE.

PROJECT EMERGENCY PLAN

The sequence of steps is detailed in Attachment (15) for action for Emergency, Fire and
Communication system at project SITE.

Actions to be in case of Accident

Whoever

first notice that an incident has occurred

shall immediately notify

CONTRACTORs/SUB-CONTRACTORs SM/SE/SO of the occurrence of the incident.

The CONTRACTORs/SUB-CONTRACTORs SM/SE/SO shall determine whether the area

of the accident remains hazardous and if so take immediate steps to evacuate all personnel
and remove the injured person to a safe place. The SM/SE/SO through the CONTRACTORs
SITE representative/RCM shall immediately notify the HPCL and the PMCs SM/SE/SO of
the incident.

The SM/SE/SO shall determine the extent of the victims injuries. If an individual cannot
walk, move unaided or is unconscious, do not attempt to relocate him without first taking
medical advice.

If the victim is unconscious the SM/SE/SO shall check for signs of breathing and a pulse.
Should the victim show no signs of breathing or no pulse can be traced, immediately
administrator artificial respiration.

The SM/SE/SO shall make necessary arrangements for medical assistance to immediately
attend the location to determine the seriousness of the inquiries and advice further required
treatment.

The SM/SE/SO shall immediately halt all works in the particular area until such times as
adequate investigations have been concluded.

The SM/SE/SO shall make such arrangement of calling ambulances or alternative transport.
The SM/SE/SO shall submit report to his RCM for the cause of accident. The RCM shall
analyze the problem and try to implement the way so as to avoid reoccurrence.

Personal Protective Equipment (PPE)

All employees shall wear Personal Protective Equipment (PPE) at the project SITE, except
inside offices, rest-room and accommodation buildings. CONTRACTOR and SUBCONTARCTOR shall arrange appropriate Personal Protection Equipment for their individual
employees that include helmets, safety shoes, and safety belts with full body harness (For
height Job) as minimum. All other PPEs like goggle, ear plug, hand gloves etc. shall be
provided as per specific job requirement as mentioned in table

Head protection (Safety helmet) and foot protection (safety shoes/gum boots) shall be worn
by all the employees while working at SITE. Safety belt with full body harness shall be used
while working at height >2 m. Safety belt shall be anchored at shoulder or above height.
Safety helmet shall be with ISI mark with chin strap.

The

Colour

codes

of

the

helmets

shall

be

followed

as

mentioned

below:-

Supervisors/Engineers and above - White Safety Personnel - Green Workers - Yellow

Electrician - Yellow with red band Visitors - Orange Name of the company with logo shall be
posted on the helmets for easy identification. Table

Personal Protective Equipments - Job Suitable PPE

A. Excavators, breakers, chippers, drillers. Protective goggles, hand gloves, Safety helmets
and Safety shoes.

B. Mixing cement, concrete, lime mortar, asphalt material, refractory material. Safety
goggles, gloves and protective foot wears.

C. Electricians Insulated tools, Rubber hand gloves and electrical resistant shoes, mat.

D. Grinders Protective goggles and leather hand gloves

E. Gas cutters ,welders helper Colored goggles, leather hand gloves.

F. Welders Welding screen, safety shoes with rubber sole, Leather hand gloves.

G. Workers engaged in insulation Dust mask ,hand gloves

H. Workers working at height Full body harness, Safety net, lifeline. Fall arrestor if required.

I. High noise level area i.e. D.G operator working near piling work, compressor operator etc
Ear plug / ear muff

J. Chemical handling Face shield, full body aprons, suitable hand gloves

ENVIRONMENT PROTECTION AND WASTE MANAGEMENT

During execution of the project different types of solid, liquid or gaseous waste is generated
at site, which may be hazardous or non hazardous in nature

Dust generated at SITE shall be controlled by spraying water. Septic tanks shall be cleaned
periodically.

All waste generated shall be disposed off properly as per the laid procedures and at
designated location of the client. This shall be done regularly to maintain hygienic conditions
at site. For effective waste management following steps shall be taken.

Waste bins shall be provided at site, fabrication yard and at storage yard. Waste shall be
collected separately like metallic/non metallic, oily and disposed at different waste bins with
blue, green, red and yellow colour.

All employees at site shall be informed and make aware of the waste disposal system. 8.
Environment protection is prime responsibility of all employees at site including client,
Contractor, sub-contractor to avoid any adverse effect on environment.

The construction CONTRACTOR/SUBCONTRACTOR is responsible for the environmental

control specified for the job site including all equipment and machines used.