Gujarat Refinery

MOCK DRILL REPORT

PROCESS MOCK DRILL

Date: 11.03.2024
Department: Production
Unit: MTBE
Scenario: Instrument Air failure
Introduction:
Methodology:

1. INCIDENT FACTS:
Date: 11.03.2024
Time: 10.30 hrs
Shift in charge (SIC): Vamsi Krishna
Mock Drill Observer (External): Ravi Bhushan
Panel Operator (PO): PR Mehta
Field operators: LR Patel
Pump Operator: Saddam Hussain

2. INCIDENT DESCRIPTION:

S NO Activity Action by Start End Remarks

time time
1 Panel Operator observed instrument air Panel operator 10:30 10:32 Done
failure as all control valves went to fail safe HRS HRS
positions.
2 Panel operator informed to pump/ field Panel operator 10:32 10:35 Done
operator and SIC regarding the issue. HRS HRS

3 Stop feed to surge drum. Divert FCC LPG to Field 10:32 10:40 Done
OM&S directly from B/L. Operator/Panel HRS HRS
Operator
4 Stop C-1 reflux pump, Isolate steam to E-1, Pump/Field 10:40 10:50 Done
E-6, E-9, E-15 and E-20. Operator HRS HRS
5 Stop C-3 reflux pump, C-5 reflux pump & C-5 Pump Operator 10:50 10:55 Done
bottom pump. HRS HRS
6 Close all B/L b/vs. i.e. feed to unit, DM water Field Operator 11:00 11:05 Done
to unit,C-1 bottom. To B/L,C-1 top to HRS HRS
B/L.,MTBE to R/D at B/Land C-6 bottom to
r/d at B/L.

Safety First is Safety Always

 Gujarat Refinery

MOCK DRILL REPORT

7 Keep watch on columns pressure. Open PSV Panel operator 11:05 11:10 Done
by pass if Pressure increases beyond limit. HRS HRS
8 Keep unit under bottled up condition. Panel/Pump/Field 11:10 11:30 Done
Operator HRS HRS

3. SHORTCOMINGS:-

 PATH FROM CHECK N CHANGE ROOM TO PUMP HOUSE WAS FOUND CROWDED DUE
TO NBA PROJECT
 POOR FUNCTIONING OF WALKIE- TALKIE OBSERVED.

4. OBSERVATIONS / COMMENTS
 PERFORMANCE OF OPERATORS FOUND SATISFACTORY.
 ALL EMERGENCY STEPS WERE TAKEN BY OPERATOR CORRECTLY.

5. Engineer Assistant at Field

 EA RESPONSE AND PERFORMANCE FOUND DELAY BUT CORRECT.
 COMMUNICATION WAS CLEAR.

6. Observations of External Observer:

Vamsi Krishna , PNE UR RATHVA, SPNM Ravi Bhushan ,PNM

Mock Drill Co-coordinator (SIC) Unit In-Charge External Observer

Safety First is Safety Always