Thesis book BY Muhammad Fahad Ansari 12IEEM14

Dedication
Every challenging work needs self efforts as well as
guidance of elders especially those who were very close
to our heart.
My humble effort I dedicate to my sweet and loving
Father & Mother,
Whose affection, love, encouragement and prays of day
and night make me able to get such success and honor,
Along with all hard working and respected
Teachers

ABSTRACT
The study emphasis on the industrial health and safety, fire fighting techniques, work permits,
ppe’s, environmental conditions and health procedure of the organizations The industrial health and
safety is being adopted throughout the world because it is a cost saving option and providing shield
to the workers and this work has high magnitude and significance.
The study was carried on at National Refinery Limited (NRL) Karachi situated at Korangi
Industrial area near the Chorangi commonly known as Chamra Chorangi. National Refinery
Limited (NRL) was incorporated on august 19, 1963 as a public limited company. Government of
Pakistan took over the management of NRL under the economic reforms order. The refinery
complex comprises of three refineries, consisting of two lube refineries and a fuel refinery where as
products are grouped into three categories:
As a result of these products stack emission, waste water effluent, noise pollution health and safety
threats remain there, which is required to analyze and mitigate by HSE Engineers. These HSE
issues are caused to serious incidents and hazards if not managed/tackle properly.
We observe during the project study that Noise level is high near the machinery compare to the
other sounding areas and the stack gaseous emissions were found within the NEQs limits where as
the chances of incidents remain present in such a big complex and its happening as well but glad to
know that these were not the sever nature that can cause permanent disabability in spite of this they
focused on the health issue of their precious workers.
In short this organization established within an aims to facilitate and promote environmental,
healthcare and education awareness among the people and the visitors. Further improvement can be
achieved to adopt the required international standards and by drillings activities.

LIST FO ABRIVIATIONS
NRL = National Refinery Limited
NEQs = National Environmental Quality Standards
EPA = Environmental Protection Agency
PEPA = Pakistan Environmental Protection Agency
UAE = United Arab Emirates
API = American Institute of Petroleum
ISO = International Standardization Organization
OHSAS = Occupational Health & Safety Advisory Services
HSE = Health Safety & Environment
COD = Chemical Oxygen Demand
BOD = Biological Oxygen Demand
TSS = Total Suspended Solids
TDS = Total Dissolved Salt
pH = Percentage of Hydrogen Ions
BTX = Benzene Toluene Xylene
LBO = Lube Base Oil
Mg/l = Milligram per liter
Kg = Kilogram
*C = Degree Centigrade
Cl = Chlorides
Pb = Lead
CO = Carbon Mono Oxide
CO2 = Carbon Dioxide
SOx = Oxides of Sulfur
NOx = Oxides of Nitrogen
H2O = Water (vapors)

LIST OF FIGURES
3.1 National Oil Refineries Limited (NRL) Karachi (00)
3.2 Policy Statement of NRL (00)
4.1 Personal Protective Equipments and their Use (00)
4.2 Eye Protector Safety Glass (00)
4.3 Ear Protector or Ear Plugs (00)
4.4 Multipurpose Head and Ear Protector (00)
4.5 Arms and Hand Protector Safety Gloves (00)
4.6 Protective Clothes and High Visible Safety Apparel (00)
4.7 Foot Protector or Safety Shoes (00)
4.8 Fire brigade vehicle uses during firing for water showering (00)
4.9 Fire fighters during operation (00)
4.10 Controlling equipments like nozzles to increase the velocity of water (00)
4.11 Workers work in Confined Space (00)
4.12 Hot work is doing in a Confined Space (00)

LIST OF TABLES
Table 5.1 High Noise Level of working area near the Machines (00)
Table 5.2 Low Noise Level in open area and working places away
from heavy machines (00)
Table 5.3 Time duration with Noise Level (00)
Table 5.4 Determination of Stacks gaseous emission in
National Oil Refineries (00)
Table 5.5 Determination of Stacks Particulate matters emission in NRL (00)
Table 5.6 Ambient Air Quality of different area of NRL (00)
Table 5.7 Ambient Particulates Matters Monitoring in NRL (00)
Table 5.8 Determination of amount of particles in waste effluent (00)
Table 5.9 Determination of VOCs and H2S inside the refinery (00)
Table 5.10 Month wise status of incidents and loss time injuries in NRL (00)

LIST OF GRAPHS
Figure 5.1 Graphical representation of Noise Variation and compared
with NEQ (00)
Figure 5.2 Graphical comparison of stacks Particulate matters emission
with NEQs (00)
Figure 5.3 Temperature value of NRL with compared with NEQs (00)
Figure 5.4 Amount of Total Dissolved solids of NRL compared with NEQs (00)
Figure 5.5 Values of COD, BOD and TDS in NRL compared with NEQs (00)
Figure 5.6 Value of Grease and Oil in NRL compared with NEQs (00)
Figure 5.7 Graphical Representation of monthly number of incidents in NRL (00)

ACKOWLEDGEMENT
No work would be completed without sacrifice, motivation and encouragement.
We are greatly thankful to almighty Allah who gave us such strength and enabled us to accomplish
this energy intensive and demanding work successfully.
To complete this work we are greatly thankful from core of our heart to our supervisor
Mr. Junaid Ahsan Arain
Lecturer Energy & Environment Engineering department QUEST Nawabshah for his valuable
cooperation, precious guidance, suggestion, constructive and comprehensive information along
with continuous encouragement during the whole work.
We are also the great thankful to the administration of National Refinery Limited. Deep thanks to
Engr: Hafiz Waseem our field supervisor and Mr. Abdul Rasheed Fire Fighter Specialist in
National Refinery Limited.
In Last we exchange our words of thankful to all of our friends and elders who boost us sprit to
work day and night to achieve our long standing desires and to complete this work.
Last but not least THANKS to all of you
Zakir Raza (G.L)
Atiqur Rehman (A.G.L)
Rao Babar (Member)
Suhail Younus (Member)

CHAPTER NO 1
INTRODUCTION
1.1 INTRODUCTION TO STUDY
Industrial health and safety has paramount importance because all the working process, products
and environmental conditions based on it.
For the auditing of any industry various activities related to health and safety issues are being
observed, that the organization either flowing in proper direction smoothly and safely or not, and
this analyze gives us the outcome which reflects the current scenario of the organization and
associated problems in the shape of Health injury, waste water (contaminated water), stack
emissions etc. to manipulate these issues different techniques are involved which contribute to
reduce the hazards which seems to associated by improper working and misuse of
equipments/devices etc.
1.1.2 INTRODUCTION TO OIL REFINERIES
An oil refinery is an industrial process plant where crude oil is processed and refined into more
useful petroleum products, such as Gasoline, Diesel fuel, Asphalt, Heating oil, and Liquid
petroleum gas (LPG). Different product of crude oil is obtained by distillation process where
different products are separated at different temperatures because of difference of boiling points.
Oil refineries are typically large sprawling industrial complexes with extensive piping running
throughout, carrying steam and fluids between large chemical processing units.
Raw crude oil is not useful in natural form as it comes out of the ground. For making it useful for
humans, the oil needs to be separated into parts and refined before its utilization as fuel and
lubricants. Some of the by products of crude oil can be used in petrochemical processes to form
other useful materials such as Plastic and Fiber. Oil refineries are large scale plants where several
hundred thousand barrels of crude oil is processed per day. This high capacity also makes process
optimization and advanced process control very desirable

1.1.3 ABOUT THESIS WORK
As we know that our thesis work is on “Occupational Health and Safety (HSE) in National Oil
Refineries Limited” (NRL). During working in oil refineries there is maximum chance of
unpleasant event or chance of accidents. So we visited and analyze the HSE standers, working
procedures, availability of personal protective equipments and their proper utilization in NRL.
During the whole month of June we studied and visited the industry with Hafiz Waseem. In our
thesis work we observe the working conditions in Oil refineries and also rate of accidents and
probability of accidents. In our case study of occupational health and safety we will provide
information about National Oil Refinery, Safety equipments, fire and fire fighting techniques,
nature of accidents, and cause of accidents, techniques to prevent accidents and proper equipments
for specific accidents.
1.1.4 SCOPE OF WORK
Industry means combination of machines, motors and workers. During work there will be chance of
accidents like explosion, broken of rotating parts of machine, problem of high level of noise that
cause of headache and fatigue etc. To minimize these factors study of occupational health and
safety is very necessary and best for providing safer work place to workers and mitigate the rate of
accidents. Human life is very precious and valuable for everyone and some accidents accurse
during work cause death and failure of body parts like legs or hands can be damage, for providing
information about safety equipments and their proper utilization, intensity of accidents and also
preventions. HSE is very important for any type of work in any industry to provide safer and
efficient work also to mitigate the rate of accidents.
Through ensuring that employees’ tasks are safe, meaningful and conducive to the development of
their personalities, We seeks to create a work environment that fosters creativity as well as
constructive and critical thinking, good learning environment by ensuring that courses, welfare
provisions and the physical environment are adapted to their needs. The work and learning
environment must support and promote its users’ capacity to work and learn, safeguard their health
and well-being, and protect them against work-related illnesses and accidents.

1.1.5 SIGNIFICANCE OF WORK
Study of Health and safety plays an important role in working place in any type of industries to
provide safer working place and safe the valuable life of workers and also provide basic
information about safety equipments.
The health, safety and environmental (HSE) work at NRL shall constitute continuous and
systematic efforts that are integrated into the primary activities. HSE-related problems should be
solved consecutively at the lowest possible level, in order to prevent employees from developing
work-related illnesses or suffering work-related accidents, and to prevent the activities from having
a negative impact on the environment and workers. We know that if there is unpleasant case accrue
like firing, destruction in moving part of machine and problem of chemical leakage etc causes
number of death and loss of valuable products, raw materials and effect the over all structure of
work and work efficiency, to avoid such type of accidents and loss HSE department is vary
essential and beneficial for plant.
HSE department or safety engineers provide us safer working place which is beneficial for worker
as well as industry and management to create awareness among employers and workers on the
importance of OH practices in industry to preserve and protect the health of workers from being
affected by hazards in the working environment. To investigate the effect of specific hazard on the
health of workers so that the short and long term measures can be taken to control the hazard.
1.1.6 PROBLEM STATEMENT
To ensure the health and safety of NRL’s employees which are engaged to perform their duties in
the field, confined space or somewhere else in the premises of NRL for them it remains a hot issue
as they work in the conducive environment than production will automatically increase. Once the
conducive environment is developed it remains for longer time period which not only give the
safety to the worker but also helps to build up their moral once invest in the side of Occupational
Health Safety it must give payback to the higher authorities in the shape of minimum chances to
happen accidents if not than may face injuries in the shape of temporary and/or permanent
disabilities, asthma, suffocation, skin burning, cardiovascular diseases, fatigue etc.

1.1.7 DESCRIPTION OF CHAPTERS:
For the partial requirement of bachelor degree this thesis comprises of several theoretical
aspects like health and safety issue, aims of HSE, Pakistan conditions of OSHAS, safety act,
personal protective equipments, fire fighting and techniques, work permit, risk assessment
regarding occupational health and safety each of these aspect give clean and crystal picture that
how much importance they exist in the completion of case study.
Chapter 1
Introduction
It contain those topic which are consider helpful for the
fulfillment of project area study, these are background, scope of
study, objectives and other terms.
Chapter 2
Literature Review
Work, References and publications of those who have been
worked on industrial health and safety.
Chapter 3
Project Area
General description of about those term which have significance
in the field of occupational health and safety like work permit,
PPE’s, fire fighting techniques at working area
Chapter 4
Importance of HS& E
Theoretical work related to HSE
Chapter 5
Experimental Work
Investigations, survey and questioner regarding to HSE in the
organization (NRL) and collection of data by utilizing
equipments.
Chapter 6
Conclusion
Conclusion and recommendation towards the working conditions
and environment and final result.
. 1.1.8 OBJETIVES OF WORK The objectives of the work are:
• To analyze the health hazards and potential of hazards during working in Oil Refineries.
• To analyze the HSE standers and availability of safety equipments for prevention or
mitigation of the intensity of accidents.
• To provide the basic information of PPE’s and proper use of PPE’s for specific hazards.
• To analyze the accident rate and to collect the HSE reports of NRL.
CHAPTER NO 2

LITERATURE REVIEW
Various works have been carried out for the safety of the workers and also environmental safety to
protect precious life of the workers as well as working area. Many scholars worked and give their
valuable ideas related to Occupational Health and Safety. Their articles are briefly discussed below:
Chun-Chieh Chi, He researched on industrial health and safety and states that petrochemical and
petroleum industries are two of the main sources of industrial air pollution in Taiwan. Data used in
this study concern outdoor air pollution and the health of individuals living in communities in close
proximity to oil refinery plants. The prevalence of delivery of preterm birth infants was
significantly higher in mothers living near the oil refinery plants than in control mothers in Taiwan.
After controlling for several possible confounders (including maternal age, season, marital status,
maternal education, and infant sex), the adjusted odds ratio was 1.14 (95% CI=1.01–1.28) for
delivery of preterm infants for mothers living near oil refinery plants. These data provide further
support for the hypothesis that air pollution can affect the outcome of pregnancies [01].
Goldenhar, Linda M et al they studied often lacked a theoretical basis; they used small samples,
and tested interventions lacking the intensity to cause the desired change. Most designs were either
no experimental or quasi-experimental with uncontrolled sources of bias. Recommendations for
future research include methods of minimizing the problems and biases caused by these
weaknesses. No methodological issues such as the costs of implementing interventions and the
cultural and political dimensions of the workplace are also addressed. Although many
methodological issues associated with field-based research are not easily addressed, researchers
should make a stronger attempt to address these issues if the field of occupational health and safety
intervention research is to be productive [02].
Craig Zwerling MD, PhD, MPH, he searched on Occupational injuries continue to exact a great
toll on American workers and their employers—the physical and financial costs are enormous.
However, in the current political climate, few employers or regulatory agencies will implement

injury prevention interventions without specific evidence of their effectiveness. This paper reviews
the literature on the design, conduct, and evaluation of occupational injury interventions. Our
review suggests that randomized controlled trials are rare and also notes that the quasi-experimental
studies in the literature often use the weakest designs. We recommend a hierarchical approach to
evaluating occupational injury interventions—beginning with qualitative studies, following up with
simple quasi-experimental designs using historical controls, continuing with more elaborate quasi-
experimental designs comparing different firms' experience, and, when necessary, implementing
randomized controlled trials [03].
Chrysanthi Lekka, Caroline Sugden they worked and suggested that there are a number of
practices that organizations can adopt to achieve high levels of reliability and safety. These
practices are often discussed in the context of major incidents to highlight the safety standards that
high hazard organizations should try to emulate. However, previous research has predominantly
focused on non-profit organizations, and comparatively little research has examined whether high
reliability practices may be meaningfully applied to commercial contexts. This paper addresses this
gap by using a qualitative approach to explore the types of reliability-enhancing practices
implemented in a UK-based oil refinery in its attempt to achieve its ethos of ‘safe and reliable
operations’. The findings illustrate the successful application of reliability-enhancing practices in
several domains, including: hazard identification and control; emergency preparedness and
collection; and analysis of incidents and near misses. Management commitment to safety emerged
as an important factor underpinning the successful implementation of reliability-enhancing
practices, highlighting its potential significance in the context of commercial organizations.
However, promoting an open reporting culture and maintaining high levels of management
visibility may be some of the challenges encountered by organizations striving to implement
reliability-enhancing practices [04].
Tarja Ketola studied and stated that it regularly results in environmental shocks and stresses and in
public outrage. Strategic planning has become very complex in practice as the traditional political
and economic factors to be taken into account have now been accompanied by environmental

factors. This paper examines the strategic environmental planning process in two companies with
different approaches to change.
It seems that top-down sophisticated strategic environmental planning leaves room for power
struggles which may compromise the environmental behavior of a company. In addition, there is
often a gap between environmental scenarios and environmental policies which should be filled
with a vision. A bottom-up approach may lead to better environmental performance because there
is little room for political games and because the operating unit can respond directly to the
environmental pressure exerted by its interest-groups. Yet the lack of scenarios and visions in a
bottom-up approach reduces the operating unit's chances to make long-term plans, and allows it
only to react to changes in its business environment. In general, companies should enrich their
strategic environmental planning with visioning and link these two with rigorous strategic
environmental leadership [05].
Faisal I Khan and SA Abbasi studied and state that in their research article of Risk Assessment in
Chemical Process Industries the use of a new computer-automated tool TORAP (Tools for Rapid
risk Assessment in Petroleum refinery and Petrochemical industries) is demonstrated through a
rapid and quantitative risk assessment of a typical petroleum refinery. The package has been
applied for an appraisal of the risks of accidents (fires, explosions and toxic release) posed by
different units of the refinery, and to identify steps to prevent/manage accidents. The studies reveal
that TORAP enables a user to quickly focus on the accidents likely to occur, and enables
forecasting the nature and impacts of such accidents. This information is directly utilizable in
identifying 'soft' spots and in taking appropriate remedial measures to prevent or control accidents.
The special attributes of TORAP are: (a) wide range of applications — achieved by incorporating
models capable of handling all types of industrial fires and explosions, (b) sophistication —
brought about by including state-of-the-art models developed by these authors and others, (c) user-
friendliness — achieved by incorporating on-line help, graphics, carefully formatted output, and,
above all, an automatic module, with which even a lay user can conduct a risk assessment. The
entire package, especially its automatic module, is supported by an extensive knowledge-base built
into the software. [06].
Faisal I Khan et al studied in Journal of Loss Prevention in the Process Industries the term domino
effect denotes `chain of accidents', or situations when a fire-explosion-missile-toxic load generated
by an accident in one unit in an industry causes secondary and higher order accidents in other units.
Most of the past risk assessment studies deal with accident in a single industry, more so in one of

the units of an industry. But, often, accident in one unit can cause a secondary accident in a nearby
unit, which in turn may trigger a tertiary accident, and so on. The probability of occurrence and
adverse impacts of such `domino' or `cascading' effects are increasing due to increasing congestion
in industrial complexes and increasing density of human population around such complexes. The
multi-accident catastrophe which occurred in a refinery in India, on 14 September 1997, claiming
60 lives and causing loss of property worth over Rs 600 million, is the most recent example of the
damage potential of domino effect Lees F.P. Loss prevention in process industries, Major accidents
in process industries and an analysis of their causes and consequences in Journal of Loss
Prevention in Process Industries, A quantitative study. Process Safety Progress, 18, 135-145.
Recently, we have proposed a systematic methodology called `domino effect analysis' (DEA). The
paper makes a strong case for making DEA an integral part of all risk assessment initiatives [07].
Bo Johansson, et al worked and the purpose of this study was to carry out a broad survey and
analysis of relevant research articles about piece rate wages and their effects on health and safety
that were published internationally until the fall of 2008. The aim was to summarize and describe
the state of the art of the research in this field and if possible draw conclusions from the
accumulated research results. Although research is still sparse and fragmented, much of the
accumulated knowledge about the effects of piece rate work tells us that piece rates in many
situations have a negative effect on health and safety. The fact that 27 of the 31 studied articles
found negative effects of piece rates on different aspects of health and safety does not prove
causality, but together they give very strong support for the hypothesis that in most situations piece
rates have negative effects on health and safety. In order to achieve better knowledge about the
effects of piece rates in branches where piece rates are regarded problematic, further research is
needed and such research has to be designed to meet the specific questions that are to be answered
[08].
Sauter Steven L et al studied and describe about NIOSH recognizes psychological disorders as a
leading occupational health problem. This document, developed by a NIOSH working group led by
the present authors, represents a first attempt to fashion a comprehensive national strategy to
protect and promote the psychological health of workers. Roles are identified for industry, labor,
government, and academia. Key initiatives include (a) steps to improve working conditions and

employee mental health services and (b) increased research and surveillance to advance
understanding of the problem. Because work-related psychological disorders appear to be a rapidly
developing problem lacking complete definition in terms of scope and etiology, this strategy is not
to be considered a final statement of NIOSH policy [09].
G.Waddell, A.K Burton, studied about back pain during work that there is increasing
demand for evidence‐based health care. Back pain is one of the most common and difficult
occupational health problems, but there has been no readily available evidence base or
guidance on management there are well‐established clinical guidelines for the management of
low back pain, but these provide limited guidance on the occupational aspects. Occupational
Health Guidelines for the Management of Low Back Pain at Work were launched by the
Faculty of Occupational Medicine in March 2000. These are the first national occupational
health guidelines in the UK and, as far as we are aware, the first truly evidence‐linked
occupational health guidelines for back pain in the world. They were based on an extensive,
systematic review of the scientific literature predominantly from occupational settings or
concerning occupational outcomes. But a compact version is presented here to aid its
dissemination [10]

Quick, James Campbell and Tetrick, Lois E. Declared about Occupational health psychology,
that it is a relatively young specialty within the science and practice of psychology. This handbook
is designed to consolidate and organize the rising knowledge in the field from the interdisciplinary
perspectives of an international group of scholars and researchers. Provide historical,
contemporary, and future-oriented perspectives on this emerging specialty after first discussing
prevention and public health in occupational settings. That addresses key causes of health and
safety at work as well as key risks to health and safety, focusing on factors both within the specific
workplace as well as broader occupational factors and factors from the personal life area.
Regardless of how effectively organizations design prevention and public health programs to
protect the health and safety of people at working place, some experience symptoms and health
disorders, and the specific primary, secondary, or tertiary interventions for health and safety, This
book addressing issues of epidemiology, program evaluation, and socioeconomic cost-benefit
analysis [11].
DEFRA (2002) and Hunt et al (2000) Both stated that the adverse health effects of exposure to
high concentration of chemicals such as Benzene, 1,3-butadiene, Carbon monoxide, Lead Nitrogen
oxides, Ozone, Particles and sulpher dioxide, range from mental impairment to cancer and with
excessive exposure death. Whilst Air quality has been improved in Urban and Rural areas during
the last 20 years, between 123000 and 24100 death are thought to be hastened annually due to air
pollution by ozone, Particulates and sulpher dioxide (ibid,:3; DEFRA, 2003:76). Poorer peoples
living in the disadvantaged areas are exposed to the highest level of air pollution [12].
L.H Vassie and W.R Lucas studied and states about health, safety and Environment that team can
be managed in different ways: using supervisor, team leaders, or self-managed. The
management of health and safety and other business risk is dependent on the way in which the
team is managed. Although the differences are not always significant, it is noticeable that
within organization using supervised work environment, there is a lack of communication of
specific health and safety information, little involvement and participation in safety activities,
and a greater reliance on the safety functions. However in organization using team leader and
self-managed groups, there is evidence of greater management involvement, more open
communication, and greater employee involvement in health and safety, Although
empowerment in its true sense was still limited in these organizations [13].

Hunt et al (2000) stated that the impact of the environment on the health is a complex and difficult
to disentangle; health within an environmental context must be considered as a Multiphase and
holistic Phenomenon, They recognize that identification of a link between environment and Public
is not a new and that Environmental Legislation targeted at protecting health through improved
housing and sanitation go back centuries (ibid.; See also Morris, 2003; Gesler, 1998). In past years,
there have been some reports (Meng et al., 1995; Meng and Zhang 1997) from many countries,
which showed significant excess of chromosomal aberration hazards of the employees of phosphate
fertilizers plant [14].
Shang hwa hsu, chun-chia lee, muh-cherng wu, these above listed professionals identify the
safety factors and their influence mechanism in Taiwan and Japan oil refinery. Taiwanese purely
emphasis on safety activities, higher devotion to supervision as well as quality of safety
performance, Where as Japanese engaged to work on systematic safety and efficient reporting
system of team work which can minimize the health safety threats. These perform task and script
provide safety improvement in emerging countries and developed countries respectively [15].

CHAPTER NO 3
PROJECT AREA
3.1 INTRODUCTION TO NATIONAL OIL REFINERIES (NRL).
A national oil refinery (NRL) is the largest petroleum refining complex in Pakistan. Comprises
of three refineries and a BTX plant located in the industrial zone of Korangi 1, Karachi
Metropolitan area 15 Km South East of Karachi.
National Refinery Limited (NRL) was incorporated on August 19, 1963 as a public limited
company. Government of Pakistan took over the management of NRL under the Economic
Reforms Order, 1972 under the Ministry of Production, which was exercising control through
its shareholding in State Petroleum Refining and Petrochemical Corporation (PERAC).
The Government of Pakistan had decided to place the National Refinery Limited under the
administrative control of Ministry of Petroleum & Natural Resources in November 1998.
In June 2003 the Government of Pakistan decided to include NRL in its privatizations
programmed.
The selling of 51% equity and transfer of management control to a strategic investor had been
proposed accordingly, the due diligence process for the privatization was initiated. After
competitive bidding NRL was acquired by Attock Oil Group in July 2005.
The Company has been privatized and the management handed over to the new owner (Attock
Oil Group) on July 7, 2005.

National Oil Refineries
Figure 3.1 National Oil Refineries Limited (NRL) Karachi

3.1.2 MAJOR PRODUCTS OF NRL
This classification of crude oil products is based on the way by which crude oil is distilled and
separated into fractions, and this process is called distillation process. Most products of oil
processing are usually grouped into three categories:
1) Light distillates (LPG, Gasoline and Naphtha).
2) Middle distillates (Kerosene, Diesel)
3) Heavy distillates and residuum (Fuel oil, Lubricating oil, wax and Tar).
3.1.3 COMMON PROCESS UUNITS FOUND IN NRL
Several number of process units in oil refineries are involved for making crude oil pure and
useable and removing of undesirable products from it.
• Distillation Unit
• Visbreaking Unit
• Dehydration Unit
• Alkyl nation Unit
• De saltation Unit
• Isomerization Unit
• Amine Treating Unit
• Catalytic Reformer Unit
• Liquefied gas storage unit
• Vacuum Distillation Unit
• Fluid Catalytic Cracker Unit
• Naphtha Hydro-treated Unit
• Coking Units

3.1.4 PRODUCTION
The refinery complex of the Company comprises of three refineries, consisting of two lube
refineries and one fuel refinery.
First Lube Refinery commissioned in 1966 with designed capacity of 539,700 tons per annum
of Crude Processing and 76,200 tones per annum of Lube Base Oils. Second Lube Refinery
commissioned in 1985 with designed capacity of 100,000 tons per annum of Lube Base Oils.
In 1974, a turnkey agreement was signed between NRL and Industrial Export Import (IEI) of
Romania, to design and construct the 1.5 million tones per year of crude oil refining capacity.
The Fuel Refinery commissioned in 1977 with designed capacity of 1,500,800 tones per annum
of crude processing and after revamp the designed capacity comes to 2,170,800 tones per annum
of crude processing.
The BTX (Benzene, Toluene and Xylene) unit was commissioned in 1985 with design capacity of
25,000 tons per annum of BTX. It was the first petrochemical unit integrated with unit of fuel
refinery.
NRL enjoys a competitive edge, as it is the only refinery producing LBO (Lube Base Oil) in
Pakistan. This was export till 1986.
At present the production capacity of LBO is 1, 97,000 tones per year with two Lube Refineries.
3.1.5 DEVELOPMENT POLICY
• To ensure that business policies and targets are in conformity with the national goals.
• To Contribute in meeting the country's demand of petroleum and petrochemical products
Customer's satisfaction by providing best value and quality products.
• Optimization of the value of barrel of crude oil and cost reduction through conservation
measures
• To achieve and maintain a high standard of Occupational Health, Safety and Environment

• Maintain modern management system conforming to international standards needed for an
efficient organization.
3.1.6 VISION
Our passion is to attain a distinctive leadership amongst the corporate success stories of tomorrow
we at NRL recognize that the realization of this passionless superior professional competencies,
continuous value addition an improvising, and development of Human capital and complete
commitment to safety, occupational health and Environment.
3.1.7 MISSION
• To remain the premium and preferred supply source for various petroleum products and
petrochemicals.
• Offer products that are not only viable in terms of desirability and price but most
• Importantly give true and lasting value to our customers. Deliver strong returns on existing
and projected investments of our stakeholders by Use of specialized and high quality
corporate capabilities.
• Business development by adoption of emerging technologies, growth in professional
Competence, support to innovation. Enrichment of human resource and performance
recognition.
• Be a responsible corporate citizen by serving the community through a variety of socio-
economic acts and maintaining a high level of safety, occupational health and
environmental care.
• Provide safer and high standers of lives and achieve the goals of NRL development policy

3.1.8 CORE VALUE
Following concepts and ideas guide the Management and Staff of National Refinery
Limited in conducting its business practices in most ethical ways
• Ethical Conduct and Integrity We value lifestyle in our organization where ethics like truth,
honesty, integrity and fair play are basic ingredients while interacting within the
organization or dealing with the outside world.
• Teamwork and Responsibility We share information and resources and step in to help out
other team members. Conflicts are worked out in spite of obstacles and difficulties. We
accept responsibility with “can do” attitude.
• Customer Satisfaction We endeavor to provide quality products to our customers at
competitive prices. We value their satisfaction essential for continued growth of our
business. Core Values
• Continuous Improvement We generates new ideas and creative approaches to upgrade and
update our refinery to best available technology and processes so that our products are at the
level of internationally accepted standards.
• Profitability we believe in enhancing our profitability to the maximum so that Employees,
Shareholders and Government all benefits from it.
• Corporate Citizenship As a good Corporate Citizen, we are more than willing and happy to
meet our social responsibilities towards the community around us. We are also committed
to meet requirements of health, safety and environment.

3.1.9 IMORTANCE
Energy conservation is vital for today’s refinery economics to reduce per unit cost of production
and to protect Natural Environment. NRL contributes to sustainable development management
through the integration of Environmental, Social and Economic considerations in its work.
The recent introduction of 90 RON unleaded motor gasoline is a further evidence of our
environment to concern towards good health and preservation of environment.
The primary function of the HSE Department is to explore opportunities for environment
improvement and energy conservation at Refinery Units, prepare and evaluate proposals and
implement them. NRL has an HSEQ policy which is the corner stone in its decision making
process to ensure compliance with the Environmental laws (NEQS) and achieve continuous
performance improvement.
Refinery consumes enormous quantity of thermal energy, supplied by combustion of fuel oils
and fuel gas at furnaces. Number of energy conservation projects has been implemented at
National Refinery, which has reduced energy consumption per barrel of crude oil. Large
quantities of liquid effluents and gaseous emissions are also encountered in petroleum
processing. Improvement programs are constantly undertaken at NRL to combat pollution in
respect of emissions and effluent waste water.
Regular monitoring of pollutants is carried out by testing of effluents and emissions samples to
measure environmental performance. In recognition to the reality that eventually sulphur will
have to be reduced in HSD to make it environment and health friendly, the management has
already initiated a preliminary feasibility study to put-up a hydro-desulphurization plant for
reduction of sulphur to limits set by the government.

3.1.10 OBJECTIVES OF HSE
The objectives of HSE are
• To establish procedures and implement work instructions sufficient to avoid injury to
employees and others who may be affected by Company operations.
• To establish standards and procedures to minimize harm to employees and others through
the Occupational health hazards and substance abuse.
• To provide facilities, plant, and equipment and maintain them in safe condition.
• To provide an effective system of communication throughout the management and with
workers to ensure active participation in all aspect of safety management.
• Through investigation, follow up, and analysis of incident reports, strive to eliminate the
accidents and incidents within the Company operations
3.2 HSE POLICY OF NRL

Figure 3.2 Policy Statement of NRL
HSE POLICY OF NRL Energy conservation is vital for today’s refinery economics to reduce
per unit cost of production and to protect Environment. NRL contributes to sustainable
development management through the integration of Environmental Social and Economic
considerations in its work environment. The recent introduction of 90 RON unleaded motor
gasoline is a further evidence of our concern towards good health and preservation of
environment.
The primary function of the HSE Department is to explore opportunities for environment
improvement and energy conservation at Refinery Units, prepare and evaluate proposals and
implement them. NRL has an HSEQ policy which is the corner stone in its decision making process
to ensure compliance with the Environmental laws (NEQS) and achieve continuous performance
improvement.
Refinery consumes enormous quantity of thermal energy, supplied by combustion of fuel oils and
fuel gas at furnaces. Number of energy conservation projects has been implemented at National
Refinery, which has reduced energy consumption per barrel of crude oil. Large quantities of liquid
effluents and gaseous emissions are also encountered in petroleum processing. Improvement
programs are constantly undertaken at NRL to combat pollution in respect of emissions and
effluent waste water. Regular monitoring of pollutants is carried out by testing of effluents and
emissions samples to measure environmental performance. In recognition to the reality that
eventually sulphur will have to be reduced in HSD to make it environment and health friendly, the
management has already initiated a preliminary feasibility study to put-up a hydro-desulphurization
plant for reduction of sulphur to limits set by the government.
3.2.1 ISO 9001, ISO - 14001 & OHSAS – 18001CERTIFICATION
In order that Quality Standards and Environment practices at NRL are according to world
standards, certification for Quality ISO 9001 Environment Management System ISO-14001
has been acquired. Likewise, for controlling of work related health and safety risks, OHSAS-
18001, certification has been acquired. Implementation of ISO 9001, ISO 14001 AND OHSAS
18001 has put NRL as the pioneer in the country in areas of Quality, Environment and
occupational health & safety certification.

3.2.2 NRL SAFETY BOARD
NRL Safety Board is updated by second week of every month. Safety Board shows the number of
Safe Man-hours worked by NRL MPT and Non MPT Staffs. By the Grace of Al Mighty Allah and
joint efforts by all of us, we have achieved 16.07 millions safe man-hours with out Lost Time
Injury as on October 31, 2011. Let us all give top priority towards safety, as there is no job, which
cannot be done in a safer way.
3.2.3 QUALITY CONTROL, RESEARCH & DEVELOPMENT AT NRL
Every product leaving the refinery has to conform to stringent international or national
specification requirements. In order to achieve the fine degree of control, extensive monitoring of
crude oil feed stock, intermediates and final products is conducted with the aid of modern
sophisticated analytical equipment in our Quality Control Laboratory. Usage of NRL produced
base oils by numerous national and international lubricating oil companies for producing world
class lubricants authenticates the supreme quality of our lube base oils. NRL strives to satisfy the
customers by providing best products within specifications.
The role of NRL Quality Control Laboratory is, however, not limited to Quality Control alone.
Research and Development work is carried out to give a basis for innovation in processes and
products.
NRL Quality Control Department, which was certified to ISO 9002 Quality Management System in
the year 2000. Currently entire Refinery is ISO 9001:2000 certified under Integrated Management
System (IMS), which include ISO 14001 and OHSAS 18001
3.2.4 HOT WORK PERMIT AT NRL
By the Grace of Al Mighty Allah and joint efforts of all concerned, all naked flame hot work
permits were performed safely.
During working days in the morning 6 to 7 Nos. of naked flame hot work permits were audited for
various jobs at different locations inside Refinery. Sr. Engineer & Engineer HSE / Fire Protection

Officers along with respective area custodians audit these permits before issuance. Total numbers
of naked flame hot work permits carried out during the month of October 2011 were 155 No in
Korangi Refinery.
3.2.5 PPE’S AT NRL
In NRL personal protective equipments are use for safety and to reduce the intensity of accidents.
There is number of PPE’s are available in NRL and latest equipments are present at NRL safety
department.
3.2.6 FIRE FIGHTING AT NRL
At NRL Korangi Refinery every Thursday at 1000 hrs sharp, fire drill is carried out at fire drill
ground. This drill helps in checking the fitness of fire fighting equipments & imparting training to
Fire Protection staffs and Auxiliary Staffs that come from Production, Security, Quality Control
and Oil movement departments to gain experience in fire fighting on live fires. HSE department
observes the response time during fire drill. The average response time of fire drill was about 4:20
to 7:37* minutes. This time includes reaching the fire tender at site, lying of water hoses / foam
hoses and the time when water showering starts. During the month of October 2011 04 No of live
fire drills were carried out at Korangi Refinery. Where as 04 Nos. of weekly fire drills were carried
out at K.T during the month of October 2011.
* Fire Tender # 3 & 5 participated in Fire Drill. Water Hose not fully unrolled, however it was
pressurized by Tender operator, which resulted in attainment of Response Time beyond benchmark.
3.3 IMS (HSEQ) Management System at NRL
This document defines the scope of NRL's Occupational Health & Safety, Environmental and
Quality Management Systems IMS (HSEQ) and provides linkages of system documents to the
elements of the ISO 9001:2008, ISO 14001:2004 and OH&SMS18001:2007 Standards.
NRL Integrated Management System IMS (HSEQ) provides a mechanism for Occupational Health
& Safety, Environment and Quality Management Systems throughout all areas, units and
departments of NRL Korangi Refinery, Kea Mari Terminal and Korangi- Kea Mari Pipeline.

• Determine the processes needed for the IMS (HSEQ) Management System and their
applications throughout the organization,
• Determine the sequence and interaction of these processes,
• Determine criteria and methods required to ensure the effective operations and controls of
these processes,
• Ensure the availability of resources and information's necessary to support the operations
and monitoring of these processes,
• Monitor measure where applicable and analyzed these processes,
• Implement actions necessary to achieve the planned results and continual improvement of
these processes.
3.3.1 IMS (HSEQ) POLICY
NRL has established its policy for Health, Safety, and Environment & Quality ensures that it:
• Is appropriate to the purpose, nature and scale of the organization,
• Includes a commitment to prevention of injury and ill health and continual improvement in
IMS (HSEQ) Management and performance.
• Provides a framework for setting and reviewing IMS (HSEQ) objectives and targets.
• Includes a commitment for prevention of pollution requirements.
• Is communicated to all persons working under the control of the organization.
• Is available to interested parties.
• Is periodically reviewed for continuing suitability at appropriate level of the organization.
The IMS (HSEQ) Policy is communicated and enforced through management reviews, training,
displayed at appropriate locations.

3.3.2 MONITORING AT NRL
NRL applies suitable methods for monitoring and, where applicable, measurement of the IMS
(HSEQ) management system processes. These methods demonstrate the ability of the processes to
achieving planned results. When planned results are not achieved, correction and corrective actions
are taken, as appropriate.
Note: When determining suitable methods, it is advisable to consider the type and extent of
monitoring or measurement appropriate to each of its processes in relation to their impact on the
conformity to product unless otherwise approved by a relevant authority and, where applicable, by
the customer.
3.3.3 Waste Monitoring & Management
During Normal / Turnaround / Shutdown operations, Steering Committee identifying waste
generates causing Environmental Load with respect to the aspect like (Air emissions, Effluent
discharge, and solid waste). Environmental Load identification for normal / turnaround operation is
carried out on format (NRL-FAF-AIA-001). On the basis of the Environmental Load Summary for
Normal operation developed on (NRL-FAF-AIA-002) and Turnaround Operation (NRL-FAF-AIA-
003). Total Environmental load at NRL on the basis of above mentioned summaries is developed
by concerned department’s e.g.
• Hot Air
• API-I Effluent
• Spent Caustic
• Cotton Waste
• Plastics
3.3.4 Drinking Water Monitoring

Three-Stage filter elements are installed at each drinking water cooler placed inside Refinery and
Kea Mari Terminal. Filter elements are changed by Maintenance-II department as per schedule.
HSE coordinates with Administration and Maintenance-II departments to send samples of drinking
water to laboratory for testing. Result of drinking water samples are found satisfactory for drinking
purpose.
3.3.5 Environmental Impact Assessment (EIA) and Initial Environmental Examination
(IEE) for New Projects
The framework for identifying and evaluating the environment and occupational health and safety
issues of new projects at NRL to ensure the appropriate consideration is given to Health, Safety,
Environment and Quality (HSEQ) issues prior to project approval and funding, to ensure aspects
and hazards generated by projects are identified & their significance evaluated, to secure approval
from regulatory agencies are well defined in the documented procedures (NRL-SPR-RIP-012) &
(NRL-SPR-RIP-019).
3.3.6 Initial Environmental Examination (IEE) Lube Refinery Revamp Project
An IEE of the proposed unit was carried out as part of the project to ascertain that said project will
not cause any possible adverse impact on the environment. The purpose of this IEE was to identify
potential source of impact due to operation of MEK-II and recommended measures for impact
mitigation and management.
3.4 RISK ASSESSMENT
Risk assessment is the process where you:
• Identify hazards.
• Analyze or evaluate the risk associated with that hazard.
• Determine appropriate ways to eliminate or control the hazard.
In practical terms, a risk assessment is a thorough look at your workplace to identify those things,
situations, processes, etc that may cause harm, particularly to people. After identification is made,
you evaluate how likely and severe the risk is, and then decides what measures should be in place
to effectively prevent or control the harm from happening.

For definitions and more information about what hazards and risks are, please see the OSH
Answers document Hazard and Risk.
Risk assessments are very important as they form an integral part of a good occupational health and
safety management plan. They help to:
• Create awareness of hazards and risks.
• Identify who may be at risk (employees, cleaners, visitors, contractors, the public,
• Determine if existing control measures are adequate or if more should be done.
• Prevent injuries or illnesses when done at the design or planning stage.
• Prioritize hazards and control measures.
3.4.1 Hazards, Evaluation and Risk Assessment Frame Work at NRL
• OH&S hazards of Normal Operation
• OH&S Turnaround / Shutdown Operation
• Routine activities
• Non Routine activities
• Access to the work place
• Facilities at work place
• Absence of control measures
3.4.2 Hazards Categories
• Ergonomics Hazards
• Mechanical hazards
• Electrical hazards
• Pressure hazards
• Pneumatic hazards

• Falling hazards
• Biological hazards
• Noise hazards
• Vibration hazards
• Toxic hazards
• Radiation hazards
• Explosion hazards
• Chemical hazards
• Fire hazards
3.4.3 OH&S Hazards Impacts Categories
• Injury / Illness
• Disability / Death
• Production delays and interruption
• Asset Loss
• Property damage
• Tools and equipment damage
• Product and material damage
• Evaluation of Risks Assessment for
3.4.4 Identified Hazard
• Legislative and regulatory requirements
• Identification of the OH&S Risks face by NRL
• Review OH&S practices, process and procedures
• Evaluation of feed back from the investigation

• Audit results & Recommendations
• Direct inspection and measurement
3.4.5 Risks Control
Residential hazard identified, even after current control measures, will be assessed for risk and
classified under tolerable risks and un-tolerable risks.
Measure taken with the principal of ERIC-P
E-Eliminate
R-Reduce,
I-Improve,
C-Control,
P-Protect
If risk can not be converted into tolerable risk than PPE's used to reduce the impact
3.4.6 Emergency Preparedness & Response Planning and Risk Management
The Fire Protection Manager and HSE Manager are responsible for developing and implementing
an emergency prevention, mitigation and response plan.
Emergency situation may be of any one or combination of two or more included Flood / Territorial
Rains / Typhoons or Cyclone, Terrorist Attacks, Fire, Earth Quake, Oil Leakage / Spills, Chemical
Leakage / Spills, LPG Emergencies, Flammable / toxic gas release, Explosion, Loss of utility
services, Epidemic, Failure of Fire Alarm and monitoring devices, Serious injuries & Traffic
Accidents
Roles and responsibilities for communications with-in the facility and for obtaining outside support
services established, maintained and addressed in the departmental emergency preparedness and
response procedures.
Environmental, health and safety emergency methods and communications tested at least
biannually basis if practicable or whenever required and maintain records of these drills.

3.4.7 Environmental Objectives
NRL has established, implemented and maintained a system procedure (NRL-SPR-EOT-016) for
environmental objectives and targets at relevant function and level.
The Environmental objective consistent with the IMS (HSEQ) Policy, including commitment to
prevention of pollution, shall be measurable (where practicable) to compliance with applicable
legal and other requirements, which organization subscribes for continual improvement.
SAFETY LABELLING
For the attention and prevention of workers for any unwanted events different safety labeling are
mention at different places like near machinery “NO SMOKING” label is mentioned.
Some safety labels are shown
Safety sign at the entrance gate of NRL
Safety sign at different exit areas

Safety sign near oil Storage
Safety sign near Storage
Safety board at different places
CHAPTER NO 4
OCCUPATIONAL HEALTH AND SAFETY
4.1 Health and Safety
Health and Safety are the two vital factors that can immensely contribute towards your performance
at different situations like workplace, sports, and so on. Often, people neglect issues pertaining to
health & safety, eventually landing in trouble. So, what is it that drives these two factors? Why are
they essential? The answers to these recurrent questions lie ahead.
Especially in workplaces, employee productivity is of core essence to build on the companies as
well as the employees’ prospect. This prospect highly rests on the performance delivery, which
further is supported by accurate health and safety. For instance, a sales officer can neither travel

comfortably nor perform effectively in an unhealthy and unsafe condition. This would only lead to
a lackluster performance, further causing a stoop in sales.
Health and Safety also have a solid impact on your personality. A charming personality can work
for you tremendously not only at work, but also in general lifestyle. While health reflects your
personality, safety acts as the solution to obtaining a perfect heath. Saying so, safety has a lot to do
with the application of appropriate techniques at the right time.
The positive characteristic of Health & Safety is its widespread practice. Even if you are unable to
recognize the adequate and exact techniques, there are scores of health and safety training
consultants, available all over the world, to provide assistance. A health & safety consultant
specializes in sophisticated related equipments, and provides exclusive training programs, in a
professional manner. With certified skills, he provides an ideal opportunity to get things right for
you within a span of just few days.
Besides a health & safety consultant, you too can work towards attaining enhanced health & safety.
Maintaining cleanliness and hygiene, intake of suitable diet, regular exercising, etc. are some of the
most prominent techniques in achieving health and safety. In this case, consistency is the key.
These activities have to be done persistently for lifetime, in order to ensure better longevity.
There are other intangible factors as well that can influence your health. For example, several
people go through stress and depression regarding their work-life and relationships. These factors
can hamper your health to a great extent, forcing you to live a miserable life. Hence, to overcome
these barriers, a health and safety consultant offers special yoga and stress management practices,
as safety techniques. However, it all depends on the individual how he follows them. If one is
honest to himself, he is bound to achieve quicker results and lead an improved life.
4.1.2 Aims of the HSE
The main aims of the HSE are to:
• Protect the health, safety and welfare of people at work
• Safeguard others, including members of the public, who may be exposed to risks from the
way work is carried out
• Carry out enforcement of health & safety law to promote a thriving local economy & a fair
and safe trading environment
• As a minimum, adhere to all requirements of the Occupational Health and Safety Act
(2000) and OHS Regulation (2001),

• Increase the awareness of its staff of the provisions and requirements of Occupational
Health and Safety Act,
• Develop and maintain regular workplace inspections and reporting procedures,
• Assess and control risks as they are identified,
• Encourage staff and students to take an active role in the development of safe working
practices,
• Implement appropriate drills for evacuation of the workplace in the event of a dangerous
situation,
• Continue the consultative process between staff, and management,
• Train appropriate staff to assist in the implementation of occupational health and safety
policies of the organization
• Provide adequate occupational health and first aid services.
4.1.3 Occupational Health & Protecting employees from Occupational Hazards
• The work-related accidents accounted for:
• 103,000 deaths in the USA,
• 122,000 in the European Union,
• 90,500 in China and

• 40,000 in India during 2005.
• In case of developing countries, where the rate of such deaths is higher, the relevant data is
either unavailable or unreliable.
4.1.4 Pakistan, Conditions of OHSAS
• Most of the 47.57 million employed workforces, including females and children, are poor,
illiterate and semi-trained.
• Thus exposed to various occupational hazards.
• The working conditions and environment in most of the workplaces are sub-standard.
• There is no concept of taking preventive and control measures to safeguarding the health of
workers.
• There is no record keeping and data collection of accidents and incidents that also go mostly
unreported.
• The range and scope of occupational safety and health covers all the industrial, commercial,
agricultural and service sectors, utilities, manufacturing, transport/ communications,
hotels/restaurants, mining/quarrying, and construction, the SMEs etc.
• There is no Proper reporting of accidents
• At local level or in small industries there is lake of skilled persons
• Shortage of Personal Protective Equipments no proper equipments are available in many
industries.
• Textile is our single largest industry. It uses a variety of chemicals for various processes
particularly spinning, weaving, knitting, scouring, printing, dyeing and finishing, which
generate noise, dust and emissions of toxic chemicals which--- all injurious to health.
4.1.5 Safety and Act

Under the provision of the labour 2002, national occupational safety and health council was to be
established to provide safety at work place, ensure compensation to the employees, and frame,
review and update regularly the requisite standards. Five years thereon there is no headway even
towards formation of the proposed triparite council
The list of legislation includes:
• Factories Act of 1934,
• Factories Rules 1975,
• Mines Act of 1923,
• Consolidated Mining Rules 1952,
• Oil & Gas (Safety in Drilling and Production) Rules 1974,
• Dock Laborers Act 1934,
• Punjab Factories Rules 1978,
• Sindh Factories Rules 1975,
• Coal Mines Regulations 1926 (NWFP),
• Hazardous Occupational Rules 1978,
• Explosives Act 1884,
• Boilers & Pressure Vessels Act 2002, to name only a few.
Safety is the state of being safe
S Spot the hazard
A Assess the risk
F Fined a safe way
E Every moment
For safety of the workers and to mitigate the industrial accidents there are many safety equipments
are used for safety like safety glasses, gloves, and ear muff etc
4.2 Personal Protective Equipment
Definition: Devices used to protect an employee from injury or illness resulting from contact with
chemical, biological, physical, electrical, mechanical, or other workplace hazard.
The need for PPE and the type of PPE used is based on hazard present.

These equipments are widely used in industries to save the life of a workers and minimized health
hazards. Personal protective equipment, or PPE, is designed to protect workers from serious
Workplace injuries or illnesses resulting from contact with workplace hazard.
There are different types of personal protective equipments are used according to the nature of
work. Some of these are discuss below which are generally used in oil refineries like
• Eye and Face protection
• Hearing protection
• Head protection
• Arm and Hand protection
• Protective Clothing
• Foot and Leg protection
Figure 4.1 Personal Protective Equipments and their Use
4.2.1 Eye and Face protection
These equipments are used to protect eyes and face from dust and harmful particles flying at the
work place. Sometimes these small particles cause hazardous for worker and as well as workplace.
To protect unwanted and danger worker should use these Protection Equipments

The Canadian Standards Association (CSA)-certified safety glasses have plastic polycarbonate
lenses. They are stronger than regular lenses, are impact-resistant, and come in prescription and
non-prescription (Plano or zero-power lens) forms
• Lenses and Frames:
Safety frames are stronger than street-wear frames and are often heat resistant. They are also
designed to prevent lenses from being pushed into the eyes. Ensure your safety glasses fit properly.
Eye size, bridge size and temple length all vary. Safety glasses should be individually assigned and
fitted. Wear safety glasses so that the temples fit comfortably over the ears. The frame should be as
close to the face as possible and adequately supported by the bridge of the nose. Clean your safety
glasses daily. Follow the manufacturer's instructions. Avoid rough handling that can scratch lenses.
Scratches impair vision and can weaken lenses.
Figure 4.2 Eye Protector Safety Glass
4.2.2 Hearing protection:
In any industry there should be noise pollution because heavy machinery produces heavy noise that
is harmful for human ears and also causing fatigue and problems for worker.

Noise induced hearing loss can occur with exposures >90 dBA
Servation program becomes a requirement at exposures >85dBA
To control the level of noise and to prevent the noise pollution ear protection equipment are used
like Ear muff, Ear plugs etc
• Ear plugs:
These are less expensive, disposable, good ones sometimes difficult to tell if employees are
wearing them and these are inserted to block the ear canal. They may be remolded (preformed) or
moldable (foam ear plugs). Ear plugs are sold as disposable products or reusable plugs. Custom
molded ear plugs are also available.
• Ear muffs:
These are more expensive, more durable, and more obvious that Can be used together in very high
noise areas consist of sound-attenuating material and soft ear cushions that fit around the ear and
hard outer cups. They are held together by a head band.
Figure 4.3 Ear Protector or Ear Plugs
4.2.3 Head protection

In many industries numbers of people die because of falling of metallic equipments on the head of
the workers. Head is very sensitive part of the body. To protect head from injuries same hard cap or
helmet are use which consist of hard substance and these safety helmets and head protector are
useful and safer.
Figure 4.4 Multipurpose Head and Ear Protector
4.2.4 Arm and Hand protection
For the safety of hand from harmful chemicals, electric current, oil and other biological diseases
safety gloves are use. Generally they are made up of plastic for physical and chemical injury but for
the prevention of biological diseases disposable gloves are use.
Figure 4.5 Arms and Hand Protector Safety Gloves
4.2.5 Protective Clothing

Protective clothing is used to protect dress from oil and grease these are used to protect street
clothes from hazards in the workplace often hazard specific protective clothing can be considered
effective, protective clothing must prevent the contaminant from reaching the clothing or skin of
the wearer High-visibility safety apparel (HVSA) is clothing that workers can wear to improve how
well other people "see" them (their visibility). Most often, high-visibility clothing is worn to alert
drivers and other vehicle operators of a worker's presence, especially in low light and dark
conditions.
Figure 4.6 Protective Clothes and High Visible Safety Apparel
4.2.6 Foot and Leg protection

As the old saying goes, "When your feet hurt, you hurt all over."There are two major categories of
work-related foot injuries. The first category includes foot injuries from punctures, crushing,
sprains, and lacerations.
They account for 10 percent of all reported disabling injuries. The second group of injuries includes
those resulting from slips, trips and falls. They account for 15 percent of all reported disabling
injuries.
Slips and falls do not always result in a foot injury but lack of attention to foot safety plays an
important role in their occurrence. Steel-toed footwear, preferably with metatarsal guards, is used to
protect feet from crushing injuries caused by heavy objects Rubber boots are often used to protect
feet from exposure to liquids.
Figure 4.7 Foot Protector or Safety Shoes
4.3 FIRE FIGHTING AND TECHNIQUES

Fire is considered as uncontrollable and rapidly expanded cause of accident and, the biggest loss of
raw material and other valuable product are because of fire, accident in any industry always loss of
Infrastructure.
4.3.1 Fire and Causes of Firing:
Fire is considering as most dangerous and uncontrolled accident in every industry and especially in
oil refineries. A fire usually has a well-defined edge and can burn very slowly or very fast
depending on conditions. Industrial fires result not only in economic lost but in much human
suffering as well. Damage to Infrastructure and Loss of valuable things
4.3.2 The factors that cause fire
• Fuel: Paper, wood, oil, solvents, gas, etc.
• Heat: The degree necessary to vaporize, fuel according to its nature.
• Oxygen: Normally at least 15% of oxygen in the air is required to sustain a fire. The
greater the concentration of oxygen, the brighter the blaze and the more rapid the
combustion
4.3.3 Types of Fires
Fires are classified into four types:
Class A: Fires generally combustible e.g. wood, paper, cloth or rubbish is usually controlled by
cooling e.g. using water to cool the material.
Class B: Fires generally liquids e.g. gasoline, oil, grease, paint are usually smothered by oxygen
control – using foam, carbon dioxide, or dry chemical.
Class C: Fires due to gases such as Methane, Ethane, LPG, Acetylene, are usually smothered by
dry powder & CO2.
Class D: Fires erupt due to combustible elements such as magnesium, lithium or sodium and
require special extinguishers and techniques.

4.3.4 How to Prevent Fire
• Know where fire extinguishers are kept?
• What each is for and how to use them?
• Maintain a neat, clean work area and prevent accumulation of rubbish?
• Put oil-soaked and paint-soaked rags in covered metal containers.
• Observe all “no-smoking” signs.
• Keep fire doors, exits, stairs, aisles, fire lanes and fire fighting equipment clear of
obstruction.
• Keep all flammable materials away from furnaces and other sources of ignition.
• Report any fire hazards that are beyond your control, especially electrical hazards, which is
the source of many fires.
• Store combustible materials in safe area.
• Remove combustible materials and fumes from paint, solvents and other flammables.
• If you should have to burn waste paper, make sure it doesn’t contain explosive materials
such as aerosol or paint cans.
• Proper maintenance procedures are important to fire safety.
• Keep mechanical equipment properly lubricated to avoid excessive friction.
• Ensure heater used in the workplace is away from flammable materials and cannot be tipped
over.
Figure 4.8 Fire brigade vehicle uses during firing for water showering

4.3.5 Leading Causes of Industrial Fires
• Electrical failure
• Friction
• Foreign substances
• Open flames
• Smoking Matches
4.3.6 How to React the Fires
• Set off the alarm
• Leave the area if the fire is too big to handle
• Deal with a small fire
• Know your fire exits
• When leaving, crawl on your hands and knees to the exits
• Fire fighter specialist person
• Proper use of fire fighting equipments
• Proper use of safety equipments
• Use non combust able clothes and face protection sheets
Figure 4.9 Fire fighters during operation

4.3.7 FIREFIGHTING TECHNIQUES
Generally we use water which has the primary effect of cooling the fuel.
This describes techniques used when water is scarce, and use of water is not possible.
Track crews also work on the other two sides of the fire triangle, removing air (smother) or fuel
(clearing) to control fire.
Effectiveness depends greatly on hard work, diligence and experience.
4.3.8 Fire fighting tools
Equipments that are use in fire fighting techniques are:
• Shovel: Beating, Digging, Scraping, Throwing soil.
• Slasher: Cutting light fuels for tracks.
• Fire rake: Scraping tools with serrated cutting edge used for removing surface fuels.
• Safe Handling of Tools: Carry tools at waist level, blade forward Keep 3 meters apart
when carrying or using pass tools handle first
• Water showering pump: Use to control the intensity of fire by water
• Fire brigade vehicle: for transfer of water quickly to the affected area

Figure 4.10 Fire Controlling equipments like nozzles to increase the velocity of water
4.4 WORK PERMIT
Work Permit Analyzing of work place and possible hazards during work and taking safety
measures and to describe procedures and guidelines on work permit system to carry out jobs of
inspection, testing, maintenance, alternation, repair, construction in safest possible manner. The
implementation of this system will help in bring down the risks at work sites to acceptable level,
thereby reducing possibility of any accident, fire, explosion, property damage and adverse effect on
environment.
4.4.1 Work That Requires Permit:
Normally all maintenance, repair, construction work shall be carried out with a proper work permit.
Jobs where work permit is required include but not limited to followings:
• Major and minor maintenance work
• Inspection
• Construction
• Any hot work (including use of normal battery driven equipment in operating areas)
• Cleaning activities of process equipment
• Entry into confined space
• Excavation
• Vehicle entry into process areas
• Work at height
• Handling of materials using mechanized means in operating areas • Isolation of electric
equipment/ facilities.
4.4.2 Types of work permit
There are so many types of work require Permit some of them are describing below:
4.4.2.1 Hot Work:
An activity that can produce a spark or flame or other source of ignition having sufficient energy to
cause ignition, where the potential for flammable vapors, gases, or dust exists This includes all

works, which produces spark, running of IC engine, breaking of concrete, use of ordinary torches,
use of battery operated devices etc are considered as hot work permit
4.4.2.2 Confined Space:
It is an enclosure with known potential hazards and restricted means of entrance and exit. It is not
meant for normal occupancy of people and is usually not well ventilated such as vessels, boilers,
storage tanks, large diameter piping etc. The excavation more than 1.2 m deep, entry into floating
roof tanks, when roof is more than 3m down from the top, space located below ground level such as
pits, drain channels etc shall also be considered as confined space. Proper ventilation and lighting
provided: Where natural ventilation is not available, fans / air educators are provided. These are
also required for speedy dispersal of fumes generated by welding job. Only approved reduced
voltage extension lights (not exceeding 24 volts) are to be allowed for work inside confined space
from consideration of personal safety.
Figure 4.11 Workers work in Confined Space

4.4.2.3 Hot work / Entry in to Confined Space Permit and clearances:
Hot Work Permit is required for carrying out any activity, which produces sufficient heat to cause
fire in a inflammable air- vapor mixture. Entry to Confined Space Permit is required for entry into
any confined space.
Shield against sparks provided: Hot works like welding, grinding etc generates sparks, which can
provide source of ignition to the surroundings. In order to protect operating area from the hazards
of sparks generated, shields are to be provided to contain the sparks generated. The shield material
shall be non-flammable and should be kept wet with water.
Proper means of exit provided: Proper means of exit is required in case of emergencies developed
on account of the work or otherwise. Availability of an alternate route of escape should be
considered. r. Area cordoned off and caution boards provided: To prevent any unwarranted entry in
the work area and also to caution other personnel taking actions which may endanger people
working on the permit job, precautionary tags / boards are to be provided to display like "No Entry"
sign on roads or "Caution - Men at Work Inside" on the manhole of a vessel, "Danger -
Radiography in progress" etc.

Figure 4.12 Hot work is doing in a Confined Space
4.4.2.4 Cold Work:
Cold Work is an activity that does not produce sufficient heat to ignite a flammable air-
hydrocarbon mixture or a flammable substance. Or cold work permit is an activity of doing work
on non combust able materials like wood work cleaning activities.
4.4.2.5 Working at Height:
Any activity that is carried out at 2.meters & above on temporary structure, scaffolds or on a
structure not meant to do particular job safely. The erection of any tubular scaffold shall not begin
before the checking of scaffold material at site (w.r.t quality and quantity), preparations at site,
availability of PPE, and availability of trained personnel for erection etc. in prescribed format on
“Pre Erection Checklist for Scaffold”. The requirements of checklist must be complied before start
of erection of scaffold at site. This check-list shall be filled up in duplicate. The original shall be
retained by executer and 1st copy with issuer (area in-charge).
All scaffolds after erection must be checked and certified in prescribed form by scaffold
supervisor and Officer of executing Dept.
Precautions during work at height
• All roof-work operations should be pre-planned and properly supervised.
• Roof work shall only be undertaken by workers who are physically and psychologically fit
and have the necessary knowledge and experience for such work.
• Work on roofs shall not be carried on in weather conditions that threaten the safety of
workers. .
• Where it is necessary for a person to kneel or crouch near the edge of the roof, necessary
precautions shall be taken.
• On a large roof where works have to be carried out at or near the edge, a simple barrier
consisting of crossed scaffold tubes supporting a tubing guardrail may be provided. For
detail refer Standard on “Working at Height”.

• All covers for openings in roofs shall be of substantial construction and be secured in
4.4.2.6 CONDITIONS FOR HOT AND COLD WORK
YES
• Ensure the availability of valid work permit before start of work.
• Ensure that work permit conditions are fully complied at site.
• Ensure that walkways and passages are free from all slip/ trip and fall hazard.
• Ensure proper illumination of work place while working in dark.
• Executor should ensure the quality of hand tools and their health.
• Always first wedge open the flanges.
• Use of proper PPE must be ensured during
NO
• Never stand or work under suspended loads.
• Never enter work area without safety helmet and shoe.
• Do not wear loose/ synthetic cloths while on work
• Do not use short cuts on work
• Do not use lamp of more than 24 V while working in confined space.
• Do not run a machine without putting back the guard on its exposed moving part.
• Do not use short cuts on work
• Do not give any other responsibility to stand by person, which may cause his absence at
many ways

4.5 INDUSTRIAL ACCIDENTS
Industrial accidents are an accident which appears suddenly during working in industries and cause
Unexpected & unwanted event and Occurrence of incident causing bodily injury to a person
making unfit for further work
4.5.1 Nature of Accidents:
• Nature of accidents vary from industry to industry
• An employee may be caught by machine
• An employee may fall against a machine
• An employee may fall from height
• An employee may expose to an explosive
• All these may lead to Disablement or Death
Disablement
• Loss of Ability to work or move
• This situation may be temporary or permanent
• Temporary disablement is of temporary nature
• Permanent Disablement is of permanent nature
• Certain accidents may result in permanent disablement like:
• Loss of both hands
• Loss of a hand and a foot

• Loss of Eyes
• Very severe face disfigurement
• Absolute deafness
4.5.2 OCCUPATIONAL HAZARD:
Occupational hazards are Source or situation with a potential for harm in terms of injury or ill
health, damage to property, damage to the workplace environment, or a combination of these all
unwanted events are known as occupational hazards.
4.5.3 TYPES OF OCCUPATIONAL HEALTH HAZARDS
1. Physical
2. Chemical
3. Biological
4. Mechanical
5. Psychosocial
4.5.3.1 PHYSICAL HAZARDS
Physical hazards Are accurse because of physical disturbance Surrounding conditions like:
• Heat: Heat Exhaustion, Heat Cramps, burns, Prickly heat.
• Cold: Frost bite,
• Light: Occupational Cataract, High intensity of light can damage the eyes
• Noise: Occupational deafness,
• Radiation: Cancer, Leukemia, anemia, Electricity - Burns, Shocks,
4.5.3.2 CHEMICAL HAZARDS
Chemical hazards are those hazards which accurse due to Chemicals and Environmental pollution
the main source of chemical hazard are Routes of entry Inhalation, Ingestion, skin absorption.
(Inhalation is the main route of entry)
Chemical agents can be classified into:
• Metals: Lead, TEL, As, Hg, Cd, Ni, Co etc.
• Aromatic: Hydrocarbons - Benzene, Toluene, phenol etc.

• Gases: N2, CH4, CO2, CO, H2S, HCN
• Dust: Inorganic Dust: Coal, Dust, Silica, Asbestos
Organic Dusts: Cane Fiber, Cotton dust (In Textile industries),
Tobacco and Grain Dust
4.5.3.3 BIOLOGICAL HAZARDS
Biological hazard are those types of hazards which cause by the inhalation of poisonous air or by
the affect of biological bacteria or viruses.
• Bacteria
• Virus
• Protozoa & Parasitic
• Fungi
4.5.3.4 MECHANICAL HAZARDS
Mechanical hazards are those types of hazards which cause due to mechanical injuries or falling,
striking like
• Injuries: Falls, cuts, abrasions, concussions, contusions, etc.
• Ergonomic: Disorders-Musculo-skeletal, disorders (MSDs), Cumulative-trauma-
Disorders (CTDs) Ergonomics: ``Adjustment of Man & Machine``
Application of human biological sciences with engineering science to achieve optimum
mutual adjustment of man & his work, the benefit being measured in terms of human
efficiency and well being
• Back Injuries due to Manual Handling:
All forces which come down the spine compresses discs and as a result of Continuous
squeezing they can rupture and bulge causing severe pain. Most back injuries are built over
along period of time by repetitive pounding on discs caused by improper methods. After
sometime some minor lift can produce such rupture
4.5.3.5 PSYCHOSOCIAL HAZARDS
• Lack of job satisfaction

• Insecurity
• Poor interpersonal relations
• Work pressure
• behavioral changes (aggressiveness, depression)
• Psychosomatic disorders (Hypertension, headache, body-ache )
4.6 SAFELY WORK WITH FALAMMABLE
AND COMBUSTIBLE
In oil refineries there is maximum chance combustion because oil is very combustible material.
This topic describes general safe work practices to use where flammable and combustible liquids
are used or stored. The document "Flammable and Combustible Liquids and their Hazards"
describes the hazards of these liquids more fully. Another document deals with safety issues related
to static electricity, bonding and grounding containers.
4.6.1 Ignition Sources
For a flammable or combustible liquid fire to start, a mixture of vapors and air must be ignited.
There are many possible ignition sources:
• Sparks from electrical tools and equipment.
• Sparks, arcs and hot metal surfaces from welding and cutting.
• Tobacco smoking.
• Sparks from grinding and crushing operations.
• Sparks caused by static electricity from rotating belts, mixing operations or improper
transfer of flammable or hot combustible liquids.
4.6.2 Eliminate Ignition source
• You can eliminate many of these ignition sources by:
• Removing open flames and spark-producing equipment.
• Not smoking around these liquids.

• Using approved explosion-proof equipment in hazardous areas.
4.6.3 What is spontaneous combustion?
Spontaneous combustion occurs when a material in contact with air can heat up sufficiently
(without an outside heat source) to burn. The oils in some wastes and rubbish can slowly react with
oxygen in the air. This reaction creates heat that can build up over time if the wastes are left
undisturbed.
When the heat level in a "self-heating material" is high enough when the temperature reaches the
auto ignition temperature a fire may start.
4.6.4 Why Is Good Ventilation Important?
Well-designed and maintained ventilation systems remove flammable vapors’ from the workplace
and reduce the risk of fire and health problems.
The amount and type of ventilation needed to minimize the hazards of flammable and combustible
liquid vapors’ depend on such things as the kind of job, the kind and amount of materials used, and
the size and layout of the work area.
4.6.5 Flammable and Combustible Liquid Containers Storage
Store flammable and combustible liquids according to the laws, including building, fire, and
electrical codes, that apply to your particular workplace. These laws specify the kinds of storage
areas, such as storage rooms and cabinets, allowed for these liquids. They also specify how to
construct these storage areas and the amounts of flammable and combustible liquids in different
types of containers that you can store in each kind of storage area. There may also be restrictions
about the volume (how much) of product that can be stored. Never use plastic or glass containers
for storing flammable liquids unless storage in metal containers would affect the required liquid
purity or if the liquid would cause excessive corrosion of the metal container.
In all cases, allow only trained, authorized people into storage areas. Before storing, inspect all
incoming containers to ensure that they are not damaged and are properly labeled. Do not accept
delivery of defective containers. Keep containers closed when not in use.
4.6.6 Good Storage Area

Storage of flammable and combustible liquids can be stores in specific areas that are:
• Well ventilated to reduce vapors concentrations.
• Free of ignition sources.
• Cool (temperature controlled) and dry.
• Supplied with adequate firefighting and spill clean-up equipment.
• Away from elevators, building and room exits, or main aisles leading to exits.
• Accessible by firefighters.
• Labeled with suitable warning signs. For example: "No Smoking".
4.6.7 Proper Deal with Combustible Fuel
Avoid storing flammable and combustible liquids in basements. Ground floor storage is usually
preferred as it provides easier access for emergency situations. Inspect storage areas regularly for
any deficiencies such as damaged or leaking containers, poor ventilation or non-approved
equipment. Unapproved modifications or damage to approve or explosion-proof equipment or
systems could result in unintended hazardous conditions. Correct all deficiencies as soon as
possible.
Many workplaces receive flammable liquids in large metal drums or barrels, and then fill smaller
containers from them. Moving full drums weighing hundreds of pounds by hand can be difficult
and hazardous. Specially designed drum cradles are available for moving drums around and can
also be used as individual drum storage racks. Check all containers used for flammable and
combustible liquids regularly to make sure that they are not damaged, that spring-operated
mechanisms are working properly and that flame arresters are not broken. Safety container
manufacturers will provide detailed ways to inspect their equipment for safe operation
Following these basic safe practices will help protect you from the hazards of flammable and
combustible liquids:
• Obtain and read the Material Safety Data Sheets (MSDSs) for all of the materials you work
with.
• Be aware of all of the hazards (fire/explosion, health, chemical reactivity) of the materials you
work with.

• Know which of the materials that you work with flammable or combustible liquids are.
• Eliminate ignition sources (sparks, smoking, flames, hot surfaces) when working with
flammable and combustible liquids.
• Use the smallest amount of flammable liquid necessary in the work area.
• Keep storage areas cool and dry.
• Store flammable and combustible liquids away from incompatible materials
CHAPTER NO 5
EXPERIMENTAL WORK AND DISDUSSION ON REDULTS
5.1 SURVEY OF NATIONAL OIL REFINERIES
Before conducting experimental analyzing program our group of students visit at National Oil
Refineries with our field supervisor Engr: Hafiz Waseem Sahib. During survey we observe that
NRL is very clean and less pollutant than other plants like Thermal power station Jamshoro. Their
security management is very active, In NRL workers and Engineers are well qualified and
responsible person. Engr Majid Chemical engineer and Mr.Rasheed sahib Fire fighter specialist
gave brief lecture about their specific field. We observe that there are many Safety Signs and
symbols are displayed on every where for the awareness of common peoples. Good alarm system
and proper maintained Personal protective equipment shows that there is a proper management of
Occupational health and safety system.
5.1.1 RESEARCH METHODOLOGY
In NRL we went through the various methods, which were beneficial for us in sense of maintaining
the data in the proper manners, by conducting surveys interviews and question answers.
We have observe various types of activities which were happening in NRL for the betterment of the
employees as well as for proper working and maintains of the machineries and we also conduct the

interview of HSE department person named Mr. Rasheed, who have gives us knowledge about the
HSE department and how they over come on the accidents cause due the operations.
During the survey of the environment of the HSE department of NRL we discuss about the
different quires of the operations, which help us to compile the data. We observe the different types
of barications in different colors, about which we ask quires from the employees of HSE
department. We also get information from about the different PPE being used according to the
nature of work.
5.1.2 RESEARCH PLANE
Six-month work was planed for this study in which our respectable teacher support us from the core
of heart and work trough out the half our year our occupational health and safety. Monday was
declared as the thesis day and enhance the work this option was the great opportunity the all the
members of group get together and discuss regarding to the academic as well as the assigned thesis
topic. Digital lab was specially kept maintain for the final year students that they can sort out
problems and then reserve them after regular classes and at Monday from 9am to 3pm.
5.1.3 LIMITATION
In order to compile these case studies we have faced no of stages during those days where we
engaged to analyze the situation regarding to occupational health and safety and were maintaining
the data, we find the concerned peoples frank, intellectual and technically sound. The time assigned
us by NRL was not the bed of roses because at that time thee was the worst law and order condition
in Karachi, which become the headache for us and we were considering us safe and séance.
Sometime it happens that we have to sacrifice our previous day that was fixed for the visit/survey
and the auditing in those days was cause interruption and barriers for us but we try our level best to
the make the most of our time and finally get the fruit of efforts.
5.1.4 Instruments Used to Analyzing HSE Parameters
For the quantification and measurement, various types of instrument used to get HSE data. Which
were reliable, durable and easy to operate. Instruments play vital role in HSE in expects of reducing
the over all ratio of the accidents. By using instruments over all efficiency of the plant is improved
and any type of the query which comes in the way of operations will be control through by using
instruments. If any type of big accidence occur it will definitely directly effects on the people as
well as on industry and also effect on the over all production of the functions.

Following are the main instruments use in the HSE department of NRL.
• Flow gas analyzer
• COD meter
• BOD meter
• PH meter
• Leak detector
• Lux meter, Etc.
5.1.5 TESTING PARAMETERS
During testing we analyze different parameters at NRL that are
• NOISE LEVEL
• STACKS GASOUS EMISSION
• WASTE WATER EFFLUENT
• VOLATILE ORGANIC COMPOUNDS
• AMBIENT AIR
• ACCIDENTS/INCIDENTS IN

5.2.1 NOISE LEVEL
In National Oil Refineries we determine the noise level from different places like lube 1 refinery,
Lube 2 refinery, fuel refinery, near to boiler R.O plant and open area of NRL by using Noise meter
and observe that noise level varies from place to place. The highest level of noise is in turbine hall,
where due to rotation of moving parts of turbine high level of noise is produced that shown in table
4.1, it is also observe that the open area of NRL is less noisy than the area near to machine.
According to NEQS standers the noise level does not exceed from 85 d BA and near the machines
the noise level is greater than 85 dBA and open area and workshops are less noisy the level of noise
is less then 85 dBA. The noise can be reduced by proper covering of machines and proper
lubrication of machine. We classified table of noise level into two categories one is high noise level
and other is less noise level table. The noise level is shown in table 4.1 and 4.2.
Table 5.1 High Noise Level of working area near the Machines
S.NO Area and Equipments Noise Level
01 LUBE 1 REFINERY 88.9 to 98.3
02 FUEL REFINERY 80.1 to 98.5
03 LUBE 2 REFINERY 90.4 to 93.5
04 BOILER IV 89.6
05 BOILER V
NOT IN OPERATION
06 BOILER VI 90.3
07 BOILER VII 92.1
08 TUBBINE HALL 102.2
09 182 WHITE PRODUCT PUMP 90.3

Table 5.2 Low Noise Level in open area and working places away from heavy machines
S.NO Area and Equipments Noise Level
01 R.O PLANT 77.5
02 FABRICATION YARD 69.2
03 WORK SHOP HALL 78.5
04 MAIN OPEN AREA 61.4
05 OPEN AREA LUBE 2 63.6
06 LAB HALL 76.4
07 FLASH ROOM 65.1
08 DISTILLATION ROOM 68.3
09 MAIN GATE NRL 76.1
10 GATE C, NRL 79.4
11 SHIPPING II OFFICE 62.0
5.2.1.1 Time Duration and Noise Level
The time duration of work depend on the noise level if the noise level is increase than the time
exposure will decrease and we know that ear protectors or noise level reduction equipments are not
able to control 100% noise, they just reduce the noise level according to their capability so at highly
noisy working place the time duration of work must be lesser than normal working place. Noise
level with time duration table is shown below:
Table 5.3 Time duration with Noise Level
Sound Level (dBA) Exposure (hours)
90 8
92 6
95 4
100 2
105 1
110 0.5
115 0.25

Figure 5.1 Graphical representation of Noise Variation and compared with NEQs
5.2.2 STACKS GASOUS EMISSION
In National Oil Refinery we observe there is good control mechanism of flu gas emission because
the Level of stack gases are not exceed the NEQs standers that shown in table 4.4 and 4.5 The
amounts of Particulate matters are less and under NEQs limits. The overall environment of NRL is
safer and clean we can observe in observation table. In NRL the amount of stacks gaseous emission
is lower then the NEQs limits that show that the environment of the working area of NRL is non
pollutant safe. In figure 4.2 the difference between NEQs limits and stacks particulates emissions is
clearly show the amount of PM is controllable. The results of gaseous emission and stacks
particulate matters are as under:
Table 5.4 Determination of Stacks gaseous emission in National Oil Refineries

S NO. Reference Point
SO2
mg / nm²
CO
mg / nm²
NOx
mg / nm²
H2S
mg / nm²

NEQS Limits 1700 800 400 10
01 BOILER IV 0 14 230 0
02 BOILER V NOT IN OPERATION
03 BOILER VI 0 11 264 0
04 BOILER VII 0 26 39 0
05 POWER GENERATION 0 713 314 0
06 FUEL REFINERY 0 02 127 0
07 103F -05 0 03 199 0
08 LUBE 1 108 220 111 7
09 LUBE 2 0 91 65 0
Table 5.6 Determination of Stacks Particulate matters emission in NRL
S NO. Reference Point
PM
mg / nm²
NEQS Limits
mg / nm²
01 BOILER IV 03
300
02 BOILER V 05
03 BOILER VI 05
04 BOILER VII 09
05 POWER GENERATION 43
06 FUEL REFINERY 03
07 103F -05 02
08 LUBE 1 08
09 LUBE 2 06
Figure 5.2 Graphical comparison of stacks Particulate matters emission with NEQs

Table 5.7 Ambient Air Quality of different area of National Oil Refineries
S. No REFERENCE POINT
CO
mg /Nm3
SO2
mg / Nm3
NOx
mg / Nm3
H2O
mg /N m3
01
BETWEEN TURBINE AND
OFFICE
- 0.5 1.3 0
02 NEAR WARE HOUSE - 0.2 4.3 0
03 RECYCLE MEMBRANE - - 3.1 0
04 INSIDE THE PLANT - - 3.9 0
05 NEAR MAIN GATE - - 4.2 0
Table 5.8 Ambient Particulates Matters Monitoring in National Oil Refineries
S. No REFERENCE POINT P M
mg /N m3
01 BETWEEN TURBINE AND OFFICE 17.7
02 NEAR WARE HOUSE 22.1
03 RECYCLE MEMBRANE 24.8
04 INSIDE THE PLANT 18.2
05 NEAR MAIN GATE 62.8
5.2.3 WASTE WATER EFFLUENT

All analytical or experimental work was done in National Oil Refineries lab and sample of waste
water was taken from waste effluent from National oil Refineries. In waste water effluent the
amount of pH is under NEQs standers Total dissolved solids are also in limited amount, other
parameters like COD, BOD, and TSS are also less than the amount/value that is given by NEQs.
The proper values of Biological Oxygen Demand (BOD) and Chemical Oxygen Demand (COD)
and other parameters are determined and shown in table 4.8 that table shoes that the quality of
waste water is under control and that is not too much pollutant and harmful for workers as well as
environment. The result of waste water effluent shows that the amount of impurities is under the
limits of NEQs.
Table 5.9 Determination of amount of particles in waste effluent
S.No. Parameter
Lab Test
Result
NEQS Limiting
Value
1 TEMPRETURE℃
32
≤ 3℃
2 PH@ 25
8.1 6-9
3 Total Dissolved Solid (TDS) mg/l
2725 3500
4 Chemical Oxygen Demand (COD) mg/l 322.7 400
5 Biochemical Oxygen Demand (BOD) mg/l 88.4 200
6 Total Suspended Solids (TSS)mg/l 54 200
7 Lead mg/l 0 0.5
8 Oil & Grease mg/l 8.5 10
9 Phenolic Compounds as Phenol mg/l 0.05 0.3
Figure 5.3 Temperature value of NRL with compared with NEQs

Figure 5.4 Amount of Total Dissolved solids of NRL compared with NEQs
Figure 5.5 Values of COD, BOD and TDS in NRL compared with NEQs

Figure 5.6 Value of Grease and Oil in NRL compared with NEQs
5.2.4 VOLATILE ORGANIC COMPOUNDS

Volatile organic compounds are toxic in nature and harmful for human being, the amount of
hydrogen sulphide and volatile organic compounds, they are found in negligible amount in NRL at
one or two places but overall condition of Volatile Organic Compounds are sustainable and do not
create pollution. In NRL the amount of VOCs are not in abundant that cause illness or nay be
harmful for human beings. The amount of VOCs and the area where they are present are shown in
table 4.9
Table 5.10 Determination of VOCs and H2S inside the refinery
5.2.5 ACCIDENTS/INCIDENTS IN NRL

After analyzing different parameters related to Health and Safety finally we collect the information
about accidents/incidents occur in National Oil Refineries. The overall Health Safety conditions are
satisfactory ands the management of NRL is sincere to provide a safer work place to workers and to
minimize the accidents and losses. According to NRL monthly accidents/incident report about 24
incidents have been accrued and there is no loss time injury that shows that the magnitudes of
incidents are not much higher that causes injuries. Table 4.10 shows the number of incidents in
NRL month
Table 5.11 Month wise status of incidents and loss time injuries in National Oil Refineries
MONTH INCIDENTS LOSS TIME INJURY
JANUARY 2011 NIL NIL
FEBRUARY 2011 01 NIL
MARCH 2011 07 NIL
APRIL 2011 NIL NIL
MAY 2011 02 NIL
JUNE 2011 03 NIL
JULY 2011 07* NIL
AUGUST 2011 04 NIL
YEAR TO DATE
TOTAL
24 NIL
*LUBE 1 Refinery
Figure 5.7 Graphical Representation of monthly number of incidents in NRL

*INCIDENT:
An incident is an unplanned, undesired event that adversely affects of tasks.
*ACCIDENT:
An Accident is an undesired event that results in personal injury or property damage
*LOSS TIME INJURY:
If any NRL employee on duty an on the job accident, which render the employee
medically unfit to resume hid duty during next 24 hours is considered as to be loss time
injury
CHAPTER NO 6

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