BPCL

Kochi Refinery, the safest place to work

BPCL-KR has achieved a safety milestone of 70 million man hours without any lost time accident (equivalent to 5579 days, i.e. fifteen years, three months and 10 days) on 09 April 2021.

BPCL believes that employee wellness is the key factor of a successful workplace. At Kochi Refinery, Health Safety and Environment are of paramount importance and result in ensuring sustainable, responsible and successful operations. Safety is effusively embedded in our culture with the motto of ‘Safety First – Safety Must’. The four pillars for this safety achievements are: a consummate safety management system, an astute implementation strategy, a self-driven top management for unconditional support and a passionate safety culture prevalent in the organization.

The Safety standards and systems are well documented in the Refinery Operating Systems (ROS), a collection of system procedures which are to be adhered to for carrying out any operations within the refinery. The QEHS Policy provides guidance to maintain a productive & safe workplace. Measures are taken to minimize the risk of accidents, injury and exposure to health hazards for all employees, contractors, customers and the communities in which it operates, while having a target of zero occupational incidents.

Processes used in the refinery are made inherently safe by virtue of extensive HAZOP studies and Risk analysis carried out prior to their implementation. Any process change is carried only through well- defined MOC.

All the plants operate on advanced Digital control with built in safety systems. HAZOP studies have been done for all process areas, process units are SIL compliant and critical equipment are operated always within their IOW and critically monitored.

After the implementation of the 20 element International Safety Rating System (ISRS) during 2003-05 period, the Safety systems got a major uplift in terms of standardization and KR could achieve 9 out of 10 rating in almost all the elements. Process Safety Management is also diligently followed in Kochi Refinery. Safety audits form an integral part of the Safety success story, with impeccable record of 100 % completion of all the safety audit recommendations continuously over the last 6 years.

The Emergency response and disaster management plan certified by PNGRB is fully evolved and on-line portal for the same is in place. Kochi Refinery is equipped with three State of the art Fire stations with a host of modern firefighting equipment, fire tenders (including HAZMAT truck, BRONTO Skylift) and a well trained work force is kept set for responding to all emergency scenarios in operating areas. Safety & Fire- fighting trainings are an integral part of keeping our workforce set for any eventualities.