NLPG PLANT EDOC AUDIT SAFETY CORRECTIVE ACTION PLAN
CHAPTER TITLE REMARKS
PRV SETTING
GENERAL SITE LAYOUT
DOCUMENTATION, TRAINING AND PROCEDURES
LPG TANK DRAIN PROCEDURE
MAP OF EXPLOSION HAZARD ZONES
SAFETY EQUIPMENT, MONITORING, INSPECTION TESTS, LIST OF EQUIPMENT ESSENTIAL FOR
MAINTENANCE SAFETY
ACCESS FENCES LIGHTING TRUCKS CONTROL
GAS DETECTORS
FIRE DETECTORS
UNLOADING HOSES CONNECTING
DEVICES
TRUCK TRAQNSFER STATION,TANKS, PUMP SYSTEM, CYLINDER
FILLING
UNLOADING HOSES
BREAK AWAY COUPLINGS
AUTOMATIC CUT OFF VALVES
DRAIN OF THE HOSES
FLANGE POSITIONS
AUTOMATIC CUT OFF VALVES POSITION tanks
LPG STORAGE UNITS
CONTINOUS MEASUREMENT SYSTEM
TANK MANUFACTURER'S PLATE
GANGWAYS
IDENTIFICATION OF PHASE, NATURE
AND DIRECTION OF PRODUCT
PIPING
CRITICALITY CORRECTIVE ACTION STATUS RESPONSIBILITY TIME FRAME COMMENTS
The PRV are set to 16 bars
X Verify the opening pressure setting of the PRV; this pressure must not
exceed the saturated vapor pressure of the product stored in the tank at
the maximum design temperature.
WIP - Contractor
X awarded works.
Awaiting
It is not visible Has to be displayed outside the office templates
WIP - Contractor
X awarded works.
Awaiting
It is not displayed in the field Show the procedure posted near the area where the operation is done. templates
WIP - Contractor
X awarded works.
Awaiting
To be modified indications of Zone 0s The actual identification of Zone 0 has to chasnge to Zone 1 templates
The essential safety equipment must be separated from the process
X
equipments. This list has to be exhaustive enough and a procedure
The list of equipment essential for safety is describing the inspection to be conducted and the results has to be
mixed with the operational equipment available.
The control of the trucks has to be more strong eg not allow enrtry of
There is a safe to load checklist but the X trucks that has changed the lighting system which does not agree with
control is not exhaustive safety regulations, bulk bridging trucks with incorrect tire size
PO issued to
oldham agent.
The gas detectors were installed long time XX Due to
ago,since they were installed thet are not Situation to be followed with the assistance of OMM - LPG to solve the commence
working problem trouble shooting
Fire detectors on
X
There is no fire detection system in place Fire detectors to be installed in this areas order
Completed.
Flange type connectors are used,these type Awaiting
XXX
of connections are no longer permitted in The loading area must have a standardized connection equipment to standardisation
Total AMO sites ensure the safety of connection and disconnection operations of trucks
The location of the connection points of the There is a project for installing loading arms.in this case attention must br
trucks are not uniform, in order to reach all paid to the situation of the connection position of the trucks, which has to
the truck connections, the LPG hose has to be standardized in all of the trucks, as well as standardization of thetruck's
be very long (12m). The hoses are weak XXX connection system.
points in case of a rupture , the amount of Awaiting
product released to the atmosphere will be standardisation
serious. of trucks
The maximum drive away angle of the hose has to be 90 degrees. The
The position of the BAC is ok,but due to the length of the hose should be reduced.
length of the hoses in case of departure of
the truck without disconnecting the hoses, XXX Awaiting
the force will not be applied to the standardisation
breakaway coupling of trucks
There are no automatic cut off valves XX At least the liquid phase of the gas must be equipped with an automatic
installed in the offloading area cut off valve and it is recommended to install it in the gas phse Completed
The loding/ offloading hose remains with Ensure by procedure that the liquid is flushed out before clsing operations
liquid during the day. XX at the end of the day to avoid the possibility of having a rupture of the
hoses due to a full hydraulic Completed
The flanges must not make a risk of ignited joint leaksthat may impinge on
Some flanges are in aposition in which if the tank directly(it must be for example fitted with an appropriate
X
there is a leak, the impact of the leak will be orientation or be fitted with a detector in case of existing wrongly oriented
directed towards the tank's shell flanges)
Some of the automatic cut off valves are
not mounted in the first flanged of the X Awaiting next
To be relocated at the next re-test of the tanks tank outage
Proposed to
change to
reliable Enraf
The site has a very good measurement X servo motor
system(radar system), but there are doubts system in Capex
to the accuracy of measurements Check the accuracy of the measurements (calibration equipments) 2017
The manufacturer's plate are painted, Plates with the equipment information must not be painted, the
X
information is not visible information should remain visible
Access to the safety valves in tank 1 and 2 is Scoping in
X
not possible, there are no gangways In tanks 1 and 2, the gangways have to be extended to the safety valves progress
Not indicated in the piping at the top of the
X
tanks To be indicated at the piping at the top of the tank

THERMAL RELIEF VALVES
PIPING
SANDWICH TYPE WITH LONG
THREADED BAR EQUIPMENTS
CYLINDER FILLING
AUTOMATIC CUT OFF VALVES
FIRE FRILLS
PLACE OF STORAGE OF THE SUITS
SITE SHUTDOWN
WATER PUMP
DELIVERY RATE OF 7 L/ M2/MIN
ACCORDING TO STANDARD
ADJUSTABLE STATIONARY NOZZLES
LPG PUMP SPRINKLER SYSTEM
FIRE FIGHTING INSTALLATIONS
BACK UP WATER PUMP
SECTIONING VALVES
SPRINKLER SYTEM IN TRUCK
UNLOADING AREA
WHEEL CHOCKS
other points
CYLINDER VENTILATION
DRAIN LPG TANK OPERATIONS
Some thermal relief valves are not located
in a safe clear xone
There is a check valve with long threaadeds
on the outside (sandwich type). This type of
equipment is not allowed in LPG
installation.
There is no ESD - cut off device in the liquid
arrival to the filling hall
The site is not suitable, very small and with
steps to access (taking to account that in an
emergency the brigade must reachthe site
quickly to take the suits
The pump start up is manual
With current facilities, fire protection
system is not able to deliver a flow of 7
l/m2/min and cover the worst case scenario
There are no adjustable nozzles to reach the
tanks
The LPG p-ump system is not equipped with
stationary means of protections (sprinklers)
There is no back up water pump
The sectioning valves for the fire fighting
are too close to the tanks
The sprinkler system in the truck unloading
area appears to not comply with the
standard (sprinklers seem to be very
highand seem not to have thebest water
spray angle)
Wheel chocks not standard
Cylinder trucks without adequate
ventilation
The frequency of drain operations in the
tank is 48/year
X
Relocate the TRV in a safe cleared sone (eg no obstacle within 1 metre)
X
Replacements on
Change this type of equipment by a not exposed long threaded bars. order
Valve ordered.
X Installation in
Install an ESD cut off device in the liquid arrival to the filling hall progress
X
Evaluate the relocation of the equipment in a more suitable place
The fire fighting pump has to be started automatically, water in the tank
X
has to be available in less than 1 minute
A review of the entire fire protection system including the possibility of
XX
moving yhe water storage tank and the inclusion of an additional position
for unloading trucks and one for railways is currently in process
A project to upgrade the systems to be inline with the standard and cover
X
the worst case scenario is in progress
X
A sprinkler system must be installed in the area of the LPG pumps
The system has to be designed with a back up pump (worst case flow rate
XX
ensured with N-1)
A project to upgrade the systems to be inline with the standard and cover
X
the worst case scenario is in progress
X
This situation should be considered as partof the upgrade of the DCI of the
site
X Wheel chokes should be standardized
The ventilation of these trucks must be improved to prevent the
X
accumulation of LPG in the interior in case of leakage in the cylinder
Evalauate the possibility of reducing the number of drain operations, to
XX reduce the possibility of BLEVE scenario in the DIRSEC 8 risk matrix