Page 13 - Flip IOCL Book.cdr

Recommendations

SOP & SMP of crane operation and maintenance to be developed, which should clearly indicate the area
designated for maintenance of crane and parameters / checklist required for crane entry inside battery area.
Maintenance of heavy equipments inside the plant should strictly be avoided.

2. Any maintenance job on crane boom has not to be carried out below the angle of hydraulic cut off
(e.g. 30 degree for this case) with zero counter weight.
If at all such activities like greasing etc to be performed for boom maintenance, then following precautions
to be taken:
2.1 Counter weight to be provided as per boom extension in line with load chart.

2.2 Lowering down the crane hook along with wire ropes (including the wire rope length required for boom
extension) to the ground level.

2.3 Safe load indicator (SLI) not to be bypassed during lifting and lowering the load. In case SLI need to be
bypassed for boom maintenance related activities, then the same has to be done through approved SOP.

2.4 Regular training (preferably bi-monthly) in this regard to be given to heavy equipments operator
covering the behavioral safety aspect.

Case 10 Date: 23.07.2019 Time: 12:30 hrs.

Incident

In PNC- Gantry Benzene loading was started in tanker GJ12AZ7081 through Auto loading system. Upon receipt
of around 40kg material in the tanker, heavy leakage was observed from the tanker manifold valve flanges.

JEA on observing the leakage immediately stopped the loading by pressing Emergency stop push button.
Subsequently, all the filled Benzene in the said tanker was emptied out from the tanker and taken in blow down
system and tanker was released without filling. This was also immediately informed to Marketing (PMC) through
phone and mail.

Root Cause

1. Inefficient tankers checking (issuance of green card) system by marketing.
2. No checking at PNC gate-03 by dedicated surveyor before entry of domestic Benzene tanker wrt integrity
of the system as is being done for export tankers.

3. Use of non-standard gaskets and manifold assembly(should have been taken care during issue of green
card by PMC).

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