ERS Manual

KENYA PETROLEUM REFINERIES LIMITED
EMERGENCY RESPONSE SCHOOL
KPRL EMERGENCY RESPONSE SCHOOL
PAGE 1 OF 45
TABLE OF CONTENTS 1.0 BACKGROUND.............................................................................................. 3 2.0 PREMISE ........................................................................................................ 3 3.0 BASIS OF INSTRUCTION.............................................................................. 4 4.0 DESCRIPTION OF FIRE TRAINING GROUND FACILITY ............................ 6 5.0 OWNERSHIP AND SUPERVISION OF THE FIRE TRAINING GROUND FACILITY .............................................................................................................. 8 6.0 THIRD-PARTY PARTICIPATION IN KPRL FIRE TRAINING ........................ 8 7.0 LEGISLATIVE INTERFACE ........................................................................... 9 APPENDIX 1: JOB SAFETY ANALYSIS FOR OPERATION OF THE KPRL FIRE TRAINING GROUND ................................................................................ 10 APPENDIX 2: STANDARD HAND SIGNALS FOR USE ON THE KPRL FIRE TRAINING GROUND.......................................................................................... 20 APPENDIX 3: STAKEHOLDER NOTIFICATION FACSIMILE........................... 20 APPENDIX 3: STAKEHOLDER NOTIFICATION FACSIMILE........................... 21 APPENDIX 4: FIRE TRAINING PROP OPERATION PHOTOGRAPHS ............ 22 A4.1: Falling film prop ......................................................................................... 22 A4.2: Heat exchanger prop ................................................................................. 22 A4.3: Burst pipe/flange at height prop ................................................................. 23 A4.4: Portable small pool fire pan ....................................................................... 23 A4.5: Flange jet fire prop ..................................................................................... 24 A4.6: Pump seal prop ......................................................................................... 24 A4.7: Burst pipe/flange at grade prop ................................................................. 25 A4.8: Large pool fire pan..................................................................................... 25 A4.9: Rescue prop .............................................................................................. 26 A4.10: Draughting prop ....................................................................................... 26 A4.11: Smoke shed............................................................................................. 27 A4.12: Rescue manikin ....................................................................................... 27 APPENDIX 5: RESCUE PROP ANCHOR POINTS ........................................... 28 APPENDIX 6: COURSE MODULES .................................................................. 29 APPENDIX 7: EXAMPLE TRAINING PLAN ...................................................... 34 APPENDIX 8: EXAMPLE TEST PAPER ............................................................ 40 APPENDIX 9: EXAMPLE COMPLETION CERTIFICATE .................................. 43 APPENDIX 10: CURRENT INSTRUCTORS TRAINING, RELEVANT QUALIFICATIONS AND EXPERIENCE ............................................................. 44 APPENDIX 11: SAMPLE TRAINING SESSION PHOTOGRAPHS ................... 45
PAGE 2 OF 45
KENYA PETROLEUM REFINERIES LIMITED 1.0 BACKGROUND Kenya Petroleum Refineries Limited (KRPL) operates a crude oil refining operation in Mombasa, Kenya. The site has two process trains with a total design throughput of 9500 MT/day of light crude. Each train consist of a crude distillation, hydrotreater and semi-regenerant platformer units. One of the trains also has a bitumen plant. Other facilities include a standalone grease plant, three oil storage tank farms with a total capacity of 623,000m3, interconnecting pipelines and a common utility plant. Whilst the facility does not operate the marine handling facilities, there is a strong interaction with the operators (Kenya Ports Authority, KPA). The facilities are located at both the main refinery site in Changamwe, Port Reitz tank farm which adjoins the Kipevu Oil jetty, and the Shimanzi Oil Terminal. The city of Mombasa plays host to a significant number of oil facilities. These include the state fuels import jetties at Kipevu and Shimanzi, the Kenya Pipeline Company (KPC) fuels transport grid head station, the Moi International Airport (MIA), the oil marketing terminals operated by Shell, GAPCO, Chevron, Solvochem, Gulfstream Investments Limited and Oilibya at Shimanzi and the jointly operated Mombasa Joint Terminal (MJT) in Changamwe. The city further supports a number of industrial ventures, including Port operations and steel and cement production. A significant storage operation, consisting of both open yards and warehouses supports the citys role as an import hub for East Africa. KPRL currently supplies approximately 50% of national hydrocarbon demand, and is accordingly a state-critical infrastructure facility. 2.0 PREMISE The KPRL operation by its nature is inseparable from the risk of hydrocarbon fire and explosion. Whilst some support during such incidents is available from the Municipal Fire Brigade, that support is currently limited. It is recognized that major accident events which may occur at oil facilities is outside the day-to-day remit of this organisation. Further support is also available from local oil industry facilities. However, it must be noted that with the exception of response to oil spill, the industry is not formally coordinated, and that standards of training, equipment and response strategy vary widely. Given the above, it is of crucial significance that KPRL maintain an in-house emergency response capability.
PAGE 3 OF 45
KENYA PETROLEUM REFINERIES LIMITED To support the in-house emergency response capability, a structured approach to training and competency assurance is required. There are a number of thirdparty service providers operating fire training classes in East Africa. However, the majority of these schools are aimed at light industrial or commercial facilities, and offer little to KPRL beyond basic use of fire extinguishers. Further, there is not currently a coordinated industry-wide emergency response suite within the region. In order to meet the above demand, KPRL operates an emergency response school. The following document aims to demonstrate the demand, basis of competence assurance and outcomes delivered by that school. The document has been written to demonstrate compliance to THE FACTORIES AND OTHER PLACES OF WORK ACT, specifically The Factories and Other Places of Work (Fire Risk Reduction) Rules, 2007 clauses as follows: 21. (1) Every occupier shall ensure that all workers are instructed in the safe use of fire fighting appliances. (2) The Minister may, on the advice of the Director, prescribe a basic training course on fire safety to be undertaken by every member of the fire fighting team. (3) The Minister may, on the advice of the Director, publish once every year, in the Gazette, a list of approved institutions for the training of the fire fighting team. (4) Every occupier shall ensure that every member of the fire fighting team undertakes the basic fire fighting training course within three months from the date of appointment into the fire fighting team. (5) Every occupier shall cause every member of the fire fighting team to undergo a fire fighting refresher course at least once in every two years. 3.0 BASIS OF INSTRUCTION The KPRL emergency response school utilizes the following principles in the development and delivery of emergency response training: a) Course modules must be relevant to the crude oil refining industry. Whilst there is a significant overlap between refinery, marketing terminal, industrial and state requirements, the primary objective of the school is to mitigate the risks associated with the KPRL operation. b) Course modules must be site specific to the KPRL operation, nomenclature and equipment. Where possible, media of actual KPRL equipment and incidents, or similar media from Africa, will be used. c) The primary audience for the course modules is the KPRL First Intervention Team (FIT) and Engineering Day Fire Crew. Whilst levels of education vary across the KPRL employee set, the language, background knowledge and degree of difficulty embedded in the course modules will target levels typically comprehended by that audience.
PAGE 4 OF 45
KENYA PETROLEUM REFINERIES LIMITED d) Given the complexity of the information to be absorbed, it is not possible for candidates to take up sufficient content over a single extended duration session. The full competency spread has been modularized into a series of eight course modules. The aim and learning outcomes associated with each module is given in Appendix 1 below. The modules are able to be delivered over a series of sessions, allowing candidates sufficient time to absorb and reflect on the module material. The modules are further split into theory and practical components. e) The competencies learnt in each of the modules is further reinforced by the use of weekly emergency response drills. The drills follow a structured agenda to ensure that lessons from previous course modules are reinforced, and that each rotating shift team is exposed to the same experiences. f) The course modules and weekly drills are delivered by the refinery Manufacturing Manager, with support from the Fire Station Technician and Fire and Safety Advisor. g) The course modules each utilize a theory component, based on a specific Microsoft PowerPoint slide presentation, which is accompanied by slideshows, digitized video recordings and animations. The theory component is generally able to be delivered from a standard laptop computer and slide beamer, with delivery times varying according to module content. Where appropriate, small props (samples and equipment) are used in the sessions to illustrate concepts. Following successful delivery of each module, a written examination paper is held. Examinations are a combination of multiple choice, free text and component identification questions. Examinations are marked and discussed prior to completion of the theory component to encourage active discussion. A minimum pass grade of 75% is set for each module paper. Each of the theory components is supported by the main presentation slidepack, embedded additional media, student course notes, a training session plan, a written test paper and a module completion certificate proforma. Examples of training session plans, test papers and completion certificates are appended below. h) Each of the theory components is complemented by a practical component. The duration of practical components varies from to one day depending on topic complexity. Practical components associated with fire fighting make use of the KPRL fire training ground. Details of the fire training ground are given in the document Fire Training Ground Operation. The premise of the fire raining ground is that trainees should be exposed to live fires which simulate as realistically as possible the types of incidents found at KPRL. The compressed air breathing apparatus module makes use of the smoke shed located at the fire training ground. The refinery rescue training module undertakes the practical component at the dedicated rescue prop facility. All practical components are subject to full Job Safety Analysis (JSA), appended below.
PAGE 5 OF 45
KENYA PETROLEUM REFINERIES LIMITED i) Following completion of each of the theory and practical components, successful trainees are awarded a module completion certificate. Records of candidates are retained to demonstrate attendance and competency achieved. j) KPRL welcomes the participation of third-parties at emergency response training sessions, both theory and practical. Such participation is a good means to share knowledge and develop the relationships key to mutual aid. Where possible, invitation to attend both practical and theory components and drills is made to the Mombasa Municipal Fire Brigade, MIA, KPA, KPC and the oil marketing terminals. 4.0 DESCRIPTION OF FIRE TRAINING GROUND FACILITY The KPRL fire training ground is located on the Changamwe refinery site, immediately northeast of the Complex 1 flare structure. The fire training ground is adjacent to, though outside of, the flare sterile area (60m radius from the flare stack). The fire training ground consists of three concrete pads (the fourth concrete pad being located inside the flare sterile area and hence not actively used). The concrete pads are curbed and drained, and are each fifteen by ten metres. Two of the concrete pads contain fire fighting props which are fed by pressurized fuel. Props are constructed from steel piping, without fireproofing. The layout of the fire training ground is as shown below:
SMOKE SHED
D B C
HYDRANTS
FUEL HOLDER
H drainage
PAGE 6 OF 45
KENYA PETROLEUM REFINERIES LIMITED a) b) c) d) e) f) g) h) Falling film prop, Heat exchanger prop, Burst pipe/flange at height prop, Portable small pool fire pan, Flange jet fire prop, Pump seal fire prop, Burst pipe/flange at grade prop, Large pool fire pan.
Fuel for the grounds is supplied by underground piping, with isolation valves at each prop. A common isolation valve exists at the fuel holder. The fuel holder is able to be filled with liquid fuel (kerosene or gasoline), which is then pressurized to the props by firewater pressure. The pads are depressed below grade and slope to centre drains. Spent firewater is drained from the props by an underground drainage system, which has a fire-trap (water seal) located at the south of the facility. Spent firewater and any uncombusted fuel flows to the refinery interceptor system. Firewater is supplied from the refinery firewater main by an adjacent fire hydrant, fitted with four 2 British Instantaneous outlets. Firewater pressure can be varied from zero to fifteen barg, and can spike to twenty barg on pump startup. Firewater is drawn from the large capacity refinery firewater tank, and is sourced from the domestic water mains. Large volumes are available, allowing extended duration hose drills to be undertaken. Vehicle access (grassed, not hardstand) for fire appliance training is possible around the perimeter of each pad. Power and lighting is not currently connected to the fire training ground, though can be accessed from the nearby contractor work area. The pads are surrounded by extensive grassed areas which provide suitable space for hose drills and equipment operation. A draughting prop is provided to allow fire appliance operators to train in open water suction and ejector pump operation. The fire training ground also has a smoke-shed, which occupies approximately half one of the concrete pads. The smoke shed is used to simulate smoke or toxic environments, and is used to train people in the use of self-contained breathing apparatus (SCBA) and building rescue operations. Smoke is provided to the smoke shed by using smoke bombs. The shed is able to be operated in a closed condition, providing poor visibility through lack of lighting. The shed is fitted with one hundred 0.5m2 removable wooden panels which allow varying maze and obstruction patterns to be built. Additionally, a rescue prop is installed adjacent to the operating plants. The prop consists of an elevated vessel, being a redundant boiler deaerator. Access to the vessel is by ladder to an elevated platform, which supports the vessel manway.
PAGE 7 OF 45
KENYA PETROLEUM REFINERIES LIMITED The vessel is suitable for instruction in confined space rescue and rescue from heights operations. 5.0 OWNERSHIP AND SUPERVISION OF THE FIRE TRAINING GROUND FACILITY The fire training ground asset is managed by the refinery Fire and Safety Advisor. The ground is operated by the Fire Station Technician and Fire Station Assistant, who will typically be assigned roles as fire ground safety officer and fuel controller. A further trainer role (by the refinery Manufacturing Manager, General Shift Supervisor or similar) is required during operation of the fire training ground. 6.0 THIRD-PARTY PARTICIPATION IN KPRL FIRE TRAINING KPRL welcomes the participation of third-parties at emergency response training sessions, both theory and practical. Such participation is a good means to share knowledge and develop the relationships key to mutual aid. However, the following controls shall apply to third-party participation. The information provided during participation shall not be taken as formal guidance from KPRL. Third parties should seek their own advice as to the suitability of various techniques, theories and equipment for their own operation. Whilst certificates of attendance and examination completion will be issued to participants, this does not imply qualification nor guarantee of competence by KPRL. KPRL reserves the right to terminate the attendance of any, or all persons at a training session at KPRLs discretion. Whilst KPRL will endeavor to discuss the reasons for termination with the parent company in line with normal business etiquette, KPRL will not be liable for any loss or discomfort as a result of the termination. Whilst KPRL will endeavor to provide prior advice, KPRL further reserves the right to modify the timetable and content of the courses indicated below without notice. Third-party attendees at practical sessions must have completed the Basic Firefighting theory component, or be assessed by their parent company as being of equivalent competence. Third-party attendees must supply their own bunker gear of equal or better protection standard to that of KPRLs equipment. Details of KPRL bunker gear are contained in the Basic Firefighting theory component course. All attendees must comply with the directions of the KPRL Safety Officer and the requirements of the Job Safety Analysis. Unsafe behavior, horseplay and practical jokes will not be tolerated. Note that responsibility for the safety of thirdparty attendees remains with the parent company.
PAGE 8 OF 45
KENYA PETROLEUM REFINERIES LIMITED The training sessions consume materials, including handouts, breathing air, fuel and firefighting foam. KPRL will cover the cost associated with these consumables for small numbers of third-party attendees in line with our Business Principle of contributing directly or indirectly to the general well being of the community within which we work. Large groups of attendees should be discussed with KPRL Management to ensure that the safety, costs and logistics involved are well managed prior to the event. Lunch during the full-day sessions is available at the refinery canteen at the attendees expense. It is possible for third-parties to organize their own business-specific training courses utilizing KPRLs training grounds. Course outlines must be submitted to and approved by KPRL Management to ensure that the safety, costs and logistics involved are well managed prior to the event. KPRL will provide a fire safety supervisor during these events, though again responsibility for the safety of third-party employees remains with the parent company. 7.0 LEGISLATIVE INTERFACE The KPRL Emergency Response School has applied for registration as an Occupational Health and Safety Trainer as required by The Occupational Safety and Health Act 2007. This registration requires the following undertakings: a) KPRL must remain a registered business under the Laws of Kenya Company Act (Cap 486) or Business Names Act Cap 499), b) The affairs of the KPRL Emergency Response School must be in accordance with the ethics of the training profession, c) The KPRL Emergency Response School must be managed to the requirements of the Director, Directorate of Occupational Health and Safety Services, Minister for Labour and Human Resource Development, d) Every individual resource person providing training at the KPRL Emergency Response School shall be restricted to his or her area of competence, e) A copy of the timetable containing details of the venue, date and time, topics and names of the resource persons must be submitted to the Director, Directorate of Occupational Health and Safety Services, Minister for Labour and Human Resource Development before commencement of the training session, f) A report of every training carried out must be submitted to the Director, Directorate of Occupational Health and Safety Services, Minister for Labour and Human Resource Development immediately after the training and not later than twenty-one (21) days. The report shall include the course content, level of the trainees (managers / shop floor workers), names of the trainees and their respective workplaces.
PAGE 9 OF 45
APPENDIX 1: JOB SAFETY ANALYSIS FOR OPERATION OF THE KPRL FIRE TRAINING GROUND Note: This JSA has been written taken into consideration the requirements of the US National Fire Protection Association Standard NFPA 1403 (Standard on Live Fire Training Evolutions, 2002). Whilst the majority of requirements are complied with, some attributes of the oil industry require deviation from the Standard, which was written with regard to urban firefighting. Step Risk Control Ensure vegetation around fire training ground is kept short. Cut grass to be removed prior to commencing training. Ensure all scrap and rubbish is removed from area. Inspect props for wasps nests/insects and remove prior to commencing training. Operate fire water to props prior to loading fuel to ensure that piping is clear. Do not load fuel if piping is blocked. Ensure only correct (20L) fuel jerry-can is used with pourer. Ensure step is used to gain correct access to fuel holder. Warm-up (stretch) before handling fuel. Do not lift jerry-can above waist height. Ensure steel-capped boots are worn to prevent toe injuries. Ensure correct personal protective equipment is worn for decanting fuel (long sleeves, enclosed boots, safety glasses, PVC gloves, A2 respirator). Ensure only correct (20L) fuel jerry-can is used with pourer. Pour fuel slowly and avoid overfill. Flush away any spilt material with fire water. Change soaked PPE (overalls, boots, jackets) immediately to prevent exposure or ignition. Ensure static strap is used on jerry-can. Ensure no sources of ignition are operating nearby, including running vehicles.
Snake/insect bite.
Blocked lines to props lead to fuel trapped in fuel holder. Preparing fire training ground for session. Manual handling injury from fuel container.
Exposure to fuel.
Fire during decanting.
PAGE 10 OF 45
Inappropriate fuel use. Damaged props leads to training injury.
Fire appliances are damaged by fire training ground operation. Access to the fire training ground and classroom Inappropriate operation of grounds due to miscommunication or unfamiliarity.
Allow fuel trays to cool (cold enough to touch by hand) before refilling. Use only designated fuel (kerosene) for pool fires. Note that kerosene cannot be used on the piped props that have jet flames as the flame tends to blow-off and requires significant fuel valve manipulation to be sustained. These props may be fired with gasoline in order to provide stability. Solid materials, automobiles, cardboard, timber, plastic and hydrocarbons other than kerosene (or gasoline) must not be burnt on the fire training ground. Inspect props for damage (heat warping, sharp edges, corrosion, inoperable valves) prior to commencing training. Isolate and do not use damaged props. Ensure status of props is communicated to all training participants prior to commencing training. Fire training ground to be inspected annually by Inspection and colour coded as per the scaffolding/lifting equipment colouring. Care to be taken that the props contain no enclosed pockets which may overpressure when heated. Props shall be run with water-only during fire ground preparation to ensure that flow of fuel and drainage is operating correctly. Park fire appliances only in designated area north of fire training ground. Ensure fire appliances can be quickly deployed to a real incident. Ensure fire appliances are not left running when not required to eliminate ignition source. Ensure all people attending fire training ground are fully inducted, including third-parties. Review Job Safety Analysis and requirements of Long-Term Fire/Safety Permit with all training participants at the fire training ground prior to commencing training.
PAGE 11 OF 45
instruction.
Commence fuel flow to prop.
FST or FSA to be nominated as fire training ground safety officer during fire training. Fire ground safety officer to observe and monitor operation of grounds and personnel at all times. Fire training to be ceased immediately should unsafe operation be evident. The safety officer shall have no role during the exercise other than the safety officer role. Both the GSS and FST/FSSA are required for supervision of the FIT complement, in addition to FST/FSA acting as the safety officer. An additional supervisor shall be added for every additional five training participants above the FIT complement. Communication during exercises shall be as per the attached standard hand signals. Undertake extended classroom instruction in shaded areas. Heat stress or inattentiveness Ensure drinking water is available and participants are encouraged to due to sun heat. rehydrate. Ensure bunker gear is doffed during extended classroom instruction. Ensure all fire training operations are undertaken outside the flare sterile area, bearing in mind that the 60m radius is adjacent to the fuel holder. Exposure to radiation or Fire training ground safety officer to monitor flare operation. Fire training burning liquids from the flare. to cease under significant flare loadings. Radio communication to the control room to be checked prior to exercise commencing. Drainage culvert to be discussed and highlighted as a hazard with Fall into the drainage culvert training participants prior to exercise commencing. during access or egress. Route for access and egress to the fire training ground to be discussed. FST or FSA to be nominated as fuel controller during fire training. (role is separate to that of fire ground safety officer). Fuel controller to man fuel High fuel flow to props leads holder during use of prop and to observe and monitor operation of props at to excessive flame. all times. Fuel flow to be immediately isolated and exercise abandoned should unsafe operation be evident.
PAGE 12 OF 45
Incorrect ignition leads to flash-over. Fuel to props is extinguished or not ignited and pools. Ignited fuel flows to drains. Vegetation is ignited by operation of props. Smoke from training operation becomes a hazard or environment threat
Nominated ignition device (long handled torch) only to be used for ignition of fuel. Jumping flames from adjacent props or using nonnominated devices is forbidden. No personnel are to be located within 15 metres of props during ignition. Fuel controller to man fuel holder during use of prop and to observe and monitor operation of props at all times. Fuel flow to be immediately isolated and exercise abandoned should unsafe operation be evident. A safety line (pressurized, manned fire hose) is to be used during ignition. Fuel controller to man fuel holder during use of prop and to observe and monitor operation of props at all times. Fuel flow to be immediately isolated and exercise abandoned should unsafe operation be evident. Flush away any spilt material with fire water. Ensure flushed material has cleared drain system, including channel drain running towards the flare adequately prior to recommencing next exercise. Fire trap located at eastern end of fire training ground to be checked for water seal and cleanliness prior to commencing fire training session. Fire ground safety officer to observe and monitor drains adjacent to fire training ground. Fire training to be ceased immediately should unsafe operation be evident. Free-fuel noted in drainage system to be flushed clear of fire training ground and flare sterile area prior to fire training recommencing. Ensure vegetation around fire training ground is kept short. Cut grass to be removed prior to commencing training. Ensure all scrap and rubbish is removed from area. Safety officer to notify the National Environment Management Authority and Moi International Aiport by facsimile prior to commencing training exercise using attached proforma. Safety officer to monitor weather and effect on smoke plume drift during
PAGE 13 OF 45
Inappropriate approach or technique taken to attack.
Commence prop attack.
Exposure to radiation or hot surfaces.
exercise. Exercise to be ceased should smoke plume cause nuisance (e.g. insufficient loft leading to plume rolling through operating complex or adjacent neighbors facilities). No person shall be allowed to breathe smoke, toxic vapors or fumes, products of combustion, or other contaminated atmospheres or be exposed to an oxygen-deficient atmosphere. Ensure all people attending fire training ground are fully inducted, including third-parties. Review Job Safety Analysis with all training participants at the fire training ground prior to commencing training. GSS and training leader to discuss use of individual prop with trainees prior to attack. Discussion to include incident being simulated, method of attack, assignment of roles, safety aspects, indicators of completion of exercise and method of communication. A walk-through of the prop prior to attack is required, including access and egress routes. Fire ground safety officer to observe and monitor operation of grounds and personnel at all times. Fire training to be ceased immediately should unsafe operation be evident. Fire ground safety officer to review personal protective equipment, including bunker gear prior for correct fitment prior to attack. All spectators to be monitored by the safety officer and kept at a safe distance from the exercise. Any spectators requiring closer access are to be accompanied, and kitted out with full firefighting PPE. No persons shall play the role of a victim or casualty during live fire exercises. Casualties may be simulated where required through the use of Rescue Robert. Fire ground safety officer to observe and monitor operation of grounds and personnel at all times. Fire training to be ceased immediately should unsafe operation be evident. Fire ground safety officer to review personal protective equipment,
PAGE 14 OF 45
Heat stress from PPE/radiation.
Fuel cannot be extinguished.
including bunker gear prior for correct fitment prior to attack. Clothing worn under protective clothing can degrade and cause injury to the wearer, even without damaging the protective clothing. All wearers of protective clothing should be aware of the dangers of clothing made from certain all-synthetic materials that can melt and adhere to and burn the wearer even while wearing protective clothing. Protective trousers might be susceptible to wicking of the kerosene fuel. Leather boots might be susceptible to degradation when contact is made with kerosene. Precautions should be taken to prevent protective trouser and leather boot contact with kerosene.. Safety line (2nd charged and manned fire hose) to be used for all approaches made to live props. Only one prop at a time may be operated. Fire ground safety officer to observe and monitor operation of grounds and personnel at all times. Fire training to be ceased immediately should unsafe operation be evident. Fire ground safety officer to review personal protective equipment, including bunker gear prior for correct fitment prior to attack.. Fire ground safety officer to monitor trainees for signs of heat stress or fatigue. Trainees to be removed from exercise and rested should such signs be noted. Proactive rotation may be necessary for extended duration exercises. Ensure drinking water is available and participants are encouraged to rehydrate. Fire ground safety officer to observe and monitor operation of grounds and personnel at all times. Fire training to be ceased immediately should unsafe operation be evident. Fuel supply to be positively isolated by fuel controller. Fuel remaining within fire training ground to be monitored and allowed to burn out.
PAGE 15 OF 45
Fuel is spilt from pool trays Fuel remains in underground line. Make-up following attack. Fuel remains in prop area.
Fuel is extinguished but flashes off.
Provision of First Aid
First Aid process unclear
Reasons for inability to extinguish fuel to be determined and discussed with trainees prior to fire training recommencing. Risk of re-ignition to be discussed with all training participants at the fire training ground prior to commencing training. Requirement for monitoring post-extinguishment and care in make-up to be discussed. Fire ground safety officer to observe and monitor operation of grounds and personnel at all times. Fire training to be ceased immediately should unsafe operation be evident. Flush away any unburnt material with fire water. Ensure flushed material has cleared drain system, including channel drain running towards the flare adequately prior to recommencing next exercise. Fuel trays to be filled with a minimum of fuel to simulate a fire. Sufficient ullage must be left for foam/water to accumulate without floating out the fuel. Water jets are not to be played onto pool fires. Cooling should be achieved by use of fog, and extinguishment by foam. Fuel controller to ensure each prop is flushed with firewater following end of exercise. Flush away any unburnt material with fire water. Ensure flushed material has cleared drain system, including channel drain running towards the flare adequately prior to recommencing next exercise Ensure First-Aiders are identified amongst training participants. Ensure radio contact is made with control room to enable activation of Medical Emergency Response Plan. Ensure First-Aid kit is located at fire training ground. Fuel controller to ensure each prop is flushed with firewater following end of exercise. Ensure fuel-trays are burnt-out or water-flushed at the end of each training session. Flush away any unburnt material with fire water. Ensure flushed
PAGE 16 OF 45
Use of smoke shed
material has cleared drain system, including channel drain running towards the flare adequately prior to recommencing next exercise. Fire trap located at eastern end of fire training ground to be checked for water seal and cleanliness following end of training session. Fuel remains in drain. Free-fuel noted in drainage system to be flushed clear of fire training ground and flare sterile area prior to fire training recommencing. Props remain hot for Allow props to cool (cold enough to touch by hand) before leaving fire extended periods. training ground. Ensure all combustibles are removed from smoke shed prior to commencement of operation. Use only approved smoke generator for making smoke. Live fire must Fire inside smoke shed. not be used inside the smoke shed. Ensure smoke generator is removed and smoke shed well ventilated prior to leaving fire training ground. Inspect smoke shed and ensure both doors are operable prior to commencing training. Check that window flap is able to be opened and fastened to provide lighting. Ensure at least one door is open prior to commencing exercise, and that escape route has been discussed with all trainees. Inability to exit smoke shed. Fire training ground safety officer and trainer to be equipped with breathing apparatus to effect rescue if required. Fire ground safety officer to monitor operation of smoke shed. Should personnel appear in difficulty, smoke supply to be ceased and both doors opened to assist ventilation and escape. Open and fasten window flap to provide lighting. Only fully qualified Self-Contained Breathing Apparatus users are to be Unfamiliarity with Selftrained in the smoke shed. Contained Breathing Full Self-Contained Breathing Apparatus checks as per document HSEApparatus equipment leads to 20-16 (Breathing Air Equipment) are to be undertaken prior to each use injury of smoke shed.
PAGE 17 OF 45
No persons shall play the role of a victim or casualty during smoke shed exercises. Casualties may be simulated where required through the use of Rescue Robert. Full Permit to Work requirements must be carried out (including gas test) prior to training activity commencing.
Exposure to toxic materials, mechanical hazards or low oxygen levels during confined space rescue activities inside V607. Manual handling risks associated with moving loads through the V607 manway or over the platform edge during lifting and lowering operations. Use of rescue prop Fall from the platform ladder opening during rescue operations.
Warm-up (stretch) before undertaking manual handling activities. Share loads through the use of multiple participants. Use manual handling techniques outlined in the Refinery Search and Rescue training module. Safety rope must be tied across the ladder opening whenever people are on the platform. For activities requiring movement through the ladder opening (e.g. stretcher lowering through the opening), all participants on the platform must be connected to a fall restraint system (not a fall arrest system as fall distance will not allow lanyard deployment). Drainage culvert to be discussed and highlighted as a hazard with training participants prior to exercise commencing. Route for access and egress to the rescue prop to be discussed. Ambulance to be located to minimize risk of approach to drain during casualty loading operations. Only designated crossing points to be used. V607 manway to be closed and single-bolted following completion of exercise. Warning sign to be affixed to V607 manway. No persons shall play the role of a victim or casualty during rescue
Fall into the drainage culvert during access or egress.
Inadvertent access to V607 following training session Delayed lifting or lowering
PAGE 18 OF 45
attempt leads to suspension trauma.
Unsuccessful lifting or lowering attempt leads to casualty being dropped.
Oxygen level inside V607 depletes due to high respiration rates during casualty removal.
Equipment dropped onto bystanders under rescue prop. Inappropriate anchor point chosen for lifting or lowering operations. Unfamiliarity with rescue equipment leads to injury
from heights exercises. Casualties may be simulated where required through the use of Rescue Robert. No persons shall play the role of a victim or casualty during rescue from heights exercises. Casualties may be simulated where required through the use of Rescue Robert. Area directly under prop and 5m radius from the prop to be kept clear of foreign objects, rubbish and debris at all times during lifting and lowering activities. Only the Chrysalis Rescue Stretcher or safety harness may be used for lifting and lowering operations. The use of folding (NATO) stretchers, clinical stretchers or direct attachment with rope is not acceptable. Ensure manway remains open during exercise. Explosimeeter to remain onsite during entry to vessel. Oxygen content to be monitored every 5 minutes to detect depletion. Should oxygen content drop below the 19.5%, exercise to be terminated and all people to exit V607. Area directly under prop and 5m radius from the prop to be kept clear of people at all times during lifting and lowering activities. Taglines to be used where required to allow steering of the casualty. Helmets must be worn by all training participants at all times. Loose equipment on the catwalk is to be minimized. Where necessary, it must be kept in a container (e.g. RescuePack bag or bucket). Only those anchor points inspected and nominated below may be used. These anchors are rated for 1500kg. Only people who have successfully completed the Refinery Search and Rescue training module are to be trained on the rescue prop.
PAGE 19 OF 45
APPENDIX 2: STANDARD HAND SIGNALS FOR USE ON THE KPRL FIRE TRAINING GROUND
PAGE 20 OF 45
APPENDIX 3: STAKEHOLDER NOTIFICATION FACSIMILE
National Environment Management Authority Airport Manager, Moi International Airport Fax: 434434
ROUTINE NOTIFICATION OPERATION OF KPRL FIRE FIGHTING TRAINING GROUND
Dear Sir/Madam, As per previous correspondence, KPRL operates a fire fighting training facility at our Changamwe refinery site. The facility is used to train our First Intervention Team in the skills required to combat industrial incidents. We wish to advise that the fire fighting training ground located will be operated today as per the following guidance: DATE:
APPROXIMATE STARTING TIME:
APPROXIMATE FINISHING TIME:
During the fire fighting training exercise, kerosene fuel will be burnt to simulate refinery incidents. Care will be taken to ensure that smoke from the exercised is minimized. KPRL recognizes that regular dialogue and engagement with out stakeholders is essential. We remain committed to our Business Principle of seeking to listen and respond to our business partners and the community honestly and responsibly. We trust that the above information provides clarity on our fire fighting training exercise. Should you have any concerns regarding the exercise, please contact our Fire and Safety Adviser Mr Norman Elisha on +254 41 3433511. Yours Sincerely,
Safety Officer KPRL fire fighting training ground Kenya Petroleum Refineries Limited
KPRL EMERGENCY RESPONSE SCHOOL PAGE 21 OF 45
APPENDIX 4: FIRE TRAINING PROP OPERATION PHOTOGRAPHS
A4.1: Falling film prop
Prop shown fired on kerosene, with fuel source running .Fuel flows under pressure down the inclined panel. Filling of the horizontal tray with burning fuel or firewater creates a pool fire, with a total surface area of 9.6m2. Overflow of the 500L horizontal tray escalates the fire to the eastern end of the pad. A4.2: Heat exchanger prop
Prop is constructed of three 12 pipes at 1.5m elevation. Prop simulates leaking head gaskets on refinery heat exchangers. Prop shown fired on kerosene, with small pan underneath leaking fuel to delay fire spread. Spilling fuel forms a pool fire adjacent to the equipment. Prop is suitable for instruction in water shielding, equipment cooling and foam application.
A4.3: Burst pipe/flange at height prop
Prop simulates leak in elevated structures (3.5m) such as pipe racks or distillation columns. Spilling fuel forms a pool fire adjacent to the equipment. Prop shown un-fired. A4.4: Portable small pool fire pan
Two 150L pans of 1m2 surface area are provided. Props allow small pool fires to be simulated, and are suitable for fire extinguisher training. Prop shown un-fired.
PAGE 23 OF 45
A4.5: Flange jet fire prop
6 pipe stub construction prop simulates pressurized leak of hydrocarbon liquid from process piping or equipment. Prop shown fired on gasoline. Isolation valve able to be accessed under water shielding and can be used to demonstrate flame bending techniques. A4.6: Pump seal prop
Prop simulates leak from centrifugal pump seal. Spilling fuel forms a pool fire adjacent to the equipment Prop shown fired on kerosene. Foam approach possible from multiple directions.
PAGE 24 OF 45
A4.7: Burst pipe/flange at grade prop
6 flanged pipe construction prop simulates a burst flange gasket on process piping. Spilling fuel forms a pool fire adjacent to the equipment. Prop shown fired on gasoline. Isolation valve able to be accessed under water shielding. Prop is suitable for instruction in water shielding, equipment cooling and foam application. A4.8: Large pool fire pan
2200L pan construction provides 7.3m2 of combustion surface area. Prop demonstrates tenacity of pool fires and amount of smoke and radiant heat generated. Prop shown fired on kerosene. Prop is suitable for instruction in water shielding, equipment cooling and foam application.
PAGE 25 OF 45
A4.9: Rescue prop
Prop is able to operate as a rescue from heights platform, or as a confined space rescue platform. Plinth construction allows use of ladders (including hook ladders), vertical and low-angle rope work. Vessel size allows three-person rescue team access, whist providing limited (manhole) egress and lighting. Adjacent road access allows integration to stretcher and ambulance operations. A4.10: Draughting prop
1,000L prop is constructed to be mobile to suit varying drills. Prop can be connected to firemain to provide continuous water supply, smoothed by the interior baffles. Exterior walls are rounded to prevent damage to fire appliance hard suction hoses. Fire appliances are able to undertake extended duration draughting (open-water suction) or ejector pump operations.
PAGE 26 OF 45
A4.11: Smoke shed
Smoke shed is constructed from galvanized iron sheeting over a steel frame, with the majority of light able to be excluded from the interior. Front wall of shed is able to be removed to provide an open marquee-type structure for protection against inclement weather during fire training operations. Interior of shed is fitted with a grid array of steel supports with interlocking wooden blank panels. One hundred 0.5m2 panels may be moved to form a variety of maze and constrictive paths. Shed is suitable for breathing apparatus and building rescue operations training. A4.12: Rescue manikin
Rescue manikin has been constructed from medium weight materials to allow simulated rescue operations with low risk from fire or heights exposure. Mannikin is fully bendable at the joints.
APPENDIX 5: RESCUE PROP ANCHOR POINTS

APPROPRIATE ANCHOR POINTS Item Description Remarks The eye-lug is welded on a steel slab of 1. Lifting lug on 1mx1m raised thickness ranging from 13.0mm to concrete drain box on the 15.0mm (UT readings 2007). Holding western side of V607. down bolts and welds are sound. The lug is capable of withstanding working load of 1,500kgs. Handrail stanchions are sound and 2. Deaerator vessel platform capable of withstanding the working load handrail stanchions (angle of 1,500kgs. iron). 3. V607 manway stud holes. Capable of withstanding the working load of 1,500kgs. Holding down bolts are sound and the 4. The vertical I-beams of the pipe track on the eastern side beams are well supported by cross members. Capable of withstanding the of V607. working load of 1,500kgs. These are steel reinforced concrete 5. The 2x1x2 tall concrete plinths on the southern side of structures. Capable of withstanding the working load of 1,500kgs. V607. INAPPROPRIATE OR POOR ANCHOR POINTS Item Description Remarks The lamposts are made of rolled sheet 1. Lampposts located at the metal. These should not be used for any eastern and western ends of the deaerator vessel platform. lifting or rigging purposes. 2. Deaerator vessel platform Handrail mid rails are made from steel flat handrail mid rail (flat bar). bar (50mm x 6mm). These should not be used for any lifting or rigging purposes. 3. Deaerator vessel platform Handrail top rails are made from angle handrail top rail (angle iron). iron (50mm x 50mm) and can be used to support a load. However, a 1,500kg working load is approaching the limit. This is a poor anchor choice and should not be used for training exercises. 4. 9 protruding bracket to the left This bracket can fail during lifting because of the bending moment applied. This is a of the V607 manway . poor anchor choice and should not be used for training exercises. 5. V607 Man way hinge bolt The bolt can sustain loads less than 500kg, but because of its overall length there is risk of failure due to bending. This is a poor anchor choice and should not be used for training exercises.
PAGE 28 OF 45
APPENDIX 6: COURSE MODULES Module Title Revision N
Aim
Learning Outcomes Learning Outcome 1: Understand the chemistry behind fires. Learning Outcome 2: Articulate the flammable and combustible nature of hydrocarbon products. Learning Outcome 3: Discuss and select appropriate extinguishing agents. Learning Outcome 4: Select and operate appropriate fire extinguishers. Learning Outcome 5: Identify and operate hose and branch assemblies. Learning Outcome 6: Identify and operate foam making facilities. Learning Outcome 7: Discuss the unique attributes of LPG fires. Learning Outcome 8: Discuss firefighting attack strategies. Learning Outcome 1: Articulate why we use breathing apparatus. Learning Outcome 2: Recognise situations where breathing apparatus is required. Learning Outcome 3: Identify the types of compressed air breathing apparatus used at KPRL. Learning Outcome 4: Identify and care for all the major components of the SCBA, breathing air compressor and Respirex suit. Learning Outcome 5: Perform a pre-operational check, don and doff breathing apparatus correctly. Learning Outcome 6: Follow safe working practices. Learning Outcome 7: Be aware of the requirements needed
Basic Firefighting
To understand the precursors and causes of fire within a refining environment and how various types of fire may be extinguished.
Compressed Air Breathing Apparatus
To understand and identify the needs, uses and operation of compressed air breathing apparatus.
PAGE 29 OF 45
Foam Appliance Operation
To understand the safe deployment and operation of the KPRL foam tender. To learn appropriate storage tank incident response strategies.
Fire Appliance Operation
To understand safe deployment operation of KPRL appliances.
the and the fire
Refinery Search and Rescue
To understand the manner in which safe muster, search and rescue operations are undertaken at KPRL.
for using breathing apparatus in confined spaces. Learning Outcome 1: Understand the way foam works to extinguish fires. Learning Outcome 2: Identify the key components of the foam tender. Learning Outcome 3: Operate the foam tender water and foam systems. Learning Outcome 4: Understand how the foam tender interacts with the foam storage system. Learning Outcome 5: Understand how the foam tender interacts with the tankage fixed foam pourer facilities. Learning Outcome 6: Articulate the attack strategies requiring the use of the foam tender. Learning Outcome 1: Understand the way water works to extinguish fires. Learning Outcome 2: Identify the key components of the fire appliances. Learning Outcome 3: Operate the fire appliance water and foam systems. Learning Outcome 4: Articulate the attack strategies requiring the use of the fire appliances. Learning Outcome 1: Understand the personal safety issues associated with refinery search and rescue. Learning Outcome 2: Articulate the alarm, muster and building search techniques used at KPRL. Learning Outcome 3: Select and safely undertake appropriate ladder-based rescue techniques. Learning Outcome 4: Select and safely undertake appropriate stretcher-based rescue techniques. Learning Outcome 5: Select and safely undertake appropriate confined space rescue techniques.
PAGE 30 OF 45
Learning Outcome 6: Select and safely undertake appropriate rescue from heights techniques. Learning Outcome 7: Discuss search and rescue strategies, including casualty handling. To gain awareness of the hazards of confined space entry and how they are controlled. To understand the confined space entry roles and responsibilities within the KPRL Permit to Work system. Learning Outcome 1: Identify a confined space. Learning Outcome 2: Understand the legislation controlling confined space entry. Learning Outcome 3: Discuss the hazards of confined spaces. Learning Outcome 4: Apply appropriate controls to confined space hazards. Learning Outcome 5: Work under KPRLs procedures for safe confined space entry. Learning Outcome 6: Identify the roles and responsibilities of the confined space entry team. Learning Outcome 1: Identify the locations and associated risks where KPRL has an interest, but which are remote from the facility. Learning Outcome 2: Select and safely undertake appropriate pipeline incident techniques. Learning Outcome 3: Select and safely undertake appropriate road transport incident techniques. Learning Outcome 4: Select and safely undertake appropriate KPRL estate incident techniques. Learning Outcome 5: Select and safely undertake appropriate Port operations incident techniques. Learning Outcome 6: Identify the roles, responsibilities, resources and logistics associated with external incidents. Learning outcome 1: Understand the potential for an oil spill incident within the Mombasa marine environment, and its likely impact.
Confined Space Entry
External Incidents
To recognize the types of incidents which may occur at locations where KPRL has an interest, but are remote from the facility.
Oil Spill Response
To understand the KPRL responsibilities as part of the
PAGE 31 OF 45
National Oil Spill Response Plan. To learn appropriate oil spill incident response strategies utilising local equipment.
KOT and SOT Preventative Maintenance
To understand and perform preventative maintenance practices in order to increase reliability of the KOT and SOT firefighting systems.
Learning outcome 2: Identify the key stakeholders for response to an oil spill incident and their role in the National Oil Spill Response Plan. Learning outcome 3: Articulate the equipment options for oil spill incident response and operate the KPRL-owned equipment. Learning outcome 4: Discuss the benefits and risks associated with beach clean-up and the use of dispersants. Operate the KPRL-owned dispersant equipment. Learning Outcome 1: Understand the firefighting equipment installed at the KOT and SOT jetties. Learning outcome 2: Demonstrate good preventative maintenance practices for the Patterson vertical turbine firewater pumps and associated Caterpillar diesel drivers. Learning outcome 3: Demonstrate good preventative maintenance practices for the Grundfos jockey pump. Learning outcome 4: Demonstrate good preventative maintenance practices for the firemain fittings. Learning outcome 5: Demonstrate good preventative maintenance practices for the Angus fire monitor system. Learning outcome 6: Demonstrate good preventative maintenance practices for the foam system. Learning outcome 7: Demonstrate good preventative maintenance practices for the Macron Fireater MF140 mobile foam carts. Learning outcome 8: Demonstrate good preventative maintenance practices for the model 883B flat fan fog partition spray nozzles and BS6391 Type 3 64mm firehose. Learning outcome 9: Demonstrate good preventative maintenance practices for the John Deere diesel driven emergency generator and Leroy Somer alternator.
PAGE 32 OF 45
10
Extrication Awareness
To understand the safe deployment and operation of the Municipal rescue trailer.
Learning Outcome 1: Understand the principle hazards relating to extrication. Learning Outcome 2: Identify the key components of the Municipal rescue trailer. Learning Outcome 3: Operate the Municipal rescue trailer electrical and lighting systems. Learning Outcome 4: Operate the Municipal rescue trailer hydraulic systems. Learning Outcome 5: Articulate the basic techniques used in vehicle extrication.
PAGE 33 OF 45
APPENDIX 7: EXAMPLE TRAINING PLAN Module N: Title: Revision: History: 1 Basic Firefighting 1 Revision 0: module built in 2007 by MM from Shell Clyde refinery and external information. Revision 1: module reviewed by Shell Manufacturing (Ed Hawthorne). Comments from first training round (Q2/3 2007) added. FSSA To understand the precursors and causes of fire within a refining environment and how various types of fire may be extinguished. By the end of the session the participant will be able to: Learning Outcome 1: Understand the chemistry behind fires. Learning Outcome 2: Articulate the flammable and combustible nature of hydrocarbon products. Learning Outcome 3: Discuss and select appropriate extinguishing agents. Learning Outcome 4: Select and operate appropriate fire extinguishers. Learning Outcome 5: Identify and operate hose and branch assemblies. Learning Outcome 6: Identify and operate foam making facilities. Learning Outcome 7: Discuss the unique attributes of LPG fires. Learning Outcome 8: Discuss firefighting attack strategies. Training room, followed by practical session at fire training ground. FSSA 2 hour classroom session. Eight hour practical session.
Owner: Aim:
Learning Outcomes:
Location: Trainer: Duration:
PAGE 34 OF 45
Resources Required:
Laptop and slide beamer. Whiteboard. Handouts. Water, CO2 and dry powder extinguishers. Foam tender and fire appliance. Fire training ground pre-checked for requirements. Fuel containers filled and safely stowed. Igniter. Bunker gear. 38mm hoses. Water branch. Dividing and collecting breeches. Ground monitor.
JSA
Pistol and log-type foam branches. Foam eductor. 20L drums of foam concentrate. Angus AF120 foam cart. Assessment Criteria: Written test paper and practical competency check of hose-handling and fire extinguisher skills. Evidence of Competency: 75% pass mark in written test paper. Deemed competent in practical. Body Welcome to participants. Outline of session: a) theory session, 5 minutes Introduction b) written test, and c) practical session at fire training ground. Introduction to firefighting. Show video clip of Clyde refinery 2004 pipetrack fire. 5 minutes Overview Brief overview of course. Assess participants previous knowledge of firefighting. Solids, liquids and gases. Learning Heat and temperature. Outcome 1: the Conduction, convection and chemistry behind radiation. 90 fires. Fire triangle. minutes Combustion process. Learning Flashpoint. Outcome 2: the Autoignition. flammable and Flammability limits. Time Section Resources
Whiteboard
Laptop and slide beamer Handouts
Laptop and slide beamer
PAGE 35 OF 45
combustible nature of hydrocarbon products.
Density. Water solubility.
Learning Outcome 3: extinguishing agents.
Fire triangle. Starve, smother, cool or interfere. Water. Foam. Carbon dioxide. Dry powder. Flashback. Show video clip of Honolulu terminal fire. Types of extinguishers. Method of operation.
Learning Outcome 4: fire extinguishers.
Water, CO2 and dry powder extinguisher Laptop and slide beamer Firehose and water branch Laptop and slide beamer Foam sample Foam cart. Firehose, foam branches (both pistol and log type) and foam inductor
Firewater reticulation system. Learning Firehose. Outcome 5: hose How to damage fire hose. and branch Branches and fittings. assemblies. Plant deluge systems. How foam works. Types of foam. Foam application techniques. Foam branches. Foam carts Common foam inductor issues. When not to use foam? Oxygenates in gasoline. Foam application methods. Tankage foam pourers.
Learning Outcome 6: foam making facilities.
Characteristics of LPG LPG emergencies BLEVE Learning Show animation of BLEVE Outcome 7: LPG mechanism. fires. Show video clip of Korean filling station and Illinois train BLEVEs. Learning Bunker gear. Outcome 8: RECEO. firefighting attack Firefighting hand signals. strategies. Tier 1, 2 and 3 incidents.
PAGE 36 OF 45
20 minutes 10 minutes
Written test. Wrap-up
First Intervention Team concept. Mutual aid. Firefighting hand signals. Issue papers, conduct examination and retrieve papers. Review session Practical Session
Test papers Fire training ground prechecked for JSA requirements. Fuel containers filled and safely stowed. Bunker gear. -
5 minutes
Introduction
Welcome to participants. Outline of session. Assess participants previous practical experience of firefighting.
5 minutes 30 minutes 15 minutes
Overview Fireground safety. Firefighting communication.
Brief overview of course. Review contents of JSA. Don bunker gear. Discuss leadership and control. Revise hand signals (attached). Discuss radio protocol.
30 minutes
1 hour
Matches. Crude, bitumen, Revise theory of flashpoint, residue, Flammability of autoignition, LEL. gasoil, hydrocarbons. Ignite samples of products in kerosene, small pool fire pan. gasoline, tops, lubeoil samples. Rollout 38mm hose from firemain and connect water branch. 38mm hoses. Manipulate water branch at Water branch. target. Dividing and Connect dividing breach. Hose rollout and collecting Connect collecting breach. connection. breeches. Connect and manipulate ground Ground monitor. monitor. Communication exercise: setup and move ground monitor to cool remote target. Review water connection points
PAGE 37 OF 45
2 hours
45 minutes
1 hour
2 hours
on two fire appliances and foam appliance. Demonstrate 3-man hose team. Dry-run approach to props with Hoseline fuel valve isolation at end of Gasoline operation approach (two hose teams and fireground approach and one safety line). fuel. shielding. Light prop and repeat approach Igniter. (extinguish fuel by isolation). Cooling following a fire. Light pool fire in small pan and Kerosene demonstrate ineffectiveness of fireground water extinguisher. fuel. Light pool fire in small pan and Fire extinguisher Igniter. demonstrate CO2 extinguisher operation. Water, CO2 (may flashback). and dry Light pool fire in small pan and powder demonstrate dry powder extinguishers. extinguisher. Lunch break Connect and manipulate Angus AF120 foam cart. Rollout 38mm hose from firemain and connect eductor and foam branch (both pistol type and older log-style branches). 38mm hoses. Manipulate foam branch to form Pistol and logfoam film on pad demonstrate type foam rain-down, bank-in and bouncebranches. off techniques. Foam eductor. Dangers of water being used in 20L drums of conjunction with foam (broken foam Foam eduction. blankets). concentrate. Connect and manipulate ground Angus AF120 monitors (both portable type foam cart. from fire appliance and trailerKerosene mounted foam cannon). fireground Light pool fire in large pan and fuel. demonstrate foam Igniter. extinguishment. Light pool fire using pump-seal prop and demonstrate foam extinguishment. Flush foam making equipment. Review foam connection points
PAGE 38 OF 45
45 minutes
Leadership
15 minutes
Equipment makeup.
on foam appliance. Review practical foam production troubleshooting. Conduct exercise of fire (fuel isolation) with the GSS injured. Check who steps up to lead. Increase scrutiny of safe practice and communication during exercise with unproven leader. Flush and rollup fire hoses. Stow equipment on fire appliances. Doff bunker gear. Muster bunker gear for cleaning. Ensure fire tenders restocked. Undertake JSA requirements for abandonment of fire training ground. Review session.
Kerosene fireground fuel. Igniter.
Equipment used during training session.
10 minutes
Wrap-up
PAGE 39 OF 45
APPENDIX 8: EXAMPLE TEST PAPER Name .. Date
Pass / Fail
1.
What are the three sides of the Fire Triangle? a) b) c) d) Fuel, Air and Heat. Solid, Liquid and Gas. Fuel, Air and Time. Fire, Water and Air. Answer: .
2. What is flashpoint? a) the time that the fire training instructor gets angry. b) the lowest temperature at which a liquid will ignite without the presence of a flame. c) the lowest temperature at which a liquid will ignite (flash) in the presence of a flame. d) is the lowest concentration of hydrocarbon which will self-support a flame. Answer:. 3. What extinguishing agents can be used on electrical fires? a) b) c) d) water. foam and CO2. dry powder and foam. dry powder and CO2. Answer. 4. Where should fire extinguishers be aimed? a) b) c) d) at the base of the fire. at the flames of the fire. at the base of the fire and at the flames. up in the air. Answer..
PAGE 40 OF 45
5. What colour is a water extinguisher? a) b) c) d) red. blue. black. purple. Answer 6. Is it OK to mix together fire fighting foam concentrates? a) b) c) d) yes, any foam can be mixed. Yes, but only at 6% proportioning. only finished foams can be mixed, never mix concentrates. only concentrates can be mixed, never mix finished foams. Answer.. 7. At what ratio does KPRL proportion foam? a) b) c) d) 2%. 3%. 6%. 100%. Answer.. 8. What does BLEVE stand for? .. 9. What does RECEO stand for? .. 10. Who can declare a Tier 3 emergency? a) b) c) d) anyone. only the GSS. only a member of the management team. only the fire training instructor. Answer..
PAGE 41 OF 45
11. What is Mutual Aid? .. .. .. .. 12. Name the hand signals:
PAGE 42 OF 45
APPENDIX 9: EXAMPLE COMPLETION CERTIFICATE
PAGE 43 OF 45
APPENDIX 10: CURRENT INSTRUCTORS QUALIFICATIONS AND EXPERIENCE
TRAINING,
RELEVANT
Mr Andrew Harvey, the KPRL Manufacturing Manager and Fire Chief, is a chemical engineering graduate with over ten years experience in oil refining. Mr Harvey is an employee of Shell Refining (Australia) Pty Ltd, and is seconded to KPRL. Mr Harveys previous roles have encompassed technology, process engineering, supply logistics, and major capital project commissioning. His role prior to joining KPRL was as the Health, Safety and Environment manager for Shells Clyde refinery in Sydney, Australia, which saw him responsible for the sites emergency response capability and integration with state major incident response teams. Mr Norman Elisha, the KPRL Fire and Safety Advisor, is a senior refinery operations technician with over thirty years experience in oil refining. Mr Elisha has previously worked for Antifire (Kenya) Limited as a fire apparatus mechanic, and was awarded the Commonwealth Fire scholarship for 1990. Mr Elisha is a holder of a Commonwealth Foundation Fire Engineering Diploma awarded by the Institution of Fire Engineers, United Kingdom. Mr Abdallah Bambaulo, the KPRL Fire Station Technician, is a seasoned career fire professional, having previously been employed as a fire instructor with the Kenya Air Force Fire School, Laikipia Air Base. Mr Bambaulos previous roles have included acting as a fireman for the African Safari Club and Fire Station Officer for the Malindi Fire Brigade. Mr Bambaulo has attained formal firemanship and breathing apparatus accreditation from the Royal Air Force, United Kingdom together with significant external learning interventions.
PAGE 44 OF 45
APPENDIX 11: SAMPLE TRAINING SESSION PHOTOGRAPHS
PAGE 45 OF 45

ERS Manual

Transféré par

Informations du document

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

ERS Manual

Transféré par

Droits d'auteur :

Formats disponibles

KENYA PETROLEUM REFINERIES LIMITED

KENYA PETROLEUM REFINERIES LIMITED

EMERGENCY RESPONSE SCHOOL

KPRL EMERGENCY RESPONSE SCHOOL

KENYA PETROLEUM REFINERIES LIMITED

KPRL EMERGENCY RESPONSE SCHOOL

KPRL EMERGENCY RESPONSE SCHOOL

KPRL EMERGENCY RESPONSE SCHOOL

KPRL EMERGENCY RESPONSE SCHOOL

KPRL EMERGENCY RESPONSE SCHOOL

KPRL EMERGENCY RESPONSE SCHOOL

KPRL EMERGENCY RESPONSE SCHOOL

KPRL EMERGENCY RESPONSE SCHOOL

KENYA PETROLEUM REFINERIES LIMITED

Fire during decanting.

KPRL EMERGENCY RESPONSE SCHOOL

KENYA PETROLEUM REFINERIES LIMITED

Inappropriate fuel use. Damaged props leads to training injury.

KPRL EMERGENCY RESPONSE SCHOOL

KENYA PETROLEUM REFINERIES LIMITED

Commence fuel flow to prop.

KPRL EMERGENCY RESPONSE SCHOOL

KENYA PETROLEUM REFINERIES LIMITED

KPRL EMERGENCY RESPONSE SCHOOL

KENYA PETROLEUM REFINERIES LIMITED

Inappropriate approach or technique taken to attack.

Commence prop attack.

Exposure to radiation or hot surfaces.

KPRL EMERGENCY RESPONSE SCHOOL

KENYA PETROLEUM REFINERIES LIMITED

Heat stress from PPE/radiation.

Fuel cannot be extinguished.

KPRL EMERGENCY RESPONSE SCHOOL

KENYA PETROLEUM REFINERIES LIMITED

Fuel is extinguished but flashes off.

Provision of First Aid

First Aid process unclear

KPRL EMERGENCY RESPONSE SCHOOL

KENYA PETROLEUM REFINERIES LIMITED

Use of smoke shed

KPRL EMERGENCY RESPONSE SCHOOL

KENYA PETROLEUM REFINERIES LIMITED

Fall into the drainage culvert during access or egress.

Inadvertent access to V607 following training session Delayed lifting or lowering

KPRL EMERGENCY RESPONSE SCHOOL

KENYA PETROLEUM REFINERIES LIMITED

attempt leads to suspension trauma.

Unsuccessful lifting or lowering attempt leads to casualty being dropped.

KPRL EMERGENCY RESPONSE SCHOOL

KENYA PETROLEUM REFINERIES LIMITED

KPRL EMERGENCY RESPONSE SCHOOL

KENYA PETROLEUM REFINERIES LIMITED

APPENDIX 3: STAKEHOLDER NOTIFICATION FACSIMILE

ROUTINE NOTIFICATION OPERATION OF KPRL FIRE FIGHTING TRAINING GROUND

APPROXIMATE STARTING TIME:

APPROXIMATE FINISHING TIME:

KENYA PETROLEUM REFINERIES LIMITED

APPENDIX 4: FIRE TRAINING PROP OPERATION PHOTOGRAPHS

A4.1: Falling film prop

KENYA PETROLEUM REFINERIES LIMITED

A4.3: Burst pipe/flange at height prop

KPRL EMERGENCY RESPONSE SCHOOL

KENYA PETROLEUM REFINERIES LIMITED

A4.5: Flange jet fire prop