Industrial Safety

Industrial Safety

The operation of an oil refinery is governed by the highest industrial, fire, and occupational safety requirements. As a result, our firm has developed a package of procedures aimed at preventing and isolating contingency scenarios, as well as limiting their impacts; the adoption of these measures decreases risks for both The Refinery staff and the community.

Following the results of the license inspection by the Federal Environmental, Industrial, and Nuclear Supervision Service, the company received a renewed license in 2022 for the operation of the first, second, and third classes of fire, explosion, and chemically hazardous production facilities.

To comply with the Kazakhstan Republic’s Government Resolution “On Approval of the Requirements for Documentation Support of Industrial Safety Management Systems” and Federal Law No. 116-KZ, the company has developed an industrial safety management system for hazardous production facilities of the first and second classes of hazards. The system includes an industrial safety statement approved by company management, goals and tasks in the field of industrial safety, and a package of relevant regulatory documents, which include the Industrial Safety System Regulations, Regulations on the Production Control Management of Industrial Safety Compliance, Regulations on the Procedure of Pre-Certification and Certification of the Company Executives and Specialists.

The Regulations on the Procedure of Pre-Certification and Certification of Company Executives and Specialists, as well as the Regulations on the Procedure of Training and Testing of Company Workers, establish requirements for the level of training of employees involved in primary production processes.

Using the OLIMP: OKS training and monitoring system, the corporate management organized examination boards to test employees’ knowledge of job functions and job and safety instructions. This technique is used to pre-certify and certify corporate executives and specialists for a variety of abilities in the field of industrial safety without the use of the so-called “human factor.”

Practical training is organized on the basis of a computer training simulating complex consisting of an integrated package of simulators of dynamic processes and controls, tolls, and system interfaces to brush up and consolidate information and apply knowledge in practice. The simulation complex satisfies all current training systems and federal industrial safety rules.

Furthermore, corporate staff visit production sites in different areas and countries on a regular basis to share experience. Employees from the company visited the Kuybyshev Oil Refinery, the Gazpromneft-Omsk Oil Refinery, TANEKO, and the largest Hungarian oil refinery, MOL, in 2022.

The company’s industrial safety professionals are hard at work on commissioning and state registration of newly-built facilities, as well as compulsory civil liability insurance for harm caused by an accident at the hazardous manufacturing site.

Industrial safety declarations were created in line with regulation documents for hazardous production facilities of the first and second classes of hazards; the declarations were verified by industrial safety specialists and recorded in the state registry.
According to Federal Law No. 116-KZ, the industrial safety of engineering devices, buildings, and structures, as well as the design documentation for hazardous manufacturing facilities, were thoroughly inspected.

Furthermore, the industrial safety department specialists conduct a thorough evaluation of the hazardous production facilities in accordance with the permitted schedule. The company’s management has created accident prevention and response plans, which are utilized to teach company staff.

The company has also designed and executed the following primary engineering measures for equipment efficiency:

– implementation of automatic and remote process control systems, alarm and instrumented protective system;

– implementation of automatic high-speed locking and (or) cutoff devices;

– dust-ignition-proof construction of the equipment;

– doubling and redundancy of the equipment, power supply and communications facilities.

The accident prevention work must begin during the technical design assignment. The standards set forth in the construction design specifications are higher than those frequently used.

As a result of this philosophy, the company’s design solutions considerably limit the risks of contingent circumstances that may arise due to technological causes.

Process staff oversee the oil refinery’s operation 24 hours a day, seven days a week. There are 62 operators on each shift. By the end of 2021, the oil refinery will employ 210 operators in total.

Another large-scale project created to increase the oil refinery’s reliability and safety is the development of the Gubernskaya in-house substation.

The business began designing and building the third technology phase of the oil refinery in 2021. A new power supply source was required for the specified manufacturing and infrastructural facilities. Four different tapping methods were presented and investigated. As a result, the decision was made to tap into the networks of FGC UES (the Federal Grid of Unified Energy Systems).

Gubernskaya substation 220/10 kV with overhead power line overhangs of 220 kV is the project code name. TPP-2 Tuymenskaya-TMMZ 1.2 Circuit, the substation is built on company-owned land near the Flare System Unit. The substation is 1.2 kilometers from the main distribution plant (10 kV), which serves as the power supply hub for all process units in the third building phase.

After the project is completed, all manufacturing facilities in the third technical phase will be compliant with the first category of power supply, reducing the likelihood of unscheduled downtime due to a power loss.