In recent years the issues of industrial, fire and environmental safety, as well as of labor protection, are of top priority for the development of fuel-and-energy enterprises both, in the Russian Federation and in the Tyumen Region. According to new legislative requirements old enterprises of the fuel and energy sector are modernized and reconstructed, and the projects of new enterprises provide for up-to-date standards in the field of industrial safety which are effectively applied at production sites.
Antipinsky Oil Refinery is a developing enterprise in the Tyumen Region which today occupies a worthy place in the respective industry. Against the background of growing oil refining volumes the solution by the enterprise of environmental-protection problems is of great interest for both, governmental structures and oil citizens of the region. The present-day production process at Antipinsky Oil Refinery requires the introduction of new technologies aimed at minimizing the impact of operating oil refineries on the environment.
The refinery is located practically within the city and it incurs great responsibility for industrial safety of the people living there. The process of oil refinery is hazardous since it takes place at high temperatures and pressure, whereas the crude and released products are inflammable substances. It is easy to imagine the consequences in case of emergency situations. That is why one of the top priorities in the strategy of Antipinsky Oil Refinery are industrial and environmental safety.
“Great attention was concentrated on the issues of environmental safety still at design and initial construction stages of the refinery. The enterprise is exercising industrial environmental control the purpose of which is to guarantee compliance with regulations of environmental legislation,” General Director of the refinery Gennady Lisovichenko points out. “To this effect a full-fledged department is functioning at the enterprise where professional employees specialized in the area of environmental protection are working. They are responsible for revealing and preventing environmental violations, planning environmental measures and exercising control over implementation thereof, ecological situation monitoring.”
Improvement of industrial-safety conditions at oil refineries begins with production development and continuous monitoring of the state of industrial complex. Industrial control over production safety is exercised at Antipinsky Oil Refinery at all levels: from operator to general director. The enterprise carries out step-by-step repair and reconstruction of equipment, modernization of existing and construction of new technological facilities in accordance with modern requirements. Serious measures are taken for reducing the concentration of hazardous substances in the air, for minimizing the impact of harmful physical factors on the refinery’s employees.
New-generation equipment has been installed at the refinery which meets all current requirements of the Russian legislation on providing high level of labor protection, industrial, fire, and environmental safety. In addition to that, the refinery’s activity is constantly controlled by such regulatory authorities as the North Urals Directorate of Rostekhnadzor (Federal Service for Environmental, Technological and Nuclear Supervision), Directorates of Rosprirodnadzor (Federal Service for Environmental Control) and Rospotrebnadzor (Federal Service for Supervision over Consumer Rights Protection and Human Welfare) for the Tyumen Region. They carry out regular and planned inspections of oil refinery workshops, pre-licensing inspections of fire and explosion hazardous facilities to be used. In compliance with the active legislation of the Russian Federation regular control is exercised at requests of Antipinsky Oil Refinery CJSC on the boundary of the protected sanitary zone of the enterprise (Antipino settlement) over emissions of harmful substances into the atmospheric air and their impact on human health, over the noise level on the territory of residential development, in inhabited and nonresidential buildings and premises, as well as on the territory of the refinery by the accredited testing laboratory center, FBUZ (Federal Budgetary Healthcare Institution) Center for Hygiene and Epidemiology in the Tyumen Region According to the results of measurements no abnormities, excessive emissions harmful substances into the atmospheric air, excessive noise level on the territory of residential development, in inhabited and nonresidential buildings and premises, as well as on the territory of the refinery, have been revealed.
Up-to-date methods applied to the treatment of industrial and rainfall as well as domestic sewage waters will enable the refinery to reuse up to 60% of effluents for technical purposes of the enterprise, to make the remaining 40% of water meet hygienic requirements applied to surface water protection. All in all, Antipinsky Oil Refinery spent more than 1.5 billion rubles for the construction of treatment facilities and for industrial safety as of 01.10.2013.
Today Antipinsky Oil Refinery is busy with the design and construction of its third workflow phase which will enable it to provide the region with Euro-5 motor gasoline and diesel fuel after commissioning of new units, and, as a consequence, to reduce environmental impact of vehicles on the ambiance of the south of the Tyumen Region.
Since water is needed for refining oil and oil products at the units the construction of a new workflow phase of the enterprise began with the building of water intake, water conditioning, and sewage treatment facilities.
In October 2011 the prosecutor’s office of Leninsky Administrative District of the city of Tyumen inspected the observance of the employees’ rights to safe labor conditions. According to the results of such inspection no violations were revealed, no sanctions were imposed on Antipinsky Oil Refinery. In October 2011 the Directorate of Rospotrebnadzor (Federal Service for Supervision over Consumer Rights Protection and Human Welfare) for the Tyumen Region carried out its planned inspection on compliance by Antipinsky Oil Refinery with the regulations of sanitary and epidemiological legislation. According to the results of such inspection a report was drawn up which stated that no violations of the regulations of sanitary and epidemiological legislation had been revealed.
Treatment facilities occupy the area of 10.73 hectares. Wastewater treatment process consists of five stages. The treatment facilities will enable the refinery to purify all industrial, rainfall, and domestic sewage waters by means of preliminary, physical and chemical (separators and impeller floatation), biological (membrane bioreactor) treatment, advanced post-treatment and disinfection (the process of dual filtration using sorption carbon filters and UV disinfection), and, finally, dehydration of trapped oil products, residues, and excess sludge. It will make it possible to:
-prevent changes of the Tura River bottom and any limitations of water traffic when using water intake structures;
- provide the refinery with water of required quality complying with regulations imposed on equipment installed in the basic and auxiliary technological units;
-reduce the area of construction four times as compared with traditional treatment technology at primary and secondary sludge basins (biological wastewater treatment technology);
-minimize operational costs (low power consumption equipment, use of advanced chemical agents, etc.); - reduce the impact of harmful factors (such as noise, vibration, emissions, and discharges, etc.) on the environment and employees.
It should be specially noted that only high-technology equipment of such most advanced Russian enterprises as “Komsomolets” Tambov Plant OJSC, LIT Research and Production Association, EKO-Umvelt CJSC, TEKO-FILTR Production Enterprise LLC, as well as of such foreign companies as Zickert (Sweden), Separation Specialist (USA), GE Water & Process Technologies (Hungary), and other firms well known all over the world, will be used at the facility of the refinery which is new for the region’s economy.
Up-to-date methods applied to the treatment of industrial, rainfall and domestic sewage waters will enable the refinery to reuse up to 60% of treated wastewaters for technical purposes of the enterprise and to make the remaining 40% of water meet hygienic requirements applied to surface water protection. All in all, Antipinsky Oil Refinery spent more than 1.5 billion rubles for the construction of treatment facilities and for industrial safety as of 01.10.2013.
Surely, industrial safety depends not only of equipment quality, but also on the level of qualification of employees who are responsible for the main production processes. Training personnel in safe operational methods and techniques is the first stage in the system of labor protection organization. All of them make it possible for the employees of Antipinsky Oil Refinery to develop and master required skills, abilities to promptly, accurately and correctly fulfill all necessary operations on carrying out technological processes and preventing accidents. There is also a labor protection center at the refinery where training and methodical activities are organized. Moreover, information posters fixed at workplaces, in operator rooms and service premises specify the principles of industrial safety. Examination boards of Antipinsky Oil Refinery are conducting tests revealing if the employees know their functions, working instructions, and labor protection regulations. The OLIMP:OKS teaching and controlling system has been acquired and implemented. It makes it possible to carry out preparation for certification and certification procedure for managers and professionals of the refinery in the area of industrial safety. Members of certification commissions undergo examinations on industrial safety rules in the North Urals Directorate of Rostekhnadzor. To master the skills acquired by personnel and to apply them in the industry practical and training lessons are held at the refinery. Safe technological process is the result of such lessons and trainings.
The enterprise has developed a large variety of criteria for reducing amounts of incentive bonuses in case of different violations by careless workers of industrial safety and labor protection requirements, and, on the contrary, incentive bonuses are possible to increase for those who worked impeccably.
The refinery’s management board has declared the creation of safe labor conditions at workplaces to be a priority area of work for the relevant services of the refinery. For the purpose of revealing harmful and hazardous industrial factors a comprehensive procedure of assessing labor conditions at workplaces was conducted at Antipinsky Oil Refinery. Despite the growing and changing structure of the enterprise more than 2/3 of the total number of workplaces at the refinery were assessed. In the past years most activities on the preparation and conducting of workplace assessment were carried out by the professionals of industrial safety and labor protection department, but in June 2011 members of the enterprise’s commission underwent relevant training on the general issues of workplace assessment with regard to labor conditions, due to what a new stage of certification began with competent coordination of their actions under their attentive methodical guidance. Therefore, they plan at the enterprise to assess the sanitary state of labor conditions, prevention of injuries, provision of individual protection means to employees, reduction of industrial injury and occupational morbidity rates, as well as certification of personnel regarding all labor-protection issues, comprehensively. As of today the action plan has been developed and implemented regarding adjustment of labor conditions in line with the state labor protection regulatory requirements. Such measures as shortened work time, additional annual paid holidays, premium labor remuneration are applied to workers engaged in heavy-duty operations, operations in harmful, hazardous and other special labor conditions. Compensations are paid to those employees who work with harmful chemical substances.
For the purpose of solving the issues of providing industrial safety, labor protection, life and health care of the refinery workers the labor collective council has established a labor protection commission in charge of exercising control over the labor environment at the enterprise. As a result of cooperation between the labor collective council and the management team of Antipinsky Oil Refinery company-supplier of individual protection means and special clothes for employees has been selected. Due to this fact most comfortable and advanced products were managed to be chosen.
The system of industrial, fire, and environmental safety created at the refinery is going on. Unique experience has been amassed in the course of its formation and further better results are not late in arriving. Even now the efforts of the refinery’s management team in the area of industrial safety and labor protection have been highly appreciated by the Government of the Russian Federation. Antipinsky Oil Refinery has won awards in two categories, namely: “For reducing industrial injuries and occupational morbidity” and “For labor market development,” in the “Russian Organization of High Social Efficiency” Russian National Contest arranged at the governmental initiative. The day before, at the IX annual big business forum “Expert-400: Who Creates the Economy of Russia,” the Expert-RA Raring Agency awarded the refinery with the prize in the “Labor Productivity Leader” category.
As of today the action plan has been developed and implemented regarding adjustment of labor conditions in line with the state labor protection regulatory requirements. Such measures as shortened work time, additional annual paid holidays, premium labor remuneration are applied to workers engaged in heavy-duty operations, operations in harmful, hazardous and other special labor conditions. Compensations are paid to those employees who work with harmful chemical substances.