Identification of Risks and Impacts: In accordance with applicable legislation, Environmental Impact Assessments (EIAs) have been completed for the new propane storage facility and the fuel retail stations. For the proposed Propane storage, the EIA identified potential noise, air pollution and traffic impacts during construction and fire and explosion and gas leaks during operation. The EIAs include Environmental and Social Management Plans (ESMPs) covering these potential impacts. Required environmental approvals have been obtained from the authorities based on these EIAs. Zener will ensure implementation of ESMPs for all these facilities.
As part of the emergency response planning, Zener has completed a basic risk assessment for the operational Butane storage and filling operations which also estimated probability and significance of impacts (thermal and pressure) due to boiling liquid expanding vapor explosion (BLEVE) of the bullet tanks. The expected zone with thermal and pressure effects leading to significant damage to structures and fatalities has been identified in this assessment and control measures identified.
Considering that with addition of the Propane storage, the cumulative significance of risks and impact zones would change, the company has also completed hazard operability (HAZOP) studies and a Quantitative Risk Assessment (QRA) to assess the level of safety risks from both the existing Butane and proposed Propane storage and pipeline operations. The QRA has been completed in line with good international industry practice and includes hazard identification, frequency assessment, consequences assessment and risk assessment in the form of iso-risk contours/impact zones and significance of the risks (e.g., fatality, serious injury or damage). The QRA concludes that the overall risk level to both workers within the plant and community are within the tolerability limit i.e., as low as reasonably practicable (ALARP) region. However, the QRA does identify a scenario that generates a risk level above the ALARP limit which is in the scenario of a flash fire. Therefore, as per the ESAP (#1), the company will need to develop and implement an off-site emergency plan as well (in addition to on-site plans discussed below). The plans will need to be prepared and implemented in coordination with the neighbouring facilities and local authorities to deal with any major event.
Also, as per ESAP(#1) and in line with the QRA recommendations, the company will need to implement (a) risk-based inspection, testing and maintenance strategy for all installed safety critical safeguards (active fire protection systems, shutdown valves, etc.) to ensure their operational reliability meets required performance standards in order to avoid operational delays or failure in mitigating the risks associated with major accident events; (b) provide training for operators on prevention and response to major fire and explosion events; and (c) develop an on-site emergency response plan. The off and on site emergency plans will have a similar scope to the similar plans as referred to below in relation to the service stations. For the project i.e., Propane storage operations and fuel retail stations, environmental and occupational, health and safety risk (OHS) assessment have not been completed. As per the ESAP (#2), environmental and OHS risk assessments will be competed for all operations covered in the project and required preventive and mitigation measures will be implemented at all facilities within agreed timelines based on corrective actions to be defined in the assessment.
E&S Policy, Management Systems and Programs: Zener has a documented Health, Safety, Security and Environment (HSSE) Policy with commitments to zero-work related incidents, non-discrimination, full compliance with its internal and legal requirements across its operations, provision of adequate training and collaboration with clients and suppliers on HSSE issues.
To implement the policies, the company has prepared a HSSE manual for its existing operations i.e., the Butane storage and filling plant. The manual describes HSSE roles and responsibilities, communication, participation and consultation mechanism, prevention and control measures, prevention of emergencies, verification, and management review. Also, operating procedures have been developed for the filling of cylinders and loading of tankers. Further, a work permit system and accident-incident investigation system has been implemented. Weekly toolbox talks are conducted which cover basic awareness on HSSE issues. During appraisal discussions, Zener has mentioned that the company is working to develop additional documents to implement environmental and OHS management systems as per ISO 14001 and ISO 45001 requirements for its Butane storage and filling operations by 2023. Based on appraisal observations, the approach described in the manual is not fully implemented at the Butane storage and documentation on implementation of the manual allied to verification of implementation needs significant improvement. As per the ESAP#2, based on the environmental and OHS risk assessments, specific E&S procedures will be developed and implemented for operations under the project which will include: (a) life and fire safety (LFS) management programs for all facilities; (b) emergency preparedness and response; (c) pollution prevention processes including chemical management, solid and hazardous waste management plans (as discussed under PS3); (e) tanker loading and unloading processes for Propane and Butane and storage, and that related to the fuel retail stations; (f) OHS management programs commensurate to the risk posed by the activities (as discussed under PS2); (g) community grievance mechanism; (h) training plans with roles and responsibilities for its employees, seasonal and contract workers; (i) monitoring and reporting framework including regular audits/inspections, key E&S performance indicators for effectiveness and compliance status of all operations and regular environmental and OHS monitoring; and (j) periodic review by senior management/board.
As set forth in the ESAP (#2), Zener will engage a qualified consultant (acceptable to IFC) for supporting development of these E&S procedures. The consultant will complete a risk assessment for all its operations against IFC PSs requirements and good international industry practice for the sector and prepare a corrective action plan with timelines, which will be shared with IFC. Zener will ensure implementation of the corrective action plans as well as E&S procedures within agreed timelines. Also, as per the ESAP, the company will prepare guidelines and training for its distributors and transporters on safe transportation and storage of gases (Propane) and Butane cylinders, as applicable.
E&S Organization Capacity: Zener currently has a team of two people responsible for safety management i.e., a Safety Manager and an assistant, who are based at the Butane storage facility. As Zener has now an expanded operational footprint, the E&S organizational structure needs to be strengthened. As per the ESAP (#3), Zener will appoint an appropriately qualified E&S professional(s)for E&S management of the fuel retail stations.
Also, as part of implementation of procedures, Zener will develop and implement a structured E&S training curriculum based on regulatory requirements, findings of the risk assessments (EIAs, QRA, environmental and OHS risks assessments) and E&S performance (e.g., OHS statistics, internal audits and inspections). The training will cover employees, seasonal and contract workers.
Emergency Response Planning: As mentioned above, Zener has completed a basic risk assessment and QRA for the operational Butane storage and filling operations including the probability and significance of impacts (thermal and pressure) due to a BLEVE. Expected impact zones and control measures have also been identified. The butane storage terminal has fire hydrants, water monitors, sprinklers (on the bullet tanks), fire extinguishers, dedicated fire water storage and pumping system. Additionally, Butane leakage sensors and alarm system have been installed. The internal operational plan has documented responsibilities, instructions, and facilities for preventing and managing disasters and emergencies. All tankers to be loaded at the facility are connected to the earthing system before loading. Based on appraisal observations, emergency response drills have not been conducted this year. Also, maintenance of fire safety systems needs to be strengthened to ensure that systems are always kept operational, and tankers should be fitted with a flame arrestor before loading.
The operational fuel retail stations were noted to have been provided with fire extinguishers.
Going forward, as per the ESAP (#4), the company will; (a) develop emergency response plans for the fuel retail stations. The plans should consider all potential emergencies (e.g., fire, fuel/gas leakage, explosion, spills, medical emergencies) and describe detailed roles and responsibilities for relevant personnel (as well as their back-up), training needs and their frequencies. Regular classroom training and mock drills shall be conducted for all operations. Coordination with neighbouring facilities and local authorities that may be potentially impacted will also have to be described in the offsite emergency response plans where applicable.
Further, as per the ESAP(#4), the company will ensure that the proposed Propane storage and fuel retail stations have appropriate earthing facilities and flame arrestors for the tankers.
Monitoring and Review: Based on the appraisal observations, accident-incidents records are maintained at the Butane storage and filling. Though internal inspections are conducted, they are not documented. No environmental monitoring is being conducted at any of the facilities, Therefore, as set forth in the ESAP(#2), Zener will develop a monitoring and reporting framework at both corporate and facilities levels. The monitoring and reporting framework will describe: (a) key performance indicators (KPIs) on E&S compliance and performance for all operations (e.g., air emissions, OHS data, waste generation and disposal, spills, mock drills and training, accidents and incidents); (b) monitoring processes (e.g., inspections, internal/external audits); (c) reporting requirements in specific formats; and (d) process of regular management review for all operations by senior management. The framework will specify KPIs to be monitored at the facilities, monitoring frequencies, type of monitoring and the definition of thresholds that signal the need for corrective actions. In addition to applicable legal requirements, the monitoring thresholds will include thresholds specified in the WBG EHS Guidelines (both general as well as sector specific).