Report on Report on RISKRISK ANALYSISANALYSIS PROJECTS & DEVELOPMENT INDIA LIMITED (A Govt. of India Undertaking) PO: Sindri - 828122, Dist: Dhanbad (Jharkhand) List ‘A’ - Accredited EIA Consultant Organization by QCI-NABET Serial No. 123 as on 11.07.2017 PDIL JOB NO.: 9720 July, 2017 9720-QRA-IOCL HALDIA REFINERY- 4 PROJECTS & DEVELOPMENT INDIA LTD. BS-VI PHASE-1 DOCUMENT NO. REV SHEET 1 OF 1 RISK ANALYSIS FOR BS-VI FUEL QUALITY UPGRADATION - PHASE-1 AT INDIAN OIL CORPORATION LTD. HALDIA REFINERY OF M/s INDIAN OIL CORPORATION LIMITED 4 July, 2017 FINAL REPORT BVH DKC AKS 3 July, 2017 DRAFT REPORT BVH DKC AKS 2 May, 2017 DRAFT REPORT BVH DKC AKS 1 Feb, 2017 DRAFT REPORT BVH DKC AKS 0 Dec, 2016 DRAFT REPORT BVH DKC AKS REV DATE PURPOSE PREPARED REVIEWED APPROVED FORM NO. F 02-0000-0021 F1 REV 2 All rights reserved 9720-QRA for IOC 1 RISK ASSESSMENT STUDY FOR BS-VI FUEL Haldia Refinery QUALITY UPGRADATION AT IOC, HALDIA DOCUMENT NO. REV REFINERY SHEET 1 OF 10 TABLE OF CONTENTS Chapter Page Description No. No. Introduction 1 1.0 1.1 Objective of the Study 2 1.2 Scope of Work 3 2.0 2.1 General 4 2.2 Project Location 5 2.3 Climate & Meteorology 6 2.3.1 Temperature, Humidity and Rainfall 6 2.3.2 Wind Speed & Wind Direction 7 2.3.3 Pasquill Stability 8 3.0 3.0 Risk Assessment 10 3.1 Definitions 10 3.2 Process of Risk Management 10 3.3 Hazard Identification 10 3.3.1 Hazards related to Flammable Hydrocarbons 11 3.3.2 Hazards associated with Toxic/Carcinogenic materials 13 3.3.3 Potential Major Hazards 14 3.3.4 Modes of Failure 14 3.3.5 Selected Failure Cases 15 3.4 Consequence Analysis 20 3.4.1 Modeling Software 20 3.4.2 Discharge Rate 20 3.4.3 Dispersion Modeling 21 3.4.4 The Consequence Event Tree 21 3.4.5 Vapor Cloud Explosions and Flash Fires 22 3.4.6 Pool Fires, Jet Fires, Fireballs and BLEVEs 23 3.4.7 Toxic Hazards 24 3.4.8 Release Quantity 24 3.4.9 Duration of Release 25 3.4.10 Damage Criteria 25 3.5 Consequence analysis of selected failure Cases 28 9720-QRA for IOC 1 RISK ASSESSMENT STUDY FOR BS-VI FUEL Haldia Refinery QUALITY UPGRADATION AT IOC, HALDIA DOCUMENT NO. REV REFINERY SHEET 2 OF 10 Clause Unit Equipment/Line Failure Case Fig/Dwg No. Page No. 3.5.1 DHDT Cold feed inlet to Leak Hole dia. 10mm dia. hole: Fig 28 fresh feed 10mm and 25mm no: 1 (Page No.A5), Coalescer drum 2(Page No.A6). (201-V-01) line 25 mm dia. hole: Fig no:3 (Pg no.A7), 4(Pg no.A8). 3.5.2 Feed Surge drum Hole dia. 10mm and 10mm dia. hole: Fig 30 (201-V-02) to 25mm no: 5 (Pg no.A9), 6 HHPS feed (Pg no.A10). exchanger line 25 mm dia. hole: Fig no:7(Pg no.A11), 8(Pg no.A12). 3.5.3 Reactor (201-R- 25% gasket failure Fig no. 9 (Pg 31 01) outlet line no.A13), 10(Pg no.A14) 3.5.4 RGC Instrument Instrument tubing Fig no: 11(Pg 33 tubing full bore failure no.A15), 12(Pg no.A16). 3.5.5 Stripper (201-C- Hole dia. 10mm and 25 mm dia. hole: Fig 35 02) outlet line 25mm no: 13 (Pg no.A17). 3.5.6 Naptha feed Drum Catastrophic Fig no.: 36 surge drum (201- failure 14(Pg no.A18) V-18) & 15(Pg no.A19). 3.5.7 Sweet gas knock Drum Catastrophic Fig no.: 38 out drum (201-V- failure 16(Pg no.A20) & 20) 17(Pg no.A21). 3.5.8 Diesel product a. Hole 10 mm & 25 a. 10mm dia. hole: 39 Coalescer o/l line mm Fig no: to hydro treated b. 20% Cross 18(Pg no.A22) & diesel b/l Sectional Area 19(Pg no.A23). (CSA) failure line 25 mm dia. hole: Fig rupture no: 20(Pg no.A24) & 21(Pg no.A25). b. Fig no: 22(Pg no.A26) & 23(Pg no.A27). 3.5.9 ARU Flashed vapor a. Hole 10 mm & 25 b. Fig no.: 41 from flash drum mm, b. Full bore 24(Pg no.A28), line to SRU failure 25(Pg no.A29) incinerator line 3.5.10 Amine Hole dia. 10 mm & 10mm dia. hole: Fig 43 regenerator 25 mm no: 26(Pg no.A30) reflux drum to 25 mm dia. hole: SRU Line failure Fig no: 27(Pg no.A31). 3.5.11 Drum 208-V-02 Catastrophic failure Fig no: 44 28(Pg no.A32). 9720-QRA for IOC 1 RISK ASSESSMENT STUDY FOR BS-VI FUEL Haldia Refinery QUALITY UPGRADATION AT IOC, HALDIA DOCUMENT NO. REV REFINERY SHEET 3 OF 10 Clause Unit Equipment/Line Failure Case Fig/Dwg No. Page No. 3.5.12 HGU- Sour Naphtha Hole dia. 10mm and 25 mm dia. hole: 46 II feed to super 25mm Fig no: heater line 29(Pg no.A33). & 30(Pg no.A34). 3.5.13 Pump (92-P- a. Discharge a. Fig no.: 47 01A/B) line flange 31(Pg no.A35) & 25% gasket 32(Pg no.A36). failure b. Fig no.: b. Pump 33(Pg no.A37) & mechanical 34(Pg no.A38). seal failure 3.5.14 Super heated a. Hole 10 mm & 25 a. 25mm dia. hole- 50 sweet Naphtha mm Fig no.: feed to b. 20% CSA failure 35(Pg no.A39) & Desulphuriser line rupture 36(Pg no.A40). line b. Fig no.: 37(Pg no.A41) & 38(Pg no.A42). 3.5.15 Process gas from a. Hole dia. 25mm a. 25mm dia. hole- 52 Boiler to HTS b. 25% line flange Fig no.: Reactor gasket failure 39(Pg no.A43) & 40(Pg no.A44). b. Fig no.: 41(Pg no.A45) & 42(Pg no.A46). 3.5.16 Feed to PSA Unit a. Hole 10 mm & 25 a. 25mm dia. hole- 54 mm Fig no.: b. 20% CSA failure 43(Pg no.A47) & line rupture 44(Pg no.A48). b. Fig no.: 45(Pg no.A49) & 46(Pg no.A50). 3.5.17 Prime Pump 87-P- a. Hole 25mm a. 25mm dia. hole- 56 G 01A/B line to b. Pump discharge Fig no.: FCC Feed line line 25% flange 47(Pg no.A51) & gasket failure 48(Pg no.A52). b. Fig no.: 49(Pg no.A53) & 50(Pg no.A54). 3.5.18 SHU Reactor O/L a. Hole dia. 10 mm b. Fig no.: 59 line b.20% CSA failure 51(Pg no.A55) & line rupture 52(Pg no.A56). 3.5.19 FCC Gasoline a. Hole dia. 25 mm a. 25mm dia. hole- 60 Splitter outlet b. Full bore failure Fig no.: Line failure 53(Pg no.A57) & 54(Pg no.A58). b. Fig no.: 55(Pg no.A59) & 56(Pg no.A60). 3.5.20 Reflux drum (87- Drum Catastrophic Fig no.: 62 B-02) failure failure 57(Pg no.A61) & 58(Pg no.A62). 9720-QRA for IOC 1 RISK ASSESSMENT STUDY FOR BS-VI FUEL Haldia Refinery QUALITY UPGRADATION AT IOC, HALDIA DOCUMENT NO. REV REFINERY SHEET 4 OF 10 Clause Unit Equipment/Line Failure Case Fig/Dwg No. Page No. 3.5.21 SWS Sour Gas from Leak: Hole dia. 10 10mm dia. hole: 64 Stripper (207- mm & 25 mm Fig no: CC-01) overhead 59(Pg no.A63). to H2SO4 plant 25 mm dia. hole: Line failure Fig no: 60(Pg no.A64). 3.5.22 Stripper (207- Line rupture Fig no.: 65 CC-01) to Pump 61(Pg no.A65) (207-PA-2A/B) Line failure 3.5.23 SA ARU gas a. Hole 10 mm & 25 10mm dia. hole: Fig 66 Plant incoming line to mm b. 20% CSA no: 62(Pg no.A66). SA plant failure line rupture 25 mm dia. hole: Fig no: 63(Pg no.A67). 20%CSA failure Fig no.: 68 (Pg.A72) 3.5.24 SWS gas a. Hole 10 mm & 25 10mm dia. hole: 68 incoming line to mm Fig no: 64(A68). SA plant b. 20% CSA failure 25 mm dia. hole: line rupture Fig no: 65(A69). 20%CSA failure Fig no.: 67 (Pg.A71) 3.5.25 Fuel gas a. Hole 10 mm & 25 25 mm dia. hole: 69 incoming line to mm Fig no: 66(A70). SA plant b. Full bore rupture Full bore failure Jet fire: Fig no.: 69 (Pg.A73) UVCE Fig no.: 70 (Pg.A74) 3.6 Frequency Estimation 71 3.6.1 Parts Count 71 3.6.2 Event Tree Analysis 71 3.6.3 Immediate Ignition 72 3.6.4 Delayed Ignition 72 3.6.5 Explosion and Flash fire 73 3.6.6 Materials those are both Flammable and Toxic 73 3.7 Risk Analysis 75 3.7.1 Individual Risk 75 3.7.2 Societal Risk 76 3.7.3 Risk Criteria 76 3.8 Risk Results 79 3.8.1 Individual Risk results 79 9720-QRA for IOC 1 RISK ASSESSMENT STUDY FOR BS-VI FUEL Haldia Refinery QUALITY UPGRADATION AT IOC, HALDIA DOCUMENT NO. REV REFINERY SHEET 5 OF 10 3.8.2 Societal Risk results 79 3.9 Conclusion and Recommendation 79 3.9.1 Recommendations 80 4.0 Disaster Management Plan 86 4.1 Definitions 86 4.2 Objectives of DMP 89 4.3 Priority Of Handling Emergencies 89 4.4 Content of DMP 90 4.5 Classification Of Emergencies 90 4.6 Implementation 92 4.7 Pre-Emergency Planning 92 4.8 Emergency Mitigation Measures 96 4.9 Emergency Preparedness Measures 103 4.10 Emergency Organizations And Responsibilities 106 4.11 Declaration Of On-Site And Off-Site Emergencies 114 4.12 Medical Facilities 118 LIST OF TABLES Table Page Description No.