Bharat Petroleum Corporation Limited, ENNORE COASTAL INSTALLATION, Athipattu village, Ponneri Taluk, Thiruvallur Dist. Tamil Nadu 600120 ADDITIONAL STORAGE FOR ETHANOL, BIO-DIESEL, KEROSENE (SKO) & AVIATION TURBINE FUEL (ATF) RISK ANALYSIS STUDY REPORT October 2016 RiskChem Engineering Chennai Project Details 1. Report No. 1604 2. Report date OCTOBER 2016 RRA STUDY FOR ADDITIONAL STORAGE AT ENNORE COASTAL 3. Title & subtitle INSTALLATION 4. Reporting RISKCHEM ENGINEERING organization name & #4 FIRST STREET, VGP GOLDEN BEACH SOUTH PART III address CHENNAI 600 119 Mob: 098401 44908 Ph: 044 2453 0699 email: [email protected] BHARAT PETROLEUM CORPORATION LTD., SOUTHERN REGIONAL OFFICE, 5. Supporting 1,RANGANATHAN GARDEN, OFF 11TH MAIN ROAD, organization name & POST BOX NO.1212&1213, address ANNA NAGAR WEST CHENNAI 600040 TAMILNADU 6. Sponsoring RFQ Number/ Date: 6000977879/ 26.09.2016 organization reference(s) COLLECTIVE RFQ Number: 1000265379 Main Report 33 7. No. of pages Annexures 21 Risk analysis studies were carried out for additional storage of ethanol. Bio-diesel, kerosene and ATF at BPCL’s POL installation at Ennore, Tamil Nadu. The exercise has been undertaken in compliance with The Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 (Amended 2000) that govern installations involving hazardous chemicals The methodology and guidelines given in INDIAN STANDARD HAZARD IDENTIFCATION AND RISK ANALYSIS - CODE OF PRACTICE (IS 15656:2006) were adopted for the analysis. Risk analysis tools used in the assessment include PHA, consequence and frequency analyses. The assessment was based on site and operation related information provided by the client. The findings are the result of the application of the best available techniques and practices applicable to the project. The conclusions drawn are the educated and unbiased opinion of the consultant. Signatory: DR. A. KOSHY (Chem. Engg.) (PROJECT CONSULTANT) OCTOBER 2016 Executive Summary of Risk Analysis Study A risk analysis study was undertaken to assess the risk levels of additional storage at BPCL’s POL Installation at Ennore. The main findings are summarized below. 1. The hazardous outcomes from eleven potential hazardous scenarios were envisaged for the the proposed additional storage at the POL installation. 2. The consequences for each of these hazardous scenarios were estimated and the effects on life & property quantified. This included effects of thermal radiation from tank fires, pool fires, and flash fires 3. The estimated effects in terms of damage distances were projected on the installation layout to demarcate vulnerable areas with respect to plant personnel, property and the public. 4. The effects from tank & pool fires and flash fires were found to be localized and fall within the proximity of dykes 5. The damage zones are largely confined within the installation with no significant impacts falling outside. 6. The risk was assessed considering the full implementation of the M.B. Lal Committee recommendations. 7. No impact is expected to fall on personnel stationed at the manned locations within the site from the proposed additional storage units. 8. The risk of fires from the proposed additional storage affecting the operating personnel was found to be negligible. The risk zones will be mainly confined within the plant site and will not have any effect on the persons outside the plant. 9. This report is to be considered as an addendum to the Risk Analysis report for the Ennore Coastal Installation. The recommendations from the report for the existing facility hold good for the current report. Additional measures for risk reduction have been provided for the proposed additional storage Table of Contents CHAPTER ONE PROJECT DESCRIPTION 1 1.1 Introduction 1 1.2 Description of the proposed additions onsite 1 1.3 Objective and Scope of Risk Analysis studies 2 APPENDIX 1 BRIEF DESCRIPTION OF PROPOSED ADDITIONAL STORAGE UNITS 4 CHAPTER TWO HAZARD IDENTIFICATION 6 2.1 Hazard Identification Methods used and the basis 6 2.2 Source characteristics - Hazard Classification based on Inherent Hazards 6 2.3 Credible accident sources/worst case scenarios - Past Accident Analysis. 7 2.4 Methodology for Hazard Identification - Fire & Explosion Index (F&EI) 8 2.5 Summary 9 APPENDIX 2 FIRE & EXPLOSION INDEX WORKSHEET 10 CHAPTER THREE CONSEQUENCE MODELLING 11 3.1 Preamble 11 3.2 System Boundaries 11 3.3 Identification and Construction of Hazardous Scenarios 11 3.4 Consequence Modelling 13 3.5 Damage Contour Plots 15 3.6 Summary 19 APPENDIX 3 OUTPUTS FROM CONSEQUENCE CALCULATIONS 20 CHAPTER FOUR DETERMINATION OF RISK AT THE INSTALLATION - PROBABILITY ASSESSMENT 24 4.1 Accident Frequency Estimation 24 4.2 Summary of Safety & Automation features 24 4.3 Failure Frequency Analysis 25 4.4 Observations 26 CHAPTER FIVE EVALUATION OF RISK TO PERSONNEL WITHIN AND OUTSIDE THE INSTALLATION 27 5.1 Preamble 27 5.2 Risk Evaluation 27 5.3 Potential for Secondary/ Cascade Events 29 5.4 Summary 29 CHAPTER SIX MAJOR FINDINGS & RECOMMENDATIONS 30 6.1 Preamble 30 6.2 Main Findings of Consequence Assessment 30 6.3 Incident Frequencies of Hazardous Outcomes within the installation 31 6.4 Summary of Risk levels arising at the Installation 31 6.5 Evaluation of Risk from additional storage units 31 6.6 Additional measures for Risk Reduction for additional storage units 32 6.7 Conclusion 33 ANNEXURE I MATERIAL SAFETY DATA SHEETS 34 ANNEXURE II PAST ACCIDENT ANALYSIS 46 ANNEXURE III INFORMATION USED IN THE STUDIES 51 ANNEXURE IV IDENTIFYING INDEPENDENT PROTECTION LAYERS (IPLS) – LAYERS FOR DEFENSE AGAINST A POSSIBLE ACCIDENT 53 ANNEXURE V MODELS USED IN CONSEQUENCE ANALYSIS 54 LIST OF ABBREVIATIONS A/G Above Ground ALARP As Low As Reasonably Practicable AR Alcohol Resistant BPCL Bharat Petroleum Corporation Limited CAS Credible Accident Scenarios CCA Cause-Consequence Analysis CCOE Chief Controller of Explosives CO2 Carbon dioxide CR Cone Roof CW Cross Wind DW Down Wind F&EI Fire & Explosion Index FR Fixed Roof FW Fire Water GPH General Process Factor HPCL Hindustan Petroleum Corporation Limited IS Indian Standard KL kiloliter MBLCR M B Lal Committee Recommendations MF Material Factor MSDS Material Safety Data Sheet OGP International Association of OIL & GAS PRODUCERS OISD Oil Industry Safety Directorate OWS Oil Water Separator PESO Petroleum and Explosives Safety Organisation PHA Preliminary Hazard Assessment PL Pipeline PM Preventive Maintenance POL Petroleum, Oils, Lubes RADD Risk Assessment Data Directory RO Retail Outlets ROSOV Remote Operated Shut Off Valve SMS Safety Management System SOP Standard Operating Procedures SPH Special Process Factor STD Standard TF Tank Farm TLFG Tank Lorry Filling Gantry TT Tank Truck U/G Underground BPCL ENNORE COASTAL INSTALLATION Risk Analysis for Additional Storage CHAPTER One Project Description 1.1 Introduction Bharat Petroleum Corporation Limited’s (BPCL) POL Installation located at Ennore, adjacent to the HPCL terminal, receives, stores and distributes Motor Spirit and High Speed Diesel (MS & HSD). The corporation proposes to provide additional storage for Ethanol, Bio-diesel, SKO and ATF at this location. The existing total petroleum storage tankage capacity is 1,17,035 KL in both aboveground and underground tanks. The proposed additional storage will increase the capacity by 48,176 KL, through the introduction of twelve aboveground tanks. These tanks are to be located within three new dykes within the installation. The proposed addition will not require any change in land acquisition, as the tanks will be located within the premises, adjacent to the existing storage tanks. The proposed introduction will in no way alter the current activities of the existing installation. As the storage involves flammable materials that are classified as hazardous1, risk analysis studies were conducted to assess the degree of risk. The report contains the results of this study carried out for the proposed onsite storage of ethanol, bio-diesel, SKO and ATF. The management of the plant has entrusted the risk analysis studies to be carried out by consultants from RiskChem Engineering (RCE), Chennai. 1.2 Description of the proposed additions onsite The installation provides bulk storage for large quantities of petroleum products in aboveground storage tanks, with smaller quantities in underground tanks. The existing and additional product wise capacity at the facility is shown in Table1.1 Table 1.1 Product wise Storage Capacity at Ennore Coastal installation (Existing & Propsed) S. No Product Existing capacity (KL) Additional capacity (KL) 1 MS (Motor Spirit) 56620 - 2 HSD (High Speed Diesel) 60115 - 3 Ethanol 200 7724 4 SLOP ( MIXED PRODUCTS) 100 - 5 Bio-diesel - 7484 6 SKO - 16484 7 ATF - 16484 TOTAL 117035 48176 The additional storage units for ethanol, biodiesel, SKO and ATF are proposed to be located within three tank farms north of the existing tankfarms for MS and diesel. 1 As per the various rules and schedules given under The Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 (Amended 2000) of the Environment (Protection) Act, 1986. RCE 1 BPCL ENNORE COASTAL INSTALLATION Risk Analysis for Additional Storage The risk analysis report for the existing installation is to be referred for details of the location and other aspects of the site description. The existing facilities for pipeline receipt, decanting facilities and loading facilities for tank trucks will be used for the receipt, storage and dispatch of the proposed products. The