RISK ASSESSMENT STUDY REPORT FOR AUGMENTATION OF FACILITIES AT CRUDE OIL TERMINAL AT MUNDRA, GUJARAT PROJECT PROPONENT HPCL-MITTAL PIPELINES LIMITED (HMPL) PLOT NO.6 (2), OLD PORT ROAD OPPOSITE MUNDRA CSF NEAR SAMUDRA TOWNSHIP MUNDRA, DISTT. KUTCH-370421 GUJARAT MCPL/EMD/TANK/2017-18/02/02 October, 2018 Prepared By MANTEC CONSULTANTS PVT. LTD. (QCI Accredited EIA Consultant at S.No.102 as per List of Accredited consultant Organizations/Rev. 70 /October 2018) (NABET Accredited EIA consultant, MoEF & NABL approved Laboratory) Environment Division, D-36, Sector-6, Noida-201 301, U. P., Ph. 0120-4215000, 0120-4215807 Fax. 0120-4215809, e-mail : [email protected] http://www.mantecconsultants.com RISK ASSESSMENT STUDY FOR AUGMENTATION OF FACILITIES AT CRUDE OIL TERMINAL AT MUNDRA, GUJARAT Table of Contents EXECUTIVE SUMMARY ............................................................................................................................ (I-IX) CHAPTER 1: INTRODUCTION.................................................................................................................. 1 1.1 Introduction ............................................................................................................................. 1 1.2 Need of the Project .................................................................................................................. 1 1.3 Scope of Study ......................................................................................................................... 1 1.4 Execution Methodology ........................................................................................................... 2 1.4.1 Kick Off Meeting with Mantec .......................................................................................... 2 1.4.2 Study of HMPL Operations ................................................................................................ 3 1.4.3 Study of HMPL Operating Parameters............................................................................... 3 1.4.4 Identification of Hazards ................................................................................................... 3 1.4.5 Consequence Effects Estimation ....................................................................................... 3 CHAPTER 2: PROJECT DESCRIPTION .................................................................................................... 4 2.1 Project Description ................................................................................................................... 4 2.2 Facility operation ..................................................................................................................... 4 2.3 Location ................................................................................................................................... 7 2.3.1 Manpower data ................................................................................................................ 9 2.3.2 Ignition Source ................................................................................................................. 9 2.3.3 Meteorological Condition ................................................................................................. 9 2.4 Pasquill Stability ....................................................................................................................... 9 2.5 Fire Fighting Equipment, Facilities and other equipments to tackle the emergency ................ 11 2.5.1 Tanks Fire Protection Facilities........................................................................................ 11 2.6 Other Safety Facilities ............................................................................................................ 13 CHAPTER 3: IDENTIFICATION OF HAZARD AND SELECTION OF SCENARIOS .......................... 15 3.1 Hazard Identification .............................................................................................................. 15 3.2 Hazards Associated with the Terminal .................................................................................... 17 3.3 Hazards Associated with Flammable Hydrocarbons ................................................................ 17 3.3.1 Crude Oil ........................................................................................................................ 17 3.4 SELECTED FAILURE CASES ....................................................................................................... 18 3.5 Hazard identification as per NFPA .......................................................................................... 18 3.6 Characterizing the Failures ..................................................................................................... 19 Mantec Consultants Pvt. 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Page i RISK ASSESSMENT STUDY FOR AUGMENTATION OF FACILITIES AT CRUDE OIL TERMINAL AT MUNDRA, GUJARAT 3.7 Operating Parameters ............................................................................................................ 20 3.7.1 Inventory ........................................................................................................................ 20 3.7.2 Loss of Containment ....................................................................................................... 20 3.7.3 Liquid Outflow from a tank ............................................................................................. 20 3.7.4 Vaporization ................................................................................................................... 20 CHAPTER 4: RELEASE CONSEQUENCE ANALYSIS ............................................................................ 21 4.1 General .................................................................................................................................. 21 4.2 Consequence Analysis Modeling ............................................................................................ 21 4.2.1 Discharge Rate ............................................................................................................... 21 4.2.2 Flash Fire ........................................................................................................................ 21 4.2.3 Jet Fire............................................................................................................................ 21 4.2.4 Toxic Release .................................................................................................................. 22 4.3 Size and Duration of Release .................................................................................................. 23 4.4 Damage Criteria ..................................................................................................................... 23 4.4.1 LFL or FLASH FIRE ........................................................................................................... 23 4.4.2 Thermal Hazard Due to Pool Fire, Flash Fire, Jet Fire ....................................................... 24 4.4.3 Domino Effect ................................................................................................................ 24 4.4.4 Boilover .......................................................................................................................... 24 4.5 Plant Data .............................................................................................................................. 25 4.6 Consequence Analysis for Crude Oil Tanks at Mundra Terminal .............................................. 25 4.6.1 Scenarios ........................................................................................................................ 25 CHAPTER 5: RISK ANALYSIS ................................................................................................................. 31 5.1 Individual Risk ........................................................................................................................ 31 5.1.1 Individual risk acceptability criteria ................................................................................. 31 5.1.2 Location Specific Individual Risk (LSIR) ............................................................................ 34 5.1.3 Individual Specific Individual Risk (ISIR) ........................................................................... 34 5.2 Societal Risk ........................................................................................................................... 35 5.3 Top risk contributors (Societal risk) ........................................................................................ 37 5.4 Fault Tree Analysis ................................................................................................................. 37 5.4.1 Fault Tree can help to: .................................................................................................... 37 5.4.2 Fault tree construction ................................................................................................... 38 5.4.3 Guidelines for developing a fault tree ............................................................................. 38 Mantec Consultants Pvt. Ltd. Page ii RISK ASSESSMENT STUDY FOR AUGMENTATION OF FACILITIES AT CRUDE OIL TERMINAL AT MUNDRA, GUJARAT 5.5 Event Tree Analysis ................................................................................................................ 39 5.5.1 Immediate Ignition ........................................................................................................