R E P O R T ON RISK ANALYSIS & DISASTER MANAGEMENT PLAN FOR POL TERMINAL AT ALINAGAR MUGHALSARAI (U.P) OF M/s INDIAN OIL CORPORATION LIMITED Prepared By An ISO 9001:2015, OHSAS 18001:2007 Certified & ISO/IEC 17020:2012 Accredited Co. PROJECTS & DEVELOPMENT INDIA LIMITED (A Govt. of India Undertaking) PO: Sindri, Pin - 828122, Dist: Dhanbad (Jharkhand) NABET Accredited Sl. No. 119; Dated: 5/03/2018 PDIL JOB NO: 9725 MARCH, 2018 9725-RA-MUGHALSARAI 1 PROJECTS & DEVELOPMENT INDIA LTD. DOCUMENT NO. REV SHEET 1 OF 2 RISK ANALYSIS & DISASTER MANAGEMENT PLAN FOR POL TERMINAL AT ALINAGAR MUGHALSARAI (U.P) OF M/S INDIAN OIL CORPORATION LIMITED 0 January, 2018 RA REPORT GB DKC AKS REV DATE PURPOSE PREPARED REVIEWED APPROVED FORM NO. 02-0000-0021 F1 REV 1 All rights reserved 9725-RA-MUGHALSARAI-161 1 RA FOR POL TERMINAL AT MUGHALSARAI, (U.P) OF M/S IOCL DOCUMENT NO. REV SHEET 2 OF 2 C O N T E N T S CHAPTER DESCRIPTION PAGE 1.0 EXECUTIVE SUMMARY 1 - 5 2.0 INTRODUCTION 1-2 3.0 PROJECT DETAILS 1-3 3.0 RISK ANALYSIS 1-27 4.0 DISASTER MANAGEMENT PLAN 1 - 33 ATTACHMENT DESCRIPTION PAGE DRG. NO. 1 LAYOUT PLAN OF POL TERMINAL AT MUGHALSARAI, M/S IOCL 01 DRG. NO. 2 ISO-RISK CONTOUR FOR POL TERMINAL AT MUGHALSARAI, M/S IOCL 01 DRG. NO. 3 F/N CURVE FOR POL TERMINAL AT MUGHALSARAI, M/S IOCL 01 THERMAL RADIATION DISTANCE DUE TO POOL FIRE FOR MS TANK (T- DRG. NO. 4 01 21) ON FIRE THERMAL RADIATION DISTANCE DUE TO POOL FIRE FOR SKO TANK (T DRG. NO. 5 01 -23) ON FIRE THERMAL RADIATION DISTANCE DUE TO POOL FIRE FOR HSD TANK DRG. NO. 6 01 (T-16) ON FIRE OVERPRESSURE DISTANCE DUE TO UVCE FOR MS TANK (T-21) ON DRG. NO. 7 01 FIRE THERMAL RADIATION DISTANCE DUE TO POOL FIRE FOR MS TANK (T- DRG. NO. 8 01 21) VESSEL CONNECTION FAILURE OVERPRESSURE DISTANCE DUE TO UVCE FOR MS TANK (T-21) DRG. NO. 9 01 VESSEL CONNECTION FAILURE THERMAL RADIATION DISTANCE DUE TO POOL FIRE FOR MS PUMP DRG. NO. 10 01 DISCHARGE LINE FULL-BORE FAILURE OVERPRESSURE DISTANCE DUE TO UVCE FOR MS PUMP DISCHARGE DRG. NO. 11 01 LINE FULL-BORE FAILURE THERMAL RADIATION DISTANCE DUE TO POOL FIRE FOR MS PUMP DRG. NO. 12 01 DISCHARGE LINE 15 MM DIA. HOLE OVERPRESSURE DISTANCE DUE TO UVCE FOR MS PUMP DISCHARGE DRG. NO. 13 01 LINE 15 MM DIA. HOLE THERMAL RADIATION DISTANCE DUE TO POOL FIRE FOR MS PUMP DRG. NO. 14 01 MECHANICAL SEAL FAILURE OVERPRESSURE DISTANCE DUE TO UVCE FOR MS PUMP DRG. NO. 15 01 MECHANICAL SEAL FAILURE THERMAL RADIATION DISTANCE DUE TO POOL FIRE FOR MS PUMP DRG. NO. 16 01 DISCHARGE LINE 25% GASKET FAILURE OVERPRESSURE DISTANCE DUE TO UVCE FOR MS PUMP DISCHARGE DRG. NO. 17 01 LINE 25% GASKET FAILURE FORM NO: 02-0000-0021 F2 REV 1 All rights reserved RA REPORT FOR BULK PETROLEUM TERMINAL AT ALINAGAR, MUGHALSARAI OF M/S IOCL Executive Summary EXECUTIVE SUMMARY PREAMBLE Indian Oil Corporation Ltd. (IOCL) is one of the Largest Commercial Enterprise in India, with a net profit of Rs. 103.99 billion (US$1.5 billion) for the financial year 2015-16. With the growth of population, industrialization, urbanization and modernization, the demand of petroleum products, such as MS, SKO, HSD and Ethanol is increasing at a very rapid pace. In view of this, the Ministry of Petroleum & Natural Gas has been encouraging Oil Companies to augment their existing facilities and/ or construct new facilities to bridge the gap between demand and supply. Accordingly, Indian Oil Corporation Limited (IOCL) has proposed to construct additional IFR tank for Ethanol (Cap.: 1600KL) at Alinagar, Mughalsarai (UP) POL Terminal. All products except Ethanol are received by Barauni-Kanpur Pipeline (BKPL) and Ethanol by road tankers. All the distributions and activities carried out at the terminal can be grouped into two parts. a. BKPL receipt in storage tanks b. Filling and distribution through tank trucks. Ethanol is proposed to be received through road tankers. OBJECTIVE As the terminal handles various petroleum products which have got potential of fire/ explosion hazard, hence it is necessary to evaluate the Risk from the facilities of the terminal. Accordingly, M/s Projects & Development India Limited (PDIL) have been retained by M/s IOCL as consultant to carryout Risk Analysis Study for the terminal. SCOPE OF THE STUDY The risk assessment has been carried out in line with the requirements of various statutory bodies for similar type of projects: The scope of Risk Analysis Study will be as follows: Identification of potential hazard areas; Identification of representative failure cases; Identification of possible initiating events; Assess the overall damage potential of the identified hazardous events and the impact zones from the accidental scenarios; Projects & Development India Limited, Sindri 1 of 5 RA REPORT FOR BULK PETROLEUM TERMINAL AT ALINAGAR, MUGHALSARAI OF M/S IOCL Executive Summary Assessment of total individual risk for activities in the plant. Assessment of societal risk due to the plant. Recommendation to reduce risk. Disaster Management Plan PROJECT FACILITIES The proposed main facility includes only one tank of Ethanol: a) Storage Facilities at the site Storage Capacity Diameter Height Tank Products Tank No. (KL) (m) (m) Type T001 HSD 7156 30.5 10 VCR T002 HSD 1369 12.9 10.6 VCR T003 HSD 2377 15.2 13 VCR T005 SKO 1574 15.2 9.1 VCR T014 MS 4213 23.9 11.3 FR T015 SKO 3778 20 12.6 VCR T016 HSD 9522 32 12.4 VCR T017 MS 2424 15.9 13.8 FR T018 SKO 4500 20 15 VCR T019 HSD 9000 28 15 VCR T020 HSD 9000 28 15 VCR T021 MS 8350 28 15 FR T022 HSD 7515 30 20 VCR T023 SKO 4959 18 20 VCR T024 Ethanol 70 2.9 3.9 HUG T025 Ethanol 70 2.9 3.9 HUG T027 Ethanol 70 2.9 3.9 HUG T028 Ethanol 70 2.9 3.9 HUG Ethanol-1 Ethanol 1600 16.0 11.0 IFR(A/G) (proposed) Projects & Development India Limited, Sindri 2 of 5 RA REPORT FOR BULK PETROLEUM TERMINAL AT ALINAGAR, MUGHALSARAI OF M/S IOCL Executive Summary Total No. of Tanks : 19 Storage Capacity of Depot: Existing: 76017 KL; Proposed: 1600 KL (Ethanol) (b) TLF : 26 Bays (c) Fire Fighting system. (d) Oil Water Separator. (e) Electricity Supply System. (f) Instrument Air System etc. CLIMATE AND METEOROLOGY Maximum & Minimum Temperature (Avg.): 34.40C & 16.70C Average Annual Rainfall: 995 mm Average Daily Relative Humidity: 70 % Annual Mean Wind Speed: 3.6 km/h Predominant wind Direction: West – East Direction RISK ANALYSIS Risk analysis of the plant includes identification of various credible and non- credible failure scenarios and consequences of those scenarios leading to various phenomena like dispersion, pool fire, jet fire, unconfined vapor cloud explosion etc. Frequency of the failure cases, magnitude of hazards and hazard distances has also been dealt with. The principal conclusions drawn from the risk analysis and recommendations based thereon are summarized below. PRINCIPAL CONCLUSIONS & RECOMMENDATIONS Conclusions a) It is observed from the Iso-Risk Contour (Drg. No. 02) that the acceptable limit of individual risk of 1.0x10-6 per year remains mainly confined within factory premises except a distance of around 47m towards the southern direction. b) Societal Risk (F/N Curve) (Drg. No. 03) developed for the plant remains mainly within the acceptable limit. c) The Hazard distances arrived from the consequence analysis reveals that in most of the cases hazard is confined within the plant premises. d) Disaster Management Plan has been prepared for POL Depot. Hence, the installation of POL Terminal is safe from environmental risk point of view. Projects & Development India Limited, Sindri 3 of 5 RA REPORT FOR BULK PETROLEUM TERMINAL AT ALINAGAR, MUGHALSARAI OF M/S IOCL Executive Summary Recommendations The recommendations as revealed from Risk analysis Study are as follows: i) Instruments should be checked and calibrated at regular intervals to prevent any wrong signalling and consequent failures. ii) Lighting adequacy should be checked so that visibility is adequately ensured for the push bottom of the MOV. iii) Fire fighting system as well as portable fire-fighting appliances should always be kept in good working condition along with the Safety appliances. iv) Emergency procedures should be written and available to all persons in the installations outlining the actions to be taken by each person during a major incident. v) Mock Drills should be conducted at regular intervals. Mock drill for on- site emergency should be done once in 6 months and company should approach and co-ordinate with the district authority for conducting off-site emergency drill. vi) The security supervisor at the gate should be provided with external telephone which will be useful in emergency during odd hours. The supervisor shall be provided with telephone numbers of all officers. A board displaying the names, addresses and phone numbers of the emergency contact points of the company as well as the local authorities shall be provided therein. vii) All terminal operating personnel including regular contractors and security personnel should be given safety and fire fighting training with the help of reputed training institutes. viii) The security staff should be trained as first responders for fire fighting and rescue operations along with plant operating personnel. ix) Regular inspection of pipelines including thickness survey and pipeline support systems shall be carried out and records maintained. x) Near miss reporting system should be immediately implemented.