REV PROJECT NO. MADE BY REVD BY DATE of ISSUE 0 1591 AR/NS/SV BS 10.02.2020 1 1591 AR/NS/SV BS 19.02.2020 1 REV 1 PUNJAB CHEMICALS & CROP PROTECTION LTD 3D QRA LALRU 19/02/2020 1. ABBREVIATIONS ...................................................................................................... 3 2. EXECUTIVE SUMMARY .......................................................................................... 4 3. INTRODUCTION ....................................................................................................... 5 4. OBJECTIVE ............................................................................................................. 11 5. ABOUT THE SOFTWARE ...................................................................................... 11 6. SCOPE OF ASSESSMENT ................................................................................... 13 7. RESULTS AND OBSERVATION ........................................................................... 17 7.1 CONSEQUENCE ANALYSIS RESULTS ........................................................... 17 7.2 RISK ANALYIS RESULTS ................................................................................... 28 7.3 ISO CONTOURS OF LSIR DISTRIBUTION: ..................................................... 29 8. RECOMMENDATIONS ........................................................................................... 31 9. CONCLUSION ......................................................................................................... 37 APPENDIX 1: FLASH FIRE ENVELOPE...................................................................... 38 APPENDIX 2: POOL FIRE ENVELOPE ....................................................................... 49 APPENDIX 3: TOXIC GAS DISPERSION ENVELOPE .............................................. 59 APPENDIX 4: 3D CONTOURS FOR CONSEQUENCES ........................................... 63 APPENDIX 5: DISASTER MANAGEMENT PLAN ....................................................... 81 APPENDIX 6: FRAMEWORK FOR MANAGEMENT OF OCCUPATIONAL HEALTH & SAFETY ......................................................................................................................... 104 2 REV 1 PUNJAB CHEMICALS & CROP PROTECTION LTD 3D QRA LALRU 19/02/2020 1. ABBREVIATIONS ALARP As Low As Reasonably Practicable BLEVE Boiling Liquid Expanding Vapour Explosion DMP Disaster Management Plan DNV Det Norske Veritas E/E/PE Electrical/ Electronic/ Programmable Electronic ERP Emergency Response Plan ERT Emergency Response Team MSDS Material Safety Data Sheet F&G Fire & Gas HCl Hydrochloric Acid HSE UK Health & Safety Executive, United Kingdom IMD Indian Meteorological Department IPA Iso-Propyl Alcohol IR Individual Risk IRPA Individual Risk Per Annum IS Indian Standard LSIR Location Specific Individual Risk OGP Guidelines Oil & Gas Producers Guidelines P&ID Piping & Instrumentation Diagram PCCPL Punjab Chemicals & Crop Protection Limited PFD Process Flow Diagram PM Preventive Maintenance PPM Part Per Million QRA Quantitative Risk Assessment REV Revision VCE Vapour Cloud Explosion SCABA Self-Contained Breathing Apparatus 3 REV 1 PUNJAB CHEMICALS & CROP PROTECTION LTD 3D QRA LALRU 19/02/2020 2. EXECUTIVE SUMMARY WIRE Consultants has been engaged by Punjab Chemicals & Crop Protection Ltd. for the Quantitative Risk Assessment (QRA) of their process plant at their facility in Lalru, Punjab. Present report is the Quantitative Risk Assessment Report for the process plant based on the data and inputs provided by the PCCPL Team. The site visit was carried out at Punjab Chemicals & Crop Protection Ltd., Lalru on 15th, by multi- disciplinary team personnel from PCCPL and Wire Consultants. The area in Scope of the Study is “Storage Area of Lalru Facility”. The Vapor Cloud Explosion scenarios were not credible because the area is open and highly ventilated and hence the software couldn’t generate the results for the same. Failure frequency rates were taken from the OGP Guidelines. The cumulative IRPA value for the site is 1.79E-05 per year and lies on the threshold of low-risk region and ALARP risk region. The societal risk lies largely in ALARP region. All the results and distance of the Heat Radiations from Jet Fire and Flash Fire, Toxic Gas Envelopes and 3D Contours are attached in the Annexures of the Report and FN Curve generated are provided in the “Results and Observation” Section. 4 REV 1 PUNJAB CHEMICALS & CROP PROTECTION LTD 3D QRA LALRU 19/02/2020 3. INTRODUCTION The Client is one of the biggest Industries in India dealing with manufacturing and sales of specialty and other chemicals. This report details the Scope of the study, Results & Observations of the Assessment. This report has been supplied in a digital format, and therefore the copy archived at WIRE server shall be considered as the primary document. This report and related files submitted should be considered as secondary documents. 3.1 FLUID PROPERTIES The basic physical &chemical properties of the materials are given in the below table with reference to the MSDS. Table 1- Hazardous Properties of Chemicals Maximum Operating Conditions S. Boiling Flash Auto-Ignition Terminal Fluid No. Point(◦C) Point(◦C) Temp. (◦C) PRESSURE TEMPERATURE (◦C) (Barg) 1. Methanol 64.7 11 464 30 Atm Dimethyl 2. 37.3 -49 205 30 atm Sulfide 3. O-Xylene 143-145 31 465 30 atm 4 Formaldehyde 90-100 50-78 - 30 atm Carbon 5 46 -30 100 30 atm disulfide 6 Ethanol 78 13 425 30 atm Acetic 7 138-140 49 332 30 atm Anhydride 8 Toluene 110.4 12.7 535.5 30 atm 9 Acetic Acid 118 40 485 30 atm 10 Chlorine -34.6 - - 30 atm IPA (Iso propyl 11 82 12 399 33 atm alcohol) 12 Sulphuric Acid 270-340 - - 31 atm 13 HCl 81.5 - - 32 atm 5 REV 1 PUNJAB CHEMICALS & CROP PROTECTION LTD 3D QRA LALRU 19/02/2020 3.2 LIST OF HAZARDOUS SUBSTANCES The hazardous substances which are expected to be stored within the facility and their intended storage capacities are summarized in the table below: Table 2- Hazardous Chemicals with Intended Storage Capacities Capacity Number of of Type of Above Operating Operating Name of Physical Storage # storage Storage ground/ Temperature Pressure Chemical state Tank tanks/ Tank* Underground (°C) (bar) (KL*) cylinders each 1 Methanol Liquid 1 45 MS AB 25-30 Atmospheric Dimethyl 2 Liquid 1 15 MS AB 25-30 Atmospheric Sulfide 3 o-xylene Liquid 1 10 MS AB 25-30 Atmospheric 4 Formaldehyde Liquid 1 40 MS AB 25-30 Atmospheric Carbon 5 Liquid 1 25 MS AB 25-30 Atmospheric Disulphide 6 Ethanol Liquid 1 12 MS AB 25-30 Atmospheric Acetic 7 Liquid 1 30 MS AB 25-30 Atmospheric anhydride 8 Toluene Liquid 1 35 MS AB 25-30 Atmospheric 9 Acetic acid Liquid 1 10 MS AB 25-30 Atmospheric 900 kgs 10 Chlorine Gas 1 MS AB 25 9 each 11 Sulphuric Acid Liquid 1 20 MS AB 25-31 Atmospheric 12 HCL Liquid 1 40 MS AB 25-32 Atmospheric 13 IPA Liquid 1 20 MS AB 25-33 Atmospheric 6 REV 1 PUNJAB CHEMICALS & CROP PROTECTION LTD 3D QRA LALRU 19/02/2020 3.3 ISOLATABLE SECTIONS Isolatable sections are defined to estimate the total inventory available for a release. Isolatable Sections considered for the entire study are: Table 3: Isolatable Sections Sl. No. Tag No. Scenario Description Small Leak from Methanol Storage Tank 1 IS1L Medium Leak from Methanol Storage Tank Full-bore Rupture from Methanol Storage Tank Small Leak from Dimethyl Sulfide Storage Tank 2 IS2L Medium Leak from Dimethyl Sulfide Storage Tank Full-bore Rupture from Dimethyl Sulfide Storage Tank Small Leak from o-xylene Storage Tank 3 IS3L Medium Leak from o-xylene Storage Tank Full-bore Rupture from o-xylene Storage Tank Small Leak from Formaldehyde Storage Tank 4 IS4L Medium Leak from Formaldehyde Storage Tank Full-bore Rupture from Formaldehyde Storage Tank Small Leak from Carbon Disulphide Storage Tank 5 IS5L Medium Leak from Carbon Disulphide Storage Tank Full-bore Rupture from Carbon Disulphide Storage Tank Small Leak from Ethanol Storage Tank 6 IS6L Medium Leak from Ethanol Storage Tank Full-bore Rupture from Ethanol Storage Tank Small Leak from Acetic anhydride Storage Tank 7 IS7L Medium Leak from Acetic anhydride Storage Tank Full-bore Rupture from Acetic anhydride Storage Tank Small Leak from Toluene Storage Tank 8 IS8L Medium Leak from Toluene Storage Tank Full-bore Rupture from Toluene Storage Tank Small Leak from Chlorine Tonner 9 IS9V Medium Leak from Chlorine Tonner 7 REV 1 PUNJAB CHEMICALS & CROP PROTECTION LTD 3D QRA LALRU 19/02/2020 Sl. No. Tag No. Scenario Description Full-bore Rupture from Chlorine Tonner Small Leak from IPA Storage Tank 10 IS10L Medium Leak from IPA Storage Tank Full-bore Rupture from IPA Storage Tank Small Leak from Acetic Acid Storage Tank 11 IS11L Medium Leak from Acetic Acid Storage Tank Full-bore Rupture from Acetic Acid Storage Tank Small Leak from HCl Storage Tank 12 IS12V Medium Leak from HCl Storage Tank Full-bore Rupture from HCl Storage Tank Small Leak from Sulfuric Acid Storage Tank 13 IS13L Medium Leak from Sulfuric Acid Storage Tank Full-bore Rupture from Sulfuric Acid Storage Tank 8 REV 1 PUNJAB CHEMICALS & CROP PROTECTION LTD 3D QRA LALRU 19/02/2020 3.4 MODEL OF FACILITY The plot plan of the facility is shown below: Figure 1: Plot Plan of the Lalru Facility, PCCPL 9 REV 1 PUNJAB CHEMICALS & CROP PROTECTION LTD 3D QRA LALRU 19/02/2020 The snapshots of 3D model prepared for the facility and used for the analysis are shown below, for reference. Figure 2: South-East Bird-Eye View of Model Figure 3: North-East Bird-Eye View of Model 10 REV 1 PUNJAB CHEMICALS & CROP PROTECTION LTD 3D QRA LALRU 19/02/2020 4. OBJECTIVE The main objective