eia & emp for 100 mw thermal power plant at...

ADANI HAZIRA PORT PVT. LTD.

FORM-1 FOR EC AMENDMENT FOR

HANDING OF BUTADIENE STORAGE

FACILITY FORM I

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2014 19

3 ANNEXURES

Annexure 1: Production Details

Total Approved Tank Capacities as per Environmental Clearance:

Out of sanctioned capacities for setting up of tanks of 3000KL as per table above, only two

tanks of 3000 KL each will be relocated for the storage and handling of butadiene as per

PESO guidelines. So there will not be any addition in the volumes or tanks which are already

approved as per environmental clearance dated 03rd May 2013.

Type of Cargo

Enclosure

No. &

Capacity

Configurations of Storage Tanks

Proposed Configurations of

Storage Tanks

Executed No. Of

Tanks

Capacity

(KL) Total (KL)

Chemical

(Acetone,

Acrylonitrile, Benzene,

Ethanol, Ethylene,

Methanol, Motor

Spirit/ Naptha, N

Hexane, Diesel /

Kerosene, Styrene,

Toluene, Xylene,

Aniline, Ethylene

Acetate, Methyl

Isobutyl Ketone,

Acetic Acid) /

Petrochemicals / Base

Oils / POL Products /

Edible Oil / Non-

Classified Oils

1-29,500 KL

2-38,000 KL

3-27,000 KL

4A-28,800 KL

4B-43,200 KL

4C-27,000 KL

5-15,500 KL

6-24,500 KL

7-16,500 KL

8-40,000KL

9-40,000KL

10-29500KL

11-42,000KL

12-27,000KL

13-60,000KL

14-60,000KL

15-20,500KL

16-23,500KL

17-23,500KL

18-48,000KL

19-48,000KL

19 500 9,500 7

46 1,000 46,000 15

36 1,500 54,000 14

43 2,000 86,000 15

54 3,000 162,000 24

40 5,000 200,000 4

10 7,200 72,000 4

6 16,000 96,000

Total 7,25,500 KL




FACILITY FORM I


Annexure 2: Existing Environmental Clearance and CRZ Clearance




FACILITY FORM I





FACILITY FORM I


Annexure 3: Site Location Map




FACILITY FORM I


Annexure 4: Butadiene Storage & Pipeline area superimpose to CRZ Mapping




FACILITY FORM I


Annexure 5: Site Layout Map for Storage Facility

ADANI HAZIRA PORT PVT. LTD. FORM-1 FOR EC AMENDMENT FOR HANDING OF BUTADIENE

STORAGE FACILITY FORM I


Annexure 6: Site Layout for Butadiene Storage




FACILITY FORM I


Table 3-1: Area Break up at Site

S.

No. Title

Area in Hector (Ha) % of Total

Area Existing Proposed Total

1 Container Freight Station Area 90.82 0 90.82 10.40

2 Coal Stack yard Area 112.44 0 112.44 12.88

3 Warehouse Area/CFS Area 68.49 0 68.49 7.84

4 Automobile PDI Area 32.61 0 32.61 3.73

5 Steel Yard Area 13 0 13 1.49

6 Liquid/Bulk Cargo Storage Area 51.26 5.1 56.36 6.45

7 Container Back-up Area 61.87 0 61.87 7.08

8 Dry Cargo Go-downs Area 14.53 0 14.53 1.66

9 Road Area 94.25 0 94.25 10.79

10 Railway Area 81.82 0 81.82 9.37

11 Port Workers Amenity Centre Area 20.51 0 20.51 2.35

12 Steel and Project Cargo Assembling

Area 13 0 13 1.49

13 Truck Parking Area 28.3 0 28.3 3.24

14 Green Belt 81.27 0 81.27 9.31

15 Land for Future Development for

SHELL 20 0 20 2.29

16 Port back up area for handling

various types of cargo 84 0 84 9.62

Total 868.17 5.1 873.27 100




FACILITY FORM I


Annexure 7: Soil Testing Report of the Site




FACILITY FORM I





FACILITY FORM I


Annexure 8: Operation Process

Petrochemical industries are setting up a dual feed cracker to produce various building blocks for

downstream petrochemical processing industry.

Butadiene is one of the products and required to be exported. Therefore many companies have

approached AHPPL to create facility at Adani Hazira Port, to handle & storage of Butadiene and facilitates

its exports.

After catering to the local demand surplus is to be exported from AHPPL facility.

The road tankers carries around 15-20 Tonnes of Butadiene and hence it is expected that port may receive

20 to 25 road tankers on daily basis. The road tankers are then unloaded and the material is transferred to

the storage tanks thru pipelines connecting the unloading bays and the storage tanks.

Butadiene will be stored under refrigeration.

The aggregation of 10-15 days quantities will then be shipped or loaded on to the export vessels/ ships. Till

such time butadiene is stored in the suitably designed tanks at AHPPL’s Hazira Port.

The storage tanks are connected to the pumps which are required to pump the material (Butadiene) thru a

pipeline connected to the manifold at the jetty.

Figure 3-1: Process Flow Diagram




FACILITY FORM I


Annexure 9: Water Consumption and Waste Water Generation Details

Table 3-2: Water Consumption Details

S. No. Area of Consumption Water Consumption in KLD

Remarks EC Received for After Relocation

I Domestic 100 100

No

Change

as only

relocation

of tank.

II Industrial

a Fire fighting 2000 2000

b Washing activities 1400 1400

c Dust Suppression system 4000 4000

Total 7500 7500

Table 3-3: Waste Water Generation Details

S.

No.

Area of

Consumption

Wastewater Generation in KLD Treatment and

Disposal Remarks

EC Received for After Relocation

I Domestic 85 85

Used for horticulture

purpose after treated

in STP

No Change

as only

relocation

of tank.

II Industrial

a Fire fighting 0 0

b Washing activities 1190 1190 Recycled back after

treated in ETP

c Dust Suppression

system 0 0

Total 1275 1275




FACILITY FORM I


Annexure 10: Details of Effluent Treatment Plant and Sewage Treatment Plant

Details of Effluent Treatment Plant

Collection Tank cum Oil Water Separator

The incoming effluent from the tank pumped at the rate of 10 cum/hr and stored here prior to

pretreatment. This is done to meet hydraulic requirement and consistency of flow for further

continuous treatment. Here Primary oil removal facility i.e. mechanical belt type oil skimmer with

baffle is provided. The oil content being considerably high it is further pumped to TPI unit.

Tilted Plate Interceptor

The oily effluent from the collection tank transferred to TPI unit where oil floating at the top is

removed by pipe type skimmer. The effluent is passed through tube pack, where oily water flows

from the top of the pack and then over an effluent weir into the treated water chamber the oil

droplet coalesces into large droplets and float at the top. This oil is removed by means of pipe

type skimmer & will be stored in oil collection tank. The sludge from the TPI unit is feed to

chemical sludge drying beds for dewatering.

Equalization Tank

The aqueous layer with whatever dissolved chemicals and some carryover oil and grease will

overflow to equalization tank. Here aeration is provided to avoid the settlement of any solids and

ensure uniform mixing. Domestic sewage also will be added in this tank by gravity. This provision

is made considering future expansion. Then the effluent from equalization Tank is pumped to

Flash mixing Tank.

Flash Mixer for Lime

The overflow from the equalization tank is pumped to Flash mixing Tank, Where lime and PAC

dosing system is provided for coagulation. Here, the flash mixing is done to ensure the uniform

mixing with the chemicals. From ET pumping main, there is 1 bypass provision to collection tank

to remove the traces of oil and grease present if any.

Flash Mixer for Alum/Neutralization tank

In this tank the effluent is neutralized by means of pH correction dosing system using Alum.

Overflow from flash mixing tank is collected in flocculation tank.

Flocculation Tank

Overflow from the flax mixing tank is collected in the flocculation tank, where floc formation is

aided by addition of polyelectrolyte dosing & slow mixing.

Primary Tube Settler

The primary Tube Settler is proposed to settle out the sludge solids. The flocs formed in

flocculation tank are allowed to settle in primary tube settler for separation of solids and liquids.

The sludge from the primary tube settler is fed to sludge drying beds for dewatering. The dried

sludge disposed of as hazardous waste and sludge filtrate will be returned to equalization tank.

The overflow from primary tube settler will be fed to FAB/MBBR Tank for biological treatment.




FACILITY FORM I


FAB/MBBR Tank

The biological treatment is designed on FAB/MBBR process for optimum utilization of space. The

FAB consist of tank filled with special media. These media are made of specially developed

material of controlled density such that they can be fluidized using an aeration device. A bio film

develops on the media which moves along the effluent in the reactor. The movement within the

rector is generated by providing diffused aeration with the help of diffusers placed at the bottom

of the reactor. The thin bio film on the media enables the bacteria to act upon the biodegradable

matter in the effluent and reduce BOD/ COD content in the presence of oxygen that is used for

fluidization. Urea/ DAP system is provided for nutrient supplement in FAB Tank.

Secondary Tube Settler

The biologically treated effluent from MBBR tank is collected in secondary Tube settler for

separation of solids and liquids. The settled sludge fed to sludge drying beds and supernant will

overflow to chlorine contact tank for disinfection.

Chlorine Contact Tank

The overflow of secondary tube settler is collected into chlorine contact tank. For disinfection of

water sodium hypo chloride solution is fed from sodium hypo tank by means of electrical metering

pump, which doses proportionately to the inflow of water. Then disinfected effluent further

pumped through dual media filter for tertiary treatment.

Dual Media Filter

The objective of Dual Media Filter is to remove suspended solids free chlorine, organic matter,

odour and colour from water. Activated carbon filters are very effective and produce best quality

water when operated properly. The filter media consists of gravel bed support at bottom and

activated carbon media at top. The treated effluent then collected in treated water storage tank.

Treated Water Storage Tank

The tertiary treated effluent is stored into this tank prior to disposal of the effluent by means of

transfer pumps.

Sludge Drying Bed (Chemical)

The sludge from the primary tube settler and TPI is fed by gravity under hydrostatic head to

sludge drying beds for dewatering. The filtrate is returned back to Equalization tank and sludge is

disposed of as hazardous waste.

Sludge Drying Bed (Biological)

The part of sludge from secondary tube settler is pumped to FAB/ MBBR tank to maintain desired

MLSS concentration in FAB/ MBBR tank as return sludge (Optional) while excess sludge will be fed

to Sludge Drying Beds for dewatering and the dried sludge can be removed intermittently for

disposal. Sludge filtrate returned to equalization tank.

Table 3-4: ETP Units with Sizing

S.

No. Units Nos.

L

(mm)

B

(mm)

LD

(mm)

TD

(mm) MOC

1 Collection

Tank 1 2500 2000 2000 2500 MS,FRP




FACILITY FORM I


S.

No. Units Nos.

L

(mm)

B

(mm)

LD

(mm)

TD

(mm) MOC

2 Tilted Plate

Interceptor 1 5000 600 2700 3000 MS,FRP

3 Equalization

Tank 1 5000 4200 2500 3000 RCC

4 Flash Mixer 1 500 500 1000 1500 MS,FRP

5 Flocculation

Tank 1 1100 1000 1200 1700 MS,FRP

6 Neutralization

Tank 1 500 500 1000 1500 MS,FRP

7 Primary tube

Settler 1 1600 1600 2700 3000 MS,FRP

8 Moving Bed

Bio Reactor 1 7000 2400 2700 3000 MS,FRP

9 Secondary

Tube Settler 1 1600 1600 2600 3000 MS,FRP

10 Chlorine

Contact Tank 1 1600 1400 2300 2700 MS,FRP

11

Treated

Water Storage

Tank

1 9000 2000 2700 3000 RCC

12

Sludge Drying

Bed

(Chemical)

3 5000 4300 350 1200 Brick

Masonary

13

Sludge Drying

Bed

9Biological)

2 5000 1000 300 1200 Brick

Masonary




Figure 3-2: Flow and Hydraulic diagram of 50 KLD ETP




FACILITY FORM I


Sewage Treatment Plant-25 m3/day

Screen Chamber: 1 No.

The sewage will be conveyed through the Sewage Network pipeline into Screen Chamber. Screen

Chamber is provided to remove the bigger size solid particles from the sewage. Screen is proposed

in the screen chamber. From this Screen Chamber Sewage will be transferred to the sewage

collection sump. The capacity of screen chamber is 1 m3.

Sewage Collection Sump

The sewage water after passing through the screen chamber is sent to the sewage collection

sump. The collection sump helps to have a consistent flow of sewerage for STP plant. This sump is

kept aerated by coarse air diffuser to avoid the foul smell. Then the sewage water will be pumped

to the biological treatment i.e. inlet to MBBR reactor. The capacity of Sludge collection sump is 30

m3.

MBBR-I & II

The sewage water from Collection cum pumping sump will be passed to the MBBR I and II serially

for biological treatment with the help of Pumps. As it is a biological system it has to be operated

continuously all 24 hours and there by constant feed of sewage is required.

The MBBR has been provided with number of air diffusers of suitable capacity to provide

necessary dissolved oxygen mixed to the sewage and it also helps in fluidization of Media. The

MBBR Reactor is also provided with plastic media for the microbial growth. This helps in efficient

BOD removal. Air Blowers for oxidation, provides the aeration. If required, Nutrients in the form of

Nitrogen & Phosphate are added for biological growth. The MBBR is able to achieve 90-95 %

reduction in the BOD level. The MBBR tank I & II provided with size 1.5m x 1.15 m x 2.7 m each.

Secondary Tube Settler

The Secondary Tube Settler tank is proposed to settle out the sludge solids. The tank is provided

with size 1.1m x 1.5m x1.9 m and retention time of 3.0 hour. Biologically treated sewage

transferred to Secondary tube settler tank. A steep slope is provided in the secondary settling tank

to eliminate the need of scrapper mechanism. A part of the sludge from the Tube Settler will be

recirculated to MBBR to maintain MLSS levels and a part will be drained to the sludge drying beds.

Secondary Tube Settler is provided with the Tube Settler Media for increasing the surface area to

increasing the settling time. The clear effluent from top of media will be transferred to

intermediate collection tank.

Intermediate Collection Tank

An intermediate tank is proposed to store secondary treated sewage for tertiary disinfection

treatment. The clarified sewage from Secondary Tube Settler Tank collected in a intermediate

collection tank. In this tank liquid chlorine in form of Sodium Hypochlorite (NaOCl) dosing is

carried out for disinfection. The sewage is than pumped to dual media filter and softener for

tertiary treatment.

Pressure Sand Filter

A pressure sand filter is provided as a form of tertiary treatment for removal of suspended solids.

The dia. of PSF is 400 mm. The filter consists of different gradations of gravel and sand bed for

filtration of suspended solids. The filter is provided with necessary valve arrangements for inflow




FACILITY FORM I


and outflow and backwashing of the system. The backwash water of the system shall be taken to

the Sewage collection sump.

Activated Carbon Filter

An Activated carbon filter is provided as a form of tertiary treatment for removal of residual

organics like color, odor etc. The dia. of ACF is 400 mm. The filter consists of different gradations

of gravel and sand bed as base over which activated carbon granular porous media having high

iodine value is proposed to be provided. The filter is provided with necessary valve arrangements

for inflow and outflow and backwashing of the system. The backwash water of the system shall be

taken to the sewage collection sump.

Final Collection Tank

Outlet of Activated Carbon Filter is collected in a Final Collection Tanks, where the treated sewage

is stored. From this tank the treated sewage is reused for onland irrigation.

Sludge Drying Bed

The Sludge from the Secondary Tube Settler is pumped by Sludge Recycling Pump to the Sludge

Drying Beds. The Beds consist of Gravel, stones, sands to filter the water sludge. The sludge

remains on the bed & is dried under the sun while the water passes through the media to the

slotted pipe from where it is taken back to the sewage collection tank.




Figure 3-3: Flow and Hydraulic diagram of 25 KLD STP




FACILITY FORM I


Annexure 11: Fuel Consumption

Table 3-5: Fuel Consumption

S.

No.

Stack Attached

to Capacity Stack Nos.

Type of Fuel

used Fuel consumption

Existing

1 Hot Water Plant 400000 KCAL/ HR 1

Furnace Oil/ HSD 46 lit/ hr

2 Hot Water Plant 400000 KCAL/ HR Furnace Oil/ HSD 46 lit/ hr

3 DG Set (3 Nos.) 1500 kVA 3 HSD 5166 lit /Day of each

4 DG Set 325 kVA 1 HSD 1632 lit/Day

5 DG Set 100 kVA 1 HSD 528 lit/Day

6 DG Set 652 kVA 1 HSD 3600 lit /Day



Proposed





FACILITY FORM I


Annexure 12: Hazardous Waste Generation

Table 3-6: Hazardous Waste Generation and Disposal

S.

No. Type of Waste

Hazardous

Waste

Category

Quantity

Treatment /

Disposal Existing Proposed Total

1

Oil containing cargo

residue, washing

water and sludge

3.1 10

KL/Month -

10

KL/Month

Collection, Storage

and Disposal by

incineration in the

approved CHWIF

facility

2

Chemical containing

cargo residue and

sludge

3.2 10

KL/Month -

10

KL/Month

Collection, Storage

and Disposal by

incineration in the

approved CHWIF

facility

3 Used Spent Oil 5.1 1.5 KL/

Month

0.01 KL/

Month

1.51 KL/

Month

Collection, Storage

and Sold out to

registered recycler

4

Contaminated

cotton and foam pig

waste

5.2 1.5

MT/Month -

1.5

MT/Month

Collection, Storage

and Disposal by

incineration in the

approved CHWIF

facility

5

Process waste,

Residues and

Sludge (Paint)

21.1 10

KG/Month -

10

KG/Mont

Collection, Storage

and Disposal by

incineration in the

approved CHWIF

facility

6 ETP Sludge 34.3 5 MT/

Month -

5 MT/

Month

Collection, Storage

and Disposal by

secured landfill in the

approved TSDF




FACILITY FORM I


Figure 3-4: Membership Certificate




FACILITY FORM I


Annexure 13: Stack Details

Table 3-7: Details of Flue Gas Stacks

S.

No.

Stack Attached

to Capacity Stack Nos. Stack Height, m Stack Top Dia, m

Existing

1 Hot Water Plant 400000 KCAL/ HR 1 30 0.4

2 Hot Water Plant 400000 KCAL/ HR

3 DG Set (3 Nos.) 1500 kVA 3 30 0.4

4 DG Set 325 kVA 1 11 0.1

5 DG Set 100 kVA 1 11 0.1

6 DG Set 652 kVA 1 11 0.1

7 DG Set 380 kVA 1 11 0.1

8 DG Set 200 kVA 1 11 0.1

Proposed

1 DG Set 1250 kVA 1 30 0.4




FACILITY FORM I


Annexure 14: Quantitative Risk Assessment for Butadiene

Table 3-8: Butadiene Storage Details

Tank no Product Type Capacity (MT) Diameter (M)

T-91 Butadiene Horton sphere 1500 17.5

T-92 Butadiene Horton sphere 1500 17.5

Table 3-9: Details of Pumps

S. No Product Capacity ( M3/Hr )

Tanker unloading pumps

1 Butadiene unloading pump for T-91 (1W+1S) 60

2 Butadiene unloading pump for T-92 (1W+1S) 60

Recirculation pump

1 Butadiene recirculation pump for T-91 (1W+1S) 60

2 Butadiene recirculation pump for T-92 (1W+1S) 60

Export pump

1 Butadiene export pump (1W+1S) 310

Pre cooling pump

1 Butadiene pre-cooling pump (1W+1S) 60

Table 3-10: List of Scenarios of Modeling

Sr. No. Scenario Code Description

1 Leak- 10mm Hole size Storage Tank (Tank No.91)

2 Catastrophic Rupture

3 Leak- 10mm Hole size Road tanker

4 Catastrophic Rupture

5 Leak- 10mm Hole size Unloading hose from road tanker

6 FBR

7 Leak- 10mm Hole size Tank lorry unloading hose to Butadiene

unloading pump inlet 8 FBR

9 Leak- 10mm Hole size Butadiene unloading pump outlet to

sphere tank inlet 10 FBR

11 Leak- 10mm Hole size Vapor condenser circuit for sphere tank

12 FBR

13 Leak- 10mm Hole size Recirculation circuit

14 FBR

15 Leak- 10mm Hole size Vapour balancing line to road tanker inlet

16 FBR

17 Leak- 10mm Hole size Sphere tank outlet to export pump inlet

18 FBR

19 Leak- 10mm Hole size Outlet of export pump to ship loading

arm 20 FBR




Table 3-11: Jet Fire Radiation Distance

Sr.

No.

Scenario

Code Description

Jet Fire radiation

Downwind Distance at 1.5F(m) Downwind Distance at 5D(m)

4.70 kW/m2 12.50 kW/m2 37.50 kW/m2 4.70 kW/m2 12.50 kW/m2 37.50 kW/m2

1 10mm Storage Tank (Tank

No.91)

26.50 19.98 15.46 22.97 16.45 11.25

2 Catastrophic

Rupture NA NA NA NA NA NA

3 10mm

Road tanker

24.61 19.51 16.15 21.29 16.05 12.61

4 Catastrophic


5 10mm Unloading hose from

road tanker

NA NA NA NA NA NA

6 FBR 13.34 6.84 NR 18.76 17.52 NR

7 10mm Tank lorry unloading

hose to Butadiene

unloading pump inlet

32.66 26.20 22.09 28.54 21.82 17.70

8 FBR 325.11 255.51 212.80 287.77 216.17 173.14

9 10mm Butadiene unloading

pump outlet to sphere

tank inlet

32.46 26.04 21.96 28.36 21.68 17.59

10 FBR 178.19 140.70 117.53 156.90 118.40 95.256

11 10mm Vapour condenser

circuit for sphere tank

27.36 21.92 18.33 23.51 18.06 14.68

12 FBR 105.61 83.64 69.66 91.25 69.46 56.27

13 10mm Recirculation circuit

33.96 27.23 22.95 29.66 22.67 18.39

14 FBR 190.65 150.36 125.35 167.18 126.21 101.56

15 10mm Vapour balancing line

to road tanker inlet

22.78 17.00 NR 19.72 13.94 9.18

16 FBR 187.55 147.97 123.53 165.70 124.79 100.13

17 10mm Sphere tank outlet to

export pump inlet

33.66 27.01 22.78 29.45 22.51 18.26

18 FBR 672.04 526.12 436.67 598.00 447.67 356.99

19 10mm Outlet of export pump

to ship loading arm

33.96 27.24 22.96 29.66 22.67 18.40

20 FBR 221.66 174.54 145.29 194.14 146.46 117.77




Table 3-12: Late Pool Fire Distances

Sr.

No.

Scenario

Code Description

Late Pool fire



1 10mm Storage Tank (Tank

No.91)

NA NA NA NA NA NA

2 Catastrophic


3 10mm

Road tanker

19.05 14.87 11.07 18.05 16.20 14.13

4 Catastrophic



road tanker

NA NA NA NA NA NA

6 FBR NA NA NA NA NA NA


hose to Butadiene


20.25 15.34 10.86 21.58 17.79 12.49

8 FBR 59.98 46.15 34.51 62.86 50.63 39.27



tank inlet

33.58 23.48 14.68 31.23 24.11 15.99

10 FBR 143.18 94.29 59.36 140.72 98.02 70.43

11 10mm Vapour condenser

circuit for sphere tank

31.44 21.26 12.4 30.09 22.39 13.87

12 FBR 166.65 105.54 62.66 149.86 100.67 69.2


35.90 24.92 15.44 33.28 25.45 16.76

14 FBR 166.69 108.26 67.12 163.48 112.12 79.34

15 10mm Vapour balancing line

to road tanker inlet

NA NA NA NA NA NA

16 FBR 48.77 41.13 34.28 46.94 42.67 36.90


export pump inlet

34.22 24.02 15.14 31.51 24.45 16.37

18 FBR 355.86 232.99 150.47 357.45 244.17 174.16

19 10mm Outlet of export pump

to ship loading arm

36.05 25.02 15.49 33.32 25.48 16.78

20 FBR 367.02 232.58 142.67 334.28 221.78 152.24




Table 3-13: Late Explosion Distances

Sr.

No. Scenario Code Description

Late Explosion overpressure

Overpressure radius at 1.5F (m) Overpressure radius at 5D (m)

0.03 bar 0.10 bar 0.30 bar 0.03 bar 0.10 bar 0.30 bar

1 10mm Storage Tank (Tank No.91)

42.50 29.60 24.79 27.29 17.38 13.68

2 Catastrophic Rupture 4844.42 3685.48 3289.58 4243.96 3088.51 2749.12

3 10mm Road tanker

40.03 28.54 24.27 25.62 16.66 13.33

4 Catastrophic Rupture 904.23 643.31 555.20 812.79 555.26 482.95

5 10mm Unloading hose from road tanker

NA NA NA NA NA NA

6 FBR 51.73 39.27 34.63 35.41 26.57 23.28

7 10mm Tank lorry unloading hose to

Butadiene unloading pump inlet

66.50 51.30 45.64 50.12 38.58 34.28

8 FBR 450.14 427.12 418.55 468.14 463.47 461.73

9 10mm Butadiene unloading pump outlet

to sphere tank inlet

80.13 62.85 56.42 50.32 38.67 34.33

10 FBR 493.34 410.05 390.00 454.45 348.66 309.28

11 10mm Vapour condenser circuit for

sphere tank

77.53 61.74 55.84 37.02 27.20 23.62

12 FBR 496.74 366.70 318.28 275.73 203.62 176.77


81.75 63.54 56.76 63.29 49.93 44.96

14 FBR 569.12 508.43 489.19 477.84 364.37 322.13

15 10mm Vapour balancing line to road

tanker inlet

28.62 17.94 13.96 25.31 16.53 13.26

16 FBR 231.89 225.07 222.53 265.11 238.60 229.29

17 10mm Sphere tank outlet to export

pump inlet

81.38 63.38 56.68 51.36 39.11 34.55

18 FBR 1031.91 847.29 778.55 1089.60 1009.54 979.73

19 10mm Outlet of export pump to ship

loading arm

94.94 74.90 67.44 63.40 49.98 44.98

20 FBR 1079.75 856.22 773.00 635.28 471.67 410.75




Table 3-14: Fire Ball Radiation Distances

Sr.


Fire ball radiation



1 10mm

Tank No.91

NA NA NA NA NA NA

2 Catastrophic

Rupture 814.49 382.12 NR 814.49 382.12 NR

3 10mm

Road tanker

NA NA NA NA NA NA

4 Catastrophic

Rupture 169.87 71.91 NR 169.87 71.91 NR

5 10mm Unloading hose from road

tanker

NA NA NA NA NA NA


7 10mm Tank lorry unloading hose to

Butadiene unloading pump inlet

NA NA NA NA NA NA


9 10mm Butadiene unloading pump

outlet to sphere tank inlet

NA NA NA NA NA NA


11 10mm Vapour condenser circuit for

sphere tank

NA NA NA NA NA NA



NA NA NA NA NA NA


15 10mm Vapour balancing line to road

tanker inlet

NA NA NA NA NA NA


17 10mm Sphere tank outlet to export

pump inlet

NA NA NA NA NA NA


19 10mm Outlet of export pump to ship

loading arm

NA NA NA NA NA NA





Table 3-15: BLEVE Overpressure Distance

Sr.


BLEVE overpressure

Overpressure radius at 1.5F (m) Overpressure radius at 5D (m)

0.03 bar 0.10 bar 0.30 bar 0.03 bar 0.10 bar 0.30 bar

1 10mm

Tank No.91

NA NA NA NA NA NA

2 Catastrophic

Rupture 339.55 142.66 73.4 339.55 142.66 73.4

3 10mm

Road tanker

NA NA NA NA NA NA

4 Catastrophic

Rupture 95.3 37.99 20.51 95.3 37.99 20.51


road tanker

NA NA NA NA NA NA



hose to Butadiene


NA NA NA NA NA NA




tank inlet

NA NA NA NA NA NA


11 10mm Vapour condenser circuit

for sphere tank

NA NA NA NA NA NA



NA NA NA NA NA NA


15 10mm Vapour balancing line to

road tanker inlet

NA NA NA NA NA NA



export pump inlet

NA NA NA NA NA NA


19 10mm Outlet of export pump to

ship loading arm

NA NA NA NA NA NA





FACILITY FORM I


Analysis of Results Jet Fire

The jet fire due to Rupture of pipeline from sphere tank outlet to export pump inlet can cause

fatality risks within 436 m distance and the equipment may be subject to major damages.

Piloted ignition of wood, melting of plastics tubing’s is possible within the distance of 526 m.

First-degree burns may be caused for persons who are within 672 m distance.

Analysis of Results Late Pool Fire

The scenarios such as Rupture of pipeline from sphere tank outlet to export pump inlet and

Rupture of pipeline from outlet of export pump to ship loading arm can cause pool fire heat

radiation to extent maximum to 370 m.

The person within this range is subjected to get First degree burns and pain within 20 sec of

exposure.

Analysis of Results Late Explosion

The maximum dispersion of flammable gas can be observed in case of a Catastrophic Rupture

of Sphere Tank.

An overpressure of 0.3 bar can be felt up to a distance of 3289 meters equipment within this

distance can suffer permanent damage, it can also cause a lethality of around 50% for

persons who are within this distance.

An overpressure of 0.10 bar can be felt up to a distance of 3685 meters, equipment within

this range can suffer repairable damages, it can also cause a lethality of around 10% for

persons who are present in this distance range.

An overpressure of 0.03 bars can be felt up to a distance of 4844 meters, shattering of glass

etc., can be experienced in this distance range.

Analysis of results Fire Ball

Catastrophic rupture of Butadiene horten sphere can cause blistering of skin or first degree

burns to the person within range of 814 m and equipment (s) are subjected to damage within

range of 382 m from the source of release.

In case of catastrophic rupture of road tankers carrying Butadiene may cause pain and

blistering of skin to the persons within 169m.

Analysis of results: BLEVE Over Pressure

Heavy damage to equipments falling within 73.4m radius is possible in case of catastrophic

rupture of horten sphere.

Shattering of glasses with significant damage is possible for 339 m radius from the center of

explosion.

BLEVE explosion effect for road tanker carrying butadiene effect can be felt maximum upto 95

m radius.




Consequence Contours

Figure 3-5: Jet Fire Risk Contour due to 10 mm leak in Butadiene Storage Tank




Figure 3-6: Late Explosion Risk Contour due to Catastrophic Rupture of Butadiene Tank




Figure 3-7: Late Pool Fire Risk Contour due to 10 mm leak in Butadiene Road Tanker




Figure 3-8: Fireball Radiation due to Catastrophic Rupture of Butadiene Road Tanker




Figure 3-9: Jet Fire Risk Contour due to Failure of Unloading Hose from Road Tanker




Figure 3-10: Late Explosion Risk Contour due to 10 mm leak in Tank Lorry Unloading Hose to Butadiene Pump Inlet




Figure 3-11: Fire Ball Risk Contour due to FBR in Tank Lorry Unloading Hose to Butadiene Unloading Pump Inlet




Figure 3-12: Jet Fire Risk Contour due to 10 mm leak in Butadiene unloading pump outlet to Sphere Tank Inlet




Figure 3-13: Late Explosion Risk Contour due to 10 mm leak in Butadiene unloading pump outlet to Sphere Tank Inlet




Figure 3-14: Late Pool Fire Risk Contour due to FBR in Butadiene unloading pump outlet to Sphere Tank Inlet




Figure 3-15: Jet Fire Radiation Risk Contour due to FBR in Butadiene unloading pump outlet to Sphere Tank Inlet




Figure 3-16: Late Explosion Overpressure Risk Contour due to 10 mm leak in Vapor Condenser Circuit for Sphere Tank




Figure 3-17: Late Pool Fire Contour due to 10 mm Leak in Vapor Condenser Circuit for Sphere Tank




Figure 3-18: Jet Fire Risk Contour due to FBR in Vapor Condenser Circuit for Sphere Tank




Figure 3-19: Late Pool Fire Risk Contour due to 10 mm Leak in Recirculation Circuit




Figure 3-20: Jet Fire Risk Contour due to 10 mm leak in Recirculation Circuit




Figure 3-21: Jet Fire Risk Contour due to 10 mm leak in Vapor Balancing Inlet Line to Road Tanker Inlet




Figure 3-22: Late Explosion Overpressure Risk Contour due to 10 mm leak in Vapor Balancing Inlet Line to Road Tanker Inlet




Figure 3-23: Late Pool Fire Risk Contour due to FBR in Vapor Balancing Inlet Line to Road Tanker Inlet




Figure 3-24: Late Pool Fire Risk Contour due to 10 mm Leak in Sphere Tank Outlet to Export Pump Inlet




Figure 3-25: Late Explosion Risk Contour due to 10 mm Leak in Sphere Tank Outlet to Export Pump Inlet




Figure 3-26: Late Pool Fire Risk Contour due to 10 mm leak in Outlet of Export Pump to Ship Loading Arm




Figure 3-27: Late Explosion Overpressure Risk Contour due to 10 mm Leak in Outlet of Export Pump to Ship Loading Arm




FACILITY FORM I


Annexure 15: Existing Risk Control Measures

Butadiene Sphere design shall be based on ASME Sec VIII Div 1 /BS 5500.

MOC of plate for sphere design shall be as per A516 gr 70.

All safety systems PSVs shall be with rupture disc.

Fire fighting equipments like Water spray, hydrants/monitors are provided as per

statutory requirements.

Refrigeration / chilling conditions are provided for butadiene in spheres to maintain

temperature & pressure.

System is provided with safety valves connecting them to a hot flare or vent stack in an

open point.

Three (3) no’s fire water pumps (2 Working +1stand by) each of pumping capacity

273m3/hr @ 88 MWC are proposed to be provided for hydrant system.

Two no’s jockey pumps electric driven 10.8 m3/hr @ 88 MWC (working) provided for

pressurizing the system.

The design of the system is as per guidelines of Fire Protection Manual & Rules for Water

hydrant system

In case of fire ship shall be towed in open sea away from jetty. The fire protection system

is treated as first aid till towing is done. Fire-fighting shall be done through tug.

In case of fire two source of water shall be available

o From fire water pump house

o Sea water from tug at one end of jetty

Fire tenders (water & foam) are available at jetty during unloading of ship.

Portable Trolley Mounted Water cum Foam Monitor 3030 lpm capacity 2 nos with Foam

Tank & inline inductor with foam trolley 1000 Ltr capacity shall provide in jetty area

Fixed Water cum foam monitor 3030 LPM capacity with fix foam connection shall provide

in the jetty area.

Manual Medium velocity water spray system on jetty area in trench for connection flanges

and oil spillage.

Water Spray ring and detection ring shall be available over spheres.

eia & emp for 100 mw thermal power plant at...

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