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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
ADANI HAZIRA PORT PVT. LTD.
FORM-1 FOR EC AMENDMENT FOR
HANDING OF BUTADIENE STORAGE
FACILITY FORM I
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2014 20
Annexure 2: Existing Environmental Clearance and CRZ Clearance
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FORM-1 FOR EC AMENDMENT FOR
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ADANI HAZIRA PORT PVT. LTD.
FORM-1 FOR EC AMENDMENT FOR
HANDING OF BUTADIENE STORAGE
FACILITY FORM I
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2014 22
ADANI HAZIRA PORT PVT. LTD.
FORM-1 FOR EC AMENDMENT FOR
HANDING OF BUTADIENE STORAGE
FACILITY FORM I
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2014 23
ADANI HAZIRA PORT PVT. LTD.
FORM-1 FOR EC AMENDMENT FOR
HANDING OF BUTADIENE STORAGE
FACILITY FORM I
KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER 2014 24
ADANI HAZIRA PORT PVT. LTD.
FORM-1 FOR EC AMENDMENT FOR
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Annexure 3: Site Location Map
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Annexure 4: Butadiene Storage & Pipeline area superimpose to CRZ Mapping
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FORM-1 FOR EC AMENDMENT FOR
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Annexure 5: Site Layout Map for Storage Facility
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Annexure 6: Site Layout for Butadiene Storage
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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
ADANI HAZIRA PORT PVT. LTD.
FORM-1 FOR EC AMENDMENT FOR
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Annexure 7: Soil Testing Report of the Site
ADANI HAZIRA PORT PVT. LTD.
FORM-1 FOR EC AMENDMENT FOR
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FACILITY FORM I
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ADANI HAZIRA PORT PVT. LTD.
FORM-1 FOR EC AMENDMENT FOR
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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
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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
ADANI HAZIRA PORT PVT. LTD.
FORM-1 FOR EC AMENDMENT FOR
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FACILITY FORM I
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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.
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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
ADANI HAZIRA PORT PVT. LTD.
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FACILITY FORM I
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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
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Figure 3-2: Flow and Hydraulic diagram of 50 KLD ETP
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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
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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.
ADANI HAZIRA PORT PVT. LTD. FORM-1 FOR EC AMENDMENT FOR HANDING OF BUTADIENE
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Figure 3-3: Flow and Hydraulic diagram of 25 KLD STP
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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
7 DG Set 380 kVA 1 HSD 2376 lit /Day
8 DG Set 200 kVA 1 HSD 1200 lit /Day
Proposed
1 DG Set 1250 kVA 1 HSD 5000 lit /Day
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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
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Figure 3-4: Membership Certificate
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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
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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
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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
Rupture NA NA NA NA NA NA
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
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Table 3-12: Late Pool Fire Distances
Sr.
No.
Scenario
Code Description
Late Pool fire
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)
NA NA NA NA NA NA
2 Catastrophic
Rupture NA NA NA NA NA NA
3 10mm
Road tanker
19.05 14.87 11.07 18.05 16.20 14.13
4 Catastrophic
Rupture NA NA NA NA NA NA
5 10mm Unloading hose from
road tanker
NA NA NA NA NA NA
6 FBR NA NA NA NA NA NA
7 10mm Tank lorry unloading
hose to Butadiene
unloading pump inlet
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
9 10mm Butadiene unloading
pump outlet to sphere
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
13 10mm Recirculation circuit
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
17 10mm Sphere tank outlet to
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
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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
13 10mm Recirculation circuit
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
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Table 3-14: Fire Ball Radiation Distances
Sr.
No. Scenario Code Description
Fire ball 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
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
6 FBR NA NA NA NA NA NA
7 10mm Tank lorry unloading hose to
Butadiene unloading pump inlet
NA NA NA NA NA NA
8 FBR NA NA NA NA NA NA
9 10mm Butadiene unloading pump
outlet to sphere tank inlet
NA NA NA NA NA NA
10 FBR NA NA NA NA NA NA
11 10mm Vapour condenser circuit for
sphere tank
NA NA NA NA NA NA
12 FBR NA NA NA NA NA NA
13 10mm Recirculation circuit
NA NA NA NA NA NA
14 FBR NA NA NA NA NA NA
15 10mm Vapour balancing line to road
tanker inlet
NA NA NA NA NA NA
16 FBR NA NA NA NA NA NA
17 10mm Sphere tank outlet to export
pump inlet
NA NA NA NA NA NA
18 FBR NA NA NA NA NA NA
19 10mm Outlet of export pump to ship
loading arm
NA NA NA NA NA NA
20 FBR NA NA NA NA NA NA
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Table 3-15: BLEVE Overpressure Distance
Sr.
No. Scenario Code Description
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
5 10mm Unloading hose from
road tanker
NA NA NA NA NA NA
6 FBR NA NA NA NA NA NA
7 10mm Tank lorry unloading
hose to Butadiene
unloading pump inlet
NA NA NA NA NA NA
8 FBR NA NA NA NA NA NA
9 10mm Butadiene unloading
pump outlet to sphere
tank inlet
NA NA NA NA NA NA
10 FBR NA NA NA NA NA NA
11 10mm Vapour condenser circuit
for sphere tank
NA NA NA NA NA NA
12 FBR NA NA NA NA NA NA
13 10mm Recirculation circuit
NA NA NA NA NA NA
14 FBR NA NA NA NA NA NA
15 10mm Vapour balancing line to
road tanker inlet
NA NA NA NA NA NA
16 FBR NA NA NA NA NA NA
17 10mm Sphere tank outlet to
export pump inlet
NA NA NA NA NA NA
18 FBR NA NA NA NA NA NA
19 10mm Outlet of export pump to
ship loading arm
NA NA NA NA NA NA
20 FBR NA NA NA NA NA NA
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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.
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Consequence Contours
Figure 3-5: Jet Fire Risk Contour due to 10 mm leak in Butadiene Storage Tank
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Figure 3-6: Late Explosion Risk Contour due to Catastrophic Rupture of Butadiene Tank
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Figure 3-7: Late Pool Fire Risk Contour due to 10 mm leak in Butadiene Road Tanker
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Figure 3-8: Fireball Radiation due to Catastrophic Rupture of Butadiene Road Tanker
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Figure 3-9: Jet Fire Risk Contour due to Failure of Unloading Hose from Road Tanker
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Figure 3-10: Late Explosion Risk Contour due to 10 mm leak in Tank Lorry Unloading Hose to Butadiene Pump Inlet
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Figure 3-11: Fire Ball Risk Contour due to FBR in Tank Lorry Unloading Hose to Butadiene Unloading Pump Inlet
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Figure 3-12: Jet Fire Risk Contour due to 10 mm leak in Butadiene unloading pump outlet to Sphere Tank Inlet
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Figure 3-13: Late Explosion Risk Contour due to 10 mm leak in Butadiene unloading pump outlet to Sphere Tank Inlet
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Figure 3-14: Late Pool Fire Risk Contour due to FBR in Butadiene unloading pump outlet to Sphere Tank Inlet
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Figure 3-15: Jet Fire Radiation Risk Contour due to FBR in Butadiene unloading pump outlet to Sphere Tank Inlet
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Figure 3-16: Late Explosion Overpressure Risk Contour due to 10 mm leak in Vapor Condenser Circuit for Sphere Tank
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Figure 3-17: Late Pool Fire Contour due to 10 mm Leak in Vapor Condenser Circuit for Sphere Tank
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Figure 3-18: Jet Fire Risk Contour due to FBR in Vapor Condenser Circuit for Sphere Tank
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Figure 3-19: Late Pool Fire Risk Contour due to 10 mm Leak in Recirculation Circuit
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Figure 3-20: Jet Fire Risk Contour due to 10 mm leak in Recirculation Circuit
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Figure 3-21: Jet Fire Risk Contour due to 10 mm leak in Vapor Balancing Inlet Line to Road Tanker Inlet
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Figure 3-22: Late Explosion Overpressure Risk Contour due to 10 mm leak in Vapor Balancing Inlet Line to Road Tanker Inlet
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Figure 3-23: Late Pool Fire Risk Contour due to FBR in Vapor Balancing Inlet Line to Road Tanker Inlet
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Figure 3-24: Late Pool Fire Risk Contour due to 10 mm Leak in Sphere Tank Outlet to Export Pump Inlet
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Figure 3-25: Late Explosion Risk Contour due to 10 mm Leak in Sphere Tank Outlet to Export Pump Inlet
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Figure 3-26: Late Pool Fire Risk Contour due to 10 mm leak in Outlet of Export Pump to Ship Loading Arm
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Figure 3-27: Late Explosion Overpressure Risk Contour due to 10 mm Leak in Outlet of Export Pump to Ship Loading Arm
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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.