Facility Description:

Facilities

The existing facilities at Gujarat Refinery include 33 Process units (including RUP) with 282 storage
tanks of size varying from 200 KL to 65000 KL. Details of the various Units in Gujarat Refinery are as
given below:

Plant Facilities

1. Atmospheric Distillation Unit: AU-1 to AU-5.

2. Catalytic Reforming Unit (CRU).
3. UDEX Plant.
4. Food Grade Hexane (FGH).
5. Vacuum Distillation Unit (VDU).
6. VisbreakerUnit (VBU).
7. Bitumen Blowing Unit (BBU).
8. Feed Preparation Unit (FPU-1).
9. Fluidized catalytic Cracking Unit.
10. Feed Preparation Unit (FPU-2).
11. Hydrocracker Unit (HCU).
12. Hydrogen Generation Unit (H2 Unit) -2Nos.
13. Diesel Hydro-Desulphurisation.
14. Methyl Tertiary Butyl Ether
15. Butene-I
16. Sulphur Recovery Units (SRU).
17. LAB
18. MSQ Unit.
19. DHDT.
20. HGU-III.
21. SRU 2
22. ISOM
23. VGO-HDT
24. DCU
25. RO Plant
26. N2-I & N2-II
27. LPG MEROX.

Offsite Facilities:
1. Storage tanks for crude oil, intermediate, finished products and handling facilities.
2. LPG storage and dispatch facilities.
3. Hydrogen bullets storage facilities.
4. Effluent Treatment plant.
Other facilities:

Water system consisting of:

1. Raw water ( drawn from river Mahi) cooling water,

2. Service water Boiler feed water.
3. Fire water system,
4. Drinking water,
5. Domestic waste water.

Steam system consisting of:

1. HP steam (40 kg/sq.cm), MP steam ( 13 kg/sq.cm), LP steam.

2. Condensate system.

Air /inert Gas system consisting of:

1. Instrument Air
2. Plant Air
3. Inert gas system

Purge gas fuel system consisting of:

1. Fuel gas
2. Fuel oil
3. Naphtha
4. Natural gas(For gas turbine).

Power Generation system- Captive power plants

1. Old TPS
2. 4 Boilers ( 3 of 75 T/hr& 1 of 130 T/hr capacity).
3. 3 Turbines ( 2× 12.0 MW & 1× 12.5 MW)
4. 1 CO Boiler ( 78 T/hr MP Steam) in FCCU.

Power plant for CGP-I

1. 3 Gas Turbines of 30 MW capacity each.

2. 3 nos. Waste heat recovery boilers of 100 T/hr each.

Power plant for CGP-II

1. 2 Gas turbines of 30 MW capacity each

2. 2 nos. Waste heat recovery boilers of 100 T/hr each.
3. 1 nos. Gas turbines of 30 MW capacity each-GT-6 Project.
4. 1 nos. Waste heat recovery boilers of 125 T/hr each-GT-6 Project.
Site, location and Vicinity
Gujarat Refinery was established in 1965 near village Koyali in Vadodara district. Close by, within
distance of 3 to 4 KM are the Bajwa&RanoilRailway stations on the Vadodara –Ahmadabad main
board gauge line and the National Highway No. 8. The main city of Vadodara is located to the south
about 5 km away from the refinery location. The geography location of Vadodara is 22°18´N latitude
and 73°15´ E longitudes.

Hazard Identification
The Hazardous scenarios considered in the CRA for the project facility will be identified based on the
properties of the materials handled and the identification of the potential hazards in the pipeline
systems which could lead to loss of containment events.

A technique commonly used to generate an incident list is to consider potential leaks and major
releases from fractures of all process pipelines & vessels. This compilation includes all pipe work and
vessels in direct communication, as these may share a significant inventory that cannot be isolated in
an emergency.

The following data were collected to envisage scenarios:

 Composition of materials stored in vessels/flowing through pipeline

 Inventory of materials stored in vessels.
 Flow rate of materials passing through pipelines.
 Vessels /pipeline conditions(phase, temperature, pressure)
 Connecting piping & piping dimensions.

Accidental releases of the flammables liquids/gases can result in severe consequences. Delayed
ignition of the flammable gases can result in blast over pressures cover large areas. This may lead to
extensive loss of life and property. In contrast fires have localized consequenses. Fire can be put out
or contained in most cases; there are few mitigating actions one can take once a flammable gas or a
vapour cloud gets released. Major accident hazards arise, therefore consequent upon the released
of flammable gases.

Consequense Analysis
Consequense assessment is conducted to understand the impact of identified scenarios in terms of
thermal radiation( Jet fire, Flash fire,Pool fire) explosion ( vapour cloud explosion) & toxic dispersion.
A range of potential consequenses are assesed for each of the releases scenarios identified. This step
identifies the fatality probality, based on hazard type and cause by each release case, to personnel at
a range of distances.
The consequenses evaluation of accidental release will include the calculation of the following
parameters as a minimum:

 Source term ( vapour and or liquid and or two phase discharge rate; release duration,
Spreading and evaporation).
 Fire characterises ( jet fire, pool fire, flash fire)
 Dispersion characterises ( flammable clouds)
 Explosion characterises
 Hazardous distances (referredto radiation from fires, UFL, LFL, and overpressure levels).
 Comparison of the physical effects model with the impact criteria.
 The consequence modeling will be performed using PHAST 7.2 software.

Frequency Analysis
Once the potential release scenarios are identified, the next stage is to estimate the failure
frequencies ( likelihood for the event to occur) based on the international standard databases.

The frequency analysis will be performed as follows:

 Identification of the base failure frequencies applicable to the pipelines and storage tanks
from the relevant internation standard database.
 The total failure frequencies will be derived from the base failure frequency data along with
the consideration of modication factors if applicable.

Risk assessment
Risk assessment will be undertaken to evaluate the risk associated with the project facilities. The
risk shall be typically presented as Location Specific Individual Risk ( LSIR) contours overlaid on a
map and Individual Risk Per Annum (IRPA).

Risk Evaluation
It involves the evaluation of the individual risk results against the UK HSE risk acceptance criteria to
determine whether the risks are boardly aceptable, ALARP or unacceptable and to make some
professional judgements about the significance of the risks.

Risk Reduction Measures

Based on the risk evaluation ,if the calculated risks fall in the unaceptable region, risk reduction
measures shall be implemented in order to reduce the risk to a tolerable or ALARP region. All
physically possible risk reduction measures shall be identified, which could be new measures or
improvement to existing measures already installed/implemented. The risk evaluation after
implementation of recommendation /risk reduction measures shall be carried out to demonstrate
that the risk shall be reduced to ALARP region and the study recommendations are adequate for the
project.
Occupancy Data & Population

The occupancy data associated with the IOCL Gujarat Refinery Vadodara are present below:

Occupancy data –Project facilities

Location of interest Working hours

IOCL Gujarat Refinery, Vadodara 24

Population:
Facility population will be considered based on the input taken from the previous
comprehensive analysis report
Population Details:

No Description Day time Night time

Plant facility
1 GR-1 control room 32 23
2 GRE control room 17 11
3 GR-2 control room 18 14
4 GHC control room 18 14
5 GRSPF control room 25 19
6 SRU control room 10 07
7 LAB control room 46 28
8 Atmospheric unit-I CCH 4 4
9 AU-II CCH 4 4
10 CRU CCH 4 4
11 AU-V CCH 4 4
12 AU-IV CCH 5 5
13 MTBE unit CCH 2 2
14 FGH unit CCH 2 2
15 FPU-II CCH 4 4
16 HCU/HGU-I CCH 4 4
17 DHDS CCH 4 4
18 LAB CCH 3 3
19 MSQU CCH 4 4
20 DHDTU CCH 2 2
21 HGU-III CCH 1 1
22 SRU-III CCH 2 2
23 ISOM CCH 2 2
 Persons working in non-plant area
1 Technical Building 200
2 MIS Building 20
3 Canteen 125
4 Training centre 25
5 Fire station 25 13
6 Second Fire station 5 4
7 MR Workshop 18
8 Elect. Workshop 7
9 Stores 35
10 Telephone Exchange 16
11 Test Lab Elect. 22
12 12 Chemical Lab 25 12

Persons working in off-site area

1 OMS control room 150 100
2 LPG control room 10 5
3 TTL operations monitoring station 10
4 TTL operations/ driver/conductors in field 45
5 GR crude P/H operator station 5 5
6 GRE crude P/H operator station 5 5
7 GRE product P/H operator station 5 5
8 GR/GRE sump operator station 1 1
9 BITUMIN truck loading gantry 52 2
10 Drum filing area
11 GT-4 & 5 control room 6 6
12 Marketing division office 40 40

Persons working in utility area

1 17 12
TPS ( it include DAM plant, inst. Air & plant air)
2 TPS ( it include DAM plant, inst. Air & plant air) CCH 3
3 CGP ( it include DAM plant, inst. Air & plant air) 15 12
4 CGP ( it include DAM plant, inst. Air & plant air) CCH 2
5 3 ETP 10 8
6 GRE fire water control room(For main FW pump 5 5
+GRE cooling Tower)
7 CGP FW P/H Control room 1 1
8 FCC cooling tower operator cabin 1
9 AU-V cooling tower operator cabin 1
10 GHC cooling tower operator cabin 1
 11 North block cooling tower operator cabin 1
12 South block cooling tower operator cabin 1

Population data of the surrounding 2000 m from the facility will be taken from
census of India database. For the locations for which the population data is
unavailable in the database, district population density will be considered.

Comprehensive Risk Assessment Study

Hazard identification
A classical definition of hazard states that hazard is in fact the characteristic of
system/plant/process that presents potential for an accident. Hence all the
components of a system /plant/process need to be thoroughly examined in order to
assess their potential for initiating or propagating an unplanned event/sequence of
events, which can be termed as an accident.
In Risk Analysis terminology a hazard something with the potential to cause harm.
Hence the hazard identification step is an exercise that seeks to identify what can go
wrong at the major hazard installation or process in such a way that people may be
harmed. The output of this step is a list of events that need to be passed on the later
steps for further analysis.
The identification of hazardous events associated with the project facility is carried
out based on the past accidents, lessons learnt, properties of the materials handled
and the potential hazards in the project scope facility which can lead to loss of
containment events.
This list includes the following elements
 Catastrophic Rupture of pressure vessel
 Large hole on outlet of process vessel
 Small hole, Cracks or small bore failure ( i.e instrument tapping
failure ,drains/ vents failure etc.) in piping and vessels.
 Guillotine- Breakage of pipe work.
 Flange leaks
 Storage tank on fire
 Leaks from pump glands and similar seals.

Hazardous materials

Various hydrocarbons, Hydrogen(H₂), Hydrogen Sulphide(H₂S), Benzene,

Chlorine(Cl), Ammonia(NH₃), Methyl-Tert-Butyl-Ether(MTBE) are the hazardous
materials in this facility.
Hazards Associated with Flammable materials

Liquefied Petroleum Gas

LPG is a colorless liquefied gas that is heavier then air and may have a foul smelling odorant
added to it. It is a flammable gas and may cause flash fire and delayed ignition.

LPG is incompatible to oxidizing and combustible materials. It is stable at normal

temperatures and pressure. If it is released at temperatures higher than the normal boiling
point it can flash significantly and would lead to high entrainment of gas phase in the liquid
phase. High entrainment of the gas phase in the liquid phase can lead to jet fires. On the fire
hand negligible flashing i.e. release of LPG at temperatures near boiling points would lead to
formation of pools and then pool fire. LPG releases may also lead to explosion in case of
ignition.

Inhalation of LPG vapours by human beings in considerable concentration may affect the
central nervous system and lead to depression. Inhalation of extremely high concentration
of LPG may lead to death due to suffocation from lack of oxygen.

Flammable properties of LPG

S. NO PROPERTIES VALUES
1 LFL (%v/v) 1.7
2 UFL (%v/v) 9.0
3 Auto ignition temperature (°C) 420-540
4 Heat of combustion (Kcal/Kg) 10960
5 Normal boiling point (°C) -20 to -27
6 Flash point (°C) -60

Hydrogen
Hydrogen(H₂) is a gas lighter than air at the normal temperature and pressure. It is highly
flammable and explosive. It has the widest range of flammable concentrations in air among
all common gaseous fuels. This flammable range of hydrogen varies from 4% by volume
(lower flammable limit) to 75% by volume (Upper flammable limit). Hydrogen flame (or fire)
is nearly invisible even though the flame temperature is higher than that of hydrocarbon
fires and hence poses greater hazards to persons in the vicinity. Constant exposure of
certain types of ferritic steels to hydrogen results in the embrittlement of the metals.
Leakage can be caused by such embrittlement in pipes, welds, and metal gaskets. In term of
toxicity, hydrogen is a simple asphyxiant. Exposure to high concentrations may exclude an
adequate supply of oxygen to the lungs. No significant effect to human through dermal
absorption and ingestion is reported.

Flammable properties of Hydrogen

S. NO PROPERTIES VALUES
1 LFL (%v/v) 4.12
2 UFL (%v/v) 74.2
3 Auto ignition temperature (°C) 500
4 Heat of combustion (Kcal/Kg) 28700
5 Normal boiling point (°C) -252
6 Flash point (°C) N.A

Naphtha and other heavier hydrocarbons

The major hazards from these types of hydrocarbons are fire and radiation. Any spillage or
loss of containment of heavier hydrocarbons may create highly flammable pool of liquid
around the source of release. If it is released at temperatures higher than the normal boiling
point it can flash significantly and would lead to high entrainment of gas phase in the liquid
phase.High entrainment of the gas phase in the liquid phase can lead to jet fires.On the fire
hand negligible flashing i.e. release of LPG at temperatures near boiling points would lead to
formation of pools and then pool fire.

Spillage of comparatively lighter hydrocarbons like naphtha may result in formation of vapor
cloud. Flash fire/ explosion can occur in case of ignition.

Flammable properties of Naphtha and other heavier hydrocarbons

S. NO PROPERTIES VALUES
1 LFL (%v/v) 0.8
2 UFL (%v/v) 5.0
3 Auto ignition temperature (°C) 228
4 Heat of combustion (Kcal/Kg) 10,100
5 Normal boiling point (°C) 130-155
6 Flash point (°C) 38-42

Hazard associated with Toxic/ Carcinogenic materials

Hydrogen sulphide
Hydrogen sulphide is a known toxic gas and has harmful physiological effects. Accidental
release of hydrocarbons containing hydrogen sulphide poses toxic hazards to exposed
population.

Toxic properties of Hydrogen sulphide

Sl. no Concentration(ppm) Concentration(ppm)

1 Odor threshold 0.0047
2 Threshold limit value(TLV) 10
3 Short term exposure limit(STEL)(15 minutes) 15
4 Immediately dangerous to life and health (IDLH) 100
level (for 30 minutes)

Benzene
The hazards associated with benzene are both toxic and flammable hazards. Benzene has a
very low flash point (-11.1°C), indicating that its vapour cloud easily gets ignited. The vapour
cloud which is about 3 times heavier than air may originate flash fire and explosions.If it is
released at temperatures higher than the normal boiling point it can flash significantly and
would lead to high entrainment of gas phase in the liquid phase.High entrainment of the gas
phase in the liquid phase can lead to jet fires.On the fire hand negligible flashing i.e. release
of LPG at temperatures near boiling points would lead to formation of pools and then pool
fire.

Inhaling very high concentration of benzene vapours can results in death, while inhalation of
lower concentration can cause drowsiness, dizziness, rapid heart rate, headaches, and
unconsciousness. The major effect of exposure to benzene for a prolonged period (365day
or longer) may adversely affect bone marrow and cause a decrease in red cell reading to
anaemia. Benzene is a recognized carcinogenic.

Flammable properties of Benzene

S. NO PROPERTIES VALUES
1 LFL (%v/v) 1.4
2 UFL (%v/v) 8
3 Auto ignition temperature (°C) 562
4 Heat of combustion (Kcal/Kg) 9700
5 Normal boiling point (°C) 80
6 Flash point (°C) -11.1
Toxic properties of Benzene

Sl. no Concentration(ppm) Concentration(ppm)

1 Odor threshold 0.16-320
2 Threshold limit value(TLV) 10
3 Short term exposure limit(STEL)(15 minutes) 5
4 Immediately dangerous to life and health (IDLH) 500
level (for 30 minutes)

Chlorine
Chlorine is required in a refinery complex of water treatment. Chlorine tonner is therefore
located near the cooling water system. Chlorine gas is not flammable but highly poisonous
in nature. Its routes of entry into the human body are human inhalation, ingestion, skin and
eyes. An exposure to chlorine can cause eye irritation, sneezing, restlessness. Exposure to
high concentration of chlorine can cause respiratory distress and violent coughing. Lethal
effects of inhalation depend not only on the concentration of the gas to which people are
exposed, but also on the duration of exposure.

Toxic properties of Chlorine

Sl. no Concentration(ppm) Concentration(ppm)
1 Short term exposure limit(STEL)(15 minutes) 2
2 Immediately dangerous to life and health (IDLH) 10
level (for 30 minutes)

Ammonia
Ammonia may be release from failure of connection tube of ammonia cylinder used in
Atmospheric Unit (AU). Ammonia is also likely to be present in sour gas produced from sour
water Stripper Unit (SWSU). The hazard associated with Ammonia is both toxic and
flammable hazards. Toxic hazards being more pronounced. Vapours of ammonia may cause
severe eye or throat irritation and permanent injury may result. Contact with the liquid
freezes skin and produced a caustic burn.
Toxic properties of Ammonia
Sl. no Concentration(ppm) Concentration(ppm)
2 Threshold limit value(TLV) 25
3 Short term exposure limit(STEL)(15 minutes) 35
4 Immediately dangerous to life and health (IDLH) 300
level (for 30 minutes)

Modes of failure
There are various potential source of large leakage, which may release hazardous chemicals
and hydrocarbons materials into the atmosphere. These cloudsbe in from of gasket failure
in flanged joints, bleeder valve left open inadvertently, instrument tubing giving way, pump
seal failure, guillotine failure, of equipment/pipeline or any other source of leakage.
Operating experience can identify lots of these sources and their modes of failure. A list of
general equipment and pipeline failure mechanisms is as follows:

Material /construction Defects

 Incorrect selection or supply of materials of construction

 Incorrect uses of design codes
 Weld failures
 Failure of inadequate pipeline supports

Pre – operational failures

 Failure induced during delivery at site

 Failure induced during installation
 Pressure and temperature effects
 Overpressure
 Temperature expansion/contraction ( improper stress analysis and support design)
 Low temperature brittle fracture (if metallurgy is incorrect)
 Fatigue loading (cycling and mechanical vibration)
Corrosion failures

 Internal corrosion (e.g. ingress of moisture)

 External corrosion
 Cladding /insulation failure ( e.g. ingress of moisture)
 Cathodic protection failure, if provided

Failures due to operational errors

 Human error
 Failure to inspect regularly and identify any defects

External impact induced failures

 Dropped objects
 Impact from transport such as construction traffic
 Vandalism
 Subsidence
 Strong winds

Failure due to fire

 External fire impinging on pipeline and equipment

 Rapid vaporization of cold liquid in contact with hot surfaces.

Consequence Analysis

Discharge Rate
The initial rate 0f release through a leak depends mainly on the pressure inside the
equipment, size of the hole and phase of the release (liquid, gas or two phase). The release
rate decreases with time as the equipment depressurizes. This reductions depends mainly
on the inventory and the actions taken to isolate the leak and blow-down the equipment.

Dispersion
Releases of gas into the open air from clouds whose dispersion is governed by the wind, by
turbulence around the site, the density of the gas and initial momentum of the release, in
case of the flammable materials the sizes of these gas clouds above their lower flammable
limit (LFL) are important in determining whether the release will ignite. In this study, the
results of dispersion modelling for flammable materials are presented LFL quantity .
Flash fire
A flash fire occurs when a cloud of vapours /gas burns without generating any significant
overpressure. The cloud is typically ignited on its edge, remote from-the leak source. The
combustion zone moves through the cloud away from the ignition point. The duration of the
flash fire is relatively short but it may stabilized as a continuous jet fire from the leak source.