Physical Properties:: Haldia Refinery

PHYSICAL PROPERTIES:
IT IS A MIXTURE OF PROPANE & BUTANE.

COLOURLESS BOTH AS A LIQUID AND A VAPOUR.
LPG IS ODOURLESS, BUT USUALLY ADDED TRACE QUANTITIES
OF ODORING AGENT(MERCAPTAN) TO ENABLE DETECTION BY
SMELL.
DENSITY: LIQUID LPG IS ONLY HALF THE WEIGHT OF WATER.
: LPG AS A GAS IS TWICE THE WEIGHT OF AIR.
EXPLOSIVE LIMIT : 1.8-9.6% VOL.IN AIR.
IGNITION TEMPERATURE : 405-450 Oc.
LIQUID TO GAS EXPANSION: 1:250
VAPOUR PRESSURE AT 37.5 deg. Cel = 7.7 kg/cm2(Appox)
Igniting Minds... Energizing Lives
Haldia Refinery
Liquefied Petroleum Gas
FIRE HAZARD:
EXTREMELY FLAMMABLE GAS
DANGEROUS WHEN EXPOSED TO HEAT OR FLAME. IT BURNS WITH A BLUE
FLAME WHEN MIXED WITH CORRECT PROPORTION OF AIR. IF THE AIR
SUPPLY IS INSUFFICIENT, THE FLAME BURNS YELLOW AT THE EDGES. NO
SMOKE IS PRODUCE DURING BURNING.
HEALTH HAZARD:
LPG CONTAINS NO TOXIC COMPONENTS SUCH AS CARBON MONOXIDE AND
IS THEREFORE NON POISONOUS.
INHALATION: EXPOSURE TO HIGH CONC. OF LPG WILL PRODUCE
UNCONSCIOUSNESS & SUBSEQUENT ASPHYXIATION.
SKIN AND EYE CONTACT: IF LIQUID LPG COMES INTO CONTACT WITH
UNPROTECTED SKIN AND EYES THEY WILL EVAPORATE QUICKLY AND THE
COOLING EFFECT COULD PRODUCE FROST BITE OR COLD BURNS.
TLV(TWA): 1000 PPM
Haldia Refinery


FACTORS AFFECT RATE OF EVAPORATION DURING LPG SPILL
AMBIENT TEMPERATURE
WEATHER CONDITIONS
SLOPE OF THE GROUND
CONDUCTIVITY OF THE GROUND
SURFACE AREA OF THE SPILL (ANY OBSTRUCTIONS SUCH AS
BOUNDARY WALLS WILL SLOW RATE OF EVAPORATION).
IF WATER IS SPRAYED ONTO A LPG LIQUID SPILL, IT WILL ACT AS A
HEAT SOURCE AND INCREASE THE EVAPORATION RATE.
Haldia Refinery
TYPES OF INCIDENTS ARISING FROM COMBUSTION
A. NORMAL FIRES
OFTEN RESULT FROM IMMEDIATE IGNITION FOLLOWING A SPILL.
USUALLY BURNS WITH A DIFFUSED FLAME WITH NO EXPLOSION.
RADIATION CAN IGNITE OTHER COMBUSTIBLES IN THE AREA
SOLUTION: CUT OFF AIR/FUEL SUPPLY TO FLAME & APPLY COOLING
B. FLASH FIRES
IGNITION OF OVERRICH CLOUD OF FUEL IN AIR
FLAME BURNS BACK AGAINST CLOUD
GENERALLY NO EXPLOSION
CAN IGNITE OTHER SOURCES OF FUEL
Haldia Refinery
BLEVE

A BOILING LIQUID EXPANDING VAPOUR EXPLOSION IS STARTED BY
THE HEATING OF A VESSEL CONTAINING FLAMMABLE LIQUID BY AN
EXTERNAL FIRE.

CONTENT IS HEATED ABOVE ITS BOILING POINT AND PRESSURE IN
THE VESSLE INCREASES.

Haldia Refinery
UVCE

AN UNCONFINED VAPOUR CLOUD EXPLOSION IS AN EVENT WHERE A
FLAMMABLE FUEL/AIR CLOUD BURNS IN FREE SPACE, GENERATING
SHOCK WAVES.

COMBUSTION MECHANISM STARTS FROM A POINT OF IGNITION SOURCE,
WITH THE FLAME FRONT ACCELERATING FROM A LOW INITIAL VELOCITY
TO SONIC VELOCITY.

Haldia Refinery
LIQUEFIED PETROLEUM GAS (LPG)
VAPOUR
LIQUID
HOT AREA
RELIEF VENT OPENS AT 17.6 kg/cm2
UNEXPOSED
SHELL
SUPPORT
SLOP
TANK SHELL OVERHEATED ABOVE LIQUID LEVEL

MAGNITUDE OF BLEVE:

PIECES OF CONTAINER CAN SHOOT OFF SOME 1000 METRE OR MORE
DISTANCE.
DEATH FROM SUCH MISSILES MAY OCCUR UPTO 250 M.
FIRE BALLS OF 30 METRE (HUNDRED FEET) DIAMETER IS NOT
UNCOMMON.
SEVERE BURN DAMAGE IN A 300-400 M RADIUS.
A SHOCK WAVE FROM BLEVE CAN BREAK WINDOWS SEVERAL
KILOMETER AWAY
FLAME TEMPERATURES AS HIGH AS 1200 deg C.

REMEMBER: THERE IS NO SAFETY PERIOD, A BLEVE CAN OCCUR AT ANY
TIME.`

Haldia Refinery

FIRE FIGHTING PROCEDURES-BLEVE SITUATIONS

WHEN THERE IS NO RISK TO LIFE OR PROPERTY, SERIOUS
CONSIDERATION MUST BE GIVEN TO EMPLOYING A NON ATTACK
STRATEGY.
IF A DECISION IS MADE TO ATTACK THE FIRE THEN IMMEDIATE,
MASSIVE WATER-COOLING MUST BE APPLIED CONCENTRATING ON
EXPOSED VAPOUR SPACE.
PERSONNEL SHOULD BE FULLY BRIEFED AND MADE AWARE OF THE
DANGER CONFRONTING THEM.
CHANGE FROM HAND HELD BRANCHES TO GROUND MONITORS.

Haldia Refinery

FIRE FIGHTING PROCEDURES-BLEVE SITUATIONS

USE OF WATER SPRAY ON EXPOSED CREW TO GIVE PROTECTION
AGAINST FIRE EFFECTS.
EVACUATION OF THE SURROUNDING ARES MIN. 1000 M.
REMEMBER THAT RELATIVELY HIGH RISK AREA IS AN END ON
DIRECTION. HOWEVER, FRAGMENTS AND MAJOR TANK SECTION CAN
FLY IN ANY DIRECTION.

Haldia Refinery

WHEN LIGHT HYDROCARBONS LIKE NAPHTHA, MS OR FLAMMABLE GASES LEAK IT
VAPOURISES AND FORMS AN EXPLOSIVE MIXTURE WITH AIR. WHEN THE LEAK IS
HEAVY AN EXPLOSIVE CLOUD IS FORMED. THIS CLOUD IS KNOWN AS A VAPOUR
CLOUD.
WHENEVER THIS VAPOUR CLOUD COMES IN CONTACT WITH A SOURCE OF IGNITION
IT CAN EXPLODE AND CAUSES FROM THE VEHICLES, SMOKING OR OTHER SOURCES
OF IGNITION.
FORMATION OF VAPOUR CLOUD
1. LEAKAGE FROM PIPELINES: IT MAY BE ON THE ROAD SIDE, INSIDE THE UNITS
OR IN THE TANK FARM.
2. LEAKAGE FROM TANKS OR TANK OVERFLOW: IT MAY BE IN THE TANK FARMS
OR FROM THE TANKS IN THE UNITS AREA.
3. LEAKAGE FROM TANKERS OR OVERFLOW OF TANKER: IT MAY BE IN WAGON
LOADING GANTRY AREA.
Haldia Refinery
Vapour Cloud
4. LEAKAGE OF LPG: IT MAY BE IN THE FOLLOWING AREAS;
i) INSIDE PROCESS UNITS OR ALONG ROAD SIDE LINE LEAKAGE .
ii) LEAKAGE FROM ROAD TANKER, WAGONS, FILLING HOSES, HORTON
SPHERES OR FROM CONNECTING PIPES.
iii) LEAKAGE FROM CYLINDERS, FILLING MACHINES, PUMPS OR CONNECTING
PIPES.
HOW TO IDENTIFY VAPOUR CLOUD:
i) BY SMELL: IF IT IS EXTRA ORDINARY ON HIGHER SIDE.
ii) BY MIST : IN MOST OF THE CASES MIST FORMATION TAKES PLACES.
iii) BY LEAK: IF HYDROCARBON LEAK IS VISIBLE.

Haldia Refinery
Vapour Cloud
IMPORTANT DOS AND DONTS IN CASE OF VAPOUR CLOUD:

DOS DONTS
INFORM CONCERNED UNIT
PERSONNEL AND FIRE STATION .
NEVER ALLOW ANY VEHICLE TO ENTER IN
THE AREA. DO NOT OPERATE ANY
ELECTRICAL SWITCHES.
CORDON-OFF THE AREA NEVER ALLOW ANY VEHICLE TO START IN
THE AFFECTED AREA.
GUIDE THE UNIT PERSONNEL/FIRE
PERSONNEL
IF VEHICLE IS ALREADY IN THE AFFECTED
AREA, REMOVE IT BY PUSHING.
IN CASE OF VAPOUR SMELL, TRY TO
DETECT THE SOURCE OF LEAK
DURING PATROLLING IF STRONG SMELL OF
HYDROCARBONS OR ANY LEAK DETECTED
STOP THE ENGINE IMMEDIATELY AND MOVE
ON FOOT TO DETECT THE LEAK.
STOP ALL HOT JOBS AND SMOKING
BOOTHS
NEVER SMOKE OR ALLOW THE SMOKING
INSIDE THE BATTERY AREA.
Vapour Cloud
Haldia Refinery

On-site Disaster Scenarios based on QRA

Sl Risk Scenario Outcome Consequence dist. (m)
to 1% fatality
1 LPG HS catastrophic failure Fire ball 1090
2 LPG HS ROV failure delayed
ignition

VCE B, 3m/s, L- 80, W-27
0.1 bar OPR.-150
E, 1m/s, L-149, W-60
0.1 bar OPR.-220
3 LPG tank truck catastrophic failure Fire ball 138
Stability Class Details:
A- Very unstable
C- Slightly Unstable
E- Stable
B-Unstable
D- Neutral
F- Very Stable

Haldia Refinery
Major Hazards: Petroleum Industry

UVCE
AN UNCONFINED VAPOUR CLOUD EXPLOSION IS AN EVENT WHERE A FLAMMABLE
FUEL/AIR CLOUD BURNS IN FREE SPACE, GENERATING SHOCK WAVES.
Some Major UVCE Incidents
Explosion at the Flixborough Plant (1974) UK.
Piper Alpha Explosion (1988)- North Sea.
Pasadena Texas (1989).
HPCL- Vizag Refinery-1997.- India.
Texas City Explosion (2005) USA.
Jaipur Oil Terminal( 2009) India.

What Happens to a Vapor Cloud?
Cloud will spread from too rich, through flammable range to too
lean.
Edges start to burn through deflagration (steady state combustion).
Cloud will disperse through natural convection.
Flame velocity will increase with containment and turbulence.
If velocity is high enough cloud will detonate.
If cloud is small enough with little confinement it cannot explode.
Haldia Refinery
Major Hazards
Factors Favoring High Over Pressures
Confinement
Prevents combustion products escaping, giving higher
local pressures even with deflagration.
Creates turbulence, a precursor for detonation.
Terrain can cause confinement.
Onsite leaks have a much higher potential for UVCE.
Haldia Refinery
Major Hazards
Cloud composition
Highly unsaturated molecules are bad
High flammable range
Low ignition energy
High flame speeds
Most UVCE C
2
- C
6
light gases disperse readily, heavy
materials do not form vapor .clouds easily
Haldia Refinery
Major Hazards
Weather
Stable atmospheres lead to large clouds.
Low wind speed encourages large clouds.
Haldia Refinery
Major Hazards
The annual mean wind speed at Haldia is around 1.9m/s.
From Jan-March : 1-2m/s
From April-June : 3m/s
From July Sep. : 2m/s
From Oct.- Dec. : 1m/s
Stability Class Details
A- Very unstable B-Unstable C- Slightly Unstable
D- Neutral E- Stable F- Very Stable
Source
flashing liquids seem to give high overpressure
vapor systems need very large failures to cause UVCE
slow leaks give time for cloud to disperse naturally
without finding an ignition source
high pressure gives premixing required for large
combustion
equipment failures where leak is not vertically upwards
increases likelihood of large cloud.
Haldia Refinery
Major Hazards
Unconfined vapour cloud Explosion

A vapour cloud exploding in open air
Haldia Refinery
Major Hazards
Confined Vapour Cloud Explosion

A cloud exploding in a confinement
Haldia Refinery
Major Hazards
Impact of Vapor Cloud
1 pound of TNT has a LHV of 1890 BTU/lb.
1 pound of hydrocarbon has a LHV of about 19000 BTU/lb.
A vapor cloud with a 10% efficiency will respond like a similar
weight of TNT.
Haldia Refinery
Major Hazards
Vapor Cloud impact depends on:
Probability of finding ignition source
Likelihood of generating any overpressure & its magnitude.
Impact of Vapor Cloud Explosions on People

Knock personnel down

Rupture eardrums

Damage lungs

Threshold fatalities

50% fatalities

99% fatalities

1

5

15

35

50

65
PEAK OVERPRESSURE, psi EFFECTS
Haldia Refinery
Major Hazards
Damage from Vapor Cloud Explosions
Haldia Refinery
Major Hazards
Peak Overpressure
(psi)
Typical Damage
0.5 1 Glass windows break
1 - 2 Common siding types fail
Corrugated asbestos, shatters
corrugated steel, panel joints fail. wood siding, blows
in
2 - 3 Unreinforced concrete or cinder block walls fail
3 4 Self-framed steel panel buildings collapse.
Oil storage tanks rupture.
5 Utility poles snap
7 Loaded rail cars overturn
7 - 8 Unreinforced brick walls fail
Impact of Vapor Cloud Explosions

Equivalent Overpressure Wind Velocities
Haldia Refinery
Major Hazards
Peak Overpressure
(psi)
Wind Velocity (mph)
2 70
5 160
10

290

20 470
30 670
50 940
Haldia Refinery

On-site Disaster Scenarios based on QRA- Fire & Explosion Case

Sl Risk Scenario Outcome Consequence dist. (m)
to 1% fatality
1 LPG HS catastrophic failure Fire ball 1090
2 LPG HS ROV failure delayed
ignition

VCE B, 3m/s, L- 80, W-27
0.1 bar OPR.-150
E, 1m/s, L-149, W-60
0.1 bar OPR.-220
3 LPG tank truck catastrophic failure Fire ball 138
4 Crude tank failure Pool fire 50 (from edge bund)
5 Hydrogen bullet catastrophic
failure
Fire ball 85
6 FCCU De-butaniser Reflux drum BLEVE 102
7 PDA Propane bullet line failure VCE B, 3m/s, L- 207, W-225
0.1 bar OPR.-600
E, 1m/s, L-289, W-407
0.1 bar OPR.-550
Haldia Refinery

On-site Disaster Scenarios based on QRA Toxic Gas leak Case

Sl. Risk Scenario Outcome Consequence dist. (m) to
1% fatality
8.a)

8.b)
Ammonia bullet line
rupture ROV upstream
Ammonia transfer line LOB
to Storage: Full bore rupture
Ammonia
Toxic cloud

Do
B, 3m/s, L- 235, W-94
E, 1m/s, L-600, W-427
B 3m/s : L-101,W-40
E 1m/s :L236 W184
9 MCC of SRU - Leakage

SO2/H2S
Toxic cloud
B, 3m/s, L- 91, W-22
E, 1m/s, L-293, W-102
10 H2S line to SRU full bore
rupture
H2S Toxic
cloud
B, 3m/s, L- 91, W-22
E, 1m/s, L-293, W-102
11 Failure of CO duct in FCCU
Bellow rupture
CO Toxic
cloud
B, 3m/s, L- 25.6, W-5.4
E, 1m/s, L-151, W-8.8
12 Chlorine leakage from toner Cl2 Toxic
cloud
B, 3m/s, L- 91, W-22
E, 1m/s, L-293, W-102
Major Contributors to Public Risks LPG storage, Ammonia storage & Chlorine
toner
Haldia Refinery
Emergency Preparedness
Basic information of Disaster.
Scenarios.
Organization charts.
Roles & Responsibilities of various coordinators.
Assembly Points & control of Visitors.
Dos & Donts during Emergency.
Overall plot plan
List of Hazardous chemicals/products
Communication system
Alarms & detection system
Reporting system to various agencies.
Resources Mobilization (Men & Materials) etc.
Haldia Refinery
On-site Disaster Organogram
Overall coordinator - ED
Alternate GM(Pj)
Chief coordinator GM(T)
Alternate GM (TS)
Incident Controller DGM (PN)
Alternate DGM (TS)
Fire
fighting
Rescue, Repair
& Salvage
Security Work
incident
De contamination
Medical
Water
supply
Communication Engg.
Finance
Materials
/ Supply
Transport,
Welfare &
Media
Haldia Refinery
Activity flow chart during Emergency
Reporting of Emergency

Response of plant, F&S, Medical & CISF

Assessment of situation

Declaration of Major Fire/Emergency

Blowing of Major Fire Siren

Intimation to Mutual-aid Partners & State Fire Service

Reporting at site by CPNMs, CPUM, CMNMs, CITM,
DGM(PN) & DGM(TS) through group communication.

Assessment of situation by Fire Chief.

Feedback to GM(T) & Declaration of Onsite Disaster

Blowing of Disaster Siren

Haldia Refinery
Activity flow chart during Emergency
Activation of Disaster Control Room

Intimation to HQ, Dist. Admn. & Statuary authority

Controlling of situation through DMP

Assessment of situation, feedback to Chief coordinator

Depending on situation declaration of
Off-site Disaster by ADM

Controlling of situation by Dist. Authority through
Off-site DMP

Situation controlled & Declaration of Normalcy

Blowing of All clear siren

De-briefing session
Haldia Refinery
Resources available for Disaster Control
Disaster Control Room ( 2
nd
Floor of Admn bldg) is equipped with:

Walkie talkie base station
Intercom & P&T Telephones
Close Circuit TV
Network PC
All operating manuals / Safety manuals / Lay out & Plot plan Drawings
Updated list of Disaster coordinators with contact numbers
Updated list of Mutual aid coordinators with contact numbers, Neighboring
industries & Dist. Admn.
Seating arrangement for about 20 persons

Haldia Refinery
Resources available
Fire Protection System:
Designed to meet double fire contingency as per
OISD norms.
Maximum water flow requirement based on LPG
HS & Process plant fire case
Storage: 3 x 9000 m3 above ground tanks.
Makeup water: PHE, Tube wells & ETP
Fire Booster Pumps: 6 X1000 m
3
/hr. [El.-3+D-3] Jockey pumps: 2 X300 m3/hr.

Haldia Refinery
Fire Protection System:
Water spray and semi fixed foam system for storage tanks as per OISD
norms.
Auto / Manual water spray system for storage vessels, hot pumps, light HC
pumps & Transformer.
Auto / Manual water spray system for TT & TW loading gantry.
Fire hydrants: 810 nos.
Water monitors: 193 nos.
HVLRM for crude tanks: 19 nos.
CO2 flooding system for GTs & TGs
Haldia Refinery
Fire Vehicles:
Foam Tender: 3 Nos.
DCP Tender : 1 No.
DCP Skid: 1 No.
Fire Jeep: 1 No.
Fire fighting foam: AFFF 100 KL

Haldia Refinery
Communication System:
Manual Call Points: 359 Nos.
Smoke / Heat detectors: 524 Nos
HC Detectors: 85 Nos
Telephone: AUTO, CENTRAX & P&T
PA & Group Communication System
7 Nos. Sirens at Refinery & 2 Nos. at Township
Walkie talkie( Nine channels )
Haldia Refinery
Medical:
First aid Center at Refinery with round the clock service & Ambulance facility.
30 bed hospital at Township with Ambulance.
Others:
Mutual aid agreement with: HPL, HBCPL & MCCPTA
SCBA sets: 30,Gas mask: 50 nos.
Rescue cutter & lifting bags
Fire Proximity Suit: 15
Emergency Chlorine kit : 3
Haldia Refinery
Emergency Mock Drills
Fire drill : Monthly

Onsite Disaster drill: Quarterly

Offsite Disaster drill: Yearly (conducted by Dist. Authority)
Glimpses of On-Site Disaster Drill at TTL
Actual disaster site
Oil installations in blaze

Physical Properties:: Haldia Refinery

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Physical Properties:: Haldia Refinery

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PHYSICAL PROPERTIES:

IT IS A MIXTURE OF PROPANE & BUTANE.

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