Quantitative Risk Assessment Study (QRA) Study Of IOCL, Haldia Refinery

A. Fuel Oil Block:

i) Crude Distillation Units (CDU-1 with revamp capacity 3.8 MMTPA & CDU- 2 capacity of 4.2 MMTPA)
(ii) Naphtha Hydrotreating (NHT) and Catalytic Reforming Unit (CRU)
(iii) Kerosene Hydro-Desulphurization Unit (KHDS)

C. DHDS Block:

(i) Diesel Hydro-desulphurization) Unit (DHDS)
(ii)Hydrogen Generation Unit (HGU-1)
(iii)Sulphur Recovery Units (SRU-II, III, IV Train-I & II)
(iv)Amine Treating Units(I/II) and Sour Water Stripping Units (SWS-I/II) (v)Vacuum Distillation Unit (VDU-2)
(vi)Resid Fluid Catalytic Cracking Unit (RFCCU)
(vii)MS Quality Upgradation (MSQ) Units:

Naphtha Splitter, Reformate Splitter and Naphtha Hydrotreating Unit
(viii) ISOM Unit
(ix)Gasoline Splitter and FCC Gasoline Treatment Unit & PrimeG+(quality revamped done under BS-VI)
(x)N2 Plant-1:1350 Nm3/hour N2 gas + 275 NM3/hr Liquid N2

F. BS-VI Block

(i) DHDT (Diesel Hydro-treating )
(ii) H2SO4 Plant (Sulphuric Acid plant)
(iii) ARU-4 (Amine Regeneration Unit)
(iv) SWS-4 (Sour Water Stripping unit)
(V) Plant Air, Instr. Air & N2 plant-3 (1100 Nm3/hr N2 gas)

B. Lube Oil Block:

(i) Vacuum Distillation Unit (VDU-1)
(ii)Propane De-asphalting Unit (PDA)
(iii)Solvent (Furfural) Extraction Unit (FEU) (iv)Lube Hydro finishing Unit (LHFU)
(v) Visbreaker Unit (VBU)

(vi)Catalytic Iso De-waxing Unit (CDWU)
(vii) New CDWU project (TOR application done before MoEF & CC)

D. OHCU Block:

(i) Once Through Hydrocracker Unit(OHCU)
(ii) Hydrogen Generation Unit (HGU-2) revamp
(iii)Feed Preparation Unit for CIDW(FPU)
(iv) N2 Plant-2: 1600 Nm3/hr. N2 gas + 400 NM3/hr Liquid N2

DYIP (Distillate Yield Improvement Project) Block:

(i) DCU (Delayed Coker Unit)
(ii) CGO-HDTU (Coker Gas Oil Hydrotreater unit) (iii) Coker LPG Merox Unit
(iv) SRU-V(Sulphur Recovery Unit)
(v) SWS-3 (Sour Water Stripping unit)
(vi) ARU-3 (Amine Regeneration Unit)

UTILITIES:

(i) 4 Nos Boilers (3 X 125 MT/hr and 1X 150 MT/hr)
(ii) 4 Nos Turbo Generators (3X 10.5 MW and 1X 16.5 MW)
(iii) 3 Nos Gas Turbines (3X 20 MW)
(iv) 3 Nos Heat Recovery Steam Generation Unit (1X100 MT/hr and 2X130 MT/hr) (v)Process Cooling Tower (PCT CT): 9 Nos cells of capacity 2300 M3 each
(vi) DHDS CT :7 Nos cells of capacity 3000 M3 each
(vii) OHCU + FPU CT: 4 Nos cells of capacity 3000 M3 each
(viii) TPS Cooling Tower (TPS CT): 3 Nos cells of capacity 3000 M3 each
(ix) GT Cooling Tower (GT CT): 8 Nos cells of capacity 125 M3 each

(x) DYIP CT: 3 Nos cells of capacity 4000 M3/hr each
(xi) BS-VI CT : 3 nos. cells of capacity 4000 M3/hr each
(xii) 5 Nos DM Water PLANT CHAINS

(xiii) Fire water tanks (3 x 9000 m3 each) and FW pump house
(xiv) 2 Nos Of Mixed Bed Resin System (MB-6/7) for Production of DM Water From TTP- RO Permeate.
(xv) DYIP- DM Plant 2 x 160 M3/hr
(xvi) Chlorine tonners and Chlorine dosing facilites near Cooling towers
(xviii) Other facilities:

• Existing Flare: 54″ (HC Flare) / 16″ (acid flare)
• DYIP Flare: 60″ (HC Flare)/ 16″ Staged/ 13″ (acid flare)