OVERVIEW OF ESSAR REFINERY AND ITS HSE POLICIES

Essar Group
The Essar group is one of Indias largest corporate houses with interests spanning the manufacturing and service sectors in both old and new economies. All the groups investments have been consolidated under Essar Global Ltd. with its six sectors holding companies: Essar steel holdings ltd. Essar power holdings ltd. Essar energy holdings ltd. Essar communication holdings ltd. Essar shipping & logistics ltd. And Essar construction

Essar Refinery
The Essar Oil Ltd. grass roots refinery in Gujarat, India (started

in 1996) was completed and commissioned in 2006 (commissioned in third quarter).

According to company reports, the refinery was 60% complete

in 1998 but had the misfortune to be struck by a cyclone that caused considerable damage.
The refinery currently has the capacity to produce 4,00,000

barrels a day (20 MMTPA). The refinery employs over 1,000 personnel (the construction process required between 3,000 and 4,000).

Crude mixes
The following crude mixes were considered for the configuration study to ensure sufficient flexibility in the refinery operation: 70%wt Arabian light / 30%wt Arabian heavy 50%wt Arabian light / 50%wt Arabian heavy 100%wt Bombay high

Major Operations
Crude oil distillation unit (CDU) Vacuum distillation unit (VDU) Hydro-treating unit Catalytic reforming Catalytic cracking Alkylation and isomerization Product blending Sulfur recovery unit (SRU)

LPG

CDU - VDU LMU

Naphtha NHT

Kero

KMU

Crude

CDU

Gas Oils

DHDS

Vacuum Distillate

Vacuum Gas Oils VDU

FCCU

Bottoms

VBU

Isomerization Unit (ISOM)

Capacity: 0.7 MMTPA Isomerization is branching of single chain hydrocarbons. It is done in

order to increase the Octane No. of Gasoline. Feed for ISOM is Naphtha mainly from NHT. In this process Octane Number of Naphtha is 68, which is increased to 88. In ISOM Reactor 4 processes take place. C5/C6 Paraffin Isomerization Benzene Saturation Naphthalene Ring opening Hydro Cracking

Diesel Hydro-treating Unit (DHDT)

Annual Capacity : 3.8 MMTPA In this unit, process uses a catalytic hydrogenation method to upgrade

the quality of petroleum distillate fractions by decomposing the contaminants like sulfur, nitrogen, metals, etc. Process makes use of hydro treating reactions to remove contaminants from the feed(mainly diesel). C2H5SH + H2 C2H6 + H2S C5H5N + 5H2 C5H12 + NH3

Diesel Hydro-treating Unit (DHDT)

These reactions are carried out at elevated temperatures and

pressures in a hydrogen atmosphere. Temperatures generally range from 290 C to 425C and pressures from 35 to 92 kg/cm2g.
Reactions are carried out in a fixed bed catalytic reactor consisting

of nickel or cobalt and molybdenum impregnated on an alumina base.

Vacuum Gas Oil Hydro-treating Unit (VGO HDT)

It is the middle cut of Vacuum Distillation Unit. Feed to the Unit are:

Vacuum Gas-Oil (VGO) from (VDU). 2. Coker Naptha from Delayed Coker Unit (DCU). 3. Coker Gasoline from Delayed Coker Unit (DCU). 4. Vacuum Gas- Oil (VGO) from Storage. Desired Properties in product (Sweet VGO) 1. Carbon number - C22-C45. 2. Specific Gravity - 0.9 gm/ml 3. Sulphur - <1000 ppm w 4. Nitrogen - <500ppm w 5. Viscosity - 6.4 Cst 6. Nickel + Cobalt - <0.2 ppm w
1.

Reaction Chemistry
VGOHT process takes place in a Fixed Bed Catalytic Reactor having 5 beds with each bed having a specific role. Catalyst used are nickel and cobalt oxides on alumina bed. Chemical reactions involved in VGOHT are generally exothermic & happen at 350 C temp. and 100 kg/cm2 pr. Metal Removal: Metal removal takes place on the 1st bed of the reactor. Eg. Nickel and Cobalt are removed. Olefin Saturation: Olefin saturation takes place on the 2nd bed of the reactor.

Reaction Chemistry
Sulphur Removal:

Sulphur removal takes place on the 3rd bed of the reactor.

Nitrogen Removal:

Nitrogen removal takes place on the 4th bed of the reactor.

Aromatic Saturation:

Aromatic saturation takes place on the 5th bed of the reactor.

VGO-HDT Products
Gas (C1-C4)

Naphtha (C5-180C)
Kerosene (180 C-270 C) Diesel (270 C-360 C) Product VGO (360 C+)

- 0.8% - 4.8% - 5.0% - 11.1% - 78.3%

Delayed Coking Unit

What is Coking :

The Coking is a thermal cracking process for upgrading heavy petroleum residues into lighter gaseous and liquid products and solid coke (green coke).
Why it Called as Delayed Coking :

With short residence time in furnace tubes, the coking of feed material is thereby delayed until it reaches the drum to form coke.
Objective of DCU:

The objective of Delayed Coker Unit (DCU) is to convert bottom of the barrel (Vacuum Residue) in to valuable distillate (49%), petroleum coke (34.7%) and to eliminate fuel oil production.

Main Products:
- Fuel Gas, Naphtha, LPG, LCGO, HCGO, HHCGO, Coke.

ESSAR DCU PROJECT:

- Second Largest Coking Unit in India with the capacity of 6 MMTPA.

Fluidized Catalytic Cracking Unit(FCCU)

FCC is mainly used to crack heavy molecular hydrocarbon into lighter

molecular hydrocarbon. Objective: To increase production of lighter hydrocarbon (Gas Oil). To maximize LPG yield Main products: LPG (Liquefied Petroleum Gas) LCO (Light Cycle Oil) HCO (Heavy Cycle Oil) In FCC unit mainly feed comes from atmospheric unit, vacuum Unit and from delayed cracker unit. The FCC unit uses a microspherical catalyst that behaves like a liquid when it is properly fluidized. The high octane number which has become an important factor for gasoline quality can only be achieved by FCC.

HSE at Essar Refinery

At the Vadinar Refinery Health, Safety, Environment and Fire

Management system is on par with the best in the industry globally.

The Essar Refinery Integrated Management System ensures

consistency in organizational resources, helps to streamline processes, reduce costs and improve efficiency.
To ensure safe operation at the refinery, about 3,000 standard

procedures have been developed and implemented, with special focus on critical operating procedures.

Health Practices
Oil refineries emit about 100 chemicals everyday. These include metals like lead which makes it hard for children to

learn.
They also include very small dust particles called PM10, that get

deep into our lungs and harms our ability to breathe.

Finally, refineries emit many gases like Hydrogen Sulphide (H2S),

sulphur dioxide (SO2), nitrogen oxide (NO2) carbon dioxide, carbon monoxide

H2S Emission
Out of these different harmful gases and particulate matters the most harmful and toxic is Hydrogen Sulphide (H2S).

General Properties
Hydrogen sulfide is a colorless, flammable, extremely

hazardous gas with a rotten egg smell.

Flammable LEL 4.3% UEL 46% . Heavier than air will settle in depressions.

Toxic Properties of H2S

Extremely toxic and irritating gas. Can cause instant death. Blocks the oxidative process of tissue cells. Reduces the oxygen carrying capacity of the blood.

Depresses the nervous system.

Causes respiratory failure and asphyxiation.

Physiological Responses
10 ppm eye irritation

50-100 ppm - conjunctivitis respiratory irritation.

100 ppm coughing, eye irritation - loss of sense of smell

2-15 minutes. 500-700 ppm loss of consciousness and death in 30 60 minutes. 700-1000 ppm Rapid unconsciousness and cessation of respiration and death.

Exposure Level Definitions

Time Weighted Average (TWA) 8 hours per day 40 hours

per week. Short Term Exposure Limit ( STEL) 15 min TWA which should not be exceeded more than 4 times per day with 60 minutes between exposures. Ceiling (C) a concentration that should not be exceeded during any part of the working exposure assuming direct reading instruments are used. Peak a one time spike if no other exposure occurs.

OSHA Regulations
20 ppm ( ceiling )

50 ppm (peak 10 minute exposure allowed only

once if no other measurable exposure occurs). ACGIH TLVs 10 ppm (8 hour time weighted average) 15 ppm ( short term exposure limit above the tlv) STEL is defined as a 15 minute TWA exposure which should not be exceeded

Detection Of Hydrogen Sulfide

Detector tubes indicate amount of gas by color change of

chemically coated granules in a glass tube. Electronic monitors.

Personal Protection Equipment (PPE)

To avoid the causalities during work it is mandatory for each personal inside the refinery units to have some basic PPEs. Major five PPEs compulsory in the ISBL area of the refinery complex are: Helmet Safety Spectacles Hand Gloves Safety shoes Ear Plugs

Safety Practices
For protection against fire, Essar Refinery premise is strictly No

Smoking zone. Training in safety and health measures is a crucial part of the induction process. Every new employee has to undergo mandatory training in safety within the first month of joining Use of electronic items is limited to only OSBL area. Carrying any kind of flammable objects is not allowed inside complex. Inside Battery Limit Area (ISBL) use of PPEs is compulsory for everyone. Cotton made clothes should be used as they do not generate static charge.

Safety Practices
Unauthorized entry to High Pressure Area and H2S prone area is

restricted. Kind of job (Hot work, Cold work, Confined space,) to be done should be specified and authorized. Use or storage of combustible material at the site should be avoided. In case of direct exposure to any chemical solution safety shower should be used to get rid of it immediately. Defective tools should not be used. Tools and material should not be dropped from heights. Safety belts or lifelines shall be used when working 3 meters or more above ground, where it is not practical to make other provision to prevent falling. Falls are the second largest cause of accidental deaths.

Safety Systems
Vadinar Refinery has following safety systems to avoid accidents and alert before any unavoidable situation. Beacons: This is a three light system which causes flashing of lights in case if there is any leakage of gas. There are three color of lights that indicate/alarm their respective leakage Red: Fire Blue: Toxic gas Yellow: Flammable gas

MCP (Manual call point): In a refinery there is a MCP, in case

of any accident or fire any worker or employee can break the glass of MCP and call to emergency center.

Safety Systems
Assembly Point: If any accident take place inside the

refinery unit, every workers should go to the assembly point where rescue operation take place after head count. Windsock Flag: This is a flag with red and white strip cloth, kept on the tall structure of refinery. From this we know direction of wind. In case of leakage of any poisonous gas any or explosion we must go in perpendicular to the direction of the wind.

Material Safety Data Sheet (MSDS)

MSDS(Material Safety Data Sheet) Includes

1.Overview of the product 2.Physical Data Physical State Color Odor Mol. Weight Mol. Formula Boiling Condensation Melting Point Critical Point Specific Gravity

Material Safety Data Sheet (MSDS)

3.Health Hazard Skin Eyes 4.Fire/Explosion Hazard Auto Ignition Temperature Flash Point Low Explosion Limit Upper Explosion Limit 5. Emergency /First Aid Measures Flammability of the Product Products of Combustion Fire Hazard in the presence of various substances Special Protective Equiptment

Environmental Policies
As a company, Essar is cognizant of the environmental

impact of its activities and have strong policies and culture in place to ensure that its businesses have the maximum positive impact on the environment and stakeholders.
The Vadinar refinery complex earned the distinction of being

ranked the best in carbon management in the Indian energy sector in the Carbon Disclosure Leadership Index 2011.
Essar Oil has formed a Core Carbon Management Team for

monitoring and tracking the GHG performance of operational units.

Environment Protection & Control Measures

Sulphur Recovery Unit (SRU) for H2S control. Flue Gas Desulphurization (FGD) in Fluidized Catalytic Cracker. Effluent treatment plant for 100% recycled and zero discharge. Hazardous & Non-hazardous waste storage facilities. Low NOx burner in all heater / furnaces . Use of floating roof tanks for storage of crude & light product Sulphur Dioxide Emission control : Low Sulphur Fuel : Mixture of

Gas / liquid fuel in all boilers and heaters. Full fledged Environment laboratory Development of Green belt in 900 acres having more than 350000 trees.

Environmental Objectives
Increase environmental awareness Conserve natural resources and improve waste management

Promote villages as an integrated eco-system

Encourage use of alternate sources of energy

Implementation of Objectives
From Effluent to Affluent Waste Water Recycling. Rain water conservation and reuse. 19 MW heat recovery plant. Social forestry Eco-restoration of coastal mangroves. Converting hazardous waste into micro-pellets Essar's award

winning initiative.
Essar Algoma: Co-generation energy from by-product gases.

Focus on Climate Change

Cleaning up the carbon footprint

Every Essar company is working strategically to reduce its

carbon footprint.
Essar has a two-pronged approach in its mitigation and

adaptation initiatives:
1. 2.

Providing Clean Solutions Reducing Its Carbon Footprint By Adopting Energy-

efficient Technology And Energy Conservation Measures.

Accolades
Achieved 1456 Lost Time Injury free days for Employees and 179 Lost

Time Injury free days for Contractors and 1041 major fire free days. Essar Refinery Integrated Management System (ERIMS) conforms to the requirement of ISO 9001:2008, ISO 14001:2004 & OHSAS 18001:2007 -within first year after commissioning. International Safety Award 2010, for the second time in a row from British Safety Council. Received Certificate of Merit for C.I.I Award for Excellence in Management of Health / Safety / Environment for the year 2009 & 2010 from Indian Chemical Council. OISD Safety Award for the year 2009-10 in the category Oil Refinery. Essar is the first private refiner to receive this coveted award. Selected for a Special Commendation for the Golden Peacock Award for Occupational Health & Safety for the year 2010. National Award for Excellence in Water Management 2011 from Confederation of Indian Industrys (CII).

Case Study on LPG Leakage on 3/05/2008

LPG Truck GJ12U 9984 carrying 17790 MT of LPG loaded from Essar Oil Dispatch area proceeded to report to Agrawal Transport office app. 1 km beyond Motikhavdi Level Crossing. At 1940 hrs TT driver noticed gushing out of LPG from the top of the bullet. He immediately informed the transporter about the incident who in turn immediately informed the local authorities, and our MCO office. In the mean time Essar & Reliance fire tender reached the spot to tackle the situation.

GJ12U 9984

Leak started in Jet form from TT

Actions Taken
Discussions were held with TT crew and many other drivers who

were present at the site. Traffic on the other side of the road was still open which was immediately blocked. Two Essar personnel daringly went up the TT to trace the source. Found PSV popped up and LPG gushing out in Jet. TT pressure observed as 6.5 kg/cm2 PSV body hammered with wooden hammer but fail to arrest. Empty TT called for Transshipment along with Hose. Transshipment done 1450 kg to reduce pressure to 4.5 kg/cm2 Again PSV was hammered using Brass hammer and leak got arrested. Clearance given to SDM for resumption of traffic.

How the Emergency Was Handled

Barricaded the area and avoid ignition source. Dispersed the LPG vapor with the help of water spray to prevent

cloud formation. Cool the TT continuously to reduce the temp and hence vapor pressure. Escorted the Emergency vehicle to reach the site at minimum possible time. Control on Site communication to ensure unity of command and Leadership. Identification and Isolation of Source of Leak. Proper Site Co-ordination and concentrated effort. Application of Knowledge and Skills. Calculated Risk Taking. Maintaining Calm and peace of mind during handling emergency.

THINK SAFETY NOW

THANK YOU!