Hazard & Operability Study - Gujarat Pollution Control Board

Kutch Chemical Industries Limited Survey No 166/1,2,3, 171/1, 172,167,168, Village : Padana Gandhidham, Dist. Kutch

Hazard & Operability Study (FOR DESUR DEPOT EXISTING FACILITIES AND PROPOSED FACILITIES)

PREPARED BY VAIBHU SAFETY CONSULTANTS FF-11, Akshat Complex, Nr. Reliance Petrol Pump, High Tension Road, Subhanpura, Vadodara-390 023 Phone: 9825756467/9427838021 (M) Ph : 0265-2395798

Prepared By HSE Department

M/s. Kutch Chemical Industries Limited

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ACKNOWLEDGEMENT

We express our sincere thanks to management of Kutch Chemical Industries Ltd for providing unstinted support during the HAZOP Study without which the HAZOP study could not have been possible. The courtesy extended to our team is highly appreciated.



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CERTIFICATE We are pleased to certify that this HAZOP Study Report of Company has been conducted by us. HAZOP STUDY is a legal requirement as per the rules 10 to 13 under Manufacture, storage and import of Hazardous chemicals rules, 2000 and environment (protection) Act, 1986. It is obligatory of the occupier to carry out a "HAZOP Study", as required under item no. (II) (2) of the format for application of the Site Appraisal Committee and as per the Schedule 1 of the Factories Act under Section 2(CB) - Item No. 11 of the Schedule. The Executive Summary is given in the beginning to highlight the important summary of our report and methodology of the HAZOP Study carried out.

FOR VAIBHU SAFETY CONSULTANT

Authorized Signatory



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CONTENTS

SECTION NO. 1

CONTENTS

NO. OF PAGES

Objective and Methodology of HAZOP Study 1.1 1.2 1.3

Objectives Scope of The Work Methodology Introduction to HAZOP

8 8 8 8 10

2.0

Hazard and Operability Study Introduction Of the Unit

10 13

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8

Introduction of the unit Details of Unit Google map Site Plan Organisation chart Details of storage of Hazardous Materials in Bulk Facilities / System Process Flow chart HAZOP Sheets

13 13 20 21 22 22 28 29 49

2

3

4



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LIST OF TABLES

TABLE NO.

CONTENTS

Page No.

Table- 4.1

Hazop Study Worksheet (Transferring of Chlorsulfonic Acid to service tank) Hazop Study Worksheet (Charging of Acetanilide) Hazop Study Worksheet (Reaction) Hazop Study Worksheet (Dumping) Hazop Study Worksheet (Reduction) Hazop Study Worksheet (Condensation) Hazop Study Worksheet (Esterification) Hazop Study Worksheet (E. O. storage tank) Hazop Study Worksheet (From outlet of storage tank to inlet of batch tank) Hazop Study Worksheet (Raw material to the storage

50

Table- 4.2 Table- 4.3 Table- 4.4 Table- 4.5 Table- 4.6 Table- 4.7 Table- 4.8 Table- 4.9 Table- 4.10

51 52 53 54 55 57 58 61 63

tank ( Day Tank ))

Table- 4.11 Table- 4.12 Table- 4.13 Table- 4.14 Table- 4.15 Table- 4.16 Table- 4.17 Table- 4.18 Table- 4.19 Table- 4.20 Table- 4.21 Table- 4.22 Table- 4.23 Table- 4.24 Table- 4.25


Hazop Study Worksheet (Reaction Process) Hazop Study Worksheet (Chilling of the HCL) Hazop Study Worksheet (Gas cleaning) Hazop Study Worksheet (Reaction) Hazop Study Worksheet (Melting of Sulfur) Hazop Study Worksheet (Burning of sulfur with air) Hazop Study Worksheet (Catalyst convertor) Hazop Study Worksheet (Rector) (Gas mixture) Hazop Study Worksheet (High Boiler fractional Distillation Column) Hazop Study Worksheet (Final Product Distillation Column) Hazop Study Worksheet (Reaction of Chlorine) Hazop Study Worksheet (Reaction) Hazop Study Worksheet (Reaction) Hazop Study Worksheet (Distillation)


64 65 66 67 68 69 70 71 72 74 75 76 78 80 81

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HAZOP SUMMARY HAZOP SUMMARY SR. NO. 1

OBSERVATION AREA UTILITY SERVICES

SUMMARY Utility is the heart of the chemical process industries. All the critical equipment shall be connected with the D. G. Set. Company has their own captive power plant. Overhead water tank for cooling operation shall be provided. Under worst case of GEB & DG failure cooling operation shall not be suffered. Stand by pump for cooling shall be provided . All the utilities line shall be provided with arrow indicators & content . this not only help of for better production but also help during the emergency it avoid the human error. A system shall be devised to maintain the sufficient quantity of water in the seal pot & scrubber to prevent escape of EO gas in the atmosphere. Common Dump tank shall be provided in the plant. The capacity of the same shall be the 1.10 times the biggest reactor in the plant. Written check procedures are not available for the checking the leak point in Vessel & piping system. Human errors may occurs during the verbal check. Written procedures shall be developed. Periodic inspection of the Sulfur burner to be ensured. To handle the chlorine emergency chorine kit to be ensured and maintained in tip top condition at all time. Flange guards needs to be provided on Acid lines. Non return Valve to be provided on pump discharge line. Arrow indicator to be provided on pipeline. Pump, storage tank & pipe line identification to be done. Color code for pipelines to be provided as per IS 2379. Periodic checking of the condenser to be followed

2

STORAGE OF CHEMICALS

All the storage has been provided with the separate area. All statutory norms are followed. It should be made restricted entry. A register shall be maintained. Double Static earthing to be provided to flammable material storage tanks as well as pipelines and powder handling machines. Electrical earthing to be checked and record to be maintained and resistance to be maintained below 1 OHMs .



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Safety valve Pressure gauges and other safety devises to be maintained in working condition and testing and calibration to be done once in a year. Thickness measurement to be done for all storage tanks and comparison records to be maintained. Tank ID, content and capacity to be displayed on each tanks and reactors. 3

INSTRUMENTATION

Instrumentation has to play key role in the maintenance of process parameters. All the interlocks shall be tested every month. And the records shall be maintained. All the instruments shall be calibrated before the date expires. Calibration date for safety valve, shall be displays at site only. Functioning of Instrumentation depend on the well supply of air. Under no circumstances the air pressure shall be reduced. The DMS & H2SO4 plant are DCS operated.

4

ENVIRONMENTAL

5

ADMINISTRTION

6

GENERAL

E. O. flow cutoff to be provided in connection with the temperature rise in VS plant. The organization has taken care of environment by converting all the by product into useful product. The concept of reduce, recycle & reuse has been vigorously followed. The generation of effluents is also well controlled. Standard Operating procedures to be prepared. Work permit procedures to be followed for the handling of hazardous chemicals. Use of Personal Protective Equipment (PPE ) are not found during the various plant operation. PPE matrix shall be defined for all the process activity. Alarms for vacuum failure in the dehydration shall be considered. Stand by pump for reflux system shall be provided in distillation section. Hot oil circulation line shall be inspected at least once in a month.



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CHAPTER I OBJECTIVE AND METHODOLOGY OF HAZOP STUDY

1.1

Objective : The specific objectives of the study are•

Identification and assessment of major hazards potential in the storage and handling of petroleum products inside the depot.

1.2

•

Study of built- in- safety measures and operational safety precautions in practice.

•

Identification and assessment of major hazards potential in the process equipment.

•

Suggesting measures to reduce risk by reducing hazard and reducing probability.

SCOPE OF THE WORK The principal objective of this study is to evaluate the potential hazards to the plant. •

To evaluate the process safety system of plant from the safety point of view considering the structural / electrical / instrumentation aspects.

•

To evaluate the system provided to protect fire & explosion in product pipe line and system full proof.

1.3

•

Evaluate the maintenance & operation system of the Terminal.

•

Evaluate provided control parameters and instrumentation.

•

Suggest better system for safe operation & maintaining plant in a safe manner.

METHODOLOGY Design data, built in safety systems are studied. Discussions are held with Officials. Safety related individual system is discussed with HAZOP team member.

HAZOP exercise is conducted taking into consideration of each and every equipments, storage tanks, Tank truck filling gantry, pump house, pipe lines, operating procedures,



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built in safety system, operating parameters and existing safety measures. Thus, this study is mainly oriented towards actual risks rather than chromic risks.

Possible causes of the possible events will be derived and consequences effect of such events will be discussed and required recommendation and follow-up sheet will be generated for implementation purpose.



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SECTION II INTRODUCTION TO HAZOP

2.0

Hazard and Operability Studies(HAZOP)

2.1

The basic concept of HAZOP is to have an exhaustive review of the plant layout and P& ID of KCIL. HAZOP study highlights the hidden operability problems and identifies hazards, which are likely to result from the expected intention of seemingly safe components or methods of operation.

2.2

This work utilizes imagination of team members to visualize ways in which a terminal can malfunction or mal-operated. Each part of the plant is subjected to a number of questions formulated around a number of guide words which are derived from method of study technique. In effect, the guide words are used to ensure that the questions which are posed to test integrity of each part of the design to explore every conceivable way in which that design could deviate from the design intention. This usually produces a number of theoretical deviations and each deviation is then considered how it could be caused and what would be consequences.

2.3

HAZOP is a brainstorming approach, which stimulates creativity and procedure for generating ideas. Possible results of this study are :(a) Identify and examining many types of risks. (b) Identifying non-optimum system reliability. (c) Suggestive qualitative recommendations regarding control, strategy, material properties, material releases alternative design option, operation and maintenance.

2.4

The important terms pertaining to Intention

HAZOP study are:-

: - The intention defines how the part is expected to operate. This can take a number of forms and can be either descriptive or diagrammatic. In many cases, it will be a flow sheet (P & ID)



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Deviation

: - These are departures from the intention which are discovered by systematically applying the guide words.

Causes

: - These are reasons why deviation might occur. Once a deviation has been shown to have a conceivable or realistic cause, it can be treated as meaningful.

2.5

Hazards

: - These are the results of the deviations

Consequences

: - These are the consequences, which can cause damage, injury or loss.

A list of guide words Table- 3.1 list of guide words Guide Words None

2.6

More of

Meanings Complete negation of the intention Quantitative increase

Less of

Quantitative decrease

Part of

Quantitative decrease

More than

Qualitative increase

Other than

Substitution

Comments No part of the intention is achieved e.g. no flow or reverse flow. More of any relevant physical properties than there should be e.g. higher flow (rate or total quantity) higher temperature, higher pressure higher viscosity, more heat, more reaction etc. Less of any relevant physical property than there should be, e.g. Lower flow (rate or total quantity), lower temperature, lower pressure, less heat, less reaction etc. Composition of system different from what it should be e.g. Change in ration of components, component missing etc. More components present in the system that there should be e.g. extra phase present (Vapor, solid), impurities (air, water, acids, corrosion products etc.) What else can happen apart from normal operation e.g. Start up, shutdown, high/low rate running, alternative operation mode, failure of plant services, maintenance, catalyst change etc.

Guidewords are applied to the design intention. The design intention informs us what the equipment is expected to do.



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2.7

A flow chart giving HAZOP procedure is given below:Select Line

Select deviation Eg. More flow Move onto next deviation

NO

Is more flow possible ?

Is it hazardous or does it prevent efficient operation ?

What change in the plant will tell him

NO

Consider other causes of more flow

NO

Yes Will the operator know that there is more flow ?

Yes

What change in plant or methods will prevent the deviation or make it less likely or protect against the consequences.

Is the cost of change justified

Consider other changes or agree to accept hazard.

NO

Agree changes. Agree who is responsible for action.

Follow up to see that action has been taken. Prepared By HSE Department


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SECTION III INTRODUCTION OF THE UNIT

3.1.

COMPANY INTRODUCTION M/s. Kutch Chemical Industries Ltd., is operating a manufacturing unit of various chemicals and dye intermediates at Survey No 166/1,2,3, 171/1, 172,167,168, Village : Padana, Gandhidham, Dist. Kutch Produce unit is classified as Major Accident Hazards unit ( MAH Installation ) based on the storage of the listed hazardous chemicals more than specified threshold quantities.(Schedule 3 under Rule 68-J of the Gujarat Factories Rules-1963 (2004). Kutch Chemical Industries Ltd, with spot light on export market potential was founded in 2004 near the Global all weather ports of Kandla and Mundra. It consists of a well integrated chemical complex consisting of Chlorination, Nitration, Sulphonation and Dyes Intermediates products.

3.2.

DETAILS OF UNITS Sr. No. 1.

2. 3.

4. 5.

6.

7.

Particulars Full Name & Address of : Kutch chemical Industries limited Unit Plot no- 165,166/1&3,168,171/1&172 Village:Padana, Nr.Aquagel Chemicals, Gandhidham, Dist – Kutch Gujarat. Telephone No. : 02836-28551-52, Fax-02836-285233 Month & Year of : 10th June 2002 Establishment Full name & Address of : Sh. Shivlal Goyal ( Director) the occupier 2, Sri Ram Society, Gotri Road Baroda Full name & Address of : Sh. D.S.Purohit the Factory manager Plot no – 23, Ward -9B(D) New Bharat Nagar, Gandhidham Pin- 370201 Man Power : 172 including all shift G Shift- 31 A Shift- 47 B Shift- 47 C Shift- 47 No. Of shift & Shift timing : Total no of shift :- 04 General shift :- 09AM To 06 PM First Shift “A”:- 07 AM To 03 PM



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Second Shift “B”:- 03 PM To 11PM Night Shift “C”:- 11PM To 07AM 8. 9.

Environs (Nearest Facilities) Meteorogical Data Latitude Longitude

23º 10’N 70º 13’ E

Temperature Maximum Minimum Relative Humadity

48º C 7.2 º C :

Maximum Minimum

100 % 1%

Annual Rain Fall

:

Minimum Maximum

73.6 mm 1393 mm (1979)

Seasonal wind directions : Jan- Feb March – Sept Oct to Dec Wind Velocity Maximum Minimum Avg. Wind Speed 1. Railway Station

10.

N / NNW / ENE SW / WSW N / NNE : 132 km/hr NNW (26.10.1975) 100 km/hr NNW (26.10.1975) 14 Km/hr : Gandhidham, Distance – 20 KM

2. Police Station

: Anjar, Distance – 20 KM

3. Fire Station

: Anjar , Distance- 20 KM

4. Hospitals

: Anjar , Distance- 20KM

Total Land at Plant


50 ACRE


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11.

30000 M2

12.

Total Built-up area at the Factory Power connection

13.

DG Set

KVA: 250 KVA

14.

Power plant details :

15.

16.

17.

18.

Demand : 3000 KVA

DG Set - 2.5 MW Turbine – 4.2 MW Water Storage and source Capacity in m3:20000 M3, Source – Gujarat water infrastructure limited (GWIL) Boiler Type Model no Capacity Licence from Gujarat Govt. Combi pack CPB-80 8Ton/Hr GT 4879 IB-147810 Ton/Hr GT 5516 Waste heat Maker no- 25 Ton/Hr GT-5207 Recovery 21943 AVU Make Chilled water plant Particulars Model No Capacity Location

Cooling Tower

VAM

------

VAM

SD30BHX/1 200TR

VAM

SD30BHX/1 200 TR

Ammonia compr 2 nos Ammonia compr 2 nos Ammonia compr 2 nos Ammonia compr 5 nos Ammonia compr 3 nos

KC6-3

150 TR

MCB & PNCB MCB

KC6-3

150 TR

PNCB

KC6-3

150 TR

PDCB

KC6

300 TR

New VS

KC6

180 TR

OLD VS

Total

1480 TR

Flow rate

TR

Plants

3260

Acid Division DMS Plant OLD VS

Particulars

Process 4200M3/H cooling water Process 1300M3/H cooling water Process 1200M3/H cooling water Prepared By HSE Department

150 TR

1000 1000


DMS Plant OLD VS

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19. 20. 14 21.

22.

Effluent treatment Plant Fire water source Fire Water Reservoir capacity : M3 Department wise List of fire extinguishers with mapping if available

SCBA sets availability and location mapping


Process 1200M3/H cooling water Process 1200M3/H cooling water Process 600m3/H cooling water

1000

Process 600M3/H cooling water Process 500M3/H cooling water Process 1350M3/H cooling water Total Capacity: 50 M3

250

1000 500

300 1100

MCB Plant Acetanilid e plant PNCB Plant PDCB Plant New VS plant TC Plant

9410

Water reservoir (GWIL) 200M3 Departments

Total nos of F/Extinguisher Benzene storage 04 nos Power plant 12 nos PNCB Plant 16 nos MCB Plant 07 nos PDCB Plant 02nos Ice plant 01 no New VS Plant 09 nos ETP 01 no Acetanilide plant 06 nos EO Storage 05 nos Capacity-25 kg FO Storage 02 nos VS OLD 06 Nos CSA Plant 02nos DMS Plant 18 nos Methanol storage 04 nos SAP Plant 15 nos Boiler house 09 nos ECC Room 10 nos as spare Total 129 nos Total Nos of SCBA Sets – 08 Nos Acid division C/R- 01No Chlorine Shed- 02 Nos DMS Plant- 01 Nos TC Plant- 02 Nos


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Emergency Control centre- 02 nos 23.

OHC facilities

24.

EMP

25. 26.

EMP plan ( Action Prepared and displayed in all department Plan) one page List of emergency facilities

A.

Dry powder (50% of fire extinguishers )

50 nos

B.

50 nos

C.

CO2 Cartridges ( 50% of fire extinguishers ) 200 gms (10 kg DCP As above 2 Kg ( 75 Kg DCP )

D.

Sand scoops

50 nos

E.

Safety helmets

500 nos

F.

Water curtain nozzles

20 nos

G.

Stretchers

01 nos

H.

First aid box with anti snake serum

10 nos

I.

Rubber hand gloves

200 nos

J.

Explosive meter

01 no

K.

Fire entry suit w/o breathing apparatus

01 no

L.

Resuscitator

05 no

M.

Electric siren with 3 km range

01 no

N.

Hand operated siren

Nil

O.

Water gel blandest

NA

P.

Red/green flags for fire drill

Nil

Q.

08 nos.

R.

Pressure type self contained breathing apparatus with spare cylinder (30 minutes) Safety Shower

27.

Fire Water Reservoir :-

200 M3

28.

Other Source of Water :

Gujarat water infrastructure limited , Anjar


Occupational Health Centre is declared near main gate and factory medical officer visit schedule is once in a week. Well equipment Ambulence VAN. Stretcher-01 Oxygen cylinder with mask-01 First aid box- 10 nos in all departments Prepared as Per ISO-14000

06 nos

14 nos.


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29.

Fire Pump Details Pump Detail

Number of Pump Jockey Pump 01 Electrical Pump 01 Diesel Pump Nil Total 02 30. Hydrant System Details Area / Plant

70 mtr 70 mtr Nil Nil

Capacity (Flow) 10.8 m3/h 270m3/h Nil Nil

KW/HP 10 120 Nil Nil

Nos. Of Hydrant with Hose Box Hydrant – 07 nos Hose box- 01 nos Hydrant – 01 nos Hose box- 01 nos Hydrant – 11 nos Hose box- 03 nos Hydrant – 06 nos Hose box- 05 nos Hydrant – 011nos Hose box- 05 nos Hydrant – 01no Hose box- 01 no Hydrant – 02 nos Hose box- 01 nos Hydrant – 05 nos Hose box- 02 nos Hydrant – 01 no Hose box- 01 no Hydrant – 02nos Hose box- 02 nos Hydrant – 47 nos Hose box- 30 nos

PNCB Plant MCB Plant Acid Division Old VS plant New VS Plant Acetanilide Plant PDCB Plant Power Plant Canteen DMS Plant Total 31.

License & Approval:

A.

Factory Inspectorate

B.

GPCB

C.

Solid waste Disposal

D.

Explosive licence No :


Head

Particulars Chlorine

Nos. Of Monitors 01 no

Nil 01 no

Licence No : 018712 Validity : 31/12/2010 Consent No: 5991/3/5/2005 Validity : 31/1/2010 Note – Application inward ID12531/Dated- 18/12/2009 for renewal of consent Member ship : TSDF, Nandesari Baroda Licence no Validity G/WC/GJ/06/109(G15607) 30/09/2011


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Ethylene oxide old VS Plant Ethylene oxide New VS Plant Furnace oil Methanol Benzene& Toluene


S/HO/GJ/03/718(SS5280)

31/03/2013

S/HG/GJ/03/1066(S32386)

31/03/2011

P/WC/GJ/15/2380(PII9928) 31/12/2010 P/HQ/GJ/15/4682(P120542) 31/12/2010 P/HQ/GJ/15/4568(P20641) 31/12.2012


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3.3.

Google Map:



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3.4.

Site Plan:



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3.5.

ORGANIZATIONAL SET UP

Safety setup organisation chart Advise Company of safety legislation & updates, safety awareness, carry out safety audits, update safety policy, provide training when required, to provide investigations and reports for any accidents.

Directors

Unit Head

Dy. Mgr ((Fire & Safety) (General Shift only)

VP Operation

GM Operation

Fire & Safety Supervisor (One in every shift)

Fireman Two in each shift

3.6.

DETAILS OF STORAGE OF HAZARDOUS MATERIALS IN BULK

NAME

OF

HAZARDOUS

MAX.

STORAGE

CAP.[Qty.]

OF

SUBSTANCE

Vinyl Sulphone Plant Ethylene 25 KL X 1 bullet Oxide 15 KL X 1 bullet

Chloro Sulfonic Acid

45 KL X 6 Nos Tank


PLACE IT’S

OPERATING

TYPE

PRESSURE

HAZARD

MEASURE PROVIDED

Fire /Explosion/ Toxic

        

STORAGE

AND TEMP.

Licenced Premises A/G SS

10 Kg/ cm2 Ambient

Tank farm area A/G MS

ATP Ambient

OF

Corrosive

CONTROL

       

Double Safety Valve Nitrogen Blanketing Double Static earthing Dyke wall Scrubber provided Jumper clips on flanges Hydrant system Fire extinguishers Fencing and No Smoking and prohibited area. Tanker unloading procedure. Shed provided on bullets. Sprinkler provided on bullets. SCBA sets available. Safety shower. Level gauge provided. Scrubber provided Required PPEs provided to


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Chloro Sulfonic Acid (Proposed) Caustic Lye

200 MT X 3 Nos.

Do

ATP Ambient

Corrosive

25 KL X 2Nos Tank

ATP Ambient

Corrosive

Caustic Lye

40 KL X6 Nos Tank 20 KL X 1Nos Tank 30 KL X 3Nos Tank

Tank farm area A/G MS Do

ATP Ambient ATP Ambient ATP Ambient

Corrosive

ATP, Ambient ATP, Ambient

Combustible

ATP, Ambient ATP, Ambient ATP, Ambient ATP, Ambient

Flammable

Sulfuric Acid Hydrochloric Acid

Do Tank farm area A/G HDPE

Corrosive Corrosive

all employees  Double drain valve will be provided to sulfuric Acid storage tank  Full body protection will be provided to operator.  Caution note and emergency first aid will be displayed and train for the same to all employees.  Safety shower and eye wash will be provided in storage tank area and plant area.  Total close process will be adopted for Sulfuric acid handling.  Dyke wall will be provided to storage tank

Acetanilide Plant Acetanilide

600 MT

Godown

Aniline

100 KL X 1 No Tank

Tank farm area A/G MS Do

Aniline

200 KL X 1 No Tank Acetic Acid 100 KL X 2 No Tank Dil. Acetic 25 KL X 2 No Acid Tank Ethyl Acetate 25 KL X 1 No Tank 15 KL X 1No Tank MCB, ODCB, PDCB, DCB Plant Chlorine 209 Tonners Chlorine

200 Tonners

Benzene

40KLX4 Nos Tank Total : 160 KL 200KLX2Nos Tank

Monochloro Benzene (MCB) PNCB ONCB Dichloro Benzene (DCB)

90KLX 2 Nos Tank 200KLX 1 No Tank 200KLX 1 No Tank


Do Do Do

Flammable

Corrosive/ Flammable Corrosive Flammable

Storage Shed Storage Shed U/G Tank MS

10 Kg/cm2 Ambient 10 Kg/cm2 Ambient ATP

Toxic

Tank farm area A/G MS DO

ATP

Fire

ATP

Fire

DO

ATP

Fire

Tank farm area A/G MS

ATP

Fire

Toxic Fire

 Flame proof plant, pumping transfer, close process, etc.  Double Static earthing  Dyke wall  Tanker unloading procedure.  SCBA sets available .  Flame proof plant, pumping transfer, close process, etc.  Jumper clips on flanges  Fire extinguishers  Fencing and No Smoking and prohibited area.  Tanker unloading procedure.  Flame arrestor provided on vent line of the tank  Chlorine Kit, Caustic Pit, SBA sets, Cl2 Shed, Cl2 Hood, EOT, etc. Provided.  Flame proof plant, pumping transfer, close process, etc.  Double Static earthing  Dyke wall  Tanker unloading procedure.  SCBA sets available .  Flame proof plant, pumping transfer, close process, etc.  Jumper clips on flanges  Fire extinguishers  Fencing and No Smoking and prohibited area.  Tanker unloading procedure.  Flame arrestor provided on vent line of the tank  Hydrant system


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NB, PNT, ONT, Plant Toluene

Benzene

40KLX4 Nos Tank Total : 160 KL 40KLX4 Nos Tank

U/G Tank MS

ATP

Fire

U/G Tank

ATP

Fire

MS Total : 160 KL

Nitric Acid Sulphuric Acid

PNT (PNitroToluene) ONT ONitro Toluene MNT (Meta Nitro Toluene)

20KLX3 Nos Tank 20KLX 1 No Tank

MS A/G Tank MS A/G Tank

ATP

Corrosive

ATP

Corrosive

200KLX1No Tank

MS A/G Tank

ATP

Fire

200 KLX 1 No Tank

MS A/G(V) Tank MS A/G (H) Tank MS A/G(V) Tank

ATP

Fire

ATP

Fire

ATP

Fire

Storage yard

ATP

Fire

90KL Tank

X1

No

200KLX 1 No Tank Total : 290 KL 150KLX 1 No Tank

NB (Nitro Benzene) Sulphuric Acid Plant Sulfur powder 5000 MT

Oleum 65 %

250 MT X2 Nos Tank

MS A/G Tank

Atmospheric Ambient

Corrosive

Oleum 23%

250 MT X 1No Tank

MS A/G Tank

Atmospheric Ambient

Corrosive

Oleum 65 %

100 MT X 2 Nos.

MS A/G Tank

Atmospheric Ambient

Corrosive


 Flame proof plant, pumping transfer, close process, etc.  Double Static earthing  Dyke wall  Tanker unloading procedure.  SCBA sets available .  Flame proof plant, pumping transfer, close process, etc.  Jumper clips on flanges  Fire extinguishers  Fencing and No Smoking and prohibited area.  Tanker unloading procedure.  Flame arrestor provided on vent line of the tank  Hydrant system  Safety Showers provided  Caution note provided  Dyke wall provided  Level gauge provided.  Double drain valve provided  Scrubber provided  Required PPEs provided to all employees  Flame proof plant, pumping transfer, close process, etc.  Double Static earthing  Dyke wall  Jumper clips on flanges  Hydrant system  Fire extinguishers  Fencing and No Smoking and prohibited area.  Tanker unloading procedure.  Flame arrestor Provided.

 Separate storage area.  Monitors provided surrounding the storage area.  Automatic conveyer system for charging in melter.  Level gauge provided.  Scrubber provided  Required PPEs provided to all employees  Double drain valve will be provided to sulfuric Acid storage tank  Full body protection will be provided to operator.


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Liq Sulphur Trioxide

MS A/G Tank

Atmospheric Ambient

Corrosive

1000 MT X 2 Nos. tank

MS A/G Tank

Atmospheric Ambient

Corrosive

50 KLX 3 Nos Tank 140 KL X 01 Tank 2000 MT X 2 Nos Tanks

MS A/G Tank

Atmospheric Ambient

Corrosive

MS A/G Tank

Atmospheric Ambient

Corrosive

200 MTX 3 Nos.

MS A/G Tank

Atmospheric Ambient

Fire

Dimethyl Aniline (DMA)

100 MTX 2 Nos.

MS A/G Tank

Atmospheric Ambient

Fire

Diethyl Sulfate (DES)

200 MTX 2 Nos.

MS A/G Tank

Atmospheric Ambient

Fire

Benzene Sulphonyl Chloride DASDA

100 MTX 2 Nos.

MS A/G Tank

Atmospheric Ambient

Fire

100 MTX 2 Nos.

MS A/G Tank

Atmospheric Ambient

Fire

Methanol

60KLX Tank

Nos

MS A/G Tank

Atmospheric Ambient

Fire

Ethanol

200 KL X 1 No. tank

MS A/G Tank

Atmospheric Ambient

Fire

Sulphuric Acid 98 %

CSA Plant Chloro sulphonic Acid Chloro sulphonic Acid Dimethyl Sulfate (DMS)


4

 Caution note and emergency first aid will be displayed and train for the same to all employees.  Safety shower and eye wash will be provided in storage tank area and plant area.  Total close process will be adopted for Sulfuric acid handling.  Dyke wall will be provided to storage tank  Level gauge provided.  Scrubber provided  Required PPEs provided to all employees  Double drain valve will be provided to sulfuric Acid storage tank  Full body protection will be provided to operator.  Caution note and emergency first aid will be displayed and train for the same to all employees.  Safety shower and eye wash will be provided in storage tank area and plant area.  Total close process will be adopted for Sulfuric acid handling.  Dyke wall will be provided to storage tank

 Flame proof plant, pumping transfer, close process, etc.  Double Static earthing  Jumper clips on flanges  Hydrant system  Fire extinguishers  Fencing and No Smoking and prohibited area.  Tanker unloading procedure.  Flame arrestor Provided.


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25 00

350 C 4 to kg/cm2

Ammonia Anhydrous ( Liquefied )

50 MT X 1 No. Bullet

MS bullet

Hydrochloric Acid

25 KL X 03 Nos

A/G HDPE Tank

Atmospheric Ambient

Corrosive

SS A/G Bullet

Atmospheric Ambient

Corrosive

Storage Shed

10 Kg/cm2 Ambient

Toxic

TC plant (PROPOSED) Thyonile 150KL X 03 Tank chloride

Chlorine

140 Toner


Toxic 10

 Flame proof equipment, pumping transfer, close process, etc.  Double Static earthing  Dyke wall  Scrubber provided  Jumper clips on flanges  Hydrant system  Fire extinguishers  Fencing and No Smoking and prohibited area.  Tanker unloading procedure.  SCBA sets available .  Safety Showers provided  Caution note provided  Dyke wall provided  Level gauge provided.  Double drain valve provided  Scrubber provided  Required PPEs provided to all employees  Safety Showers provided  Caution note provided  Dyke wall provided  Level gauge provided.  Double drain valve provided  Scrubber provided  Required PPEs provided to all employees  Level gauge provided.  Scrubber provided  Required PPEs provided to all employees  Double drain valve will be provided to sulfuric Acid storage tank  Full body protection will be provided to operator.  Caution note and emergency first aid will be displayed and train for the same to all employees.  Safety shower and eye wash will be provided in storage tank area and plant area.  Total close process will be adopted for Sulfuric acid handling.  Dyke wall will be provided to storage tank  Chlorine Kit, Caustic Pit, SBA sets, Cl2 Shed, Cl2 Hood, EOT, etc. Provided.  Scrubber provided .


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26 00

Sulpher trioxide

100 MT X 02 Tank

MS Tank

Chlorinated Paraffin Wax CPW (PROPOSED) HNP 65KLX 04 TANK MS Tank

Atmospheric Ambient

Corrosive

      

Safety Showers provided Caution note provided Dyke wall provided Level gauge provided. Double drain valve provided Scrubber provided Required PPEs provided to all employees

Atmospheric Ambient

Flammable

      

Safety Showers provided Caution note provided Dyke wall provided Level gauge provided. Double drain valve provided Scrubber provided Required PPEs provided to all employees Safety Showers provided Caution note provided Dyke wall provided Level gauge provided. Double drain valve provided Scrubber provided Required PPEs provided to all employees Safety Showers provided Caution note provided Dyke wall provided Level gauge provided. Double drain valve provided Scrubber provided Required PPEs provided to all employees

HCL

75KLX 6 TANK

HDPE TANK

Atmospheric Ambient

Corrosive

      

Chlorinated Paraffin oil

20 KLX 03

FRP

Atmospheric Ambient

Corrosive

      

Furnace LDO HSD

27 KLX 2 Nos U/G tanks 21 KL Tank

MS Tank

Atmospheric Ambient Atmospheric Ambient

Fire

 Flame proof plant, pumping transfer, close process, etc.  Double Static earthing  Jumper clips on flanges  Hydrant system  Fire extinguishers  Fencing and No Smoking and prohibited area.  Tanker unloading procedure.  Flame arrestor Provided.

3.7.

Oil/

MS Tank

Fire

Facilities / System for process safety, transportation, fire fighting system and emergency capabilities to be adopted Following facilities and system will be installed / implemented. 1. 2. 3.

Total enclosed process system. DCS operation plant. Instrument & Plant Air System for control all parameters.



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27 00

4.

5. 6. 7. 8. 9.

10.

11.

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

24. 25. 26. 27. 28.

High level, low level, High pressure, low pressure, high temp, high flow, low flow indication and cut off interlocking provided on storage as well as process reactors. Safety valve, rupture disk provided on reactor and pressure storage tanks. Static earthing and electric earthing (Double) will be provided. Jumpers for static earthing on pipeline flanges of flammable chemical provided. Flame proof light fitting installed where ever it is required. Emergency handling equipments like SCBA sets, Fire extinguishers, Gas mask, PPEs, Chlorine emergency Kit, chlorine hood, caustic pit, Air line respirator, provided. Full fledge ETP plant made and it will take care of liquid effluent of the plant and final discharge parameter will be maintained as per GPCB norms. Scrubbers provided on all process vent and air monitoring carried out and parameters will be maintained as per GPCB norms. Fire Water reservoir for fire hydrant and sprinkler system. Storage tank area are away from the process plant and Separation Distance has been maintained. Dyke wall provided to all above ground storage tanks, collection pit with valve provided. Flame arrestor with breather valve is installed on flammable material storage tank vent. Lightening arrestor on all chimneys and building provided. Fencing and caution notes and hazard identification boards displayed. Only authorized person are permitted in storage tank farm area. Safety permit for hazardous material loading unloading is prepared and implemented. Static earthing provision is made at all loading unloading points of flammable chemical storage tank farm area. TREM CARD provided to all transporters and trained for transportation Emergency of Hazardous chemicals. Fire hydrant system and water sprinkler system installed at tank farm area. Caution note, safety posters, stickers and emergency preparedness plan will be displayed. Emergency facilities and medical emergency facilities are available at site. Occupational Health centre facility generated at factory premises and paramedical staff is available round the clock. Wind direction indicators are provided. Safety Shower and eye wash are installed at acid/ alkali handling area. Tele Communication system and mobile phone will be used in case of emergency situations for communication. Emergency siren installed at main gate as well as in all plant. Training programme are being conducted regularly and induction training are being provided to all employees on chemical safety and process safety.



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28 00

3.1

BRIEF DESCRIPTION OF PROCESS AND FLOW CHART

3.1.1

Vinyl Sulphone & Vinyl Sulphone Condense: Chloro Sulphonation: Chloro Sulphonic Acid is charged into the sulphonation reactor. Acetanilide is then slowly added to maintain the temperature below 80° C. The temperature is then maintained between 50-60 °C. The batch thus prepared is transferred to the storage tank. Dumping: Sulphonated mass is charged into the Reactor cooled with brine. Ice water is then added slowly to remove all the HCl formed due to decomposition of excess Chloro Sulphonic Acid. The HCl is scrubbed and absorbed in water to make HCl. Further Ice water is added to dilute the concentrated Sulfuric Acid formed due to the decomposition of Chloro Sulphonic Acid. Here we get of Sulfuric Acid of strength 30-40%. The mass is then filtered out (ASC Cake). Reduction: Sodium Bi Sulphite slurry is added to the reactor. The pH is maintained neutral by adding Caustic Lye. The ASC wet cake is then charged under controlled temperature and pH. After addition is over the temperature is raised up to 50 °C. The mass is then filtered and transferred to condensation vessel. Condensation: The reduction mass in condensation vessel is maintained at 50°C. Ethylene Oxide is slowly added. The pH is maintained to 5-7 by adding dilute sulphuric acid. The material after condensation is transferred to the Nutsch Filter. The Mother liquor is stored in storage tank. The condensed product is then washed and dried. Esterification: The condensed product is charged in esterification reactor. Concentrated Sulphuric Acid is added. The temperature is then raised and maintained at 160°C for 4 hours. Vacumm is applied to take out acetic acid vapors and being condensed. The product is then collected a tank. The dried Vinyl Sulphone is pulverized and packed in PVC bags. Chlorosulphonation: NHCOCH3

NHCOCH3 +

+

2Cl.SO 3H

HCl +

H2SO 4

SO 2Cl ACETANILIDE


CHLORO SULPHONIC ACID


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29 00

Reduction: NHCOCH3

NHCOCH3 +

NaOH +

+ Na2SO 4

NaHSO 3

SO 2Cl

+

NaCl

SO 2Na

Ethoxylation: NHCOCH3

NHCOCH3 H2 C + H2SO4 + H2O

SO2Na

CH2 + Na2SO4

+ O

SO2CH2CH2OH

ETHYLENE OXIDE

Esterification: NHCOCH3

NH2 + H2SO 4

SO 2CH2CH2OH

+ CH3COOH SO 2CH2CH2OSO 3H VINYL SULPHONE



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30 00

Process Flow Chart: Acetanilide 2182 CHLOROSULPHONIC 10182 ACID

CHLOROSULPHONATION 12364

Ice

14545

DUMPING(ICE) 26909

FILTERATION(Nutch)

H2SO4 (35-40%)

12364

SOD. BISULPHITE SLURRY(30%)

6545

CAUSTIC LYE

2182

14545

REDUCTION 21091

PRODUCT FROM FILT ETHYLENE OXIDE H2SO4

1018 2269.00

ETHOXYLATION 24378.00 Salt FILTER

17753

SODIUM SULPHITE SALT (BYPRODUCT)

8299

6625.00 ETP CONDENSED PRODUCT

9454

6625.00 2262

MOISTURE LOSS

DRYER 4363.00 PRODUCT FROM Dryer H2SO4

1455

ESTERIFICATION 5818.00 ACETIC ACID 1818 VINYL SULPHONE 4000.0

MASS BALANCE/FLOW CHART OF THE VINYL SULPHONE



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3.1.2

Sulphuric Acid The process for the manufacture of sulphuric acid comprise the following steps:

1. Solid Sulphur after weighment is fed to sulphur melter which is provided with steam coils. The ash content of the molten sulphur settles in the melter cum settler and molten sulphur free of impurities is pumped to the sulphur burner where it is burnt with air. Sulphur is converted in to SO2 in the sulphur burner as per the following reaction S

+ O2

SO2

2. SO2 is further converted to SO3 in presence of Vanadium Pentoxide catalyst in the converter as per the following reaction: 3. SO2 + ½ O2 SO3 The conversion of SO2 to SO3 is carried out in stages in all the five pass of the convertor. The conversion is optimized by intermediate cooling of gases between the different stages and also by interpass absorption of SO3 after 3rd pass of the convertor. 4. The gas from the 3rd & 5th pass of the convertor containing SO3 is cooled & then fed to the interpass & final absorption tower where SO3 is removed by circulating Sulphuric Acid in the absorption towers. The concentration of sulphuric acid is controlled by addition of water in the pump tank. 5. Air for sulphur burner is routed through Air Filter to drying tower and further to suction side of Centrifugal Air Blower. 98.5% acid is circulated through drying tower at 70°C, thus heating to 125°C before entering sulfur burner. This system helps to increase generation of steam and hence power generation. 6. SO2 emission during start up of the plant is controlled by a Venturi Scrubber using alkali as scrubbing medium. The plant therefore does not cause any pollution either during start up or during normal operation. The process as described above has been divided into five main sections described as follows: •

Sulphur Circuit The weighed quantity of sulphur of about 99.5% purity is fed to the first compartment of sulphur melter. The heat for melting sulphur is provided through steam coils. The optimum pressure to be maintained for melting sulphur in the first compartment is upto 7 kg/cm2 G. The molten sulphur flows from compartment no. 1 to pumping compartment through underflows/overflows. The sulphur pumps for feeding sulphur are fitted in pumping compartment. The total time of retention in the compartments corresponds to more than 72 hrs at normal rated production capacity of the plant. In order to achieve



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32 00

optimum results, it is necessary that the feeding of sulphur to the melter should be maintained at specified temperature of 135 °C. All compartments are fitted with steam coil to provide the necessary heat for maintaining the temperature of molten sulphur at the desired level. Molten sulphur from the pumping compartment is pumped to the sulphur burner through one of the submersible type sulphur pumps through specially designed sulphur feeding gun. The rate of feed of sulphur to the sulphur burner is controlled by operation of sulphur feed control valve. Drain lines have been provided in the molten sulphur discharge line at two different points. The optimum steam pressure for coils located in 2nd, 3rd , 4th through pumping compartments of the sulphur melter is around 4 kg/cm2 G. This regulated steam pressure is achieved through pressure reducing valve. Molten sulphur line starting from the discharge flange of the sulphur pump to the inlet of the sulphur burner is suitably steam jacketed to maintain correct temperature of molten sulphur fed to the sulphur burner. •

SO2 Scrubber It is very important that SO2 emission during plant startup is controlled within persmissible limits. This is achieved by use of a alkali scrubber located after the final absorption tower where gas is scrubbed with circulating alkali solution.

•

DM and Water Softening Plants For generation of steam of high quality DM water is required for this purpose RO plant and DM plant will be installed.

•

The plant is provided with data logging system through DCS control circuits for control of parameters like Acid concentration control, pump tank level control, Boiler feed water level control, boiler feed water from deaerator temperature control. All the output signals are fed to a computer and output data is collected based on reports to be prepared including log sheets.

Chemical Reaction: S

+

O2

SO2

SO2

+

1/2O2

SO3

SO3

+

H2O

H2SO4

Overall S M.W


3/2O2 32

48

+

H2O

H2SO4

18


98

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33 00

3.1.3

Oleum & SO3 Oleum (23%) Oleum 23% is manufactured by absorbing SO3 gas with Sulphuric Acid. H2SO4

+

SO3

H2S2O7

Oleum 23% means free SO3 in the product is 23%, which is equivivalent to 105.17% Sulphuric Acid. This way 23% Oleum is equivalent to 1.07 of 98% Sulphuric Acid. The sulphur required for 1 ton of 23% oleum is 0.326 x 1.07 = 0.349 ton. Oleum (65%) Oleum 65% means, the free SO3 in this product is 65% which is equivalent to 114.626% sulphuric acid. This way the oleum 65% is equivalent to 1.17 times of 98% sulphuric acid. The sulphur required for 1 ton of 65% Oleum 0.326 x 1.17 = 0.381 ton Liquid SO3 Liquid SO3 is = 1.25 times of 98% Sulphuric Acid. The Sulfur required for 1 ton of liquid SO3 = 0.326 x 1.25 = 0.41 ton.



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34 00

Metler (135°C)

Sulphur 163.25 MT 904341 M3

Air

Furnace (1100°)

Drying Tower

(Oxygen: 245 MT) Water WHB

Steam

Steam Turbine to Generate 4 MW Power

Convertor (upto 3rd pass)

100 MT DM Water

Acid Pump Tank

IPAB(Inter Pass Absorption Tower

P

99% H2SO4

Oleum Tower

Convertor (4th pass)

H2SO4 (98.5%) Oleum Pump Tank (Oleum 23% or 65%)

Oleum Storage (23% or 65%)

99% H2SO4 H2SO4 (98.5%) Storage 500 MT/Day

Final Absorption Tower

Alkali Scrubbe r

Vent to Atmosphere

Wastewater 0.8 KLD

PROCESS FLOW CHART OF H2SO4(98.7%), Oleum (23% & 65%)



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35 00

SO3 Convertor (132 °C)

Condenser

SO3 Liquid 7500

Oleum Tower (23%)

Oluem Pump Tank (23%) 8070

PROCESS FLOW CHART OF SO3 LIQUID

3.1.4

Chloro Sulphonic Acid The HCl gas is refrigerated and cleaned in gas cleaning tower. The dry HCl is reacted with liq SO3 to get Chloro Sulphonic Acid. The unconverted gas is scrubbed in caustic scrubber. Chemical Reaction: SO3 (l) 80

+

HCl (g) 36.5

ClSO3H (l) 116.5

Mass Balance: 1567

HCl

Chilling 1567 Chilled HCl

H2SO4

3433 Liq SO3 100.00%

Gas Cleaning Bleed 1567 Dry HCl

99.90%

Reactor Gas to Stack Caustic Scrubber 0.8 Castic Solution Wastewate To ETP 10% 0.8 KL/Month 5000 Chlorosulphonic Acid

MASS BALANCE OF CHLOROSULPHONIC ACID


Kutch Chemical Industries Ltd.

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36 00

3.1.5

Sulfonation (of ONT/PNT, Tobias, VS) Take ONT/PNT in as sulfonator and charge 98% Sulphuric Acid and 65% Oluem in it slowly. After completion of reaction blow sulfomass in another vessel containing water, charge common salt, mix it, cool it and filter in neutsch. Material is then centrifuge. Collect filterate as Spent Sulphuric Acid for sale. Sulphonated ONT/PNT from centrifuge is then packed in HDPE bags and sent for sale. For Tobias, Take Oleum (65%) in sulfonator, charge Tobias Acid slowly and after completion of charging raise temperature and maintain it. Now cool the sulphonated mass and blow it in Brine water. Allow for mixing, filter and give wash of brine water. Centrifuge the mass and collect the wet cake as product and packed in HDPE bags. Chemical Reaction (o-NT/p-NT): CH3

CH3

98

NO2

H2SO4

NO2 +

H2SO4

H2S2O7 SO3H

178 o-Nitro Toluene

Sulphonated o-NT 217

137

Sulfuric Acid 98

Chemical Reaction: (Tobias) SO3H

SO3H

SO3H

NH2

NH2 +

H2S2O7

Tobias Acid (TA) 223

178

+

H2SO4

STA (Sulfo Tobias Acid) 303

98

MASS BALANCE: ONT H2SO4 H2S2O7

137 98 178

Sulfonator 413

Water Common Salt (NaCl)

18 117

Drawning Vessel 548 Filteration 217 Centrifuge

Spent Acid (25%) (Water+Salt+Sulfuric Acid) 331 2 (Recycle to Drawning Vessel)

Wet Cake 215 MASS BALANCE OF SULPHONATION ONT/PNT



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3.1.6

BENZENE SULPHONYL CHLORIDE Benzene is reacted with Chloro Sulphonic Acid in a agitated vessel at low temperature at about 20 -25 °C. Chloro Sulphonic Acid is used in excess for the reaction. The reacted mass is then kept under agitation for some time. It is then transferred to another vessel containing chilled water. During the addition, the vessel is cooled up to desire temperature till the addition complete. The contents are kept under agitation for some time. The mass is then separated. The acid layer is transferred to the storage tank for sale. The organic layer is washed, dried & distilled under vacuum to get the product. The HCl gas evolved during the reaction & isolation is send to CAS plant for making Chloro Sulphonic Acid. Chemical Reaction: C6H6

M.W

+

Benzene (l) 78

HOSO2Cl

C6H5SO2Cl +

HCl

CSA (l) 116.5

BSC (l) 176.5

Hydrochloric Acid Gas (g) 36.5

Mass Balance/Flow Chart: 663

Benzene

1980

CSA

HCl gas

Reactor

310

2333 Isolation

Dilute H2SO4 1500

Distillation

833 Crude Dimethyl Sulphone

1485

15

Benzyl Sulphonyl Chloride

MASS BALANCE OF BENZYL SULPHONYL CHLORIDE

3.1.7

Thionyl Chloride Sulphur is charged in sulfur monochloride reactor along with chlorine in measured quantity and reacted over a period of 12 hours to Sulphur Monochloride (SMC), which is stored for further reaction. Thionyl Chloride reacted is fed with SMC, SO3 and Chlorine. Reactor is fitted with fractionating column. TC gas thus produced is passed through 3 condenser, out of which first condenser used cooling water and other two condenser use chilled water. Crude TC is then sent to Distillation column as reflux. A part of crude TC is reacted with sulfur to get pure Thionyl Chloride.



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38 00

Alkali Scrubber is provided to absorb SO2 when required; similarly chlorine scrubber removes traces of chlorine. Byproduct is recycled back to sulfuric acid plant, where it is converted to Sulphur Trioxide for reuse in TC Plant. Chemical Reaction: 2S

Cl2

+

Sulphur

Chlorine

64

S2Cl2

S2Cl2 Sulphur Monochloride (SMC)

70

134

2SO3

+

134

+

160

SMC

Sulphur Trioxide

Cl2

2SOCl2

70

236

Chlorine

+

2SO2 128

TC

Overall Chemical Reaction: 2S

2Cl2

+

64

+

140

2SO3

2SOCl2

160

236

+

2SO2 128

Mass Balance: 818 Sulphur 890 Chlorine

SMC Reactor

2044 SO3 890 Chlorine

TC Reactor

1708 To Sulfuric Acid & SBS plant (Recycle) 1627

3015 Condenser

Distillation Column

2400 Product

600 Product

15 Total Product

3000

MASS BALANCE OF THIONYL CHLORIDE

3.1.8

DASDA Sulfuric Acid & Oluem (65%) are taken in Sulfonator, Para Nitro Toluene (PNT) is then charged. The mass in then dumped in to the water, cooled and filtered in Neutsch filter. The acid is then separated, The mass (PNTOSA) is then oxidized with sodium hypochloride. After completion of the reaction common salt is charged at the room temperature the mass is then filtered in Neutsch Filter . Then reduction of PNTOSA is carried out with Fe, HCl and NH4Cl. Filter the reduction mass & isolate the filterate using dilute H2SO4 & filter it in Neutsch filter. Material thus prepared is DASDA. Which is then centrifuged and packed in the HDPE bags.



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39 00

Chemical Reaction: CH3

CH3 +

H 2 SO 4

+

SO3H + 2H2SO4

H2S2O7

NO 2

NO 2 98

178

2NaOCl

+H2O

149

18

PNTSA (217)

CH3

SO3N

PNT(137)

SO3Na

+ H

SO3Na

H 474

SO3N

NO 2 217

2HCl + 3H2O

NO2

- C = C

O2N

73

54

SO3N

SO3H +

2

SO3Na Fe/HCl NH4Cl

H

H

SO3Na

H

SO3H NH2 + H2SO4

- C = C

H

Di-Sodium Salt (Amino form) 414

SO3N

Di-Sodium Salt (Nitro form)

H2N

NH2

- C = C

H2N

SO3H

H (DNSDA)

NO2

- C = C

O2N

NH

- C = C

H2N

H

H

H

DASDA

414

370

Mass Balance: PNT H2SO4 Oleum

63 45 82

Water Salt

20 15

Sulfonator

190 Drawning Vessel 225 Neutsch Filter

58

To ETP

30

ML(Recycle) Drawning

58

To ETP

167 Centrifuge 137 Common Salt Soda Ash NaOCl Water

15 18 69 25

Oxidation 264 Neutsch Filter 206 Centrifuge 201

Fe HCl NH4Cl

5 8 15

5

ML(Recycle) Drawning

Reduction Vessel 229 Filter Press 202

27

To ETP

26

To ETP

Isolation Vessel 202 Neutsch Filter 176 Centrifuge 170

6

ML(Recycle) Isolation Vessel

Product

DASDA MASS BALANCE OF DASDA



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40 00

3.1.9

Power Generation of 10 MW (Coal) For power generation steam will be generated from the boiler, which is then sent to steam turbine to generated the power. At the outlet of the turbine steam goes to condenser to recover the water utilized and further sent back to the boiler. The fuel utilized for the boiler will be Coal. To generated 10 MW, a steam of 40 MTD required, which is generated from the coal based boiler. The coal consumption for the required steam would be approximately 10 MTD. For Power plant, separate coal yard will be made in which coal will be stored, from coal yard the coal will be sent to crusher. The crushed coal is then sent to silo for ultimate feed in to the combustion chamber. Process Flow Chart:

Turbine Generator Set

High Pressure Steam 45 kg/cm2 410°C

Exhaust 0.1 kg/cm2 100 °C Condenser

3.1.10

Condensate back to Boiler feed water

Sodium Bi Sulphite Sodium Carbonate and Water is charged in the reactor. Sulphur Dioxide is then passed slowly to the reactor. The mass is then allowed for continuous mixing. The material thus prepared is Sodium Bi Sulphite. Chemical Reaction: Na2CO3 + 106 Sodium Carbonate

2SO2 + 64

H2O 18

2NaHCO3 + CO2 208 SBS

28

Mass Balance: Sodium Carbonate SO2 Water

106 64 18

CO2 28 Reactor

160

MASS BALANCE OF SODIUM BI SULPHITE



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41 00

3.1.11 Dimethyl Sulphate Methanol from day tank in the plant is taken through metering pump passed through heat exchanger and condenser in gas cycle. The methanol gas is passed through the aluminum catalyst, further it is reacted with liquid SO3. The ration of consumption of methanol + SO3 for DMS produced is as follows: SO3 = 0.70 MT Methanol = 0.55 MT. The moisture shall be collected out of Methanol and sent to ETP. After reaction of SO3 + Methanol gas in a closed reaction , Which will have chilled water circulation in jacket. The crude DMS formed is having a high acidity. The distilled and acid thus produced is 98% Sulphuric Acid. This is a by product and will be sold. Chemical Reaction: 260°C 2 CH3OH

CH3-O-CH3

+

H2O

Catalyst(Al2O3) Methanol 2 x 32

Dimethyl Ether 46

CH3-O-CH3 +

SO3

(CH3)2SO4 Dimethyl Sulphate 126

46

SO3

18

+ 80

H2O 18

H2SO4 98

Mass Balance :

1979

Liq SO3

DME Gas 1138

1524

Methanol Day Tank

386

Heat Exchanger

Reactor Containing Al2O3 Catalyst(260°C)

Water To ETP

Condensation Tank

Pure Dimethyl Sulphate

3000

Reactor

Distillation

117 98% Spent Sulfuric Acid

MASS BALANCE OF DIMETHYL SULPHATE



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3.1.12 Dimethyl Aniline Methanol from day tank in the plant is taken through metering pump passed through heat exchanger and condenser in gas cycle. The methanol gas is passed through the aluminum catalyst, further it is reacted with Aniline. The product is then distilled to get Dimethyl Aniline The moisture shall be collected out of Methanol and sent to ETP. Chemical Reaction: 260°C 2 CH3OH

CH3-O-CH3

+

H2O

Catalyst(Al2O3) Methanol 2 x 32

Dimethyl Ether 46

CH3-O-CH3 +

46

C6H5NH2

18

(CH3)2C6H5NH2 Dimethly Aniline 123

93

Mass Balance: DME Gas Aniline 1134

780

Methanol Day Tank

560 Reactor Containing Aluminium Catalyst

Heat Exchanger

Reactor

Condensation Tank

220 Water To ETP

1694 1500

Pure Dimethyl Aniline

Distillation 194 Wastewate to ETP

MASS BALANCE OF DIMETHYL ANILINE

3.1.13 Diethyl Sulfate Ethyl Alcohol and SO3 reacts in presence of catalyst Sodium Sulphate and Urea and formed Ethyl Hydrogen Sulfate (EHS). This EHS mass is ammoniated by ammonia and EHS gets converted into Diethyl Sulfate. Ammonia is passed in Ethyl Hydrogen Sulfate mass. The product thus formed is crude Diethyl Sulphate. Moisture content present in the Ethyl Alcohol reacts with SO3 and forms Sulphuric Acid. Distillation of crude EHS takes place under vacuum. The pure DES is produced and transported to the storage tanks.



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43 00

Chemical Reaction: 2C2H5OH

+

2SO3

2C2H5OSO3H Catalyst

Ethyl Alcohol 92

Ethyl Hydrogen Sulfate 228

160

2C2H5OSO3H +

NH3

(C2H5)2SO4

EHS

Ammonia 17

Diethyl Sulfate 154

228

+

NH4SO4 Ammonium Sulfate 114

Mass Balance:

896 Ethyl Alcohol

Reactor (Catalyst: Urea+Sod. Sulfate)

1558 SO3 Cooler 354

2100 NH3 166

Ammoniation Reactor 2266

Distillation

Spent ST Tank 766

1500 Pure Diethyl Sulfate MASS BALANCE OF DIETHYL SULFATE

3.1.14

Calcium Chloride

Calcium Carbonate is reacted with Hydrochloric Acid to get Calcium Chloride. Chemical Reaction: 2CaCO3 +4 HCl


2CaCl2 + 2 HCO3


Page Rev.

: :

44 00

Mass Balance: 0.2 Water 5 Lime Stone

Ventury Scrubber (Alkali) Reactor

ETP

4 HCl

0.2 9

Sludge to ETP 1

Filter Press 8

CaCl2 Clear Liquid Mosture Loss Evaporator

5 Dry CaCl2 Product MASS BALANCE OF CALCIUM CHLROIDE

3.1.15 Di Calcium Phosphate Rock Phosphate is reacted with Hydrochloric Acid to generated Phosphoric Acid, which is further reacted with Lime stone to get DCP which separated and crystallized. Chemical Reaction: Ca F2 3 ( Ca3(PO4)2) + 14 HCl

7 CaCl2 + 3Ca H(PO4)2 + 2HF

3Ca (OH)2

6CaHPO4 DCP

Mass Balance: Rock Phosphate

1800

HCl (30%)

3600

Reactor 5400

Lime

200 Neutralisation 5600

Hydrated Lime

200

Sodium Silicate

10

Separation 5810

Filteration 5310 Recycle to Reactor to recover DCP

1500

Process Sludge 500

Centriguge 3810 Dryer 3000

Mositure Loss 810

Finished Product

MASS BALANCE OF DI CALCIUM PHOSPHATE



Page Rev.

: :

45 00

3.1.16 Sulphur Mono Chloride Sulphur Monochloride is generated by reacting sulphur & Hydrochloric Acid in a reactor. Chemical Reaction: 2S

+

Sulphur

Cl2

S2Cl2

Chlorine

64

Sulphur Monochloride (SMC)

70

134

Mass Balance: 95.5 Sulphur 104.5 Chlorine

SMC Reactor

200 MASS BALANCE OF SULPHUR MONOCHLORIDE

3.1.17

Sulphuryl Chloride Sulphur, Chlorine & Sulphur Trioxide is reacted to gether to get Sulphuryl Chloride. Chemical Reaction:

S

+

32

3Cl2

+

210

2SO3

3SO2Cl2

160

402 Sulphuryl Chloride

Mass Balance: 16 Sulphur 17.5 Chlorine

Reactor

33.5 80 SO3 89.5 Chlorine

Reactor 203 190

Condenser

Product 13

Distillation Column

Residue

Product

10

3

MASS BALANCE OF SULPHURYL CHLORIDE



Page Rev.

: :

46 00

3.1.18 Aluminium Sulphate (Alum) Aluminium Sulphate is manufactured by the reaction of Aluminia Hydrate and Bauxite with Sulphuric Acid. Bauxite is ground in the pulveriser to 90% passing through 200 mesh and elevated to batch hopper through bucket elevator. Measure quantity of water is added in the lead bonded reactor and slowly sulphuric acid is to be added in the reactor.. After getting the required temperature in the reactor, slowly ground bauxite i.e added. After the addition of measure quantity of bauxite/alumina hydrate, the agitator is kept on for about 45 minutes, solution is then dumped in to the settling tank. The decanted solution of Aluminium Sulphate is then taken to the reactor and the required quantity of sulphuric acid is added after getting the required temperature Hydrated Alumina is added slowly. After addition, Aluminum Sulphate is moulded in the trays with the help of tray filling arrangements. The slabs after cooling are to be taken out from the trays and stacked in the store. Chemical Reaction: 2Al(OH)3 156

+

3H2SO4 294

Al2(SO4)3 + 342

6H2O 108

Mass Balance: Water 860 Alumina Hydrate/Bauxite Reactor 456 Sulphuric Acid 1316

Settling Tank 1316 456 Sulphuric Acid

Reactor

Moulding in to Slab

MASS BALANCE OF ALUM



Page Rev.

: :

47 00

3.1.19

Sulfamic Acid Urea & 23-25% Oleum are fed at controlled rates to reactor, which is cooled by chilled water/brine and cooling water. The reaction products are diluted by mixing with recycled mother liquor (available after separation of crystals of sulfamic acid). Temperature is controlled during mixing by chilled water/brine. Dilute acid streams (70% sulfuric acid) is separated after the mixing operation and is sold to SSP/Alum manufacturer. Chemical Reaction: NH2CONH2

+

SO3

NH2CONHSO3H +

NH2CONHSO3H

H2SO4

2NH2SO3H

+ CO2

+ CO2

Overall Reaction NH2CONH2 + SO3 + H2SO4 60

80

2NH2SO3H

98

+

CO2

2 x 97

44

Mass Balance: 350 Urea 3300 SO3/Oleum (23-25%)

Reactor 3650 R/C Mother Liquor Mixing 5150 Spent Acid 2750

Separation 2400 100 Water

Make -Up 2500 Cyrstallisation 1500 1000 Packing/Bagging

Figure are in Ton/Month MASS BALANCE OF SULFAMIC ACID



Page Rev.

: :

48 00

SECTION IV HAZOP SHEET

HAZOP SHEET



Page Rev.

: :

49 00

VS PLANT Table: 4.1 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent

Parameter Flow


Transferring of Chlorsulfonic Acid to service tank. Revision No. Mr. Deepak Chanchad Storage tank, Pump Activity PRES. TEMP FLOW VACU. Material : Amb Amb ---Source : Guide Words No

Possible causes 1. No material in the storage tank. 2. Pump tripped. 3. Pump valve closed.

NIL

08.07.2010

Transferring of Chloro Sulfonic Acid to Service Tank. Chloro Sulfonic Acid Form the storage Tank

Possible consequences No material to service tank.

Less

1. Valve partially closed. 2. Leakage in the pipe line. 3. Less material in the storage tank.

More time taken to fill the service tank.

More

1. Pump Ampere more. 2. Discharge valve fully open than required set value.

Early filling of Service tank


Date

Measures/Existing facilities Action Required safeguard Pressure gauge provided on the 1. Level indicator to be pump discharge valve. provided on service tank. 2. Arrow indicators to be provided on pipeline

1. Level indicator provided. 2. Vents are connected to scrubber.

Page Rev.

: :

50 00

Table: 4.2 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent

Parameter Charging


Charging of Acetanilide Mr. Deepak Chanchad -PRES. TEMP FLOW Nil Amb NA

VACU. --

Revision No.

NIL

Activity Material : Source :

Charging of acetanilide Acetanilide Bag packing

Guide Words No

Possible causes

Less

1. Human error. 2. Material weight is less than what is mentioned on the bag.

1. Disturbance in the process. 2. More

More

1. Human Error 2. Material packing weight is more than what is printed on it.

1. Disturbance in the process. 2. Product quality may detoriate.

Wrong

1. Human error. 2. Wrong labeling. 3. Wrong supply of material from supplier.

Disturbance in the process.

No material

Possible consequences No process will take place.


Page Rev.

Date

Measures/Existing facilities safeguard Material is charge under the supervision.

08.07.2010

Action Required Separate storage to be identified with the marking

1. Charge batch to be earmarked. 2. Identification of bag to be done in local language.

: :

51 00


Parameter Pressure

Reaction

Rector PRES. ----Guide Words More

Less

Temperature

Water Entry in the reactor


More Less

Leakage

TEMP 80

FLOW ----

VACU. -----

Possible causes 1. Chilled water supply low. 2. More quantity of CSA. 3. No stirrer operation. 4. Entry of water in the reactor 5. No scrubbing of HCL water, Accumulation of vapor in the reactor. 6. Choking in the scrubber. 1. Good cooling 2. Control Rate of Raw material addition. As per pressure Good cooling water flow

Revision No.

NIL


Reaction Acetanilide + Chlorosulfonic. From the storage tank & Manual charging of bag.

Possible consequences Pressure & temperature will go on increasing. Exothermic Reaction will take place.

Date

Measures/Existing facilities safeguard 1. Vent provided to scrubber. 2. Pressure gage provided on Reactor. 3. Temperature gauge provided on reactor. 4. Safety valve & pressure gauge are provided on reactor cooling jacket. 5. Sight glass provided.

No process hazards

No process hazards. It is process requirement. Temperature & Pressure will go on increasing.


Page Rev.

1. Thickness monitoring of the reactor is carried out. 2. Hydro testing of the jacket at periodic interval. : :

52 00

08.07.2010

Action Required 1. Standard operating procedure to be prepared. 2. Arrow indicators to be provided on pipe line.


Parameter Temperature

Dumping

Dumping vessel PRES. TEMP Gravity 5 Guide Words More

Less

Pressure

More

Flow

Less More

Less Other than Part of Prepared By HSE Department

FLOW ----

VACU. ----

Revision No.

Nil


Dumping of sulphonated mass. Sulphonated mass. From sulfonator

Possible causes

Possible consequences 1. No addition of ICE water. 1. Maximum 2. Poor cooling of the temperature will reactor. be the ambient. 3. Choking in the HCL scrubber line. Good cooling 1. It is good for the process 2. No safety & health hazards. Increase in temperature due No process & safety to above hazards. hazards Not Applicable

Date

Measures/Existing facilities safeguard 1. Temperature Gauge 2. Pressure gauge provided. 3. Total closed process 4. Safety valve provided on Chilled water cooling line.

There is no flow measurement as sulphonated reaction mass is directly dumped in the dumping vessel.

Not applicable No full charging

Process delayed


Physical inspection Page Rev.

: :

53 00

08.07.2010

Action Required 1. Only administrative checks to be ensured. 2. SOP to be prepared.



Reduction

Reduction PRES. TEMP 50 Guide Words More

Less

Pressure

More

Less


FLOW

VACU.

Possible causes 1. Poor/No cooling. 2. Damaged insulation 3. Stirrer not moving/stopped 4. More addition of caustic. 5. Charging of normal water. 1. Good cooling. 2. Controlled addition of material in controlled way.

Revision No.

Nil

Activity Material Source

Reduction SBS + Caustic Lye From

Possible consequences 1. Desired process will not achieved. 2. Temperature will rise.

No process & safety hazards as it is requirement of the process. No effect on pressure rise as it is only neutralization & reduction by adding caustic lye. Not possible.


Page Rev.

Date

Measures/Existing facilities safeguard 1. Temperature Gauge 2. Pressure gauge provided. 3. Total closed process 4. Safety valve provided on Chilled water cooling line.

No process & safety hazards

: :

54 00

08.07.2010

Action Required Visual check by the operator




Condensation

Condensation Rector PRES. TEMP FLOW 50 -----Guide Words More

VACU. ----

Possible causes 1. Hot oil circulation is more. 2. More hot material from the reduction it self. 3. Flow of EO in case above desired level.

Revision No.

Nil


Reduction Mass + Ethylene Oxide Reduction & EO form storage tank

Possible consequences Increase in temperature & pressure.


Date

Measures/Existing facilities safeguard 1. Safety valve provided on reactor & day tank 2. Rupture disc provided on reactor & day tank. 3. Temperature & Pressure gauge provided. 4. Stand by pump for the cooling have been provided. 5. Safety valve provided on Chilled water cooling line. 6. Temperature control at50 C by providing chilling cooling & hot oil circulation in reactor jacket. 7. Dump vessel provided to transfer reaction mass in case pressurize & increase in temperature. 8. Load shell tank provided 9. Nitrogen PRV skid provided for the Nitrogen blanketing. Page Rev.

: :

55 00

08.07.2010

Action Required 1. Visual check by the operator 2. E. O. flow cutoff to be provided in connection with the temperature rise. 3. Arrow indicators to be provided on pipeline. 4. Nitrogen blanketing to during reaction to be provided.

Parameter

Possible causes

Temperature

Guide Words Less

Pressure

More

Increase in temperature due to above mentioned causes

Human error- Chilled water circulation valve is open.

Less Flow ( EO )


Possible consequences Desired process will not achieve.

Measures/Existing facilities safeguard BMR is prepared & followed.

Temperature Increase.

Pressure Gauge provided on reactor & operator will take action accordingly.

Not possible

More

1. Human Error 2. Valve passed.

Increase in temperature & pressure.

No/Less

1. No material 2. Valve jammed 3. Wrong setting of the valve

Delayed in the process.


1. Sight glass 2. Line Sight Glass Provided. 3. Flow meter provided on Inlet of reactor. 4. Double mechanical seal in stirrer 5. Total closed process 6. Flameproof fitting provision. 7. Double static earthing provided. 8. Jumpers provided on flange joint. 9.

Page Rev.

: :

56 00

Action Required Physical checks are required.

Table: 4.7 HAZOP STUDY WORKSHEET

Study Title Drawing No. Hazop Team Part Considered Design intent

Esterification Revision No. Esterification Reactor PRES. TEMP FLOW ---160

VACU. Yes


Date

08.07.2010

Esterification Sulfuric Acid + Condensed product. From Condensation

Parameter

Guide Words

Possible causes

Possible consequences

Measures/Existing facilities safeguard

Temperature

More

1. Increase in flow of Sulfuric acid. 2. Jacket temperature is more. 3. Less quantity of condensed material.

1. Pressure will increase. 2. PH may affected.

1. Temperature & pressure gauge Physical & administrative provided. checks to be ensured. 2. Safety valve & Pressure gauge provided on Reactor jacket. 3. Sight glass provided. 4. Vent are connected to scrubber.

Less

1. No heating in the jacket. 2. No flow of sulfuric acid.

1. No safety & health hazards. 2. Desired process temperature will not achieved. 3. Delayed in the batch cycle.

More

As per the temperature

Less

As per the temperature

Pressure



Page Rev.

: :

57 00

Action Required


E. O. storage tank NIL Deepak Chanchad Storage Tank PRES. TEMP FLOW N. A.

VACU. N.A.

Revision No.

NIL

Date


Storing of E. O. E. O. E. O. Storage tank

28-06-2008

Parameter

Guide Words

Possible causes



Action Required

Temperature

More

1. No chilled water supply. 2. Ambient temp high. 3. Poor insulation (water entry inside insulation). 4. E. O. not consumed for some days.

1. Development of pressure in Ethylene Oxide tank. 2. Blow off from Safety Valve. 3. Toxic & Fire Hazards. Explosion Hazards. Air pollution. Leakage from flange may occur. 4. Metallic impurities. 5. In case temperature is more than 20 C then polymerization may occur.

1. PSV provided. 2. Chilled water cooling provided. Safety Valve provided. 3. Rupture disc provided. 4. Insulation to tank provided. 5. Magnetic level type flow indicator provided. 6. Ethylene Oxide gas sensor monitoring system provided. 7. Pressure Gauge provided. 8. Fix Fire water monitor system provided. 9. Sprinkle on System on EO tank provided. 10. Hi temperature alarms provided. 11. Chilling coil provided. To storage tank covers 90 % in the bottom 2-3 tons E. O. left without chilling.

1. To dilute the 1 liter of EON, 18 liters water is required. Considering this sufficient quantity of water shall be ensured. 2. All flange joints shall be checked regularly.



Page Rev.

: :

58 00

Parameter

Guide Words

Possible causes



Temperature

Less

1. Good Chilling. 2. Too cold atmosphere during the winter.

1. Decrease in E. O. Pressure.

1. Temperature Gauge provided. 2. Insulation provided.

Pressure

More

1. N2 valve passing. 2. More temperature in the storage tank.

1. Leakage from flange may occur 2. Blow off from Safety Valve. 3. Toxic & Fire Hazards. Explosion Hazards. Air pollution.

1. Pressure switch provided on 1. During the pop of E. O. tank. Safety valve it shall be 2. Inbuilt N2 pressure is 5.8 ensured the sufficient kg/cm2 so by human error N2 quantity of water for dilution. valve remains open than also 2. In case Safety valve do it will not rise up to 5.8 not set to its back kg/came. Safety valve of position after venting Storage tank set at 6.5 Kg/cm2 the extra pressure (this scenarios shall be considered.) 3. Foam type monitor shall be considered. 4. Calibration for all instruments shall be done vigorously.

Less

1. Leakage from flange joints, 2. Pump discharges less. 3. Mal functioning FCV 4. Valve partially closed. In case activation of any interlock than also the flow will be low.



Page Rev.

: :

59 00

Action Required

Parameter

Guide Words

Possible causes

Flow

More Less

Covered under pressure Covered under pressure

Reverse

Not Possible

Other than

Leakage from cooling coil

Leakage of water in storage tank.



Process disturbance. Spillage hazards No Safety hazards


Auto shut off valve provided.

Moisture in E.O. quality problem in EO. Wastage of material


Page Rev.

: :

60 00

Action Required

1. During the pop of Safety valve it shall be ensured the sufficient quantity of water for dilution. 2. In case Safety valve do not set to its back position after venting the extra pressure (this scenarios shall be considered.) 3. Foam type monitor shall be considered. Calibration for all instruments shall be done vigorously. Pressure gauge on the outer side of the cooling coil shall be provided.



Pressure


From outlet of storage tank to inlet of batch tank. 0 Revision No. Mr Deepak Chanchad Storage tank & pump Activity PRES. TEMP FLOW VACU. Material : Amb Source : Guide Words More

Possible causes

Less

1. Seasonal effect 2. lekage of chilled water in E.O. from tank.

More

Covered under flow

Less

Covered under flow

1. Seasonal effect 2. Poor insulation of pipeline. 3. Falling of hot water on uninsulated line. 4. Incoming E. O. from storage tank itself has high temperature.

NIL

Date

Transferring of Raw material E. O. From storage tank

Possible consequences 1. More pressure in the pipeline may give rise to leakage. 2. From poor flange joints, valve. Fire & health hazards.

Measures/Existing facilities safeguard Insulation on pipeline & batch tank provided.

No workplace Hazards. It the basic requirement but High moisture in E.O. Wastage of E. O.

Safety valve provided on batch tank.


28-06-2008

Page Rev.

: :

61 00

Action Required 1. To dilute the 1 liter of EON, 18 liters water is required. Considering this sufficient quantity of water shall be ensured. 2. All flange joints shall be checked regularly.

Parameter Flow


Guide Words More

Possible causes

Less

1. Choking in the excess flow valve. (Holes are choked.) 2. Low pressure of N2 itself. 3. Valve choked.

Reverse

No chances

1. 2. 3. 4.

N2 pressures more. Valve failure FIC mal function. Human error.

Possible consequences 1. Pressure rise in batch tank. 2. Leakage in flange joint. 3. Safety valve of batch tank may popup. 4. Tank filling operation completed in less time. No safety hazards but it will take more time for filling operation.



Pressure gauge shall be provided on batch tank.

1. NRV provided. 2. Auto shut off valve provided.

Page Rev.

Action Required

: :

62 00

ACETALININDE PLANT Table 4.10 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent

Raw material to the storage tank ( Day Tank ) 0 Mr. Deepak Chanchad Storage tank & pump PRES. TEMP FLOW VACU. Am Am

Revision No.

NIL


Transfer Acetic Acid From storage tank.

Parameter

Guide Words

Possible causes

Flow Pressure

No

1. No material in the storage No material to service tank. tank. 2. Pump tripped. 3. Pump discharge valve closed. 4. Heavy leakage in pipe line.

More

1. Valve opened more than set value 2. Human Error. Not possible

Reverse Less



Date

08.07.2010


Action Required

Pressure gauge provided on the pump discharge valve.

1. Non-returnable Valve to be provided. 2. Arrow indicator to be provided on pipeline. 3. Stand by pump to be provided. 4. Pump, storage tank & pipe line identification to be done. 5. Color code to be provided. 6. Work permit procedure to be followed for handling of hazardous chemicals. 7. PPE compliance to be followed during handling of acid.

More material to the service tank.

SOP to be prepared.


Page Rev.

: :

63 00

Table 4.11 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent


Pressure

Reaction Process 0 Mr. Deepak Chanchad Storage tank & pump PRES. TEMP FLOW Am 130 Guide Words More

Possible causes

Less

1. Ambient temperature is low. 2. Good cooling. 3. Hot oil circulation temperature is low. Atmospheric pressure reaction Not possible

More Less Power failure


VACU.

1. Hot oil circulation temperature is more. 2. Choking of pipeline of inlet & out let of condenser. 3. Poor cooling in condenser.

Revision No.

NIL


Reaction Acetic Acid & Aniline + Acetic anhydride. From the storage tank.

Possible consequences 1. Process Disturbance. 2. (Reaction time will be more.) 3. Product will char.

Date

Measures/Existing facilities safeguard 1. Pressure gauge & temperature gauge to be provided. 2. Safety valve provided on reactor’s jacket.

08.07.2010

Action Required 1. Arrow indicator to be provided. 2. Sand tray to be provided for the collection of storage. 3. SOP to be prepared.

Efficient process will not take place.

SOP to be prepared.

No process will take place.


Page Rev.

DG set provided.

: :

64 00

CHLORO SULPHONIC ACID PLANT Table 4.12 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent

Parameter Chilling


Chilling of the HCL 0 Mr Deepak Chanchad Storage tank & pump PRES. TEMP FLOW ------Guide Words No

Possible causes

More

Not possible.

Reverse

Not possible.

VACU. ----

1. No supply of chilling media. 2. Power failure 3. Insulation damaged. 4. Seasonal effect 5. HCL flow is low. 6. More impurities of organics from the other plant.

Revision No.

NIL


Chilling HCL Form MCB plant

Possible consequences 1. Poor chilling of the HCL. 2. Process delayed.


Page Rev.

Date

Measures/Existing facilities safeguard 1. Temperature controller is provided. 2. Insulation provided on the chiller.

: :

65 00

08.07.2010

Action Required


Parameter Cleaning

Temperature


Gas cleaning Revision No.

NIL

Date


Cleaning of HCL HCL From chilling section

08.07.2010

Mr Deepak Chanchad PRES.

Guide Words No

TEMP

FLOW

VACU.

Possible causes 1. No supply of HCL. 2. Cleaning media circulation stopped. 3. Poor circulation. 4. H2SO4 exhausted.

More

Good quality of cleaning media.

More

Choking in scrubber & vapor. Accumulation in gas phase.

Possible consequences 1. No Health & Safety hazards. 2. Quality of cleaning of the HCL will be affected. (Moister will not removed and due to moisture wet gas will carry over in the reaction.


1. Physical check for the cleaning media which is to be changed after certain cycle. 2. Pump stop alarm to be provided.

No process & safety hazards.


Page Rev.

Action Required

: :

66 00


Parameter Flow

Reaction

PRES. 3-5 kg /cm2 Guide Words More

More

Less Power failure


NIL

Date


Reaction Dry HCL & SO# From the storage tank.

08.07.2010

Mr. Deepak Chanchad

Less/ No Temperature

Revision No.

TEMP Am

FLOW As per blower

VACU. ---

Possible causes

Possible consequences 1. HCL flow as per blower. 1. No process 2. SO3 flow more than set disturbance. 2. Un reacted sulfur value. trioxide generation 3. Human error. will be more. 1. Blower amp low. Process Delayed. 2. Blower stopped Flow of HCL & SO3 are Increase in more. temperature & pressure. Flow of HCL & SO3 are Decrease in pressure less. & temperature --1. Un-reacted gas will come out from the scrubber. 2. Circulation will be stopped & reaction will take place.


Page Rev.

Measures/Existing facilities safeguard 1. Temperature indicator provided. 2. Pressure gauge provided.

Captive Power plant.

: :

67 00

Action Required Arrow indicators & pipeline color code to be provided.

SULFURIC ACID PLANT Table 4.15 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent

Melting of Sulfur 0 Mr Deepak Chanchad Storage tank & pump PRES. TEMP FLOW 135

VACU.

Revision No.

NIL

Date


Melting Sulfur From the Sulfur storage tank.

07.07.2010

Parameter

Guide Words

Possible causes



Action Required

Temperature

More

1. Low quantity of sulfur (Sulfur fed poorly. 2. Steam temperature high. 3. Ambient temperature high.

Good for the process.

1. 2. 3. 4. 5. 6.

Interlocks between the Burner temperature & steam flow is suggested.

Less

1. Incoming steam temperature low. 2. Ambient temperature low. 3. More quantity of sulfur fed in the burner. 1. Temperature is very high. 2. Choking in the upward stream.

Over pressurization may affect on there factory wall over a long run.

Pressure indicator provided. Temperature gauge provided.

Temperature gauge & pressure gauge provided. Captive Power Plant.

Pressure

More

Sulfur & Steam

Less Mixing

As per low temperature. Leakage in the steam coil.

Material will spoil.

Power failure

----

Sulfur May jammed



Page Rev.

: :

DSC operated plant. Pressure indicator provided. Temperature gauge provided. Level indicator provided. Closed process Controls on flow. Temperature & pressure are provided.

68 00

1. Physical checks to be ensured. 2. Periodic inspection of the Sulfur burner to be ensured.

Critical equipment should be connected with the DG supply.


Burning of sulfur with air. 0 Mr. Deepak Chanchad Sulfur Burner PRES. TEMP Sulfur 1100 -

VACU. ----

Revision No.

NIL

Date


Pumping Sulfur From the Sulfur storage tank.

08.07.2010

Parameter

Guide Words

Possible causes



Action Required

Temperature

More

1. Incoming air temperature is high. 2. Efficient operation of furnace. 1. Poor incoming air temperature 2. Poor flow of fuel. 1. Incoming air flow is more than set value. 2. Discharge of SO2 gas restricted due to choking. 3. Rupture of partition wall. 4. More incoming pressure from the sulfur melter. 1. No flow of air. 2. No sulfur from the melter. As per more pressure. As low pressure. Jamming of sulfur In burner.

No process hazards as it is the process requirement.

1. Temperature controller provided. 2. Glass window provided.

Arrow indicators to be provided on fuel line.

Less

Pressure

More

Less Flow


More Low Power failure.

Conversion process of the SO2 will not take place. Heavy leakage may started form the panel door & also some time rupture of furnace.

No Health & safety hazards.


DG set provided.

Page Rev.

: :

69 00


Catalyst convertor 0 Mr. Deepak Chanchad Sulfur Burner PRES. TEMP FLOW

VACU.

Revision No.

Nil

Date


SO3, Vanadiumpentoxide.

Parameter

Guide Words

Possible causes



Temperature

More

1. Incoming air temperature is high. 2. Efficient operation of furnace. 1. Poor incoming air temperature 2. Poor flow of fuel.

No process hazards as it is the process requirement.

1. Temperature controller provided. 2. Glass window provided.

1. Incoming air flow is more than set value. 2. Discharge of SO2 gas restricted due to choking. 3. Rupture of partition wall. 4. More incoming pressure from the sulfur smelter. 5. 1. No flow of air. 2. No sulfur from the melter. As per more pressure. As low pressure. Jamming of sulfur In burner.

Heavy leakage may started form the panel door & also some time rupture of furnace.

Less

Pressure

More

Less Flow


More Low Power failure.

Conversion process of the SO2 will not take place.

No Health & safety hazards.


DG set provided.

Page Rev.

: :

70 00

08.07.2010

Action Required

THYONYL CHLORIDE PLANT Table 4.18 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent

Rector 0 Mr Deepak Chanchad

Revision No.

NIL

PRES.


Reaction process Chlorine & Sulfur From Storage

TEMP 105

FLOW

VACU.

Parameter

Guide Words

Possible causes

Temperature

More

1. More quantity of Catalyst, Pressure & temperature 2. More Charge quantity of will go on increasing. either Chlorine & Sulfur 3. Hot oil temperature is more.

Less

1. Less quantity of catalyst. 2. Hot oil temperature is less or less quantity of HO is fed due to leakage valve partially closed.



Date


Action Required

1. Temperature gauge & pressure gauge provided. 2. Rotometer provided for the chlorine control. 3. Sight glass provided. 4. Safety valve provided. 5. Cooling & chilling arrangement with alternative provided. 6. Chlorine PRV station provided. 7. In case of increase of temperature chlorine charging supply will closed. 8. In case of increase of pressure raw material charging supply will closed.

1. Arrow indicator to be provided on pipeline. 2. Stand by pump to be provided. 3. Pump, storage tank & pipe line identification to be done. 4. Color code to be provided. 5. Work permit procedure to be followed for handling of hazardous chemicals. 6. PPE compliance to be followed during handling of acid.

Reaction time will increase.


Page Rev.

08.07.2010

: :

71 00

Parameter Pressure

Guide Words More

Possible causes



As per temperature

Less Flow


More

Human error. More charging of material.

Power failure

No GEB supply.

Pressure & temperature will go on increasing.


Captive power plant provided.

Page Rev.

: :

72 00

Action Required


Gas mixture 0 Mr Deepak Chanchad

Revision No.

NIL

PRES.


Gas Mixing Chlorine, SO2 & SDC From Storage

TEMP FLOW VACU.

Date

08.07.2010

Parameter

Guide Words

Possible causes



Action Required

Temperature

More

1. More quantity of Catalyst, 2. More Charge quantity of eithe Chlorine & Sulfur 3. Hot oil temperature is more. 4. More SO2 from the holder tank. 1. Less quantity of catalyst. 2. Hot oil temperature is less or less quantity of HO is fed due to leakage, valve partially closed.

Pressure & temperature will go on increasing.

1. Temperature gauge & pressure gauge provided. 2. Rotometer provided for the chlorine control. 3. Sight glass provided. 4. Safety valve provided . 5. Cooling & chilling arrangement with alternative provided. 6. Chlorine PRV station provided.

1. Non returnable Valve to be provided. 2. Arrow indicator to be provided on pipeline. 3. Stand by pump to be provided. 4. Pump, storage tank & pipe line identification to be done. 5. Color code to be provided. 6. Work permit procedure to be followed for handling of hazardous chemicals. 7. PPE compliance to be followed during handling of acid. 8. Periodic checking of the condenser to be followed.

Less

Pressure

Flow

More Less More

As per temperature 1. Human error. 2. More charging of material. No GEB supply.

Reaction time will increase.

Pressure & temperature will go on increasing. Pump circulation will stop.

Power failure




Page Rev.

: :

73 00



Pressure Flow


High Boiler fractional Distillation Column 0 Revision No. Mr. Deepak Chanchad HBFC, Condenser, Heat Exchanger & Carbon bed. PRES. TEMP FLOW VACU.

NIL Activity Material : Source :

Guide Words More

Possible causes


Good Heating

1. No process hazards. It is part of the requirement. 2. It will accelerate the distillation process

Less

Poor Heating

More Less More Power failure

Not possible Not Possible Not possible No GEB supply.

No distillation will take place. Process delayed. ------------Distillation will not achieve.


Date

Page Rev.

Distillation Crude TC From the Crude TC Reciever.

Measures/Existing facilities safeguard 1. Temperature gauge & pressure gauge provided. 2. Sight glass provided. 3. Safety valve provided . 4. Cooling & chilling arrangement with alternative provided. 5. Chlorine PRV station provided.


: :

08.07.2010

74 00

Action Required 1. Non return Valve to be provided. 2. Arrow indicator to be provided on pipeline. 3. Stand by pump to be provided. 4. Pump, storage tank & pipe line identification to be done. 5. Color code to be provided. 6. Periodic checking of the condenser to be followed.



Pressure Flow


Final Product Distillation Column 0 Mr Deepak Chanchad HBFC, Condenser, Heat Exchanger & Carbon bed. PRES. TEMP FLOW VACU. Yes Yes Guide Words More

Possible causes

Less

Poor Heating

More Less More Power failure

Not possible Not Possible Not possible No GEB supply.

Good Heating

Revision No.

NIL

Activity

TC Distillation

Material : Source :

Crude TC From HBFC.

Possible consequences 1. No process hazards. It is part of the requirement. 2. It will accelerate the distillation process

No distillation will take place. Process delayed. ------------Distillation will not achieved.


Page Rev.

Date

Measures/Existing facilities safeguard 1. Temperature gauge & pressure gauge provided. 2. Sight glass provided. 3. Safety valve provided . 4. Cooling & chilling arrangement with alternative provided.


: :

75 00

08.07.2010

Action Required 1. Non returnable Valve to be provided. 2. Arrow indicator to be provided on pipeline. 3. Stand by pump to be provided. 4. Pump, storage tank & pipe line identification to be done. 5. Periodic checking of the condenser to be followed.

MONOCHLORO BENEZEN PLANT Table 4.22 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent


Reaction of Chlorine 0 Mr. Deepak Chanchad

Revision No.

NIL

PRES.


Reaction Chlorine & Benzene From the storage tank

Guide Words More

Less


TEMP FLOW VACU.

Possible causes


Measures/Existing facilities safeguard 1. Flame Proof fitting are provided. 2. Rota Meter is provided. 3. Double static earthing provided to all equipment. 4. Jumpers are provided on all the pipe line joint. 5. Benzene flow cut off at high temperature in reactor have been provided. 6. Temperature controllers are provided in front of Operators cabin.

1. More quantity of chlorine due to wrong setting of Rotometer. 2. Rotometer malfunction 3. Poor cooling of reactor. 4. Ambient temperature is high. 5. More flow of benzene due to human error. 1. Flow of chlorine is less. 2. Rotometer malfunctions. 3. No benzene flow or choking in spray nozzles. 4. Chlorine sprayer got choked.


Date

Page Rev.

: :

76 00

08.07.2010

Action Required 1. To handle the chlorine emergency chorine kit to be ensured. 2. Chlorine detectors to be provided.

Parameter Pressure

Flow

Guide Words More

Possible causes

Less

As per flow

More

1. Rotometer failure Temperature will go 2. More flow from the on increasing chlorine header itself. 1. Rotometer malfunction. Process delayed. 2. Less flow from the chlorine itself. 3. Valve closed. 1. No supply due to electrical fault 2. & also the captive power plant not running.

Less

Power failure




Action Required


1. Chlorine supply to be closed immediately as it leads to environmental hazards. Un reacted chlorine will go to the atmosphere. 2. DG set to be provided & all critical equipment shall be connected with the DG supply.

As per flow


Page Rev.

: :

77 00

DMS PLANT Table 4.23 HAZOP STUDY WORKSHEET Study Title Drawing No. Hazop Team Part Considered Design intent


Pressure


Reaction 0 Mr Deepak Chanchad PRES. Yes

TEMP FLOW VACU. 260 No

Guide Words More

Possible causes

Less

Low catalyst quantity of catalyst due to human error.

More

As per flow

Less

As per flow

1. Hot oil circulation is more. 2. More temperature of the methanol gas. 3. More charging of the catalyst. 4. Ambient temperature is more.

Revision No.

NIL


Reaction Methanol From the Heat exchanger & condenser

Possible consequences 1. Pressure will go on increasing. 2. No process hazards. 3. It is the part of requirement.

Date

Measures/Existing facilities safeguard 1. DSC Plant operation 2. Flow control valve provided on the methanol. 3. Flame Proof fitting are provided. 4. Double static earthing provided to all equipment. 5. Jumpers are provided on all the pipe line joint. 6. Safety Valve & Pressure gauge are provided on Hot oil circulation circuit.

1. Process delayed. 2. DMS gas will not produced.


Page Rev.

: :

78 00

08.07.2010

Action Required 1. Calibration of all instruments to be carried out. 2. SOP to be prepared. 3. Annual shut down to be carried out and corroded plant to be replaced. 4. Thickness monitoring of the vessels to be carried out.

Parameter Flow

Guide Words More

Less

Power failure


Possible causes Pump Ampere more. Valve fully open In the system. Human error. Pump amp low Leakage in the pipe line. Valve partially closed in the HE & condenser system. 4. No material in the storage tank. 1. No GEB supply. 2. Sudden failure in the electrical system.



Process disturbance.


1. 2. 3. 4. 1. 2. 3.


Page Rev.

: :

79 00

Action Required



Pressure

Flow


Reaction 0 Mr. Deepak Chanchad PRES. Yes

TEMP FLOW VACU. No

Guide Words More

Possible causes

Less

1. Good chilling effect. 2. Winter days. 3. Good insulation

More

Not possible

Less

Not possible

More

Not possible

Less

Not possible.

Power failure

1. No GEB supply. 2. Sudden failure in the electrical system.

Revision No.

NIL


Chilling Reaction SO3 & Methanol From the reactor.


Date

Measures/Existing facilities safeguard 1. DCS operated plant. 2. Closed process 3. Pressure gauge provided on the chilled water jacket. 4.

1. Not Possible. 2. Chilling process

1. Good for the process. 2. No safety hazards

Process Disturbance


Page Rev.


: :

80 00

08.07.2010

Action Required



Pressure Flow


Distillation 0 Mr. Deepak Chanchad PRES. Yes

TEMP FLOW VACU. No

Guide Words More

Possible causes

Less

Poor Heating

More Less More Less Power failure

Not Possible Not Possible Not Possible Not Possible. 1. No GEB supply. 2. Sudden failure in the electrical system.

Good Heating

Revision No.

NIL


Distillation DMS vapour. From the reactor.

Possible consequences 1. No process hazards. It is part of the requirement. 2. It will accelerate the distillation process No distillation will take place. Process delayed.

Date

Measures/Existing facilities safeguard 1. Temperature gauge & pressure gauge provided. 2. Sight glass provided. 3. Safety valve provided . 4. Cooling & chilling arrangement with alternative provided. 5. Chlorine PRV station provided.

Captive power plant provided. Process Disturbance


Page Rev.

: :

81 00

08.07.2010

Action Required 1. Non returnable Valve to be provided. 2. Arrow indicator to be provided on pipeline. 3. Stand by pump to be provided. 4. Pump, storage tank & pipe line identification to be done. 5. Color code to be provided. 6. Periodic checking of the condenser to be followed.



Page Rev.

: :

82 00

Hazard & Operability Study - Gujarat Pollution Control Board

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