Annexure - 1 - Gujarat Pollution Control Board

Annexure - 1

PART – II

COMPLIANCE REPORT OF ENVIRONMENT CLEARANCE FOR EXPANSION OF REFINERY FROM 9 MMTPA TO 60 MMTPA AND PETROCHEMICAL COMPLEX AT

KHAMBHALIA, JAMNAGAR

EC No. : J-11011/320/2006-IA-II (I) dated 16th September, 2008

Sr. No. SPECIFIC CONDITIONS ACTION TAKEN REPORT

I M/s Essar Oil Limited shall comply with new standards

/ norms for Oil Refinery Industry Under the

Environment Protection Rule 1986 vide GSR 186 (E)

dated 18th March 2008.

The design of refinery unit shall incorporate process

features and equipments to comply with the emission

and effluent standards for petroleum refinery.

Nayara Energy Limited (Formerly known as Essar Oil Limited) are in compliance with the

conditions given for Oil & Gas Industries in GSR 186 (E) dated 18th March, 2008. The detailed

compliance report is attached as Annexure 1.1.

The design of refinery units incorporates process features and equipment in such a manner to

comply with all the norms prescribed in GSR 186 (E) dated 18th March 2008.

Following features have been adapted at design stage to reduce air emission:

Low Temperature Shell Claus off Gas Treating Units (LT SCOT) at sulfur recovery unit.

Sulfur Recovery Unit having sulfur recovery efficiency 99.9%.

Multistage multiple Cyclones in Fluidized Catalytic Cracking & Regeneration unit for particulate

emission control.

Amine Absorbers - The fuel gas produced in the refinery contains H2S. This is removed in the

Amine absorber columns and the sweet gas is routed to Refinery fuel gas system.

Use of Low Sulfur Refinery fuel Gas and Fuel Oil in heaters / furnaces. Installed Low NOX burners

in all heaters / furnaces.

Floating roof tanks are provided for storage of class A products; this reduces HC vapor loss.

Double seal has been provided in order to minimize vapor leakage.

Annexure - 1

PART – II





All vent offs are connected to the flare to take care emergency releases from refinery plant.

As shown under Annexure 1.1 all parameters monitored to comply with the emission & effluent

standards for petroleum refinery as per GSR 186 (E) dated 18th March, 2008 are well below the

prescribed limits.

II The gaseous emissions (SO2, NOx, H2S, NH3, NMHC,

HC, VOC and Benzene) from various process units shall

confirm to the standards prescribed by the concerned

State Pollution Control Board.

All the measures detailed in the Environment

Management Plan (EMP) and response to the public

hearing shall be taken to control the point / stack and

fugitive gaseous emission from the proposed facilities

for ensuring that the ambient air quality around the

The gaseous emissions parameters as prescribed by Gujarat Pollution Board in Consolidated

Consent & Authorization (CC & A) from stacks attached to heaters / furnaces and to various

process units are being complied. It may kindly be noted that the CC&A specifies only SO2, NOx,

PM, CO, Ni+V, H2S gases and there is no gaseous emission source for NH3 & NMHC from process

units.

Regarding HC and VOC since refinery is operated in a closed loop hence VOC emission is

minimum. However, VOC are monitored as a part of LDAR programme as per GSR 186 (E) dated

18th March, 2008.

Gaseous emissions monitoring results for Mar’18 to Aug’18 are tabulated in Table no. : 01A, 01

B, 2A & 2B:

All the measures taken as detailed in Environmental Management Plan for mitigation of adverse

impacts on environment due to Refinery operations is as follows:

Air Pollution Prevention / Control Measures:

Air pollution prevention / Control measures adopted at site are as following:

Annexure - 1

PART – II





refinery due to the expansion is maintained with in

prescribed limit under the EPA, 1986.

Installed Low Temperature Shell Claus off Gas Treating Units (LT SCOT) at sulfur recovery

unit.

Installed Multistage multiple Cyclones in Fluidized Catalytic Cracking & Regeneration

unit for particulate emission control.

Installed Amine Absorbers - The fuel gas produced in the refinery contains H2S. This is

removed in the Amine absorber columns and the sweet gas is routed to Refinery fuel

gas system.

Use of Low Sulfur Fuel - Refinery fuel Gas and Fuel Oil are used as fuel in heaters /

furnaces.

Installed Low NOX burners in all heaters / furnaces.

Installed Sulfur Recovery Unit having sulfur recovery efficiency 99.9%.

Floating roof tanks: Floating roof tanks are provided for storage of class A products; this

reduces HC vapor loss. Double seal has been provided in order to minimize vapor

leakage.

Good Flare Management- all vent offs are connected to the flare to take care emergency

releases from refinery plant.

Leak Detection and Repair Program (LDAR) has been implemented in the refinery.

No issues raised regarding control of the fugitive gaseous emission during the Public hearing.

However, Adequate control measures as mentioned above have been taken to ensure that

ambient air quality around the refinery is maintained within prescribed limit. The summary of

the ambient air quality monitoring for the period March’18 to August’18 are as shown in Table

no. 03A & 03B.

Annexure - 1

PART – II





The summary of the stack monitoring for the period March’18 to August’18 are as shown in

Table no. 01 A,01 B 02 A & 02 B., all parameters are well below the limits prescribed by statutory

authority.

Manual monitoring result of stack emission for the month of Mar’18 to Aug’18 carried out by M/s Unistar Environment & Research Labs Pvt. Ltd.

(NABL accreditation no. for Chemical & Biological: TC-7753 in lieu of T-2239, T-2240 valid till 14.09.20):

(A) Emission through heater’s/furnace’s stacks (Table no. 01 A):

Sr.

No.

PLANT Parameters monitored

PM

(mg/Nm3)

SO2

(mg/Nm3)

NOx

(mg/Nm3)

CO

(mg/Nm3)

Ni

(mg/Nm3)

Vanadium

(mg/Nm3)

Min-Max Min-Max Min-Max Min-Max Min-Max Min-Max

1 CDU/VDU 15-46 190-255 92-110 15-28 0.030 0.20

2 CDU - II 52-86 443-739 124-157 17-26 0.040 0.29

3 DHDT 7-14 11-41 56-82 5-13 NA NA

4 VGOHT 7-29 26-49 64-84 7-16 NA NA

GPCB Limit (for Sr. No. 1 to 4

above )

100 1700 450 200 5 5

5 NHT/CCR 5-7 11-29 54-80 6-15 NA NA

6 DHDS 4-8 8-12 58-82 6-10 NA NA

7 FCC Feed heater 5-8 12-22 43-108 5-11 NA NA

8 HMU – 1 4-8 22-41 31-82 6-18 NA NA

9 HMU-2 5-8 8-44 21-74 08-12 NA NA

10 DCU - 1 5-8 17-27 57-86 12-26 NA NA

11 DCU - 2 6-8 12-31 37-48 14-27 NA NA

12 DCU - 3 4-7 6-24 32-52 11-26 NA NA

GPCB Limit (for Sr. No. 5 to 12) 10 50 350 150 - -

Annexure - 1

PART – II





(B) Emission through processes stacks (Table no. 02 A):

Sr. No. Plant Parameters monitored

Sulfur recovery (%) H2S (mg/Nm3) NOx (mg/Nm3) CO (mg/Nm3)

Min-Max Min-Max Min-Max

1 SRU 99.8 1 18-44 11-22

2 SRU - 1 99.7 1 32-51 10-16

GPCB Limit (for Sr. No. 1 & 2) 98.7 15 350 150


PM

(mg/Nm3)

SO2

(mg/Nm3)

NOx

(mg/Nm3)

CO

(mg/Nm3)

Ni (mg/Nm3) V (mg/Nm3)


3 FCC

Regenerator

31-62 229-457 72-112 52-273 0.05-0.07 0.21-0.35

GPCB Limit (for Sr. No. 3) 100 1700 450 400 5 5

Legends:

CDU/VDU Crude Distillation Unit / Vacuum Distillation Unit

CDU - II Crude Distillation Unit - II

NHT/CCR Naphtha Hydro Treater/ Continuous Catalytic Reforming

DHDS Diesel Hydro de Sulfurization

FCCU Fluidized Catalytic Cracking Unit

HMU Hydrogen Manufacturing Unit

DHDT Diesel Hydro Treater

VGOHT VGO Hydro Treater

Annexure - 1

PART – II





DCU Delayed Coker Unit

SRU Sulfur Recovery Unit

PM Particulate Matter

SO2 Sulfur Dioxide

NOx Oxides of Nitrogen

H2S Hydrogen Sulfide

CO Carbon Monoxide

Ni Nickel

V Vanadium

NA: Not Applicable

The Monitoring report by M/s Unistar Environment & Research Labs Pvt. Ltd. (NABL accreditation no. for Chemical & Biological: TC-7753 in lieu of T-2239,

T-2240 valid till 14.09.20 is attached as Annexure 1.1.1.

Note: The Monitoring is carried out by NABL accredited third party, i.e. Unistar Laboratories Private Limited, Vapi. The NABL accreditation certificate are

shown below:

Annexure - 1

PART – II





Annexure - 1

Annexure - 1

PART – II





Continuous Emission Monitoring system

Apart from this Continuous emission monitoring system is provided & hooked up with CPCB server for all stacks. Stack emission data for the month of

Mar’18 to Aug’18 are shown in table below:

(A) Emission through heater’s/furnace’s stacks (Table no. 01 B) :

Unit SO2 NOx CO PM

mg/Nm³ mg/Nm³ mg/Nm³ mg/Nm³

Min Max Min Max Min Max Min Max

CDU 77.6 539.08 1.07 137.05 1.16 162.41 2.49 69.21

VDU 59.8 551.73 44.26 98.97 14.72 91.36 3.95 29.13

CDU-II 97.9 1134.29 7.4 199.41 26.83 121.34 4.84 84.54

FCCR 312.3 690.2 112.75 306.75 198.58 373.68 22.82 43.26

NHT/CCR 3.2 37.41 49.01 61.07 7.77 21.15 Will be installed by

TA18* DHDS 7.7 45.68 4.36 67.77 7.74 16.9

FCCH 1.5 43.65 45.58 133.13 5.42 14.4

DHDT 36.4 187.8 11.36 193.55 14.05 145.11

VGOHT 1.3 80.58 3.28 177.39 1.04 177.71

HMU-1 1.3 24.55 0.49 37.28 Will be installed by

TA18 HMU-2 1.2 17.97 0.19 19.97

DCU-1 1.7 42.43 15.49 162.19 17.57 145.99

DCU-2 4.4 43.48 15.9 49.43 2.82 146.5

DCU-3 2.0 39.28 1.06 60.8 9.06 110.64

SRU Not in Consent 30.29 79.82 Will be installed by

TA18

Not in Consent

TA18* - Turn around 2018,Planned in November – December 2018

Annexure - 1

PART – II





(B) Emission through processes stacks (Table no. 02 B):

Sr. No. Plant

NOx (mg/Nm3)

Min-Max

1 SRU 2-80

2 SRU - 1 6-21

GPCB Limit (for Sr. No. 1 & 2) 350

Sr. No. Plant

PM

(mg/Nm3)

SO2

(mg/Nm3)

NOx

(mg/Nm3)

CO

(mg/Nm3)

Min-Max Min-Max Min-Max Min-Max

3 FCC

Regenerator

24-43 89-690 68-307 199-374

GPCB Limit (for Sr. No. 3) 100 1700 450 400

Legends:

NA: Not applicable

Note : Calibration detail for analyzers from SAP is shown below:

Annexure - 1

PART – II





For CDU I :

Detailed calibration reports for analyzers are maintained in our SAP server. Screen shot of the same is attached as Annexure 1.1.2.

Annexure - 1

PART – II





Calibration Schedule:

Detailed calibration schedule is attached herewith as Annexure 1.1.3.

Annexure - 1

PART – II





Ambient Air Quality for Mar’18 to Aug’18 are shown in Table no. 03 A.

Manual Monitoring by Third Party, M/s Unistar Environment & Research Labs Pvt. Ltd. (NABL accreditation no. for Chemical & Biological: TC-7753 in

lieu of T-2239, T-2240 valid till 14.09.20).

Table no. 03 A: Analysis results for Ambient Air Quality

Sr.

No

Particulars/

Parameters Unit

GPCB

CC&A

Limit

At 93 gate Refinery

main gate Labor Gate

PORT A

CAMP


1

Wind

Direction

(From)

NW NW NW NW NW NW NW NW

2 PM10 μg/m3 100 61 88 56 78 61 88 54 88

3 PM2.5 μg/m3 60 16 28 16 26 17 28 14 28

4

Sulphur

Dioxide

(SO2)

μg/m3 80 12 28 14 26 12 26 16 27

5

Nitrogen

Oxides

(NO2)

μg/m3 80 16 32 18 29 16 28 19 32

Annexure - 1

PART – II





6

Carbon

Monoxide

(CO)

mg/m3

4 <1 <1 <1 <1 <1 <1 <1 <1

7 Benzene μg/m3 5 <1 <1 <1 <1 <1 <1 <1 <1

8 Benzo(a) -

Pyrene μg/m3 1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1

Online Monitoring for Ambient Air Quality (Table no. 03 B) :

Table no. 03 B: Analysis results for Ambient Air Quality

Sr.

No

Particulars/

Parameters Unit

GPCB CC&A

Limit AAQMS 1 AAQMS 2

Min Max Min Max

1 PM10 μg/m3 100 34 85 29 78

2 PM2.5 μg/m3 60 14 56 5 54

3 Sulphur Dioxide (SO2) μg/m3 80 1 52 1 64

4 Nitrogen Oxides (NO2) μg/m3 80 4 30 20 40

5 Carbon Monoxide

(CO) mg/m3 4 <1 2 <1 1

Annexure - 1

PART – II





6 Benzene μg/m3 5 <1 <1 <1 <1

7 Benzo(a) - Pyrene μg/m3 1 <0.1 <0.1 <0.1 <0.1

III The company shall confirm to the process vent

standards for organic chemicals including non-VOCs

and all possible VOC i.e. TOCs standards and process

vent standards for top priority chemicals.

Regular monitoring shall be carried out for VOC and

HC and on–line monitors for VOC measurements may

be installed.

We confirm to the process vent standards for organic chemical including non VOCs and all

possible VOC. All process vents are connected to flare. The pilot burners on the flare are

continuously on and therefore there is no chance of unburned HC release to the atmosphere.

Regular monitoring is being carried out for VOC as under:

Manual monitoring for VOC are regularly carried out as per GSR 186 (E) dated 18th March, 2008

The company has well established procedure for leak detection and repair under which VOCs are

monitored in all the units manually though photo-ionization VOC meters since 2010. No leak has

been detected till date. The procedure in brief for LDAR (Leak Detection and Repair) is shown

below. (For detailed procedure please refer Annexure 1.2).

Annexure - 1

PART – II





Procedure for VOC monitoring :

- The VOC Meter should be assembled and started in open & clean atmosphere.

- The instrument should be calibrated as per recommendation of instrument supplier.

- Concentration of VOCs emitted by the leaking component should be checked at the

surface interface (e.g. at the interface between a valve stem and packing).

- The probe inlet should be placed at the surface of the component interface where there

is possibility of Leak. It should be moved along the periphery while observing the

instrument readings.

- The interface where leakage is indicated should be sampled slowly until the maximum

reading is obtained. If the maximum reading exceeds the defined concentration limit

then record the reading. Set the meter to zero reading and again take the maximum

reading for cross verification.

Annexure - 1

PART – II





Annexure - 1

PART – II





Apart from above, VOC emissions are manually monitored in the vicinity of potential sources of

VOC emissions. VOC emission monitoring results for the month of Mar’18 to Aug’18 are tabulated

in Table no. 04.

Table no. 04: VOC monitoring results

Sr.

No. VOC monitoring area / unit / plant Unit

VOC

Min-Max

1 Near Truck Gantry No. 5 (HC Truck Loading) Ppm 40-60

2 Primary Treatment Plant of Truck Dispatch Area ppm 38-104

3 Expansion ETP ppm 191-243

4 Hazardous waste storage sites ppm 0

5 Primary Treatment Unit of ISBL-1 process ppm 132-194

6 At Battery Limit in CDU/VDU ppm 2-5

7 At Battery Limit in CDU - II ppm 1-5

8 Downwind of equalization tank (Oil Separation

Basin Unit-8400) of base ETP ppm 263-292

9 Primary Treatment Plant of Crude Tank Storage

(COT) Area ppm 9.1-10.8

Annexure - 1

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The detection limit of the instrument used for measurement of VOC is 0 to 10,000 PPM.

Instrument are regularly calibrated. Calibration report is shown below.

Annexure - 1

PART – II





IV The total SO2 emission load for 32 MMTPA refinery

capacity and petrochemical complex will be below

24.60 tons/ day and for III phase for 60 MMTPA

production petrochemicals shall not exceed 38.69

tons /day.

Regular record on sulfur emission shall be maintained

as part of the environmental data record.

SRU of 99% sulfur removal will be established and

efficiency will be monitored at regular intervals.

Presently, refinery is operating at 20 MMTPA capacity. Minimum SO2 emission load is 15.04

MT/day. Maximum SO2 emission load is 15.23 MT/day, which is within limit.

Regular record on sulfur emission are being maintained as a part of environmental data record.

Details are as shown below:

Table no.: 05 Sulfur emission records

Sulfur emission records based on the monitoring carried out

by NABL accredited laboratory are maintained as given

below.SO2 emission from Stacks, Tons/Day

Mar'18 Apr'18 May'18 Jun'18 Jul'18 Aug'18

15.05 15.03 15.04 15.06 15.23 15.18

SRU of 99% sulfur removal efficiency have been established and efficiency is being monitored at

regular interval as under:

Sulfur removal efficiency for SRUs are shown in table no 06 A, 06 B, 07 A & 07 B

Annexure - 1

PART – II





For SRU Base (Table 06 A)

CA

SE

AA

G T

rain

I

Flo

w,

kg/h

r

AA

G T

rain

II

Flo

w,

kg/h

r

CR

U g

as

Flo

w,

kg/h

r H2S in Feed

Gas, wt %

H2S in Feed

Gas, kg/hr

S in Feed Gas,

kg/hr

Poten

tial

Sulph

ur,

TPD

Amine CRU Amine CRU Amine CRU

Actual 7342 6344 1464 94.38 93.25 12917 1365 12157 1285 322.6

For SRU Base (Table no. 06 B)

St

ack

Ga

s

Sox

wt%

H2

S w

t%

SOx in

Stack

gas,

kg/hr

H2S in

Stack

gas,

kg/hr

S in

Sox,

kg/hr

S in

H2S,

kg/hr

S in

Stack

Gas,

kg/hr

Total S

in Stack

gas, t/d

Potenti

al

Sulphur

, TPD

Sulph

ur

Recov

ery

Act

ua

l

73

41

7

0.0

41

1

0.0

01

30.20 0.73 15.10 0.69 15.79 0.3790 322.6 99.9%

For SRU Expansion (Table 07 A)

CA SE

Am

ine

Aci

SW S Aci H2S in Feed

Gas, wt %

H2S in Feed

Gas, kg/hr

S in Feed Gas,

kg/hr

Potentia

l

Annexure - 1

PART – II





Amine CRU Amine CRU Amine CRU

Sulphur,

TPD

Actual 26651 3867 94.99 47.0 25315 1818 23826 1711 612.9

For SRU Expansion (Table no. 07 B)

St

ack

Ga

s

Sox

wt%

H2

S w

t%

SOx in

Stack

gas,

kg/hr

H2S in

Stack

gas,

kg/hr

S in

Sox,

kg/hr

S in

H2S,

kg/hr

S in

Stack

Gas,

kg/hr

Total S

in Stack

gas, t/d

Potenti

al

Sulphur

, TPD

Sulph

ur

Recov

ery

Act

ua

l

10

53

07

0.0

34

4

0.0

01

36.20 1.05 18.10 0.99 19.09 0.4582 612.9 99.9%

Refinery has two units of SRU. One, base SRU which has been upgraded to 99.9% design

efficiency from 99.4 % by replacing Super Clause Process by LT-SCOT Process. Second, SRU

expansion which was installed during expansion of the base refinery; it is also based on LT- SCOT

Process designed to operate at 99.9% efficiency.

Annexure - 1

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Performance evaluation will be done for all these

activities on annual basis to check adequacies and

improve on the deficiencies.

Performance evaluations of SRUs are done annually.

Presently, both SRUs are operating more than 99.7% sulfur recovery efficiency.

Following measures are adapted for maintaining the performance:

1. Process analyzer are monitored on daily basis for smooth running of plant.

2. And when there is any deviation in reading from the design limit then immediately

analyzer is attended.

3. Stack Analyzer is being attended every 3 month.

V On-line monitoring shall be carried out for stack

emission of SO2 & NOx contributed mainly from CDU,

VDU, SRU, etc and data shall be transferred to CPCB

and SPCB regularly.

Online monitoring is being carried out for stack emission of SO2 & NOx in all stacks including CDU,

VDU and SRU. Online data are being transmitted to CPCB server since June’ 2015. Earlier we have

contacted GPCB to upload the data on their server, but at that time GPCB server did not have

enough capacity. We have again approached GPCB office to suggest a way forward. Request

letter to GPCB for the same is as given below.

Annexure - 1

PART – II





The instruments used for ambient air quality

monitoring shall be calibrated regularly.

The monitoring protocol shall ensure continuous

monitoring of all the parameters.

The Instruments used for ambient air quality are periodically calibrated by M/s Chemtrol. The

calibration report is as given below.

Two stations of Continuous Ambient Air Quality monitoring have been installed in upwind and

downwind direction and on line data are being transmitted to CPCB server since March’2013.

One of our Environment Engineer is assigned to check continuous operation of online analysers,

in case of any abnormality the concerned department is immediately informed and prompt action

is being taken to rectify the problem.

Annexure - 1

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Calibration report:

For AAQMS I : For AAQMS II :

VI The existing plant is using low NOx burners and the

same or the one which are more efficient than the

existing shall be used for the expansion of the projects

too in all furnaces/ heaters.

For the expansion of the project to 20 MMTPA low NOx burner has been provided in the existing

DCU heaters, DHDT, VGOMHC, which are similar to the burners installed in the preexisting unit

i.e. CDU, VDU, NHTCCR, FCCH,DHDS.

We confirm to use the same or the one which are more efficient than the existing, for the

expansion of the projects in all furnaces/ heaters.

Annexure - 1

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VII The company shall install Hydro desulphurization and

sulfur recovery unit with efficiency more than 99%

Hydro desulphurization & sulfur recovery unit with efficiency 99.9 %. were installed and

commissioned in November, 2006.

VIII For additional LPG storages, refrigerated storage or

mounded bullets shall be installed.

No additional LPG storages has been created after issuance of this EC & we confirm that For

additional LPG storages required in future , refrigerated storage or mounded bullets will be

installed.

IX Low sulfur internal fuel oil and fuel gas shall be fired in

process heaters.

Low sulfur Internal fuel gas is being fired in all the process heaters except CDU, VDU, CDU-II,

VGOHT and DHDT wherein mixture of low sulfur fuel oil and fuel gas is being fired.

Quality of fuel oil & fuel gas for the month of Mar’18 to Aug’18 is shown in table no. 08 A & 08

B.

Table no. 08 A Table no. 08 B

Sulphur Concentration in Wt% in Fuel Oil

Sr. No.

Month Monthly Average

1 Mar 0.74 2 Apr 0.84 3 May 0.77 4 Jun 0.59 5 Jul 0.44 6 Aug 0.57

H2S Concentration in mg/Nm3 in

Fuel Gas

Sr.

No. Month Monthly Average

1 Mar 32.5

2 Apr 21.9

3 May 14.3

4 Jun 11.8

5 Jul 16.8

6 Aug 19.4

Annexure - 1

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X

Quarterly monitoring of fugitive emissions will be

carried out by Fugitive Emission Detectors (GMI Leak

Surveyor).

Guidelines of CPCB shall be followed for monitoring

fugitive emissions.

Quarterly Monitoring of fugitive emissions is being carried out as per GSR (186) E, 2008. (Detailed

compliance is covered under Annexure 1.1 GSR condition no.ii)

Guidelines of GSR (186) E, 2008 are being followed for monitoring fugitive emissions.

XI Floating roof double seal tanks will be provided to

reduce the VOC fugitives’ emission.

For management of fugitive emissions, all unsaturated

hydrocarbons will be routed to the flare systems. The

flare system shall be designed for smoke less burning.

Floating roof double seal tanks have been provided to reduce the VOC fugitives’ emission for all

Class-A & B Hydrocarbons (HC).

For management of fugitive emissions, all unsaturated hydrocarbons are being routed to the flare

system which is designed for smokeless burning with steam.

XII Flare Gas Recovery (FGR) system shall be installed for

reduction of hydrocarbon loss and emission of VOCs,

NOx, N2O, and SOx & CO2 to the environment.

At present flare losses are minimal therefore it is flared directly. However, we have already made

provision for installing Flare Gas Recovery System for reduction of hydrocarbon loss and emission

of VOCs, NOx, N2O and SOx & CO2 to the environment.

XIII FCC shall be provided with an ESP and other sources

of particulate will be controlled to meet E (P) Act

standards.

FCC has been provided with high efficiency cyclones so as to ensure that the particulate emissions

are within the limit. We are meeting the E (P) Act standards by installing cyclones. This is a general

practice to provide cyclones in FCC.

Monitoring report for the stack emission parameter for the period of Mar’18 to Aug’18 is as given

in Table no. 09 A & 09 B.

Monitoring results for FCC regenerator for the month of Mar’18 to Aug’18 carried out by M/s Unistar Environment & Research Labs Pvt. Ltd. (NABL

accreditation no. for Chemical & Biological: TC-7753 in lieu of T-2239, T-2240 valid till 14.09.20) :

Annexure - 1

PART – II





Table no. 09 A


PM

(mg/Nm3)

SO2

(mg/Nm3)

NOx

(mg/Nm3)

CO

(mg/Nm3)



1 FCC

Regenerator

31-62 229-457 72-112 52-273 0.05-0.07 0.21-0.35


Continuous Emission Monitoring System

Table no. 09 B

Sr. No. Plant

PM

(mg/Nm3)

SO2

(mg/Nm3)

NOx

(mg/Nm3)

CO

(mg/Nm3)


1 FCC

Regenerator

22-43 313-690 113-307 199-374


Annexure - 1

PART – II





XIV Regular Ambient Air Quality Monitoring shall be

carried out.

The location and results of existing monitoring

stations will be reviewed in consultation with the

concerned State Pollution control Board based on the

occurrence of maximum ground level concentration

and downwind direction of wind.

Regular Ambient Air Quality Monitoring is being carried out at 4 nos. of Ambient air quality

sampling stations installed within the Refinery premises one in in up wind & one in down wind

direction and 2 nos in cross wind direction.

Ambient Air Quality Monitoring is being carried out once a week at 4 locations. Reports are

regularly submitted to GPCB.

Monitoring results for the month of Mar’18 to Aug’18 carried out by M/s Unistar Environment

& Research Labs Pvt. Ltd. (NABL accreditation no. for Chemical & Biological: TC-7753 in lieu of

T-2239, T-2240 valid till 14.09.20) are as given in Table no. 10.

Table no. 10

Sr.

No

Particulars/

Parameters Unit

GPCB

CC&A

Limit

At 93 gate Refinery

main gate Labor Gate

PORT A

CAMP


1

Wind

Direction

(From)

NW NW NW NW NW NW NW NW

2 PM10 μg/m3 100 61 88 56 78 61 88 54 88

Annexure - 1

PART – II





Additional stations shall be set up, if required, It will

be ensured that at least one monitoring station is set

up in up wind & in down wind direction along with

those in other direction.

3 PM2.5 μg/m3 60 16 28 16 26 17 28 14 28

4

Sulphur

Dioxide

(SO2)

μg/m3 80 12 28 14 26 12 26 16 27

5

Nitrogen

Oxides

(NO2)

μg/m3 80 16 32 18 29 16 28 19 32

6

Carbon

Monoxide

(CO)

mg/m3

4 <1 <1 <1 <1 <1 <1 <1 <1

7 Benzene μg/m3 5 <1 <1 <1 <1 <1 <1 <1 <1

8 Benzo(a) -

Pyrene μg/m3 1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1

Apart from above sampling stations, 2 nos. of Continuous AAQM (One in upwind & one in

downwind) installed within the Refinery premises. Real time data of CAAQMS are transmitted to

CPCB through M/s Chemtrol server since March 2013.

Monitoring result of CAAQMS for the month of Mar’18 to Aug’18 are as given in Table no. 11

Annexure - 1

PART – II





Table no. 11: Monitoring result of CAAQMS

Sr.

No

Particulars/

Parameters Unit

GPCB CC&A

Limit AAQMS 1 AAQMS 2

Min Max Min Max

1 PM10 μg/m3 100 34 85 29 78

2 PM2.5 μg/m3 60 14 56 5 54

3 Sulphur Dioxide (SO2) μg/m3 80 1 52 1 64

4 Nitrogen Oxides (NO2) μg/m3 80 4 30 20 40

5 Carbon Monoxide

(CO) mg/m3 4 <1 2 <1 1

6 Benzene μg/m3 5 <1 <1 <1 <1

7 Benzo(a) - Pyrene μg/m3 1 <0.1 <0.1 <0.1 <0.1

Annexure - 1

PART – II





XV The practice of acoustic plant design shall be adopted

to limit noise exposure for personnel to an 8 hr time

weighted average of 90 dB (A).

The practice of acoustic plant design is being adapted., in refinery to limit noise exposure for

personnel to an 8 hr time weighted average of 90 db (A), All the equipment have been designed

and are operated with noise level of <90 dB (A).

The design of project is such that the sound level in the work area is not exceeding 90 dB (A).

Wherever practicable, attempts have been made to reduce the noise level below 90dB (A).

However the areas where it is not reasonably practicable to reduce the noise level below the

limit have been designated high noise area, where the movement is restricted and limited

exposure is allowed to the working personnel.

Following measures have been adapted to reduce the noise exposure:

Annexure - 1

PART – II





The major areas of concern for noise generation has been addressed by considering it

during procurement of the machinery from vendors, project implementation stage and

by giving correct specification during tender floating.

Periodic audiometric test is being conducted for employees working close to noise prone

areas, such as compressors, DG Sets, the loading and unloading sections.

PPE’s are provided to ensure for eardrum protection of the employees, workers as well

as visitors.

Acoustic barriers or acoustic enclosures and silencers are provided for the high noise

generating equipment.

Sound proofing / glass paneling have been provided at critical operating stations / control

rooms.

Further Periodical Monitoring of the exposure to the person working in high noise is being done.

Results of noise exposure for personnel to an 8 hr time weighted average is as shown in Table

no. 12.

The below result indicates that the personal working in the high noise area are not continuously

exposed to high noise.

Table no. 12 Results of Personal Noise dosimetry at Nayara Energy Limited, Vadinar, India.

Date of Project: 29-01-2018 to 7-02-2018

Calibrator: QUEST QC-10, Acoustic Calibrator, Serial No.: QIH010149 Date of Samplin

g

Instrument ID

Employee Name

Employee ID

Location/

Depa

Activity

Pre-calibratio

Post-calibratio

Shift

Duration of Sampling

Total Duratio

n

Total Durat

The Factories Act

(5 dB Comments

Observations

Annexure - 1

PART – II





rtment

n (dB)

n (dB)

ion (min)

Exchange Rate)

& Recommendations

Start

Time

Stop Tim

e

Lavg (dBA)

TWA (dBA

)

To view additional details, please unhide the columns. Personal Noise sample at HMU-2

29/1/2018

EHM010022

Mr. Hardik Pobhoraniya

20045659

HMU-2

Routine operation in the

plant

114.0 114.0 B 14:1

3 21:4

2 7:29 449 76.6 76.1

The monitored employee took routine rounds in the plant for 2 hours and spent rest of the time in the porta cabin. None

30/1/2018

EHH050012

Mr. Rahul Paliwal

20044255

HMU-2


plant

114.1 114.0 B 15:0

2 22:2

7 7:25 445 74.8 74.2

The monitored employee spent 2 hours at the pump house area and rest of the time at the porta cabin.

Personal Noise sample at HMU-1

31/1/2018

ENS100709

Mr. Satish Yadav

20050197

HMU-1


plant

114.0 114.0 A 6:11 14:1

5 8:04 484 76.3 76.3 The monitored

employee spent three to four hours at the pump house area and rest of the time at the porta cabin.

None

1/2/2018 EHH05001

2

Mr. Tarun Dhameliya

2004232 HMU

-1


plant

114.0 113.9 A 6:22 13:5

6 7:34 454 82.7 82.4

Personal Noise sample at DHDT

29/1/2018

EHH050012

Mr. Arvind Kumar

20053295

DHDT

Routine operation in

114.0 114.1 B 14:5

5 22:5

6 8:01 481 77.7 77.8

The monitored employee spent four hours on routine rounds in the plant and spent

None

Annexure - 1

PART – II





the plant

rest of the time in the porta cabin.

30/1/2018

EHH050012

Mr. Mustaq Vohra

20045664

DHDT


plant

114.0 114.0 A 6:15 13:4

0 7:25 445 77.9 77.1

The monitored employee spent four hours on routine rounds in the plant and spent rest of the time in the porta cabin.

Personal Noise sample at DHDS

30/1/2018

EHH050012

Mr. Parth Desai

20045662

DHDS


plant

114.0 113.8 B 14:1

0 21:5

0 7:40 460 79.5 79.2

The monitored employee spent four hours on routine rounds in the plant and spent rest of the time in the porta cabin.

31/1/2018

NXG080022

Mr. Sanjay Chawhan

20045052

DHDS


plant

114.0 113.9 A 6:40 14:1

0 7:30 450 80.6 79.9

The monitored employee spent four to five hours on routine rounds in the plant and spent rest of the time in the porta cabin.

Personal Noise sample at CDU/VDU

29/1/2018

NXG080033

Mr. Dipak Kumar Mantri

20049375

CDU/VDU


plant

114.0 113.9 B 15:4

0 21:5

0 6:10 370 79.1 77.3

The monitored employee took routine rounds in the plant for three hours. The rest of the time was spent at the porta cabin.

None

30/1/2018

ENS100709

Mr. Savan Vachhani

20053199

CDU/VDU


plant

114.0 113.7 B 14:5

5 21:4

4 6:49 409 83.8 83.1

The monitored employee was at the compressor area for three hours and took routine rounds in the plant for one hour. The

Annexure - 1

PART – II





rest of the time was spent at the porta cabin.

31/1/2018

NXG080033

Mr. Viral Shah

20046190

CDU/VDU


plant

114.1 114.0 A 6:47 13:5

6 7:09 429 81.5 81.0

The monitored employee took routine rounds in the plant for two-three hour. The rest of the time was spent at the porta cabin.

XVI All the pumps and other equipment’s where is a

likelihood of HC leakages shall be provided with LEL

indicators and Hydrocarbon detectors.

Provision for immediate isolation of such equipment,

in case of a leakage will also be made.

All the pumps and other equipment where there is a likelihood of HC leakages are being provided

with hydrocarbon detectors with LEL indicators. Around 619 nos. of Hydrocarbon detectors have

been installed in all areas where there is a likelihood of HC leakages from pumps and other

equipment.

The range of detector is 0-100% LEL of the Hydrocarbon of respective area and Alarm value is L1:

20% LEL and L2: 40% LEL.

Standby pumps have been provided so that leaky pumps are immediately isolated and

maintained.

Annexure - 1

PART – II





The company shall provide a well-defined Leak

Detection and Repair (LDAR) programme for

quantification and control of fugitive emissions. The

detector sensitivity will be in PPM levels.

The company has well established procedure for leak detection and repair as per GSR 186 (E)

dated 18th March, 2008 under which VOCs are monitored in all the units manually though photo-

ionization VOC meters since 2010. NO leak has been detected till date.


LDAR program summary for the month of Mar’18 to Aug’18 is shown in Table no. 13.

Table no. 13. LDAR PROGRAM SUMMARY- March’2018 to August’2018

Sr.

No Unit Dates

Total Component

Monitored

Min VOC

in PPM

Max VOC

in PPM

Leak

Observed

1 HMU-1 01/03/2018 to

14/03/2018 4238 0 224 Nil

2 HMU-2 15/03/2018 to

30/03/2018 2920 0 0 Nil

3 FCCU 01/04/2018 to

14/04/2018 7481 0 23 Nil

4 Utility-1 15/04/2018 to

29/04/2018 1027 0 61 Nil

5 Utility-2 01/05/2018 to

30/05/2018 491 0 285 Nil

6 DCU 01/06/2018 to

29/06/2018 9601 0.1 5 Nil

7 DHDS 01/07/2018 to

14/07/2018 3022 0 500 Nil

Annexure - 1

PART – II





8 NHT/ CCR 15/07/2018 to

30/07/2018 5995 0 800 Nil

9 COT 15/08/2018 to

30/08/2018 281 0.1 16.2 Nil

Total 35055 components were monitored from Mar’18 to Aug’18.

XVII The product loading gantry shall be connected to the

product sphere in closed circuit through the vapor arm

connected to the tanker.

Data on fugitive emission from here shall be regularly

monitored and records will be maintained.

The LPG Loading gantry has been connected to the product sphere in closed circuit through the

vapor arm connected to the tanker.

Data on fugitive emission from product gantry & nearby area are tabulated in table no. 14.

Table no. 14

Sr.

No. VOC monitoring area / unit / plant Unit

VOC

Min-Max

1 Near Truck Gantry No. 5 (HC Truck Loading) ppm 0

2 Primary Treatment Plant of Truck Dispatch Area ppm 38-104


4 Hazardous waste storage sites ppm 0

5 Primary Treatment Unit of ISBL-1 process ppm 132-194

6 At Battery Limit in CDU/VDU ppm 0

7 At Battery Limit in CDU – II ppm 0

Annexure - 1

PART – II





8 Downwind of equalization tank (Oil Separation

Basin Unit-8400) of base ETP ppm 263-292

9 Primary Treatment Plant of Crude Tank Storage

(COT) Area ppm 9.1-10.8

XVIII The company shall ensure that no halogenated

organic is sent to the flares.

If any of the halogenated organic are present, then the

respective streams may be incinerated, if there are no

technically feasible or economically viable

reduction/recovery options.

Any stream containing organic carbon, other than

halogenated shall be connected to proper flaring

system, if not to a recovery device or an incinerator.

There is no halogenated organic presently handled at the Refinery.

In case same is required to be handled it will be ensured that no halogenated organic is sent to

the flares and suggested treatment will be implemented.

All other streams containing organic carbon stream are routed to flare system.

XIX Water requirement of the refinery and petrochemical

complex shall be met from sea water desalination and

no water shall be drawn either from the ground or

from the surface.

Water requirement of refinery is being met through existing sea water desalination plant and no

water is being drawn either from ground or from the surface.

Necessary approval like FCA (permission obtained vide letter no.8C/12/385/96-FCW dated 8th

December, 99), CRZ (permission obtained vide letter no.16011/22/2000-IA-III dated 3th

November, 2000) & WLPA (permission obtained vide letter no. FCA/WLP/29/1043-48/2003-04

dated 27th February, 2004) clearance was obtained for sea water intake and associated facilities.

Annexure - 1

PART – II





XX No discharge of wastewater from sweet water ETP

shall be carried out. The quantity of wastewater

generation is 3726 m3/hr from the project.

This effluent after appropriate treatment will be

reused in process/ utilities or cooling or for green belt

development.

Wastewater from ETP is being reused in Fire Water, Service Water & Cooling Towers make up

and horticulture

The quantity of wastewater from ETP for the month of March’18 to August’18 is as shown in

Table no. 15:

Table no. 15 : Wastewater from ETP

Sr. No. Mar’18 Apr’18 May’18 June’18 July’18 Aug’18

01

Trade

effluent,

M3/hr*

698 596 588 631 627 621

*Note: The quantity shown for wastewater from ETP is for 20 MMTPA refinery.

The influent is being routed to Effluent Treatment Plant (ETP) for required treatment and the

entire Treated Effluent is then reused as Fire Water, Service Water & Cooling Towers and

horticulture and as RO feed. Permeate of Reverse osmosis plant is used as boiler feed water after

DM treatment.

Details of Effluent Treatment Plant(ETP):

All AOC (Accidental Oil Contamination) and COC (Continuous Oil Contamination) water from

plant sent to Primary Treatment unit (PTU) for removal of free oil and dirt by gravity separation

through Tilted Plate Interceptor and oil skimmer. In refinery five PTU is provided at different

location.(Process, PIT, RLCB,TLCB, COT). All the primary treated water are collected & equalized

Annexure - 1

PART – II





in the oil separation basin. After that Physico chemical Treatment given which comprises of four

units like pH Adjustment Tank, Flash Mixer, Flocculator, and Dissolved Air Floatation Tank.

A two stage biological treatment is provided for biodegradation of organic matter for reduction

of BOD/COD. It comprises of Bio tower followed by extended aeration type activated sludge

process.

The treated effluent is then pumped to Dual Media Filter followed by Activated Carbon Filter

(ACF) for tertiary treatment.

Quality of treated waste water for the month of Mar’18 to Aug’18 is given in Table no 16 carried

out by M/s Unistar Environment & Research Labs Pvt. Ltd. (NABL accreditation no. for Chemical

& Biological: TC-7753 in lieu of T-2239, T-2240 valid till 14.09.20):

Table no. 16: Quality of treated waste water for the month of Mar’18 to Aug’18

Pollutant Parameters Limiting value for concentration

(mg/l except for pH)

Quality of Treated Effluent

Min-Max

pH 6.0-8.5 7.35-7.51

Oil & Grease 5.0 <4

BOD (3 days, 27 ºC) 15.0 9.0 - 13.0

COD 125.0 29.40 - 45.700

Suspended Solids 20.0 10.0 - 16.0

Phenol (as C6H5OH) 0.35 <0.1

Sulphide (as S) 0.50 0.25 - 0.470

Cyanide (as CN) 0.2 <0.05

Ammonia as N 15 <5

TKN 40 <5

P 3 0.22 - 0.560

Annexure - 1

PART – II





Cr (Hexavalent) 0.1 <0.1

Cr (Total) 2 <0.001

Pb 0.1 <0.003

Hg 0.01 <0.002

Zn 5 0.04-0.067

Ni 1 0.08-0.123

Cu 1 0.04-0.085

V 0.2 <0.01

Benzene 0.1 <0.001

Benzo(a)- Pyrene 0.2 <0.001

ETP block diagram is shown below :

Annexure - 1

PART – II





Only brine from desalination plant and cooling tower

blow down will be discharged to sea through a well

designed diffuser at a location identified by National

Institute of Oceanography (NIO). The quantity of sea

water return is 26932 m3/hr.

Brine from desalination plants and cooling tower blow down is being discharged to sea through

well designed diffuser at a location identified by National Institute of Oceanography.

The quantity of sea water return to sea is monitored daily and is well below the stipulated limits

as shown in Table no. 17.

Table no. 17: Sea Water return quantity:

Mar’18 Apr’18 May’18 June’18 July’18 Aug’18

Sea water

return,

M3/hr

(Min-

Max)*

3456 - 4133 3531 - 4079 3663-4269 2783-4502 2896 -3516 2906-3618

*Note: The quantity shown for sea water return is for 20 MMTPA refinery.

XXI Regular monitoring of relevant parameters for the

underground water in the surrounding areas will be

undertaken and the results will be submitted to the

relevant States pollution Control Boards.

Monitoring of relevant parameters for the underground water in the surrounding areas is being

carried out six-monthly, recent was monitored in Aug’18, results given in Table no. 18.

Report submitted to State pollution Control Board six monthly along with EC compliance report.

Acknowledgement copy for letter submitted to GPCB, Gandhinagar is shown below.

Annexure - 1

PART – II





Table no. 18 Groundwater monitoring in surrounding villages

Parameters Unit Vadinar Timbdi Bharana Mithoi Kathi

Devaliya

Zakhar Singach Kajurada Sodha

Taragadi

pH --- 6.86 7.85 8.15 7.56 7.95 7.36 7.78 8.06 7.75

TDS mg/l 1840 1590 378 1720 1634 1650 1450 730 1040

Chloride mg/l 859 670 220 658 805 305 770 240 410

Sulphate mg/l 338 81 15 97 80 270 94 21 49

T-Hardness mg/l 515 130 200 540 310 505 450 490 385

O & G mg/l <4 <4 <4 <4 <4 <4 <4 <4 <4

Annexure - 1

PART – II





XXII All organic waste shall be sent to incinerator only. For

potential of heat recovery, the possibility of installing

incinerator at site shall be explored and plan may be

submitted to the SPCB.

Alternatively, it will be sent for use as fuel in the

cement Kiln.

All organic waste, i.e. Oily Sludge with high CV is being co-processed in DCU in refinery.

Data of oily sludge co-processed in DCU for the month of Mar’18 to Aug’18 is shown in Table

no.19:

Table no. 19

Refinery is also a member of GPCB approved TSDF facility of M/s SEPPL located at Gandhidham

& M/s Recycling Solution Pvt Ltd (RSPL), Panoli. Membership certificate is shown below, which

can be utilized if need be.

Sr.

No.

Organic

Waste Mar Apr May June July Aug

01

Oily

Sludge

(Dry

Basis

30%

moisture

)

Gen.(MT) 196 0 347 1686 1977 143

Co-

processed

(MT)

177 34 342 1580 1672 379

02

Oily

Sludge &

BSW

Gen.(MT) 400 0 0 0 0 250

Incinerati

on(MT) 12 190 74 62 0 11

Annexure - 1

PART – II





XXIII Solid waste generated as Pre-treater and Reformer

Catalysts, Sulphur guard absorbent and Alumina Balls

will be disposed off as the authorization from the State

Pollution Control Board.

The company has obtained authorization from GPCB vide order no.: AWH-81987 issued in 2016

and valid till 2022 for collection, treatment, storage and disposal of hazardous waste, and

conditions there under are being complied with.

Type of hazardous waste, their mode of disposal and permitted quantity mentioned in CC&A is

as given below in Table no. 20.

Annexure - 1

PART – II





Table no. 20: Type of hazardous waste, their mode of disposal and permitted quantity

Sr.

No.

Description

of Wastes

Schedule

- I

Quantity

per Year

Mode of Handling & Disposal

1 Oily Sludge

from ETP

35.3 13000

MT

Collection, Storage, Transportation and

disposal through TSDF/ Incineration / actual

users / Co-processing in Delayed Coker Unit

(DCU)

2 Slop Oil 4.3 120000

MT

Collection, Storage and Recycle within the

Plant

3 Oily rags/ Oil

contaminate

d waste

5.2 5000 MT Collection, Storage, Transportation and


users /

4 Used

Lubricating

Oil

5.1 300 MT Collection, storage, transportation and

siposal by selling it to registered re-refiner

units

5 Oily Sludge &

BSW



users / Co-processing in Delayed Coker Unit

(DCU)

6 Spent

Catalyst from

Various Units

4.2 8000 MT Collection, Storage, Transportation &

Disposal through actual users / TSDF/

Incineration

7 Contaminate

d cotton rags

or other


Disposal through actual users / TSDF/

Incineration

Annexure - 1

PART – II





cleaning

materails

8 Discarded

Empty

Drums/

Containers

33.1 50000

Nos

Collection, Storage, Transportation &

Disposal through actual users

9 Spent Resin

Waste



users

10 Insulated

copper wire

scrap/ copper

with PVC

sheathing

cable

IV/7 200 MT Collection, storage and disposal by selling it

to registered recycler, reprocessors/ actual

user

11 Lead Acid

Battery

Waste

- 10 MT Collection, Storage, Transportation &

Disposal through actual users

12 Expired

Hazardous

Chemicals

II/ E3 100 MT Collection, Storage, Transportation and


users

13 Spent Carbon 36.2 200 MT Collection, Storage, Transportation and


users/ incineration in power plant boilers

14 e- waste - 20 MT Collection, storage and disposal by through

actual user/ registered recycler

Annexure - 1

PART – II





15 Waste Coke II- Class A-

70

100 MT Collection, storage and disposal by through

actual user

16 Spent

Catalysts and

Molecular

Sieves



users

The details of HW generated and disposed in Financial Year 2017-18 is shown in Table no. 21 A

& 21 B

The details of HW generated and disposed for the month of March’18 to August’18 is shown in

Table no. 21 C

Table no. 21 A Details of HW generated during the FY 2017-18.

Sr.

No.

Type of waste Schedule

Unit

Quantity

Generated

in FY 17-18

Method of Storage Mode of Disposal

1. Oily Sludge from

ETP (Semi- Solid) 35.3/I MT 3584

Oily sludge is stored in Reinforced Cement concrete

(RCC) pits lined with 1.5 mm thick HDPE liner &

connected to leachate collection sump which is

finally connected to ETP where leachate is treated.

Reprocessing at Delayed Coker Unit

of Refinery (In-house)/ Co-

processing in Cement Plant (M/s

Ultratech Cement, Kovaya)

2

Used Lubricating Oil

(Liquid)

5.1/I MT 51

The waste is packed in closed 200 Kg. MS drums and

storage facility having HDPE liner, Reinforced

Cement concrete (RCC) floor, covered at the top &

Leachate collection and treatment facility.

Sold to GPCB authorized Re-refiner

M/s Reliance Barrels Supply Co,

Ahmedabad

Annexure - 1

PART – II





3 Oily sludge & BSW /

emulsion 4.1/I MT 400

The waste is packed in MS drums of 200 Kg and

storage facility having HDPE liner, Reinforced

Cement concrete (RCC) floor, covered at the top &

Leachate collection and treatment facility.

Sent to Pollution Control Board

authorized TSDF / Incineration

facility M/s Saurashtra Enviro

Projects Pvt. Ltd. (Bhachau)

4

Discarded Empty

Drums / Containers

(Solid)

33.1/I Nos. 14295

Stored in the storage facility having Reinforced

Cement concrete (RCC) floor and covered at the top.

Sold to GPCB authorized

Decontamination and

Reconditioning Facility M/s Reliance

Barrels Supply Co., Ahmedabad

5 Slop Oil (Liquid) 4.3/I MT 27272 Slop oil generated is collected in slop oil Tanks

having combined capacity of 6500 m3.

In-house recycling / reprocessing in

mfg. process.

6 Spent Resins waste 35.2/I MT 12.58

Packed in 200 lit MS Drums, closed from top with lid

& ring and then stored in the storage facility having

Reinforced Cement concrete (RCC) floor and

covered at the top.


authorized recycling facility M/s

Recycling Solutions Pvt. Ltd

7 Heater Deposits II-Class, A70 MT 14.57

Stored in 1 MT jumbo bags at storage facility having


covered at the top.


authorized recycling facility M/s

Recycling Solutions Pvt. Ltd

8

Spent Catalyst From

Various Units

(Solid)

4.2/I MT 180.23

Packed in 200 lit MS Drums, closed from top with lid

& ring and then stored in the storage facility having


covered at the top.

Sold to Pollution Control Board

authorized & registered recyclers

M/S Bravo Agrotech, M/s

Vyankatesh Metals and Alloys, M/s

Refracast Metallurgical Pvt. Ltd. and

M/s Rubamin Ltd.

9

Electronic and

Electric Waste

(Solid)

B-1110

GC010.18 MT 11.4

Stored in the storage facility having Reinforced



authorized recycler M/s Eco Green

Recycling, Valsad

Annexure - 1

PART – II





10 Lead Acid Battery

Waste (Solid) 17/IV MT 10.15

Stored in the storage facility having HDPE liner,

Reinforced Cement concrete (RCC) floor, covered at

the top & Leachate collection and treatment facility.


authorized & registered recycler M/S

S.K. Metal Industries, Rajkot & M/S

Mateshwari Metals, Surat

11 Spent Carbon

(Solid) 36.2/I MT 141.63

The waste is packed in closed MS drums of 200 Kg

stored in the storage facility having Reinforced


Incineration in VPCL Boiler

12 Wastes or residues

containing oil 5.2 MT 20.5

Stored in the storage facility having HDPE liner,

Reinforced Cement concrete (RCC) floor, covered at

the top & Leachate collection and treatment facility.


authorized TSDF/Incineration facility

M/s Saurashtra Enviro Projects Pvt.

Ltd. (Bhachau)

13

Insulated Copper

Cable with PVC

Sheathing (Solid)

7/IV MT 0.86

At Warehouse Sold to Pollution Control Board

authorized & registered recycler M/s

Rechotech E-waste Management.

Table no. 21 B: details of HW disposed during the FY 2017-18.

Type of Waste as

authorized in CC &A Date of Dispatch Unit

Quantity dispatched in

FY17

Recycler/Reprocessor/

Coprocessor details

Recycler/Reprocessor/

Coprocessor authorization details

Used Lubricating Oil

17.05.17

KG

7500

M/s Reliance Barrels Supply

Co, Ahmedabad AWH 61732 Valid till 12/02/2019

26.08.17 8680

31.08.17 7560

27.02.18 2320

Discarded Empty Drums Throughout the

Year Nos. 11380

M/s Reliance Barrels Supply

Co, Ahmedabad AWH 61732 Valid till 12/02/2019

Annexure - 1

PART – II





Spent Catalyst from

Various units (Spent Ni-Co-

Mo Catalyst)

Throughout the

Year MT

337 M/s Rubamin Ltd., Baroda AWH 66619 Valid till 02/11/2019

26 M/s, Vyankatesh Metals &

Alloys, Indore

MPPCB/INDORE/REG/NEW/12/B

Valid till 14/09/2019

98

M/s Refracast Metallurgical

(P) Ltd, Raipur

1962/RO/TS/CECB/2007 valid till

31/03/2018

Spent Catalyst from

Various units (Spent ZnO

Catalyst)

28.06.17

MT

52.56 M/s Bravo Agrotech,

Surendranagar AWH-89563 Valid till 19/09/2022

22.02.18 27.8

Spent Resins Waste 05.10.17 MT 12.58 M/s Recycling Solutions Pvt.

Ltd. Panoli, Ankleshwar AWH-83687, Valid till 31/12/2021

Lead Acid Batteries Throughout the

Year MT 17.68

M/s S.K. Metal Industries,

Rajkot & M/s Mateshwari

Metals Olpad (Surat)

AWH 48984 Valid till 07/05/2017

AWH 63034 valid till 09/03/2019

E waste 06.02.18

08.02.18 MT

8.7

M/s Eco Green Recycling,

Valsad

AWH-85342 valid till 11/01/2020

Heater Deposits 04.12.17 MT 14.57

M/s Recycling Solutions Pvt.


Spent Carbon 36.2/I MT 7.13 M/s Recycling Solutions Pvt.


Insulated Copper Cable

with PVC Sheathing 28.03.18 MT 15.45

M/s Rechotech E-waste

Management AWH 72839 Valid till 22/04/2020

Annexure - 1

PART – II





Table no. 21 C Details of HW generated & disposed for the Month of April’2018 to September’2018.

Type of Waste Opening Stock as

on 01.04.2018

Generation till

30.09.2018

Disposal till

30.09.2018

Closing Stock as

on 30.09.2018

Disposal Mode

Oily sludge from ETP 379.10 3975.30 4148.71 205.69 Inhouse reprocessing in DCU unit

Used Lubricating Oil 34.94 17.61 27.34 25.21 Sold to authorized recycler M/s Reliance Barrels

Discarded Empty

Drums

8443.00 7626.00 8747.00 7322.00 Sold to authorized recycler M/s Reliance Barrels

Slop Oil 0.00 14090.00 14090.00 0.00 Inhouse reprocessing

Spent Catalyst from

Various units (Spent Ni-

Co-Mo, Spent ZnO,

Spent Super Claus,

Spent TK250)

39.83 45.17 85.00 0.00 27.48 MT Spent ZnO Catalyst sent to authorized

recycler M/s Bravo Agrotech. 57.70 MT Spent Ni-

Mo Catalyst sent to authorized recycler M/s

Rubamin limited

Lead Acid Batteries 4.22 4.27 0.00 8.49 ─

E waste (SCRAP CFL) 3.67 19.30 0.00 22.97 ─

Oily Sludge and BSW 387.50 0.00 337.61 49.89 Sent to authorized Incineration facility M/s

Saurashtra Enviro Projects Pvt Ltd

Oily Cotton Rags/ Oil

Contaminated Waste

8.39 8.89 4.71 12.57 Sent for coprocessing to M/s Ultratech Cement

Spent Carbon 0.00 67.11 67.11 0.00 Resuing as fuel in Power Plant Boilers

Insulated Copper Cable

with PVC Sheathing

189.09 2.34 124.34 67.09 Sold to authorized recycler M/s Recotech

Annexure - 1

PART – II





Spent catalysts shall be regenerated and waste oil will

be sold to the registered recycler only.

Spent catalyst generated from refinery is being sold to actual users. Details for last six month is

shown in Table no. 22.

Table no. 22

Opening

Stock as on

01.04.2018

Generation

till

30.09.2018

Disposal

till

30.09.2018

Closing

Stock as on

30.09.2018

Disposal Mode

Spent Catalyst

from Various

units (Spent

Ni-Co-Mo,

Spent ZnO,

Spent Super

Claus, Spent

TK250)

39.83 45.17 85.00 0.00 27.48 MT Spent ZnO

Catalyst sent to

authorized recycler

M/s Bravo Agrotech.

57.70 MT Spent Ni-

Mo Catalyst sent to

authorized recycler

M/s Rubamin

limited

Used/spent oil generated from equipment is being sold to GPCB authorized recyclers as shown

in Table no. 23.

Table no. 23: Used Oil generated & disposed

Opening

Stock as on

01.04.2018

Generation

till

30.09.2018

Disposal

till

30.09.2018

Closing

Stock as on

30.09.2018

Disposal Mode

Used

Lubricating Oil 34.94 17.61 27.34 25.21 Sold to authorized

recycler M/s Reliance

Barrels

Annexure - 1

PART – II





Copy of work order with hazardous waste authorized recycler is attached as Annexure-1.3.

Manifest copies for the hazardous waste disposed is attached as Annexure-1.4.

Refinery is already a member of GPCB approved TSDF facility of M/s Saurashtra Enviro Projects

Pvt Ltd (SEPPL) located at Gandhidham and M/s Recycling Solution Pvt Ltd (RSPL), Panoli.

Membership certificate is shown below.

Annexure - 1

PART – II





XXIV Oily sludge shall be sent to melting pit treatment for

recovery of oil. The recovered oil shall be recycled into

the refinery system.

The residual sludge will be stored in HDPE lined pit for

disposal after treatment. The sludge will be

incinerated in the premises only.

Oily sludge is being co-processed in Delayed coker unit.

Oily sludge is being stored in sludge drying pit with HDPE liner & leachate collection facility and

is being sent to Delayed coker unit for co-processing in our refinery.

XXV The project authorities shall strictly comply with the

provisions made in Manufacture, Storage and Import

of Hazardous Chemicals rules, 1989 as amended in

2000 for handling of hazardous chemicals.

We are in compliance with all the applicable conditions under MSIHC Rules 1989.

The details of the compliance of the applicable conditions are as given in the Table no 24.

Table no. 24: compliance of the applicable conditions of MSIHC

Sr. No Condition Compliance Status

1 An occupier who has control of an industrial activity in

term of sub-rule (I) shall provide evidence to show that he

has,-

(a) identified the major accident hazards; and

a) Refinery has identified all the

hazards linked with all kinds

of operational,

administrative and technical

activities. Each department

and units have their Aspect

Impact Risk Register as per

the activities being carried

out which is being updated

timely.

Annexure - 1

PART – II





(b) taken adequate steps to -

(i) prevent such major accidents and limit their

consequences to persons and the environment;

(ii) Provide to the persons working on the site with the

information, training and equipment including antidotes

necessary to ensure their safely.

b)

(i) Refinery has well established

safety systems and procedures

in place. It also has Emergency

Response Disaster Management

Plan for prevention of major

accidents. Mock drills are carried

out timely as a part of

prevention plan.

(ii)Refinery has dedicated

training centre known as

Nalanda Knowledge Centre

wherein Induction training

including fire fighting, first

aider, safety system

awareness is being allotted to

all the employees and

contractors. In addition to this,

Emergency Response Disaster

Management Plan training,

first aider training and safety

refresher training is allotted

every three years to all the

personnel.

2 An occupier shall prepare and keep up-to-date an on-site

emergency plan detailing how major accidents will be

dealt with on the site on which the industrial activity is

Refinery has Emergency


Plan in line with the industrial

Annexure - 1

PART – II





Necessary approvals from Chief controller of

explosives must be obtained before commissioning of

the expansion project.

Requisite On-site and off-site Disaster Management

plans will be prepared and implemented.

Regular mock drill shall be carried out for both On-Site

and Off-site plans.

carried on and that plan shall include the name of The

person who is responsible for safety on the site and the

names of those who are authorized to take action in

accordance with the plan in case of an emergency.

activity as well as crude handling

operations. The Plan is attached

herewith as Annexure 1.6.

3 The occupier shall ensure that the emergency plan

prepared in accordance with sub-rule (I) lakes into account

any modification made in the industrial activity and that

every person on the site who is affected by the plan-is

informed of its relevant provisions.

Refinery has Emergency


Plan in line with the industrial

activity as well as crude handling

operations The Plan is attached

herewith as Annexure 1.6.

4 An occupier, who has control of an industrial activity in

term of sub-rule 1 of this rule, shall arrange to obtain or

develop information in the form of safety data sheet as

specified in Schedule 9. The information shall be accessible

upon request for reference.

Refinery has a separate portal

known as Process Safety

Management portal wherein all

the MSDS as well as chemical

database are available.

All necessary approvals from Chief Controller of Explosives have been obtained prior

commissioning of the expansion project.

Detailed approval from PESO are attached as Annexure 1.5.

Emergency Response Disaster Management Plan (ERDMP) for onsite and offsite has been

prepared and is attached herewith as Annexure 1.6.

Regular mock drills on ERDMP are conducted. Schedule of the Mock drill for the year 2018-19 is

as given in Table no. 25.

Annexure - 1

PART – II





Table no. 25: Mock drill schedule for the year 2018-2019

Annexure - 1

PART – II





Mock drill carried out during the month of Mar’18 to Aug’18 is shown in Table no. 26 and

detailed reports are attached as Annexure-1.7.

Table no. 26: Mock Drill details

Annexure - 1

PART – II





Plant Date

NHT/CCR 15.06.2018

Laboratory 25.07.2018

FCCU 27.08.2018

XXVI Green belt shall be provided to mitigate the effects of

fugitive emissions all around the plant in a minimum

of 33% of the plant area in consultation with DFO as

per CPCB guidelines.

Green Belt has been developed in area of 410 Ha around the periphery and in vacant area*.

Apart from this we have also done voluantary mangrove aforestation in area of 175 Ha.

Annexure - 1

PART – II





*Note : currenltly 20 MMTPA refinery is established in 1171 Ha area out of total project

area of 2275 Ha. As per the current establishment, we have developed green belt in 410

Ha area which is 35.04 % of the plant area.

We confirm to develop the balance green belt area required for the 46 MMTPA refinery

to make minmimum 33% of total Plant area as green belt.

The layout map showing existing & proposed green belt is as attached herewith as

Annexure-1.8.

XXVII The company shall strictly follow all the

recommendations mentioned in the Charter on

Corporate Responsibility for Environmental Protection

(CREP).

CREP compliance report is attached as Annexure-1.9.

XXVIII The Company shall harvest surface as well as

rainwater from the rooftops of the buildings proposed

in the expansion project and storm water drains to

recharge the ground water and use the same water for

the various activities of the project to conserve fresh

water.

Four reservoirs / ponds have been created within refinery premises for storage and recharging of

ground water. Total capacity of these ponds is 3, 25,000 m3.

Four ground water recharge wells have been made within refinery.

Annexure - 1

PART – II





XXIX Occupational Health Surveillance of the workers shall

be done on regular basis and records be maintained

as per the Factories Act.

Occupational health Surveillance of the worker is being done six monthly and records are

maintained at Occupational Health Centre (OHC) at refinery site as per Factory Act.

Some of the records are shown below.

Annexure - 1

PART – II





XXX All the recommendations made in the EIA / EMP and

Risk Assessment Reports in respect of environmental

management and risk mitigation measures relating to

refinery and petrochemical complex shall be

implemented.

All recommendations made in the EIA / EMP and Risk Assessment Reports in respect of

environmental management and risk mitigation measures relating to refinery have been

implemented. Details are given below.

Annexure - 1

PART – II





Following measures have been adapted as per Environmental Management Plan indicated in EIA for mitigation of adverse impacts on environment

due to Refinery operations:

Air Pollution Prevention / Control Measures:

Air pollution prevention / Control measures adapted at site are as following:

Installed Low Temperature Shell Claus off Gas Treating Units (LT SCOT) at sulfur recovery unit.

Installed Multistage multiple Cyclones in Fluidized Catalytic Cracking & Regeneration unit for particulate emission control.

Installed Amine Absorbers - The fuel gas produced in the refinery contains H2S. This is removed in the Amine absorber columns and the sweet

gas is routed to Refinery fuel gas system. Subsequently H2S is stripped out from rich amine in amine regeneration unit. Lean amine is reused

while H2S is sent to sulfur recovery unit.

Use of Low Sulfur Fuel - Refinery fuel Gas, Natural gas and Fuel Oil are used as fuel in heaters / furnaces.

Installed Low NOX burners in all heaters / furnaces.

Installed Sulfur Recovery Unit having sulfur recovery efficiency 99.9%.

Floating roof tanks: Floating roof tanks are provided for storage of class A products; this reduces HC vapor loss. Double seal has been provided

in order to minimize vapor leakage.

Good Flare Management- all vent offs are connected to the flare to take care emergency releases from refinery plant.

All access roads (internal as wells as external) which is being used are paved either with concrete or bitumen to suppress the dust generation

along the roads.

Air Environment:

The major sources of air emission is process emissions from FCCU, SRU and emissions from fuel burning in the different heaters / furnaces of refinery’s

plant operations. To minimize impacts, major steps taken are following:

Regular monitoring and record keeping of emission at refinery as part of environmental data records.

Annexure - 1

PART – II





Monitoring the Performance of Sulfur Recovery Units (SRU) on monthly basis.

Energy conservation schemes have been launched, for instance, steam traps management variable speed control drive.

Leak Detection and Repair Program (LDAR) has been implemented in the refinery. The program includes leak detection of valves, flanges and

pumps etc. Total 35505 nos. of components were monitored during period of Mar’18 to Aug’18.

Stack Monitoring Facility (SMF) have been provided at proper location in all stacks.

Ambient air quality is being monitored simultaneously at 4 locations within refinery premises once a week.

Two Continuous On-line Ambient Air Quality Monitoring stations (CAAQMS) have been installed. The same has been hooked up with CPCB server

since March 2013.

Continuous Emission Monitoring has been hooked up with CPCB server since June 2015.

Noise Environment:

The design of project is such that the sound pressure level in the work area is not exceeding 90 dB (A). Restricted areas are those locations where it is

not reasonably practicable to reduce the noise level below the work area limit. Wherever practicable, attempts have been made to reduce the noise level

below 90 dB (A). The noise level is not exceeding 70 dB (A) during day time and 65 dB (A) during night time at the boundary of the project site. The

equipment have been chosen in such a way that the above noise limit is never exceeded. The noise levels at the nearest habitation after refinery expansion

is less than the stipulated standards of CPCB. Good Standard Operational Procedure, the following generic measures have been implemented in base

refinery and same will be implemented in addition to the existing green belt, in the future expansion of the project:

The major areas of concern for noise generation has been addressed by considering it during procurement of the machinery from vendors, project

implementation stage and by giving correct specification during tender floating.

Monitoring of job and location specific noise levels for compliance with HSE regulations by verifying acceptability of noise levels caused by the

project activities and comparison with noise criteria.

Periodic audiometric test is being conducted for employees working close to noise prone areas, such as compressors, DG Sets, the loading and

unloading sections.

Annexure - 1

PART – II





PPE’s are provided to ensure for eardrum protection of the employees, workers as well as visitors.

Acoustic barriers and silencers have been used in equipment wherever necessary.

Sound proofing / glass paneling have been provided at critical operating stations / control rooms.

Either acoustic barriers/ shelters shall be developed in noisy workplaces or acoustic enclosures are provided for the high noise generating

equipment

Monitoring of ambient noise levels is carried out regularly inside the refinery area.

Water & Waste water Environment:

Water: The main source of water requirement of refinery is sea water. Sea water is drawn from Gulf of Kutchh by a 44 inch pipeline laid from

Gulf of Kutchh to refinery site. Sea water is mainly used as cooling media in cooling towers and for producing sweet water by desalination plant.

Cooling Tower blow down, desalination plant reject and RO reject are sent back to sea via a 52 inch pipeline and diffuser system. Sweet water is

used for producing DM water, steam and potable water and in process / operation.

Wastewater: Main source of wastewater generation is refinery operations. Wastewater is treated in the wastewater treatment plant. Full

quantity of treated waste water, is reused / recycled for cooling towers, fire water make-up and feed to RO plant and green belt.

The quality of treated water is daily monitored to ensure that treated water quality is always in compliance with statutory limits.

Continuous Effluent Monitoring has been hooked up with CPCB server since November’2015.

Land Environment:

Soils in the adjoining areas are sandy loam to silty loam with moderate infiltration rates, amenable to groundwater pollution. Considering this

fact, every precaution have been taken

Annexure - 1

PART – II





to avoid spillage of oils and other petroleum products on soils to protect groundwater contamination and to avoid any danger to other soil

microbial groups which are sensitive to oil pollution.

Green belt coverage inside the refinery is well maintained.

Adequate storage facility for temporary storage of hazardous and non-hazardous wastes with HDPE liner facility has been created within refinery

premises.

Green Belt Development:

Along the periphery of the Essar Oil’s Refinery at Vadinar, a large green belt has been developed.

410 Ha area is covered under thick Green Belt in refinery and associated facilities.

In respect of activities in the marine national park, the

recommendations of NIO shall be followed for

protection of marine national park.

In respect of activities in the marine national park, the recommendations of NIO have been

implemented for protection of marine national park. Details are given below.

Recommendations of NIO

NIO carried out Environment Impact Assessment (EIA) sequential studies for marine facilities of M/s Nayara Energy Limited (Formerly Known as Essar Oil

Ltd), Vadinar from 1994 onwards. The compliance status of the salient recommendations stipulated in those studies is given in Table no. 27.

Table no. 27: Compliance status of the salient recommendations given by NIO

Sr.no. NIO recommendations Compliance status

01 Diffuser for discharge of return sea water

into Gulf of Kutch

Diffuser has been installed as per the design and recommendations of NIO

02 Overall Risk Assessment of Marine Facility Risk assessment was carried out through the third party, viz. M/s Enviro-Software, Bangalore.

Annexure - 1

PART – II





03 Contingency plan for Oil Pollution Control Based on overall risk assessment, Oil Spill Disaster Contingency Plan has been prepared, vetted

by Indian Coast Guard and then implemented. Attached as Annexure-1.10.

04 Translocation of Corals Coral Translocation was carried out by NIO in consultation with Department of Forests,

Government of Gujarat

05 Periodic Monitoring of Corals and

Mangroves

Initially, monitoring were carried out on half yearly basis for couple of years and thereafter it

were undertaken on yearly basis as per NIO’s recommendation and GoG’s directives. Latest

comprehensive marine monitoring along with the monitoring of Corals & Mangroves was done

by NIO in April 2018.

06 Monitoring of Marine Environment Marine environment is being monitored for water and sediments quality every month by third

party – M/s Gujarat Institute of Desert Ecology (GUIDE), Bhuj from November’2010 onward

07 Erection and Installation of all Marine

Structures

was carried out as per the recommendation of CWPRS (Central Water Power Research Station)

and NIO

08 Periodic Inspection and Replacement of

Flexible Hoses

Periodic inspection and replacement of hoses are carried out as per schedule and maintained

as per OEM, OCIMF and requirements of our Class ABS. The flexible hoses were tested during

Nov’2017 for their integrity as per International norms and most of them were found

satisfactory after pressure test. The balance flexible hoses were replaced with new ones. The

safety breakaway coupling has been provided in the system.

XXXI The company shall undertake all relevant measures, as

indicated during the public Hearing for improving the

Socio-economic conditions of the surrounding area.

CSR activities will be undertaken by involving local

village and administration.

During public hearing following point has been discussed and the compliance of the same as

submitted in GPCB is as given in Table no. 28.

Table no. 28: Compliance status of Public Hearing points on Socio-economic & CSR activities.

Sr.

No

Public Queries PH coordinating Officer’s Reply

Shri Jitubahi Bhatt local villager, stated

Annexure - 1

PART – II





Apart from that we are committed to making positive impact in communities in surrounding

village of Vadinar. We are committed to maintaining the highest standards of CSR in its business

activities. The facilitates development initiatives in line with provisions under the Companies’ Act,

2013, and aligns its vision with Nayara’s philosophy of 4Ps – PEOPLE at the core, PROGRESS

towards aspirations, POWER of synergy, and PASSION with compassion.

1 Due to any Industrial activity people get

direct employment as well as indirect

employment. This company should

therefore keep local village people in direct

employment.

Skilled category people are being recruited

from outside the State. Company should

make necessary arrangement to see that

locals are made skilled and then recruited

these locally skilled people within the

company.

They are already complying with the GR

of Government of Gujarat regarding 85%

of local employment. Since the definition

of the local as stated earlier is restricted

to state of Gujarat as whole and so it is

not within the purview of this company to

change the definition of “locals”. The

company officials further informed that if

qualified persons are available from

nearby area the company is committed to

give top priority to them. List of

employees from nearby local area is

attached as Annexure 1.11.

Shri Dilipbahi Jadeja, Ex Sarpanch of Vadinar, stated

2 Each farmer whose land has been acquires

should be given employment within the

company.

At present no additional land is going to

be acquired. The present land was

acquired way back in 1993. Also that

preference would be given to people of

the nearby village as per their skills.

Annexure - 1

PART – II





3 Fodder for the cattle of nearby villages

should be provided by the company

Fodder distribution in nearby villages is

being done; Infrastructures - Gaushalas of

nearby area have been upgraded.

4 Pipelines for water supply in vadinar village

should be provided by the company.

Water supply Pipeline has been laid to 4

villages namely Mithoi, Zankhar, Singach

& Vadinar and rest 6 villages are provided

with drinking water by road tankers.

Gaushala Construction

Gaushala Renovation

Annexure - 1

PART – II





The initiatives are strategically designed on the basis of community needs assessment, mapping,

participatory planning and considering local feasibility. In all locations, the local Government's

effort in development is supplemented with the company's resources and facilitation.

Shri Chandubhai Jadeja of village Vadinar, stated

5 The company should give preference in

employing people of nearby area so that

socio economic status of the nearby area

also as upgraded. He further added that

company should initiate for an ITI center in

coordination with Government, so that

youth of the nearby village can take

necessary advantage.

They welcome the suggestion for setting

up an ITI center and would try to support

such institute, if the government proposal

is this regard comes to it. Separate

budget is allocated for under CSR as

shown in table below.

Shri Kishorsinh Jadeje of Jankhar village, stated

6 The company should give employment to

people whose land has been acquired.

At present no additional land is going to

be acquired. The present land was

acquired way back in 1993. However

company has taken 300 people of nearby

area for greenbelt development purpose.

Shri Mahesh Pandya from Paryavaran Mitra, stated

7 Government GR of 85% local employment

should be implemented.

Government GR of 85% local

employment has been already

implemented.

8 Nearby villagers should be given

preference for new recruitment.

If qualified person are available nearby

area, company is giving priority to them.

Annexure - 1

PART – II





According to this philosophy whatever amount is needed as a part of CSR is spent for surrounding

villagers.

Local people is being trained for technical skill required for plant operation and maintenance.

These local trained people are appointed in plant.

CSR activities undertaken during last five years are shown in Table no. 29:

Table no. 29 CSR activities undertaken during last five years.

CSR Expenditure in Crores

Essar Oil Limited (April 2014 to March 2018)*

Thematic Area 2014-15 2015-16 2016-17 2017-18

Healthcare & Swachh Bharat 1.20 1.48 1.22 2.68

Education, Sport Promotion, Art & Culture 2.37 2.78 1.11 2.06

Environment 0.33 1.33 0.16 3.60

Livelihood & Skill Development 2.86 1.29 1.32 1.61

Rural Development Projects 1.59 4.05 0.92 3.19

Total 8.36 10.92 4.73 13.14

Annexure - 1

PART – II





* Now Nayara Energy Limited

CSR activities undertaken during Mar’18 to Aug’18 are shown in Table no. 30:

Table no. 30 Expenditure Nayara Energy limited (Mar’18 to Aug’18)

S.No Thematic Area as per companies’ act Sector Name of the Project Expenditure In Cr

1

Eradicating hunger, poverty and

malnutrition, promoting health care,

Sanitation & safe drinking water

Health Community Health Project (Curative and

Preventive) in Khambhaliya and Lalpur Block 0.86

Sanitation Solid waste Management project in 8 villages 0.25

Contribution to India Sanitation Coalition 0.25

2 Promotion of Education, Special

Education & vocational skill

School

Education

Rural Education Project (Gram Shiksha Project; ISA

British Council Project; Shala Pravehotsav) 0.55

3 Entrepreneurship and Startup

Social

Enterpreneu

rship

Building Social Entrepreneurs (Acumen Fund

partnership) 2.15

4 Skill Development

Skill

Developme

nt

ILABSS at ITI Khambhaliya 0.05

5

Ensuring environmental

sustainability, Ecological balance,

wildlife & natural resource

conservation

Livelihood

Agri and Livestock development Program

Livelihood program for women Livelihood program

for fishing community

0.56

Environmen

t (Water

Harvesting,

&

Water Resource Development 0.25

Annexure - 1

PART – II





Promotion

of Clean

Energy)

Total 4.92

Annexure - 1

PART – II & III




Sr. No. GENERAL CONDITIONS ACTION TAKEN REPORT

I The project authorities must strictly adhere to the

stipulations made by the concerned State pollution

Control Board (SPCB) and the State Government.

We are in compliance with the stipulations made by the concerned Gujarat pollution Control

Board (GPCB) and the State Government.

CCA compliance report is attached herewith as Annexure 1.12.

II No further expansion or modifications in the plant

shall be carried out without prior approval of the

Ministry of Environment and Forests.

We confirm that No further expansion or modifications in the plant will be carried out without

prior approval of the Ministry of Environment and Forests.

III At no time, the emissions should go beyond the

prescribed standards. In the event of failure any

pollution control system adopted by the units, the

respective until should be immediately put out of

operation and should not be restarted until the

desired efficiency has been achieved.

It is ensured that the emission does not go beyond the prescribed standard as per CCA. For the

same continuous emission monitoring of stacks (source of emissions) are provided with online

monitoring analyzers.

Alarm has been set in each stack for each parameter at the 90% value of emission standards

mentioned in CC&A to ensure corrective action in well advance. Operators are 24X7 watching

pollutants emission level of all stacks and immediately actions will be taken in case of failure of

any pollution control device/ system.

IV Adequate number of influent and effluent quality

monitoring stations shall be set up in consultation with

the SPCB.

All effluent from plants is being collected in effluent collection tanks provided & required

treatment is being given to achieve the norms prescribed in CCA for the Effluent Treatment Plant

(ETP). Influent / effluent’s quantities & qualities are being monitored on daily basis in the ETP.

Monitoring results are given below. Apart from this online effluent quality monitoring systems

have been established & hooked up with CPCB server.

Annexure - 1

PART – II & III





Quality of treated waste water for the month of Mar’18 to Aug’18 is given in table no. 31

(carried out by M/s Unistar Environment & Research Labs Pvt. Ltd. (NABL accreditation no. for

Chemical & Biological: TC-7753 in lieu of T-2239, T-2240 valid till 14.09.20 ):

Table no. 31: Quality of treated wastewater

Pollutant Parameters Limiting value for concentration


Quality of Treated Effluent(mg/l

except for pH)*

Min-Max

pH 6.0-8.5 7.35-7.51

Oil & Grease 5.0 <4

BOD (3 days, 27 ºC) 15.0 9.0 - 13.0

COD 125.0 29.40 - 45.7



Sulphide (as S) 0.50 0.25 - 0.47


Ammonia as N 15 <5

TKN 40 <5

P 3 0.22 - 0.56


Cr (Total) 2 <0.001

Pb 0.1 <0.003

Hg 0.01 <0.002

Zn 5 0.04-0.067

Ni 1 0.08-0.12

Cu 1 0.04-0.085

V 0.2 <0.01

Benzene 0.1 <0.001


Annexure - 1

PART – II & III





Regular monitoring shall be carried out for relevant

parameters for both surface and ground water.

We have appointed third party consultant for monitoring of Marine area. Gujarat Institute of

Desert Ecology (GUIDE) engaged to carry out monthly monitoring of marine area to ensure that

marine life is not adversely affected. Apart from GUIDE, we have also appointed National Institute

of Oceanography (NIO) for Comprehensive Marine Monitoring of Marine Ecology off Vadinar on

yearly basis. Report of the GUIDE & NIO is shown below.

Ground water quality of the surrounding villages is monitored six-monthly which was monitored

in Aug’18, results given in Table no. 32.

Ground water quality of the surrounding villages for the month of Mar’18 to Aug’18:

Table no. 32: Ground water quality of the surrounding villages

Parameters Unit Vadinar Timbdi Bharana Mithoi Kathi

Devaliya

Zakhar Singach Kajurada Sodha

Taragadi

pH --- 6.86 7.85 8.15 7.56 7.95 7.36 7.78 8.06 7.75

TDS mg/l 1840 1590 378 1720 1634 1650 1450 730 1040

Chloride mg/l 859 670 220 658 805 305 770 240 410

Sulphate mg/l 338 81 15 97 80 270 94 21 49

T-Hardness mg/l 515 130 200 540 310 505 450 490 385

O & G mg/l <4 <4 <4 <4 <4 <4 <4 <4 <4

Annexure - 1

PART – II & III





Report of the GUIDE & NIO is shown below:

V Industrial wastewater shall be properly collected and

treated so to conform to the standards prescribed

under GSR 422 (E) dated 1st May 1993 and 31st

December, 1993 or as amended from time.

The treated wastewater shall be utilized for plantation

purpose.

Industrial wastewater is being collected at effluent treatment plant having primary, secondary and tertiary

treatment system for treatment of effluent to meet the standards prescribed. Effluent quality parameter

is within the prescribed limit mentioned in GSR 186 (E) dated 18th March, 2008

Treated water quality for the month of Mar’18 to Aug’18 is given in Table no. 33 A & 33 B.

The entire Treated Effluent is then reused as Fire Water, Service Water , Cooling Towers, horticulture,RO

feed and green belt.

Annexure - 1

PART – II & III





The results for treated effluent for the month of Mar’18 to Aug’18 (carried out by M/s Unistar Environment & Research Labs Pvt. Ltd. (NABL

accreditation no. for Chemical & Biological: TC-7753 in lieu of T-2239, T-2240 valid till 14.09.20 ) table no. 33 A & 33 B

Table no 33 A: Quality of treated wastewater

Pollutant Parameters Limiting value for concentration (mg/l

except for pH)

Quality of Treated Effluent(mg/l except for

pH)Min-Max

pH 6.0-8.5 7.35-7.51

Oil & Grease 5.0 <4

BOD (3 days, 27 ºC) 15.0 9.0 - 13.0

COD 125.0 29.40 - 45.7



Sulphide (as S) 0.50 0.25 - 0.47


Ammonia as N 15 <5

TKN 40 <5

P 3 0.22 - 0.56


Cr (Total) 2 <0.001

Pb 0.1 <0.003

Hg 0.01 <0.002

Zn 5 0.04-0.067

Ni 1 0.08-0.12

Cu 1 0.04-0.085

V 0.2 <0.01

Benzene 0.1 <0.001

Annexure - 1

PART – II & III





Online Monitoring results for effluent quality for the period of Mar’18 to Aug’18:

Table no. 33 B: Online Monitoring results for effluent quality

Pollutant

Parameters

Limiting value for concentration



Min-Max

pH 6.0-8.5 6.17-8.25

Oil & Grease 5.0 0.97-4.36

BOD 15.0 2.6-14.9

COD 125.0 29.7-90.8

Suspended Solids 20.0 5-16.9

Phenol 0.35 0.01-0.24

Ammonia 15 0.06-5.14

VI The overall noise levels in and around the plant area

shall be limited within the prescribed standards by

providing noise control measures including acoustic

hoods, silencers, enclosures etc. on all sources of noise

generation.

The design of project is such that the sound pressure level in the work area is not exceeding 90

dB (A). Restricted areas are those locations where it is not reasonably practicable to reduce the

noise level below the work area limit. Wherever practicable, attempts have been made to reduce

the noise level below 90 dB (A). The noise level is not exceeding 70 dB (A) during day time and 65

dB (A) during night time at the boundary of the project site. The equipment have been chosen in

such a way that the above noise limit is never exceeded.

The major areas of concern for noise generation has been addressed by considering it

during procurement of the machinery from vendors, project implementation stage and

by giving correct specification during tender floating.

Periodic audiometric test is being conducted for employees working close to noise prone

areas, such as compressors, DG Sets, the loading and unloading sections.

Annexure - 1

PART – II & III





The ambient noise level shall conform to the

standards prescribed under EPA Rules, 1989 viz. 75

dBA (day time) and 70 dBA (night time).

PPE’s are provided to ensure for eardrum protection of the employees, workers as well

as visitors.

Acoustic barriers or acoustic enclosures and silencers are provided for the high noise

generating equipment.

Sound proofing / glass paneling have been provided at critical operating stations / control

rooms.

The ambient noise level are monitored during day and night in the periphery of refinery and

found to be well within the prescribed standards. The reports of the same are being submitted

to GPCB regularly.

Annexure - 1

PART – II & III





Monitoring results are as given in Table no. 34.

Frequency of monitoring: Monthly

Period: Mar’2018 to August’2018

Table no. 34: Ambient noise level in the periphery

Locations Noise Level, dB(A)

during Day Time

06:00 am to 10:00 pm

Noise Level, dB(A)

during Night

Time

10:00 pm to 06:00

am

Ambient Station at Port A Camp1 50 - 53 49 - 51

Ambient Station at Labour Gate1 52 - 53 50 - 52

Ambient Station at West side of Main Flare1 49 - 52 47 - 50

Nr. Batching Plant 52 - 53 51

Ambient Station at 93 Gate 50 - 52 49 - 51

Storm water drain outlet 51 - 54 50 - 52

Ambient Station at Refinery Main Gate1 51 - 52 49 - 51

Essar Petrol Pump (Near Delhi Darbar) 51 - 55 50 - 53

Ambient Station at Pet Coke Rail Loading

Yard

51 - 52 48 - 50

Annexure - 1

PART – II & III





Ambient Air Quality standards in terms of

Noise for industrial area

75 dB(A) 70 dB(A)

VII Authorization from the State Pollution Control Board

must be obtained for collection / treatment /storage

/disposal of Hazardous wastes.

Consolidated Consent & Authorization has been obtained from Gujarat Pollution Control Board

vide Ref. No AWH-81987 dated 13.10.2016 which is valid till 16.09.2022.

VIII The project authorities will provide RS. 3853.00 Crore

to implement the conditions stipulated by the Ministry

of Environment and Forests as well as the State

Government. Adequate funds for recurring

expenditure shall also be provided. The funds so

provided shall not be diverted for any other purposes.

Funds of Rs. 1089 Crores (The cost of 1089 Crores mentioned here as a part of EMP is for 20

MMTPA refinery against the earmarked cost of 3853 Crores for 60 MMTPA refinery.) have been

ear-marked and implemented for the identified actions as per the EMP. It will not to be diverted

for any other purposes. Details of Year wise expenditure is as given in Table no. 35 A & 35 B.

Table no. 35 A: Year Wise Expenditure incurred in Crores (CAPEX)

Environment Protection

Facilities

Year Wise Expenditure incurred in Crores (CAPEX)

2008-09 2011-12 2013-14 2018-19

Base ETP 53.53 - - -

Base SRU 443.34 - - -

Expansion ETP - 171.40 - -

RO Unit - 75.51 - -

Expansion SRU - 234.07 - -

Hazardous waste shed & Pit - 26.08 - -

Online Ambient Air Quality

Monitoring System - - 2.00 -

Online emission monitoring

analyzers - - - 2.00

Green Belt Development 0.6 5.4 3.9 7.9

Annexure - 1

PART – II & III





TOTAL 497.47 513 5.9 9.9

Adequate funds for recurring expenditure are being provided and utilized as indicated below up

to 2017-18. Further for future years the funds will be provided and the same shall not be diverted

for any other purposes. The funds for recurring expenditure for the year 2018-19 will not be

diverted for any other purposes.

Table no. 35 B: Year Wise Expenditure incurred in Crores (OPEX)


Facilities

Year Wise Expenditure incurred in Crores (OPEX)

2013-14 2014-15 2015-16 2016-17 2017-18

Opex - Environment Cost

Centre

1.01 0.19 0.89 1.23 0.81

O & M EXPANSION SRU 0.29 0.09 0.17 6.07 4.25

O & M OF BASE SRU 0.90 0.23 0.36 3.03 0.94

O & M OF EXPANSION WWTF

& RO

10.21 4.31 3.52 5.35 5.06

O & M OF BASE WWTF 0.62 0.20 0.15 0.16 2.05

Green Belt Development 6.6 1.72 1.74 1.5 -

TOTAL 19.63 6.74 6.83 17.34 13.11

IX The stipulated conditions will be monitored by the

concerned Regional Office of this Ministry / Central

pollution Control Board/State Pollution Control Board.

A six monthly compliance report and the monitored

Six monthly compliance and data monitoring report is regularly submitted to MoEF- Bhopal,

CPCB-New Delhi and GPCB - Gandhinagar. Last six monthly EC compliance report has been

submitted vide letter no. EOL/ENV/EC compliance report/2018/741 dated 17/05/2018 to The

Regional Office-MoEF&CC, Bhopal.

Annexure - 1

PART – II & III





data shall be submitted to them regularly. It will also

be displayed on the website of the Company.

Reports submitted during last three years are as given in Table no. 36:

Table no. 36: Details of EC compliance report submitted

Sr. No. Period for which EC compliance

submitted

Date of report

submitted

Letter reference

01 October’17 to March’18 17/05/2018 EOL/ENV/EC Compliance

Report/2018/741

02 April’17 to September’17 22/11/2017 EOL/ENV/EC Compliance

Report/2018/705


Report/2018/674

04 April’16 to September’16 02/11/2016 EOL/ENV/EC Compliance

Report/2018/642


Report/2018/595


Report/2018/513

Report is also displayed on company website. (Link: https://www.nayaraenergy.com/corporate-

social-responsibility/sustainability)

X The date of financial Closure and final approval of the

project by the concerned authorities and the date of

commencing the land development work as well as

the commissioning of the project will be informed to

the Ministry and its regional Office.

The proposed expansion of 60 MMTPA is not yet complete. Presently we are operating our

refinery at 20 MMTPA. All the necessary approval for the same are in place.

The details of financial closure and final approval of the project at various stages was submitted

to the Ministry and its regional office vide letter no. EOL/ENV/EC refinery/2012/334,

Dated.25.10.2012.

Annexure - 1

PART – II & III





XI Proper House-keeping and adequate occupational

health program shall be taken up.

Regular Occupational Health Surveillance program for

the relevant diseases shall be carried out and the

records shall be maintained properly for at least 30-40

years.

We have implemented 5S work place management systems for continuous improvement in

workplace.

Occupational Health Center has been established which takes care of surveillance program and

maintain the records. Staff details is as shown below.

1) Details of Doctors and other Staffs

Doctors:

Dr. Maulesh Patel

Dr. Krutarth Agravat

DR H G SHAH

DR H M BADAMIA

DR NITIN VINZODA

DR ASHOK PATEL

DR PARAG DODIA

DR NICKY SAHOO

DR HARDIK POPAT

WE ARE HAVING VISITING PHYSAICIAN WITH TWICE A WEEK OPD SERVICES

Annexure - 1

PART – II & III





Nursing staff:

Akash Patel

Ashwin Ajmeriya

Dilip Hirapara

Harish Khatri

Hiren Damaniya

Imran Vadher

Jagadish Parnaliya

Jashu Bandhiya

Jyoti Patel

Mrs.Ramee Bhatiya

Mrs.Samju Mendpara

Prashant Punjani

Radhika Karangia

S.P.Singh

Radhika Karangia

Lab. Technician :

Deepak Lakkad

Divyasha Bhalodiya

Pharmacists:

Mr. R K Donga

2) Frequency of Medical Examination of Employees as well as Contract Staff

Annexure - 1

PART – II & III





Employees:

• Employees working in hazardous process – Once in six month

• Employees not working in hazardous process – >40 once in year, <40 once in two

year

Contract staff:

• Person working in hazardous process – Once in six month

• Person not working in hazardous process – once in year

3) Summary of the Tests Carried out in brief

Employees:

Once in six months

1. Physical Examination,

2. Vision examination

3. PFT,

4. Blood investigation {CBC, FBS, kidney profile, Liver profile}

5. Urine Routine.

Once in year above + ECG + lipid profile + X ray chest

Contractor staff:

Once in six months

1. Physical Examination,

Annexure - 1

PART – II & III





2. Vision examination,

3. PFT,

4. Audiometry,

5. Blood investigation {CBC, RBS, S.Creat, SGPT} and Urine Routine

6. X- Ray chest (if required based on examination).

4) Total Employees in the refinery is – 1747 and Month wise Number of the Employees

and Contract Staff for whom the Medical Examination has been carried out (From

March’2018 to August’2018 is as given below

Month Employees Contract staff

March. 18 - 1517

April. 18 193 1574

May.18 230 1995

Jun. 18 292 1954

July. 18 298 1391

Aug. 18 126 1465

5) Sample of Test Report in last six months for both employees and Contractors is given

below:

Annexure - 1

PART – II & III





Sufficient preventive measures shall be adopted to

avoid direct exposure to emission and other

Hydrocarbons etc.

Hydrocarbon and H2S detectors have been installed in strategic locations at all the units. Apart

from this it is mandatory to wear respiratory protective equipment when in the unit. Timely H2S

and hydrocarbon awareness training is being given to all the contract workman as well as

employees.

Annexure - 1

PART – II & III





XII A separate environment management cell with full

fledge laboratory facilities to carry out various

management and monitoring functions shall be set

up under the control of Senior Executive.

The Environment Management Cell is in position, headed by senior executive and reports

directly to the Director. Technical qualification of staff is as shown in Table no.37.

Head HSEF Directly reports to Director Refinery.

Table no.37: Details Environment Management Cell

Sr. No. Name of the Person Designation Technical Qualification

1 P. R. Dixit VP & Head- HSEF M. Tech Environment

2 Asmita Patel Head Environment M. Tech Environment

3 Priya Ayengar Sr. Manager

Environment

B.E Electrical & PG Diploma in

Environment & Sustainability

4 Harshit Shah Manager

Environment

B.E Electrical & PG Diploma in

Environment & PG Diploma

Safety

5 Ravirajsinh Gohil Dy. Manager

Environment

M. Tech Environment

6 Nirav Patel Dy. Manager

Environment

M. Tech Chemical & PG

Diploma in Industrial Safety

We already have well equipped laboratory & with required technical staff. Details attached as

Annexure 1.13.

Annexure 1.1 GSR Compliance

Page 1 of 31

Compliance status report of the conditions stipulated in the notification published by Ministry of Environment and Forests, New Delhi dtd 18th March,2008


I Industry shall comply with new standards/ norms for Oil Refinery

Industry under the Environment Protection Rule 1986 vide GSR

186 (E) dated 18th March 2008

A. Effluent

We are in compliance with the various stipulations made for Oil & Gas Industries

in EPA Rules, 2008 by Ministry of Environment & Forest.

A) Effluent: ETP with primary, secondary & tertiary treatment units is

provided to treat the industrial effluent. The results for treated effluent for

last six month is tabulated below. All parameters are well below the

prescribed limits as shown in Table no. 01 A & 01 B.

Manual monitoring result of treated effluent for the month of Mar’18 to Aug’18 carried out by M/s Unistar Environment & Research Labs Pvt. Ltd.

(NABL accreditation no. for Chemical & Biological: TC-7753 in lieu of T-2239, T-2240 valid till 14.09.20:

Table no. 01 A: Manual monitoring result of treated effluent for the month of Mar’18 to Aug’18

Pollutant Parameters Limiting value for

concentration (mg/l

except for pH)


Min-Max


pH 6.0-8.5 7.35-7.51

Oil & Grease 5.0 <4

BOD (3 days, 27 ºC) 15.0 9.0 - 13.0

COD 125.0 29.40 - 45.7



Sulphide (as S) 0.50 0.25 - 0.47


Ammonia as N 15 <5

TKN 40 <5

P 3 0.22 - 0.56


Cr (Total) 2 <0.001

Pb 0.1 <0.003


Page 2 of 31



Hg 0.01 <0.002

Zn 5 0.04-0.067

Ni 1 0.08-0.123

Cu 1 0.04-0.085

V 0.2 <0.01

Benzene 0.1 <0.001


Online Monitoring results for effluent quality for the period of Mar’18 to Aug’18:

Table no. 01 B: Online Monitoring results for effluent quality for the period of Mar’18 to Aug’18

Pollutant

Parameters

Limiting value for concentration


Quality of Treated Effluent*

Min-Max


pH 6.0-8.5 6.17-8.2

Oil & Grease 5.0 0.97-4.4

BOD (3 days, 27 ºC) 15.0 2.60-15

COD 125.0 29.68-90.9

Suspended Solids 20.0 05-17

Phenol (as C6H5OH) 0.35 0.01-0.24

Ammonia as N 15 0.06-5.14

B. Emission B) Emissions: All flue gas & process gas stacks are provided with required

APCM to control the emission. The stack emission results for last six month

is shown in table below. All parameters are well below the prescribed limits

as shown in Table no. 02 A, 02 B 03 A & 03 B.


Page 3 of 31



Manual monitoring result of stack emission for the month of Mar’18 to Aug’18 carried out by M/s Unistar Environment & Research Labs Pvt. Ltd.

(NABL accreditation no. for Chemical & Biological: TC-7753 in lieu of T-2239, T-2240 valid till 14.09.20):

(A) Emission through heater’s/furnace’s stacks (Table no. 02 A):

Sr.

No.

PLANT Parameters monitored

PM

(mg/Nm3)

SO2

(mg/Nm3)

NOx

(mg/Nm3)

CO

(mg/Nm3)

Ni

(mg/Nm3)

Vanadium

(mg/Nm3)


1 CDU/VDU 15-46 190-255 92-110 15-28 0.030 0.20

2 CDU - II 52-86 443-739 124-157 17-26 0.040 0.29

3 DHDT 7-14 11-41 56-82 5-13 NA NA

4 VGOHT 7-29 26-49 64-84 7-16 NA NA

GPCB Limit (for Sr. No. 1 to 4

above )

100 1700 450 200 5 5

5 NHT/CCR 5-7 11-29 54-80 6-15 NA NA

6 DHDS 4-8 8-12 58-82 6-10 NA NA

7 FCC Feed heater 5-8 12-22 43-108 5-11 NA NA

8 HMU – 1 4-8 22-41 31-82 6-18 NA NA

9 HMU-2 5-8 8-44 21-74 08-12 NA NA

10 DCU - 1 5-8 17-27 57-86 12-26 NA NA

11 DCU - 2 6-8 12-31 37-48 14-27 NA NA

12 DCU - 3 4-7 6-24 32-52 11-26 NA NA

GPCB Limit (for Sr. No. 5 to 12) 10 50 350 150 - -

(B) Emission through processes stacks (Table no. 03 A):


Sulfur recovery (%) H2S (mg/Nm3) NOx (mg/Nm3) CO (mg/Nm3)

Min-Max Min-Max Min-Max

1 SRU 99.8 1 18-44 11-22


Page 4 of 31



2 SRU - 1 99.7 1 32-51 10-16

GPCB Limit (for Sr. No. 1 & 2) 98.7 15 350 150


PM

(mg/Nm3)

SO2

(mg/Nm3)

NOx

(mg/Nm3)

CO

(mg/Nm3)



3 FCC

Regenerator

31-62 229-457 72-112 52-273 0.05-0.07 0.21-0.35


Legends:

CDU/VDU Crude Distillation Unit / Vacuum Distillation Unit

CDU - II Crude Distillation Unit - II

NHT/CCR Naphtha Hydro Treater/ Continuous Catalytic Reforming

DHDS Diesel Hydro de Sulfurization

FCCU Fluidized Catalytic Cracking Unit

HMU Hydrogen Manufacturing Unit

DHDT Diesel Hydro Treater

VGOHT VGO Hydro Treater

DCU Delayed Coker Unit

SRU Sulfur Recovery Unit

PM Particulate Matter

SO2 Sulfur Dioxide

NOx Oxides of Nitrogen

H2S Hydrogen Sulfide

CO Carbon Monoxide

Ni Nickel

V Vanadium


Page 5 of 31



NA: Not Applicable

The Monitoring report by M/s Unistar Environment & Research Labs Pvt. Ltd. (NABL accreditation no. for Chemical & Biological: TC-7753 in lieu of T-

2239, T-2240 valid till 14.09.20 is attached as Annexure 1.1.1.

Note: The Monitoring is carried out by NABL accredited third party, i.e. Unistar Laboratories Private Limited, Vapi. The NABL accreditation certificate

are shown below:


Page 6 of 31


Page 7 of 31



Continuous Emission Monitoring system

Apart from this Continuous emission monitoring system is provided & hooked up with CPCB server for all stacks. Stack emission data for the month of

Mar’18 to Aug’18 are shown in table below:

(A) Emission through heater’s/furnace’s stacks (Table no. 02 B) :

Unit SO2 NOx CO PM

mg/Nm³ mg/Nm³ mg/Nm³ mg/Nm³


CDU 77.6 539.08 1.07 137.05 1.16 162.41 2.49 69.21

VDU 59.8 551.73 44.26 98.97 14.72 91.36 3.95 29.13

CDU-II 97.9 1134.29 7.4 199.41 26.83 121.34 4.84 84.54

FCCR 312.3 690.2 112.75 306.75 198.58 373.68 22.82 43.26

NHT/CCR 3.2 37.41 49.01 61.07 7.77 21.15 Will be installed by

TA18* DHDS 7.7 45.68 4.36 67.77 7.74 16.9

FCCH 1.5 43.65 45.58 133.13 5.42 14.4

DHDT 36.4 187.8 11.36 193.55 14.05 145.11

VGOHT 1.3 80.58 3.28 177.39 1.04 177.71

HMU-1 1.3 24.55 0.49 37.28 Will be installed by

TA18 HMU-2 1.2 17.97 0.19 19.97

DCU-1 1.7 42.43 15.49 162.19 17.57 145.99

DCU-2 4.4 43.48 15.9 49.43 2.82 146.5

DCU-3 2.0 39.28 1.06 60.8 9.06 110.64

SRU Not in Consent 30.29 79.82 Will be installed by

TA18

Not in Consent

TA18* - Turn around 2018,Planned in November – December 2018


Page 8 of 31



(B) Emission through processes stacks (Table no. 03 B):

Sr. No. Plant

NOx (mg/Nm3)

Min-Max

1 SRU 2-80

2 SRU - 1 6-21

GPCB Limit (for Sr. No. 1 & 2) 350

Sr. No. Plant

PM

(mg/Nm3)

SO2

(mg/Nm3)

NOx

(mg/Nm3)

CO

(mg/Nm3)


3 FCC

Regenerator

24-43 89-690 68-307 199-374


Legends:

NA: Not applicable

Note : Calibration detail for analyzers from SAP is shown below:


Page 9 of 31



For CDU I :

Detailed calibration reports for analyzers are maintained in our SAP server. Screen shot of the same is attached as Annexure 1.1.2.

Calibration Schedule:


Page 10 of 31



Detailed calibration schedule is attached herewith as Annexure 1.1.3.


Page 11 of 31



ii C-Fugitive Emission

Storage of volatile liquids : General Petroleum Products

1. Storage tanks with capacity between 4 to 75 M3 and total

vapour pressure (TVP) of more than 10 kpa should have Fixed

Roof Tank (FRT) with pressure valve vent.

2. Storage tanks with the capacity between 75 to 500 M3 and

total vapour pressure (TVP) of 10 to 746 kpa should have

Internal Floating Roof Tank (IFRT) or External Floating Roof

Tank (EFRT) of Fixed Roof Tank with vapour control or vapour

balancing system.

1. Not Applicable.

2. Storage tanks with capacity between 75 to 500 m3 and TVP between 10 to 76

kPa are having either External floating roof or Internal Floating roof. Storage

tanks details are shown in Table no.04

Table no.04: Storage Tank with capacity

Tank No Nominal Cap (m3)

161T-456 117

161T-457 395

77T-302 200

77T-201 500

77T-202 500

60T-201 150

80T-101 150

81-T-265 100

176T-102 500


Page 12 of 31



3. Storage tanks with capacity of more than 500 M3 and total

vapour pressure (TVP) of 10 to 76 kpa should have Internal

Floating Roof Tank (IFRT) or External Floating Roof Tank (EFRT)

of Fixed Roof Tank with vapour control system.

3. Storage Tanks having capacity more than 500 m3 and total vapor pressure

between 10 to 76 kPa are having external floating roof (Both single deck and

double deck) and Internal Floating roof; Fixed Roof tanks contain have vapor

control system.

Tank No Nominal Cap

(m3)

61T-001A 16000

61T-001B 16000

61T-220A 15000

61T-220B 15000

61T-221A 15000

61T-221B 15000

61T-222A 6500

61T-222B 6500

61T-222C 6500

61T-250A 15000

61T-250B 15000

61T-250C 15000

61T-250D 15000

61T-250E 15000

61T-250F 15000

61-T-253 1000

61T-260A 30000

61T-260B 30000

61T-260C 30000

61T-260D 30000

61T-301 4000

61T-350A 10000


Page 13 of 31



61T-350B 10000

61T-350C 10000

61T-350D 10000

61T-351A 10000

61T-351B 10000

61T-402 4000

61T-422A 3000

61T-422B 3000

61T-424A 30000

61T-424B 30000

61T-450A 50000

61T-450B 50000

61T-450C 50000

61T-450D 50000

61T-450E 50000

61T-450F 50000

61T-502 2500

61T-503A 20000

61T-503B 20000

61T-503C 20000

61T-503D 20000

61T-520A 10000

61T-520B 10000

61T-520C 10000

61T-550A 10000

61T-550B 10000

61T-560A 20000

61T-560B 20000


Page 14 of 31



61T-560C 20000

61T-560D 20000

61T-552A 3000

61T-552B 3000

61T-552C 3000

61T-552D 3000

61T-620 1000

61T-622 5000

161T-222D 30000

161T-240A 10000

161T-240B 10000

161T-223C 30000

161T-223D 30000

161T-230A 10000

161T-220C 15000

161T-220D 15000

161T-223A 60000

161T-223B 60000

161T-424C 5000

161T-351C 30000

161T-351D 30000

161T-351E 30000

161T-351F 30000

161T-351G 30000

161T-351H 30000

161T-520D 30000

161T-520E 30000


Page 15 of 31



161T-520F 30000

161T-520G 30000

161T-506A 60000

161T-506B 60000

161T-450G 60000

161T-450H 60000

161T-450I 60000

151T-001 30000

151T-002 30000

177T-302B 5000

177T-302C 5000

177T-500C 5000

177T-300A 5000

77T-502A 800

77T-502B 800

77T-500A 4000

77T-500B 4000

77T-501A 800

77T-501B 800

77-400A 10000

77-400B 10000

77-401A 3000

77-401B 3000

77T-301A 900

77T-301B 900

77T-200A 4000

77T-200B 4000


Page 16 of 31



4. The tanks with the capacity of more than 75 M3 and total

vapour pressure of more than 76 kpa should have Fixed Roof

Tank with vapour control system.

77-T-701A 540

77-T-701B 628

60T-101 88000

60T-102 88000

60T-103 88000

60T-104 88000

60T-105 88000

60T-106 88000

60T-107 88000

60T-108 88000

60T-109 88000

60T-110 88000

160T-111 120000

160T-112 120000

260T-115 120000

330-T-001A 3343

331-T-001A 3343

81T-201AX 8640

81T-201-BX 8640

64T-101A 8640

64T-101B 8640

4. Not Applicable


Page 17 of 31



5. Requirement for seals in Floating Roof Tanks:

1. (a) IFRT and EFRT shall be provided with double seals with

minimum vapour recovery of 96 %.

(b) Primary seal shall be liquid or shoe mounted for EFRT.

Maximum seal gap width will be 4 cm and maximum

gap area will be 200 cm2/m of tank diameter.

(c) Secondary seal shall be rim mounted. Maximum seal

gap width will be 1.3 cm and maximum gap area will be

20 cm2/m of tank diameter.

(d) Material of Seal and construction shall ensure high

performance and durability.

2. Fixed Roof Tanks shall be have vapour control efficiency of

95 % and vapour balancing efficiency of 90%.

3. Inspection and maintenance of storage tanks shall be

carried out under strict control. For the inspection, API RP

575 may be adopted. In-service inspection with regard

seal gap should be carried out once in every six months

and repair to be implemented in short time. In future,

possibility of on-stream repair of both seals shall be

examined.

5. Seals are provided in Floating Roof tanks:

1. (a) Double seals are available in both EFR and IFR tanks

(b) Primary seals are foam type seals

(c) Secondary seals are rim mounted and the conditions are met.

(d) High quality foam is used for seal to ensure high performance &

durability.

2. Not applicable

3. LDAR is carried out by operation department; Inspection on the condition

of Rim seal is carried out every year by inspection and repairs carried out

as and when required

Storage of Volatile Liquids: Benzene Storage

1. FRT with vapour to incineration with 99.9 % of removal

efficiency for volatile organic compounds (VOC) shall be

provided.

1. Not applicable

2. Not applicable


Page 18 of 31



2. IFRT/EFRT with double seals, emission-reducing roof

fitting and fitted with fixed roof with vapour removal

efficiency of at least 99% shall be provided.

Solvents for Lube-Base oil production (Furfural, NMP,

MEK, Toluene and MIBK)

IFRT with double seals and inert gas blanketing with

vapour removal efficiency of at least 97% shall be

provided.

(Emission control for Road tank truck/ rail tank wagon loading)

Loading Volatile

Products

Gasoline and Naptha:

(i) VOC reduction, %

(ii) Emission, gm/m3

(i) 99.5

(ii) 5

Benzene:



(i) 99.99

(ii) 20

Toluene/xylene:



(i) 99.98

(ii) 150

Note:

(i) It shall be applicable for

Gasoline, Naptha, Benzene,

Toluene and xylene loading.

(ii) Road tank truck shall have

bottom loading and rail tank

wagon shall have top

submerged loading.


Page 19 of 31



(iii) Annual leak testing for vapour

collection shall be done.

Standards for Equipment Leaks

1. Approach: Approach for controlling fugitive emissions from

equipment leaks shall have proper selection, installation and

maintenance of non-leaking or leak-tight equipment.

Following initial testing after commissioning, the monitoring

for leak detection is to be carried out as a permanent on-

going Leak Detection and Repair(LDAR) programme. Finally

detected leaks are to be repaired within allowable time

frame.

1. Refinery has designed its equipment as per the standards. Approach has been

provided to all kind of devices and equipment. There is a preventive

maintenance schedule for all the equipment. The testing of hydrocarbons

using detectors was done after commissioning. Radiography was also carried

out to ensure the fittings of all the valves, joints etc.

Refinery has documented management procedure for Leak Detection and

Repair (LDAR) Program. LDAR was carried out in phases. In the first phase the

points were identified by Lab India Instruments Pvt Ltd. In the second phase

the LDAR was carried out by Lab India Instruments Pvt Ltd. From the third

phase the LDAR is being carried in-house using Photoionization principle

through PhotoVac 2020 VOC Meter. Till date no leak has been identified. The

LDAR Report carried out till date has shown in Table no. 05

Table no. 05: LDAR programme for components for various plants

Sr.

No

Unit Dates Total

Component

Monitored

Min

VOC

in

PPM

Max

VOC

in

PPM

Leak

Observed

1 HMU-1 01/03/2018 to

14/03/2018

4238 0 224 Nil

2 HMU-2 15/03/2018 to

30/03/2018

2920 0 0 Nil

3 FCCU 01/04/2018 to

14/04/2018

7481 0 23 Nil


Page 20 of 31



4 Utility-1 15/04/2018 to

29/04/2018

1027 0 61 Nil

5 Utility-2 01/05/2018 to

30/05/2018

491 0 285 Nil

6 DCU 01/06/2018 to

29/06/2018

9601 0.1 5 Nil

7 DHDS 01/07/2018 to

14/07/2018

3022 0 500 Nil

8 NHT/ CCR 15/07/2018 to

30/07/2018

5995 0 800 Nil

9 COT 15/08/2018 to

30/08/2018

281 0.1 16.2 Nil

Calibration report for the instrument used is shown below:


Page 21 of 31


Page 22 of 31



2. Components to be covered: Components that shall be

covered under LDAR programme include (i) Block valves; (ii)

Control valves; (iii) Pump seals; (iv) Compressor seals; (v)

Pressure relief valves; (vi) Flanges – Heat Exchangers; (vii)

Flanges - Piping; (viii) Connectors - Piping; (ix) Open ended

lines; and (x) Sampling connections. Equipment and line sizes

more than 1.875 cm or ¾ inch are to be covered.

2. All the components Valves, Flanges, Glands of the all the equipment are being

covered in the LDAR. The unit wise details of the components are given in

Table no. 06:

Table no. 06:unit wise details of components for LDAR programme

Sr.

No

Unit Valves Flanges Valve

Glands

Seals

1 CDU/VDU/SGU 4081 8786 0 0

2 CDU-II 897 541 0 0

3 NHT/ CCR 2718 1654 1591 32

4 DHDS 885 1754 0 0

5 SRU 697 1673 681 31

6 FCCU 1825 3807 1777 62

7 DHDT 1472 2785 580 15

8 VGOHT 757 1851 737 0

9 HMU-1 1072 2206 1068 0

10 HMU-2 640 2099 181 0

11 DCU 2687 6914 0 0

12 ISOM 1392 3507 0 0

13 COT (281

components)

Tanks – 12 Nos. Pumps – 13 Nos.

14 PIT 72

15 Utility- I 334 367 326 0

16 SRU-I 5170 2245 2007 58

17 Utility - 2 360 120

120 11 0


Page 23 of 31



3. Applicability: LDAR programme would be applicable to

components (given at 2 above) for following

products/compounds: (i) hydrocarbon gases; (ii) Light liquid

with vapour pressure @ 20oC > 1.0 kpa; and (iii) Heavy liquid

with vapour pressure @ 20 oC between 0.3 to 1.0 kpa.

3. LDAR Programme is being carried out for all the components given in the point

2. The List of the Volatile Organic Compounds monitored in the program are

as under:-

4. For Heavy liquids the pipe, valve, flange and all the equipment are timely

checked and Preventive Maintenance is also done in order to avoid any kind

of Leak.


Page 24 of 31



4. While LDAR will not be applicable for heavy liquids with

vapour pressure < 0.3 kpa, it will be desirable to check for

liquid dripping as indication of leak.

5. Definition of Leak; A leak is defined as the detection of VOC

concentration more than the values (in ppm) specified below

at the emission source using a hydrocarbon analyzer

according to measurement protocol (US EPA – 453/R-95-

017,1995 Protocol) for equipment leak emission estimates

may be referred to:

Component General Hydrocarbon

(ppm)

Benzene (ppm)

Till 31st

Dec. 2008

w.e.f.

January

01,2009

Till 31st

Dec. 2008

w.e.f.

January

01,2009

Pump/

Compressor

10000 5000 3000 2000

Valves/

Flanges

10000 3000 2000 1000

Other

components

10000 3000 2000 1000

5. The definition of leak according to the concentration has been incorporated

in the Leak Detection and Repair Program. The same is being followed in the

entire refinery to determine leak and take action accordingly. However, till

date no leak has been observed.

6. In case of any kind of leak noticed by sight, sound or smell it is attended and

repaired immediately. Refinery ensures zero leak.


Page 25 of 31



6. In addition any component observed to be leaking by sight,

sound or smell regardless of concentration (liquid dripping,

visible vapour leak) or presence of bubbles using soap

solution should be considered as leak.

7. Monitoring requirements and repair schedule: Following

frequency of monitoring of leaks and schedule for repair of

leaks shall be followed:

Component Frequency of

monitoring

Repair Schedule

Quarterly (semiannual

after two consecutive

periods with < 2% leaks)

Repair will be

started within 5

working days and

shall be

completed within

15 working days

after detection of

leak for general

hydrocarbons. In

case of benzene,

the leak shall be

attended

immediately for

repair.

Pump Seals Quarterly

Compressor

Seals

Quarterly

7. Refinery has not observed any kind of leak till date. However, LDAR is carried

out in all the units. The detailed schedule for the year 2018-19 is as given in

Table no. 07:-

Table no. 07: Schedule for LDAR programme

Sr. No. Unit Dates

1 FCCU 01/04/18 to 30/04/18

2 Utility-1 01/05/18 to 31/05/18

3 Utility-2

Expansion

01/06/18 to 30/06/18

4 DCU 01/07/18 to 31/07/18

5 DHDS & SRU 01/08/18 to 31/08/18

6 COT, PIT &

NHT/CCR

01/09/18 to 30/09/18

7 DHDT &

VGOHT

01/10/18 to 31/10/18

8 ISOM & SRU-I 01/11/18 to 30/11/18

9 CDU/VDU &

Utility-1 Base

01/12/18 to 31/12/18

10 HMU-II 01/01/19 to 31/01/19

11 HMU I 01/02/19 to 28/02/19

12 CDU-II 01/03/19 to 20/03/19


Page 26 of 31



Pressure

relief devices

Quarterly

Pressure

relief devices

(after

venting)

Within 24 hours

Heat

Exchangers

Quarterly

Process

drains

Annually

Components

that are

difficult to

monitor

Annually

Pump seals

with visible

liquid

dripping

Immediately Immediately

Any

component

with visible

leaks


Any

component

after

Within five days

8. No leak has been observed in the Refinery. However, the monitored details

of VOC for the month Mar’18 to Aug’18 is given in Table no. 8:


Page 27 of 31



repair/replac

ement

8. The percentage leaking component should not be more than

2 % for any group of components, monitored excluding

pumps/compressors. In case of pumps/compressors, it

should be less than 10% of the total number of

pumps/compressors or three pumps and compressors,

whichever is greater.

Table no. 8: VOC monitoring details for the month of March’2018 to

August’18

Sr. No Unit Dates

Total

Component

Monitored

Min

VOC

in

PPM

Max

VOC

in

PPM

Leak

Observed

1 HMU-1 01/03/2018 to

14/03/2018 4238 0 0 Nil

2 HMU-2 15/03/2018 to

30/03/2018 2920 0 0 Nil

3 FCCU 01/04/2018 to

14/04/2018 7481 0 23 Nil

4 Utility-

1

15/04/2018 to

29/04/2018 1027 0 61 Nil

5

Utility-

2

Expansi

on

01/05/2018 to

30/05/2018 491 0 107 Nil

6 DCU 01/06/2018 to

29/06/2018 9601 0 5 Nil

7 DHDS 01/07/2018 to

14/07/2018 3022 0 43.6 Nil

8 NHT/

CCR

15/07/2018 to

30/07/2018 5995 0 32 Nil

9 COT 15/08/2018 to

30/08/2018 281 0 15 Nil


Page 28 of 31



9. Emission inventory: Refinery shall prepare an inventory of

equipment components in the plant. After the instrumental

measurement of leaks, emission from the components will be

calculated using stratified emission factors (USEPA) or any

other superior factors. The total fugitive emission will be

established.

9. Refinery had engaged Lab India Instruments Pvt Ltd for identifying the

equipment components in the Phase-I of LDAR. The emissions are calculated

using OISD- GDN- 224 and shown in Table no 09.

Table no. 09.:The total fugitive emission from March’18 to August’18

Units Valves (Total

VOC in PPM)

Flanges

(Total VOC in

PPM)

Valve Glands

(Total VOC in

PPM)

Seals (Total

VOC in PPM)

HMU-1 0 0 0 0

HMU-2 0 0 0 0

FCCU 0 120.1 101.1 0

Utility-1 2.7 127.9 1.8 0

Utility-2

Expansion 1773 0 107 0

DCU 0.2 260 0.4 0

DHDS 2.8 26.2 550.5 0

NHT/ CCR 815.1 773.5 3093.9 0

COT 0 0 0 15

Total 2593.8 1307.7 3854.7 15

Emission

(kg/hr.)

(3.8 X 10^-5) X

(ppm)^0.74

(1.7 X 10^-5) X

(ppm)^0.82

(3.8 X 10^-5) X

(ppm)^0.74

(1.7 X 10^-5) X

(ppm)^0.82

0.0127 0.0061 0.01711 0.00014

Total Kg/

hr. 0.03605


Page 29 of 31



10. Monitoring: Following types of monitoring methods may be

judiciously employed for detection of leaks: (i) Instrumental

method of measurement of leaks; (ii) Audio, visual and

olfactory (AVO) leak detection: and (iii) Soap bubble method.

11. Data on time of measurement and concentration value for

leak detection; time of repair of leak; and time of

measurement & concentration value after repair of leak

should be documented for all the components.

12. Pressure relief and blow down system should discharge to a

vapour collection and recovery system or to flare.

13. Open-ended lines should be closed by a blind flange or

plugged.

14. Totally closed-loop should be used in all routine samples.

10 Photoionization method is used to detect Volatile Organic Compounds

through PhtoVac 2020 combi Pro VOC meter.

11 The format for LDAR consists of date, time, responsible person, minimum

and maximum concentration, data after attending the leak. The same is

being documented. Please find below the format:-

12 Pressure relief systems of all units and blow down systems are connected

to common flare system via separate collection system.

13 All open ended flanged lines are blinded or plugged with seal weld.

14 All routine samples are closed loop and sample point flushing is done

through the same.

15 High quality packing material is used for valves to ensure low emissions.

16 High quality foam is used for seal to ensure high performance & durability.


Page 30 of 31



15. Low emission packing should be used for valves.

16. High integrity sealing materials should be used for valves.

D. Emission Standards for VOC from wastewater collection and Treatment


Page 31 of 31



1. All contaminated and odorous wastewater streams shall be

handled in closed systems from the source to the primary

treatment stages (oil-water separator and equalization

tanks).

2. The collection systems shall be covered with water

seals(traps) on sewers and drains and gas tight covers on

junction boxes.

3. Oil-water separators and equalization tanks shall be provided

with floating/fixed covers. The off-gas generated shall be

treated to remove at least 90% of VOC and eliminate odour.

The system design shall ensure safety (prevention of

formation of explosive mixture, possible detonation and

reduce the impact) by dilution with air/inert gas, installing LEL

detector including control devices, seal drums, detonation

arrestors, etc. The system shall be designed and operated for

safe maintenance of the collection and primary treatment

system.

4. Wastewater from aromatics plants (benzene and xylene

plants) shall be treated to remove benzene & total aromatics

to a level of 10, 20 ppm respectively before discharge to

effluent treatment system without dilution.

1. All AOC (Accidentally Oil Contaminated) and COC(Continuous Oil

Contaminated) of each plant are in closed system .wastewater from AOC

& COC sent to Primary Treatment unit (PTU) for removal of free oil and dirt

by gravity separation through Tilted Plate Interceptor and oil skimmer. In

refinery five PTU is provided at different location. (Process, PIT, RLCB, TLCB,

COT) All the primary treated water are collected & treated in effluent

treatment plant followed by reverse osmosis plant.

2. Collection tanks are covered with RCC top slab.

3. Oil water separator are covered.

4. Not Applicable


Page 32 of 31



Quantum limit in Kg/1,000 tonne of crude processed

Parameter 1 Standard 2

Quantum limit in Kg/1,000 of

crude processed

1. Oil & Grease 2.0

2. BOD 3 days, 27oC 6.0

3. COD 50

4. Suspended Solids 8.0

5. Phenols 0.14

6. Sulphides 0.2

7. CN 0.08

8. Ammonia as N 6.0

9. TKN 16

10. P 1.2

11. Cr(Hexavalent) 0.04

12. Cr(Total) 0.8

13. Pb 0.04

14. Hg 0.004

15. Zn 2.0

16. Ni 0.4

17. Cu 0.4

18. V 0.8

19. Benzene 0.04

20. Benzo(a)-Pyrene 0.08

Quantum limit in Kg/1,000 tonne of crude processed for the Month of Mar’18 to

Aug’18 as shown Table no. 10:

Table no.10: Quantum limit in Kg/1,000 tonne of crude processed for the Month

of March’18 to August’18


Quantum limit in Kg/1,000 of crude processed

1. Oil & Grease 0.05

2. BOD 3 days, 27oC 0.15

3. COD 0.50

4. Suspended Solids 0.18

5. Phenols 0.0013

6. Sulphides 0.0047

7. CN 0.00069

8. Ammonia as N 0.07

9. TKN 0.07

10. P 0.01

11. Cr(Hexavalent) 0.00137

12. Cr(Total) 0.0001

13. Pb 0.0004

14. Hg 0.00003

15. Zn 0.00068

16. Ni 0.00145

17. Cu 0.00090

18. V 0.0014

19. Benzene 0.00001

20. Benzo(a)-Pyrene 0.00001

ANNEXURE - 1.1.1

Annexure 1.1.2: Online Analyzers Calibration reports

AAQMS-1


AAQMS-2


CDU-1


CDU-2


VDU


FCCU

EQUIPMENT ROOM AT ANALYSER APPLICATION FREQ Mar-18 Apr-18 May-18 Jun-18 Jul-18 Aug-18 Sep-18

1000012900 OSA_CDU2 GAS NOX DUCT 3 MON 1000553465 1000570024

1000012901 OSA_CDU2 GAS SOX DUCT 3 MON 1000553466 1000570025

1000025024 OSA_DHDS GAS CO 40F001 HEATER 3 MON 1000527834 1000542858 1000559941

1000025028 OSA_DHDS GAS SOX 40F001 HEATER 3 MON 1000527833 1000542857 1000559940

1000034535 OSA_VDU1 GAS CO HEATER 3 MON 1000553457 1000570016

1000034536 OSA_VDU1 GAS NOX DUCT 3 MON 1000553458 1000570017

1000034541 OSA_CDU1 GAS SOX STACK 3 MON 1000553450 1000570009

1000034542 OSA_CDU1 GAS NOX STACK 3 MON 1000553451 1000570010

1000034545 OSA_VDU1 GAS CO HEATER 3 MON 1000553456 1000570015

1000034568 OSA_FCCU GAS CO STACK 3 MON 1000527910 1000542949 1000560037

1000036218 OSA_HMUM GAS SOX REFORMER STACK 3 MON 1000546331 1000564519

1000036219 OSA_HMUM GAS NOX REFORMER STACK 3 MON 1000546332 1000564520

1000043521 OSA_UTY1 LIQUID PH 197FX001A SERVICE O/L 3 MON 1000542742 1000559753 1000576247

1000044625 OSA_HMU1 GAS SOX REFORMER STACK 3 MON 1000532288 1000547207

1000044626 OSA_HMU1 GAS NOX REFORMER STACK 3 MON 1000532287 1000547206

1000064339 OSA_SRU1 GAS NOX STACK 3 MON 1000542589 1000559569 1000576121

1000064340 OSA_SRU1 GAS SOX STACK 3 MON 1000542590 1000559570 1000576122

1000068593 OSA_DCU GAS NOX 121F101 COKER HEATER STACK 3 MON 1000532300 1000547219

1000068628 OSA_DCU GAS SOX 121F103 COKER HEATER STACK 3 MON 1000532322 1000547241

1000070154 OSA_UTY2 LIQUID COD D/B SWT WATER PUMP 3 MON 1000554430 1000571071

1000070155 OSA_UTY2 LIQUID PHENOL D/B SWT WATER PUMP 3 MON 1000554431 1000571072

1000070156 OSA_UTY2 GAS NH3 D/B SWT/SALT WATER PUMP 3 MON 1000554432 1000571073

1000070164 OSA_UTY2 LIQUID PH RO TREATED EFFLUENT 3 MON 1000542919 1000559992 1000576547

1000071525 OSA_UTY2 LIQUID COD D/B SALT WATER PUMP 3 MON 1000554435 1000571076

1000071527 OSA_UTY2 LIQUID TSS AOC COC ACF COM DISCHARGE 3 MON 1000554418 1000571059

1000071534 OSA_UTY2 GAS NH3 SALT BIO TWR FEED PUMP 3 MON 1000554422 1000571063

1000071539 OSA_UTY2 LIQUID TSS SW ACF COM DISCHARGE 3 MON 1000554427 1000571068

1000071540 OSA_UTY2 LIQUID PHENOL D/B SALT WATER PUMP 3 MON 1000554437 1000571078

1000077394 OSA_AQMS GAS PM2.5 AMB AIR NEAR RLCB 3 MON 1000537719 1000554309

Annexure 1.1.3 Calibration Schedule

1000077395 OSA_AQMS GAS PM10 AMB AIR NEAR RLCB 3 MON 1000537720 1000554310

1000077396 OSA_AQMS GAS SOX AMB AIR NEAR RLCB 3 MON 1000537711 1000554301

1000077397 OSA_AQMS GAS NH3/NOX AMB AIR NEAR RLCB 3 MON 1000537712 1000554302

1000077398 OSA_AQMS GAS CO AMB AIR NEAR RLCB 3 MON 1000537713 1000554303

1000077400 OSA_AQMS GAS PM2.5 AMB AIR NEAR LABOUR GATE 3 MON 1000537721 1000554311

1000077401 OSA_AQMS GAS PM10 AMB AIR NEAR LABOUR GATE 3 MON 1000537722 1000554312

1000077402 OSA_AQMS GAS SOX AMB AIR NEAR LABOUR GATE 3 MON 1000537715 1000554305

1000077403 OSA_AQMS GAS NH3/NOX AMB AIR NEAR LABOUR GATE 3 MON 1000537716 1000554306

1000077404 OSA_AQMS GAS CO AMB AIR NEAR LABOUR GATE 3 MON 1000537717 1000554307

1000077442 OSA_FCCU GAS SOX FGD STACK 3 MON 1000527911 1000542950 1000560038

1000077443 OSA_FCCU GAS NOX FGD STACK 3 MON 1000527908 1000542947 1000560035

1000079434 OSA_HMU2 GAS SOX REFORMER STACK 3 MON 1000539392 1000567090

1000079435 OSA_HMU2 GAS NOX REFORMER STACK 3 MON 1000539393 1000567093

3000002430 OSA_FCCU GAS CO HEATER 3 MON 1000527915 1000542954 1000560042

3000002435 OSA_FCCU GAS NOX STACK 3 MON 1000527913 1000542952 1000560040

3000002436 OSA_FCCU GAS SOX STACK 3 MON 1000527912 1000542951 1000560039

3000004206 OSA_UTY1 LIQUID PH EFFLUENT PUMP DISCHARGEHARGE

HEADER

3 MON 1000554215 1000570823

3000005522 OSA_CCR GAS SOX DUCT 3 MON 1000546307 1000564499

3000005523 OSA_CCR GAS NOX DUCT 3 MON 1000546308 1000564500

1000084972 OSA_HMU1 GAS H2S NG COMPRESSOR (SAT GAS) PRVN

ABONDENDE

D ROA1000034482 PIT Sulphur HSD

1000077424 PIT DISTILLAITON HSD HEADER 2 BLENDING

Refinery Integrated Management System

NAYA-MGT-HSEF-ENV-01 Rev: 01.00 Dated: 28.08.2018 - 1 - of 9

Procedure for Leak Detection and Repair Program (LDAR)

Procedure for Leak Detection and Repair Program

Document Number NAYA-MGT-HSEF-ENV-01

Version / Revision 01 / 00

Date 28 / AUG / 2018

Prepared by System Coordinator

Reviewed by Head HSEF Head Technical

Approved by Director and Head of Refinery

Annexure 1.2 LDAR Procedure




AMENDMENT DETAILS

Amendment Discard Insert Notes on Amendments

No Date dd.mm.yyyy

Details RevNo. Details Rev No.

1 28.08.2018 Old Procedure EOL–

MGT–DP–TS–ENV-

001

03 Revised

Procedure

NAYA-MGT-

HSEF-ENV-01

01.00

2 28.08.2018 EOL ESSAR OIL Essar Logo ERIMS

03 NAYA (In Doc. Numbering) Nayara Energy Limited Nayara Logo RIMS

01.00 Organizational Change Requirement




Contents

AMENDMENT DETAILS ...........................................................................................................................................- 2 -

1. OBJECTIVE ......................................................................................................................................................- 4 -

2. SCOPE ............................................................................................................................................................- 4 -

3. DEFINITIONS: .................................................................................................................................................- 4 -

3.1. Volatile Organic Compounds (VOC): .....................................................................................................- 4 -

3.2. Fugitive Emission: ..................................................................................................................................- 4 -

3.3. Essential Equipment: .............................................................................................................................- 4 -

3.4. Leak: ......................................................................................................................................................- 5 -

4. PROCEDURE FOR MONITORING: ...................................................................................................................- 5 -

5. MONITORING REQUIREMENTS & REPAIR SCHEDULE: ..................................................................................- 6 -

6. PRECAUTIONS: ...............................................................................................................................................- 6 -

7. RESPONSIBILITY: ............................................................................................................................................- 7 -

7.1 Head Operations is responsible for: ......................................................................................................- 7 -

7.2 Head Environment is responsible for: ...................................................................................................- 7 -

7.3 Head Maintenance is responsible for: ..................................................................................................- 7 -

8. REFERENCES: .................................................................................................................................................- 7 -




1. OBJECTIVE

This procedure includes identification of fugitive emission sources, procedure for monitoring,

repair schedule, reporting and record keeping in a systematic manner.

2. SCOPE

This procedure is applicable for identification and control of fugitive VOC emissions from

process plants, Rail & Truck loading are, Crude oil tankage & Product intermediate tankage

area of Refinery.

Equipment or accessories which include pump seals, compressor seals, seal oil degassing

vents, flanges of heat exchangers, pipeline valves, flanges and other connections, pressure

relief devices, process drains, open-ended pipes, sampling connections etc. that could

potentially leak to emit VOCs into the atmosphere are the components covered under LDAR.

The scope excludes:-

Lines having diameter < 1 inch

Chemical compounds used or stored which has vapour pressure < 0.3 kPa at 20 oC

however to be checked for liquid dripping

Equipment under vacuum service

3. DEFINITIONS:

Volatile Organic Compounds (VOC): These are the organic compounds whose vapour pressure at 20oC exceeds 1.0 kPa (0.145

psi). As a result, these can easily become vapour or gas from the solid or liquid state.

Fugitive Emission: Also known as “equipment leaks”, the fugitive emissions are the result of leaks of volatile

organic compounds from components as above including the hydrocarbon transfer lines and

associated equipment.

Essential Equipment: Any equipment in the process whose outage from service will cause cut in unit throughput

by 33%.




Leak: Gaseous hydrocarbon emission found to be in excess of 5000 ppm, when measured by a

portable hydrocarbon detector at a distance of one (1) centimetre from the surface of

potential source with the instrument calibrated with methane. However, in case of Benzene,

which is highly carcinogenic, the leak is defined as the emission value measured in excess of

2000 ppm above the background concentration level.

Regardless of concentration, a leak is also identified by sight, sound or smell at a component

caused by liquid dripping or vapour leak, which is sometimes visible through bubbles in

presence of soap solution. The dripping of liquid VOCs at a rate of more than three (3) drops

per minutes can be construed as leak.

*AS PER MOEF NOTIFICATION DTD.18TH MARCH’2008, POINT NO.2 (C) 5

4. PROCEDURE FOR MONITORING:

The VOC Meter should be assembled and started in open & clean atmosphere.

The instrument should be calibrated as per recommendation of instrument supplier.

Concentration of VOCs emitted by the leaking component should be checked at the

surface interface (e.g. at the interface between a valve stem and packing).

The probe inlet should be placed at the surface of the component interface where there

is possibility of Leak. It should be moved along the periphery while observing the

instrument readings.

The interface where leakage is indicated should be sampled slowly until the maximum

reading is obtained. If the maximum reading exceeds the defined concentration limit then

record the reading. Set the meter to zero reading and again take the maximum reading for

cross verification.

Components Generated Hydro Carbon (ppm)* Benzene (ppm)*

Pump/compressor 5000 2000

Valves/flanges 3000 1000

Other

components 2000 1000




Record the readings of the identified points in a structured format given in the Annexure

– I

5. MONITORING REQUIREMENTS & REPAIR SCHEDULE:

Component Frequency of monitoring Repair schedule

Quarterly (semiannual after two consecutive periods with <2% leaks and annual after five periods with <2% leaks)

Repair will be started within 5 working days and shall be completed within 15 working days after detection of leak for general hydrocarbons. In case of benzene, the leak shall be attended immediately for repair.

Pump seals Quarterly

Compressor seals Quarterly

Pressure relief devices

Quarterly

Pressure relief devices (after venting)

Within 24 hours

Heat exchangers Quarterly

Process drains Annually

Components that are difficult to monitor

Annually

Pump seals with visible liquid dripping


Any component with visible leaks


Any component after repair/replacement

Within five days --

*AS PER MOEF NOTIFICATION DTD.18TH MARCH’2008, POINT NO.2 (C) 7

6. PRECAUTIONS:

The probe of the instrument should be about 1 cm from leaking interface, in upwind

direction from any component to be inspected.

Tip of the probe should not touch greasy areas. It should always remain clean and

thorough.

Monitoring activities may be avoided during rain to protect the analyzer from bad

weather.

LDAR training should be given to all the concern personnel monitoring VOC Concentration

at their unit.




7. RESPONSIBILITY:

7.1 Head Operations is responsible for: Identifying the points as per P & ID

Monitoring each component as mentioned in point no. G at regular interval.

Identifying the leaky points as per point no. E (5).

Coordinating with maintenance department for attending the leaks.

Compiling the leak survey report in a structured format given in the Annexure – I

Ensuring repeat survey after attending the leaks.

Submitting the records to Environment department.

The Leaks which cannot be repaired during operation must be tagged separately to

attend them during next shutdown of the facility.

Prepare a master list of equipment, components and the points which are to be

monitored in these components.

7.2 Head Environment is responsible for: Maintaining consolidated report of fugitive emissions in Overall Refinery in the format

as per Annexure II.

Ensuring that LDAR program running as per schedule.

7.3 Head Maintenance is responsible for: The repairing/replacing of the leaky equipment/joints in coordination with operation

8. REFERENCES:

Charter on Corporate Responsibility for Environmental Protection from the Central

Pollution Control Board.

MoEF notification dtd.18th March’2008

US-EPA Method 21, regarding Determination of Volatile Organic Compound Leaks.

OISD-Guidelines - 224, Monitoring and Control of Volatile Organic Compounds

emission.

Environment Clearance given by MoEF, vide letter no: J-11011/320/2006-IA-II (I),

dated 20 July-2007 amended on 16/09/2008 and 16/09/2018




ANNEXURE-I

VOC Monitoring Report

UNIT –

ANNEXURE – II

LDAR CONSOLIDATED REPORT

Sr.

No.

Units

monitored

Total nos. of

Components

monitored

Total nos. of

leaky points

found

Min TVOC

observed

(PPM)

Max TVOC

observed

(PPM)

Location

where Leak

found

VOC before

attending

leak (PPM)

VOC before

attending

leak (PPM)




LIST OF ANNEXURES

SR. NO. ANNEXURE DETAILS PAGE NO

1 ANNEXURE – I VOC MONITORING REPORT 8

2 ANNEXURE – II LDAR CONSOLIDATED REPORT 8

GUJARAT POLLUTION CONTROL BOARDPARYAVARAN BHAVAN

Sector-10-A, Gandhinagar-382 021.Website: www.gpcb.gov.in

Bv R.P.A.D.

In exercise of the power conferred under section-25 of the Water (Prevention a;d Control ofPollution) Act-1974. under section-21 of the Air (Prevention and Control of Pollution)-1981 andAuthorisation under rule 3(c) & 5(5) of the Hazardous \\aste ('.lanagement and Handling)Rules" 1989& as amended up to year 2003 framed under the Environmental (Protection) Act-l986.

And whereas Board has received consolidated consent application lener dated 131021201-1forthe Consolidated Consent and Authorizatioo (CC & A) of this Board under the provisions rules of

the aforesaid Acts. Consents & Authorization are hereby granted as under:

CONSENTS AND AUTHORISATION:(under the provisions /rules of the aforesaid environmental acts)

To;MIS. RELIANCE BARREL SUPPLY CO,PLOT NO: 200/34, B/H. KASHIR TEXTILE MILL,NAROL-DlST,AHMEDABAD.

I. Consent Order No. AWH- 61732 dale of Issue: 18/04120142. The consents shall be valid up to 12102/2019 lor use of outlet lor the discharge of trade

effluent & em iss ion due to operation of industrial plant for manllt~lCtllre of the followingitems/products:

Sr.No. Product~-

Quantitv !

I Re-Cycled waste oil 600 KLiMonth2 Re-re.fined used oil 600 KLiMonth

De contamination, De toxic and Recyclers /-----_.

3. 8000 Nos.·Month

~ reconditionin!! of emotv barrels (MS & (llasticslL ____ . ____ ~ _

3. CONDITIONS UNDER THE WATER ACT:3.1 The quantity of trade eftluent from the factory shall nol exceed 7600 lits/day. Out of which

treated eftluent partly reused and other treated emuent shall be evaporation Incineration tomaintain zero discharge.

3.2 The quantity of Sewage eftluent trom the factory shall not exceed 800 lit/day.3.3. The directives issued by the Board frol11 time to time in vie\\' of direction issued bv the

Honorable High of Gujarat in the matter of S.C.A.770'95 and any other shall have io becomplies with.

4. CONDITIONS UNDER THE AIR ACT:

4.1 The :~~o:in ;~~::I be used as~ -"'Quantity l1 LDO 20. Iiters!hr

Wood Io.0J<:~~ __ ~_ .....J

4.2 The applicant shall install & operate air pollution control sy'stem in order to achieve normsprescribed below.

I

Clean GujaratGreen GujaratISO - 9001 - 2008 & ISO - 14001 - 2004 Certified Organisation

Annexure 1.3 Work Orders & CCA for Authorised HW recyclers

~,~U'

GPCB

GU]ARAT POLLUTION CONTROL BOARDPARYAVARAN BHAVAN

Sector-10-A, Gandhinagar-382 021 .Website: www.gpcb.gov.in

4.2.1 The flue gas emission through stack attached to hoilerlurnaceiheater shall conform to thefollowing standards:

Stack Attached Stack Height InAir Pollution

Permissible IStackControl Parameter

No To Meter Limit IS\'Stem

I. Thermic Fluid --- Particulate Maner 150mgNmHeater

SO, 100 ppm

2.Furnace no. I

--- NO, 50 ppm&2

PM 50 mg/NW

30SO, 200 mg/NWNO, 400 mg/NW

captiveAlkali Scruhher

HCr, 50 mg/NM'3.

Incinerator CL, 09 mg/NM'HF 04 mg/NM'CO 100 mg/NM'

TOC 20 mg/NW4.2.2

5080408060100

Concentration in: Ambient air

Time WeightedAvera e

Annual24 Hours

Annual24 HoursAnnual24 Hours

Sulphur Dioxide (502), fig/m3

Nitrogen Dioxide (N02), fig/m3

Particulate Matter(Size less than 10 fun) OR PM I 0

/m3

Particulate Maner (Size less than 2.5 I ;(",lua-1 --- 40

mm) OR PM 2.5 m3 24 Hours 60

The applicant shall provide portholes, ladder, platform etc at chimney(s) for monitoring theair emissions and the same shall be open for inspection to/and for use of Board's staff. Thechimney(s) vents attached to various sources of emission shall be designed by numbers slichas 5-1, 5-2, etc. and these shall be painted/displayed to faei litate identification.The industry shall take adequate measures for control of noise levels from its own sourceswithin the premises so as to maintain ambient air quality standards in respect of noise to lessthan 75dB(a) during day time and70 dB (A) during night time. Daytime is reckoned inbetween6a.m. andlO p.m. and nighttime is reckoned between 10 p.m. and 6 a.m.The applicant shall provide proper ventilation and exhaust facilities so as to maintain healthyworking atmosphere within the factory premises.

4.

I.

2.

3.

4.4.

4.5

4.3.

55.1

GENERAL CONDITIONS:-

Any change in personnel, equipment or working conditions as mentioned in the consentsform/order should immediately be intimated to this Board.

2

Clean Gujarat Green GujaratISO - 9001 - 2008 & ISO - 14001 - 2004 Certified Organisation

~~,~U

GPCB6.


Sector-10-A. Gandhinagar-382 021.Website: www.gpcb.gov.in

AUTHORISATION FOR THE MANAGEMENT & HANDLING OF HAZARDOUSWASTES Form-2 (See rule 3 (c) & 5 (5)

Fonn for grant of authorisation for occupier or operator handling hazardous "aste

6.1 Number or authorisation: AWH-61732 Date or issue: 1810412014.

6.1.1 MIS. RELIANCE BARREL SUPPLY CO., is hereby granted an authorisation to operatefacility for following hazardous wastes on the premises situated at PLOT NO: 200/34, B/H.KASHIR TEXTILE MILL,NAROL-DIST,AHMEDABAD.

Sr.No.

I.

4

6

Waste Quantity

ETP Waste 900 KG/Yr

Distillation Residue 1200 KLlYr

Spent clay 180 MTlYearContaining Oil

Filters & Filtering 1200 KGlYrmaterials

Incineration Ash 180 MT/Yr

Discarded Container 24000 Nos./Yr

Oily Sludge 72 KLlYr

Used Oil 600 KLiMonth

Waste Oil 600 KLiMonth

ProcessCate"orv34.3

4.4

4.5

35,1

36.2

33.3

4.1

5.1(Reception)

5.2(Reception)

Facility

Co!lection, Storage,Transporlolion, Disposal af

rSDF approved hy board.Co!lection, Storage.Transportation. Di~posal b)'incineration at CHWIF facilityapproved hy hoard and/or atOl-vn Incineration.Collection. Storage,Trampor/ulion, Dhposa/ byincineration at CHWIF(acili(l'approved by board and/or atown Incineration.('allee/ion, Storage,Transportation, Disposal atrSDF avvroved by board.,

Co!lection, Storage,Transportation, Disposal orrSDF aV{Jl'ovedby board.Coliection, Storage,Decan/amino/;on,Transportation, Disposal bysellin£ /0 aUlhorised recvclerCollection. Storage,Transportation. Disposal hyincineration at CHWIF(acili(l'approved by board and/or atown Incineration..(~()liectio;,-,--- Storage,

Revrocessin£ within oremises

Coliection. Storage,Revrocessin't!,wilhin [Jremises

6.1.2 The authorisation is granted to operate a facility for collection. storage. within Ihe facIOi'!'premises, transportation and ultimate disposal of Hazardous wastes as mentioned above,

3 G .Clean Gujarat Green uJarat

ISO - 9001 - 2008 & ISO - 14001 - 2004 Certified Organisation

GU]ARAT POLLUTION CONTROL BOARDPARYAVARAN BHAVAN

Sector-1 a-A, Gandhinagar-382 021.

Website: www.gpcb.gov.in

6.15a)

6.1.3 The authorisation shall be in force for a period of 12/02/2019 trom Ihe date of application.6.1.4 The authorisation is subject to the conditions stated belov·,. and such other conditions as lllay

be specified in the rules from time to time under the Environment (Protection) Act-1986.

TERMS AND CONDITIONS OF AUTHORISATIONThe applicant shall comply with the provisions of the Environment (Protection) Act - In6and the rules made there under.

b) The authorisation shall be produced for inspection at the request of an officer authorized b)the Gujarat Pollution Control Board.

e) The persons authorized shall not rent, lend, selL transfer of othenvisc transport the hazardouswastes without obtaining prior permission of the Gujarat Pollution Control Board.

d) Any unauthorized change in personnel, equipment or working conditions as mentioned in theauthorisation order by the persons authorized shall constitute a breach of this authorisation.

e) It is the duty of the authorised person to take prior permission of the Gujarat Pollution ControlBoard to close down the facility.

I) An application for the renewal of an authorisation shall be made as laid dO\\11 in rule 5 (6) Iii).g) Industry shall have to mange waste, oil, discarded containers etc as per Kulcs 2008.h) Industry shall submit annual report within 15 days and sub sequently by 31" Jmluary ever)

y'ear.

NO: PC/CCA/ABD/NL-119/1D-13367/ '2-'2);) ~::,

Issued to:·~M/S. RELIANCE BARREL SUPPLY CO.,

PLOT NO: 200/34, B/H. KASHIR TEXTILE MILL,NAROL-DIST,AHMEDABAD.

For and on behalf ofClljarat Pollution COlltrol Board

~.%tEnvironmental Engineer

J):\ t> 2.h~ 'ro1~

Copy to:I. The Regional Officer. G.P.C.Soard. Ahmedabad with a request to carry out monitoring

sampling and inspection under the provisions of the Water Act 1974. Air Act. 1981& EP /let1986.

o Unit-I.

ISO - 9001 -

4

Clean Gujarat Green Gujarat

2008 & ISO - 14001 - 2004 Certified Organisation

Req. No: Sale Contract No: 40000376

ESSAR OIL LIMITEDP.O.Box No.24, KHAMBHALIYA, DIST:- JAMNAGAR, PIN - 361 305.Ph: 02833-241444, FAX: 02833-662977TIN GST No. 24100800560. TIN CST No. 24600800560.GSTIN No. 24AAACE0890P1ZF

ESSAR OIL LIMITED (REFINERY DIVISION)

Date: 07.12.2017SCRAP CONTRACT NO: 40000376

BUYER:9999900029M/s.Reliance Barrel Supply Co,200/34 Behind Kashiram Textile Mill, Narol,,,Ahmedabad, ,382405,Gujarat.

GSTIN No: 24ACLPJ1362R1Z7

Validity: 21.12.2017 To 31.12.2018

CONSIGNEE9999900029M/s. Reliance Barrel Supply Co,200/34 Behind Kashiram Textile Mill, Narol,,,Ahmedabad,,382405,Gujarat

TIN: 24075000663 DT. 01.10.2005

Dear Sir,With reference to your offer ref DIRECT OFFER dated and subsequent discussion we had with you we here by issue ourScrap Sale Contract for lifting of above scrap material on "AS IS WHERE IS BASIS" from our site subject to followingterms & conditions.

1.PRICES, TAXES & DUTIES

Sr No. Material Code Item Description Unit Qty. Rate in Rs. Amount(Rs.)10 4001010226 DISCARDED EMPTY DRUM PLASTIC

25LTRHSN:

NOS2,000.000

23.00 46,000.00

CGST@9% 4,140.00

SGST@9% 4,140.00

20 4001010056 EMPTY CONTAMINATED DRUMPLASTIC 200 LTR

HSN: 3923

NOS5,000.000

370.00 1,850,000.00

CGST@9% 166,500.00

SGST@9% 166,500.00


HSN: 3923

NOS10,000.000

38.00 380,000.00

CGST@9% 34,200.00

SGST@9% 34,200.00

40 4001010096 EMPTY CONTAMINATED DRUM MS200 LTR

HSN: 7310

NOS4,900.000

233.00 1,141,700.00

CGST@9% 102,753.00

SGST@9% 102,753.00

50 4001010106 EMPTY CONTAMIN DRUM PLASTIC35LTR SCRAP

HSN:

NOS10,000.000

32.00 320,000.00

CGST@9% 28,800.00

SGST@9% 28,800.00

60 4002070106 DRUM PAINT TIN SCRAPHSN: 7310

KG18,000.000

2.00 36,000.00

Regd. Office: Khambhalia Post, P.O. Box 24, Dist. Jamnagar, Gujarat - 361 305Tel. 02833 241444, Fax 02833 662977

Page1 of 3

CGST@9% 3,240.00

SGST@9% 3,240.00


HSN: 3923

KG 200.000 2.00 400.00

CGST@9% 36.00

SGST@9% 36.00


HSN: 3923

NOS1,000.000

18.00 18,000.00

CGST@9% 1,620.00

SGST@9% 1,620.00

90 4001010036 SCRAP EMPTY MDEA CONTAINERHSN: 7310

NOS 500.000 650.00 325,000.00

CGST@9% 29,250.00

SGST@9% 29,250.00


HSN: 3923

NOS1,000.000

120.00 120,000.00

CGST@9% 10,800.00

SGST@9% 10,800.00

110 4001010276 EMPTY CONTAMINATED#DRUMPLASTIC 30 LTR

HSN: 3923

NOS2,000.000

28.00 56,000.00

CGST@9% 5,040.00

SGST@9% 5,040.00

120 4001140936 DAMAGED DISCARDED EMPTYDRUMS MS 200L

HSN:

MT 10.000 1,550.00 15,500.00

CGST@9% 1,395.00

SGST@9% 1,395.00

130 4001140946 DAMAGED DISCARD EMPTY DRUMSPLASTIC 200L

HSN:

MT 5.000 1,550.00 7,750.00

CGST@9% 698.00

SGST@9% 698.00

140 4001140956 DAMAGED DISCARD EMPTY DRUMSPLASTIC 50L

HSN:

MT 2.000 1,550.00 3,100.00

CGST@9% 279.00

SGST@9% 279.00

150 4001140966 DAMAGED DISCARDED EMPTYDRUMS < 50 LTR

HSN:

MT 5.000 1,550.00 7,750.00

CGST@9% 698.00

SGST@9% 698.00 Total Basic Value(Rs.)

4,327,200.00 Total value of taxes 778,898.00

TAX COLLECTED SOURCE 51,061.00 Total Value incl. Taxes(Rs.)

5,157,159.00


Page2 of 3

2.PAYMENTS TERMS

ADVANCE AS PER ATTACHED ANNEXURE

3.SALE ORDER & INVOICES:

[1] FOR SALE ORDER : CONTACT PERSON : MR. VIPUL PANCHAL [M = 9925153654] [2] FOR PAYMENT / REFUND AND INVOICES : CONTACT PERSON : MR. SANJAY MEHTA [ACCOUNTS DEPT] [M = 9925150902]

4.DELIVERY ORDER & GATE PASS:

[1] FOR DELIVERY OF MATERIAL : CONTACT PERSON : MR. JATIN JOSHI [EOL-WAREHOUSE] [M = 9925206221] [2] MR. JOSEPH AUGASTIN [M # 9979891308]

5.Special Terms and Conditions

EOL also reserves the right to Cancel/Terminate/Modify the Contract at any time during the peroid with out assigning any reasonthereof.

You or a person duly authorized by you are requested to sign the duplicate copy of this letter in token of your acceptence to theabove terms & conditions and send it back to us.

For ESSAR OIL LIMITED

AUTHORIZED SIGNATORY

Thanking you,

Yours Sincerely,


Page3 of 3

Req. No: Sale Contract No: 40000411

NAYARA ENERGY LIMITEDP.O.Box No.24, KHAMBHALIYA, DIST:- JAMNAGAR, PIN - 361 305.Ph: 02833-241444, FAX: 02833-662977TIN GST No. 24100800560. TIN CST No. 24600800560.GSTIN No. 24AAACE0890P1ZF

NAYARA ENERGY LIMITEDFormerly known as Essar Oil Limited

Date: 18.07.2018SCRAP CONTRACT NO: 40000411

BUYER:9999900052M/s.RUBAMIN LIMITED,23, Shree Industrial Estate, Vill. Dunia, Halol, Dist.Panchmahal, Gujarat.,,,HALOL, VADODARA, ,389350,Gujarat.Suresh K.R.GSTIN No:

Validity: 08.08.2018 To 15.09.2018

CONSIGNEE9999900052M/s. RUBAMIN LIMITED,23, Shree Industrial Estate, Vill. Dunia, Halol, Dist.Panchmahal, Gujarat.,,,HALOL, VADODARA,,389350,GujaratSuresh K.R.TIN: 241711100251

Dear Sir,With reference to your offer ref dated and subsequent discussion we had with you we here by issue our Scrap SaleContract for lifting of above scrap material on "AS IS WHERE IS BASIS" from our site subject to following terms &conditions.

1.PRICES, TAXES & DUTIES

Sr No. Material Code Item Description Unit Qty. Rate in Rs. Amount(Rs.)10 4001010176 SPENT NIMO CAT WITH ALUMINA

BALL IN DRUMHSN: 3815 90 00

KG67,000.000

79.00 5,293,000.00

CGST@9% 476,370.00

SGST@9% 476,370.00Total Basic Value(Rs.)

5,293,000.00 Total value of taxes 952,740.00

TAX COLLECTED SOURCE 62,457.00 Total Value incl. Taxes(Rs.)

6,308,197.00

2.PAYMENTS TERMS

ADVANCE AS PER ATTACHED ANNEXURE

3.SALE ORDER & INVOICES:

[1] FOR SALE ORDER : CONTACT PERSON : MR. VIPUL PANCHAL [M = 9925153654] [2] FOR PAYMENT / REFUND AND INVOICES : CONTACT PERSON : MR. SANJAY MEHTA [ACCOUNTS DEPT] [M = 9925150902]

4.DELIVERY ORDER & GATE PASS:

[1] FOR DELIVERY OF MATERIAL : CONTACT PERSON : MR. JATIN JOSHI [EOL-WAREHOUSE] [M = 9925206221]


Page1 of *

All obligations/liabilities incurred prior to and which by their nature would continue beyond termination or expiration of this Order shall survive such termination or expiration.

<H>AMENDMENTS :</> Amendments, modifications or supplements to this order as agreed by the parties shall be effective only if made in writing and signed by authorized signatory/representative of the parties.

<H>JURISDICTION :</> All disputes arises relating to this Contract, if any, will be deemed to have arisen within the jurisdiction of the court at Jamnagar, Gujarat State.

<H>FORCE MAJEURE :</> Acts of Gods like floods, earthquakes and other occurrences such as war, riots etc., totally beyond the control of nayara energy/or BUYER shall only be considered as force majeure conditions.

Nayara Energy limited also reserves the right to Cancel/Terminate/Modify the Contract at any time during the peroid with outassigning any reason thereof.

You or a person duly authorized by you are requested to sign the duplicate copy of this letter in token of your acceptence to theabove terms & conditions and send it back to us.

For NAYARA ENERGY LIMITED

AUTHORIZED SIGNATORY

Thanking you,

Yours Sincerely,


Page10 of 10

Sr Quantity Hazardous Waste Type1 11.030 5.1 - Used or Spent Oil

1

Registration No: AWH 81987 till 16.09.2022

Transporter's Name & Address : 2 Reliance Barrels Supply Co., AHMEDABAD Ph: 9824090021

Transporter's Registration No : 3 AWH61732 valid till 12.02.2019

Vehicle No & Type : 4 GJ27U0777 - EICHER TEMPO

Waste Description & Codes :

Total Quantity :

Consistency :

Waste Description :

8

9

10

11

5.111.030 Metric Tonne

Semi-SolidUSED OIL

Designated Facility Name & Site Add:

Facility's Reg No with PCB :

Waste Type :

5

6

7

IND:Reliance Barrel Supply Company

PLOT NO:S.NO. 62-66......,JAMNAGAR-OKHA HIGHWAY(SH-25), PO BOX NO:24,VILL: VADINAR - 361305DIST : Devbhoomi Dwarka, TAL : Khambhalia , GIDC : Not In Gidc

27398 - Essar Oil Ltd. (Refinery Division)

Containers: 60

Occupier's Name & Mailing Address:

Signature

Occupier's Certificate : I hereby declare that the contents of the consignment are fully and accurately decribed above by proper shipping name and are categorised, packed, marked, and labeled, and are in all respects in proper condition for transport by road according to applicable national government regulations.

12

Name & Stamp of Industry Signature

13 Transporter Acknowledgement of Receipt of Wastes

Stamp of: Signature

14 Discrepancy Note Space

15 Facility Owner or Operator's Certification of Receipt of Hazardous Waste

Stamp of:

IND:Reliance Barrel Supply Company( Hazardous Waste Manifest )

To be forwarded by the occupier to the State Pollution Control Board or Committee.

11/05/2018

Manifest No: 703863

Copy 1

Date :

Date:

Date :

-

11/05/2018

Reliance Barrels Supply Co. 11/05/2018 0:00

IND:Reliance Barrel Supply Company

Recylable Waste

N I C1 ( Through XGN )29/09/2018

Annexure 1.4 Manifest copies for HW disposed to authorised recyclers

Sr Quantity Hazardous Waste Type1 24.220 4.2 - Spent Catalyst

1

Registration No: AWH81987 VALID TILL 16/09/2022

Transporter's Name & Address : 2 Saurashtra Trasport, PANOLI Ph: 7622002232

Transporter's Registration No : 3 -

Vehicle No & Type : 4 GJ37T8651 - TRUCK


Total Quantity :

Consistency :

Waste Description :

8

9

10

11


SolidSPENT NI-CO-MO CATALYST WITH CERAMIC BALLS



Waste Type :

5

6

7

IND:REFRACAST METALLURGICALS PVT LTD



Containers: 145


Signature


12



Stamp of: Signature



Stamp of:

IND:REFRACAST METALLURGICALS PVT LTD( Hazardous Waste Manifest )


16/04/2018

Manifest No: 691202

Copy 1

Date :

Date:

Date :

-

16/04/2018

Saurashtra Trasport 16/04/2018 0:00

IND:REFRACAST METALLURGICALS PVT LTD

Recylable Waste



1


Transporter's Name & Address : 2 Ambica Transport Services, Narol, A'BAD. Ph: 9824017404

Transporter's Registration No : 3 APPLIDE

Vehicle No & Type : 4 GJ12AU8579 - TRUCK


Total Quantity :

Consistency :

Waste Description :

8

9

10

11


SolidSPENT NI-MO CATALYST WITH ALUMINA BALLS



Waste Type :

5

6

7

IND:RUBAMIN LIMITED



Containers: 88


Signature


12



Stamp of: Signature



Stamp of:

IND:RUBAMIN LIMITED( Hazardous Waste Manifest )


29/08/2018

Manifest No: 746520

Copy 1

Date :

Date:

Date :

-

29/08/2018

Ambica Transport Services 29/08/2018 0:00

IND:RUBAMIN LIMITED

Recylable Waste



1


Transporter's Name & Address : 2 Self, Surendranagar Ph: 7984396487

Transporter's Registration No : 3 SELF

Vehicle No & Type : 4 GJ12Y9806 - TRUCK


Total Quantity :

Consistency :

Waste Description :

8

9

10

11


SolidSPENT ZnO CATALYST



Waste Type :

5

6

7

IND:BRAVO AGROTECH



Containers: 50


Signature


12



Stamp of: Signature



Stamp of:

IND:BRAVO AGROTECH( Hazardous Waste Manifest )


04/06/2018

Manifest No: 716117

Copy 1

Date :

Date:

Date :

-

04/06/2018

Self 04/06/2018 0:00

IND:BRAVO AGROTECH

Recylable Waste


Annexure 1.5 PESO Permissions

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All communications intendedfor this Office should be addressedto the 'Chief Con (roller ofExplosives' and NOT to hrm by

~~GOVl~RNMENTOF INDIA

tt~~~~eR:tI'l'1~=+1m.rr fct'Nl~cij)~m ~Petroleum and Explosives Safety Organisation

(jcf 7f11- f4i(:q>]c CJj fiNrTT)(Formerly- Department of Explosives)

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Wft;rtt~, ~-440 006 (lfflJ.)Seminary Hills, Nagpur- 440006

~/No. P-5(2) 150IRefinery/IV/Expansion

~ ~ /Nagpur, dated 30110,2008.

To, '.Mis. Essar Oil Limited,P.O. Box No. 24, Head P.O. Khambhalia,Distt. Jamnagar 361 305 (Guj.).

Sub: Expansion of existing refinery capacity from 10.50 MMTPA to 34 MMTPA approval 0[.

Deer Sirs,

Reference your letter No. EOLIRefinery-Expn.lPhl & Ph2/2008 dated 07108/2008.

Overall key plan No. 0010011R-00, overall plot plan No. 0010081R-OB and overall plot plan forCOT area tankages bearing no. OOlOOllR-A submitted with your letter under reference showing theexpansion of existing refinery capacity to 34 MMTPA meets with the approval of this office with thefollowing conditions :-

1) A separate approval for laying of pipelings from Jetty to COT area and COT Area to refineryshould be taken on finalisation of detailed engineering and approval of 2nd SBM.All existing and operating process units and storage tanks of petroleum shall be dulyseparated from construction activity of incoming process units by providing screenwalls/barricading and gas free permit systems as per OISD 105 standard shall be strictlyobserved.All proposed floating roof tanks (8 Nos.) each of 120000 KL of COT .Areashal1 be providedlinear heat detection system for rim-seal fire on permitting height of dyke upto 2.75 meters asdesired and accepted under provision clause of condition 3(i) of licence in form XV.

2)

3)

A copy each of the drawing duly approved is forwarded herewith.Yo

( Ajai Nigan )Chief Controller ofExplosi es

Copy to :-

1) The Jt. Chief Controller of Explosives, West Circle, Mumbai.

2) The Dy. Chief Controller of Explosives, Baroda.

Chief Controller of Explosives

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Annexure 1.6 ERDMP

MOCK DRILL REPORT(LEVEL-1)


NAYARA ENERGY LIMITED , VADINAR

REPORT NO- ERDMP/MD/2018-19/07

Doc. No. - NAYA/HSEF/FIRE/R/032 Rev-02.00 19.09.2018 Page 1 of 14

Date : 27.08.2018

Plant /Unit : FCCU

Location : Main Fractionator Column Area

Equipment : HCO Pump Around Pump 35 P 104 S

Scenario:-

Large leakage hot HCO from pump discharge immediate flange of HCO Pump Around Pump 35 P 104 S above auto ignition temperature of the fluid.

The first isolation valve MOV # 35 HZV 152 got stuck up and could be closed only about 90 %.

Subsequently, it catches fire as it is operating above AIT resulting in jet fire of about 25 mtrs. height flame is seen.

Process Conditions Temp- 320-330 ºC , Pressure – 9.0 – 10.0 Kg/Cm² , Flow – 450 M3 /Hr , Density – 950 Kg/ m3

Hold up volume - 100.0 m3 , Auto Ignition Temp- 260 ºC

Hold up that will leak before suitable action is taken (20 Min) – 0.5 m3

Composition - Heavy Cycle Oil

Casualty -01 One contract workmen who was working nearby got engulfed in the jet fire ,got major burn injuries, and collapsed on the ground.

Time of Initiation : 15:13:00 Hrs. Time of Alarm : 15:13:45 Hrs

Time of “All Clear” : 15:29:32 Hrs. Total Duration of Drill: 16 Min 32 Sec

Observers

S.N. Observer's location Name 1 Emergency Site - Site Incident Controller (SIC) Shri Mahesh Savaliya ,Head– Safety

2 Emergency Site- Operations & Maintenance Shri Krishnakumar S.,GM – Process

Annexure 1.7 Mock Drill






3 Refinery Fire Control Room Shri Sanjiv Kumar , JGM- Instrumentation

4 CCB Control Room-DCS -Panel Shri Vinod Sagar , DGM – Operations , DHDT 5 Emergency Site – Security / Medical Services Shri Amitrajit Sengupta ,JGM- HR 6 Emergency Site – Fire Services Shri Ramkrishna Paramhans ,JGM– Mechanical 7 Mock Drill – Co-Ordinator Shri Himanshu S. Mishra , DGM –HSEF

Emergency Management Team

Site Incident Controller : Shri Madhusudhan C., GM-Ops. & A M –NHT/CCR/CDU2

Refinery Shift Manager : Shri Rahul Wani

Area Manager : 1. Shri Nelakanthi Murthy , Area Manager

2. Shri Dipesh Modi , JGM- Operations 3.Albert S.–JGM -Operations

Shift –In-Charge (Operation) : 1. Shri Ramesh Chaudhary

Maintenance Manager : 1. Shri Rajnish Verma , Mechanical 2. Shri Chintan Patel – Mech

3. Shri Chinna Pillai , Instruments 4. Shri Anand Vijay Kumar , Electrical

Fire Officer : 1.Shri Ankit R. Kapupara,

Security Officer : 1. Shri Ramesh Bhonsle

Panel Officer : 1. Shri Rajnikant Patel 2. Shri Ranmal Modvadia

Field Engineer : 1. Shri Nikhil Chauhan , Main Fractionation Area

2.Shri Antu Savalia , RR Area , 3. Shri Nirmal Patel , MAB

4. Shri Pravin Kumar , Gascon -1 Area 5.Shri Ashwin Kumar – Gascon 2

Admin Co-ordinator :- 1. Major (Retd) Vikram Sinha

Auxiliary Fire Squad :- Shri Arpan Shah- Lab

Trained First Aider :- Shri Rahul Rakholiya –Lab

Injury, if any: - : 01 (Contract Workman)






Mock Drill Chronology

Time Actions 15:13:45 Hrs

Flame detector # 34 AT 311 got activated. Panel Officer Rajnikant Patel alerted Field Officer Shri Nikhil Chauhan, MF Area.

15:13:45 Hrs

MCP 34 HS 208 was activated by Shri Nikhil Chauhan , Field Officer, hooter and beacon activated, fire alarm received at FCCU Panel and the same got repeated at Refinery Fire Station.

15:13:45 Hrs Shri Rajnikant Patel , Panel Officer ,FCCU , informed fire control room about “ Large leakage and Fire in hot HCO from pump discharge immediate flange of HCO Pump Around Pump 35 P 104 S in MF Area.”on emergency number 1111.

15:13:45 Hrs

Shri Ranmal Modvadia ,Panel Officer, FCCU made announcement in Hindi / English/Gujarati “Large leakage of hot HCO from pump discharge immediate flange of HCO Pump Around Pump 35 P 104 S in MF Area , stop all jobs and evacuate .”

15:14:00 Hrs

Evacuation of all non - essential personnel from FCCU started. All occupants evacuated to Safe Assembly Point within two minutes.

15:14:00 Hrs Throughput for FCCU was decreased by Panel Officer. 15:14:00 Hrs HCO Pump around Pump 35 P 104 S stopped and isolated. 15:14:00 Hrs Feed to FCCU was stopped and safe shut down of the unit was taken. 15:14:02 Hrs

Foam Tender FT-04 with crew followed by Ambulance and Shift Fire Officer Shri Ankit R. Kapupara in Fire Jeep J6 ,turned out from Refinery Fire Station.

15:14:02 Hrs

Simultaneously, Dry Chemical Powder (DCPT-01) with crew turned out from Auxiliary Fire Station, CPP.

15:14:59 Hrs Foam Tender FT-02 with crew followed by Ambulance and Shift Fire Officer Shri Ankit R.Kapupara in Fire Jeep J6 arrived at incident site from Refinery Fire Station.

15:15:00 Hrs Water Spray System DV # 14 for hot pump area was operated by Shri Ranmal Modvadia ,Panel Officer from DCS.

15:15:00 Hrs

Shri Ramesh Chaudhary ,Shift In Charge - Operations arrived at incident site and took control of the situation.

15:15:00 Hrs The first isolation valve MOV # 35 HZV 152 was closed by the Panel Officer , but it got stuck up and could be closed only about 90 %.

15:15:00 Hrs

One contract worker- helper who was working nearby, got engulfed in jet fire, got severe burn injury and collapsed on the ground. He was spotted in MF Area and was shifted to a safe area by Mr. Antu Savalia and Mr. Albert S.

15:15:00 Hrs

Fire Crew donning SCBA sets and single layer inherent fire resistant (IFR) Nomex Suits carried out search and rescue.

15:15:00 Hrs Foam application by Foam Tender, over jet fire, by Fire Crew started . 15:15:00 Hrs

Security – Patrolling officer Shri Ramesh Bhonsle with QRT team -08 guards arrived at the incident site. Cordoned and evacuated the area. Regulated traffic.

15:15:10 Hrs Dynamic Blast Call (Group 4) – phone activated by Fire Control Room operator to






inform all primary responders. 15:15:50 Hrs

DCP Tender DCPT-01 with crew arrived at incident site from Auxiliary Fire Station- CPP and took position on south side of FCCU.

15:16:00 Hrs

Shri Rahul Wani , Refinery Shift Manager (RSM), arrived at incident site and supported the Site Incident Controller (SIC).

15:17:28 Hrs

Dynamic Blast Call (Group 1) – phone activated by Fire Control Room operator to inform all primary responders.

15:18:00 Hrs The casualty was shifted to OHC by Ambulance and was accompanied by an employee.

15:19:00 Hrs Incident Site Area was effectively barricaded by Operations team. 15:20:00 Hrs One DCP 9 Kgs Stored Pressure type fire extinguisher was operated by Shri Nikhil

Chauhan, Field Officer. 15:20:00 Hrs

Shri Nelakanti Murthy , Area Manager – FCCU arrived at incident site and took control of the situation.

15:20:00 Hrs Shri Madhusudhan C. , GM – Operations and Area Manager – NHT/CCR /CDU-2 arrived the incident site and took charge as Site Incident Controller (SIC).

15:20:00 Hrs Mechanical Maintenance Team with Shri Chintan Patel , Rajnish Verma along with Riggers -02 and Supervisor -01 arrived at incident Site with flame proof tool kit.

15:20:00 Hrs Instrument Maintenance Team with Shri C. Pillai along with one Instrument Technician arrived at incident Site with tool kit.

15:20:00 Hrs Electrical Maintenance Team with Shri Anand Vijaykumar along with one Electrical Technician arrived at incident Site with tool kit.

15:22:00 Hrs

Shri Dipesh Modi , JGM-Operations arrived at incident site and took control of the situation.

15:22:00 Hrs

Auxiliary Fire Squad - Shri Arpan Shah- Lab and Trained First Aider Shri Rahul Rakholiya –Lab, arrived at incident site and reported to Shift Fire Officer. Later they helped in emergency handling.

15:23:00 Hrs MOV # 35 HZV 152 was isolated with the help of Maintenance Team. 15:24:00 Hrs Second Ambulance arrived at Incident Site. 15:25:00 Hrs Site Incident Controller took feedback about the injured person from OHC. 15:26:00 Hrs Fire under control. Water spray application continued for structural cooling. 15:26:00 Hrs Fire crew searched the area once again for any more casualty. 15:28:00 Hrs Head Count report given by Security Officer Shri Ramesh Bhonsle – at Assembly

Point and incident site – Contract workmen- 40 , Employees – 16 , Casualty -01(Contract Workman ) ,Visitor – Nil , Total- 57 personnel.

15:28:32 Hrs Fire extinguished completely. 15:29:00 Hrs LEL checked by Fire Crew and Operations team as well – Nil. 15:29:32 Hrs All Clear – declared by Shri T.Chandrashekhar Site Incident Controller (SIC) 15:30:00 Hrs Knock Off and make up ordered for Fire Crew. 15:33:42 Hrs Dynamic Blast Call (All Clear ) – phone activated by Fire Control Room operator to

inform all key personnel. It worked well.






15:45:00 Hrs Debriefing Session was held at FCCU Check & Change Room Pantry. 24 employees participated.

Head Count

Personnel Reported for Duty on the day / shift

Actual head count at incident site

Head count Safe Assembly

Points

Total head count

Employees 16 10 06 16 Contract Workmen 41 05 35 40 Casualty / Injured Nil 01 Nil 01 Visitors Nil Nil Nil Nil Total 57 16 41 57

41

16

0

0

57

40

16

1

0

57

0 10 20 30 40 50 60

CONTRACT WORKMEN

EMPLOYEES

Casualty / Injured

VISITORS

TOTAL

HEAD COUNT TALLY - FCCU - 27.08.2018

Actual head count during incident Present on date






Evaluation Sheet # 1

Location :- Refinery Fire Station Control Room

Observer :-– Shri Sanjiv Kumar , JGM - Instrumentation

The observers assessment was based on the following Actions Events

Fire Control Room Events Time & Date of call : 15:13:45 Hrs on 27.08.2018 Mode of call ( Incident Information received ) :- MCP/Gas Detector/ Toxic gas detector/Heat/Smoke

Flame Detector – 34 AT 1311 MCP # 34 HS 208

Telephone / Hotline/ Landline/ CUG/wireless/Messenger/

From 1711 to 1111

Record Name of Caller: Shri Rajnikant Patel , PO-FCCU Information to :- (All below information to be conveyed within 3 minutes time.) Information to Yes / No Marks (max) Evaluation Remarks

Shift Fire Officer Yes 1 1 Turnout crew / Turn out bell Yes 2 2 Dynamic Blast Call – (Primary Responders/Secondary Responders & Key Personnel as per level of Emergency ; All Clear) First Turn Out – Group 4 Yes 4.5 4.5

Level1 Yes 5 5

Level2 ------ ------ ------ Not required L1

All Clear Yes 2 2

Panel Officer of affected unit Yes 1 1 In case of failure of Dynamic Blast Call Inform all key personnel of Group-4 as per Dynamic Call Blast annexure. ------ ------ ------ Not required

Inform affected Plant/Unit Panel Officer to communicate all key personnel of Operations & Maintenance for help.

------ ------ ------ Not required

Inform Head – Laboratory to mobilise Auxiliary Fire Squad and Trained First Aiders ------ ------ ------ Not required

In case of declaration of level 2 and higher emergency level Emergency Siren actuation ( As per direction of SFO)

Level 2 Level 3 All Clear ------ ------ ------ Not required L1

Mutual Aid Members ( As per direction of SFO) ------ ------ ------ Not required L1

Total- 15.5 15.5







Location :- Respective Plant / Unit Process Central Control Building (CCB)

Observer :-– Shri Vinod Sagar , DGM – Operations (DHDT)

Respective Plant / Unit Process CCB Control Room Events Events Time & date of call 15:13:45 Hrs on 27.08.2018 Mode of call ( Incident Information received ) :- MCP/Gas Detector/ Toxic gas detector/Smoke detector

Flame Detector – 34 AT 1311 MCP # 34 HS 208

Telephone: Landline/ CUG/wireless/In person

Walkie Talkie

Record Name of Caller from whom information received :

Shri Nikhil Chauhan , Field Officer , MF Area

Information to :- (All below information to be conveyed within 3 minutes time.)

Information to Yes / No Marks (max) Evaluation Remarks Shift In Charge - Operation Yes 1 1

Refinery Fire Station ( Hot Line / Ext -1111) Yes 2 2 Announcement on PA system in three languages ( Hindi, English, Gujarati ) for stopping all the jobs & evacuation

Yes 1 1

Area Manager Yes 1 1 WWTF ( Utility ) Yes 1 1 Emergency Control Actions :- Execution of Emergency Control actions on DCS.

Yes 2 2

Information to upstream / downstream / neighboring units / other stake holders Yes 1 1

Announcement on PA system in three languages ( Hindi, English, Gujarati )- All Clear

Yes 1 1

Total- 10 10







Location :- Incident Site – FCCU

Observer :-– Shri Krishnakumar S., GM – Process

Actions by Operations team at Incident Site Events Yes / No Marks (max) Evaluation Remarks Call Initiation – MCP / Emergency No. Yes 2 2

Sounding of Local Siren / Hooter Yes 1 1 Alert other people around in nearby units/ facilities – as per emergency conditions Yes 1 1

Stop Hot /cold jobs Yes 1 1

Casualty search and initial handling by operation team /AFS Yes 1 0.5

Casualty handling not proper

Equipment isolation, valve closing as per SOPs Yes 2 2

DCS control, instruction issued to Field Yes 1 1 Fire & Gas detection system available & their performance Yes 2 2

Fire Extinguishers available & used. Their performance Yes 2 2

DCP-09 Kgs -01 Operated.

Hydrant/Monitor used and their performance Yes 2 2

Deluge System (DV) / Water spray and their performance Ok 4 4

Tower mounted Elevated Long Range Monitor and its performance Ok 4 4

Did not operate as per site evaluation

Assemble at Safe Assembly Point. Yes 1 1

Direction to Fire Services / Emergency Responders and necessary information Yes 1 0

Fire Crew was not directed towards casualty.

SCBA set / BA Trolleys used & their performance Yes 1 1

Environment related actions – Information to WWTF / Environment Yes 1 1

Communication by Shift Incharge - Operations to all concerned as per Incident Communication Protocol – RSM , SFO

Yes 1 1

Communication by Area manager to all concerned as per Incident Communication Protocol- Head – ISBL, Head- EPS , Lead – Maintenance- Mech,Elect, Inst,Civil

Yes 2 1

PPE's Helmet/Safety shoes/ gloves/ goggles / Earplugs Yes 1 1

Total 31 29.5






Evaluation Sheet # 3A


Observer :-– Shri Krishnakumar S., GM – Process

Actions of Maintenance Team at Incident Site

Timely response of Maintenance Team with tools & tackles & manpower(Max- 8 Min for Base Refinery, 12 Minutes for Train -1 units and off sites , 20 Minutes for COT)

06 Min 15 Sec

2 2

Use of proper tools & tackles – flame proof / precautions/ PPEs as per TBRA Yes 2 2

Mechanical Maintenance Team with flame proof /Adequate Tool Kit and Manpower Yes 2 2

Two Engineers Sup-01 Riggers-02

Electrical Maintenance Team with flame proof /Adequate Tool Kit and Manpower Yes 2 2 One Engineer

One Technician Instruments Maintenance Team with flame proof /Adequate Tool Kit and Manpower Yes 2 2 One Engineer

One Technician Civil Maintenance Team with flame proof /Adequate Tool Kit and Manpower No NR NR Not required as per

site evaluation Inspection Team with adequate tool kit / manpower

No NR NR Not required as per site evaluation

Special PPE's – HR Suits , SCBA sets , BA Trolley Yes 2 2

TOTAL 12 12







Location :- Incident Site – FCCU , Observer :-– Shri Mahesh Savalia ,Head- Safety

Actions by SITE INCIDENT CONTROLLER (SIC) Events Yes / No Marks (max) Evaluation Remarks Response Time (Max- 4 Min for Base Refinery, 6 Minutes for Train -1 units and off sites/VPCL, 20 Minutes for COT)

02 Minutes 15 Sec 3 3

RSM – 02 min 15 Sec SIC – 06 Min 15 Sec

Co-Ordination with Emergency Responders :- Fire Coordinator – Fire & rescue operations , Special Services

Yes 2 2

Security & Evacuation Co-Ordinator : Head Count / Traffic Control / Mob Control Yes 2 2

Medical Team- Casualty shifting and handling at OHC , further actions Yes 2 2

Emergency Support Co-Ordinator – Mobilisation of Auxiliary Fire Squad(AFS) ,Trained First Aiders (TFA)

Yes 1 1 AFS -01 TFA-01

Unit /Plant Operations – Fuel / Energy/Toxic isolation, Safe Shut Down, Emergency Control Actions / Environment related actions.

Yes 4 4

Maintenance Team – Leak Sealing, Insulation removal , Power Isolation , Heavy Equipment Mobilization, Lighting, Dewatering , hot bolting etc.

Yes 2 2

Utility Team – Fire Pump Operation , Hydrant System Pressure , Water Make Up , Steam , Nitrogen , Plant Air etc.

Yes 1 0 Did not communicate

Incident Command & Control :- Sizing up the situation – Overall effective emergency response & control actions Yes 3 3

Communication - with Fire /Security/Operation / Maintenance Yes 3 3

Overall Incident Command and control skill Yes 3 3

Declaration of "All Clear" (in consultation with other Emergency Responders & CIC , after final Search & Rescue , LEL / Toxic Gas Check.)

Yes 1 1

Jacket & PPE's including SCBA / Escape set (ELSA) Yes 1 1

Communication :- Communication by Refinery Shift Manager as per Incident Communication Protocol – Head- Operations/Head –Technical Services/Head-HSEF/Head-Maintenance/Head- CPP &U.

Yes 2 2

Communication by Site Incident Controller as per Incident Communication Protocol – Head- Technical

Yes 1 1 Debriefing at Safe Assembly Point -of all employees, Contract Workmen and Visitors

Yes 2 0 Did not communicate

Total- 33 30






Evaluation Sheet # 5 Location :- Incident Site – FCCU

Observer :-– Shri Ramkrishna Paramhans , JGM - Mechanical

Actions by FIRE CREW

Events Yes / No Marks (max) Evaluation Remarks

Response Time (Max- 3 Min for Base Refinery, 6 Minutes for Train -1 units and off sites , 20 Minutes for COT from RFS)

01 Minutes

14 Seconds 3 3

FT-02 DCPT-01 J6

Proper approach and Parking of Fire tender Yes 1 1

Utilization of Auxiliary Fire Squad & Trained First Aiders Yes 2 2

Fire Extinguishing Media application & its effectiveness Yes 2 2

Search and Rescue Yes 3 2 The casualty was left unattended for some time.

Help to Operations / Maintenance personnel for closing /opening the valves for isolation etc.

Yes 1 1

Command & Control of the Fire crew and fire-fighting/ Emergency operations

Yes 2 1 Needs improvement

Method and speed of Action Yes 2 2

Co-ordination with SIC/ Shift In Charge /RSM by Fire coordinator. Yes 1 1

Feedback by Fire Coordinator to Refinery Fire Control room. Yes 1

1

Fire Fighter appropriate PPE's used - Fire Suits / Chemical Suits / SCBA / Gum Boot etc.

Yes 4 4

Mobilisation of additional resources – Fire Tenders , Manpower , Special equipments , SCBA sets , Trailer Mounted HVLRMS etc.

Yes

5 5

27 25








Observer :-– Shri Amitrajit Sengupta , JGM – HR

Actions by Security team


Response Time (Max- 6 Min for Base Refinery, 10 Minutes for Train -1 units and off sites/ VPCL , 20 Minutes for COT from Refinery)

01 Minutes 15

Sec 2 2

Road Clearing/Barriers clearing. Yes 0.5 0.5

Proper approach, cordoning off area Yes 1 1

Report to SIC/RSM/Shift- In-Charge -Operation Yes 0.5 0.5

Facilitate Evacuation of Non- Essential Personnel Yes 1 1

Head count Done 2 2

Traffic Control at entry and exit points Yes 1 1

Removal of unwanted vehicles Yes 0.5 0.5 Help in Controlling Emergency Yes 0.5 0.5

PPE's Helmet/Safety shoes/gloves/goggles/Earplugs /SCBA etc

Yes 1 1

Total- 10 10

Actions by OHC - Medical team Response Time (Max- 3 Min for Base Refinery, 6 Minutes for Train -1 units and off sites/VPCL , 20 Minutes for COT )

01 Minutes 14

Seconds 1 1

Parking Ok 1 1 Casualty Shifting Ok 2 2 Mobilizing other Ambulances and treatment at OHC Ok 1 1

Total- 5 5






Emergency Responders Performance Rating

Sr. No. Emergency Responder

Marks obtained Full Marks

Marks obtained %

Rating

1 FIRE SERVICES 40.5 42.5 95.29% Excellent

2 OPERATION 39.5 41 96.34% Excellent

3 MAINTENANCE 12 12 100.00% Excellent

4 OCCUPATIONAL HEALTH SERVICES

5 5 100.00% Excellent

5 SECURITY 10 10 100.00% Excellent

6 SITE INCIDENT CONTROLLER (SIC)

30 33 90.91% Very Good

TOTAL 137 143.5 95.47 %

Overall Rating 95.47 % EXCELLENT

Rating Criteria 95 to 100 % Excellent 75 to 84.99 % Good Less Than 70% Needs improvement 85 to 94.99 % Very Good 70 to 74.99 % Average

95.29%96.34%

100.00% 100.00% 100.00%

90.91%

FIRE SERVICES OPERATION MAINTENANCE OCCUPATIONAL HEALTH SERVICES

SECURITY SITE INCIDENT CONTROLLER (SIC)

OVERALL RATING -95.47 %

PERFORMANCE OF EMERGENCY RESPONDERS , MOCK DRILL ,LEVEL-1 , FCCU , 27.08.2018






Some of the good points / strengths observed

1. All Communication was done as per new procedure for Incident Communication. 2. Fire protection systems- Fire Extinguishers / Fire Hydrants / Water Monitors/ Water

Spray Systems were actually operated and they worked well. 3. Refinery Shift Manager and Site Incident Controller were very active and had very good

incident command & control. 4. All Fire crew were donning SCBA sets and three layer Inherent Fire Resistant (IFR)

Nomex Suits.

Discussion Points

1. The casualty was left unattended for some time and Fire Crew was not informed to rescue the casualty initially,

2. Site Incident Controller did not address employees and Contract Workmen assembled at Safe Assembly Point and did not appraised them of the incident.

3. Identification for different Emergency Responders viz Maintenance Team.

Areas for Improvement

Sr. No.

Observation Recommendation Responsibility Target Date

1. Nil Nil Nil Nil

This report shall be discussed in next Area Safety Committee Meeting.

……………………..END OF REPORT……………………….






Date : 25.07.2018

Plant /Unit : LABORATORY

Location : ELECTRICAL ROOM

Equipment : Distribution Board LAB NP-5614 A/B

Scenario:-

Fire in Distribution Board of Electrical Room in the Laboratory, causing dense smoke; which is suck by the HVAC inlet and the smoke spreads all over the Laboratory through HVAC duct. This warrants immediate evacuation of the Laboratory Building.

Building Description

Laboratory Building consists of GC Lab , R&D Lab , Expansion Lab , Water Lab , Petroleum Section Lab , Sample Retention Room , Sample Bottle Washing Area , Electrical Room , ATF Lab, TBP Engine Room Floor Area of the Building ( Approx) - 2500 Square Mtrs.

Nos. of Occupants ( Approx) – 50

Occupant Density (Approx.) – 50 Sq. Mtrs / Person

Nos. of Exits – 5

Casualty -01 One Lab Chemist in the nearby Petro Lab got exposed to toxic smoke and collapsed on the ground.



Observers

S.N. Observer's location Name 1 Emergency Site - Site Incident

Controller (SIC) Shri Anil Vishwambharan, Head– CRG






2 Emergency Site- Operations & Maintenance

Shri Ashish Kumar Sen, JGM-Security

3 Refinery Fire Control Room Shri Amit Kumar Parmar, Sr. Manager – Instrumentation

4 Laboratory Shift Incharge Room Shri Himanshu S. Mishra , DGM –HSEF

5 Emergency Site – Security / Medical Services

Shri IVN Raju, DGM- Operations , Utility 2 Base

6 Emergency Site – Fire Services Shri Sudhir Ingle , Head -Fire 7 Mock Drill – Co-Ordinator Shri Himanshu S. Mishra , DGM –HSEF

Emergency Management Team

Site Incident Controller : Major Vikram Sinha , Head- Administration

Refinery Shift Manager : Shri Samir Bhowmick

Area Manager : 1. Dr. Pradeep Prabhu, Area Manager

2. Shri Dhiraj Gondalia , JGM- Technical Services

Shift –In-Charge (Operation) : 1. Shri Divyesh Desai

Maintenance Manager : 1. Md. Amir Khan , Electrical

Fire Officer : 1.Shri Y.B.Zala 2. Shri Karthik M.I. , 3. Shri Shivam Tripathi

Security Officer : 1. Shri Virender Singh

Lab Chemist ( Communication) : 1. Shri Bhowmick Kaneria

Lab Chemist : 1. Shri Rajesh Butani, 2. Milan Nathwani

3. Mahesh Jesadia

Auxiliary Fire Squad : 1. Shri Sanjay Prajapati , FCCU

Injury, if any: - : 01 (Employee) Shri Chintan Patel







Time Actions 11:46:00 Hrs Emergency Scenario activated by Laboratory team after the scenario was

explained to the Lab Chemist Shri Mahesh Jesadia by Observers. 11:46:18 Hrs

MCP 57 HS 1003 was activated by Shri Mahesh Jesadia , Lab Chemist, hooter and beacon activated and the same got repeated at Refinery Fire Station.

11:46:18 Hrs Shri Bhowmick Kaneria , Lab Chemist , informed fire control room about “ Fire in Electrical Room ” on emergency number 1111.

11:46:18 Hrs

Evacuation of all non - essential personnel from Laboratory started. All occupants evacuated to Safe Assembly Point within two minutes.

11:46:40 Hrs

Multi Purpose Fire Tender (MPFT) with crew followed by Ambulance and Shift Fire Officer Shri Y.B.Zala in Fire Jeep J6 ,turned out from Refinery Fire Station.

11:46:58 Hrs

Simultaneously, Dry Chemical Powder (DCPT-01) with crew turned out from Auxiliary Fire Station, CPP.

11:47:00 Hrs One CO2 9 Kgs fire extinguisher was operated by Shri Ashish Dhamsania , Lab Chemist.

11:47:15 Hrs

Dynamic Blast Call (Group 4) – phone activated by Fire Control Room operator to inform all primary responders. It worked well.

11:47:30 Hrs

Shri Divyesh Desai ,Shift In Charge – Laboratory arrived at incident site and took control of the situation.

11:48:20 Hrs Multi Purpose Fire Tender MPFT with crew followed by Ambulance and Shift Fire Officer Shri Y.B.Zala in Fire Jeep J6 arrived at incident site from Refinery Fire Station.

11:49:00 Hrs

Fire Crew donning SCBA sets and single layer inherent fire resistant (IFR) Nomex Suits carried out search and rescue.

11:49:00 Hrs

Shri Samir Bhowmick , Refinery Shift Manager (RSM), arrived at incident site and supported Site Incident Controller (SIC).

11:49:10 Hrs

One Lab Chemist in the nearby Petro Lab got exposed to toxic smoke and collapsed on the ground. He was rescued by Laboratory personnel, given safety shower and taken to OHC by Ambulance with the help of Fire Operators.

11:49:53 Hrs

DCP Tender DCPT-01with crew arrived at incident site from Auxiliary Fire Station- CPP and took position on east side of Lab.

11:50:00 Hrs

Security – Patrolling officer Shri Virendra Singh with QRT team -06 guards arrived at the incident site. Cordoned and evacuated the area. Regulated traffic.






11:52:00 Hrs

Level-1 declared & Dynamic Blast Call (Group 1) – phone activated by Fire Control Room operator to inform all primary responders. It failed.

11:52:00 Hrs Major (Retd.) Vikram Sinha arrived at incident site and took charge as Site Incident Controller(SIC).

11:54:00 Hrs Site Incident Controller took feedback about the injured person from OHC. 11:54:00 Hrs Electrical Maintenance Team with Shri Amir Khan along with two Electrical

Technician arrived at incident Site with tool kit and carried out electrical isolation from nearby Sub Station ES - 53

11:56:00 Hrs Fire under control. 11:56:00 Hrs Fire crew searched entire laboratory area including terrace once again for any

more casualty. No more casualty found. 11:58:00 Hrs Fire extinguished completely. 11:58:00 Hrs Head Count report given by Security Officer Shri Virendra Singh – at

Assembly Point and incident site – Contract workmen- 16 , Employees – 59 , Casualty -01(Employee ) ,Visitor – 02 , Total- 78 personnel.

12:00:15 Hrs All Clear – declared by Major (Retd.) Vikram Sinha ,Site Incident Controller (SIC)

12:01:00 Hrs Knock Off and make up ordered for Fire Crew. 12:02:18 Hrs Dynamic Blast Call (All Clear ) – phone activated by Fire Control Room

operator to inform all key personnel. It worked well. 12:03:00 Hrs Site Incident Controller Major (Retd.) Vikram Sinha addressed the employees

and Contract Workmen assembled at Safe Assembly Point and appraised them of the incident and the emergency control measures and that it was safe to go back to work now.

12:10:00 Hrs Debriefing Session was held at LAB – Pantry Room.28 employees participated.






Head Count

Personnel Reported for Duty on the day / shift

Actual head count at incident site

Head count Safe Assembly

Points

Total head count

Employees 59 03 55 58 Contract Workmen 17 00 17 17 Casualty / Injured Nil 01 Nil 01 Visitors 02 Nil 02 02 Total 78 04 74 78

17

59

0

2

78

16

59

1

2

78

0 10 20 30 40 50 60 70 80 90

CONTRACT WORKMEN

EMPLOYEES

Casualty / Injured

VISITORS

TOTAL

HEAD COUNT TALLY - LAB - 25.07.2018

Actual head count during incident Present on date







Location :- Refinery Fire Station Control Room

Observer :-– Shri Amit Kumar Parmar , Sr. Manager – Instrumentation.

The observers assessment was based on the following Actions Events

Fire Control Room Events Time & Date of call : 11:46:18 Hrs on 25.07.2018 Mode of call ( Incident Information received ) :- MCP/Gas Detector/ Toxic gas detector/Heat/Smoke

MCP # 57 HS 1003

Telephone / Hotline/ Landline/ CUG/wireless/Messenger/

From 1727 to 1111

Record Name of Caller: Shri Bhowmick Kaneria , Lab –Chemist.

Information to :- (All below information to be conveyed within 3 minutes time.) Information to Yes / No Marks (max) Evaluation Remarks

Shift Fire Officer Yes 1 1 Turnout crew / Turn out bell Yes 2 2 Dynamic Blast Call – (Primary Responders/Secondary Responders & Key Personnel as per level of Emergency ; All Clear)

First Turn Out – Group 4 Yes 4.5 4.5 Blast call failed 5 times.

Level1 Yes 5 5

Level2 ------ ------ ------ Not required L1

All Clear Yes 2 2

Panel Officer of affected unit Yes 1 1 In case of failure of Dynamic Blast Call Inform all key personnel of Group-4 as per Dynamic Call Blast annexure. ------ ------ ------ Not required

Inform affected Plant/Unit Panel Officer to communicate all key personnel of Operations & Maintenance for help.

------ ------ ------ Not required

Inform Head – Laboratory to mobilise Auxiliary Fire Squad and Trained First Aiders ------ ------ ------ Not required

In case of declaration of level 2 and higher emergency level Emergency Siren actuation ( As per direction of SFO)

Level 2 Level 3 All Clear ------ ------ ------ Not required L1

Mutual Aid Members ( As per direction of SFO) ------ ------ ------ Not required L1

Total- 15.5 15.5







Location :- Respective Plant / Unit Process

Observer :-– Shri Himanshu S. Mishra , DGM – HSEF

Respective Plant / Unit Process Control Room Events ( Laboratory ) Events Time & date of call 16:02:58 Hrs on 21.07.2018 Mode of call ( Incident Information received ) :- MCP/Gas Detector/ Toxic gas detector/Smoke detector

MCP # 20 HS 811

Telephone: Landline/ CUG/wireless/In person

In person by shouting – “Fire ! Fire!! Fire !!!”

Record Name of Caller from whom information received :

Shri Mahesh Jesadia , Lab Chemist

Information to :- (All below information to be conveyed within 3 minutes time.)

Information to Yes / No Marks (max) Evaluation Remarks Shift In Charge - Laboratory Yes 1 1

Refinery Fire Station ( Hot Line / Ext -1111) Yes 2 2 Announcement on PA system in three languages ( Hindi, English, Gujarati ) for stopping all the jobs & evacuation

NA NA NA

Refinery Shift Manager (RSM) Yes 1 1

Site Incident Controller (SIC) Yes 1 1

Area Manager Yes 1 1 Asstt. Area Manager Yes 1 1 Maintenance Manager – Shift I/C Yes 1 1

Head – Technical Services Yes 1 1 WWTF ( Utility ) NR NR NR Emergency Control Actions :- Execution of Emergency Control actions Yes 2 2

Information to upstream / downstream / neighboring units / other stake holders Yes 1 1

Announcement on PA system in three languages ( Hindi, English, Gujarati )- All Clear

NA NA NA

Total- 12 12







Location :- Incident Site – LABORATORY

Observer :-– Shri Ashish Kumar Sen , JGM – Security

Actions by Operations team at Incident Site Events Yes / No Marks (max) Evaluation Remarks Call Initiation – MCP / Emergency No. Yes 2 1 MCP # 57 HS 007 did not

activate.

Sounding of Local Siren / Hooter Yes 1 1 Alert other people around in nearby units/ facilities – as per emergency conditions Yes 1 1

Stop Hot /cold jobs Yes 1 1

Casualty search and initial handling by operation team /AFS Yes 1 1

Equipment isolation, valve closing as per SOPs Yes 2 2

DCS control, instruction issued to Field Yes 1 1 Fire & Gas detection system available & their performance Yes 2 2

Fire Extinguishers available & used. Their performance Yes 2 2

CO2 -09 Kgs -01 operated.

Hydrant/Monitor used and their performance Yes 2 2

Assemble at Safe Assembly Point. Yes 1 1

Direction to Fire Services / Emergency Responders and necessary information Yes 1 1

SCBA set / BA Trolleys used & their performance Yes 1 1

PPE's Helmet/Safety shoes/ gloves/ goggles / Earplugs Yes 1 1

19 18

Actions of Maintenance Team at Incident Site

Timely response of Maintenance Team with tools & tackles & manpower(Max- 8 Min for Base Refinery, 12 Minutes for Train -1 units and off sites , 20 Minutes for COT)

07 Min 42 Sec

3 3

Use of proper tools & tackles – flame proof / precautions/ PPEs as per TBRA Yes 2 1.5

Electrical Technician without proper PPEs

Special PPE's – HR Suits , SCBA sets , BA Trolley

Yes 1 1

6 5.5







Location :- Incident Site – LABORATORY

Observer :-– Shri Anil Vishwambharan , JGM and Head-CRG

Actions by SITE INCIDENT CONTROLLER (SIC) Events Yes / No Marks (max) Evaluation Remarks Response Time (Max- 4 Min for Base Refinery, 6 Minutes for Train -1 units and off sites/VPCL, 20 Minutes for COT)

02 Minutes 42 Sec 3 3

RSM-02 Min 42 Sec SIC – 05 Min 42 Sec

Co-Ordination with Emergency Responders :- Fire Coordinator – Fire & rescue operations , Special Services Yes 2 2

Security & Evacuation Co-Ordinator : Head Count / Traffic Control / Mob Control Yes 2 2

Medical Team- Casualty shifting and handling at OHC , further actions Yes 2 2

Emergency Support Co-Ordinator – Mobilisation of Auxiliary Fire Squad ,Trained First Aiders

Yes 2 2

Unit /Plant Operations – Fuel / Energy/Toxic isolation, Safe Shut Down, Emergency Control Actions / Environment related actions.

Yes 4 4

Maintenance Team – Leak Sealing, Insulation removal , Power Isolation , Heavy Equipment Mobilization, Lighting, Dewatering , hot bolting etc.

Yes 2 2

Utility Team – Fire Pump Operation , Hydrant System Pressure , Water Make Up , Steam , Nitrogen , Plant Air etc.

Yes 2 1.5 Did not talk to Utility Team even though checked hydrant press.

Incident Command & Control :- Sizing up the situation – Overall effective emergency response & control actions Yes 3 3

Declaration of Level2 emergency in consultation with CIC ---------- -------- --------

Two way Communication with Emergency Control Centre ---------- -------- --------

Communication - with Fire /Security/Operation / Maintenance Yes 3 3

Overall Incident Command and control skill Yes 3 3

Declaration of "All Clear" (in consultation with other Emergency Responders & CIC , after final Search & Rescue , LEL / Toxic Gas Check.)

Yes 1 1

Jacket & PPE's including SCBA / Escape set (ELSA) Yes 1 1

Total- 30 29.5






Evaluation Sheet # 5 Location :- Incident Site – LABORATORY

Observer :-– Shri Sudhir Ingle, Head- Fire

Actions by FIRE CREW


Response Time (Max- 3 Min for Base Refinery, 6 Minutes for Train -1 units and off sites , 20 Minutes for COT from RFS)

02 Minutes

52 Seconds 3 3

MPFT DCPT-02 J5 J6

Proper approach and Parking of Fire tender Yes 1 1

Mobilization and utilization of Auxiliary Fire Squad & Trained First Aiders

Yes 2 2

Fire Extinguishing Media application & its effectiveness Yes 2 2

Search and Rescue Yes 3 3

Help to Operations / Maintenance personnel for closing /opening the valves for isolation etc.

Yes 1 1

Command & Control of the Fire crew and fire-fighting/ Emergency operations

Yes 2 1

Method and speed of Action Yes 2 2

Co-ordination with SIC/ Shift In Charge /RSM by Fire coordinator. Yes 1 1

Feedback by Fire Coordinator to Refinery Fire Control room. Yes 1

1

Fire Fighter appropriate PPE's used - Fire Suits / Chemical Suits / SCBA / Gum Boot etc.

Yes 4 4

Mobilisation of additional resources – Fire Tenders , Manpower , Special equipments , SCBA sets , Trailer Mounted HVLRMS etc.

Yes

5 5

27 27







Location :- Incident Site – Laboratory

Observer :-– Shri IVN Raju, DGM – Operations , Utility 2 Base

Actions by Security team


Response Time (Max- 6 Min for Base Refinery, 10 Minutes for Train -1 units and off sites/ VPCL , 20 Minutes for COT from Refinery)

03 Minutes 42

Sec 2 2

Road Clearing/Barriers clearing. Yes 0.5 0.5

Proper approach, cordoning off area Yes 1 1

Report to SIC/RSM/Shift- In-Charge -Operation Yes 0.5 0.5

Facilitate Evacuation of Non- Essential Personnel Yes 1 1

Head count Done 2 2

Traffic Control at entry and exit points Yes 1 1

Removal of unwanted vehicles Yes 0.5 0.5 Help in Controlling Emergency Yes 0.5 0.5

PPE's Helmet/Safety shoes/gloves/goggles/Earplugs /SCBA etc

Yes 1 1

Total- 10 10

Actions by OHC - Medical team Response Time (Max- 3 Min for Base Refinery, 6 Minutes for Train -1 units and off sites/VPCL , 20 Minutes for COT )

02 Minutes 52

Seconds 1 1

Parking Ok 1 1 Casualty Shifting Ok 2 2 Mobilizing other Ambulances and treatment at OHC Ok 1 1

Total- 5 5






Emergency Responders Performance Rating

Sr. No. Emergency Responder

Marks obtained Full Marks

Marks obtained %

Rating

1 FIRE SERVICES 42.5 42.5 100 % Excellent

2 LABORATORY 30 31 96.77 % Excellent

3 MAINTENANCE 5.5 6 91.67 % Very Good

4 OCCUPATIONAL HEALTH SERVICES

5 5 100.00 % Excellent

5 SECURITY 10 10 100.00 % Excellent

6 SITE INCIDENT CONTROLLER (SIC)

29.5 30 98.33 % Excellent

TOTAL 122.5 124.5 82.39 %

Overall Rating 98.39 % Excellent

Rating Criteria 95 to 100 % Excellent 75 to 84.99 % Good Less Than 70% Needs improvement 85 to 94.99 % Very Good 70 to 74.99 % Average

100.00%

96.77%

91.67%

100.00% 100.00%

98.33%

FIRE SERVICES LABORATORY MAINTENANCE OCCUPATIONAL HEALTH SERVICES

SECURITY SITE INCIDENT CONTROLLER (SIC)

OVERALL RATING -98.39 %

PERFORMANCE OF EMERGENCY RESPONDERS , MOCK DRILL ,LEVEL-1 , LAB, 25.07.2018







1. Entire laboratory was evacuated within 90 Seconds. 2. Good casualty handling by laboratory personnel and safety shower given. 3. Good communication between Emergency Responders and to all key personnel.

Discussion Points

1. Portable Loud phone to be used by Site Incident Controller to addressed employees and Contract Workmen assembled at Safe Assembly Point. It is available with Security.

2. Refinery Shift Manager Vehicle is not properly identified and needs to have placard or some clear identification. It should be properly identified like fire vehicle.

3. HVAC air inlet should not be through Electrical Room and should be from fresh air source.

4. Wardens for different floor areas / sections of Laboratory to be appointed and to given identification with fluorescent jackets.

5. Head- Laboratory and JGM- Laboratory immediately evacuated and did not participate in emergency handling.

6. Paramedics are not available in Ambulance and only a transport driver handles the casualty , who remains unattended during transit from incident site to OHC – point raised by SIC.


Sr. No.


1. Glass doors of electrical room not properly marked (Exit/ Entrance) and need to be identified.

Glass doors of electrical room not properly marked (Exit/ Entrance) and need to be identified.

Dr. Pradip Prabhu 31.09.2018

2. Laboratory Chemist broke three manual call points (MCPs) but none of them activated.

All MCPs in the Laboratory to be checked for reliability and training to be given to all Laboratory Personnel to activate MCP properly.

Shri Sudhir Ingle 12.08.2018






3. HVAC suction is through Electrical Room and is directly connected with HVAC Room , thus enabling smoke suction by HVAC during fire and its fast spread into all areas of Laboratory.

Fire doors to be provided at Electrical Room to not to allow smoke suction by HVAC and its fast ingress into all areas of Laboratory – after a review of passive fire protection.


4. Cable Trenches in Electrical Room not covered properly, posing fall hazard.

Cable Trenches in Electrical Room to be covered properly.


5. Stair Case Area for terrace is blocked with Cup Boards, broken chairs , obsolete furniture etc. The same blocks the exit. The same to be cleared as soon as possible.

Stair Case Area for terrace to be cleared of Cup Boards , broken chairs , obsolete furniture etc.


This report shall be discussed in next Area Safety Committee Meeting.

……………………..END OF REPORT……………………….

MOCK DRILL REPORT (LEVEL-2)





Date : 15.06.2018

Plant /Unit : NHT/CCR

Location : Pump Area

Equipment : Stripper Column 32 C-001

Scenario:-

1. Large leak from Stripper Column 32 C-001, bottom line 20” flange, due to gasket failure at an

elevation of about 3 Mtrs. 2. Large Vapor cloud of naptha is formed and toxic release of Hydrogen Sulphide takes place

affecting all the nearby units. 3. Subsequently, it catches fire from unknown source, resulting in Vapor Cloud Explosion and

major fire. 4. This results into full bore rupture of the line and further escalation of fire and toxic release.

Process Condition

Temp- 180-190 ºC, Pressure – 10.5 – 11.0 Kg/Cm², Column volume - 160 m3

Hold up that will leak before suitable action is taken (20 Min) – 55 MT.

Composition - Naphtha (C1-C-4 in off gas, H2S – 4-5 % in off gas, rest naphtha at the bottom)

Casualty - 02

1. One contract workmen (Civil - Insulator) who was working nearby got exposed to toxic release and felt unconsciousness.

2. Later, one field officer got engulfed in the pool fire, got major burn injuries, toxic exposure and collapsed on the ground.








Observers

S.N. Observer's location Name 1 Emergency Site - Site Incident

Controller (SIC) Shri Sanjay Kulwal , GM –Operations and Area Manager – DHDS/ARU/SRU

2 Emergency Site- Operations & Maintenance

Shri Dipal Phukan , GM –Operations and Area Manager – HMU-2

3 Refinery Fire Control Room Shri Jilesh Lalani , DGM – Operations ,CPP 4 CCB Control Room-DCS -Panel Shri Chetan Popat , JGM – Operations , PIT

5 Emergency Site – Security / Medical Services

Shri Amarjitsinh Jadeja , DGM- Administration

6 Emergency Site – Fire Services Mr. Omprakash Luhana ,DGM- Operations,CDU1 7 ECC 1, Security Command Centre Mr. Samirkumar Dave ,Head –Operations -CPP 8 Fire Pump House Shri Jigar Parikh, DGM – Mechanical Maintenance 9 Occupational Health Centre(OHC) Shri Rajendra Arya ,JGM- Operations ,Utility 1

base 10 Refinery Main Gate Shri Jatin Joshi ,DGM – Warehouse 11 Mock Drill – Co-Ordinator Shri Himanshu S. Mishra , DGM –HSEF


Time Actions 15:09:25 Hrs Emergency Scenario activated after H2S Gas detector # 30 AT 130 was

activated by Instrumentation Team. 15:09:50 Hrs MCP # 30HS 224 was activated by Shri Mehul Goswami, Pump Area, Field

Officer; hooter and beacon started, fire alarm received at RFS and NHT/CCR Panel.

15:09:50 Hrs

Shri Manoj Vora , Panel Officer, NHT/CCR informed Refinery Fire Control Room on Emergency Number -1111 about leakage of Naptha and H2S in Pump Area of NHT/CCR.

15:09:50 Hrs Evacuation of all non - essential personnel from NHT/CCR area started. All occupants evacuated to Safe Assembly Point within two minutes.

15:10:00 Hrs

Shri Manoj Vora, Panel Officer, NHT/CCR made announcement in Hindi, English and Gujarati “Leakge of H2S in Pump area. Stop all jobs and evacuate”.

15:10:05 Hrs Multipurpose Foam Tender (MPFT) with crew followed by Ambulance and Shift Fire Officer Shri Mahesh A. Patel by Fire Jeep J6 turned out from






Refinery Fire Station. 15:10:05 Hrs DCP Tender DCPT-02 with crew turned out from Auxiliary Fire Station ,CPP 15:11:00 Hrs Shri Mehul Goswami, Field Officer after donning SCBA set, located a

contract workmen (Civil - Insulator) who was working nearby got exposed to toxic release and felt unconsciousness. He shifted him to a safer location.

15:11:00 Hrs Water Spray System of NHT/CCR process area was operated by Field Officer. DV Nos. 8,9,10,14,15 activated.

15:11:30 Hrs High Volume Long Range Monitors (HVLRMs) on west and east side of the NHT/CCR units were operated.

15:11:46 Hrs Dynamic Blast Call (Group 4) – phone activated by Fire Control Room operator to inform all primary responders. It worked well.

15:12:00 Hrs Shri Kirit Patel, Shift In Charge - Operations arrived at incident site and took control of the situation.

15:13:47 Hrs

Multipurpose Foam Tender (MPFT) with crew followed by Ambulance and Shift Fire Officer Shri Mahesh A. Patel by Fire Jeep J6 reached at spot.

15:13:47 Hrs DCP Tender DCPT-02 arrived at incident site at NHT/CCR from Auxiliary Fire Station.

15:14:00 Hrs Shri Madhusudhan C. (Area Manager) and Shri Yogeshkumar Patel (Astt Area Manager) - Operations, NHT/CCR arrived at site and took control of the emergency situation.

15:14:15 Hrs Sh T. Chandrashekhar, Refinery Shift Manager (RSM) arrived at site and took control of the emergency situation.

15:14:50 Hrs Dynamic Blast Call (Level-1) – phone activated by Fire Control Room operator to inform all key personnel It worked well.

15:14:59 Hrs Ambulance left for OHC with casualty. 15:15:00 Hrs Smt Priya Ayengar (Environment) arrived at site. 15:15:00 Hrs One DCP -9 Kgs Fire Extinguishers were operated by field officer. Fire crew

provided water curtain on west side of Stripper Column 32 C 001. 15:15:00 Hrs Security Officers Shri Surendrasinh Jam , Patrolling Officer followed by Shri

T.Cherian with Quick Response Team of Security personnel arrived at incident site from upwind direction, after cordoning the area and ensuring safe evacuation of non- essential personnel at Safe Assembly Point .

15:15:00 Hrs Shri Amar Kumar arrived at site and took control of the emergency situation as Site Incident Controller (SIC).

15:15:00 Hrs Shri Jayesh Gajjar, Head – ISBL1 arrived at site and took control of Plant –Operations.

15:15:00 Hrs Sh Sudhir Ingle, Head - Fire arrived at site by Fire Jeep J3 and took command of firefighting and rescue operations.






15:15:00 Hrs DCP tender-2 , vessel No- 1 was charged and started DCP application 15:15:30 Hrs Mechanical Maintenance Team with Shri Darshan Thanki ,

One Supervisor and one two mechanical technician with spark proof tools and Tool Box arrived at the incident site.

15:16:00 Hrs Electrical Maintenance Team with Shri Vishnu Prajapati arrived at the incident site with two electrical technicians.

15:16:00 Hrs 2 I/C Security Officer Mr. A.K.Sen arrived at Site and took control of the situation

15:17:00 Hrs Instrumentation Maintenance Team with Shri Darshit Dholakia arrived at the incident site with one instrument technician.

15:17:39 Hrs Combined Fire Tender CFT with Shift Fire Officer Shri Sudhir Singh turned out from Refinery Fire Station to NHT/CCR.

15:18:00 Hrs Fire situation escalated and engulfed the entire area of NHT/CCR – Unconfined Vapour Cloud Explosion (UVCE) takes place.

15:18:40 Hrs Level 2 Emergency declared by SIC Shri Amar Kumar 15:19:00 Hrs Sh Vinay Kumar, Field officer NHT/CCR got injured and collapsed on the

ground. He was rescued by Fire crew & sent for treatment at OHC. 15:20:00 Hrs 2nd Ambulance reported at site 15:20:32 Hrs Dynamic Blast Call (Level-2) – phone activated by Fire Control Room

operator to inform all key personnel It worked well. 15:20:32 Hrs Emergency Siren of ISBL-1 was blown to declare level 2 emergency in the

Refinery Complex. 15:20:33 Hrs Combined Fire Tender CFT reached at site and took position from east side,

starting foam application from Medium Expansion Foam Generator. 15:22:04 Hrs Mutual Aid Scheme assistance requisitioned by Head- Fire and the same

was communicated to MAS control Room, Jamnagar from Refinery Fire Control Room.

15:25:00 Hrs Shri Jimeet Patel, with Team Administration arrived at ISBL 1 Gate with food & beverages along with 5 service boys. But, they could not deliver the same to Emergency Responders.

15:25:00 Hrs Emergency Support Co-Ordinator Shri Dhiraj Gondalia with Auxiliary Fire Squad (AFS) -02 personnel and Trained First Aider -03 Personnel arrived at the incident site and reported to Head- Fire for help.

15:25:00 Hrs NHT/CCR Unit safe shut down and depressurization started. 15:25:15 Hrs One transport bus reported at Incident Site for evacuation purpose. 15:26:00 Hrs Chief Medical Officer Dr. Maulesh Patel called OHCs of RIL, EPGL for

Mutual Aid Assistance. 15:30:00 Hrs Inspection team reported at site






15:30:33 Hrs Fire under control – message by Head -Fire 15:31:00 Hrs Maintenance team started leak sealing activities. 15:36:00 Hrs Site Incident Controller checked casualty status, they had been referred to

Jamnagar for further treatment by Chief Medical Officer. 15:36:00 Hrs Head Count report given by JGM -Security Shri A.K.Sen – at Assembly Point

and incident site – Contract workmen- 138 including 6 women, Employees – 05 , Casualty -2, Visitor – Nil, Total- 145 personnel.

15:36:00 Hrs Fire Crews carry out search & rescue for any more casualties including the upper floors of the unit.No more casualty found.

15:36:50 Hrs Duty Doctor from OHC informed PO that injured personnel were referred to Jamnagar for further treatment- feedback

15:36:50 Hrs Operation personnel and Fire Personnel checked LEL and H2S in the area. It was nil.

15:36:52 Hrs All Clear – declared by Site Incident Controller (SIC), Shri Amar Kumar. 15:37:00 Hrs All Clear announcement by Panel Officer in Hindi,English,Gujarati. 15:37:15 Hrs Emergency Siren of ISBL-1 was blown in All Clear mode. 15:38:00 Hrs Dynamic Blast Call (All Clear) – phone activated by Fire Control Room

operator to inform all key personnel. It worked well. 15:38:00 Hrs 3rd time Ambulance reported at site 15:40:00 Hrs Shri Amar Kumar, Site Incident Controller (SIC) addressed employees and

Contract Workmen assembled at Safe Assembly Point and appraised them of the incident.

15:45:13 Hrs Mutual Aid Scheme team of RIL, Motikhavdi with Foam Tender and Ambulance reported at Site.

15:45:46 Hrs Mutual Aid Scheme team of BORL, Vadinar with Foam Tender and Fire Crew reported at Site.

15:55:00 Hrs Mutual Aid Scheme team of IOCL, Vadinar with Foam Tender and CISF -Fire Crew reported at Site.

15:57:00 Hrs Mutual Aid Scheme team of GSFC, Sikka with Foam Tender and CISF -Fire Crew reported at Site.

16:00:00 Hrs Debriefing Session was held at Emergency Control Centre 1, Security Command Centre - 28 Employees participated.







1. Very good co-ordination between all Emergency responders including Operations, Maintenance, Fire Services, OHC, Utility etc.

2. Seamless communication between incident site, Emergency Control Centre and between Chief Incident Controller and Site Incident Controller.

3. Fire protection systems- Fire Extinguishers / Fire Hydrants / Water Monitors/ Water Spray Systems were actually operated and they worked well.

4. Fire Pumps in Refinery Fire Pump House started in sequence in Auto Mode as per fire water demand and water make up was done.

5. All Fire crew were donning SCBA sets and three layer inherently Fire Resistant Nomex Suits.

6. Auxiliary Fire Squad (AFS) and Trained First Aiders (TFA) were mobilized by Emergency Support Coordinator at incident Site very promptly.

7. All communication systems were operated and worked well including –Dynamic Call Blast System, Wireless Communication – VHF, Tetra and BSNL phone.

8. The whole incident was being monitored by CCTV from Emergency Control Centre. 9. Transport Bus was mobilized to evacuate the area effectively. 10. Mutual Aid Scheme members viz. IOCL, BORL, RIL, GSFC responded very promptly

with Fire Tender /Crew and Ambulance also.

Discussion Points

1. Refinery Complex level Emergency Sirens for ISBL 1 was blown and it worked well. Employees / Workmen / Community personnel responded well to the same. However, the same was not audible at Refinery Pump House.

2. CCTV Camera was being viewed by Chief Incident Controller and Team at Emergency Control Centre – in a TV monitor which could be made available on a larger screen with the help of OHP Projector.

3. Economic Planning & Scheduling (EPS) department was not informed about the NHT/CCR unit shut down.

4. Affected Area at Incident Site was not barricaded to warn about the leakage/ fire. 5. Food and Beverages for Emergency Response Team was mobilized by Team

Administration, but the same could not be delivered to the destination, as the catering team kept waiting at Safe Assembly Point rather than finding proper route of delivery.







Sr. No.


1. There was no alternative power supply for Emergency Control Centre in case of total / partial black out / power failure. UPS back up is only for some systems and that too for one hour.

Reliable UPS power back up for Emergency Control Centre to be reviewed and provided.

Atul Koranne 31.08.2018

2. Several spray nozzles of water spray system ( Deluge System) were found choked for DV # 8,9,10,14,15

All the Deluge Water Spray Systems in NHT/CCR to be checked for spray nozzle choking and to be rectified.

Madhusudhan C. 31.07.2018






Some Snaps of the Mock Drill Level-2 at NHT/CCR

Chief Incident Controller (CIC) and Secondary Emergency Responders in action at Emergency Control Centre,

Security Command Centre.






Site Incident Controller (SIC) in action at Incident Site. After all clear , he is addressing the contract workmen

and employees.






Operations and Maintenance Team in action at Incident Site.

Right - Debriefing at Emergency Control Centre after All Clear. Left – Mutual Aid Scheme Fire Crews






Note: This report shall be discussed in next Area Safety Committee Meeting.

……………………..END OF REPORT……………………….

Fire Services Team in action at Incident Site. Auxiliary Fire Squad and Trained First Aiders reporting to Head –

Fire Services.

Annexure 1.8 Green Belt Layout Plan

Annexure 1.9: CREP compliance

CHARTER ON CORPORATE RESPONSIBILITY FOR ENVIRONMENTAL PROTECTION Sector: Petroleum Crude Oil Refineries

Name of Industry: Nayara Energy Limited (Formerly known as ESSAR OIL LIMITED), (Refinery Division)

Address: Nayara Energy Limited, Post Box 24 PO: Khambhalia, Jamnagar – Okha

Code: 09 Highway, Dev bhumi Dwarka-361005

Sr. No./ Activity code

No Action Point (in brief) Action Taken Report

A AIR POLLUTION MANAGEMENT

1. All the refineries located in the critically polluted areas, identified by CPCB, will submit an action plan (within six months) for phase wise reduction of SO2 emission from the present level

Not Applicable:(Our refinery is neither identified by CPCB nor located in critically polluted area, hence condition is not applicable to us)

2. Future refineries will have Sulphur Recovery Unit (SRU) with minimum 99% efficiency

SRU is operated at more than 99.7% efficiency.

3. To enhance the efficiency of SRUs in the existing refineries, an expert committee will be constituted to look into various aspects and suggest a road map within six months.

Refinery SRU are always being at efficiency more than 99.7 %.

4. With regard to NOx emission, the new refineries/process units will install low NOx burners. For retrofitting of low NOx burners in existing units, the expert committee will suggest the strategies and action plan within six months including NOx standard.

All Heaters / boilers are equipped with Low NOx burners.

5. The flare losses will be minimized and monitored regularly

Flare loss is being estimated based on material balance and immediate actions are being taken to minimize losses.

6. Refineries will install continuous emission monitoring systems for SOx and NOx in major stacks with proper calibration facilities. Action plan for this will be submitted within six months

Stacks are already provided with continuous on-line emission monitoring systems for parameters SO2 and NOx since start-up of refinery in 2006. Coninuous Emission Monitoring data has been sent to CPCB server since June 2015. Regular calibration is being carried out for analyzers & calibration report & schedule given in Annexure-1.1.2 & 1.1.3



7. Refineries will also monitor total HC and Benzene in the premises (particularly at loading / un-loading operations and ETP). The status and action plan will be submitted within six months.

VOC monitoring is carried out in the viscinity of all potential sources of HC emission such as Primary ETP, Secondary ETP, Truck Loading Gantry, and Rail Loading Gantry. This is being done on monthly basis. VOC emission monitoring results for the month of Mar’18 to Aug’18 are shown below.

Sr. No.

VOC monitoring area / unit / plant

Unit VOC

Min-Max

1 Near Truck Gantry No. 5 (HC Truck Loading)

ppm 0

2 Primary Treatment Plant of Truck Dispatch Area

ppm 38-104


4 Hazardous waste storage sites

ppm 0

5 Primary Treatment Unit of ISBL-1 process

ppm 132-194

6 At Battery Limit in CDU/VDU

ppm 0

7 At Battery Limit in CDU - II ppm 0

8 Downwind of equalization tank (Oil Separation Basin Unit-8400) of base ETP

ppm 263-292

9 Primary Treatment Plant of Crude Tank Storage (COT) Area

ppm 9.1-10.8


8.

The expert committee will also suggest an action plan, within six months, for control and monitoring of hydrocarbon loss & VOC emissions, leak detection and repair (LDAR) program and vapor recovery systems (for loading & unloading operations within refineries only.

We have established LDAR program. Under this program, total 35055 components have been monitored in period of Mar’18 to Aug’18.

B

WASTE WATER MANAGEMENT

1. Refineries will prepare action plan for conservation of water resources and maximizing reuse/ recycling of treated effluent within six months. The treated effluent discharge quantity (excluding once through cooling water) will be limited to 0.4 m3/per Ton (for 90% of time) except for the monsoon season.

Treated effleunt was reused / recycled with in refinery for the fire water make up, service water and feed to cooling tower make up,as a RO feed.



2. Oil spill response facilities at coastal refineries will be in position within two years. To facilitate this, MoEF will coordinate with Coast Guards, Port Trust and other departments

Oil Spill Disaster Contingency Plan Tier-1 response has been approved by Indian Coast Guard (ICG). Regular Oil spill mock drills (once in 6 month Tier-1 mock drill) are conducted with ICG & Deendayal Port Trust(DPT).

C

SOLID WASTE MANAGEMENT`

1. Refineries will explore new technologies for reduction in the generation of oily sludge. Strategy and action plan for liquidation of existing sludge will be submitted within six months

Oily sludge is co-processed in Delayed Coker Unit(DCU)

2. The petroleum coke having high sulphur content will only be sold to/ reused by organized industries (having consent from SPCBs), which have systems to control SO2 emissions. This will be ensured by June 2003.

Pet coke is sold to reputed Cement Manufactures such as ACC, Ambuja, Shree Cement, JK Cement,Ultratech, Diamond cement,Manglam Cement,Orient Cement etc.

NEW ACTION POINTS AS PER FIRST MEETING ON REVISED NATIONAL TASK FORCE HELD ON OCTOBER 09, 2009

1 Refineries will carry out monitoring and survey to assess HC loss and concentration of VOC in Ambient Air/ Wastewater treatment plant. (Action plan was to be submitted by Jan 2010)

We have established LDAR program. Under this program, total 35055 components have been monitored in period of Mar’18 to Aug’18.

2 Refineries will assess the quantity of flare gas. (Install the measurement system if the same is not possible) (Action plan was to be submitted by March 2010)

The flare loss is being asssed on mohtly basis and for last six months avg. flare loss is 0.21% of crude processed.

3 Assessment of Potential leakages from petroleum storage tanks. (Action plan was to be submitted by Jan 2010)

All tanks are above grounds. The highly volatile products / crudes are stored in floating roof tanks which are monitored regularly; so far we did not find any leakages from these tanks.

4 Cleaner Technology options and information to be provided to CPCB. (to be submitted by Feb 2010)

Low sulfur FO and FG, we are being used in heaters / furnaces.

Abbreviations: FO: Fuel Oil FG: Fuel Gas LDAR: Leak Detection & Repair VOC: Volatile Organic Compounds DPT: Deendayal Port Trust SPCB: State Pollution Control Board CPCB: Central Pollution Control Board

Annexure 1.10 Approval for OSDCP

Vadinar Power Company Limited Domicile Detail of Employee as on 31.12.2016

Sr.

No.

Employee

CodeEmployee Name Level

Date Of

JoiningDept Supervisor Name Domicile

1 20000498 Suresh Intwala M-6 01.07.1993 Electrical Kishor Makadia Gujarat

2 20002161 Manish Desai M-8 14.06.2004 Mechanical Rakesh Kanani Gujarat

3 20003374 Samirkumar Dave M-4 19.04.2005 Operation Snehal Pandya Gujarat

4 20004035 Isaac Abraham M-7 29.08.2005 Operation Samirkumar Dave Other

5 20004095 Kishor Makadia M-2 14.09.2005 Head-VPCL Kalakota Reddy Gujarat

6 20004209 Snehal Pandya M-4 03.11.2005 Head-O&M Kishor Makadia Gujarat

7 20004238 Meval Das Mahant M-8 14.11.2005 Electrical Ashit Gothi Other

8 20004780 Manoj Mishra M-5 18.02.2006 C&I Sanjay Kumar Gupta Other

9 20005190 Ajay Kuvad M-8 24.05.2004 Electrical Vijay H Chauhan Gujarat

10 20005427 Krunal Patel M-6 07.04.2006 Operation Samirkumar Dave Gujarat

11 20006659 Udaysingh Solanki M-8 01.04.2006 Procurement Nilesh Dave Gujarat

12 20007464 Kantilal Makwana M-8 19.09.2006 IT Bhavesh Champaneri Gujarat

13 20009434 Manoj Kundu M-8 03.03.2007 Operation Ashok Chandna Other

14 20009523 Alok Ranjan M-8 15.03.2007 Operation Dipak Soni Other

15 20010605 RahulVardhan Sharma M-7 15.06.2007 Procurement Nilesh Dave Gujarat

16 20011247 Sanjaykumar Shah M-5 05.07.2007 Technical Services Kishor Makadia Gujarat

17 20011530 Rupak Patel M-6 16.07.2007 Operation Samirkumar Dave Gujarat

18 20011901 Girish Patel M-8 30.07.2007 C&I Manoj Mishra Gujarat

19 20011998 Sunil Desai M-8 12.07.2007 Technical Services Sanjaykumar Shah Gujarat

20 20012481 Manoj Makadia M-8 18.08.2007 C&I Manoj Mishra Gujarat

21 20012741 sandeep verma M-8 05.09.2007 C&I Manoj Mishra Gujarat

22 20013041 Sandeep Parmar M-8 01.07.2007 Civil Jayanti Kachhadiya Gujarat

23 20013478 Alpeshkumar Dhamsania M-8 24.10.2007 Electrical Lalitkumar Jethwa Gujarat

24 20015188 Vasant Chavda M-9 01.01.2008 HR Admin Santosh Tanwar Gujarat

25 20015901 Rahul Mudgil M-8 21.01.2008 C&I Manoj Mishra Other

26 20015909 Chandrakant Dehariya M-9 21.01.2008 Electrical Alpeshkumar Dhamsania Other

27 20015917 Robin singh M-9 21.01.2008 Electrical Alpeshkumar Dhamsania Other

28 20015924 Ketankumar Pancholi M-7 24.01.2008 C&I Manoj Mishra Gujarat

29 20017145 Sanjay Kumar Gupta M-4 05.04.2008 Head-Maintenance Snehal Pandya Other

30 20017754 Vipul Vaghasiya M-7 01.05.2008 Electrical Lalitkumar Jethwa Gujarat

31 20019970 Jayantilal Ramoliya M-8 03.07.2008 Electrical Vipul Vaghasiya Gujarat

32 20020004 Mitesh Bhatia M-7 07.07.2008 Operation Krunal Patel Gujarat

33 20020065 Sandeep Sudhakaran M-8 05.07.2008 Procurement Nilesh Dave Other

34 20020068 Avikal Sharma M-8 05.07.2008 Mechanical Hitesh Patel Other

35 20021190 Ajay Kumar Pal M-7 24.07.2008 Mechanical Hitesh Patel Other

36 20021529 Jayesh Vora M-8 07.08.2008 Electrical Amit Kumar Kansagara Gujarat

37 20022225 Neerav Nayak M-7 11.09.2008 Operation Rupak Patel Gujarat

38 20022893 Sanghesh Khobragade M-8 06.09.2008 Mechanical Hitesh Patel Other

39 20022894 Shyam Kumar Beshra M-8 06.09.2008 Mechanical Dinesh Prajapati Other

40 20022895 Giridharan Damodharan M-8 06.09.2008 Mechanical Jayanti Kachhadiya Gujarat

41 20022928 Amit Morzaria M-7 30.09.2008 Mechanical Sanjay Kumar Gupta Gujarat

42 20023382 Amit Kumar Kansagara M-7 06.10.2008 Electrical Lalitkumar Jethwa Gujarat

43 20023510 Ashish Kumar Godhani M-8 07.10.2008 C&I Manoj Mishra Gujarat

44 20023861 Ashit Gothi M-7 25.10.2008 Electrical Lalitkumar Jethwa Gujarat

45 20024062 Samir Patel M-7 06.11.2008 Power Commercial Kishor Makadia Gujarat

46 20024351 Anirudh Patel M-8 14.11.2008 Electrical Ashit Gothi Gujarat

47 20024384 Brijeshkumar Lalani M-9 17.11.2008 C&I Ketankumar Pancholi Gujarat

48 20024392 Sandeep Mandle M-10 05.11.2008 C&I Janak Pansuria Other

49 20024413 Vishwanath Khandare M-9 05.11.2008 Operation Rupak Patel Other

Annexure 1.11 Local Employee List


Sr.

No.

Employee


Date Of


50 20024414 Naveen S Choudapurkar M-9 05.11.2008 Operation Rupak Patel Other

51 20024416 Bishwanath Naik M-9 05.11.2008 Electrical Ashit Gothi Other

52 20024418 Pravin Mankar M-10 05.11.2008 Mechanical Hitesh Patel Other

53 20024421 Dipak Choudhury M-9 05.11.2008 Operation Rakesh Kharat Other

54 20024478 Jaydeep Trivedi M-8 24.11.2008 Operation Krunal Patel Gujarat

55 20024479 Dhirajlal Chavda M-8 24.11.2008 Operation Rakesh Kharat Gujarat

56 20024484 Vijay H Chauhan M-7 28.11.2008 Electrical Lalitkumar Jethwa Gujarat

57 20024501 Mritunjay Kumar Gupta M-8 01.12.2008 C&I Manoj Mishra Other

58 20024578 Amit Vithalani M-8 08.12.2008 Electrical Vijay H Chauhan Gujarat

59 20024799 Vasantkumar Patel M-7 18.12.2008 Mechanical Jayanti Kachhadiya Gujarat

60 20024801 Janak Pansuria M-6 25.12.2008 C&I Manoj Mishra Gujarat

61 20024802 Bhavin Parmar M-8 29.12.2008 C&I Manoj Mishra Gujarat

62 20026133 Ajay Kumar M-10 20.07.2009 Electrical Alpeshkumar Dhamsania Other

63 20026326 Bela Bhatt M-8 15.07.2009 C&I Janak Pansuria Gujarat

64 20027333 bhavesh madhavi M-8 19.08.2009 HSE SUDHIR KUMAR SINGH Gujarat

65 20027641 Harshal Langaliya M-8 21.09.2009 Electrical Ashit Gothi Gujarat

66 20027642 Harshit Shah M-8 21.09.2009 HSE SUDHIR KUMAR SINGH Gujarat

67 20027646 Alpesh Pithwa M-8 21.09.2009 Mechanical Vasantkumar Patel Gujarat

68 20027758 Jerry Alexander M-8 05.10.2009 Operation Rohit Patel Other

69 20027764 Devkant Lande M-8 05.10.2009 Operation Suresh Kalaskar Other

70 20027938 Jemish Ladani M-8 15.10.2009 Operation Krunal Patel Gujarat

71 20027939 Santosh Thakur M-9 15.10.2009 Mechanical Hitesh Patel Other

72 20027940 Kartik Hingrajiya M-8 16.10.2009 Operation Ashok Chandna Gujarat

73 20028134 Manoj Khatri M-8 03.11.2009 Operation Ashok Chandna Gujarat

74 20028136 Jilesh Lalani M-7 04.11.2009 Operation Samirkumar Dave Gujarat

75 20028659 Vikesh Nigam M-8 20.11.2009 Operation Suresh Kalaskar Other

76 20028667 DIGVIJAYSINH Zala M-8 20.11.2009 Operation Rupak Patel Gujarat

77 20028802 Mahendra Chhatrola M-8 16.12.2009 Electrical Ashit Gothi Gujarat

78 20029165 Ravindra Patel M-7 04.01.2010 C&I Manoj Mishra Gujarat

79 20029660 Dinesh Prajapati M-7 11.01.2010 Mechanical Jayanti Kachhadiya Gujarat

80 20029661 Ashish Jani M-9 11.01.2010 Electrical Vijay H Chauhan Gujarat

81 20029801 Bhavik Shah M-8 18.01.2010 Operation Jilesh Lalani Gujarat

82 20031020 Ritesh Vyas M-7 12.04.2010 Operation Krunal Patel Gujarat

83 20031104 Rakesh Kanani M-6 19.04.2010 Mechanical Jayanti Kachhadiya Gujarat

84 20031201 Saurabh Vyas M-7 21.04.2010 Mechanical Hitesh Patel Gujarat

85 20031277 Sandip Patel M-7 27.04.2010 Mechanical Hitesh Patel Gujarat

86 20031588 Chirag Machchhar M-9 17.05.2010 Operation Rupak Patel Gujarat

87 20031852 Hrishikesh Bhatt M-9 31.05.2010 Operation Suresh Kalaskar Gujarat

88 20032052 Vimal Solanki M-9 14.06.2010 Operation Rupak Patel Gujarat

89 20032172 Hiren Undhad M-8 21.06.2010 Operation Krunal Patel Gujarat

90 20032323 Chetan Ghodasara M-8 05.07.2010 Operation Ashok Chandna Gujarat

91 20032431 Hitesh Patel M-6 12.07.2010 Mechanical Jayanti Kachhadiya Gujarat

92 20032504 Ashish Sharma M-9 15.06.2010 Operation Ashok Chandna Other

93 20032510 Shashank Shekhar M-9 15.06.2010 Operation Dipak Soni Other

94 20032624 Prahlad Sharma M-9 19.07.2010 Operation Ashok Chandna Other

95 20032625 Lalitkumar Jethwa M-5 19.07.2010 Electrical Sanjay Kumar Gupta Gujarat

96 20032947 Mahesh Paradava M-9 05.07.2010 Mechanical Rakesh Kanani Gujarat

97 20032948 Chintan Kavar M-9 05.07.2010 C&I Janak Pansuria Gujarat

98 20032956 Nikhil Vachhani M-8 02.08.2010 Power Commercial Samir Patel Gujarat


Sr.

No.

Employee


Date Of


99 20033166 Apurva Tare M-8 22.07.2010 Mechanical Hitesh Patel Gujarat

100 20033183 Surbhi Chaturvedi M-9 22.07.2010 Electrical Vijay H Chauhan Other

101 20033200 Krishnakant Shah M-8 22.07.2010 Procurement Nilesh Dave Gujarat

102 20033359 Hiren Bhuva M-8 22.07.2010 Mechanical Vasantkumar Patel Gujarat

103 20033365 Madhurendra Tiwari M-8 15.07.2010 Technical Services Sanjaykumar Shah Other

104 20033597 Yuvraj Sahu M-10 05.07.2010 Operation Krunal Patel Other

105 20033627 Ashok Chandna M-7 23.08.2010 Operation Samirkumar Dave Gujarat

106 20033650 Sagar Kumar Kanjariya M-10 09.08.2010 Mechanical Hitesh Patel Gujarat

107 20033651 Jaysukh Kumar Sonagra M-10 09.08.2010 Mechanical Dinesh Prajapati Gujarat

108 20033654 Naresh Kumar Mandaliya M-10 09.08.2010 Mechanical Jayanti Kachhadiya Gujarat

109 20033655 Sagar Parmar M-10 09.08.2010 Operation Krunal Patel Gujarat

110 20033656 Kamlesh Tirthani M-10 09.08.2010 Electrical Alpeshkumar Dhamsania Gujarat

111 20033657 Jignesh Kumar Parmar M-10 09.08.2010 Operation Rohit Patel Gujarat

112 20033658 Haresh Dharajiya M-10 09.08.2010 Mechanical Rakesh Kanani Gujarat

113 20033661 Dhiral Pandya M-10 09.08.2010 Operation Jilesh Lalani Gujarat

114 20033664 Nikunj Solanki M-10 09.08.2010 Operation Rakesh Kharat Gujarat

115 20033667 Hardik Gosai M-10 09.08.2010 Operation Dipak Soni Gujarat

116 20033668 Pradip Kumar Savaliya M-10 09.08.2010 Mechanical Vasantkumar Patel Gujarat

117 20033669 Hardik Koria M-10 09.08.2010 Electrical Alpeshkumar Dhamsania Gujarat

118 20033671 Dhruvrajsinh Parmar M-10 09.08.2010 Operation Rakesh Kharat Gujarat

119 20033672 Yogesh Dave M-10 09.08.2010 Operation Jilesh Lalani Gujarat

120 20033675 Paras Bataviya M-8 09.08.2010 Mechanical Rakesh Kanani Gujarat

121 20033677 Narendra Sinh Jadeja M-10 09.08.2010 Mechanical Dinesh Prajapati Gujarat

122 20033678 Vijay Somani M-10 09.08.2010 Operation Jilesh Lalani Gujarat

123 20033679 Upendra Rathod M-10 09.08.2010 Operation Rohit Patel Gujarat

124 20033680 Kishan Anadkat M-10 09.08.2010 C&I Ketankumar Pancholi Gujarat

125 20033681 Mitesh Chavda M-10 09.08.2010 Electrical Vijay H Chauhan Gujarat

126 20034161 Chirag Prajapati M-8 20.09.2010 Operation Rakesh Kharat Gujarat

127 20034162 Jagdish Kavar M-8 20.09.2010 Electrical Vijay H Chauhan Gujarat

128 20034349 Jayanti Kachhadiya M-5 27.09.2010 Mechanical Sanjay Kumar Gupta Gujarat

129 20034350 Nilesh Motivaras M-8 27.09.2010 Electrical Ashit Gothi Gujarat

130 20034351 Nainesh Kumar Kharva M-9 27.09.2010 Mechanical Vasantkumar Patel Gujarat

131 20034372 Piyush Kukadia M-9 23.08.2010 C&I Ketankumar Pancholi Gujarat

132 20034419 Jatin Dattani M-8 23.08.2010 C&I Janak Pansuria Gujarat

133 20034782 Prafulla Kumar Mahto M-10 13.09.2010 Operation Jilesh Lalani Other

134 20034809 Anil Dabhi M-8 18.10.2010 Mechanical Dinesh Prajapati Gujarat

135 20035008 Vijay Parmar M-10 01.10.2010 IT Kantilal Makwana Gujarat

136 20035023 Ashish Kataria M-10 01.10.2010 IT Bhavesh Champaneri Gujarat

137 20035073 Mahesh Lakhatariya M-8 21.10.2010 Operation Dipak Soni Gujarat

138 20035327 Suresh Bharadwa M-8 15.11.2010 Electrical Vijay H Chauhan Gujarat

139 20035537 Rajendra Parmar M-8 13.12.2010 Mechanical Dinesh Prajapati Gujarat

140 20035949 Rohit Patel M-7 17.01.2011 Operation Samirkumar Dave Gujarat

141 20038609 Venkataraman Nagarajan M-8 11.07.2011 Technical Services Sanjaykumar Shah Other

142 20038614 Suchit Changela M-9 15.06.2011 Mechanical Hitesh Patel Gujarat

143 20038954 Prashanta Naik M-9 18.07.2011 Mechanical Rakesh Kanani Other

144 20038955 Anupam Xess M-9 18.07.2011 Mechanical Rakesh Kanani Other

145 20040875 Basant Ojha M-9 20.09.2011 Operation Rakesh Kharat Other

146 20041097 Ansar Inamdar M-10 24.09.2011 Operation Suresh Kalaskar Other

147 20041101 Bavbhai Faga M-10 24.09.2011 Operation Ashok Chandna Gujarat


Sr.

No.

Employee


Date Of


148 20041105 Dilip Kidecha M-10 24.09.2011 Operation Dipak Soni Gujarat

149 20041111 Haresh Kachhela M-10 24.09.2011 Operation Jilesh Lalani Gujarat

150 20041113 Jaydip Ganatra M-10 24.09.2011 Mechanical Vasantkumar Patel Gujarat

151 20041114 Ketan Mori M-10 24.09.2011 Operation Ashok Chandna Gujarat

152 20041115 Laxman Behera M-10 24.09.2011 Operation Krunal Patel Other

153 20041117 Mahantesh Magadum M-10 24.09.2011 Mechanical Amit Morzaria Other

154 20041118 Mehul Oza M-10 24.09.2011 Operation Krunal Patel Gujarat

155 20041120 Milan Mori M-10 24.09.2011 Operation Krunal Patel Gujarat

156 20041123 Nikunj Kariya M-10 24.09.2011 Operation Jilesh Lalani Gujarat

157 20041125 Prashant Barot M-10 24.09.2011 Operation Dipak Soni Gujarat

158 20041128 Rakesh Dave M-10 24.09.2011 Operation Krunal Patel Gujarat

159 20041132 Sharad Dharasandiya M-10 24.09.2011 Mechanical Dinesh Prajapati Gujarat

160 20041141 Yogesh Tiwari M-10 24.09.2011 Mechanical Hitesh Patel Gujarat

161 20041267 Mayur Mehta M-10 15.11.2011 Mechanical Amit Morzaria Gujarat

162 20041936 Virendra Singh M-8 30.01.2012 Mechanical Dinesh Prajapati Other

163 20042095 Gurutej Nittala M-9 13.02.2012 Operation Krunal Patel Other

164 20042096 Rajendra Dadhich M-8 16.02.2012 Operation Krunal Patel Other

165 20042283 Dipak Soni M-7 01.03.2012 Operation Samirkumar Dave Gujarat

166 20042284 Rakesh Kharat M-7 01.03.2012 Operation Samirkumar Dave Gujarat

167 20042285 Suresh Kalaskar M-7 01.03.2012 Operation Samirkumar Dave Other

168 20042286 Manish Ranjan M-9 01.03.2012 Operation Jilesh Lalani Other

169 20042347 Rajendra Yadav M-8 12.03.2012 Operation Rohit Patel Other

170 20042395 Amit Prasad M-10 17.03.2012 C&I Janak Pansuria Other

171 20042544 Sreedhar Govardhanam M-9 10.04.2012 Operation Dipak Soni Other

172 20042545 Arunprasad Arivazhagan M-9 10.04.2012 Operation Rohit Patel Other

173 20045542 Shubham Suneja M-10 29.05.2013 Operation Dipak Soni Gujarat

174 20046162 Satyam Kumar M-10 02.09.2013 C&I Manoj Mishra Other

175 20046411 Shivangi Patel M-10 17.10.2013 C&I Ketankumar Pancholi Gujarat

176 20046669 SUDHIR KUMAR SINGH M-6 16.12.2013 HSE Kishor Makadia Other

177 20048619 Pranav Shukla M-11 25.09.2014 Operation Rupak Patel Gujarat

178 20048621 Ajit Sharma M-11 25.09.2014 Operation Rupak Patel Other

179 20049407 Santosh Tanwar M-8 16.02.2015 HR Admin Kishor Makadia Other

180 20049946 RajKumar Kakkad M-10 26.05.2015 Mechanical Dinesh Prajapati Gujarat

181 20049977 Hitesh Mavjibhai Dori M-11 05.06.2015 C&I Manoj Makadia Gujarat

182 20050189 Rajnish Faldu M-11 15.07.2015 Mechanical Rakesh Kanani Gujarat

183 20050377 Hardik Trivedi M-10 10.08.2015 Operation Jilesh Lalani Gujarat

184 20050621 Vipin Nigam M-9 16.09.2015 Operation Krunal Patel Gujarat

185 20051197 Asha Nimavat M-11 02.01.2016 Operation Ashok Chandna Gujarat

186 20051198 Dharmraj Dave M-7 02.01.2016 CRG Anil Vishwambharan Gujarat

187 20052811 Sasank Loya M-10 02.12.2016 Procurement Rahulvardhan Sharma Other

188 20052799 Brijesh Kachhadia M-11 28.11.2016 Operation Rohit Patel Gujarat

189 20052791 Pinak Bhalodia M-10 21.11.2016 Power Commercial Samir Patel Gujarat

190 20052797 Dolatsinh Jadeja M-11 21.11.2016 Safety Bhavesh Madhavi Gujarat

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Annexure 1.12: CCA compliance

CCA Compliance Report of Nayara Energy Limited AWH-81987 dtd 13/10/2016 and amended on 27/05/2017 valid till 16/09/2022

Sr No. CONDITIONS PRESENT STATUS

Specific Conditions:

Industry shall have to comply with all the conditions stipulated in the Environment Clearance, CRZ clearance and approval of Wild Life Board.

Detail Compliance reports of EC, CRZ and Wild Life clearance are submitted separately to MoEF & CC/CPCB/GPCB. Recent EC compliance has been submitted vide our letter EOL/ENV/EC compliance Report/2018/741 dated 17/05/2018. Recent CRZ and Wild Life clearance compliance has been submitted vide our letter no. Nayara Energy/ENV/Compliance report 2017-18/2018/751 dated 7th June 2018.

Applicant shall have to submit copy of approval of chief controller of explosives for storage & handling: up dated disaster management plan along with onsite & off site Emergency plans as well as periodical compliance report for 'CREP' action in respect of petroleum refinery & other guidelines/directives issued/ being issued / CPCB / DOEF / Hon’ble court from time to time.

Approval of chief controller of explosives for storage & handling have been obtained. Copy attached herewith as Annexure 1.5. Nayara Refinery Disaster Management Plan has been prepared along with onsite and offsite emergency plan. Updated ERDMP is attached herewith as Annexure 1.6. CREP compliance report is submitted 6 monthly to MoEF & CC/CPCB/GPCB. Copy attached herewith as Annexure 1.9.

Applicant shall have to carry out mock drill both onsite and offsite for all the possible eventualities at regular interval of time. For any of the disastrous situations. Escape route shall have to be predefined, properly marked and shall be brought to the knowledge of the concerned.

Mock drills are carried out as per schedule every month. Mock drill report has been attached herewith as Annexure 1.7.

Applicant shall have to obtain the ISO 14001: 2004 and ISO 18001 certification and shall have to implement the Suggestion/recommendations of the same.

We have implemented our own Refinery Integrated Management Systems (RIMS) comprising of ISO 9001 (Quality), ISO 14001 (Environment), ISO 45001(Occupational Health & Safety) & ISO 50001.

Applicant shall to prepare and implement the special oil spill contingency plan.

Oil Spill contingency plan prepared. Attached herewith as Annexure 1.11.1.

Applicant shall have to carry out the regular health check up of employee as well as of the nearby villages. For the medical services to all. 'Mobile van with medical facilities shall be provided.

Six monthly health check-up of all the employees working in hazardous area. Records shown below. Mobile Van with medical facilities has been provided to surrounding villages.


Applicant shall have to utilize low sulfur fuel as much as possible & also to install adequate storage facilities in order to minimize fugitive & air emission.

Low sulphur fuel (<1% S) - Oil and Fuel Gas is utilized within plant. Quality of Fuel Oil & Fuel Gas for the last six month is shown Table no. 01 & 02. Table no. 01: Sulphur Concentration in Wt% in Fuel Oil

Sulphur Concentration in Wt% in Fuel Oil

Sr. No.


1 Mar 0.94 2 Apr 0.84 3 May 0.77 4 Jun 0.59 5 Jul 0.44 6 Aug 0.57

Table no. 02: H2S Concentration in mg/Nm3 in Fuel Gas.

H2S Concentration in mg/Nm3 in Fuel Gas

Sr. No.


1 Mar 32.5


2 Apr 21.9

3 May 14.3

4 Jun 11.8

5 Jul 16.8

6 Aug 19.4

Applicant shall have to provide continuous on line monitoring facilities for the monitoring of the different pollutants.

Two Nos. of Continuous ambient air monitoring stations, Continuous emission monitoring systems in all the stacks and Continuous effluent monitoring system for treated effluent installed and hooked up with CPCB Server.

Applicant shall comply with provision of the Forest (conservation Act-1980 and Rule- 1981. The Petroleum and Minerals (pipeline acquisition of right of user land) Act-1962. CRZ notification and all Environmental Acts/Rules/Notifications and their amendments from time to time.

Refinery is complying with Forest (conservation Act-1980 and Rule- 1981 and submit 6 monthly compliance report for the Forest Clearance given vide No.8C/12/385/96 FCW, dated. 08.12.1999

Agreed.

Applicant is also required to comply with the Manufacturing, storage and Import of Hazardous Chemicals rules- 1989 framed under the Environment (protection) Act-1986.

All legal requirements of MSIHC rules are being taken

care off as per integrated management system

requirements. (Detailed compliance covered under

specific condition no. xxv in comprehensive

compliance report.)

GPCB reserves the right to stipulate additional conditions if found necNayaray. The company will implement these conditions in a time bound manner.

Agreed.

1

The Consolidated Consent and Authorization shall be valid up to 16.09.2022 for use of outlet of the discharge of the trade effluent & emission due to operation of industrial plant for Crude processing capacity 21 MMTPA for the following items/products

Complied with Production data for last six month are shown in Table no. 03:

1. LPG: 3.4 – 5.4 %Yield

2. Kero + ATF: 0 – 8.6%Yield

3. Naphtha/ MS/ Gasoline: 16.0 – 24.6 %Yield

4. HSD: 48.6 – 52.9 %Yield

5. Furnace Oil/VGO: 0 – 22.9 % Yield

6. Sulfur: 1.4 – 1.7 % Yield

7. Bitumen: 0.0 – 3.4 % Yield

8. Fuel & Loss (Refinery) 7.8 – 8.7 % Yield

9. Pet Coke 9.1 – 12.9 % yield


Table no.03: Production Data for the month of March’18 to August’18

Type of product Unit

Mar'18 Apr’18 May'18 Jun'18 Jul'18 Aug'18

LPG % Yield 4.6 4.8 4.8 4.3 4.7 4.5

% Yield % Yield 2.8 3.1 3.0 2.7 4.2 6.0

% Yield % Yield 16.8 15.9 16.6 16.8 15.9 15.7

% Yield % Yield 4.5 3.8 3.5 3.6 5.2 4.1

% Yield % Yield 52.7 53.8 52.9 51.6 52.3 50.8

% Yield % Yield 0.0 3.1 1.7 2.4 2.6 1.3

% Yield % Yield 0.0 0.0 0.0 0.0 0.0 0.0

% Yield % Yield 1.6 1.4 0.3 1.2 0.0 0.8

% Yield % Yield 1.6 1.6 1.6 1.5 1.6 1.6

% Yield % Yield 10.3 11.2 11.1 10.4 11.7 11.2

Total Production

MT/Month 95 99 95 95 98 96

Total crude Processed

MT/Month 1785294

1729837 1789717 1723994 1787021 1781148

2 CONDITIONS UNDER THE WATER ACT:

2.1 The Quantity of trade effluent from factory shall not exceed 25400 m³ / day

Actual Qty is monitored on hourly basis which is in the range of 18000 - 19000 m3/day. The Quantity of trade effluent from factory for last six month is shown in Table no. 04.

Table no. 04: The Quantity of trade effluent from factory

Sr. No. Mar’18 Apr’18 May’18 June’18 July’18 Aug’18

01

Trade

effluent,

M3/Day

16752 17872 18235 18939 19430 19266

2.2 The Quantity of sewage from factory shall not exceed 405 m³ / day

Actual Qty., 200-250 m3/day

2.3 TRADE EFFLUENT:

2.3.1 The quality of treated effluent as per GPCB norms mentioned below:

Effluent monitoring is done on daily basis. All parameters are well within limit.


Quantum limit in Kg/1,000 tonne of crude processed

for the Month of Mar’18 to Aug’18 is shown in Table

no.05:

Table no.05: Quantum limit in Kg/1,000 tonne of

crude processed


Quantum limit in

Kg/1,000 of crude

processed

1. Oil & Grease

0.05

2. BOD 3 days, 27oC

0.15

3. COD 0.50

4. Suspended Solids

0.18

5. Phenols 0.0013

6. Sulphides 0.0047

7. CN 0.00069

8. Ammonia as N

0.07

9. TKN 0.07

10. P 0.01

11. Cr(Hexavalent)

0.00137

12. Cr(Total) 0.0001

13. Pb 0.0004

14. Hg 0.00003

15. Zn 0.00068

16. Ni 0.00145

Sr No. Parameters Limit

Kg/ MT of

crude

processed

1 pH 6-8.5

2 SS 20 mg/l 8

3 O&G 5 mg/l 2

4 Phenol 0.35 mg/l 0.14

5 Sulphides 0.5 mg/l 0.2

6 BOD (5days 20) 15 mg/l 6

7 COD 125 mg/l 50

8 Cyanides (as CN) 0.2 mg/l 0.08

9 Ammonia (as N) 15 mg/l 6

10 TKN 40 mg/l 16

11 P 3 mg/l 1.2

12 Cr(Hexavalent) 0.1 mg/l 0.04

13 Cr(Total) 2 mg/l 0.8

14 Pb 0.1 mg/l 0.04

15 Hg 0.01 mg/l 0.004

16 Zn 5 mg/l 2

17 Ni 1 mg/l 0.4

18 Cu 1 mg/l 0.4

19 V 0.2 mg/l 0.8

20 Benzene 0.1 mg/l 0.04

21Benzo (a)-

Pyrene0.2 mg/l 0.08


17. Cu 0.00090

18. V 0.0014

19. Benzene 0.00001

20. Benzo(a)-Pyrene

0.00001

2.3.2

The Refinery effluent conforming to the above standards shall be utilized for fresh water Cooling Tower and Sea Water cooling tower make - up and remaining quantity shall be used for fire water make – up, horticulture, dust suppression so as to achieve 100% recycle. The Quality of trade effluent shall not exceed 25400 kl/day

Full quantity of treated water is utilized with in refinery as fire water make - up, service water & in cooling tower make – up and Green belt.

2.3.3

The total quantity of treated waste water, R.O. Reject and Desalination plant reject of 206496 kl/day shall be returned to sea via pipeline and shall be released through diffuser at a point 220 29’ 39’’ N; 690 39’ 54” E and in a manner recommended by NIO vide their letter bearing no. NIO/B-2007/NAYARA (Salaya) dt. 31/05/2007.

Cooling tower blow down and desalination reject is discharged to sea through diffuser system designed as per NIO recommendation.

2.3.4

All the effluent treatment units shall be operated and maintained efficiently so that the treated effluent always conforms to the specifications referred in condition no. 2.3.1 above.

ETP is performing well. Stream wise analysis is done daily and is confirming to the specifications to ensure efficiency of ETP.

2.3.5

Domestic effluent generated from part of refinery shall be treated in the biological sections of ETP. Domestic effluent from Jetty shall be treated separately to conform to the standard and discharged into the Jetty.

Sewage is treated with trade effluent in secondary treatment plant meeting to GPCB limits.

BOD (5 days 20°C) <20 mg/l

SS <30 mg/l

Residual Chlorine Minimum 0.5 ppm

3 CONDITIONS UNDER THE AIR ACT:

3.1 The following shall be used as fuel: Complied Fuel quantity for last six month is shown below.

Fuel consumption, MT/hr

Mar’18

Apr’18

May’18

June'18

July'18

Aug'18

LCO/ GT FUEL/ IFO/

75.45

74.37

75.40

73.65

75.91

75.93

Fuel Type Fuel Consumption Rate

Liquid Fuel (LCO/ GT FUEL/ IFO/ HSD/ 101 MT/ Hr. LDO) / Fuel Gas


HSD/ LDO) / Fuel Gas

3.2 The applicant shall install and operate air pollution control system in order to achieve norms prescribed below:

Cyclone separator, Low NOx burners are installed to control emission

3.2.1 (a) The flue gas emission through stacks attached to Boiler/ Furnace/ Heater/ plant shall conform to the following standards:

Manual monitoring is carried out by NABL accredited third party M/s Unistar Environment and Research Labs, Vapi every month and monthly report is submitted to GPCB. Continuous Emissions monitoring analysers installed in stacks and hooked up with CPCB server

M

3.2.1

(b) The following stacks attached to boiler/ furnace/ heater shall conform to the standards referred in conditions no. 4.2.1(a)

Sr. No Stacks attached to

Stack dia. meters

Stack Height meters

1 CDU/VDU 5.7 130

2 CDU-II 3.5 100

3 NHT/CCR 5.7 130

4 DHDS 2.4 70

5 FCC Feed Heater

3.7 110

6 HMU Furnace

1.1 60

7 HMU I & II 4.7 45

8 DCU Heater I, II & III

2.5 65

9 DHDT 2.8 60

10 VGOHT 3.1 60

3.2.2 Industry shall have to vent flammable gases through the following flares

Flammable gases are vented through flare.

Sr No. Stacks Limits

Gas - 50 mg/ Nm³

Liquid - 1700 mg/ Nm³

Gas - 350 mg/ Nm³


Gas - 10 mg/ Nm³


Gas - 150 mg/ Nm³


5 Nickel & Vanadium(Ni + V) Liquid - 5 mg/ Nm³

6Hydrogen Sulphide (H2S) in

Fuel GasGas - 150 mg/ Nm³

7Sulphur Content in Liquid

Fuel weight %Liquid – 1

1

2

3

4

Sulphur Dioxide (SO2)

Nitrogen Oxide(NOx)

Particulate Matter (PM)

Carbon Monoxide (CO)


Sr. No

Type of Flare

No of flare stack

Flare stack height in m

1 Hydrocarbon Base Flare

1 100

2 Hydrocarbon Expansion Flare

1 150

3 H2S Flare 1 100

4 H2S Expansion Flare

1 150

5 LPG Flare 1 65

3.2.3 (a)

(a) The process emission through various stacks / vents of reactors, process, vessel shall conform to the following standards: FCC Regenerator

Sr No.

Parameters Hydroprocess Feed (mg/Nm³)

Other than Hydroprocess feed (mg/Nm³)

1 Sulphur Dioxide

500 1700

2 Nitrogen Oxide

400 450

3 Particulate Matter

100 100

4 Carbon Monoxide

400 400

5 Ni+V 2 5 6 Opacity 30% 30%

Manual monitoring is carried out by NABL accredited third party M/s Unistar Environment and Research Labs, Vapi every month AND monthly report is submitted to GPCB Continuous Emissions monitoring analysers installed in stacks and hooked up with CPCB server

3.2.3 (b)

(b) Sulphur Recovery Units Sr. No

Parameter Permissible Limit

1 Sulphur recovery 98.7% 2 H2S 15 mg/ Nm3

3 Nitrogen Oxide 350 mg/ Nm3 4 Carbon Monoxide 150 mg/ Nm3

(c)

Manual monitoring is carried out by NABL accredited third party M/s Unistar Environment and Research Labs, Vapi every month AND monthly report is submitted to GPCB.

Continuous Emissions monitoring analysers installed in stacks and hooked up with CPCB server


3.2.4

(b) The following emission stacks/ vent of reactors, process and vessel shall conform to the standards referred in condition no. 3.2.3 (a)

Sr No. Stack attached to Height (mt)

1 FCC Regenerator 110

2 SRU 80

Noted and agreed

3.2.5

The concentration of the parameters in the ambient air within the premises of the industry shall not exceed the limits specified in NATIONAL AMBIENT AIR QUALITY STANDARDS – E(P)A Seventh Amendment Rules – 2009 , as mentioned below,

Manual monitoring is carried out by NABL accredited third party M/s Unistar Environment and Research Labs, Vapi weekly once at four locations upwind, downwind and two cross winds and monthly report is submitted to GPCB. Two Continuous ambient air quality monitoring stations set up and hooked up with CPCB server

3.2.6 For all combustion processes either sulphur free or desulfurized fuel shall be used.

Desulphurized fuel is being used.

3.2.7

Low NOx burners and/or De NOx system shall be incorporated for controlling NO2 into atmosphere. The residual NOx emission shall be in such a way that it will be dispersed effectively before reaching ground level.

Low NOx Burners are installed in all stacks

3.3

The application shall provide portholes, ladder, platform etc at chimney(s) for monitoring the air emissions and the same shall be open for inspection to/and for use of Board’s staff. The chimney(s) vents attached to various sources of emission shall be designed by numbers such S-1, S-2 etc. and these shall be painted/displayed to facilitate identification.

Portholes, ladder, platform etc at chimney(s) for monitoring the air emissions is provided. The chimney(s) vents attached to various sources of emission has been designed by numbers such S-1, S-2 etc. and these are painted/displayed to facilitate identification.

3.4

The industry shall take adequate measures for control of noise levels from its own sources within the premises so as to maintain ambient air quality standards in respect of noise to less than 75 B (A) during day time and 70 dB (A) during night time. Daytime is reckoned in between 6 a.m. and 10 p.m. and night time is reckoned between 10 p.m. and 6 a.m.

The industry has taken adequate measures for control of noise levels source within the premises so as to maintain ambient air quality standards.

However to ensure compliance with the standard

noise levels are monitored during day and night in the

Sr.

NoPollutant

Time

weighted

average

Concentration

in ambient air

Annual 50

24 Hrs 80

Annual 40

24 Hrs 80

Annual 60

24 Hrs 100

Annual 40

24 Hrs 60

8 Hrs 2

1 Hr 4

6 Benzene (C6H6) µg/m³ Annual 5

7Banzo (a) Pyrene (BaP) particulate

phase only, µg/m³Annual 1

5 Carbon Monoxide (CO) mg/Nm³

Nitrogen Dioxide( NO2)µg/m³

1 Sulphur Dioxide( SO2) µg/m³

2

3Particulate matter(size less than

10 ppm) or PM 10 µg/m³

4Particulate matter(size less than

2.5 ppm) or PM 2.5 µg/m³


periphery of refinery. Monitoring results are as given

below.

Period: Mar’18 to Aug’18

Locations

Noise Level, dB(A)

during Day Time

06:00 am to 10:00 pm

Noise Level, dB(A) during Night

Time

10:00 pm to 06:00 am

Ambient Station at Port A Camp1 50 - 53 49 - 51

Ambient Station at Labour Gate1 52 - 53 50 - 52

Ambient Station at West side of Main Flare1 49 - 52 47 - 50

Nr. Batching Plant 52 - 53 51

Ambient Station at 93 Gate 50 - 52 49 - 51

Storm water drain outlet 51 - 54 50 - 52

Ambient Station at Refinery Main Gate1 51 - 52 49 - 51

Nayara Petrol Pump (Near Delhi Darbar) 51 - 55 50 - 53

Ambient Station at Pet Coke Rail Loading

Yard

51 - 52 48 - 50

Ambient Air Quality standards in terms of

Noise for industrial area

75 dB(A) 70 dB(A)

3.5

Industry shall have to comply with EIA Notification No – SO 1533(E) dated 14th Sept – 2006 and its amendment issued from time to time by Ministry of Environment and Forest Govt. of India, New Delhi. Industry shall comply all the conditions stipulated in obtained Environmental Clearance

We are complying with EIA Notification, dated 14th Sept – 2006 and its amendment issued from time to time by Ministry of Environment and Forest.

3.6

The industry shall comply all conditions issued by Ministry of Environment and Forest, GOI, New Delhi in their environmental clearance issued time to time and any directions issued from time to time. Regular compliance of it shall be submitted half yearly to this Board.

6 monthly compliance report of conditions given in the clearance is submitted 6 monthly to MoEF &CC, CPCB and GPCB.


3.7

The applicant shall also comply with all standards/ notes etc. mentioned under GSR 186(E) dt. 18/03/2008 issued viz. notes for effluent, emissions, FCC Regenerators, Sulfur Recovery Units as wells as standards/guidelines etc. under part c entitled fugitive emission, storage of volatile liquid: Benzene storage, solvent for lube-base oil production (furfural, MEK, Toluene and MIBK); standards for equipment leaks; emission standards for VOC from waste water collection and treatment. You are directed to comply these conditions judiciously and send reports about the action taken regularly to this office.

We are complying with GSR 186(E) dt. 18/03/2008 for effluent, emissions, FCC Regenerators, Sulphur Recovery Units as wells as standards/guidelines. Detailed compliance is given as Annexure-4.

4 CONDITIONS UNDER THE HAZARDOUS & OTHER WASTES (MANAGEMENT AND TRANSBOUNDARY MOVEMENT) RULES, 2016

4.1

The authorization is granted for the following hazardous waste, its quantity and mode of handling & disposal:

Sr. No.

Description of Wastes

Schedule - I

Quantity per Year

Mode of Handling & Disposal

1 Oily Sludge from ETP

35.3 13000 MT

Collection, Storage, Transportation and disposal through TSDF/ Incineration / actual users / Co-processing in Delayed Coker Unit (DCU)

2 Slop Oil 4.3 120000 MT

Collection, Storage and Recycle within the Plant

3 Oily rags/ Oil


The hazardous wastes authorized for generation in the unit are well within the authorized quantity and disposed as per the mode in CC&A.


contaminated waste

disposal through TSDF/ Incineration / actual users /

4 Used Lubricating Oil

5.1 300 MT Collection, storage, transportation and siposal by selling it to registered re-refiner units

5 Oily Sludge & BSW

4.1 5000 MT Collection, Storage, Transportation and disposal through TSDF/ Incineration / actual users / Co-processing in Delayed Coker Unit (DCU)

6 Spent Catalyst from Various Units

4.2 8000 MT Collection, Storage, Transportation & Disposal through actual users / TSDF/ Incineration

7 Contaminated cotton rags or other



cleaning materails

Disposal through actual users / TSDF/ Incineration

8 Discarded Empty Drums/ Containers

33.1 50000 Nos

Collection, Storage, Transportation & Disposal through actual users

9 Spent Resin Waste

35.2 15 MT Collection, Storage, Transportation and disposal through TSDF/ Incineration / actual users

10 Insulated copper wire scrap/ copper with PVC sheathing cable

IV/7 200 MT Collection, storage and disposal by selling it to registered recycler, reprocessor/ actual user

11 Lead Acid Battery Waste

- 10 MT Collection, Storage, Transportation & Disposal through actual users


12 Expired Hazardous Chemicals

II/ E3 100 MT Collection, Storage, Transportation and disposal through TSDF/ Incineration / actual users

13 Spent Carbon

36.2 200 MT Collection, Storage, Transportation and disposal through TSDF/ Incineration / actual users/ incineration in power plant boilers

14 e- waste - 20 MT Collection, storage and disposal by through actual user/ registered recycler

15 Waste Coke II- Class A-70

100 MT Collection, storage and disposal by through actual user

16 Spent Catalysts and Molecular Sieves

1.6 100 MT Collection, Storage, Transportation and disposal


through TSDF/ Incineration / actual users

4.2 You shall keep complete records of the types, quantities and characteristics of hazardous waste and its management from collection to ultimate disposal.

Inventory management sheet having the details of hazardous wastes generated in the Refinery is maintained and also uploaded in the monthly patrak of GPCB XGN site.

4.3

Storage site will be prepared and maintained as follows:-

a. Storage site will have sufficient capacity for storage of solid hazardous waste impervious lining having four- side adequate boundary protection.

Two nos. of Hazardous waste storage shed with 11600 m2 area with HDPE linear facility and have dedicated 3 no. of sludge drying pit with 3000 m3 capacity each

b. A Leachate collection and drainage line at all storage sites shall be provided and connected to the inlet of Effluent treatment plant for treatment.

Leachate collection system has been provided in all sludge storage pits, which is connected to Expansion ETP for sending Leachate for treatment.

c. Additional precautions shall be taken to prevent surface runoff through waste body during monsoon.

Additional precautions has been taken to prevent surface runoff during monsoon.

4.4 Unit shall explore the possibilities of waste minimization, avoidance, reuse, recycling etc. and submit the complete plan for approval of GPCB.

Unit has succeeded in projects like reusing Spent Carbon and Oily Sludge inside the Refinery. Also we have applied and received consent for reusing Spent Carbon in Power Plant Boilers. Reprocessing Oily Sludge in DCU.

4.5 The waste generator shall be totally responsible for collection, storage, transportation and ultimate disposal of the wastes generated

We have a dedicated Waste Management Procedure which is strictly followed in our Refinery for proper management of wastes.

4.6

Waste after required treatment shall be stored with due care that in no case any waste shall be released from this site into Environment causing surface water or underground water or soil pollution.

No waste is being treated in Refinery. All the wastes are reused, sold to SPCB authorized recyclers or sent to GPCB authorized TSDF Site.

4.7 In no case waste shall be disposed off on land, within or outside factory premises, sold out to traders/dealers or transferred, without prior approval of the Board.

All the wastes are reused, sold to SPCB authorized recyclers or sent to GPCB authorized TSDF Site.

4.8 At the storage site, “Hazardous Waste Storage Site” & “Danger” signboards shall be provided with all safety devices.

Boards have been provided with danger sign as well as with the details of the wastes stored in the site at the Hazardous Waste storage sheds and Pits.

4.9 Each type of waste shall be stored in a separate storage cell. In no case more than one waste shall be stored in one cell.

All the wastes generated are stored in separate dedicated cells provided at Hazardous Waste Storage Site.

4.10 Post storage monitoring shall be regularly carried out and report of the same shall be submitted to GPCB

It is not applicable as NAYARA’s is not TSDF Site.


4.11

The occupier may store the hazardous waste for a period not exceeding 90 days and shall maintain the records of sale, transfer, storage, recycling and reprocessing of such waste and make these records available for inspection. GPCB may extend the said period under certain conditions specified in the Hazardous and other Wastes( Management, and Transboundary Movement ) Rules - 2016

Noted

4.12 The storage area shall have appropriate containment system as described in Guideline prepared by M.O.E.F. Government of India.


4.13 During all above activities, due care shall be taken to avoid any leakage or release of hazardous waste into environment.


4.14 Preparation of containers it’s total No. Map of storage site nearby activity etc. shall be maintained and submitted to GPCB.


4.15 Emergency plan shall be prepared for storage site of Hazardous waste and submitted to GPCB, Gandhinagar.


4.16 The generator shall not offer his hazardous waste to transportation and to disposal facilities that have not been authorized by Gujarat Pollution Control Board.

All the wastes are reused, sold to SPCB authorized recyclers or sent to GPCB authorized TSDF Site.

4.17

The generator, occupier, transporter and operator of the TSDF facility shall comply with the directives specified by MOEF, Govt. of India, under the Hazardous and other Wastes( Management, and Transboundary Movement ) Rules - 2016


4.18

For transportation of waste the generator & transporter shall ensure that the hazardous wastes are collected and packed separately as per characteristic wise category wise in such type of suitable container that it does not react with the wastes.

Reactivity of the wastes is studied and then it is properly packed and sent in suitable packaging material to SPCB authorized recyclers or sent to GPCB authorized TSDF Site.

4.19 During transportation container shall be closed from all the sides except at the time of removal of wastes.

While transportation all the trucks are covered with tarpaulin to ensure no spillage of wastes

4.20 Hazardous waste shall be packaged and labelled as per guidelines issued by Central Pollution Control Board from time to time.

All the wastes except oily sludge are packed in drums/ jumbo bags and labelled as per the guidelines.

4.21 Sludge shall be dewatered before packing into containers. Oily Sludge from ETP is being sent for reprocessing to DCU. Oily Sludge and BSW from the storage tanks are dewatered and then stored in Containers.

4.22 Each container shall be inspected at least once in a week for any leakages or spillage problem

Each container/ bags are inspected regularly

4.23 The transporter shall be given relevant information in Form -9 (TREMCARD).

Complied with :TREMCARD is being provided to transporter during the time of disposal

4.24 Transporter driver and person handling Hazardous waste shall be trained and drivers shall be educated/ trained properly.

Tool Box Talk given to persons and drivers handling hazardous wastes


4.25 A copy of TREMCARD shall be forwarded before operation carried out to the Gujarat Pollution Control Board, Gandhinagar

It is not applicable as NAYARA is not the transporter

4.26 Transporter shall be given all safety devices like goggles, gloves, mask, fire extinguisher, gumboots etc.


4.27 Vehicles, which are proposed to be used for transportation, shall be registered under Motor Vehicle Act.


4.28

During transportation activity packing material and containers shall be such that there shall be no significant chemical and galvanic reaction among any of the material in package.

Each container/ bags is inspected and ensured that there will not be any reaction or leakage while transporting

4.29 Labelling and marking on containers of the Hazardous waste and whole transportation operation shall be as per Motor Vehicles Rules’89.


4.30 Due care shall be taken during transportation to avoid leakages or spillage.


4.31 Emergency plan shall be prepared for transportation activity.


4.32 Source of waste generation and final destination of disposal place shall be informed to GPCB, Regional Office in that Area.

Manifest is prepared and sent yearly, also monthly patrak is filled monthly to make aware of the generation and disposal of wastes

4.33 Transporter shall dispose Hazardous waste only at authorized cell of notified disposal facility located at your own secured landfill site.


4.34 The transporter shall be responsible for taking appropriate steps to clean up spillage, which may occur during transit as specified in TREMCARD


4.35 In case, of an accident or spillage of hazardous waste during transit report in Form-11 shall be made to GPCB, Gandhinagar with a copy to Regional Office.

Till date there has not been any incident while transportation of wastes. However, in case of any incident we will give the report in Form- 11 to GPCB, Gandhinagar as well as Regional Office

4.36 A contingency plan shall be prepared and made known to the transporter for emergency action.

TREM CARD provided to transporter to handle any emergency situation

4.37

The generator/occupier or operator of facility or transporter shall prepare a manifest and shall forward copy to each other and also to the Regional office of GPCB in such a way that one can assure that Hazardous Waste is properly transported and disposed.

Manifest is prepared and procedure is followed while disposal and transportation of wastes

4.38 The generator/an occupier/ operator of the facility or transporter shall prepare a manifest, which shall consist of six copies in different colors.

Six copies of manifest are prepared and given to concern facility while transport and disposal of wastes

4.39 The color codes and the movement of the manifest shall be as per the guidelines prepared by MOEF, Government of India

Manifest prepared and given to the concern as per the guidelines issued by MoEF&CC


4.40

In case of any change in process, product, mode of management of any waste generated other than specified in the application and correspondence, the applicant shall approach to the board with fresh application and requisite fee.

Noted

4.41 The fresh application shall be made in Form 1 before expiry of authorization validity period.

Noted.

4.42 Records of waste generation and its management shall be maintained in Form – 3 and annual return shall be submitted to GPCB in Form – 4.

Form -4 is submitted every year to GPCB before 30th June. Records of waste are maintained in Form-3 format.

4.43 In case of any accident, details of the same shall be submitted in Form – 11 to GPCB

Till date there has not been any incident while transportation of wastes. However, in case of any incident we will give the report in Form- 11 to GPCB, Gandhinagar as well as Regional Office

4.44 As per “Public liability Insurance Act – 91” company shall get Insurance policy, if applicable.

We have PLI policy vide letter No. OG-18-1919-3304-00000033,dated.21.09.2018,which is valid till 21.09.2019

4.45

Empty drums and containers of toxic and hazards material shall be treated as per guideline published for “management & handling of discarded containers”. Records of the same shall be maintained and forwarded to GPCB regularly.

Empty contaminated drums are being sold to GPCB approved recycler.

4.46 In no case any kind of solid waste shall be imported without prior approval of appropriate authority.

No wastes have been imported or exported till date at our site and same will be complied in future.

5.00 GENERAL CONDITIONS

5.1 Any change in personnel, equipment or working conditions as mentioned in the consents form/ order should immediately be intimated to this Board.

Noted

5.2 Applicants shall also comply with the general conditions given in Annexure – I

We are complying with the conditions given in Annexure-I

5.3

Industry shall have to display the relevant information with regard to Hazardous waste as indicated in the Hon’ble Supreme court order in W.P. No.657 of 1995 dated 14th October 2003.

Noted

5.4

Industry shall have to display on-line data outside the main factory gate with regard to quantity and nature of hazardous chemicals being handled in the plant, including waste water and air emissions and solid hazardous waste generated within the factory premises.

Noted

5.5

The applicant shall have at his cost get samples of emission collected and analyzed from an approved laboratory once in a month for the parameters indicated in condition 3 and 4 and shall submit in duplicate the report there of to the Board by the 10th of the succeeding month. The applicant shall also maintain records of the analytical results properly and shall keep these records/ charts open for inspection.

Third party M/s Unistar Environment and Research Labs, Vapi accredited by NABL has been given contract for this year for monitoring and the monthly monitoring report is submitted to GPCB.

Annexure 1.13: Details of Laboratories with employee list

List of Laboratory Instruments

Sr. No. Instrument Details Make

1 Analytical Balance Shimadzu

2 Auto Titrators Mettler

3 BOD Incubator HACH

4 BOD Track HACH

5 COD Reactor (Duel block) HACH

6 Conductivity Meter HACH

7 DO meter HACH

8 IC (Ion Chromatography) Dionex

9 Microwave Furnace CEM

10 Millipore system Millipore

11 Oven Bio Tech India Ltd.

12 pH meter Thermo Scientific

13 TOC Analyser Shimadzu

14 Turbidity Meter HACH

15 UV VIS Spectrophotometer Perkin Elmer/Shimadzu

16 Visible spectrophotometer HACH

17 Atomic Absorbtion Spectrophotometer

Perkin Elmer

18 GC - (RGA) Perkin Elmer

19 GC - DHA (PAC) Agilent

20 GC - Hi Speed RGA Agilent

21 GC - Low Oxygenates Perkin Elmer

22 GC - Methaniser Perkin Elmer

23 GC - PIONA - Reformulyzer Agilent

24 GC - Simdist Perkin Elmer

25 GC-ASTM 4420 Agilent

26 GC-ASTM 5580 Agilent

27 GC-MS for Lo-oxigenates & FEM Agilent

28 GC-SCD (Sulfur Chemiluminance detector

Agilent

29 HPLC Perkin Elmer

30 ICP Analyser Perkin Elmer

31 ICP-MS Analyser THERMO FISHER SCINTIFIC

32 Mercury analyzer ( PE-1 ) NIC

33 Spectroil Q_100 Spectro Scientific


List of Employees:

St No

Emp Code

Emp Name Cadre / Level

Qualification

1 20008207 Pradeep Prabhu M-3 PHD 2 20004678 Ketankumar Patel M-5 BSc 3 20004967 Dhiraj Gondaliya M-5 MSc 4 20005391 Narhar Deshpande M-5 MSc 5 20010321 Anil Patil M-5 PHD 6 20001404 Hitesh Sojitra M-6 MSc 7 20004549 Harish Lalani M-7 MSc 8 20008156 Shailesh Chhatrala M-7 MSc 9 20009741 Mohan Satyadev M-7 MSc

10 20021910 Atul Dave M-7 MSc 11 20002295 Divyesh Desai M-8 BSc 12 20004818 Hiren Dave M-8 MSc

13 20007702 Ambrishkumar

Kachhia M-8

MSc 14 20021240 Girish Thanki M-8 MSc 15 20021963 Brijesh Bhuva M-8 MSc 16 20005906 Padmesh Shah M-9 MSc 17 20006936 Mithun Dave M-9 MSc 18 20007775 Manish Joshi M-9 Diploma, bsc 19 20009567 Ashok Maghodiya M-9 BSc 20 20011782 Ashish Dhamsania M-9 MSc 21 20012043 Rajesh Butani M-9 MSc 22 20012055 Satish Bhalodia M-9 BSc 23 20012150 Paresh Rana M-9 BSc 24 20013886 Jasmin Vora M-9 MSc 25 20014100 Shailesh Gadhvi M-9 MSc 26 20014455 Gajera Naresh M-9 MSc 27 20032157 Bhaumik Kaneria M-9 MSc 28 20032158 Tushar Patel M-9 MSc 29 20033981 Kaushikkumar Patel M-9 BSc 30 20035533 Kinjal Patel M-9 BSc 31 20053551 Harshal Modi M-9 MSc 32 20021369 Mayur Joshi M-10 BSc 33 20032964 Milan Nathwani M-10 MSc 34 20033431 Hardik Trivedi M-10 BSc 35 20033705 Gunvanti Panchal M-10 BSc

36

20033879 Arpan Shah M-10 Post Diploma Course-2000,BSc-2000,

37 20033982 Mayur Talpara M-10 MSc 38 20033983 Mahesh Jesadiya M-10 MSc 39 20033984 Girish Trala M-10 MSc 40 20033985 Pankaj Tilva M-10 MSc 41 20033986 Jayesh Kamani M-10 MSc 42 20034806 Dharmesh Bhuva M-10 MSc 43 20035142 Rahul Rakholiya M-10 MSc


44 20053151 Angrej Singh M-10 BSc 45 20053157 Tejas Trivedi M-10 MSc 46 20053150 Paresh Bhatt M-11 MSc 47 20053152 Gautam Rana M-11 BSc 48 20053153 Kishan Kapuriya M-11 MSc 49 20053156 Chintan Patel M-11 MSc 50 20053232 Rahul Patel M-11 MSc 51 20053268 Chetan Busa M-11 MSc 52 20053411 Suresh Modhavadiya M-11 MSc

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GUJARAT POLLUTION CONTROL BOARD Parvavaran Bhavan

.#

Sector - l0.-A,Gandhinagar - 382 O l 0. Fax : (079) 23232'156

Website : w & ~ . ~ ~ e ; b . ~ o v . i n

Consent to Establish (NOC)

PNO: PCICCA-JMN -3661 5 '30

To, MIS. ESSAR d LTD.

(Refinery division) PO BOX NO:24,Village: Vadinar, Post: Khambhalia, Dist:Jamnagar Pin:361 350

SUB: Consent to Establishment (IVOC) under Section of Water and Section 21 of Air Act 1981.

REF: Your Application no: nil dated:2310612007 and consecutive Correspondence with this office.

Sir,

Without prejudice to the powers of this Board under the Water (Prevention and Control of Pollution) Act-1974, the Air Act-1981 and the Environment (Protection) Act- 1986 and without reducing your responsibilities under the said Acts in any way, this is to inform you that this Board grants Consent to Establish (NOC) for propose enhacement of crude refining capacity from present 9WIMTA Capacity to 60 MMTA for the products tabulated below by a way of Debottlenecking and capacity maximization of the existing process units and augmentation with the new primary,secondary and the balancing processing units of integrated refinery cum petrochemical complex at survey no:62- 66,7712,88,97,286-297,299-310,312-323,363-366,368-377,378 p 1 &2,379-381,534,56- 61 etc of village Zankhar, Survey number 96 p,112-148,150-156,159 of village Timbdi,survey number 187-196,199-214,338,197,198,215-227,336 of village Kathi,Devalia, Survey number J-14,19,42,71,72 p,7-6p, 16-1 8 etc of village Sodhani Targadhi,dist: Jamnagar in phase mmanner. The total cost of the project is 54918 crore and out of that 3125 crore are earmarked for EMS and total Area is 2330 Hector.

PRODUCT PROFILE FOR REFINERY& PETROCHEMICAL COMPLEX

I Sr. I Product I Quantity 1 Quantity I Quantity (REFIENERY) (10.5MMTPA) (32MMTPA) (GOMMTPA)

PHASE-I PHASE-II PHASE-Ill1 1 1 LPG 0.65 MMTPA 2.16 MMTPA 2.77MMTPA 2 ATF 0.4 MMTPA 2.50 MMTPA 3.70 MMTPA 3 HSD 4.81 MMTPA 17.15MMTPA 20.98WIMTPA 4 PC NAPTHA 0.27 IVIIVITPA 1.49 WIMTPA 2.67 MMTPA 5 GASOLINE 1.85 MMTPA 9.75MMTPA 19.5 MMTPA 6 SULPUR 0.03 MMTPA 0.75 MMTPA 0.84 MMTPA

ANNEXURE - 2 CTE &CCA

GUJARAT POLLUTION CONTROL BOARD

Sector-1 0-A, Gandhinagar - 382 01 0. Fax : (079) 232321 56

Website : www.gpcb.gov.in

PRODUCT PROFILE FOR PETROCHEMICAL

14 1 IPA 1 75 1

SR NO 1 2 3

15 I

I LLDPE-HDPEIHDPE 1 4001400

PRODUCT OX0 ALCOHOLS

ppp

Phenol/Acetone/Bisphenol-A PROPOLEIIE

112 1 Ethvl BenzeneIStvrene 1 500

CAPACITY In KTA 137+150 20011 2011 50 1000

I Butadiene 1 180

160+80 8001600 200

7 8 9

Acrylic acid Para xylene1PTA LAB

SUBJECT TO THE FOLLOWING CONDITIONS:

15 16

The validity period of the order will be Five years from the date of issue

SPECIFIC CONDITIONS (* If the proposed project attracts EIA Notification &I CRZ Rules):

Butene-I -- MEG

1. Applicant shall not start any construction activities without getting Environment Clearance Certificate from SElAAl MoEF under EIA Notification dated 14/09/2006.

2. Applicant shall comply with the all conditions stipulated by SElAAl MoEF in the order of Environment Clearance as and when issued.

3 Applicant shall obtain CRZ clearance from competent authority under CRZ Rules and all conditions of the same shall be complied with.

4 Applicant shall obtain The permission under FCA-1980 for the forest land from GO1

5 CTE of the board will get effect after the permission is accorded under FCA- 1980 from GOI.

55 700

Annexure C CCA


Sector-10-A, Gandhinagar 382010Phone (079)23222425

(079) 23232152Fax (079)23232156

Website. www.gpcb.gov.in

NO: PC/CCA-JMN-366 (17)/ID-27398/TO,M/s. ESSAR OIL LTD. (REFINERY DIVISTON) (27398),PLOT NO: S.NO, 62-66 ,JAMNAGAR-OKHA HIGHWAY (SH-25), PO BOX NO: 24,VILL: VADINAR - 361305TAL: KHAMBHALIA,DIST: DEVBHOOMI DWARKA,

Date:

Sir,

SUB: Correction in renewal of the consolidated consent & Authorization of the Hoard.REF: Your letter reference no: EOLlE"\lV 117398/CC&A Amcndmentl20 16/646, 07112/2016.

With reference w the above suhject and reference letter, typographic correction in consolidatedconsent and Authorization order no. AWH-81987 date ofIssue: 13/1012016 is as under.

The said CCA order is further Correction as below:

First paragraph is corrected as below:In exercise of the power conferred under section-25 of the Water (Prevention and Control of

Pollution) Act-1974, lUlder section-21 of the Air (Prevention and Control of Pollution)-1981 amiAuthorization under rule 3(c) & 5(5) of the Hazardous and other Waste (Management, Trans boundaryVlovement) Rules'2016 framed under the Environment (Protection) Act-1986.

1. Condition No-l of the said CCA order is read as below:

Consolidated Consent and Authorization order No.: AWH-81987 date oflssue: 13/1012016.The c{)nsents shall be valid up to 16/0912022 for use of outlet for the discharge of tradc effluent & emissiondue to operation of industrial plant for crude processing capacity 21 MMTPA for the tollo\\-ingitems/products.

Sr. NO. ; Product i%y;"q21MMTPA

LPG 3.4-5.4

Kero+ATF 0-8.6Naphtha/ MSJ Gasoline 16-24.6

HSD 48.6-52.9Furnace Oil I V.G.O. 0-22.9

Sulfur 1.4-1.7

Bitumen 0-3.4

Fuel & Loss 7.8-8.7, Pet Coke 9.1-12.9

Condition No-2 of the saId CCA order IS read as below.2. CONDITIONS UNDER THE WATER ACT:

2.1. The Quantity of trade effluent from factory shall not exceed 25400 m' i Day.

2.2. The Quantity of sewage from factory shall not exceed 405 m' i Day.

Condition No-3 of the said CCA order is read as below:

3. CONDITIONS VNDER THE AIR ACT:

Fuel Consumption rate (Tihr.)iOlMTiHr

3.2.J(b) The following stacks attached to boileri furnacei heater shall eonfonn to the standards referred in

CO"dHiO;;;~~~aratGreen GujaratISO-9001-2008 & ISO-14001 - 2004 Certified OrganisatIOn

Outward No:413519,26/05/2017

http://www.gpcb.gov.in

Stack attacbed to Stack Dia. Meters Stack Hei1!bt. MetersCDUI VOU Heaters 5.7 130 ==1COU II Heaters 3.5 10ONIH,' CCR Heaters 5.7 130DllDSHcaters 2.4 70FCC Feed Heater 3.7 11OHMlJ Furnace 1.1 30HMU1&Il 4.7 45OCU Heater I, II & lU 2.5 65DHDT 2.8 60 -----jVGOHT 3.1 60

Sr. No.

103.2.2 Industrv shall have to vent t1ammahlc gases throu h the followin flares:

~,r·~t~~~-----L. :=-,'Offl""tack J:Em Stack h'iglrt~

h -1--.!::!ldrocarbon Base flare _,~__ ,100 m " "ih-=--. I 1Tydrocarbon~Tonfure--W-----=----=----=-~--=-_~ ~_----=-_---:-~--=-lrT.-_:::JH2Sfl'-"-----H- - --j-'"O-"' --1tL-Th~~~~~_=_--=-~~_=__=____=__=__=_J~~,~~~~~_=____j

4. CONDITIONS UNDER THE HAZARDOUS AND OTHER WASTE (MANAGEMENTTRi\NSBOlINDARY MOVEMENT) RULES, 2016:

4.1 The authorization is granted for the following hazardous waste, its quantity and mode ofhandlin & dis osal:

Sr. No .

. 2

Disposal

regi~tcred decontamination Ifacihlyiactual user only

Spent I Collection, St~rage, transportation and!

~_~I_w_as_"__ ~ ~ ~:-",~~::;","lto lSDF'I",in'mtiOW"ct~

Outward No:413519,26/05/2017


Sector-10-A, Gandhinagar 382010Phone (079)23222425

(079) 23232152Fax (079)23232156

Website. www.gpcb.gov.in

Battery waste

liiClassE-3 I JOOMT

I

12 ExpiredHazardous

I chemicals(Li uid/Solid)

14 E- Waste 1-- 2QMT

15 Waste Coke U-C\ass,A 70 lOOMT

16 Spent Catal)'st 1.6and MolecularSieves

13 Spent Carbon I 36.2, (Solid) I 1200MT

4.11 The occupier may store the hazardous waste tor a period not exceeding 90 days and shall maintainthe records of sale, transfer, storage, recycling and reprocessing of such wa~te and make theserecords available for inspection. GPCB may extend the said period under certain conditions specifiedin the Hazardous and other Wastes( Management and Transboundary Movement) Rules - 2016.

4.17 rhe generator, occupier, transporter and operator of the rSDF tacility shall comply with thedirectives specified by MOEI-", Govt. of India, under the Hazardous and other Wastes( Managementand Transboundary Movement) Rules - 2016.

4.23 The transporter shall be given relevant information in Form -9(TREMCARD).4.35 In case, of an accident or spillage of hazardous waste during transit report in Form-II shall be made

to GPCB, Gandhinagar with a copy to Regional Office.4.43 In case of any accident, details ofthe same shall be submitted in Form - II to GPCB.

2. The rest ofthe conditions of the above referred CCA order shall remain unchanged You an: directed tocomply with these conditions judiciously.

For and on behalf of

Guj."" Ponution con"o~

(R.V. Patel)

Senior Environmental Engineer

Clean Gujarat Green GujaratISO-9001-2008 & ISO-14001 - 2004 Certified OrganisationOu

tward No:413519,26/05/2017

http://www.gpcb.gov.in

GuJarat Pollutlon Control BoardPery.v.r.n Bh.v.n5ect0l- to-A. GANOHINAGAR-382043Phone: 22756. 22095, ~ Gram: CLEANWATERFax: 02712·32156

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bout""i! 6l<1ql6\"ql'li "'lqit.

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(w(.cll,1.t2.c-{1 iq\}'6'Pfu!?'lqN;" __ ;;

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it. "-"''' oil's" c-{\.(~,l"'{[ ($<fi",,,,).

'<:1\e.,(."-"'.,(.51-". "''l''''l.1-oilWl ~l0'q("-""-'H~).1.U vUs-M a1..<'ll', :lLLl{-cuSlotL(63S'l.3011.

rll."'(>UC-{\~l.~.Eq"lli\ Ol16l.

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utward No:418919,31/07/2017

ANNEXURE- 3 GPCB SCN

Annexure-II

Coal Handling Guideline

Page 1 of 4

Compliance Status as on 15/05/2017

SR. No.

Instruction EOL Compliance Status

1 Coal handling unit/Agency shall not use any agriculture land and shall be located at a minimum 250 meters away from the surrounding agricultural land.

Location is within refinery premises

2 Government waste land not suitable for any agricultural purpose meeting with requisite siting / distance criteria shall be preferred for establishing coal handling units.

Location is within refinery premises

3 Coal handling unit/Agency shall be minimum 500 meters away from the residential area, school/colleges, Historical Monuments, Religious Places, Ecological sensitive area as well as forests area.

Complied. Pet coke storage location is far from the residential area, school/colleges, Historical Monuments, Religious Places, Ecological sensitive area as well as forests area.

4 Coal handling unit/Agency shall be located at a minimum 500 meters away from the Railway line, Express ways, National Highways, State ways and District Roads and from water bodies like River, Nala, Canal, Pond etc.

Complied. Pet coke storage location is far from Railway line, Express ways, National Highways, State ways and District Roads and from water bodies like River, Nala, Canal, Pond etc.

5 In case of coal handling activities at the ports and jetties or extension thereof, the distance and land use criteria may be relaxed and compensated by advanced/sophisticated pollution control measures and mechanization & thick plantation, however all such ports & jetties, where coal handling is carried out, shall provide closed conveyor belt and mechanization for handling of coal.

Not Applicable

6 Coal handling unit/Agency shall store coal in such a way that coal heap should not be higher than 5 meter and clear distance between two adjoining heaps at G.L should be 5 meters, so that in case of fire approach is available.

Pet coke heap height is maintained below 2.5-3.0 meter and distance between two adjoining heaps at G.L is maintained more than 5 meter.

7 There should be mechanized loading/ unloading system from the loading /unloading area to the stacking yards and in to the vehicles.

Automatic truck loading system is provided for pet coke loading from Silo. Front end loader used when lifting from yard.

8 Coal handling unit/Agency shall take all corrective steps to resolve the issue of air pollution at permitted coal storage/handling area where coal is being stored.

We have taken all preventive measures to resolve the issue of air pollution at permitted coke storage/handling area where coke is being stored.

9 Coal handling unit/Agency shall ensure that all trucks before leaving the storage yard shall be showered with water with adequate system, Shall be covered with tarpaulin or any other effective measure/device completely and also that trucks are not over loaded as well as there is no spillage

Truck / dumpers are covered with Tarpaulin while they are plying on the road from one location to other.

Wagons are loaded by pay-loader and loaded wagons are covered with tarpaulin

Outward No:457144,02/06/2018

The company had been issued two direction from CPCB regarding online monitoring. Details are as

below:

Sr. No. Direction Issued Points given in direction Present Status

01 Implementation of dynamic emission limit for OCMES for oil refineries vide letter no. B-29016/04/06/PCI-I/16243 dated 10th January, 2018.

Implement the dynamic emission limit and submit the documentary evidence of implementation of limits where mixed fuel is used in the stacks for all the parameters.

Dynamic emission limit has been implemented in all the four stacks using mixed fuel (FO & FG) attached to CDU/VDU, CDU II, DHDT & VGOHT for all the parameters. Continuous data for dynamic emission limit is being uploaded on CPCB server.

02 Direction under section 5 of the Environment (Protection) Act, 1986-notice thereof. Vide letter B-29016/04/06/IPC-I/ dated 06.06.2018.

1. In FCC-R unit the measured CO value was BDL, but the OCEMS value was 320.37 mg/ Nm³, the value is within the GPCB prescribed limit of 400 mg/ Nm³

1. M/s Nayara Energy Limited has carried out recalibration of the OCEMS in FCCR unit immediately as per your suggestions during your visit to our site on 02.05.2018. The calibration of each analyzer is conducted on quarterly basis as per the schedule & the instrumentation team is strictly following the calibration schedule.

2. In DCU- 1 & 3 the measured CO Value was BDL, but the OCEMS values in DCU-H1 576.65 mg/ Nm³, DCU- H3 240.27 mg/ Nm³ are exceeding the GPCB prescribed limit of 150 mg/ Nm³

2. The OCEMS is showing

erroneous value due to

calibration issue. M/s

Nayara Energy Limited has

carried out recalibration of

the OCEMS in DCU

immediately as per your

suggestions during your visit

to our site on 02.05.2018.

The calibration of each

analyzer is conducted on

quarterly basis as per the

schedule & M/s Nayara

Energy Limited is strictly

following the calibration

schedule.

ANNEXURE- 4 DIRECTION OF CPCB regarding Online Monitoring

3. The Unit has not provided OCEMS for the measurement of PM and SOX in the stacks attached to SRU unit as per inspection report and CPCB , IT division report dated May 28, 2018

3. The Consolidated Consent

and Authorization

(enclosed as Annexure- I)

received from Gujarat

Pollution Control Board

has not prescribed limit for

PM and SOX in SRU stacks.

Hence, M/s Nayara Energy

Limited has not installed

PM and SOX analyzers in

SRU Unit.

4. The unit has not installed online PM analysers in 13 stacks out of 17 stacks except CDU, VDU and FCCR unit as per IT division report dated May 28, 2018

4. M/s Nayara Energy Ltd. has already installed SOX, NOX, and CO in all the units and have hooked up the same with CPCB server since 2015. PM analyzers have been installed earlier in four units CDU, VDU, CDU-II and FCCR units.

The Consolidated Consent and Authorization CC&A received from Gujarat Pollution Control Board has not prescribed any limit for PM in SRU & SRU-1 stacks. Mini HMU unit is not in operation.

For remaining 10 units,

orders have been placed

for accessories of PM

analyzers. Quotations have

been received which are

under Technical

Evaluation. PM analyzers in

all remaining 10 stacks will

be installed in the

forthcoming turn around in

November 2018. We

would like to mention that


we burn Fuel Gas in these

heaters.

5. The unit shall take appropriate measures and calibrate the OCEMS system to reflect the correct value of CO emissions in the stacks attached to FCCR, DCU-1 & DCU-3.

5. M/s Nayara Energy Limited

has carried out

recalibration of the OCEMS

in FCCR, DCU-1 & DCU-3

units immediately to

reflect the correct value of

CO emissions as per your

suggestions during your

visit to our site on

02.05.2018. The

calibration of each

analyzer is conducted on

quarterly basis as per the

schedule & M/s Nayara

Energy Limited is strictly

following the calibration

schedule.

6. The unit shall provide OCEMS in all stacks for the measurement of SOx, NOx, PM and CO.

6. M/s Nayara Energy Ltd. has already installed SOX, NOX, and CO in all the units and have hooked up the same with CPCB server since 2015. PM analyzers have been installed earlier in four units CDU, VDU, CDU-II and FCCR as these units are Furnace Oil based units.

The Consolidated Consent and Authorization CC&A received from Gujarat Pollution Control Board has not prescribed any limit for PM in SRU & SRU-1 stacks. Mini HMU unit is not in operation.

For remaining 10 units,

orders have been placed

for accessories of PM


analyzers. Quotations have

been received which are

under Technical

Evaluation. PM analyzers in

all remaining 10 stacks will

be installed in the

forthcoming turn around in

November 2018. We

would like to mention that

we burn Fuel Gas in these

heaters.


Annexure - 5

Monitoring the Implementation of Environmental Safeguards

Ministry of Environment, Forest & Climate Change

Western Region, Regional Office, Bhopal

MONITORING REPORT

PART-1

DATA SHEET

EC No. : F No. J-11011/320/2006-IA-II (I) dated 16th September, 2008

1. Project type: River- valley / Mining/ Industry /

Thermal / Nuclear / Other (Specify)

: Crude Oil refinery with Petro-chemical complex

2. Name of the project : M/s Nayara Energy Limited. Dist. – Devbhumi

Dwarka, Gujarat.

3. Clearance Letter (s) OM No. & date : F No. J-11011/320/2006-IA-II (I) dated 16th

September, 2008

4. Location

A) District (s)

B) State (s)

C) Location Latitude/ Longitude

:

:

:

Refinery Site, 39 KM, Jamnagar-Okha Highway, Vadinar

361305, Gujarat, India

Devbhumi Dwarka

Gujarat

5. Address for correspondence

A) Address of the concerned Chief Engineer

(With Pin Code & telephone/ telefax/ fax

numbers)

B) Address of the executive Project Engineer/

Manager (With Pin Code & telephone/

telefax/ fax numbers)

:

:

Mr. Prabhanjan Dixit



Mobile no. : + 91 2833662017

Ms. Asmita Patel



Mobile no. : + 91 2833662506

6. Salient Features

A) of the Project

B) of the environmental management plans

:

:

(A) Project Features: Refinery is currently operating

at 20 MMTPA capacity. It is now proposed to

expand the refining capacity to 46 MMTPA along

with Petrochemical Project.

The expansion project will be within the existing

premises & shall be interlinked with the existing

unit.

(B) Environmental Management Plans (EMP) :

Environment Management Plan (EMP) was

prepared based on the baseline data collected by

NEERI and impact prediction were done using

mathematical models and superimposition of

those impacts on the baseline. EMP includes

provision of state of the art Effluent Treatment

Plant and Air Pollution control equipment, solid

waste management and Green Belt development.

Regular environment monitoring is also a part of

EMP. Major points implemented as per EMP e.g.

1. Use of Low Sulfur Refinery fuel Gas and fuel oil are

used as fuel in heaters / furnaces.

2. Installed Amine Absorbers - The fuel gas produced

in the refinery contains H2S. This is removed in the

Amine Absorber Columns and the sweet gas is

routed to Refinery fuel gas system.

3. Installed Low NOX burners in all heaters / furnaces.

4. Installed Low Temperature Shell Claus off Gas

Treating Units (LT SCOT) at Sulfur Recovery Unit

having sulfur recovery efficiency more than

99.7%.

5. Leak Detection and Repair Program (LDAR) has

been implemented in the refinery.

6. Continuous Emission Monitoring System,

Continuous effluent monitoring system and

continuous Ambient Air Quality Monitoring

system have been installed. The same has been

hooked up with CPCB server. Request has already

been made to SPCB for connecting to their server.

Earlier request has been declined due to

insufficient capacity of SPCB server.

7. State of art waste water treatment plant installed

with sufficient capacity. The entire Treated

Effluent is then reused as Fire Water, Service

Water & Cooling Towers and green belt.

8. Hazardous waste (HW) management procedure is

in place for effective waste management. HW is

being disposed to GPCB authorized actual users.

Details of type of hazardous waste and their mode

of disposal is as given below.

Type of hazardous waste and their mode of disposal is as given below.

Sr. No.

Type of waste Method of disposal

1. Oily Sludge from ETP (Semi- Solid) Reprocessing at Delayed Coker Unit (In-house)/co-processing in cement industries.

2 Used Lubricating Oil (Liquid) Sold to authorized actual users 3 Discarded Empty Drums /

Containers (Solid) Sold to authorized actual users

4 Slop Oil(Liquid) In-house recycling / reprocessing

5 Oily Rags/ Oil Contaminated Cotton Waste (Solid)

Sold to authorized actual users / incineration facility

6 Spent Catalyst From Various Units (Solid)

Sold to authorized actual users

7 Electronic and Electric Waste (Solid)


8 Lead Acid Battery Waste (Solid) Sold to authorized actual users 9 Spent Carbon (Solid) Incineration in VPCL Boiler

10 Insulated Copper Cable with PVC Sheathing (Solid)


11 Oily Sludge & BSW Sent to Pollution control board authorized TSDF / Incineration facility

12 Spent Resin Waste Sent to Pollution Control Board authorized recycling facility.

7. Break-up of the project area

A) Submerged Area : Forest and non-forest

B) Others

:

:

Total Area : 2275 Ha

Green Belt Area : 410 Ha

Currenltly 20 MMTPA refinery is established in

1171 Ha area out of total project area of 2275

Ha. As per the current establishment, we have

developed green belt in 410 Ha area which is

35.04 % of the plant area.

A) Submerged Area: 15.49 Ha of forest land is used for

laying of pipelines & construction of jetty.

Permission was granted vide letter no.:

8C/12/385/96-FCW dated 08/12/1999. (For

detailed letter please refer Annexure 5.1)

8. Break-up of the project affected population with

enumeration of those losing house/dwelling units

only, agricultural land only, both dwelling units &

agricultural land & landless labourers/ artisans:

a) SC, ST/Adivasi

b) Others

(Please indicate whether these figures are based in

any specific survey carried out or only provisional

figures, if a survey is carried out, give details & year

of survey)

: Not applicable, as the project does not require

additional land as the proposed project will be

established in the existing refinery complex.

9. Financial details

:

A) Project Cost as originally planned and

subsequent revised estimates and the year

of price reference:

B) Allocation made for environmental

management plans with item wise & year

wise break-up.

C) Benefit cost ratio/ internal rate of return

and year of assessment

D) Whether it includes the cost of

environmental management as shown in

the above

E) Actual expenditure incurred on the project

so far

F) Actual expenditure incurred on the

environmental management plans so far

:

:

:

:

:

A) Cost of Project was Rs.78,730 Crore (For 60

MMTPA) as originally planned in 2006.

B) Allocation made for environment protection

measures with item wise & year wise break up

is given below.

C) Since the refinery project is very large and

entails a very long period & also get affected by

international crude prices & fluctuations. At

present it is not possible to provide such

details.

D) Yes.

E) Actual cost of project as on date is 51000 Crore

(For 20 MMTPA).

F) Actual expenditure incurred on the

environmental management plans from 2008-

09 to 2018-19 is as given below.

Allocation made for environment protection measures:


Facilities

Year Wise Expenditure incurred in Crores (CAPEX)

2008-09 2011-12 2013-14 2018-19

Base ETP 53.53 - - -

Base SRU 443.34 - - -

Expansion ETP - 171.40 - -

RO Unit - 75.51 - -

Expansion SRU - 234.07 - -

Hazardous waste shed & Pit - 26.08 - -

Online Ambient Air Quality

Monitoring System - - 2.00 -

Online emission monitoring

analyzers - - - 2.00

Green Belt Development 0.6 5.4 3.9 7.9

TOTAL 497.47 513 5.9 9.9


Facilities

Year Wise Expenditure incurred in Crores (OPEX)

2013-14 2014-15 2015-16 2016-17 2017-18

Opex - Environment Cost

Centre

1.01 0.19 0.89 1.23 0.81

O & M EXPANSION SRU 0.29 0.09 0.17 6.07 4.25

O & M OF BASE SRU 0.90 0.23 0.36 3.03 0.94

O & M OF EXPANSION

WWTF & RO

10.21 4.31 3.52 5.35 5.06

O & M OF BASE WWTF 0.62 0.20 0.15 0.16 2.05

Green Belt Development 6.6 1.72 1.74 1.5 -

TOTAL 19.63 6.74 6.83 17.34 13.11

10. Forest Land requirement

A) The status of approval for diversion of forest

land for non-forestry use

B) The status of cleaning felling

C) The status of compensatory afforestation, if

any

D) Comments on the viability & sustainability of

compensatory afforestation program in the

light actual field experience so far.

:

A) 15.49 Ha of forest land is used for laying of

pipelines & construction of jetty. Permission has

been granted vide letter no.: 8C/12/385/96-

FCW dated 08/12/1999 is given below. (For

detailed letter please refer Annexure 5.1).

B) Not major cleaning felling is required. However,

compensatory afforestation was done in 9.6 Ha

area against the damaged 3.2 Ha area. Detail of

the same is covered under point (C) below.

Apart from this we have also done voluentary

mangrove aforestation in area of 175 Ha.

Details are attached as Annexure 5.2).

C) Rs.14,03,168 were paid vide cheque

no.1158348 dated 7.1.1998 toward the

payment of compensatory afforestation. Copy

of letter No. LFS/OP/MNP-801,dated.7.1.1998

sent to CCF (MNP) is as given below (For

detailed letter please refer Annexure 5.3).

D) Equivalent Non Forest Land handed over to

forest department for compensatory

afforestation & afforestation program is done &

monitored by forest department themselves.

11. The status of clear felling in non-forest areas (such

as submergence area or reservoir, approach roads),

if any with quantitative information required

: There was no clear felling in forest area for the project.

12 Status of construction (Actual or planned)

A) Date of commencement (Actual or

planned)

B) Date of completion (Actual or planned)

: The construction activity for 14 MMTPA refinery was

completed & commissioned during 2010. Then

expansion for achieving 20 MMTPA in the year 2012.

13 Reason for delay if the project is yet to start : Company is operating at 20MMTPA capacity in refinery

complex at Vadinar.

However, owing to the business requirement the plan

for further expansion up to 60 MMTPA could not be

implemented as planned.

14 Dates of site visits

a. The dates on which the project was

monitored by the RO in the previous

occasions, if any.

b. Date of site visits for this monitoring report

:

a. Project was monitored by Director (S) dated

28.08.2008

b. The site visit for above monitoring report was

carried out on 30/08/2018

15 Details of correspondence with PA for obtaining

action plans/information on status of compliance

to safeguards other than the routine letters for

logistic support for site visits.

:

Date & No. Letter from RO Date & No. Letter/ Reply from PA

23/06/2018 Letter No. : Nayara Energy/ENV/EC

Compliance Certificate/2018/758 Request

letter along with EC compliance status for

seeking certified compliance report.

25/07/2018 Letter no. File no.5-26/2008(Env)/285

dated 25/07/2018 from MoEF& CC,

Regional Office, Bhopal.

08/08/2018 Mail from MoEF&CC for certified

compliance report to be uploaded on

portal

30/08/2018 Visit by MoEF&CC officials (Scientist D) for

certification of EC compliance

Annexure 5.1 Formal clearance for ROW under FCA 08 12 1999

Annexure 5.2 mangrove plantation certificate

Annexure 5.3 Deposit Compensatory afforestation

Annexure - 1 - Gujarat Pollution Control Board

Documents

Transcript of Annexure - 1 - Gujarat Pollution Control Board