ONGC Hazira Plant is experiencing rising operational constraints & frequent breakdowns due to

deteriorating structural & systemic failure in SRU due to aging. Since the plant is about 30 years old with
extremely corrosive inherent conditions, a short term operational safety and maintenance could not be
able to guarantee its overall integrity & reliability. With the advancement of technology during recent past,
it was envisaged not only to replace existing melter system with the new pressure filtration system but to
go for a complete revamp of all 03 trains (TR 61, 62 and 63) of existing SRU excluding incinerator with
installed capacity per train to treat 7000Nm3/Hr Acid Gas and to produce 12.5 MT/Day of Sulphur.
Revamp Scope of SRU also includes replacement of 03 out of 06 numbers of blowers and a new SRR
building.
E-bids, under single stage two envelopes bid system, for the works covered under the Bidding Document
(are invited on Global Competitive Bidding) from competent Global agencies with sound technical and
financial capabilities meeting the Qualification Criteria specified herein.
2. BRIEF SCOPE OF WORK:
Design, engineering, procurement of materials and bought out components, manufacture, fabrication, assembly
at shop, inspection, testing, painting, packing, supply and supervision of erection, installation, precommissioning,
commissioning and performance guarantee testing for Automatic Vertical Pressure Filtration
System to be installed at ONGC’s Hazira Plant at Surat, Gujarat.
PARAMETER DESCRIPTION
Service : Separation of Sulphur in cake from catalyst solution
Slurry Flow (Min/Nor/Max) : 8.3 m3/hr 16.6 m3/hr 18.3 m3/hr
Sulphur concentration (Min/Nor/Max) : 5 %wt 10 %wt 15 %wt
Type : Automatic Vertical Pressure Filtration system
(belt type filter cloth)
Sulphur Product
- Type : Cake
- Purity : 99.5 %wt (on dry basis)
- Moisture Content : 10% wt (max)
For other process related details, refer PDS doc. no. B115-60-03-DS-1801 enclosed.
For complete details, refer bidding document.
*: For complete details, refer enquiry document.
3. BIDDER QUALIFICATION CRITERIA (BQC):
Bidders intending to participate shall meet the following qualification criteria:
3.1. Experience Criteria (Technical):
3.1.1. The bidder shall be a supplier of Automatic Vertical Pressure Filtration system as a Single Point
Responsibility
Vendor (SPRV).
3.1.2. Bidder shall have designed, engineered and supplied at least one (1) no. Automatic Vertical Pressure
Filtration
system with belt type filter cloth for any process industry, for inlet slurry feed flow of 10 m3/hr (minimum) and
which shall have been commissioned within the period not exceeding ten (10) years and not less than One (1)
year reckoned from bid due date.
3.1.3. In case, the Indian Bidder does not meet the criteria as specified in cl. no. 3.1.2 above on his own, the
bidder
can still be qualified based on experience of their Foreign Principal (or) Group Company (*), who meets the
criteria as specified in cl. no. 3.1.2 above, provided:
i) The Foreign Principal (or) Group Company (*) shall be in the business of manufacturing of the offered product
line (for atleast last five years) for which the Indian Bidder is seeking to bid.
ii) The bidder shall be atleast 51% owned Indian subsidiary of their Foreign Principal for at least one year as on
bid due date.
iii) The Foreign Principal (or) Group Company (*) provides the following as a minimum:
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Page 2 of 13
a) Basic design & engineering
b) Review of all detailed design and engineering carried out by the bidder
c) Quality control / Quality assurance by Foreign Principal (or) Group Company (*) during project execution
stage
d) Supply of critical components
e) Supervision of erection, installation, pre-commissioning, commissioning and performance guarantee
testing at project site
f) Provide backup guarantee regarding design, mechanical integrity and performance of the complete
system.
iv) The bidder shall also furnish an MOU for this project with the Foreign Principal (or) Group Company (*)
alongwith the bid.
a) The MOU shall define responsibility scope matrix between the Bidder and Foreign Principal (or) Group
Company (*) for the offered Automatic Vertical Pressure Filtration system. The MOU shall confirm that the
Foreign Principal (or) Group Company (*) shall carryout the services as mentioned above.
b) The MOU between the bidder and Foreign Principal (or) Group Company (*) shall be valid at the time of
Bidding & shall also continue to remain valid till the pendency of the contract.
(* Group Company shall be atleast 51% owned subsidiary of the Foreign Principal (or) of the Foreign
Principals Holding Company)
3.1.4. For qualification of the Bidder, all the above clauses shall be read in conjunction .
3.2. Financial Criteria :
3.2.1. Annual Turnover :
Annual Turnover of the Bidder shall not be less than INR 9,00,00,000.00 (Rupees Nine Crore) for Indian
Bidders or USD 1,304,000.00 (USD One Million Three Hundred Four Thousand) for Foreign bidders
as per the audited annual financial results in at least one of the immediate preceding three financial years
as on the due date of bid submission.
3.2.2. Net-Worth :
Net Worth of the Bidder shall be positive as per the immediate preceding year’s Audited financial results.
3.2.3. Working Capital :
(a) The minimum working capital of the bidder as per the immediate preceding year’s audited financial
results shall be INR 90,00,000.00 (Rupees Ninety Lakh) for Indian bidders or USD 130,000.00
(USD One Hundred Thirty Thousand) for foreign bidders.
(b) In case bidder is unable to meet the working capital requirement as above, the bidder can supplement
the working capital with a fund based line of credit from any scheduled bank in India or a commercial
bank having Net worth more than equivalent INR 100 Crore (USD 14.5 Million). In such a case, bidder
shall furnish a declaration from the bank (dated any date between the tender floatation and bid due
date) for availability of unutilized fund based line of credit for the shortfall in working capital of above
mentioned value, in the format enclosed as Annexure-A.
3.3. GENERAL
3.3.1. The failure to meet the above Qualifying Criteria(s) at 3.1 and/or 3.2 above, will render the bid to be
summarily rejected.
3.3.2. Experience of only the bidding entity shall be considered subject to other provision of clause no. 3.1
above of technical bidder qualification criteria. A job executed by a bidder for its own plant/projects cannot
be considered as experience for the purpose of meeting requirement of BQC of the tender. However, jobs
executed for Subsidiary/ Fellow subsidiary/ Holding company will be considered as experience for the
purpose of meeting BQC subject to submission of tax paid invoice(s) duly certified by Statutory Auditor of
the bidder towards payments of statutory tax in support of the job executed for Subsidiary/ Fellow
subsidiary / Holding company. Such bidders to submit these documents in addition to the documents
specified in the bidding documents to meet BQC.
3.3.3. The bidders who are on Holiday / Negative list / Suspension / Banning list of ONGC / EIL on due
date of
submission of bid / during-the process of evaluation of the bids, the offers of such bidders shall not be
considered for bid opening/evaluation/Award.
3.4. Documentation:
3.4.1. BQC (Technical): Bidder shall furnish the following:
Bidder shall complete and submit the Experience Record Pro-forma enclosed with the bidding document
to establish that the bidder meets the Bidder Qualification Criteria as per clause no. 3.1 above.
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Page 3 of 13
3.4.2. Bidder shall furnish all the relevant documents towards meeting the Technical Criteria as mentioned
in
clause 3.4.1 above. In case bidder is qualifying based on 51% owned Indian Subsidiary of a Foreign
Principal and the technical qualification criteria is met by the foreign principal OR by the Foreign
Principal’s holding company OR by another 51% owned subsidiary of the Foreign Principal called Group
Company, the bidder from his statutory auditor or statutory auditor/CEO/CFO/Company Secretary of the
qualifying company, shall submit the letter clearly stating the relationship (51% owned subsidiary and time
period from the date of issue of enquiry) between them or any other document to substantiate the same.
3.4.3. BQC (Financial): Bidder shall furnish complete audited annual report including auditor’s
report, Balance Sheet, Profit & Loss Account Statement and all other schedules for the
immediate three preceding financial years or a letter from the statutory auditor or CA* (as per
Annexure-2A) or a letter from the bidder duly certified by statutory auditor or CA* (as per
Annexure-2B).
*CA - (not being an employee / director and not having any interest in bidder’s company) certificate
is acceptable where audited accounts are not mandatory as per law (in line with present system).
The above financial details, as per Annexure-2A or 2B, shall be submitted without any
reservation/qualification remarks. In case of any qualification remarks, complete booklet of audited
financial statements along with auditor’s report shall also be submitted with the bid.
3.4.4. Bidder to evidence the meeting of financial criteria shall submit audited Balance sheet and Profit &
Loss
Account along with the schedules referred there in and Auditor’s Reports for the preceding three financial
years, in line with one of the followinga)
In case the last financial year closing date was within 9 months prior to bid due date and audited
Balance sheet and profit and loss account of last financial year are not available, bidder has an option
to submit the financial details of the three previous years immediately prior to the last financial year.
b) Otherwise, it is compulsory to submit the financial details of the immediate three preceding
financial years.
Example, In case, bid due date is up to 31st December and Financial details of immediate preceding
financial year (year ending 31st March of the same year) are not available, the financial details of the
three previous years immediately prior to the last financial year may be submitted.
3.4.5. The financial statements stated under clause no. 3.4.3, shall be reviewed in respect of financial
criteria
under clause no. 3.2. However, in case any matter is referred in the “notes to accounts and schedules
referred in balance sheet and profit & loss account” than, only quantified qualified / adverse / disclaimer
opinion in the statutory auditor’s report, if any, having impact on financial criteria shall be considered for
evaluation.
3.4.6. For working capital in case bidder opts for supplementing the working capital with a line of credit from
any
scheduled bank or commercial bank having net worth more than equivalent INR 100 crore (USD 14.5
Million), the bidder shall furnish the declaration letter as per Annexure-A from the bank for availability of
line of credit.
3.4.7. In case of Foreign Bidders, if Audited Financial Report is in currency other than US Dollars, the
respective/desired figure for calculation of above details shall be converted into equivalent US Dollars
considering the conversion factor indicated in Bidder’s Audited Financial Report. In case the same is not
indicated, the conversion rate of USD as on last date of Bidder’s financial year shall be considered based
on RBI reference Rates.
3.4.8. In case a bidder (a Parent Company) is having wholly owned subsidiaries but only a single
consolidated
annual report is prepared and audited which includes the financial details of their wholly owned
subsidiaries etc. consolidated audited annual report shall be considered for establishing the financial
criteria subject to statutory auditor/CEO/CFO of the bidder certifying that separate annual report of bidder
(without the financial data of subsidiaries) is not prepared and audited.
3.4.9. Further, in case a bidder is a subsidiary company and separate annual report of the bidder is not
prepared
or audited, but only a consolidated annual report of the Parent Company is available, consolidated audited
annual report shall be considered for establishing the financial criteria subject to statutory auditor/CEO /
CFO of the parent company certifying that separate annual report of bidder is not prepared and audited.
Net-worth calculation: Net-worth means paid up share capital, Share Application Money pending
allotment* and reserves# less accumulated losses and deferred expenditure to the extent not written off.
Networth has been calculated using the following formula, as per provisions of the enquiry document:
# Reserves to be considered for the purpose of networth shall be all reserves created out of the profits
and securities premium account but shall not include reserves created out of revaluation of assets, write
back of depreciation and amalgamation.
*Share Application Money pending allotment will be considered only in respect of share to be allotted.
Paid up share capital XXXX
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Page 4 of 13
Add: Share Application Money pending allotment XXX
Add: Reserves (As defined Above) XXXX
Les: Accumulated Losses XX
Less: Deferred Revenue Expenditure to the extent not written off XX
Networth XXXX
a. Working Capital calculation: Working Capital shall be Current Assets minus Current Liabilities.
b. Turnover: Turnover shall be calculated including Excise Duty but excluding other Incomes.
3.4.10. Certification of Documents:
All supporting documents, pertaining to “Bid Qualification Criteria (Experience as well as Financial)”
including MSE certificate shall be submitted duly certified as follows:
Documents shall be submitted duly certified by CEO/CFO/Company Secretary or any member of
the Board of Directors in case of limited companies (Private / Public limited).
CEO/CFO/Company Secretary or any member of the Board of Directors can either sign all the
pages of the documents or submit a certificate signed by them, listing out all the BQC
documents/MSE document submitted in the bid along with basic details, duly referenced.
However, in case of Proprietorship/Partnership firms, the authentication by notary public on all pages of
the documents shall be acceptable.
If the above supporting documents are not in English language, then the English translation copy of the
same shall also be furnished duly certified, stamped and signed by Local Chamber of Commerce or
Indian Embassy in their country or their Embassy in India or any translator in India recognized /
authorised by their Embassy.
Requirement of above certification shall not be applicable to published audited annual financial
statements in English, if original booklets are submitted.
Since the bids are being obtained through e-tendering, bidders shall be required to upload the digitally
signed certified copies of documents for meeting BQC on the e-tendering portal only. In that case,
bidder shall not be required to submit the original certified documents in physical form to EIL.
In addition, Bidder shall confirm (as per Annexure-C of NIT) that all documents submitted for meeting
the BQC requirement are certified as per certification requirement mentioned in the Bidding Document.
Wherever the bidder has not submitted the certified documents through e-tendering as per the
requirement of bidding document, bidder shall submit the certified document in original.
In case bidder submits the certified document towards meeting Bid qualification Criteria in original, the
same shall be submitted by the bidder in a separate booklet titled as “Documentation against Bidder
Qualification Criteria (Experience & Financial) with proper index”.
3.4.11. Bidders are required to submit all such past experience(s) (PTR) meeting the BQC along with
relevant
supporting documents in the first instance itself, along with the bid. Accordingly, only such past
experience(s) shall be considered for qualification, details of which are provided in the bid by the bidder
and subsequently no additional past experience (PTR) shall be sought from the bidder.
3.4.12. Note:
a) Submission of authentic documents is the prime responsibility of the bidder.
b) Wherever EIL has concern or apprehension regarding the authenticity / correctness of any
document, EIL reserves a right of getting the document cross verified from the document issuing
authority.
3.4.13. Bidder should not be under liquidation, court receivership or similar proceedings. Bidder shall
submit selfcertificate
in this regard.
4. Delivery Period/Completion Period:
For Indian Bidders:
i. For Supply:
Within 28 Weeks on FOT despatch point basis from the date of award. Date of LR/GR shall be
considered the date of delivery.
For Foreign Bidders:
i. For Supply:
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Page 5 of 13
Within 24 Weeks on FOB (Incoterms 2010) international sea port of exit basis from the date of
award. Date of clean bill of lading shall be considered the date of delivery.
5. The salient features of the bidding document are as follows:
a) Earnest Money Deposit (EMD) / Bid Security : For Indian Bidder: INR 16,00,000.00
For Foreign Bidder: USD 23,200.00 or EURO
19,800.00
b) Bidding Document available on Web-site : From 20.07.2018 to 09.08.2018
c) Last Date and time of submission of Bids : Up to 1200 Hrs. on 09.08.2018
d) Pre-bid meeting : At 10:30 AM. on 27.07.2018 at EIL, New Delhi
e) Last date for pre-bid queries : 26.07.2018
f) Opening of Techno-commercial (Unpriced) Bids : 1400 Hrs. on Next Working Day of Final Bid
Due date
g) Cost of Bidding Document (Non- Refundable) : Nil
h) Opening of Priced Bids : On the date & time to be intimated later
6. EARNEST MONEY DEPOSIT (EMD)/BID SECURITY :
6.1. Refer Clause 18 of Instructions to Bidder of Bidding Document.
7. GENERAL
7.1. The complete Bidding Document can be downloaded from the CPP portal
http://eprocure.gov.in/eprocure/app only.
7.2. Bidders are required to submit their e-bids only through CPP portal
http://eprocure.gov.in/eprocure/app in
accordance with the instructions and terms & conditions of this Bidding Document.
7.3. The following documents in addition to uploading on the e-tendering website along with the bid shall
also
be submitted in Original physical form within the final bid due date & time indicated in the Invitation for
bids at the address mentioned in Bid Data Sheet (BDS):
i) Bid Security
ii) Booklet titled as “Documentation against Bidder Qualification Criteria (Experience/ Technical &
Commercial)” if not submitted digitally signed on NIC portal on or before cut-off date & time.
7.4. In case the bidder fails to submit the Bid Security in original physical form within the bid due
date
& time, his bid shall be rejected, irrespective of their status/ ranking in tender and notwithstanding
the fact that a copy of the same has been uploaded by the bidder.
7.5. Subsequent to the submission of bid, bidders are not allowed to change the price or substance of the
bid
i.e. scope of work, specifications, delivery schedule, completion period etc. including modification of the
bid to meet the BQC.
7.6. EIL reserves the right to assess Bidder’s capabilities and capacity to execute the work using in-house
information.
7.7. In case any bidder is found to be involved in cartel formation, his bid will not be considered for
evaluation/
placement of order. Such bidder will be debarred from bidding in future.
7.8. Canvassing in any form by the Bidder or by any other Bidder on their behalf may lead to
disqualification of
their Bid.
7.9. Bids received after the due date and time shall be rejected and representative of such bidders shall
not be
allowed to attend the bid opening.
7.10. Consortium / Joint Venture Bids are not acceptable.
7.11. EIL shall not be responsible for any expenses incurred by bidders in connection with the preparation
&
delivery of their bids, site visit and other expenses incurred during bidding process.
7.12. EIL shall allow purchase preference to Indian Central Government Public Sector Undertakings /
Enterprises as admissible under existing policies of Government of India from time to time.
7.13. EIL shall allow price preference to MSEs Bidders under Public Procurement Policy 2012 of
Government
of India.
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Page 6 of 13
7.14. EIL shall allow price preference to bidders under PP-LC policy of Government of India.
7.15. Physical / Fax / Telex / e-mail Bids (other than the documents specifically required to be
submitted
in hard form) shall not be accepted.
7.16. Please acknowledge receipt of Bidding Document and immediately conform your participation in the
subject bidding as per proforma attached under section Proposal Forms (ACKNOWLEDGEMENT CUM
CONSENT LETTER) enclosed in the Bidding Document.
Clarification, if any, can be obtained from DGM (SCM), Engineers India Limited, EI Bhawan, 1 st Floor, 1,
Bhikaiji Cama Place, R.K. Puram, New Delhi-110066 Fax: 91-11-26191714; Telephone: 91-11-2676 3203
/3645/ 3209 E-mail: d.chatterjee@eil.co.in , amit.gupta@eil.co.in , vivek.dixit@eil.co.in
Dy. General Manager
Engineers India Limited, New Delhi
Prepared by
Page 14

. Risk Assessment
7.1 INTRODUCTION
ONGC has proposed 108 Developmental Drilling Locations in nine ML Blocks/fie lds
of Cambay sub Asset, spread over Vadodara, Anand & Kheda Districts in Gujarat. The
total Block Area is 816.82 km2. This chapter elucidates the Risk Assessment (RA),
Disaster Management Plan (DMP) and Emergency Response Plan (ERP) for the
proposed project.
7.2 RISK ASSESSMENT
Hydrocarbon Operations are generally hazardous in nature by virtue of intrins ic
chemical properties of hydrocarbons or their temperature or pressure of operation or a
combination of them. Fire, Explosion, Hazardous Release or a combination of these are
the hazard associated with Hydrocarbon Operations. These have resulted in the
development of more comprehensive, systematic and sophisticated methods of Safety
Engineering such as Identification and Analysis of Hazards and Risk Assessment to
improve upon the Integrity, Reliability and Safety of Hydrocarbon Operations.
The RA studies are based on Quantitative Risk assessment Analysis (QRA).Normally
a three ‘levels’ risk assessment approach is adopted for the industrial activities. The risk
assessment levels are generally consistent with the practices encountered through
various assignments for medium and large chemical complexes. The brief outline of the
three tier approach is given below:
A. Level 1 – Risk Screening
The Top-Down Review of Worst- Case Potential Hazards/Risks, present in identifying
Drilling Sites or location within Blocks is identified and listed, various screening factors
considered include:
Inventory of Hazardous Materials;
Hazardous Materials Properties;
Storage Conditions (e.g. Temperature and pressure);
Location Sensitivity (Distance to Residential Areas / Populace).
The Data/Information is obtained from Site. The results provide a relative indicat ion
of the extent of hazards and Potential for Risk Exposure.
B. Level 2 – Major Risk Survey (Semi - Quantitative)
The survey approach combines the Site Inspection with established Risk Assessment
Techniques applied both Qualitative as well Quantitative Mode. The primary objective
is to identify and select Major Risks at a specific Location in the Drilling Site
considering possible soft spots / weak links during Operation / Maintenance. Aspects
covered in the Risk usually include:
Process Hazards;
Process Safety Management Systems;
Fire Protection and Emergency Response Equipments and Programs;
Security Vulnerability;
Impact of Hazards Consequences (Equipment Damage, Injury, Fatalities etc.);
EIA Report for Development Drilling of 108 wells, laying of, 4” and8” dia. O il and gas flow lines & establishment of 03 nos.
of EPS, 01 No. of WHI, 03 Nos. of Water injection Facilities and 03 nos. of ETP’s in operational areas of ONGC Cambay Sub As set
7- 2
Qualitative Risk Identification of Scenarios Involving Hazardous Materials.
Risk Reduction Measures
Selection of critical scenarios and their potential of damage provide means of
prioritizing Mitigate Measures and allocate the resources to the areas with Highest
Risks.
C. Level 3 – Quantitative Risk Assessment (Deterministic)
This is the stage of Assessment of Risks, associated with all Credible Hazards
(scenarios) with potential to cause an undesirable outcome such as Human Injury,
Fatality or Destruction of Property. The four basic elements include:
Hazards Identification utilizing formal approach (Level 2, HAZOP etc.);
Frequency Analysis: Based on past Safety Data’s (incidents / accidents), identifying
likely pathway of failures and quantifying the toxic / inflammable material release;
Hazards Analysis to quantify the consequences of various hazards scenarios (Fire
and Explosion [due to uncontrolled release of NG/Crude], Toxic Vapour Release
[due to release of H2S] etc.). Establish minimum value for damage (e.g. IDLH,
Over Pressure, Radiation Flux) to assess the Impact on Environment.
Risk Quantification: Quantitative techniques are used considering effect / impact
due to weather data, population data, and frequency of occurrences and likely hood
of Ignition / Toxic release. Data are analyzed considering likely Damage (in terms
of Injury / Fatality, Property Damage) each scenario is likely to cause.
QRA provides a means to determine the relative significance of each of a number of
undesired Events, allowing Analyst and the Team to focus their Risk Reduction Efforts,
which will be most beneficial.
Risk Screening Approach
Some of the common hazards associated with the regular drilling operations are:
Fires and Explosions
o Non-Process Hydrocarbon Leak (Diesel, lubricating Oil, etc.);
o Non-Process Fire;
o Control system failure including electrical failure in control room.
Impact and Collisions
o Accidental Falling of Object from Crown Block.
Loss of Station Keeping / Loss of Stability
o Structural Failure;
o Equipment Failure.
External Hazards
o Failure due to Extreme Weather, Strong Winds, Earthquake and Sabotage
etc.
These have resulted in the development of more comprehensive, systematic and
sophisticated methods of Safety Engineering such as, Hazard Analysis and Risk
EIA Report for Development Drilling of 108 wells, laying of, 4” and8” dia. O il and gas flow lines & establishment of 03 nos.
of EPS, 01 No. of WHI, 03 Nos. of Water injection Facilities and 03 nos. of ETP’s in operational areas of ONGC Cambay Sub As set
7- 3
Assessment to improve upon the Integrity, Reliability and Safety of Hydrocarbon
Operations.
The primary emphasis in Safety Engineering is to reduce Risk to Human Life and
Environment. The broad tools attempt to minimize the chances of Accidents Occurring.
Yet, there always exists, no matter how remote, that Small Probability of a Major Accident
occurring. If the accident involves hydrocarbon in sufficient large quantities, the
consequences may be serious to the project, to surrounding area and the population therein.
Drilling Rig floor is the centre stage of all the drilling operations and it is most Susceptible
to accidents. Safety precaution with utmost care is required to be taken during drilling as
per the Prevailing Regulations (Mines Act, Mines Rules, and Oil Mines Regulation) and
Practices so that accidents can be avoided. Due to advancement in technology, number of
equipment has been developed over a period to cater the need of smooth operation on Rig
Floor. Various standards are required to be referred to cover the variety of equipment used
for safe operation in drilling and it is desirable to use a properly prepared manual for
occupational safety while working or drilling using a non land Rig. It may, however, be
noted that Well Testing and Production Testing of hydrocarbons also require proper
Analysis of Hazards involved in production testing operations and preparation of an
appropriate Emergency Response Plan.
7.2.1 Identification of Hazards in Drilling and Production Testing Operations
Various hazards associated with onshore hydrocarbon drilling and testing operations
are briefly described in following sub-sections.
7.2.1.1 Minor Oil Spill
Testing at Well Site: Drill Stem Testing leading to an Oil Spillage from Lines, Valves,
Separator and Tank failure.
During the well testing operation, there exists a possibility of Hydrocarbon (gases / oil)
getting released due to some unavoidable incidents. Once the flow of Oil / Gas from
well is stopped, then on-site access for clean-up is possible.
7.2.1.2 Major Oil Spill
Significant hydrocarbon inventories will not be maintained at the rig. A major spill can,
therefore, only arise as a result of an uncontrolled flow from a well i.e. Blowout.
Provided that ignition does not take place and the well head is not obstructed the well
can be shut in at the wellhead.
7.2.1.3 Blowout
Blowout means uncontrolled violent escape of hydrocarbon fluids from a well. Blowout
followed by ignition which prevents access to the wellhead is a major hazard.
Contributors to blowout are:
Primary
Failure to keep the hole full;
Mud weight too low;
Swabbing during trips;
Lost circulation; and
Failure of differential fill-up equipment.
Secondary
Failure to detect and control a kick as quickly as possible;
EIA Report for Development Drilling of 108 wells, laying of, 4” and8” dia. O il and gas flow lines & establishment of 03 nos.
of EPS, 01 No. of WHI, 03 Nos. of Water injection Facilities and 03 nos. of ETP’s in operational areas of ONGC Cambay Sub As set
7- 4
Mechanical failure of BOP;
Failure to test BOP equipment properly;
Damage to or failure of wellhead equipment;
Failure of casing; and
Failure of formation or bond of cementing around casing.
If the hydrostatic head exerted by the column of drilling fluid is allowed to drop below
the formation pressure then formation fluids will enter the wellbore (this is known as a
kick) and a potential blowout situation has developed.
Fast and efficient action by operating personnel in recognizing the above situations and
taking precautionary measure can avert a blowout.
Hydrogen Sulphide (H2S)
Hydrogen sulphide gas (H2S) is extremely toxic, even very low concentrations can be
lethal, depending upon the duration of exposure. Without any warning, H2S may render
victims unconscious and death can follow shortly afterwards.
The Occupational Safety and Health Act (OSHA Regulations) set a 10 ppm ceiling for
an eight hourly continuous exposure (TWA limit), a 15 ppm concentration for Short
Term Exposure Limit for 15minutes (STEL) and a Peak Exposure of 50 ppm for 10
minutes.
7.2.2 Proposed Development Drilling in 9ML/NELP Onshore Block
108 Developmental Drilling Locations in nine ML Blocks/fields of Cambay sub Asset,
spread over Vadodara, Anand & Kheda Districts in Gujrat. The total Block Area is
820.82 km2. The Geographical coordinates of the block are presented in Table 2.3 to
Table 2.10.
The fuel for the drilling rigs, DG sets, other machineries and vehicles will be Diesel
(HSD with low sulphur < 0.05%). Daily fuel requirement for diesel sets will be 6 KLD.
The HSD storage will be limited to 30 KL. The exhaust stacks of the DG sets are likely
to vent the emissions. The Bulk Hazardous Chemical Storage Facility at Drilling Site
(Tentative) is given in Table 7.1.
Table 7.1 Bulk Hazardous Chemical Storage facility at Drilling Site (tentative)
Compound Stored Quantity
HSD (low Sulphur) 30 Kilo litter
7.2.3 QRA Approach
Identification of hazards and likely scenarios (based on Level-1 and Level-2 activit ies)
calls for detailed analysis of each scenario for Potential of Damage, Impact Area (may
vary with Weather Conditions / Wind Direction) and Safety System in place.
Subsequently each incident is classified according to Relative Risk Classificat ions
provided in Table below:
EIA Report for Development Drilling of 108 wells, laying of, 4” and8” dia. O il and gas flow lines & establishment of 03 nos.
of EPS, 01 No. of WHI, 03 Nos. of Water injection Facilities and 03 nos. of ETP’s in operational areas of ONGC Cambay Sub As set
7- 5
Table 7.2 Risk Classification
Stage Description
High
(>1/100)
A failure which could reasonably be expected to occur within the
expected life time of the plant.
Examples of high failure likelihood are process leaks or single
instrument or valve failures or a human error which could result
in releases of hazardous materials.
Moderate
(1/100 to
1/1000)
A failure or sequence of failures which has a low probability of
occurrence within the expected lifetime of the plant.
Examples of moderate likelihood are dual instrument or valve
failures, combination of instrument failures and human errors, or
single failures of small process lines or fittings.
Low
(<1/1000)
A failure or series of failures which have a very low probabilit y
of occurrence within the expected lifetime of plant.
Examples of ‘low’ likelihood are multiple instruments or valve
failures or multiple human errors, or single spontaneous failures
of tanks
Minor
Incidents
Impact limited to the local area of the event with potent for ‘knock
– on- events’
Serious
Incident
One that could cause:
Any serious injury or fatality on/off site;
Property damage of $ 1 million offsite or $ 5 million onsite.
Extensive
Incident
One that is five or more times worse than a serious incident.
7.2.3.1 Damage due to Explosion
The explosion of oil or gas (either as a deflagration or detonation) results in a reaction
front moving outwards from the ignition source preceded by a shock wave or pressure
front. After the combustible material is consumed the reaction front terminates but the
pressure wave continues its outward movement. [In oil exploration the likely chances
of explosion (due to blow out and consequential release of NG/Crude) are very less]
Blast damage is based on the determination of the peak overpressure resulting from the
pressure wave impacting on the object or structure. Damage estimates based on
overpressure are given in Table 7.3 below:
Table 7.3 Damage due to Overpressure
Sl.
No
Overpressure
(bar)
Damage
1. 0.04 Loud Noise / sonic boom glass failure
2. 0.15 Typical pressure for glass failure
3. 0.5 – 1 Large and small windows usually shattered
4. 0.7 Minor damage to house structure
EIA Report for Development Drilling of 108 wells, laying of, 4” and8” dia. O il and gas flow lines & establishment of 03 nos.
of EPS, 01 No. of WHI, 03 Nos. of Water injection Facilities and 03 nos. of ETP’s in operational areas of ONGC Cambay Sub As set
7- 6
5. 1 Partial demolition of houses, made
uninhabitable.
6. 2.3 Lower limit of serious structure damage
7. 5 – 7 Nearly complete destruction of houses
8. 9 Loaded train box wagons completely
demolished
9. 10 Probable total destruction of houses
10. 200 Limits of crater lip
7.2.3.2 Thermal Incidents / Fire in Storage Area
The diesel storage on the drilling site is limited to 30 KL. Any fire in the tank area if
not controlled in time (less chances/ unlikely) may soon spread in the rig site. During
blow out some Natural Gas coming out with some oil can also catch fire. However its
thermal radiation impact (1st degree burn) will be limited (as the fuels are stored in
remote place).
Minor spill can occur as various scenarios and may also catch fire. If fire is not
controlled these can lead to domino effect as major scenarios. During the drilling crude
oil production will be nil or very limited; some well water may come out which can be
treated and disposed off or pushed back in the nonproducing well. The likely impact
due to major scenario considered as given below in Table 7.4.
Table 7.4: Possible Major Scenarios
S.
No.
Scenario Impact Zone Remarks
1. HSD Tank failure, spillage &
Fire (~ 5 m Pool fire)
~ 8.5 From edge of pool
The impact due to the above scenarios will be within the block. It may have some
impact on the nearby vegetation but will not have any impact on local population.
H2S and Its Effects
Important characteristics of H2S gas are given as below:
H2S is a toxic colourless gas heavier than air.
It has an odour of rotten eggs but see ‘point 6’ below.
In concentrations greater than 100 ppm, it will cause loss of senses in 3 to 15
minutes and death within 48 hours.
In concentrations greater than 600 ppm death occurs in less than 2 minutes.
The safe concentration for a normal working period without protection is 10 ppm.
In concentration greater than 10 ppm, the Oil factory Nervessense to smell the gas
is lost, the need for detectors is apparent.
It attacks the body through the respiratory organs.
It dissolves in the blood and attacks through the nervous system.
It is very irritating for the eyes as it forms sulphurous acid together with water.
The Occupational Safety and Health Act (OSHA) sets a 10 ppm ceiling for an 8
EIA Report for Development Drilling of 108 wells, laying of, 4” and8” dia. O il and gas flow lines & establishment of 03 nos.
of EPS, 01 No. of WHI, 03 Nos. of Water injection Facilities and 03 nos. of ETP’s in operational areas of ONGC Cambay Sub As set
7- 7
(eight) hour continuous exposure (TWA limit), a limit of 15 ppm for short term
exposure limit for 15 minutes (STEL) and a peak exposure concentration of 50 ppm
for 10 minutes.
The best protection is breathing apparatus, with mask covering the whole face and
a bottle containing breathing air.
It burns with a blue flame to sulphur dioxide which is almost as dangerous as H2S.
It forms an explosive mixture with air at concentrations from 4% to 46%.
Short exposure of high tensile steel to as little as 1 ppm in aqueous solution can
cause failures.
Concentrations greater than 15 ppm can cause failure to steel harder than Rockwell
C-22. High stress levels and corrosive environments accelerate failures.
When pH is above 9 and solubility is relatively high, it is readily soluble in mud
and especially in oil mud.
The compressibility factor (Z) is higher than that for natural gas and H2S will thus
expand at rather lower pressures; or further up in the bore hole than natural gas.
A 35% hydrogen peroxide solution will neutralize H2S gas in the mud or 20 gallons
of H2O2 per 100 barrels of mud.
It occurs together with natural gas in all oil provinces of the world.
In characteristic H2S gas areas concentration above 42% in natural gas have been
reported.
Coughing, eye burning and pain, throat irritation, and sleepiness are observed from
exposure to low concentrations of H2S.
Exposure to high concentrations of H2S produces systems such as panting, pallor,
cramps, paralysis of the pupil and loss of speech. This is generally followed by
immediate loss of consciousness. Death may occur quickly from respiratory and
cardiac paralysis.
The effect of H2S concentration on Living Being/Human Being & Animal is given
in Table 7.5.
Table 7.5: H2S Effects on Living Being/Human Being & Animal
H2 S
Concentration
Effect on Living Being/Human Being & Animal
<10 ppm Safe for normal Working Period, without protection.
>10 ppm Effect on Olfactory Nerves, resulting Sense to Smell is Lost.
>100 ppm Loss of sense within 3 to 15 Minutes
Death within 48 Hours
>600 ppm Death within Less Than 2 Minutes