HES DESIGN PHILOSOPHY

Installation of Integrated Carbon Complex consisting of Coal Tar Distillation &

Coal Tar value added unit.
At Jharsuguda

:ECAPL-HSED- 25 July 2023 Issue for Design Kanna Rao PTV Rangnath Dubey
01 Rambabu

P00 Issue for Approval Kanna Rao Rangnath Rajesh Sharma

Dubey
Rev. Date Description Prepared Verified Approved

Page 1 of 26
 Installation of Integrated Carbon Complex DOCUMENT No: ECAPL-
EPSILON CARBON ASHOKA HSED-01
PRIVATE LIMITED consisting of Coal Tar Distillation & Coal Tar
value added unit. REV. 1

HES DESIGN PHILOSOPHY

SUMMARY

1 GENERAL ............................................................................................................................................... 4
2 OBJECTIVE ............................................................................................................................................. 5
3 DEFINITION AND ABBREVIATION ........................................................................................................ 5
4 REFERENCE DOCUMENTS .................................................................................................................. 6
4.1 Company specifications ..................................................................................................................... 6
4.2 feed specifications .............................................................................................................................. 6
4.3 project documents .............................................................................................................................. 6
4.4 standards ............................................................................................................................................ 7
5 DESIGN CRITERIA ................................................................................................................................. 8
5.1 Inherently safe design ........................................................................................................................ 8
5.2 key design points ................................................................................................................................ 8
5.3 early hazard identification................................................................................................................... 8
5.4 HAZOP study ..................................................................................................................................... 9
6 PLANT LAYOUT ...................................................................................................................................... 9
6.1 General ............................................................................................................................................... 9
6.2 layout principles .................................................................................................................................. 9
6.3 requirements for equipment layouts ................................................................................................. 10
6.4 escape routes ................................................................................................................................... 11
6.5 drain systems ................................................................................................................................... 11
6.6 process drains .................................................................................................................................. 12
6.7 emergency power /lighting ............................................................................................................... 13
7 HAZARDOUS AREA CLASSIFICATION .............................................................................................. 13
7.1 General ............................................................................................................................................. 13
7.2 EQUIPMENT SELECTION............................................................................................................... 14
7.2.1 Electrical equipment ............................................................................................................... 14
7.2.2 Mechanical equipment ........................................................................................................... 14
7.2.3 Earthing and lightning protection ........................................................................................... 15
7.2.4 Ventilation .............................................................................................................................. 15
7.2.5 Fired equipment ..................................................................................................................... 15
7.2.6 Area classification drawings ................................................................................................... 16
8 PROCESS DESIGN SAFETY CRITERIA ............................................................................................. 16
8.1 General ............................................................................................................................................. 16
8.2 Flare and blowdown systems ........................................................................................................... 16
9 PROCESS CONTROL AND SAFETY SYSTEMS ................................................................................ 16
9.1 General ............................................................................................................................................. 16

Page 2 of 26
 Installation of Integrated Carbon Complex DOCUMENT No: ECAPL-
EPSILON CARBON ASHOKA HSED-01
PRIVATE LIMITED consisting of Coal Tar Distillation & Coal Tar
value added unit. REV. 1

HES DESIGN PHILOSOPHY

9.2 PROCESS CONTROL SYSTEM ..................................................................................................... 17

9.3 EMERGENCY SHUTDOWN (ESD) AND DEPRESSURISATION (EDP) SYSTEMS...................... 17

9.4 FIRE AND GAS DETECTION SYSTEM .......................................................................................... 18
9.4.1 Flammable Gas Detection ..................................................................................................... 19
9.4.2 Fire Detection ......................................................................................................................... 19
9.4.3 Fire and Gas Detection Panel and Alarms ............................................................................ 20
10 FIRE PROTECTION SYSTEMS ........................................................................................................... 20
10.1 GENERAL ........................................................................................................................................ 20
10.1.1 Fire Protection Philosophy ..................................................................................................... 20
10.2 ACTIVE FIRE PROTECTION .......................................................................................................... 21
10.2.1 Fire Protection ........................................................................................................................ 21
10.2.2 Existing Firewater and Foam Systems .................................................................................. 21
10.2.3 Water Spray System .............................................................................................................. 21
10.2.4 Total Flooding CO2 System for new facilities ......................................................................... 22
10.2.5 Clean Agent Fire Extinguishing System................................................................................. 22
10.2.6 Portable Fire Extinguishers .................................................................................................... 22
10.3 PASSIVE FIRE PROTECTION ........................................................................................................ 22
11 PERSONNEL HEALTH AND SAFETY ................................................................................................. 23
11.1 General ............................................................................................................................................. 23
11.2 personnel safety equipment ............................................................................................................. 23
11.3 personnel protection ......................................................................................................................... 23
11.4 safety showers and eyewashes ....................................................................................................... 24
11.5 safety signs ...................................................................................................................................... 24
11.6 medical facilities ............................................................................................................................... 24
12 ENVIRONMENTAL PROTECTION ....................................................................................................... 25
12.1 General ............................................................................................................................................. 25
12.2 emission to air................................................................................................................................... 25
12.3 soil & groundwater protection ........................................................................................................... 25
12.4 waste management .......................................................................................................................... 26
12.5 noise and vibration ........................................................................................................................... 27

Page 3 of 26
 Installation of Integrated Carbon Complex DOCUMENT No: ECAPL-
EPSILON CARBON ASHOKA HSED-01
PRIVATE LIMITED consisting of Coal Tar Distillation & Coal Tar
value added unit. REV. 1

HES DESIGN PHILOSOPHY

1. Purpose
A Safety Design Philosophy is a deliverable document of the Detailed Design and Engineering
developed by a Process Safety discipline.

2. SCOPE
This document details the procedures related to identification of hazards, evaluation of the risk
associated and bringing the risk to acceptable level through implementation of Process Safety
Management in design phase of the Project. This procedure is applicable for Greenfield Project site
at Jharsuguda Epsilon Carbon Ashoka Private Ltd.

Epsilon Carbon Ashoka Private Limited installing a green field Project of Integrated
Carbon Complex consisting of Coal tar distillation (CTD) unit of capacity 300,000
TPA and Coal tar value added (CTVA) unit of capacity 180,000 TPA with the
production of following combination of Products as below;

Page 4 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY
3. HES Policy

4. OBJECTIVE
The objective of this document is to define the general principles and strategy for the safety of the New
Integrated Carbon Complex and the facility personnel, to ensure that the same design philosophy is
applied to all elements and phases of the project.

The Project HSE philosophy has been developed around the principle that the most cost-effective design
results from adopting inherently safe design solutions, such that hazards are identified at an early stage
and either eliminated or proper measures to effectively control or mitigate them are provided.

Page 5 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY
5. DEFINITION AND ABBREVIATION

PSM Process Safety Management

BDV Blowdown valve

DCS Distributed Control System

ESD Emergency Shutdown

EDP Emergency Depressurization

FEED Front End Engineering Design

F&G Fire and Gas

HAZOP Hazard and Operability Study

HES Health, Environment and Safety

HVAC Heating Ventilation and Air Conditioning

LSD Local Shutdown

P&ID Piping & Instrumentation Diagram

PEM Project Engineering Manager

PLC Programmable Logic Controller

PM Project Manager

PSD Process Shutdown

QRA Quantitative Risk Assessment

UPS Uninterrupted Power Supply

PSSR Pre Startup Safety review

6. REFERENCE DOCUMENTS

a. Statutory Licenses
[1] Environment Clearance
[2] Environment Impact Assessment
[3] Factory License
[4] Fire NOC
[5] Consent to Establish & Consent to Operate
b.

b. Project documents

[1] Emergency Response procedures

[2] Waste Management procedures
[3] HSE Philosophy
[4] Fire and Gas Detection Philosophy
[5] Escape Route Layouts with safety Signal
[6] HAC Data Sheet
Page 6 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY
[7] Fire water demand study
[8] Fire &Gas - C&E Chart
[9] Quantitative Risk Assessment
[10] Layers of Protection System
[11] Firewater Deluge System
[12] P&ID Fire Foam Solution Bladder System
[13] Fire Fighting & Safety Equipment Specification
[14] HAZOP Report
[15] HAZOP Follow-up Report
[16] Hazardous Area Classification
[17] Escape route layout with safety signal
[18] P&IDs New Inlet Gas Compression Area
[19] Fire & Gas Detection layouts
[20] HSE Manual for Construction, pre-Commissioning and Commissioning
[21] Design Specification for Civil Works
[22] Shutdown Philosophy
[23] SIL Assessment study
[24] Arc Flash Assessment
[25] Quantitative Risk Assessment
[26] Flare Radiation & Dispersion Study
[27] Lighting Risk Assessment

7. DESIGN CRITERIA – PROCESS SAFETY MANAGEMENT

a. Hierarchy of controls
Process Safety during the design phase provides an opportunity to eliminate, substitute, or engineer
out hazards on the front end rather than as a change order on the back end of installation or after
installation is completed. Incorporating process safety during design also can help determine where
vessels, storage tanks, and equipment are located to prevent additional facility siting hazards and an
understanding of quantities of chemicals being stored.

b. Process safety management & safety management system

Epsilon Carbon has identified 18 important elements of PSM & SMS in the Design phase, erection,
construction, commissioning and during operations, which are paramount important to Risk
Management and achieve process safety culture.

Page 7 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY

c. Process safety information

The compilation of written Process Safety Information is to enable the employer and the employees
involved in operating the process to identify and understand the hazards posed by those processes.
This process safety information shall include information pertaining to:

i. Information pertaining to hazards of highly hazardous chemicals used or produced by process.

ii. Information pertaining to technology of process and
iii. Information pertaining to equipment in process.

d. Inherently safe design

The principal objectives are to ensure an inherently safe design of the facilities with due regard to
the climatic and environmental conditions to (Ref.[8]):

a) Minimise the likelihood and consequences of an accidental event, such that the risk to
on-site personnel is as low as reasonably practicable.
b) Minimise the potential for hazardous occurrences.
c) Ensure a safe working environment for personnel.
d) Ensure adequate means of escape are provided.
e) Maximise the benefits of protection measures, such as layout and the separation of
identified non-hazardous and hazardous areas.
f) Provide sufficient safety devices and redundancy to isolate and minimise uncontrolled
releases of flammable liquids and gases.
Page 8 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY
g) Provide appropriate fire protection systems to control any reasonably foreseeable fires
which could develop during normal operations.
h) Minimise the potential for pollution of the environment from accidental spills, venting or
flaring of hazardous materials.
i) Ensure that the new proposals complement existing facilities and do not compromise
or conflict with them.

e. Key design points

The engineering and design of the facilities shall pay specific attention to the following (Ref.[8]):

• Personnel protection.
• Protection of the environment.
• Plant and equipment layout.
• Hazardous area classification.
• Safeguarding by instrumentation and control.
• Start-up, shutdown and blowdown.
• Fire and gas detection and alarm systems.
• Fire protection systems.
• Overpressure protection systems.
• Equipment isolation for maintenance.
• Specification breaks.
• Vents and flares.
• Drains.
• Escape routes.

This is in addition to any risk-based design techniques and general principles of inherently safer
design.

f. Early hazard identification

In inherently safer design, hazards are avoided by identification early in the design process,
leading to several possibilities (Ref.[8]):
• The hazard can be eliminated at source ('designed out').
• Inventories of hazardous materials can be reduced so that the consequences of a leak
are minimised ('intensification').
• Less hazardous operating conditions can be employed, where economic and practicable
(e.g., low pressure).
• lf the hazard remains, it can be isolated or local protection provided.

g. HAZOP Study

A Hazard and Operability (HAZOP) study shall be performed to identify hazards and potential major
operability problems associated to the project design, verify the adequacy of the protection
measures and recommend actions to be incorporated into the design for improving the level of
protection and/or operability.
The HAZOP study involves a multi-disciplinary team reviewing the design, the HAZOP study
sessions for the project.
In particular, the following P&IDs will be subject to HAZOP study:

• New P&IDs.
• Relevant sections of existing site P&IDs were modified during engineering of the
project.

Changes to P&IDs after the HAZOP study will be carried out according to the requirements
describedin company procedures.
A HAZOP Chairman will be appointed by Company. The Chairman will lead the HAZOP study and,
with the co-operation, will prepare the HAZOP Study Report (Ref. [26]). All actions of the HAZOP

Page 9 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY
Analysis will be reviewed by the Contractor’s relevant disciplines and a Project response will be
prepared for Company review and approval.
A formal HAZOP Follow-up activity (Ref.[27]) shall be developed to ensure that all action items
from HAZOP will be reviewed and appropriate mitigation measures will be implemented in the
design with an auditable track.
h. Pre-Startup Safety Review
PSSR is a formal review of a manufacturing process to verify that critical areas of the affected process
have been assessed and addressed prior to using the process.
It ensures that shut down processes are verified to be in a safe condition for re-start.
This element considers how long the process was in the shutdown condition and deals with startup
from the shutdown scenarios.

The PSSR must confirm.

• Construction and equipment are in accordance with design specifications.
• Safety, operating, maintenance, and emergency procedures are in place.
• A PHA has been performed for new facilities and recommendations have been resolved
or implemented before start up, and modified facilities meet the MOC requirements
• Training of each employee

Conducting the PSSR

The PSSR Coordinator schedules the team meetings and assigns roles for the team members. The
review will consist of two parts:
• A review of the changes and the PSSR checklist to discuss the status of the checklist items
not requiring a field visit (e.g., training, procedures, etc.) and to generate a list of items for
review in the field.
Page 10 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY
• A field visit by the PSSR team to verify the status of items requiring a field visit, as well as to
verify the status of issues identified during the review mentioned above.

Authorization for Startup.

Upon completion of all pre-start-up action items, the PSSR report and corresponding form are
forwarded to Head - Operations of the facility for approval to implement and start-up the project or
modification.
After start-up, MOC Coordinator shall ensure that the “after start-up” action items are completed by
the target date, and that the new or modified equipment is safe to operate.

Startup clearance certificate:

• All concerned departments shall adopt their own existing internal checklist system for follow
up of work completion as Certificate.
• Based on internal checklist system of each department, “Exception lists” of jobs not
completed will get generated
• The “Exception List” is to be discussed with other concerned departments for confirming the
reasons due to which the jobs as planned could not be done/completed and the list is signed
by the departments.
• The responsible persons for each activity from concerned departments will sign against that
activity given below in the Start-up Clearance Certificate. As a default, ‘NO exception list’ will
be incorporated in each activity. If a particular activity does have an exception list, the same
to be mentioned in the activity column.
• All the above-mentioned activities should be completed before any hazardous Chemicals is
taken into the unit.
• a prerequisite for signing the Start-up Clearance

Closure of PSSR
• The PSSR Coordinator will verify that all recommendations and issues have been
satisfactory resolved and proceeded to signature and closure of the PSSR process.
• The PSSR shall be closed only when all before and after start-up items are completed.
• The closure of a PSSR shall be communicated to all concerned persons, including the
PSSR team members.
• The PSSR Coordinator should seek out all appropriate approvals prior to reviewing the
PSSR with Head – Operations

8. PLANT LAYOUT

a. General

The primary consideration when laying out process plants is its impact on the public and the
environment. Economics also affect the layout of the facilities; therefore, there must be balance
between the incremental benefit resulting from greater spacing and additional costs.

The layout and design of the Project shall reflect the results and recommendations of the hazard
assessment studies, plot plan reviews and the basic guidelines given in this document, as well as
codes of practice. As new equipment is being added within an existing plant, the availability of
space within existing plant areas for new equipment will need to be carefully considered in contrast
to the layout principles detailed below.

b. Layout principles

The following principles governing the location and layout of the new equipment shall be followed
(Ref.[8]):

a) Adequate separation between flammable hydrocarbons and ignition sources shall be

provided.

b) Adequate separation shall be provided between hydrocarbon-handling areas and

emergency services, main safety systems and areas considered non-hazardous.

c) Structural integrity shall be maintained during an incident to avoid escalation and provide
sufficient time to enable orderly and safe evacuation.
Page 11 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY

d) Control facilities and related buildings are already existing but shall be preferentially
located so that they are largely unaffected by leaks of flammable material for the new
facilities, incident heat radiation or explosion overpressures resulting from credible
accidents. Where this cannot be achieved, construction of buildings shall be sufficient to
ensure that residual risks arising from the addition of the new equipment due to accidental
loads are within acceptable limits.

e) Adequate access to all areas for firefighting shall be provided.

f) Sufficient means of escape to enable efficient evacuation from all areas to designate
assembly points under accident conditions shall be provided.

g) Suitable drainage and spill control shall be provided, reviewing where necessary the
provision and the existing philosophy.

h) The new equipment shall be located and oriented such that prevailing winds direct
flammable gases and routine emissions away from safe areas and away from identifiable
strong sources of ignition, e.g., fired heaters.

i) Atmospheric vents shall be located to cause minimum interference or hazard to the facility
and personnel.

j) Process piping and equipment which are sources of hydrocarbon leaks should be routed to
minimise the likelihood of external impacts.

k) Emergency shutdown valves shall be provided and located in such a way that the risk of
involvement in a developing accident is minimised.

l) Vales shall be fire-rated and located at a minimum practicable distance from the vessels
and equipment served.

Reference Standards:
• IS 8091(2008) – Industrial Plant Layout Code of Safety Practice
• OISD-STD-118 - Layouts for oil and gas installations
• Odisha Factories Rules 1950

c. Escape routes

At least two escape routes shall be provided from all areas and buildings throughout the facilities.
The escape routes shall be based on providing the shortest route from the hazard to a point of
safety.

Escape routes in process areas shall take the most direct route from the immediate hazard to an
area of lesser hazard and shall avoid directing personnel escaping from a non-hazardous area
through a hazardous area to a piece of safety.

Escape routes are to be designed in accordance with specifications (Ref.[3] and [1]) as designated
below:

a) Primary escape routes from all areas to assembly points shall have a minimum clear width
of 1000 mm.
b) Assembly points shall be designated and shall be located a safe distance from the process
area or building being evacuated to avoid interference with fire department
operations.
c) Secondary escape routes where escape is in one direction only shall have a minimum clear
width of 800 mm.
d) Stair widths on primary escape routes shall be a minimum of 1000 mm subject to the
number of personnel that will be expected to use the stair in an emergency. On secondary
routes, this may be reduced to 800 mm. Platforms will be provided at levels suitable for
access to equipment and provided with local lighting appropriate to the tasks to be
undertaken.
e) The clear height of any escape route shall be 2100 mm.
Page 12 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY
f) The configuration of primary escape routes shall provide adequate room for fire-fighting
and rescue teams to operate unhindered. Where changes in elevation of escape routes
occur, or a potential tripping hazard exists, ramps or stairways shall be provided.

The minimum clear width of stairways shall generally be the same as the escape route they serve.

• Every escape route and assembly point shall be readily accessible, unobstructed, well-
marked and provided with adequate lighting. Direction arrow markers shall be strategically
positioned along escape routes where it is necessary to guide personnel to assembly
points. Equipment and fixtures, if located along escape routes, shall be recessed so as not
to reduce the effective width of the passageway.

• Any doors on escape routes shall be easily opened from either side and shall not be
capable of being permanently locked except by frangible elements. In determining the
direction of opening of doors, consideration shall be given to the effects of pressurization
in the respective area. All doors shall be illuminated by an emergency Lighting system.

• The escape way outdoors must be at least 0.7m.

d. Drain systems.

Drainage systems involved in the handling, processing and storing of hydrocarbons become
an important part of both fire and environment protection and should satisfy the growing
concern of health, safety and environment related issues.

The drainage system shall consider the following basic concepts in the layout and early design
phase as below:
▪ Route flammable fluids away from ignition sources and into closed drains and
should isolate flammable pours in drainage piping from ignition sources.
▪ Direct spills of burning liquid to a safe location, away from equipment that might
rupture and add fuel to the flames.

▪ Minimise the spread and area of exposure from spills and fires.
▪ Drain off rainwater quickly and prevent flooding from outside sources.
▪ Minimize air emissions from evaporation of volatile fluids by capturing them in closed
drains.
▪ Keep waste out of soil, groundwater and surface water.
▪ Segregate clean and contaminated water to reduce the amount of water to be
treated.
▪ Develop catchments, in case of emergency, to prevent flow towards the plants
orfacilities.
▪ Safely dispose of hydrocarbons during drain-down of process vessels and
equipment

Hazardous and non-hazardous drain systems shall be completely segregated from each other, so
that there is no risk of contaminating non-hazardous areas via back flow from a hazardous area.

No drain system shall be routed to a location which could affect the local environment.
The dimension of the system collecting this part of plant drainage (oily water sewer) must be comply
with the volume of the liquid drained in emergency.

The drainage system shall be dimensioned in order to evacuate the highest quantity of water
coming from the controlled equipment (cooling water or meteoric waters).

e. Process drains

Page 13 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY
Equipment shall be drained only after being depressurized and shall be positively isolated from the
drain system during normal operation.

Chemical leakage from equipment shall be contained within curbed paved areas sloping into a
pit, where they shall be locally neutralized.

Manhole shall be provided at any change of direction and at every connection between main and
secondary lines. Manholes covers, in hazardous areas, shall be gastight (Ref.[33]).

f. Emergency power /lighting

EMERGENCY LIGHTING

Emergency lighting of adequate intensity shall be provided wherever the safety of persons or plant
may be endangered in the event of loss of normal main lighting. A suitable number of lighting units
are to be used as emergency lighting for the new facility. Emergency lighting fixture shall be self-
powered with a suitable battery to guarantee the requested performance.

The lighting fixtures for outdoor installation shall be IP55 minimum.

All the lighting fixtures shall be certified for the classification of the area where they will be installed
(Ref.[7]).

9. HAZARDOUS AREA CLASSIFICATION

a. General

The facilities shall be classified according to the likelihood of flammable gases and liquids being
released and the hazards which they would present. The identification of release sources and the
definition of Gas group and Class temperature shall be carried out in accordance with IEC 60079
(Ref.[45]). The extent of hazardous areas shall be in accordance with recommendations in API RP
505 (Ref.[38]).

The electrical equipment shall be certified according to IEC 60079 and selected for use in one of
the specific hazardous areas classified according to API RP 505, as follows:

A zone in which an explosive gas air mixture is continuously

Zone 0
present.

A zone in which an explosive gas air mixture is likely to occur in

Zone 1
normal operation.

A zone in which an explosive gas air mixture is not likely to occur

Zone 2 during normal operation and, if it does, will exist only for a short
time.

All other areas will be deemed non-hazardous and normal industrial apparatus will be used,
except for reasons of standardization.

The layout of the new facilities shall ensure that hazardous areas are completely contained within
the boundaries of the facility and that ignition sources are located outside hazardous areas.
Care shall also be taken to ensure that shelters or equipment enclosures do not inadvertently
impair ventilation.

Page 14 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY

The layout and design of the facilities shall ensure that control and electrical rooms, as well as
any manned buildings, are non-hazardous by location and/or by positive pressurization through the
ventilation system.

b. Equipment selection

7.2.1 Electrical equipment

Electrical equipment installed in hazardous areas shall be suitable for use in the appropriate area
classification and shall comply with the requirements of IEC 60079 (Ref.[46]).

As a minimum the electrical material in hazardous areas shall be suitable for gas group IIB and
temperature class T3 and IIC T3 if installed in battery rooms.

For reasons of uniformity, maintenance and spare parts the equipment to be installed in the safe
process area shall be suitable for installation in area classified Zone 2 (Ref.[7]).

The default method of protection shall be flameproof EEx’d’ in line with the existing plant standard.
Where EEx’d’ is not commercially available or practical EEx’e’ or EEx’n’ shall be used. Intrinsically
safe EEx’i’ shall be used only when the previous methods of protection are unsuitable (Ref.[9]).

The mechanical protection degree of electrical equipment shall be selected according to IEC
60529 (Ref.[47])

7.2.2 Mechanical Equipment

All mechanical equipment installed in hazardous areas shall be of a type that is non-sparking (or
otherwise protected) and adequately protected against the generation of a static charge. All hot
surfaces shall be suitably insulated and/or segregated from personnel.

For a product to be approved for a hazardous location, it must be designed so that an explosion
of the flammable or combustible material surrounding the device does not occur. Two usual
methods are used: Intrinsic Safety and Explosion Proof (Flame Proof) (Ref. [8])

Intrinsic Safety
An Intrinsically Safe piece of equipment is an electrical device that is incapable of causing an
ignition of the prescribed flammable gas, vapour, or dust, regardless of any spark or thermal effect
that may occur in normal use, or under any conditions of fault likely to occur in practice.

Explosion Proof (Flame Proof)

An Explosion Proof (or Flame Proof, as classified in IEC and Cenelec standards) device is an
electrical device designed with an enclosure capable of withstanding, without damage, an
explosion within it of a specific gas, fiber, or dust. In turn, it prevents ignition of these same
materials surrounding the enclosure by a spark or flame from the explosion within.

The applicable code and standards for equipment installed in hazardous areas are indicated in
Figure 2.

Page 15 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY

NEC
DESCRIPTION NEC 505 CSA IEC CENELEC
500
Intrinsically Safe for all IntrinsicallySafe Entity Class I Zone 0 AEx
for uses in Class I, II, d IICT4 Ex ia IIC
gases, dusts and fibers Certified for
III Div.1 T4
continuously present at Class I Div.1 EEx ia IIC T4
external temperature to Groups A-
Groups A-D
135°C (Certifiedwith G
Class II
Intrinsically safe barrier hazardous
Div.2
parameters locations
Groups E-G
Class III for
hazardous
locations

Explosion prooffor all

Explosion Prooffor Class I Ex d IIC
gasses, dusts and fibers EEx d IIC T6
Class I Div.1Groups Zone 0 T6
intermittently present at
A-D hazardous AEx d IIC
external temperature of
locations T6
85°C

Figure 2 – Applicable code for equipment installed in hazardous

areas.

7.2.3 Earthing and lightning protection

The earthing and lightning protection system shall follow the ENI specification for Grounding and
Lightning Protection n° 20210.VAR.ELE.SDS (Ref.[6]).

The main purpose of the earthing system is to achieve equipotential bonding of the network, in
order to avoid differential potentials between two parts connected to earth.

All metallic structures shall be used as the main earth loop. The interconnection of non-welded
part of bridges (foot bridges etc.) shall be made at two separate points by means of tin-plated
copperbraid welded to the structure.

Each technical and electrical room shall have an earth loop connected to the structure via earthing
conductors and sispatchers.

7.2.4 Ventilation
To minimise the classification of a hazardous area, adequate ventilation is necessary. In
unrestricted open areas a natural airflow across an area is considered sufficient by area
classification codes for it to be considered adequately ventilated.

In other cases, as per sect. 6.6.2.1 of API 505 (Ref. [38]) the ventilation (natural or artificial) is
defined adequate if it is sufficient to prevent the accumulation of quantities of vapour - air
mixture in concentration above 25% of their lower flammable limit.

For any enclosed areas in which flammable hydrocarbon processing equipment is to be installed,
there are specific ventilation requirements, as defined by codes.

Enclosed areas (rooms, buildings or spaces) that are provided at least 0.028 m 3 (1.0 ft3.) of air
volume flow per minute per square foot of floor, but at least 6 air changes per hour, can be
considered as adequately ventilated (sect.6.6.2.4.2 of Ref. [38]). This ventilation rate can be
accomplished by either natural or mechanical means.

7.2.5 Fired Equipment

The existing fired equipment presents an obvious source of ignition to any leaks which might
Page 16 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY
occur. The layout principles identified in Sections 4.2 and 4.3 shall ensure adequate spacing with
related equipment which could leak far exceed area classification spacing requirements.

7.2.6 Area Classification Drawings

Hazardous equipment schedules and area classification drawings shall be prepared and shall
include the following information:

• Identification of sources of release.

• The classification and extent of all hazardous zones.
• Notes regarding selection of electrical equipment.

10. PROCESS DESIGN SAFETY CRITERIA

a. General

The following general aspects shall be taken into consideration during the design of the new
facilities:

• Maintenance activities on process equipment will be protected by ensuring positive

isolation from the process.
• All major hydrocarbon vessels will incorporate relieving systems which will be vented to
flare (Relieving systems shall meet the requirements of API RP 521)
• All hydrocarbon-bearing pipes will be arranged in such a way as to minimise the risk of
mechanical damage.

11. PROCESS CONTROL AND SAFETY SYSTEMS

a. General

The suitability and provision of monitoring and trip functions of the Project will be assessed during
design reviews, according to the criteria below.

b. Process control system

One of the main functions of the process control/safety systems is to detect any abnormal process
conditions that might result in a dangerous situation. The systems have a logic with several levels
of intervention in relation to the possible effects of the process deviation on safety and production
continuity. The following general criteria shall be applied to the new equipment.

• The process safety systems will be designed such that they can be tested without
interrupting operations.
• Sensors and valves included in safety/trip systems will be kept independent of, and in
addition to, the process control functions.
• The critical high-Iow situations on the process parameters will be monitored by dedicated
instruments.
• When the sensors activate a protection function, the location of the incident shall be
automatically signalled in the control room (the alarm condition shall be signalled in the
Instrument Control Room, and it shall be repeated in the Central Control Room).

Control of the fire and safety systems shall be exercised from one command point, located in the
instrument control room, which is a safe and permanently manned area. All pertinent information
from production, fire and gas detection and protection equipment, together with alarm and
communication systems, shall be monitored, displayed and controlled from this point and repeated
in the Central Control Room and Fire Station.

Equipment and instrumented parts of the process safety and control systems will be of the fail- safe
type.

Page 17 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY

c. Emergency shutdown (ESD) and depressurization (EDP) systems

The main purpose of the ESD/EDP system is to prevent potentially hazardous conditions from
developing into hazard or accident, as well as to minimise the consequences of accidental events.
The following criteria will be applied to the Project.

• The activation of the ESD system shall result in a shutdown of all the relevant facilities and
it will be possible to actuate it either automatically or manually by means of push- buttons
located in the control room, and to the “plant shutdown” push button located in Central
Control Room.
• The shutdown system, including sensors, actuators and associated connections and
circuits, shall operate independently of other processes and alarm systems.
• Automatic sequences of shutdown will be actuated by means of air operated on-off valves.
• The ESD circuits and actuators will fail to a safe position on loss of power.
• The ESD system design will consider interference from electromagnetic sources and will
incorporate suitable protection.
• It will be possible to test critical items of the ESD system without stopping normal process
operation.
• Inhibition of ESD functions shall be possible for a limited period only with the consent of the
control room operator and shall inactivate a single safety function. Optical warning will be
provided in the control room.
• ESD actuators and cables will have resistance to the effects of fires and falling objects.
• ESD hands-witches located in the main control room will be clearly marked and protected
from inadvertent use.
• ESD valves shall not auto-reset. Local reset switches shall be provided for identified, critical
ESD valves.

The design of the Emergency Shutdown (ESD) and Emergency Depressurization (EDP) will be in
accordance with API RP 520 and API RP 521

The shutdown level hierarchy is correlated in the various plant units. The shutdown system is
designed in order to divide the plant in two section: the division follows the priority level defined by
gravity of the situation causing the shutdown.

The highest priority level (ESD) is associated to the process or utilities unit whereas other levels
of shutdown (PSD and LSD) are respectively associated to plant section homogeneous for their
type of fluid or single equipment.

The shutdown system occurring in hazardous situation (leaks, overpressure, under pressure, liquid
overflow etc.) and induced by manual actions or automatic actions (refer to activation of fire and
gas sensors or some process instrumentation) causes as effect a protective action through visual
and acoustic alarms signals on installations to the Control Room, and through the controlon the
installations.

d. Fire and gas detection system

Fire and Gas detection systems shall be provided for this Project. A risk-based approach shall be
employed in the design to ensure that the systems provided are commensurate with the identified
risks presented by the facilities protected. Thus, the flammability, ignition likelihood and quantitative
assessment of the associated risks shall all be considered.

The Fire and Gas system for this Project shall be in compliance with the existing sections of the
statutory requirements in India & International best practices; however, detection requirements shall
be determined based on the perceived risks and other detection criteria identified above.

The design of the Fire and Gas Detection System will be in accordance with the NFPA 72 "National
Fire Alarm Code, 2007 Edition" (Ref.[43]) and according to the existing Fire and Gas Detection
System. When one subject is not covered by this code, the criteria to be adopted shall be in
Page 18 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY
accordance with the accepted safety standards as currently applied in the Petroleum Industry and
generally called "Good Engineering Practice".

9.4.1 Flammable Gas Detection

The requirement for a gas detection system will be considered for this project, in order to provide
the earliest indication of a flammable gas leak. The requirement for, number and type of detectors
will be based on an evaluation of:

• Hydrocarbons (or other materials) processed in each fire zone;

• Gas evolution rate;
• Process conditions which could affect the subsequent dispersion of the released material;
• The likelihood of successfully detecting any released material.

The selection and positioning of hydrocarbon detectors shall take into account local ambient
conditions and strong ignition sources to ensure successful operation, reliability and minimise
spurious alarms.

Flammable gas detectors shall indicate two levels for detection of explosive mixtures in order to
facilitate prompt action in case of accidental gas release. The gas detectors set a two different
alarm levels (low and danger) shall generate an alarm signal (pre-alarm and alarm respectively)
and in case of confirmed gas detection (two or more detectors reaching danger level) shall initiate
the appropriate actions (shutdown, isolation of unprotected sources of ignition, etc.).

Flammable gas detectors shall be provided in open area (process area) and also for enclosed
spaces as HVAC and combustion air inlets.

The requirement for gas detection measures in ventilation ducting for manned areas or
combustion air intakes will be based on an assessment of the proximity of the area to hydrocarbon
sources.

In addition H2 detectors shall be installed in rooms where batteries are present (i.e., battery room).

9.4.2 Fire Detection

The requirement for fire detection devices will be considered for all areas of the new facilities. The
requirement for, and type of, fire detectors employed will be based on the identified fire hazard,
burning characteristics of the fuel(s) involved and the environment in which the fire could occur
(open area or enclosed space).

Devices employed will include flame detectors (open process areas) and heat and smoke
detectors (enclosed areas, non-process).

Smoke detectors (optical type) shall be provided for Instrument Control Building and LERs. Smoke
detectors are designed to sense the presence of particles of combustion, based on principle of
photosensitive sensor that produces an alarm signal when the reduction of received light.
According to section 5.5.2.1 of NFPA 72 (Ref. [43] ) the detector protection extended includes all
rooms, halls, basements, spaces above suspended ceilings, raised floors and other subdivisions
and accessible spaces as well as the inside of all closets.

The location and the spacing of smoke detectors shall be based upon the anticipated smoke
flow due to the plume and ceiling jet produced by the anticipated fire as well as any pre-existing
ambient air flows that could exist in the protected compartment.

Combined ultraviolet (UV) and infrared (IR) detectors shall be used around the gas compressor
modules and in turbine enclosure.

Point type heat detection shall be installed in rooms or over equipment where the earliest
indications of fire are most likely to be temperature raise, or where normal conditions preclude use
of smoke detectors.

Page 19 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY
Heat detectors, rate of rise (ROR) type, shall be used in areas subject to large (but relatively slow)
temperature increases. They shall be considered for use in open process areas where water spray
systems are required to be automatically activated, in order to avoid the spurious actuation of
adjacent water spray systems; this can occur if flame detection is used if process areas are
relatively compact, unless appropriate shielding is provided.

In addition to automatic fire detection devices, local manual alarm call points will be strategically
installed throughout the facilities. The call points will be provided in order that personnel working
at the unit can raise the alarm if a hazardous situation is detected. Manual detection could be a
more effective means of detecting small fires in open process areas, depending on manning levels
and time of day.

9.4.3 Fire and Gas Detection Panel and Alarms

Fire and gas detectors provided for the new facilities shall be monitored and controlled by new fire
and gas alarm control panel, to be installed in the new local Compressor Control/Equipment
Room. Fire and gas detection serving the new facilities will be tied into the existing fire and gas
alarm control panel, located in the main site Control Room and repeated in the Fire Station.

Audible alarms in the new areas will be generated via the new public address (P.A.) system to
be provided in those areas, on receipt of appropriate signals from the new fire and gas system.
Different alarm tones shall be generated for each condition of concern (general fire, gas). In
order that audible alarms are generated across the new Inlet Gas Compression Station, fire and
gas systems and related instrumentation shall be incorporated into the existing control system
and shall be installed with the purpose of taking in a safe state the process or affected
equipment in the emergency event or plant upset.

Audible alarms in the new process areas will be generated in the same manner as in the existing
process and utility areas.

Audible alarms resulting from detection of incidents occurring in any enclosed areas shall be
limited to the affected area and the control rooms only.

12. FIRE PROTECTION SYSTEMS

a. GENERAL

10.1.1 Fire Protection Philosophy

The fire protection philosophy is one of removal/elimination of fuel sources, reliable automatic
detection and rapid application of extinguishing media to control and extinguish the fire. The
removal of the fuel source results from automatic emergency process and production shutdown,
with relief systems provided for hydrocarbon vessels, and equipment used to minimise the release
of the fuel source.

Although the principal means of fire limitation is by adequate separation distances between
individual items of equipment and between equipment areas, fire-fighting and protection facilities
shall be installed to control or extinguish potential fires and provide exposure protection.

The fire protection requirements of the new facilities shall be determined by investigation of the
fire hazards, the nature of the equipment, the layout and manning levels. In addition, the existing
fire fighting capability shall be considered in establishing the requirements for passive, fixed and
portable fire protection. The fire hazards associated with new facilities are essentially the same as
those far the existing facilities, the process and operating conditions being very similar.

The design of the fire protection systems far the new facilities will be based on one major fire or
incident occurring at any one time, which is assumed to be the design basis for the existing
systems.

Design of fire protection systems will be generally in accordance with the applicable NFPA

Page 20 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY
standards (Ref. [50][51][52][53][54][55][56][57][58])

b. ACTIVE FIRE PROTECTION

10.2.1 Fire Protection

Active fire protection shall be considered in order to reduce, as far as reasonably practicable, the
risks presented by ignited material to the facility. The objectives shall be to:

• Extinguish fires.
• Control the spread of fire.
• Protect personnel from heat radiation.
• Cool structures, equipment and buildings were exposed to the effects of a fire.

10.2.2 Existing Firewater and Foam Systems

The fire protection facilities shall consist of the fire water system that ensures the maximum safety
degree in firefighting operations, with maximum independence from availability or all services and
utilities provided in the plant.

The fire water network is keptalways in pressure which takes feed from existing Fire Water
Tanks.

The firewater pumps are provided with automatic, local and remote manual starting facilities. Once
started they can be shut down manually and locally only. Low pressure in the firewater ring starts
the spare jockey pump, and in case of pressure decreasing, the selected main pump is started.

10.2.3 Water Spray System

Water spray systems (through fixed distributors) shall be provided for exposure protection
andheat input from adjacent fires and for vapor dispersion. It shall be manually and/or

automatically and it shall be controlled by suitable deluge valve located at safe distance from
exposures.

In case of fire detection, the deluge system starts providing only cooling by water application.
The water spray system shall be sized to guarantee application of water in compliance with the
latest issue of NFPA 15 (Ref. [55]). Any system shall consist of:

• One control deluge valve having the following characteristics:

- Clapper deluge-valve electric operated type with control electro valve including
alarm test and drain trim.
- Upstream block valve type OS&Y
- Upstream water filter
- Any necessary support for auxiliary facilities
- Deluge valve supplied full preassembled with all auxiliary facilities.

• Spray nozzle as necessary for protection.

Nozzle shall produce a cone shaped spray pattern with uniform discharged characteristics.

10.2.4 Clean Agent Fire Extinguishing System

Total flooding clean agent fire extinguishing systems linked to the fire detection system shall be
installed for the identified critical equipment from business continuity prospectus. This system
shall be provided to protect electrical/electronic and telecommunication equipment and subfloor
space. According to NFPA 2001 all requirements and measures to avoid unnecessary exposure
to inert gas agent resulting in low oxygen atmospheres in a normally occupied area shall be
applied.

10.2.5 Portable Fire Extinguishers

Page 21 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY
The selection of extinguishers shall be rationalized as far as possible to simplify maintenance.
These shall neither use nor generate highly toxic chemicals and shall have simple operating
instructions attached.

Portable fire extinguishers according to IS & NFPA 10 (Ref. [50]) shall be mounted at a height not
exceeding 1.5 m from floor level to the bottom of the extinguisher and at a minimum distance of
1.2 m from the edge of door openings (where located in enclosures). Extinguishers shall be
recessed if located along escape routes. Extinguishers shall employ CO2, dry chemical or foam
as the extinguishing medium, according to the fire risks and equipment to be protected.

10.3 PASSIVE FIRE PROTECTION

The aim of Passive Fire Protection is to reduce the risk of escalation of a fire scenario, providing
additional time to control and extinguishing the fire, thus minimizing both the risk to personnel, plant
damage and economical loss and to:
• Identify major liquid hydrocarbon fire hazards originating from the process
plant to be installed as part of the project.
• Define fire zones.
• Define fireproofing requirements for Structures, Vessel Supports, Pipe racks
etc.

Passive fire protection will be considered for important load-bearing structural members, vessel
saddles, supports and process structures in conjunction with the potential for prolonged fire
exposure in case of hydrocarbon pool fires according to API 2218 criteria (Ref.[41]).

13. PERSONNEL HEALTH AND SAFETY

a. General

The construction of this Project facility and its integration into the existing plant involves specific
health and safety issues within a construction and normal operation context. Typical hazards such
as working at height, electrical shock, excavation, ergonomic conditions, confined spaces, etc.
shall be considered during the construction phase of the project to ensure local compliance with
the health and safety legislations and company HSE requirements.

b. Personnel safety equipment

Except where risks are adequately controlled by other means, suitable Personal Protective
Equipment (PPE) shall be used by the plant personnel, contractors and visitors as required by the
local HSE authorities and plant/company internal safety standards and regulations.
PPE is not to be considered a first line of defense, but only a final means of protection. In all cases,
failings which pose possible hazard or risk shall be designed or managed out of systems,
situations, works or operations.
Suitable PPE must:

- Be appropriate for the risk(s) involved and the conditions at the location.
- Take ergonomic considerations fully into account and be capable of being used
effectively by the employee concerned.
- So far as is practicable, prevent or adequately control the risk of exposure without
creating or increasing overall risk(s).
- Be designed and manufactured to an approved standard.

c. Personnel protection
Page 22 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY
Insulation for personal safety is envisaged for piping, equipment and machinery that normally
are not insulated, but feature a service temperature that exceeds 60 °C.
This protection shall be restricted to areas for maneuvers or passages for personnel. Said
protection shall be extended 600 mm horizontally and 2100 mm vertically from operational areas
or gangways.
When working outdoors the effects of the weather in this environment can potentially have a very
serious impact on an employee's welfare if the risks have never been previously considered or
managed properly. This impact may be immediate, or it occurs over a long time period.
Exposure to the sun can cause skin damage including sunburn, blistering and skin ageing and in
the long term can lead to an increased risk of skin cancer.

Plant personnel can avoid unnecessary exposure by such means as:

- Wearing long sleeve shirts or loose clothing with a close weave.

- Wearing Safety Helmet
- More frequent rest breaks.
- Taking breaks in the shade whenever possible.
- Scheduling work to cooler times of the day; and
- If possible, provide shade where work tasks are being undertaken.

Sun protection is important, and plant and construction personnel need to realize that sun-burnt
skin is damaged skin. A suntan is not a sign of good health. Process and utility pipework
carrying hot fluids, and any hot equipment, will have suitable insulation and/or guarding to prevent
personnel injury from contact with hot surfaces.

d. SAFETY SHOWERS AND EYEWASHES

Considering that safety showers should be provided in areas where personnel may meet
hazardous substances (chemicals), for the new Inlet Compression Area this safety devices
is not required. Only an eyebath fountain shall be provided for the battery room of the local
Control Room in this Unit. Potable water shall be provided for the eyewash, and it shallbe cooled,
and temperature shall be maintained between 25°C to 28°C. The Eyewash Unit shall be capable
of providing flushing water to eyes at not less than 1.5 litres per minute (0.4 gpm) for 15 minutes
with stay-open valve as per ANSI Z358.1-2004 (Ref.[42]). The eyewash units shallbe provided
with a proximity switch for the purpose of providing an alarm in the plant main control room. The
eyewash units shall be suitable for use in a hazardous area.

e. SAFETY SIGNS

Safety signs shall be provided throughout the plant combining the geometrical shape, colour and
pictorial symbol to give specific health/safety or emergency information and/or instructions for
personnel. Text shall be in English. Safety signs shall be in accordance with applicable national
regulations and normal international practice.

Normally unmanned buildings, such as the LERs, should be provided with emergency signs at all
entrances. Emergency signs shall be provided to inform personnel of escape routes, emergency
exits and the location of fire-fighting equipment.

All emergency signs shall be illuminated by one of the following means:

- Directly by the provision of emergency lighting.
- Self-powered luminescent.
- Photoluminescence.

Rooms or enclosures protected with gaseous fire-extinguishing systems shall be equipped at their
entrance(s) with warning signs located as per Ref. [52] outside the rooms to inform the personnel
of possible extinguishant discharge. This will be in addition to audible and visual alarms in the
protected area to warn of any impending gaseous extinguishant release.

Page 23 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY

f. MEDICAL FACILITIES

This Project is located from 4 kms existing JSW Bhushan Steel and will utilize their hospital facility
for any emergency. ECAPL will have an ambulance & Occupational Health Center with medical
staff as per the statutory provisions.

14. ENVIRONMENTAL PROTECTION

a. GENERAL

The following environmental issues should be considered as a part of comprehensive assessment

and management program that addresses project-specific risks and potential impacts. Potential
environmental issues associated with the new Inlet Gas Compressor Station project include the
following:

• Emissions to Air
• Soil and Groundwater Protection
• Waste Management
• Noise and Vibration

Environmental parameters shall comply only with the limits detailed in the applicable local laws and
Company or recognized International Standards.

b. EMISSION TO AIR

The burning of hydrocarbon gas and liquids in flares, gas turbines, power generators and fired
heaters results in emissions of combustion gases to the atmosphere. The combustion products
comprise mainly carbon dioxide, with smaller volumes of nitrogen oxides, sulfur dioxide, carbon
monoxide and, to a lesser extent, particulate matter and methane derived from incomplete
combustion processes.
Even if fugitive emissions are usually small, it can be expected from oil storage tanks, valves,
pipe fittings and instruments. These largely comprise volatile organic compounds (VOCs, including
methane) which are a range of hydrocarbon gases, some of which contribute to depletion of
stratospheric ozone.
Air emission specifications should be considered during all equipment selection and procurement.
The engineering design approach shall be to minimise emissions to air where practicable and
economically feasible. Where emissions are unavoidable the approach shall be to provide, for point
sources, stacks of adequate height to offer good dispersion and to apply good engineering practice
in the choice of materials and equipment in order to minimize emissions. In general:

- The design of arrangements for taking samples of process fluids shall limit the loss of
volatile organic compounds (VOCs)
- Fugitive losses from valves, flanges, pump seals, etc. shall be limited by good design and
operational maintenance
- Hydrocarbon vapors from emergency relief/equipment depressurization shall be directed
to a flare
- Continuous vents to atmosphere from process equipment shall be avoided (all discharges
from process equipment shall be collected and flared); vents are only allowed for small
relief to depressurize in emergency some packaged equipment.

An environmental impact assessment is required for new developments and equipment where the
gases and particulate emissions in the atmosphere could have local environmental impacts of poor
air quality.

Statutory document: Consent to Establish & Consent to Operate.

c. SOIL & GROUNDWATER PROTECTION

In the Carbon Industry soil and groundwater pollution is one of the major environmental concerns
when uncontrolled and unconfined liquids spillages and escapes occur inside the facility.
Page 24 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY
The design approach to protecting groundwater resources shall be to ensure that all the areas that
could be contaminated by process fluids, chemicals, etc. are served with an appropriate hard
surface and drainage system to prevent contaminated waters or pollutant liquids being dispersed
on the ground and entering the groundwater.

Provisions shall be taken to contain any potential leakage and spillage from this Project to have
a system to recover the liquids for reuse or safely disposed off. Any potential sources spills shall
be provided with an adequate drain system to assure the spills are direct to a safe location where
can be retained and either recovered or disposed off (Ref.[33]).

Statutory document: Consent to Establish & Consent to Operate.

d. WASTE MANAGEMENT

Sources of sludge and solid wastes during construction, pre-commissioning, commissioning and
operation activities are likely to include:

- Scrap metals and wood.

- Waste drums.
- Waste oil and chemicals.
- Special wastes (e.g., radiographic materials used during weld checks).

The site organization and the design of the process shall be optimized in order to minimize waste
production. Non-hazardous waste material may be stored for a short period in a specific temporary
storage before disposal.

Non-hazardous wastes shall be stored and collected in a way that prevents:

- vermin breeding and harborage.
- hazards to workers, users and the public.
- air, water and soil pollution.
- objectionable odors, dust, unsightliness and nuisance conditions.
- corrosion or wear of storage containers and accidental spillage.
- leakage during storage or transport.

Non-hazardous storage areas shall be sited considering the following considerations:

- maximization of distance from domestic areas.
- avoidance of flood areas.
- minimization of wind exposure.
- minimization of sun exposure.

Hazardous waste can be temporarily stored on-site for 90 days, but specific facilities for final
disposal shall be located considering the characteristics of the hazardous waste.
Hazardous waste shall not be allowed to accumulate at the storage sites. Quantities stored shall
be kept to the minimum. Hazardous waste shall be stored in a suitably designed reception facility
with impervious flooring, roofing, and suitable drainage control; these waste materials shall be
moreover stored in a separate storage area specifically dedicated for this purpose.
All hazardous waste shall be stored in tightly closed, leakage proof containers made of, or lined
with, materials that are compatible with the hazardous waste to be stored.

Special precautions shall be taken to treat surface run-off from this area and for the
disposal of fire water.

Materials shall be stored in good order, with labels. Containers shall be marked with clearly
identifiable labels to accurately describe their contents, chemical and commercial denomination,
type and degree of hazard.
Different categories of hazardous waste, such as reactive, flammable, acidic corrosive and caustic
corrosive materials, shall not be stored/ placed in the same storage/containers area and they shall
be segregated separately.

The first preference for the disposal of all solid hazardous wastes shall be to recycle byreturning
the materials to the original vendor or to a reclaimer for commercial regeneration. When no market
or capability exists for a given waste, the waste shall be sent to an offsite disposal facility.
Page 25 of 26
 PROJECT AND LOCATION: DOCUMENT
EPSILON CARBON ASHOKA No:ECAPL-HSED-01
PRIVATE LIMITED Installation of Integrated Carbon Complex
consisting of Coal Tar Distillation & Coal Tar value REV. 01
added unit, Jharsuguda.
HES DESIGN PHILOSOPHY

Solid waste generated onshore would most likely be disposed of to a licensed waste disposal
facility. Any other disposal method, such as local landfill, will require a Waste Management
License from the local Environment Agency/Authorities. Usually, it is only likely to be of
significance during the construction and abandonment phases of a facility, since during normal
operations waste volumes will be small and will most likely be disposed of to a licensed landfill
site. However, all acts of waste disposal shall be subject to scrutiny and authorization by the local
Environment Agency / Authorities and according to the facility internal environmental standards
and requirements.
Waste identification, handling, storage and disposal shall comply with the site Waste Management
System in accordance with consent to Operate conditions from Pollution Control Board.

e. NOISE AND VIBRATION

The main sources of noise and vibration pollution from hydrocarbon installations are likely to
emanate from:

- Mechanical equipment and associated activities during construction, such as

excavations and piling.
- from flaring, venting, control valves and rotating equipment during operations.

Construction noise shall be monitored, assessed and controlled to ensure facility sites and
localnoise limits are not exceeded. Noise levels shall be limited throughout the installations to:
- Minimize the risk of hearing damage to personnel.
- Ensure alarms are audible.

The acoustic environment inside the plant area shall be monitored in order to identify "restricted
areas" where warning signs, access restriction and/or use of ear protectors shall be provided to
safeguard the operator’s health.

Hand arm vibration (HAV), basically associated to the excessive use of powered hand tools, and
whole-body vibration (WBV) associated to factors such as the industrial construction vehicles
driving, poor posture and heavy lifting, are the causes of significant ill health.

Where excessive vibration exposures are exceeded, it is required to establish good practice
controls which can help to eliminate or reduce vibration risk as reasonably as practicable or
identify alternative methods for specific high-risk activities. Where vibration risks remain, it is
required to look for evidence that the risks are being managed adequately and that suitable health
surveillance is in place.

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