Minimum national standards for effluent and emissions

(1) All petroleum refineries, including refinery processing units, shall comply with the minimum national standards for the discharge of effluent and emissions contained in the Eleventh Schedule and Twelfth Schedule, respectively. (2) Without prejudice to subregulation (1) above, all petroleum refineries, including refinery processing units, shall also comply with the following national minimum emission standards– (a) in case of mixed fuel (gas and liquid) use, the limit is to be computed based on heat supplied by gas and liquid fuels; (b) all the furnaces/boilers with heat input of 10 million kilo calories/hour or more shall have continuous systems for monitoring of SO2 and NOX. Manual monitoring for all the emission parameters in such furnaces/boilers shall be carried out once in two months; (c) all the emission parameters in furnaces/boilers having heat input less than 10 million kilo calories/hour shall be monitored once every three months; (d) in case of continuous monitoring, one hourly average concentration values shall be met 98% of the time in a month. Any concentration value obtained through manual monitoring, that exceeds the limiting concentration value, shall be considered as non–compliance; (e) data on Ni + V content in the liquid fuel (in ppm) shall be reported. Ni + V content in the liquid fuel could be monitored once every six months, if liquid fuel source & quality are not changes. In case of changes, measurement is necessary after each change. 126 Environmental Protection (3) The minimum national standards for emissions for fluids catalytic cracking (FCC) regenerators shall be as contained in the Twelfth Schedule, including the followingSchedule 12. (a) in case part feed is hydro-processed, the values shall be calculated proportional to the feed rates of untreated and treated feeds; (b) FCC regenerators shall have continuous systems for monitoring of SO2 and NOX. One hourly average concentration values shall be met 98% of the time in a month, in case of continuous monitoring. Manual monitoring for all the emission parameters shall be carried out once in two months; (c) any concentration value obtained through manual monitoring, if exceeds the limiting concentration value, shall be considered as non–compliance; (d) data on Sulphur (weight %), Ni (ppm) and V (ppm) content in the feed to FCC shall be reported; (e) limit of CO emissions shall be met except during annual shut down of CO boiler for statutory maintenance. Schedule 12. (4) The minimum national standards for emissions from sulphur recovery units shall be as contained in the Twelfth Schedule, including the following– (a) sulphur recovery units (SRUs) having capacity above 20 tonnes/day shall have continuous systems for monitoring of SO2 Manual monitoring for all the emission parameters shall be carried out once in a month; Environmental Protection 127 (b) data on sulphur dioxide emissions (mg/Nm3) shall be reported; (c) sulphur recovery efficiency shall be calculated on a monthly basis, using quantity of sulphur recovered. (5) The minimum national standards for emissions from the storage of volatile liquids (general petroleum products excluding benzene) shall be as contained in the Twelfth Schedule, including the followingSchedule 12 (a) requirements for seals in floating roof tanks– (i) IFRT & EFRT are to be provided with double seals with minimum vapour recovery of 96%; (ii) primary seal shall be liquid or shoe mounted for EFRT and vapour mounted for IFRT. Maximum seal gap width shall be 4cm and maximum gap area will be 200 cm2/m of tank diameter; (iii) secondary seal will be rim mounted. Maximum seal gap width shall be 1.3 cm and maximum gap area will be 20 cm2/m of tank diameter; (iv) material of seal and construction should ensure high performance and durability. (b) fixed roof tanks shall have vapour control efficiency of 95% and vapour balancing efficiency of 90%. (c) inspection and maintenance of storage tanks should be carried out under strict control. For the inspection, API RP 575 may be adopted. 128 Environmental Protection In–service inspection with regard seal gap should be carried out once in every six months and repair to be implemented in short time. In future, possibility of non–stream repair of both seals shall be examined. (6) The minimum national standards for the storage of benzene shall be as follows– (a) FRT with vapour to incineration with 99.9% of removal efficiency for volatile organic compounds (VOC); (b) EFRT with double seals, emission– reducing roof fitting and fitted with fixed roof with vapor removal efficiency of at least 99%. (7) In respect of the storage of solvents for lube–base oil production (Furfural, N-Methyl-2-Pyrrolidone (NMP), Methyl Ethyl Ketone (MEK), Toluene and Methyl Isobutyl Ketone (MIBK)), IFRT with double seals and inert gas blanketing, with vapour removal efficiency of at least 97% shall be complied with. (8) In respect of the storage of off-gas from bitumen tanks, the odorous off-gas shall be disposed of in an incinerator or other proper burning device approved by the Department of the (9) In respect of the storage of off-gas from liquid sulphur storage, the vent from the sulphur storage tanks shall be fed to sour gas or to a proper abatement system. (10) In respect of LPG odorant plants, the designs and operation of the plants shall ensure an odour-free environment and comply with guidelines set for the purpose by the Department of the Environment. Environmental Protection 129 (11) The following national minimum standards shall be observed for the purpose of reducing pollution to water, soil and ground water from petroleum refineries, petroleum refinery complexes, and petroleum refinery units; namely– (a) the system design, level of automation and operation should ensure minimum oil carry over during the water drainage operation. Oil carry over in turn will result in VOC emission from the effluent from different stages and higher oil content in the effluent discharge; (b) proper instrumentation/operating procedure and additional level alarm must be observed to avoid overfilling that may lead to soil (c) for avoiding persistent leakage from tanks, the refineries should follow regular tank inspection, leak detection from tank bottoms, provision of double tank bottoms or impervious membrane liner below the tank bottom and there should be ground water (d) in order to avoid consequences of major oil spills from storage tanks, impermeable tank far bund containment system shall be implemented across the petroleum industry. (12) The minimum national standards for controlling fugitive emissions from equipment leaks shall be as contained in the Twelfth Schedule, including the following approach, components, applicability, and leak definition; namelySchedule 12. (a) Approach: Approach that will be employed for controlling fugitive emissions from equipment leaks is to have proper selection, installation and maintenance of non–leaking 130 Environmental Protection or leak–tight equipment. Following initial testing after commissioning, the monitoring for leak detection is to be carried out as a permanent on–going Leak Detection and Repair (LDAR) programme. Finally, detected leaks are to be repaired within an allowable time frame. (b) Components to be covered: Components that shall be covered under LDAR programme include– (i) Block valves; (ii) Control valves; (iii) Pump seals; (iv) Compressor seals; (v) Pressure relief valves; (vi) Flanges - Heat Exchangers; (vii) Flanges - Piping; (viii) Connectors - Piping; (ix) Open ended lines; and (x) Sampling connection. Equipment and line sizes more than 1.875 cm or ¾ inch are to be covered. (c) Applicability: LDAR programme would be applicable to components (given at (b) above) for the following products/compounds– (i) Hydrocarbon gases; Environmental Protection 131 (ii) Light liquid with vapour pressure @ 20°C > 1.0 kPa; and (iii) Heavy liquid with vapour pressure at 20°C between 0.3 to 1.0 kPa. (d) While LDAR will not be applicable for heavy liquids with vapour pressure <0.3 kPa, it will be desirable to check for liquid dripping as indication of leak. (e) Leak definition: A leak is defined as the detection of VOC concentration more than the values (in ppm) specified below at the emission source using a hydrocarbon analyzer according to measurement protocol (US EPA453/R-95-017, 1995 Protocol for equipment leak emission estimates may be referred). (f) In addition, any component observed to be leaking by sight, sound or smell, regardless of concentration (liquid dripping, visible vapour leak) or presence of bubbles using soap solution shall be considered as leaking. (13) The minimum national standards for VOC emissions from wastewater collection and treatment shall be as follows– (a) all contaminated and odorous wastewater streams shall be handled in closed systems from the source to the primary treatment stages (oil-water separator and equalization tanks); (b) the collection system shall be covered with water seals (traps) on sewers and drains and gas tight covers on junction boxes; 132 Environmental Protection (c) oil-water separators and equalization tanks shall be provided with floating/fixed covers. The off-gas generated shall be treated to remove at least 90% of VOC and eliminate odour. The system design shall ensure safety (prevention of formation of explosive mixture, possible detonation and reduce the impact) by dilution with air/inert gas, installing LEL detector including control devices, seal drums, detonation arrestors, etc. The system shall be designed and operated for safe maintenance of the collection and primary treatment systems; (e) wastewater from aromatics plants (benzene and xylene plants) shall be treated to remove benzene/aromatics to a level of 10 ppm before discharge to effluent treatment system without dilution. (14) The frequency for sampling the parameters for the minimum national standards for the discharge of effluent and emissions for all petroleum refineries, including petroleum refinery units, shall be done in accordance with these Regulations and the requirements in the Eleventh Schedule and Twelfth Schedule. Schedule 11. Schedule 12. (15) The analytical methods for the parameters referred to in subregulation (14) above shall be done in accordance with standard methods acceptable to the Department of the Environment or those contained in the Fourteenth Schedule. Schedule 14. Schedule 13.