risk assessment 1.1 introduction · m/s. delta finochem pvt. ltd., wadivarhe, igatpuri, nashik,...
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M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
Risk Assessment
1.1 Introduction
As indicated in the earlier chapters of EIA the expansion project facilitates to manufacture
API and Intermediate chemicals poses various types of hazards due to storage, handling &
transportation of various chemicals, which are indicated in Chapter no. 2 of EIA report.
In order to study the risks envisaged by the activities, the following methodology was
adopted.
1.1.1 The factory would be manufacturing different products under the category of API &
Intermediate chemicals accounting to a production of 13619.3 MT/A & By-product
generation with rate of 1860 MT/A. However, HAZOP studies have been carried out for
some hazardous operations and process.
1.1.2 A detailed scrutiny of all the raw materials and products was done which would be
stored on the site. The detailed list of raw materials is tabulated below in Table no – 1.
1.1.3 Plot layouts showing locations of tanks, fire hydrant tanks & other safety features are
depicted in the plot layout discussed in the onsite emergency plan.
1.2 MSDSs:
Brief MSDSs of all the above chemicals and other raw materials which would be used in the
manufacturing processes of products are used as reference for preparation of Quantitative risk
assessment & HAZOP study.
1.2.1 A Quantitative Risk Assessment based on the software ALOHA – Arial Locations of
Hazardous Atmospheres was carried out. The criteria failure scenarios considered for
ALOHA depend on the type of storage whether above ground/ underground, physical state of
the chemical stored, chemical properties of the chemical. The summary of the ALOHA
footprints are attached as Annexure 7.1 in EIA report.
Table 1: Details of Raw Materials/Bi products/ Products Stored in Tank
Sr.
no
Name of Raw
Material
Storage
Tank Dimensions of Tank
Maximum
Storage
Quantity at
any given
time as per
CS
Dyke Dimension
1 Methanol 1 ⌀ 1.8 m X 6.35 m
Length 16000 L 34 Sq.m. X 1.0 m
2 Toluene 1 ⌀ 1.8 m X 6.35 m
Length 16000 L 34 Sq.m. X 1.0 m
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
3
MDC
(Dimethyl
chloride)
1 ⌀ 1.8 m X 6.35 m
Length 16000 L 34 Sq.m. X 1.0 m
4 Iso Propyl
Alcohol 1
⌀ 2.46 m X 4.2 m
height 20000 L
23.5 Sq.m. X 1.0
m
5 Acetone 1 ⌀ 2.40 m X 3.82 m
height 15000 L
20 Sq.m. X 0.85
m
6 Ethyl Acetate 1 ⌀ 2.02 m X 4.0 m
height 12000 L
16.0 Sq.m. X 0.85
m
7 Liquefied
AMMONIA 1
⌀ 2.46 m X 4.2 m
height 20000 L 25 sqm. X 1 m
8 Aq. Ammonia
solution (25% ) 1
⌀ 2.46 m X 4.2 m
height 20000 L 25 sqm. X 1 m
Table No 2: Gases storage details
Sr.
No.
Name of
Raw Material
Number
of
cylinder
Dimensions of
cylinders
Cylinder
pressure
bar
Volume
of gas
in lit
Storage
qty. at
any
given
time
1 Ammonia gas 60 dia.370 mm
Length 1015 mm 7 kg/cm
2 50 lit 60
2 Hydrogen chloride
gas (HCl gas) 24
dia.232 mm
Length 1450 mm
156 Kgf/
cm2
50 lit 24
3 Hydrogen 2
Out side dia. 235
mm
Length 1450 mm
140
kg/cm2
5900 L 2
Table No 3: ALOHA Footprints
Substance Scenario. Effects
considered
LOC Distance,
m
Toluene Spill of entire
chemical
contained in
tank-
evaporating
puddle
Toxic area of
vapor cloud
AEGL-3 3700 ppm 10
AEGL-2 560 ppm 23
AEGL-1 67 ppm 86
Flammable area
of vapor cloud-
non burning
liquid pool
60% LEL 6600 ppm <10
10% LEL 1100 ppm 18
Blast area of
vapour cloud
Destruction
of building
8.0 psi LOC never
exceeded
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
explosion
Serious
injury likely
3.5 psi <10
Shatter
glass
1.0 psi <10
Burning Puddle
/ Pool Fire
Thermal
radiation from
pool fire-
burning puddle
Red 10 kW/sq.m. <10
Orange 5 kW/sq. m. 15
Yellow 2 kW/sq. m. 25
Leak from hole
in horizontal
cylindrical tank
Heavy Gas AEGL-3 3700 ppm 11
AEGL-2 560 ppm 35
AEGL-1 67 ppm 124
Flammable Area
of Vapor Cloud
60% LEL 6600 ppm <10
10% LEL 1100 ppm 23
Overpressure
(blast force)
from vapor
cloud explosion
Red 8.0 psi LOC was
never
exceeded
Orange 3.5 psi <10
Yellow 1.0 psi 10
Thermal
radiation from
pool fire
Red 10.0 kW/sq.
m.
<10
Orange 5.0 kW/sq.
m.
<10
Yellow 2.0 kW/sq.
m.
<10
BLEVE of
flammable
liquid in
Horizontal
cylindrical tank
Thermal
radiation from
fireball
Red 10.0 kW/sq.
m.
301
Orange 5.0 kW/sq.
m.
425
Yellow 2.0 kW/sq.
m.
664
Methanol
Evaporating
Puddle (Note:
chemical is
flammable)
Toxic area of
vapor cloud
AEGL-3 7200 17
AEGL-2 2100 47
AEGL-1 530 103
Flammable area
of vapour cloud
60% LEL 43080 <10
10% LEL 7180 19
Overpressure
(blast force)
from vapor
cloud explosion
Destruction
of building
8.0 psi No part of
cloud is
above LEL Serious
injury likely
3.5 psi
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
Shatter
glass
1.0 psi
Burning puddle-
pool fire
Thermal
radiation from
pool fire
Red 10.0 kW/sq.
m.
<10
Orange 5.0 kW/sq.
m.
<10
Yellow 2.0 kW/sq.
m.
<10
Leak from hole
in horizontal
cylindrical tank
Toxic area of
vapour cloud
Red 7200 ppm 19
Orange 2100 ppm 40
Yellow 530 ppm 91
Flammable Area
of Vapor Cloud
Red 43080 ppm
= 60% LEL
<10
Yellow 7180 ppm =
10% LEL
19
Overpressure
(blast force)
from vapor
cloud explosion
No
explosion:
no part of
the cloud is
above the
LEL at any
time
Leak from hole
in horizontal
cylindrical tank-
Flammable
chemical is
burning as it
escapes from
tank
Thermal
radiation from
pool fire
Red 10.0 kW/sq.
m.
<10
Orange 5.0 kW/sq.
m.
<10
Yellow 2.0 kW/sq.
m.
<10
BLEVE of
flammable
liquid in
horizontal
cylindrical tank
Thermal
radiation from
fireball
Red 10.0 kW/sq.
m.
194
Orange 5.0 kW/sq.
m.
280
Yellow 2.0 kW/sq.
m.
442
Acetone Evaporating
Puddle (Note:
chemical is
flammable)
Heavy Gas Red 5700 ppm 96
Orange 3200 ppm 127
Yellow 200 ppm 553
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
Flammable Area
of Vapor Cloud
Red 15600 ppm 61
Yellow 2600 ppm 141
Overpressure
(blast force)
from vapor
cloud explosion
Red 8.0 psi LOC was
never
exceeded
Orange 3.5 psi 40
Yellow 1.0 psi 67
Burning Puddle
/ Pool Fire
Thermal
radiation from
pool fire
Red 10.0 kW/sq.
m.
28
Orange 5.0 kW/sq.
m.
41
Yellow 2.0 kW/sq.
m.
65
Leak from hole
in vertical
cylindrical tank-
Flammable
chemical
escaping from
tank (not
burning)
Heavy Gas Red 5700 ppm 21
Orange 3200 ppm 29
Yellow 3200 ppm 129
Flammable Area
of Vapor Cloud
Red 15600 ppm 11
Yellow 2600 ppm 32
Overpressure
(blast force)
from vapor
cloud explosion
Destruction
of building
8.0 psi LOC was
never
exceeded
Serious
injury likely
3.5 psi <10
Shatter
glass
1.0 psi 19
Thermal
radiation from
pool fire
potentially
lethal within
60 sec
10.0 kW/sq.
m.
<10 m
2nd degree
burns within
60 sec
5.0 kW/sq.
m.
<10 m
pain within
60 sec
2.0 kW/sq.
m.
<10 m
BLEVE of
flammable
liquid in vertical
cylindrical tank
Thermal
radiation from
fireball
potentially
lethal within
60 sec
10.0 kW/sq.
m.
230
2nd degree
burns within
60 sec
5.0 kW/sq.
m.
329
pain within
60 sec
2.0 kW/sq.
m.
515
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
Dimethyl
Chloride
Evaporating
Puddle (Note:
chemical is
flammable)
Heavy Gas Red 6900 ppm =
AEGL-3 [60
min]
49
Orange 560 ppm =
AEGL-2 [60
min]
164
Yellow 200 ppm =
AEGL-1 [60
min]
288
Flammable Area
of Vapor Cloud
Red
84000 ppm
= 60% LEL
= Flame
Pockets
18
Yellow
14000 ppm
= 10% LEL
36
Overpressure
(blast force)
from vapor
cloud explosion
Red 8.0 psi LOC was
never
exceeded
Orange 3.5 psi 10
Yellow 1.0 psi 17
Thermal
radiation from
pool fire
potentially
lethal within
60 sec
10.0 kW/sq.
m.
<10
2nd degree
burns within
60 sec
5.0 kW/sq.
m.
<10
pain within
60 sec
2.0 kW/sq.
m.
<10
Leak from hole
in horizontal
cylindrical tank
Flammable
chemical
escaping from
tank (not
burning)
Heavy Gas Red 6900 ppm =
AEGL-3 [60
min]
34
Orange 560 ppm =
AEGL-2 [60
min]
112
Yellow 200 ppm =
AEGL-1 [60
min]
200
Flammable Area
of Vapor Cloud
Red 84000 ppm 11
Yellow 14000 ppm 23
Overpressure
(blast force)
from vapor
Red 8.0 psi LOC was
never
exceeded
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
cloud explosion Yellow 1.0 psi 16
Thermal
radiation from
pool fire
potentially
lethal within
60 sec
10.0 kW/sq.
m.
<10
2nd degree
burns within
60 sec
5.0 kW/sq.
m.
<10
pain within
60 sec
2.0 kW/sq.
m.
<10
Thermal
radiation from
fireball
potentially
lethal within
60 sec
10.0 kW/sq.
m.
99
2nd degree
burns within
60 sec
5.0 kW/sq.
m.
170
pain within
60 sec
2.0 kW/sq.
m.
285
Iso propyl
alcohol
Evaporating
Puddle (Note:
chemical is
flammable)
Heavy Gas Red 12000 ppm
= PAC-3
<10
Orange 2000 ppm =
PAC-2
19
Yellow 400 ppm =
PAC-1
47
Flammable Area
of Vapor Cloud
Red
12000 ppm
= 60% LEL
= Flame
Pockets
<10
Yellow 2000 ppm =
10% LEL
19
Overpressure
(blast force)
from vapor
cloud explosion
Red 8.0 psi LOC was
never
exceeded
Orange 3.5 psi <10
Yellow 1.0 psi <10
Burning Puddle
/ Pool Fire
Thermal
radiation from
pool fire
potentially
lethal within
60 sec
10.0 kW/sq.
m.
<10
2nd degree
burns within
60 sec
5.0 kW/sq.
m.
10
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
pain within
60 sec
2.0 kW/sq.
m.
17
Leak from hole
in vertical
cylindrical tank
Flammable
chemical
escaping from
tank (not
burning)
Heavy Gas Red 12000 ppm
= PAC-1
<10
Orange 2000 ppm =
PAC-2
20
Yellow 400 ppm =
PAC-3
48
Flammable Area
of Vapor Cloud
Red 12000 ppm
= 60% LEL
= Flame
Pockets
<10
Yellow 2000 ppm =
10% LEL =
20
Overpressure
(blast force)
from vapor
cloud explosion
Red 8.0 psi =
destruction
of buildings
LOC was
never
exceeded
Orange 3.5 psi =
serious
injury likely
<10
Yellow 1.0 psi =
shatters
glass
<10
Leak from hole
in vertical
cylindrical tank
Flammable
chemical is
burning as it
escapes from
tank
Thermal
radiation from
pool fire
Red 10.0 kW/(sq
m) =
potentially
lethal within
60 sec
<10
Orange 5.0 kW/(sq
m) = 2nd
degree burns
within 60
sec
<10
Yellow 2.0 kW/(sq
m) = pain
within 60
sec
<10
BLEVE of
flammable
liquid in vertical
Thermal
radiation from
Red 10.0 kW/(sq
m) =
potentially
261
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
cylindrical tank fireball lethal within
60 sec
Orange 5.0 kW/(sq
m) = 2nd
degree burns
within 60
sec
372
Yellow 2.0 kW/(sq
m) = pain
within 60
sec
582
Ethyl
Acetate
Evaporating
Puddle (Note:
chemical is
flammable)
Heavy Gas Red 10000 ppm
= PAC-3
11
Orange 1700 ppm =
PAC-2
23
Yellow 1200 ppm =
PAC-1
30
Flammable Area
of Vapor Cloud
Red
13080 ppm
= 60% LEL
= Flame
Pockets
10
Yellow
2180 ppm =
10% LEL
22
Overpressure
(blast force)
from vapor
cloud explosion
Red 8.0 psi =
destruction
of buildings
LOC was
never
exceeded
Orange 3.5 psi =
serious
injury likely
<10
Yellow 1.0 psi =
shatters
glass
14
Thermal
radiation from
pool fire
Red 10.0 kW/(sq
m) =
potentially
lethal within
60 sec
<10
Orange 5.0 kW/(sq
m) = 2nd
degree burns
within 60
sec
<10
Yellow 2.0 kW/(sq
m) = pain
14
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
within 60
sec
Leak from hole
in vertical
cylindrical tank
Flammable
chemical
escaping from
tank (not
burning)
Heavy Gas Red 10000 ppm
= AEGL-3
[60 min]
11
Orange 1700 ppm =
AEGL-2 [60
min]
23
Yellow 1200 ppm =
AEGL-1 [60
min]
29
Flammable Area
of Vapor Cloud
Red 13080 ppm
= 60% LEL
= Flame
Pockets
10
Yellow 2180 ppm =
10% LEL
21
Overpressure
(blast force)
from vapor
cloud explosion
Red 8.0 psi =
destruction
of buildings
LOC was
never
exceeded
Orange 3.5 psi =
serious
injury likely
<10
Yellow 1.0 psi =
shatters
glass
14
Leak from hole
in vertical
cylindrical tank
Flammable
chemical is
burning as it
escapes from
tank
Thermal
radiation from
pool fire
Red 10.0 kW/(sq
m) =
potentially
lethal within
60 sec
<10
Orange 5.0 kW/(sq
m) = 2nd
degree burns
within 60
sec
<10
Yellow 2.0 kW/(sq
m) = pain
within 60
sec
<10
BLEVE of
flammable
liquid in vertical
cylindrical tank
Thermal
radiation from
fireball
Red 10.0 kW/(sq
m) =
potentially
lethal within
60 sec
201
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
Orange 5.0 kW/(sq
m) = 2nd
degree burns
within 60
sec
288
Yellow 2.0 kW/(sq
m) = pain
within 60
sec
454
Aqueous
ammonia
solution
(25%)
Evaporating
Puddle (Note:
chemical is
flammable)
Heavy Gas Red 1100 ppm =
AEGL-3 [60
min])
286
Orange (160 ppm =
AEGL-2 [60
min])
815
Yellow 30 ppm =
AEGL-1 [60
min])
2.1
Flammable Area
of Vapor Cloud
Red 90000 ppm
= 60% LEL
= Flame
Pockets
19
Yellow 15000 ppm
= 10% LEL
79
Overpressure
(blast force)
from vapor
cloud explosion
Red 8.0 psi =
destruction
of buildings
LOC was
never
exceeded
Orange 3.5 psi =
serious
injury likely
LOC was
never
exceeded
Yellow 1.0 psi =
shatters
glass
14
Ammonia
gas
Direct Source-
Entire gas is
leaked at once
Heavy Gas Red 1100 ppm =
AEGL-3 [60
min]
1.8 km
Orange 160 ppm =
AEGL-2 [60
min
4.0 km
Yellow 30 ppm =
AEGL-1 [60
min])
8.0 km
Flammable Area
of Vapor Cloud
Red 90000 ppm
= 60% LEL
= Flame
448
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
Pockets
Yellow 15000 ppm
= 10% LEL
860
Overpressure
(blast force)
from vapor
cloud explosion
Red 8.0 psi =
destruction
of buildings
LOC was
never
exceeded
Orange 3.5 psi =
serious
injury likely
LOC was
never
exceeded
Yellow 1.0 psi =
shatters
glass
383
Leak from hole
in vertical
cylindrical tank
Flammable
chemical
escaping from
tank (not
burning)
Overpressure
(blast force)
from vapor
cloud explosion
No
explosion:
no part of
the cloud is
above the
LEL at any
time
Leak from hole
in vertical
cylindrical tank
Flammable
chemical is
burning as it
escapes from
tank
Thermal
radiation from
jet fire
Red 10.0 kW/(sq
m) =
potentially
lethal within
60 sec
<10
Orange 5.0 kW/(sq
m) = 2nd
degree burns
within 60
sec
<10
Yellow 2.0 kW/(sq
m) = pain
within 60
sec
<10
Hydrogen
chloride gas
Leak from hole
in vertical
cylindrical tank
Non-flammable
chemical is
escaping from
tank
Heavy Gas
Red 100 ppm =
AEGL-3 [60
min]
22
Orange 22 ppm =
AEGL-2 [60
min]
48
Yellow 1.8 ppm =
AEGL-1 [60
min]
160
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
Release of
entire gas
instantaneously
Heavy Gas Red 100 ppm =
AEGL-3 [60
min]
1.7 km
Orange 22 ppm =
AEGL-2 [60
min]
3.0 km
Yellow 1.8 ppm =
AEGL-1 [60
min]
8.1 km
Hydrogen
Gas
Direct Source Toxic area of
vapor cloud
Red 400000 ppm
= PAC-3
133
Orange 230000 ppm
= PAC-2
166
Flammable Area
of Vapor Cloud.
Chemical is not
burning
Red 24000 ppm
= 60% LEL
= Flame
Pockets
489
Yellow 4000 ppm =
10% LEL
941
Overpressure
(blast force)
from vapor
cloud explosion
Red 8.0 psi =
destruction
of buildings
414
Orange 3.5 psi =
serious
injury likely
419
Yellow 1.0 psi =
shatters
glass
465
Leak from hole
in vertical
cylindrical tank
Flammable
chemical
escaping from
tank (not
burning)
Overpressure
(blast force)
from vapor
cloud explosion
Red 8.0 psi =
destruction
of buildings
200
Orange 3.5 psi =
serious
injury likely
221
Yellow 1.0 psi =
shatters
glass
309
Leak from hole
in vertical
cylindrical tank
Flammable
Thermal
radiation from
jet fire
Red 10.0 kW/(sq
m) =
potentially
lethal within
60 sec
<10
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
chemical is
burning as it
escapes from
tank
Orange 5.0 kW/(sq
m) = 2nd
degree burns
within 60
sec
<10
Yellow 2.0 kW/(sq
m) = pain
within 60
sec
14
Interpretation:
Based on the unsafe distances identified by
the software output, the MCLS (maximum
credible loss scenario) for the factory works
out to about 8100 meter for entire release of
hydrogen chloride gas with 1.8 ppm
concentration in the atmosphere.
The scenario considered for assessing the
impact by quantitative risk assessment was
taken from CPR18 E.
The probability of occurrence of the scenario
is 5 × 10-6
y-1
, which is very less. The Disaster
management plan highlights the suggestive
measures to be taken during the occurrence of
such an accident.
Table No. 4: Interpretation Table
Threat
zone
Toxic Level of Concern Receptors Effects
Red -
1700
meters
AEGL-3 - 100 ppm
susceptible individuals,
could experience life-
threatening health effects or
death.
Workers working near
in the premises, people
residing and working
surrounding the plant
and agricultural area
and biotic
environment towards
west
Environmental Effects
:-
This can cause life
threatening effects on
aquatic plant and
animal life. The acidic
fumes are corrosive in
nature and can cause
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
Orange-
3000
meters
AEGL-2 - 22 ppm
Susceptible individuals
could experience
irreversible or other
serious, long-lasting
adverse health effects or an
impaired ability to escape.
Surrounding biotic
environment towards
west of the company.
Traffic on Murambi-
Avarli road
damage to metallic
structures and buildings
etc.
The soil may become
acidic in nature after
deposition of
hydrochloric acid and
can facilitate soil
erosion.
Human Effects:-
Hydrochloric acid is
corrosive to the eyes,
skin, and mucous
membranes. Acute
inhalation exposure
may cause coughing,
hoarseness,
inflammation and
ulceration of the
respiratory tract, chest
pain, and pulmonary
edema in humans.
Chronic occupational
exposure to
hydrochloric acid has
been reported to
cause gastritis,
chronic bronchitis,
dermatitis, and
photosensitization in
workers. Prolonged
exposure to low
concentrations may
also cause dental
discoloration and
erosion
Presently No
information is
available on the
carcinogenic effects
of hydrochloric acid
in humans.
Yellow -
8100 m
AEGL-1 – 1.8 ppm
Susceptible individuals
could experience notable
discomfort, irritation, or
certain asymptomatic
nonsensory effects.
However, the effects are
not disabling and are
transient and reversible
upon cessation of exposure.
Major receptors are
people in Murambi
and Modale village,
and surrounding flora
and fauna
However to further reduce the occurrence of such accidents, following precautions would be
taken by M/s Delta Finochem Pvt. Ltd.
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
Recommendations suggested for HCL and other Corrosive Liquid storage tanks and
cylinders:
i) HCl storage tank breather valve is connected to scrubber to control HCl vapors in
atmosphere.
ii) Dedicated storage area is provided.
iii) HCl storage tank is covered with acid proof tiles, the dyke is coated with acid/alkali
proof paint and the flooring is also covered with acid/alkali proof tiles.
iv) Store away from the combustible materials.
v) Appropriate PPEs to be used during handling of solutions / chemicals.
vi) Keep containers in tightly closed and in cool, dry and well ventilated area.
vii) Keep in proper storage cabinets and shelving. Use lowest shelve possibly.
viii) Assure all bottles are properly labeled.
ix) Proper precautions to be taken during chemical preparation.
x) Wearing PPEs, Laboratory work surface should be cleaned at the end of each working
day.
xi) Dispose off contaminated material in accordance with hazardous waste disposal
guidelines.
xii) Decontaminate all the equipment before removing from designated area.
Recommendations for Flammable Liquids Storage:
i) Dedicated storage area to be provided.
ii) Keep containers tightly closed/sealed until ready for use.
iii) Keep containers in cooled and ventilated area.
iv) Avoid all possible source of ignition.
v) Keep away from heat and their sources.
vi) Use suitable PPE during handling of chemicals.
vii) Storage area should be away from incompatibilities such as oxidizing agents,
metals & acid.
viii) Avoid direct contact with body.
ix) Chemical spill kit to be maintained to avoid possible effects from spillage.
x) Chemical transfer line should be periodically inspected and well maintained to
avoid possibility for leakage of chemical.
xi) Periodic inspection of dykes to be done.
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
1.3 DOW Fire and Explosion Index
The DOW index is performed for all flammable chemicals which is to be stored in raw
material storage building for proposed expansion activity. Details of DOW index is given in
table below, The DOW summary sheet is displayed below in table no. 5. The DOW index
worksheet is attached in Annexure 7.2 in EIA report.
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
Table No. 5: List of hazardous chemicals and its respective DOW F & E Index
Chemical Storage
Considered N h N f N r
Material
Factor,
MF
F1
(General
Process
Hazard)
F2
(Special
Process
Hazard)
F3
(Hazard
Factor)
Fire &
Explosion
Index
Degree
of
Hazard
Tributyl bromide Drums 2 3 0 16 2.55 1.66 4.233 67.72 Moderate
Acetonitril Drums 2 3 0 16 2.55 1.66 4.233 67.72 Moderate
N Butyl bromide Drums 2 3 0 16 2.55 1.72 2.38 63.64 Moderate
Butanol Drums 1 3 0 16 2.55 1.46 3.73 59.6 Light
Carbon Bags 1 3 0 16 2.3 1.71 3.93 62.9 Light
Ethyl
Chloroformate Drums 4 3 1 16 2.55 2.06 5.25 84.04 Moderate
Ethanol Drums 2 3 0 16 2.55 1.66 4.23 67.7 Moderate
Methyl isobutyl
ketone Drums 2 3 1 16 2.55 1.66 4.233 67.72 Moderate
Pentanol Carboy 1 3 0 16 2.55 1.46 3.72 59.56 Light
Tetrahydrofuran Drums 2 3 1 16 2.55 1.66 4.23 67.72 Moderate
Triethyl amine Drums 3 3 0 16 2.55 1.88 4.79 76.8 Moderate
FO Tank 1 2 0 10 1.95 1.9 3.705 37.05 Light
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
Storage recommendation for CCOE Area (PESO controlled area)
The Petroleum and Explosive Safety Organization standards are followed for storage of solvents/
flammable chemicals.
1. Earthing is provided to the storage area for dealing with the static charges that might generate
during the loading and unloading of the solvents.
2. Provision of sand buckets, foam monitor, fire extinguishers & hydrant line near PESO area
were made available.
3. Appropriate drainage with the slope of 2 % is provided to remove small and large spillage of
the chemicals.
4. Provision of spill kit is provided to deal with the minor spillage scenario.
5. Permission of Joint Chief Controller (explosives), West circle is obtained
6. Petroleum storage is constructed of non combustible materials. Non-bulk storage of ‘class A’
petroleum is done in the separated building which complies license conditions.
7. The secondary containment is provided and is kept clean and free from any accumulation of
inflammable liquids.
8. The storage shed is ventilated near the ground level and also near the roof. The ventilators
are covered with two layers of fine copper or non corrodible metal wire gauge of mesh not
less than 11 meshes per linear cm.
9. No alterations are carried out without written permission of licensed authority.
10. The safety distance of 7.5 m is kept from the shed.
11. All the empty receptacles are kept securely closed unless they have been thoroughly cleaned.
12. The suitable extinguishers (DCP) are kept immediately outside the storage shed.
13. Access of un-authorized person to petroleum receptacles is restricted.
14. Daily inventory of petroleum is maintained.
Recommendation/Suggestions for non-PESO area
1. The raw materials are stored according to their compatibility with other raw materials.
2. Company has adequate written operating instruction and fully documented operating
discipline for emergency shutdown, normal operating conditions, routine shutdown etc. which
are important for maintaining satisfactory control of a unit.
3. The raw materials are stored in a dedicated area with minimum interference.
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
4. The provision of fire water supply is provided through the hydrant line passing from the raw
material storage area.
5. Provision of hand Extinguishers are provided and found to be adequate with reference to the
storage quantity of raw materials.
1.4 Toxicity (Mond’s) Index
Introduction
The principle and general approach used in the DOW method of hazard evaluation have been
further developed by ICI Mond Division, the revised Mond Fire, Explosive and Toxicity index is
a series of papers by Lewis (1979). The main developments made to the DOW Index in the
Mond Index are:
1. It covers a wider range of process and storage installation
2. It covers the processing of chemicals with explosive properties
3. A calculation procedure is included to allow for the off-setting effects of good design and
control and safety instrumentation
4. The procedure has been extended to cover plant layout
5. Separate indices are calculated to access the hazards of fire, internal explosion and aerial
explosion.
Some of the raw materials stored in the site are toxic in nature. Hence appropriate standard
operating procedures are established by the company for ensuring the safety of the workers
handling the raw materials on daily basis. Some selected toxic raw materials are used for
calculating the toxicity index using Mond's index. The Mond's index worksheet is attached as
Annexure 7.3 in EIA report.
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
Table No. 6: Monds Toxicity index of toxic chemicals
Sr. No. Raw Materials Storage
Quantity
No. of
Drums/Tanks/bags
Nh Exposure limit,
ppm
1 Ammonia gas 20 Kl 1 above ground
tank
4 20
2 Liquor ammonia 20 Kl 2 above ground
tanks
4 30
3 Sulphuric Acid 4 MT 67 3 0.25 ppm
4 Nitric acid 4 MT 89 3 15
5 Phosphoric acid 3 MT 11 3 2
6 Acetic acid 2 MT 58 3 10 ppm
7 Phosphorous Oxychloride
3 MT 60 3 0.2
8 Phosphorous
trichloride
3 MT 176 3 0.5
9 Piperazine 3 MT 60 4 5 mg/m3
10 Hydrochloric acid 2 MT 50 3 2 ppm
11 Thioglycolic Acid 3 MT 75 3 2
12 Thionyl chloride 3 MT 11 4 4.9
13 Thiourea 4 MT 15 3 --
14 Tripropyl amine 3 MT 19 3 6.4
15 Triethyl amine 3 MT 20 3 1
16 Formaldehyde 2 MT 40 3 0.3
17 Chloroform 2 MT 7 4 0.5
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
Table no. 7: Calculated Mond’s Index and degree of Hazard for Hazardous chemicals.
Chemicals Storage
Nh (NFPA
Index
Number)
Th
(Toxicity
factor)
Ts
(Correction
factor)
F1
General
Process
Hazard
F2
Special
Process
Hazard
Toxicity
Index
Degree of
Hazard
Ammonia gas Tank
4 325 125 2.55 2.0 10.18 High
Liquor ammonia Tank
4 325 125 2.55 1.8 9.93 High
Sulphuric Acid Drum
3 250 125 2.55 1.7 9.06 Moderate
Nitric acid Drum 3 250 125 2.55 1.7 9.06 Moderate
Phosphoric acid Drum 3 250 125 2.55 1.7 9.06 Moderate
Acetic acid Drum 3 250 125 2.55 1.86 9.26
Moderate
Phosphorous Oxychloride Drum 3 250 125 2.55 1.6 8.93
Moderate
Phosphorous trichloride Drum 3 250 125 2.55 1.6 8.93 Moderate
Piperazine Bags 4 325 125 2.55 2 10.18 High
Hydrochloric acid Drum 3 250 125 2.55 1.7 9.06
Moderate
Thioglycolic Acid Drum 3 250 125 2.55 1.6 8.93
Moderate
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
Thionyl chloride Drum 4 325 125 2.55 1.8 9.93 High
Thiourea Bags 3 250 125 2.55 1.6 8.93
Moderate
Tripropyl amine Drum 3 250 75 2.55 1.6 6.36
Moderate
Triethyl amine Drum 3 250 125 2.55 1.76 9.13
Moderate
Formaldehyde Drum 3 250 125 2.55 1.6 8.93
Moderate
Chloroform Drum 4 325 125 2.55 1.8 9.93 High
M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment
Sadekar Enviro Engineers Pvt. Ltd
Toxicity (Mond) Index recommendations:
1. The raw materials are stored according to their compatibility.
2. Toxic materials are stored in cool place and kept away from heat.
3. Toxic material can cause breathing difficulty therefore storage area is well ventilated.
4. Good housekeeping practice is implemented in storage area.
5. Appropriate drainage with the slope of 2 % is provided to remove small and large spillage of
the chemicals.
6. The provision of fire water supply is provided through the hydrant line passing from the raw
material storage area
7. PPE’s are used wherever necessary.
8. MSDS recommendations are strictly followed while chemical storage and handling.
Recommendations for ‘High’ Mond Index chemical storage:
1. The chemicals are isolated from another chemical in well-ventilated area and hazard
warning information is shown.
2. SOP is prepared for handling such chemicals and it should be strictly followed.
3. Spill kit is provided for storage to limit the spill of materials. Suitable Absorbent like
sodium bi carbonate is used to absorb the spill.
4. Proper training is provided to workers prior to handling and transporting chemicals.
5. PPE’s like face shield, goggles, apron, gloves, gumboots are used while handling the
chemicals to avoid exposure to chemicals.
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