chapter -7 risk assessmentenvironmentclearance.nic.in/writereaddata/online/...m/s. chemtech...

M/s. Chemtech Intermediates Pvt. Ltd. G.I.D.C., Nandesari, Vadodara.

M/S. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD., ANKLESHWAR 243

CHAPTER -7

RISK ASSESSMENT

7.1 INTRODUCTIONM/s. Chemtech Intermediates Pvt. Ltd. is already engaged in manufacturing oforganic chemicals at plot C1-128/14-15, GIDC Estate, Nandesari, Dist. Vadodara,Gujarat. The Unit is having valid Consolidated Consent & Authorization (CC&A) fromGujarat Pollution Control Board vides CC&A order no.: AWH-85623 with validity upto 31/12/2021 for manufacturing of organic chemicals. Now, unit has purchased newtwo adjoining plots for proposed expansion. The expansion will be carried out at plotC1-128/13,14,15,16 GIDC Estate, Nandesari, Dist. Vadodara, Gujarat, existing plot &new adjoining plots located in GIDC.The unit is going for expansion for range of products like pharma advancedIntermediates. The unit has existing production quantity is 90 MT/Month of syntheticorganic chemicals; therefore total production quantity after expansion becomes 1080MT/Month. The details of products are given in Table no.1.1.The product proposed bythe unit fall in the Schedule attached to the EIA Notification, i.e. Project No. 5(f).

1.1 Experts from Vaibhu Safety Consultants visited the site on 14.09.2019 and

subsequently inspection of site as per site plan and the environs along with

collection of relevant information about the existing and proposed installation

and the operations of the plant. Also a detailed discussion was held on various

aspects including storage facilities, process safety and emergency preparedness

with the officers of the company.

1.2 Most of hazardous chemicals like flammable/combustible/ Toxic liquid/solid

chemicals are received in drums or bags or in carboys and are stored in

warehouse as per its incompatibility and other properties like flammable, toxic,

corrosive and reactive safety measures are provided. Bromine bottles are

received in 6 bottle crate wooden packing and stored separately.

1.3 Based on the data furnished and the study of the installation, certain hazards

have been identified and their consequences are modeled mathematically using

DNV PHAST- SAFETI 8.22 and HAMSGAP software. Mapping of various

scenario are with hazardous distances and safe distances are drawn on site plan

for easy understanding of the consequences of the accident/ incident.

1.4 The study indicates that possible hazards associated with the plant are confined

to (a) Benzyl Chloride storage tank area (b) Hydrogen Cylinder bank storage

area. (c) Bromine bottle storage area. (d) Chlorine Tonner storage area (e)

Ammonia 40 Kg Cylinder storage area. Various hazardous scenarios have been

identified for Risk Assessment and the consequences modeled.

1.5 The results of the analysis have been summarized in the table appended.

1.6 Conclusion Based on the



1) Risk Analysis study and information regarding the layout plan and safety

systems.

2) Discussions with company officials.

7.2 OBJECTIVE, PHILOSOPHY AND METHODOLOGY OF RISKASSESSMENT

7.2.1 OBJECTIVE

The main objectives of the Risk Assessment (RA) study is to determine damagedue to major hazards having damage potential to life & property and provide ascientific basis to assess safety level of the facility.

The principle objective of this study was to identify major risks in themanufacture of specialty fine chemicals and storage of hazardous chemical atsite and to evaluate on-site & off-site consequences of identified hazardscenarios. Pointers are then given for effective mitigation of hazards in terms ofsuggestions for effective disaster management, suggesting minimum preventiveand protective measures & change of practices to ensure safety.

7.2.2 PHILOSOPHY

This report is limited to the following:

Identification of major risk areas. Hazard identification/Identification of failure cases Consequential analysis of probable risks / failure cases

o Evaluation of heat radiation & pressure wave profiles for identifiedfailure cases

o Risk assessment on the basic of the above evaluation & riskacceptability

o Minimum preventive & protective measures to be taken to minimizerisks to maximum possible extent.

Giving pointers for effective disaster management Suggesting other measures to further lower the probability of risk

7.2.3 METHODOLOGY

The procedure used for carrying out the Quantitative Risk Assessment Study isoutlined below:-

Identify Credible Loss Scenarios for the facility under the study by discussionwith M/s. Chemtech Intermediates Pvt. Ltd Simulate loss Scenarios todetermine the vulnerable zones for toxic dispersion, pool fire, Tank on fire(Thermal Radiation), Flash fire, Explosion over pressure (Vapour cloudExplosion, Ball fire using software packages DNV-PHAST-7.11 andHAMSGAP.



Suggest mitigating measures to reduce the damage, considering all aspects ofthe facilities. The flowchart of the methodology for the present study is shownin following page.

RISK ASSESSMENT STUDY METHODOLOGY FLOWCHART

7.3 INTRODUCTION OF THE UNIT7.3.1 COMPANY INTRODUCTION

START

FACILITY, PROCESS AND METEOROLOGICAL DATA COLLECTION

LISTING OUT OF HAZARDOUS OPERATIONS & STORAGE DETAILS

DEFINING OF PARAMETERS FOR EACH OF CHEMICALS & EACH OFHAZARDS

IDENTIFICATION OF FAILURE SCENARIOS & QUANTIFICATION OFPROBABLE HAZARDS ASSOCIATED WITH THEM

DEFINING RELEASE TYPE (CONTINUOUS OR INSTANTANIOUS ) &DETERMINE RELEASE RATES

SIMULATION OF SELECTED CASES FOR CONSEQUENCE MODELING

PREPARATION OF SUMMERY OF CONSEQUENCE RESULTS

EVALUATION OF POTENTIAL RISK TO THE SURROUNDINGPOPULATION

DISCUSSION & RECOMMENDATION OF MITIGATIVE / REMEDIALMEASURES

END



M/s Chemtech Intermediates Pvt. Ltd. is an existing Chemical Unit locatedon Plot No. C1/128/13-14-15-16, GIDC, Nandesari - 391340, Dist.Vadodara, Gujarat a designated Chemical Zone.

The unit is located in GIDC, Nandesari about 17 kms North of Vadodara. GIDC,Nandesari is equipped with a common Effluent Treatment Plant running on thelatest technology of Hydrodynamic cavitation developed indigenously by CETP,NIA, which has been authenticated by NEERI as an advanced oxidation processfor waste water treatment. The facility for disposal of Hazardous waste bylandfill and Plasma gasification is also available at NECL, GIDC and Nandesari.

7.3.2 DETAILS OF UNITSTABLE: 7.1DETAILS OF UNITS

Sr.No.

Particulars

1. Full Name & Address of Unit Chemtech Intermediates Pvt. Ltd.Plot No. C1/128/13-14-15-16,GIDC, Nandesari - 391340,Dist. Baroda, Gujarat.

2. Telephone No.Fax Number:Email ID :

0265-2840463, 2841037+91 [email protected]

3. Month & Year of Establishment July 19984. Company details about company Company is in manufacturing of pharma

intermediates.5. Full name & Address and phone

number of the occupierMr. Ripalbhai N. Patel, CMD9, Kailash Park, Opp. T.B. Hospital,Gotri Road, Vadodara – 390021.Mob. 9825021759

6. Full name & Address and phonenumber of the Factory manager

Mr. Rajeshbhai Gajjar, GM-Technical101, Saheli Park Apartments,B/h 7 Seas Mall, Fatehganj,Vadodara.Mob. 9099061784

7. Name of Safety Officer Mr. Mahesh PatelMobile: 9408150682

8. Name of Factory Medical Officer Dr. P.C JainDeepak Foundation

9. HSE organization chart CMD

GM - Technical

Lab chemists Prod. In-charge Adminofficer

Production Supervisors Utility



Sr.No. Particulars

Operators

Plant Operators ETP operatorsHelpers

Helpers10. Factory license copy No. 14729 Dt. 01/07/1998

For 50 workers and 100 BHPValid up to 31/12/2022

11. Factory Plan Approval ref. No &Date

PLAN/VDR/2124 Dt: 17.05.2018

12. Stability certificate copy Dt. 10/07/2018Issued by HELPS

13. GPCB/PCB consent copy ( CCA) AWH – 85623 Dt. 02.03.2017Valid up to Dt. 31.12.2021

14. Solid waste Disposal authorizationletter copy

AWH – 85623 Dt. 02.03.2017Valid up to Dt. 31.12.2021

15. Explosive license No. P/WC/GJ/16/189 (P146866)Valid up to 31/12/2022For Class A – 7.5 KL & Class B – 7.5 KLstg.

16. Poison License Available17. Man Power Company employees - 25 No.

Contract employees – 20 + 02 (Security)No.Total – 47 No.

18. No. Of shift & Shift timingGeneralFirstSecondThird

Total : 4 Shift9.00 to 17.30 Hrs.7.00 to 15.00 Hrs.15.00 to 23.00 Hrs.23.00 to 7.00 Hrs.

19. Nature of process Manufacturing of pharma intermediates(Batch process)

20. Process description & Flow chartwith chemical reaction

Cyanosis reaction

Layer separation

Crude vacuum distillation

Hydrolysis

Separation

Vacuum Distillation

Flaking

Packing



Sr.No. Particulars

21. DG Set details 300 KVA22. Power plant details : 300 KVA demand23. Process Water Storage and source Source – GIDC supply 2 inch ¢ – 01 No.

U/G MS tank – 20 KL – 01 No.O/H Syntax tank – 02 KL - 03 No. (inplant)

24. Boiler GT 5665 – 2 TPH at 10.54 kg/cm225. Thermo pack Existing 01 No. & proposed 10 Lac kcal/hr

– 02 No.26. Chilled water plant 10 TR X 1 No.27. Cooling Tower 250 TR X01 No.28. Effluent treatment Plant

Lit/day capacity?Primary / secondary / tertiary

Chlorine treatment method – 40 KL/DayTreated effluent is sent to CETP,Nandesari.

29. Fire water source GIDC supply line30. Water Reservoir capacity : M3 No dedicated storage.31. As per fire load calculation

minimum water requirementNot done.

32. Fire Hydrant details WithAutoCAD drawing with pumpsdetails.

Not available.

33. Fire pump Details Not available.34. Sprinkler system with drawing

AutoCAD drawingNot available.

35. MCP and smoke detection systemlocation map and testingcalibration record.

Not available.

36. Department wise List of fireextinguishers with mapping ifavailable

Total – 06 No.

37. SCBA sets availability andlocation mapping

45 min capacity – 01 set

38. List of emergency facilities Cyanide kit – 03 No.39. Evacuation plan on drawing and

rehearsal reportNot available.

40. Electrical earthing pit location mapwith ID and testing record.

Earth pits provided. Testing done

41. OHC facilities / First Aid centre/First Aid boxes

First aid box available.

42. Certified First aider/ CPR trainedpersons

Training on cyanide poisoning given toworkers.SOP prepared and displayed.

43. Safety Training record Available44. EMP plan ( Action Plan) one page Available.45. Health & Safety Policy copy Health and safety policy available without

occupier signature and date.46. Safety Committee meeting Done Last meeting conducted on



Sr.No. Particulars

constitution & MOM record. 17.01.2019 and MOM available.47. Last Safety Audit report with

compliance hard/soft copyLast safety audit done in Dec-2016.

48. Risk Assessment study reporthard/ soft copy

Not done.

49. HAZOP Study report hard copy/soft copy

Not done.

50. On-site/Off-site emergency Planhard copy/ soft copy

On site emergency plan prepared andrevised on March 2015 Rev 00

51. Safety Manual as per GFR-68 K &P

Not available.

52. Mock Drill report Conducted on Dated 01.02.2019 and01.08.2018Report is available.

53. Safety Report as per GFR-68 JSchedule-8 hard/ soft copy

NA

54. Safe Operating Procedure (SOP)record

SOP’s are available.

55. Public liability insurance copy No. 2018-L-0120633-PBLValidity: 11/09/2018 to 10/09/2019Future General insurance co.

56. Group Personal Accident Policy Not available.57. Accident investigation Procedure

as per & all record with accidentstatistics record last 5 years.

SOP not available.

58. Workman Compensation Actcopy of WC policy if applicable

ESIC No. 38000219270000304

59. Work Permit system procedurewith all formats and SOP

Not available.

60. HSE Training record Available61. Mutual Aid arrangement with

other companiesDone with Nandesari IndustriesAssociation, Nandesari.

62. Material Safety Data Sheet[M.S.D.S.]

Available in QC lab.

63. Testing record of Hoist & Lift inForm No 9

Testing records of goods hoist not done.

64. Form No 10 Lifting tools &tackles

Available.

65. Form No 11 Pressure vessel Available.66. Form No 29 Accident register Available67. Form No 32 Periodic medical Available.68. Form No 33 Pre employment Available.69. Form No 37 Work area

MonitoringWork place monitoring carried out on13.04.2019

70. Centrifuge testing record Available.71. Thermic fluid heater testing record Available72. Noise, Illumination and ventilation Available



Sr.No. Particulars

testing report.73. Preventive Maintenance Schedules

for all equipmentSOP not available.

74. Electrical Inspection / Audit as perrequirements

Available.

75. Change management procedure SOP not available.76. Environs (Nearest Facilities):

Particulars Details Approx. DistanceVillage Nandesari 1.44 Km

Taluka/ Tehsil Nandesari 1.44 KmDistrict Vadodara 9 Km

Approx. Geographicalpositioning

Latitude: 22°24'21.15"N,

Longitude: 73° 5'47.66"E

--

Nearest City Vadodara 9 KmNearest Town Vadodara 9 Km

Nearest Highway NH8 3 KmNearest State highway SH 188 3 KmNearest Railway line/

Railway stationNandesari 1.5 Km

Nearest Airport/ Airbase Vadodara 15 KmNearest River Mahi River 2.30Km

77. Nearby Industries In The Vicinity:Name of Industry Direction w.r.t

project siteAddress

Supra Combines South C-1/128/16, GIDC, Nandesari,Vadodara.

JineshwarChemicals

North C-1/128/08, GIDC, Nandesari,Vadodara.

Ester India East C-1/128/29-30 GIDC, Nandesari,Vadodara.

Base MetalChlorination Pvt.Ltd.

West C-1/128/18, GIDC, Nandesari,Vadodara.

78. Metrological Data:Latitude 220 24’20.37”NLongitude 730 05’49.76”E

7.3.3 PROJECT SETTING

The unit is located in GIDC, Nandesari about 17 kms North of Vadodara.GIDC, Nandesari is equipped with a common Effluent Treatment Plant runningon the latest technology of Hydrodynamic cavitations and Electro-Oxidation.The facility for disposal of Hazardous waste by landfill and Plasma gasificationis also available at GIDC, Nandesari.



Latitude : 22°24'21.49"NLongitude: 73° 5'47.85"E

Proposal site is shown as Figure 7.1. & Plot plan is shown in figure 7.2.

FIGURE: 7.1NANDESARI PLANT



FIGURE: 7.2PLOT PLAN

EIA OF M/S. CHEMTECH INTERMEDIATES PVT LTD, GIDC NANDESARI, VADODARA


7.3.4 SAFETY ORGANIZATIONAL SET UP

7.3.5 LIST OF PRODUCTS

List of Product is covered under table no. 1.1 of chapter – 1.

7.3.6 LIST OF PRODUCT WISE RAW MATERIAL CONSUMPTION

List of product wise raw material consumption is covered under section no. 2.3.2 of chapter – 2.

7.3.7 DETAILS OF STORAGE OF RAW MATERIAL

TABLE: 7.2DETAILS OF STORAGE OF RAW MATERIAL

NAME OFHAZARDOUSSUBSTANCE

MAX.STORAGECAP.[Qty.]

PLACEOF IT ’SSTORAGE

OPERATINGPRESSUREAND TEMP.

TYPE OFHAZARD

CONTROLMEASUREPROVIDED

MOC

Chlorine 900 Kg X 5 Nos. Tonner 4-10 Kg/cm2 Toxic Provided in point no HDPE

Advise Company of safetylegislation & updates,safety awareness, carryout safety audits, updatesafety policy, providetraining when required, toprovide investigations andreports for any accidents.

Directors

Factory manager ( GM)(Safety Manager)

Safety Committee member



7.4.1Bromine 3 Kg X 6 Nos. Glass

Bottle CrateATP Toxic Provided in point no

7.4.7Glass

HydrogenCylinder Rack

1000 M3 1000 M3 150 Kg/cm2 Fire andExplosion

Provided in point no7.4.6

MS

Benzyl Chloride 25 KL X 2 Nos. StorageTank

ATP Fire andExplosion

Provided in point no7.4.2

HDPE

Methanol 5 KL DrumStoragearea


Provided in point no7.4.4 & 7.4.5

HDPE

Toluene 5 KL DrumStoragearea


HDPE

Chloroform 5 KL DrumStoragearea

ATP Toxic HDPE

Cyclohexane 2 KL DrumStoragearea

ATP Fire HDPE

MethyleneDichloirde

2 KL DrumStoragearea

ATP Fire HDPE

DimethylFormamide

2 KL DrumStoragearea

ATP Fire HDPE

Pyridine 2 KL DrumStoragearea

ATP Fire HDPE

7.4 PRECAUTION TO BE TAKEN DURING STORAGE7.4.1 Risk Assessment plan due to Chlorine Storage and handling:



1. Chlorine shed will be made as per SMPV rules.2. Chlorine will be stored in 900 kgs. tonners at site3. Chlorine tonner storage area will be away from the process plant.4. Chlorine KIT, HOOD, PIT, SCBA sets will be kept ready and maintained in tiptop working condition.5. Chlorine Hood with blower will be provided with scrubbing arrangement.6. Safety Shower and eye wash will be provided in Chlorine shed area.7. Tonner handling EOT crane will be installed in Chlorine shed area for safe tonner handling.8. Safety Valve will be provided on chlorine header line and it will be connected to caustic scrubber.9. Barometric lag height will be maintained up to maximum height of the process building.10. SCBA sets will be kept ready at chlorine handling area.11. Safety valve will be provided on vaporizer header and outlet of safety valve connected to scrubber.12. Flow and temperature controllers will be provided on process line.13. SOP will be prepared for safe handling of Chlorine tonners.14. Caution note and emergency handling procedure will be dwell be played and trained all employees.15. Neutralizing chemicals will be kept ready in tonner storage area.16. Regular Mock-drill conducted for chlorine emergency.

Emergency capabilities:1. Chlorine Emergency Kit will be kept at site.2. Chlorine scrubber with sparger and with blower will be provided surrounding chlorine tonner shed.3. Sprinkler will be provided surrounding chlorine shed.4. On line Gas detection will be provided.5. Fire hydrant system to be installed as per NFPA Norms in each plant and buildings.6. On Site emergency Plan will be prepared.7. Emergency drill will be conducted regularly and train employees for chlorine emergency.8. 03 Nos. SCBA sets will be provided.9. Area evacuation plan, Emergency assembly point, Emergency control centre will be prepared and will be maintained roundthe clock.10. OHC facility with part time Doctor and male nurse will be prepared and maintained.11. Emergency siren and wind shock will be provided.12. Tele Communication system and mobile phone will be used in case of emergency situations for communication.



For Chlorine1. SOP will be prepared for safe handling of Chlorine tonners.2. Chlorine Emergency Kit will be procured and kept ready at chlorine shed.3. Chlorine Hood with blower will be provided with scrubbing arrangement.4. Safety Shower and eye wash will be provided in Chlorine shed area.5. Tonner handling EOT crane will be installed in Chlorine shed area for safe tonner handling.6. Safety Valve will be provided on chlorine header line and it will be connected to caustic scrubber.

7.4.2 For Above ground Non PESO storage tank farm :7. MS storage tank provided as per IS code.8. Dyke wall will be provided to storage tank.9. Level gauge will be provided with low level high level.10. Fire hydrant monitor with foam trolley facility will be provided.11. FLP type pump will be provided.12.Double static earthing will be provided to storage tank.13.Double Jumper clip will be provided to all pipeline flanges.14.Road tanker unloading procedure will be prepared and implemented.15. Lightening arrestor, PPEs will be provided.16. Safety shower, eye washer will be provided.17.NFPA labelling system will be adopted for storage tanks.

7.4.3 For Drum Storage area :1. FLP type light fittings will be provided.2. Proper ventilation will be available in Drum storage area.3. Proper label and identification board /stickers will be provided in the storage area.4. Conductive drum pallets are provided.5. Drum handling trolley / stackers/fork lift are used for drum handling.6. Separate dispensing room with local exhaust and static earthing provision will be available.7. Materials are stored as per its compatibility study and separate area will be available for flammable, corrosive and toxicchemical drums storage.



8. Smoking and other spark, flame generating item are banned from the Gate.9. NFPA labels are provided on drums for hazard identification of the chemicals.10. Exhaust will be provided at ground level in drum storage area.11.Drum loading unloading procedures are prepared and implemented.

7.4.4 For Ware House Safety Measures:1. FLP type light fittings are provided.2. Proper ventilation will be available in godown.3. Proper label and identification board /stickers are provided in the storage area.4. Pallets are provided for material bag storage.5. Material handling trolley / stackers/fork lift are used.6. Materials are stored as per its compatibility study and separate area will be available for flammable, corrosive and toxicchemical storage.7. Smoking and other spark, flame generating item are banned from the Gate.

7.4.5 For Hydrogen skid :1. Hydrogen road skid will be received by road and skid will be stored away from process plant.2. PRV station provided with shut off valve and safety valve .3. Flame proof light fitting installed.4. Static earthing and electric earthing (Double) provided.5. Jumpers for static earthing on pipeline flanges of flammable chemical will be provided.6. Non sparking tools will be used for hydrogen line fitting.7.4.6 Bromine bottle Storage & Handling Safety

1. The amount of bromine in storage kept to a minimum.2. Floors of impervious construction, preferably concrete.3. Bromine bottle wooden carriage stored on collection pallets4. Area where bromine used or stored enclosed so that unauthorized persons are prevented from entering the area.5. Personnel escape routes clearly marked and it maintained without any obstructions including adequately sized doors and

windows.



6. Facilities like offices, eating, showering and changing rooms, located in up wind direction and remote from the area wherebromine will be handled or stored. Provide an adequate supply of clean water for washing and showers.

7. Emergency siren, telephone provided in storage area for the reporting of accidents or emergency situations. The emergencytelephone numbers displayed at prominent locations and it include the fire department, ambulance service, emergencyresponse team, hospital and police.

8. A wind sock provided which will clearly visible from all points on the site and replaced as required. This will be required forindicating wind strength and direction.

9. Emergency respirator equipment cabinets (Cupboard) installed not more than 30 meters or 10 seconds walking distance fromany location in the storage area.

10. Showers and eyewash fountains provided, clearly marked, well lit and with unobstructed access.11. Signs posted prominently at the site entrance and throughout the installation with area maps showing access ways, hydrant

locations, emergency showers, location of emergency equipment and emergency telephone numbers.12. All management and operating personnel involved in the use or handling of bromine will undergo safety training, in addition

to specific task training.13. Only experienced well-trained operators allowed to handle Bromine.14. Bromine glass bottle capacity 1 litters and six bottles stored in one packing box.15. Bromine stored in dry and cool place and well ventilated area.16. The driver and assistant driver of any vehicle transporting bromine should be comply with the following requirements:17. Open space separated from public highway and public dwellings, where public does not normally pass. No passengers will be

allowed.18. The driver or driver's assistant may not open a package containing bromine.19. Parking brakes will be to be applied whenever parked.20. If the vehicle will be parked on a road at night or with poor visibility, warning signs are to be placed 10 meters ahead of and

behind the vehicle.21. TREM CARD will be provided to all transporters and trained for transportation Emergency of Hazardous chemicals.22. American National Standards Institute (ANSI) approved chemical safety goggles will be there at all times when handling Br2.23. Full face shield over eyewear provided..24. Full body protection PVC suite provided.25. Eyewash fountains should be located in areas where bromine will be handled, used or stored.



26. When in danger of contact with liquid bromine, wear an approved chemical resistant suit.27. Leather or other non-woven ANSI approved steel-toed shoes or Gum boot provided.28. Protective rubber boots should be worn over shoes for extra protection.29. Have NIOSH approved respirators and self-contained breathing apparatus available.

Safety Practices in the Work Area

1. We will inform our all employees of the potential hazards of contact with bromine and train them in appropriate first-aidprocedures.

2. Bromine handling areas clearly marked and restricted to qualified, trained personnel only

Ventilation

3. We will maintain bromine vapour concentration in the work area to less than 0.1 ppm with adequate exhaust hoods,ventilation systems and scrubbers. Analyze air for proper control.

4. Transfer or repackage bromine will be only in a controlled, closed environment.5. Exhaust ventilating systems will be used in enclosed areas where bromine will be handled.

Storage

1. Bromine glass bottle capacity 1 litters and six bottles will be stored in one packing box.2. Bromine will be stored in dry and cool place and well ventilated area.3. Neutralization will be in case of spillage leakage4. Neutralization with sodium bisulfite requires 3 moles of sodium hydroxide: 1 mole sodium bisulfite: 1 mole bromine.5. Neutralization with sodium sulfite requires 2 moles sodium hydroxide: 1 mole sodium sulfite: 1 mole bromine.6. The weights and volumes specified include a 10% excess of sodium hydroxide and sodium bisulfate or sodium sulfite.

Emergency ProceduresIn case of bromine emergencies, follow recommended first aid and emergency response procedures adopted

Transportation EmergenciesIn emergency situations resulting from vehicle accidents:

1. Notify the local police, fire departments, emergency responders and the carrier.



2. Isolate the area.3. Any person not dressed in proper protective clothing and not using a NIOSH approved self-contained breathing apparatus

should be kept a safe distance away.4. Call to the supplier5. Seek immediate medical assistance for those injured and follow recommended first aid procedures.

Leaking Containers

When handling a leaking bottle personal protective clothing, goggles and NIOSH approved self contained breathing equipmentmust be worn.

1. Clear contaminated area of non-essential personnel and send them to assembly point.2. Maintain a slight ammonia atmosphere throughout the clean up. Carefully release anhydrous ammonia gas to neutralize

bromine vapor. The ammonia gas will convert bromine to white ammonium bromide “smoke.”3. Do not allow liquid bromine and liquid ammonia to combine; a violent reaction will occur. Ammonia (16 to 25% by

volume) can form an explosive mixture with air.4. Pour hypo solution*, lime and water slurry or soda ash solution over the spill. Hypo-bromine reactions produce

hydrobromic acid.5. Dry sodium thiosulfate and liquid bromine produce a violent reaction; do not mix them.6. Using cold water, wash neutralized bromine into a sump for transfer to an approved waste disposal facility where the waste

can be processed.7. Ventilate the area to remove the ammonium bromide and any bromine fumes. Scrub the floors and equipment will be with

soap and water.

First Aid Procedure

1. Immediate medical assistance will be required if bromine is swallowed, inhaled or has contacted the eyes or skin.2. If bromine has been ingested, do not give anything by mouth. Seek medical attention immediately. Do not induce

vomiting.3. If bromine has been inhaled, move the exposed person to a well ventilated area. Seek medical attention immediately. The

victim should be placed in a comfortable sitting or partly reclining position. The exposed individual should avoid exertion.If vomiting occurs, turn the patient on his side to avoid choking. Keep the patient warm. If the patient is coughing andshowing signs of respiratory distress, properly trained personnel should administer oxygen.

4. For skin contact, the affected area must be flooded immediately with large amounts of clean water from a safety shower orother appropriate source of flowing water. Seek medical attention immediately. All contaminated clothing, including



shoes, should be removed as quickly as possible while the victim is under the shower. Washing should be continued for aminimum of 30 minutes. If possible, continue to wash the affected area during transport to medical facilities. (Extendedwash times of two hours or more have proven beneficial.)

Bromine charging procedure:Following procedure adopted while Bromine glass bottle in reactor

1. Full body protection with air line respirator suite will be provided to operator.2. Air line respirator will be used for bromine charging3. Bottle will be charged in to glass flask by vacuum and from glass flask will be charged in to reactor by gravity gradually.

Sketch :

7.4.7 Safety Measures for Sodium Cyanide1. Separate stored in locked room.2. Away from water sources.3. Total body protection suite is provided to charging operator with air line respirator.



4. Safe operating (Charging) procedure is prepared and displayed in process and storage area.5. Total close process for charging and handling.6. Antidote kit for cyanide is kept ready in OHC.7. Training is being provided to handle NACN,8. SCBA sets are available in handling area.9. Operator having cuts and sores should not use cyanides.10. If a little poisoning, inhale cyanide antidote kit (amyl nitrite, sodium nitrite and sodium thiosulfate) and oxygen for 15-30seconds as first aid measures11. Use sodium hypochlorite, calcium hypochlorite solution or potassium permanganate for washing balance, glass apparatus,spatula, workplace and in case of spillage12. Use Apron, eye protecting glass, Mask and gloves during transferring, work-up and decomposition of chemicals.13. Issued quantity will be used fully for reactions cannot be stored in the process area14. Separate Log Book for issuing above cyanides and Manager has to sign on the register.

7.5 SPECIFY SAFETY PRECAUTION TO BE TAKEN FOR CHEMICAL STORAGE, PROCESS, AND HANDLING &TRANSPORTATION HAZARD

Table no: 7.3Transportation, Unloading and handling procedure Flammable material:

SR.NO. ACTIVITY TYPE OF POSSIBLEHAZARD

PROCEDURES.

1 Transportation of Solventslike Flammable materialby road tanker

Leakage, Spillage, fire,explosion, Toxic release

Training will be provided to driver and cleaner regarding thesafe driving, hazard of Flammable chemicals, emergencyhandling, use of SCBA sets.

TREM card will kept with TL. SCBA set will be kept with TL. Fire extinguishers will be kept with TL. Flame arrestor will be provided to TL exhaust. Instructions will be given not to stop road tanker in populated

area. Clear Hazard Identification symbol and emergency telephone

number will be displayed as per HAZCHEM CODE. Appropriate PPEs will be kept with TL.




PROCEDURES.

2 Flammable material Roadtanker unloading at site.

Leakage, Spillage, fire,explosion, toxic release

Priority will be given to Tanker to immediately enter the storagepremises at site and will not be kept waiting near the gate or themain road.

Security person will check Licence, TREM CARD, Fireextinguisher condition; SCBA set condition, Antidote Kit,required PPEs as per SOP laid down.

Store officer will take sample as per sampling SOP fromsampling point.

After approval of QC department unloading procedure will beallowed be started.

Following precautions will be adopted during unloading Wheel stopper will be provided to TL at unloading platform. Static earthing will be provided to road tanker. Tanker unloading procedure will be followed according to

check list and implemented. Flexible SS hose connection will be done at TL outlet line. The quantity remaining in the hose pipeline will be drained to a

small underground storage tank, which will be subsequentlytransferred by nitrogen pressure to the main storage tank thusensuring complete closed conditions for transfer from roadtanker.

All TL valves will be closed in TL. Finally earthing connection and wheel stopper will be removed. Only day time unloading will be permitted.

3 Flammable materialStorage tank safety

Leakage, Spillage, Fire,Explosion, Toxic release.

SS storage tank will be provided as per WILL BE code. Dyke wall will be provided to storage tank. Level transmitter will be provided with low level high level auto

cut-off provision. Vent will be connected to water trap and vent of water trap will

be provided with flame arrestor.




PROCEDURES.

Water sprinkler system will be provided to storage tank. Fire hydrant monitor with foam attachment facility will be

provided. Dumping / Drain vessel/alternate vessel will be provided to

collect dyke wall spillage material. FLP type pump will be provided. Nitrogen blanketing will be provided to storage tank. Double static earthing will be provided to storage tank. Double Jumper clip will be provided to all Solvent handling

pipeline flanges.4 Flammable material

Solvents transfer fromstorage tank to Day tank

Leakage, Spillage due toLine rupture, FlangeGasket failure, Fire,Explosion, Toxic release.

Double mechanical seal type FLP type pump will be provided. Double on / off switch will provided at tank farm and process

area near day tank. Pump auto cut off with day tank high levelwill be provided.

Flame arrestor will be provided on day tank vent. Over flow will be provided for additional safety and it will be

connected to main storage tank. NRV will be provided on pump discharge line. Double Jumper clip will be provided to all solvent handling

pipeline. Double static earthing will be provided to day tank.

5 Flammable materialtransfer from Day tank toreactor.

Leakage, Spillage due toLine rupture, FlangeGasket failure, Fire,Explosion, Toxic release.

Gravity transfer. Total quantity of day tank material will be charged in to reactor

at a time. NRV will be provided on day tank outlet line. Static earthing will be provided to storage tank. Double Jumpers will be provided to pipeline flanges.

TABLE: 7.4Drums Transportation, Unloading and handling procedure



SR.NO. ACTIVITY TYPE OFPOSSIBLEHAZARD

PROCEDURES.

1 Transportation of drums Leakage, Spillage,fire, explosion, Toxicrelease

Training will be provided to driver and cleaner regarding thesafe driving, hazard of Flammable chemicals, emergencyhandling, use of SCBA sets.

TREM card will kept with TL. SCBA set will be kept with TL. Fire extinguishers will be kept with TL. Flame arrestor will be provided to TL exhaust. Instructions will be given not to stop road tanker in

populated area. Clear Hazard Identification symbol and emergency

telephone number will be displayed as per HAZCHEMCODE.

Appropriate PPEs will be kept with TL.2 Drums unloading at site. Leakage, Spillage,

fire, explosion, toxicrelease

Priority will be given to truck to immediately enter thestorage premises at site and will not be kept waiting near thegate or the main road.

Security person will check Licence, TREM CARD, Fireextinguisher condition, SCBA set condition, Antidote Kit,required PPEs as per SOP laid down.

Store officer will take sample as per sampling SOP fromsampling point.

After approval of QC department unloading procedure willbe allowed be started.

Following precautions will be adopted during unloading Wheel stopper will be provided to TL at unloading platform. Only day time unloading will be permitted.

3 Go down / warehouse safety Leakage, Spillage,Fire, Explosion,Toxic release.

FLP type light fittings will be provided. Proper ventilation will be provided in godown. Proper label and identification board /stickers will be



SR.NO. ACTIVITY TYPE OFPOSSIBLEHAZARD

PROCEDURES.

provided in the storage area. Conductive drum pallets will be provided. Drum handling trolley / stackers/fork lift will be used for

drum handling. Separate dispensing room with local exhaust and static

earthing provision will be made. Materials will be stored as per its compatibility study and

separate area will be made for flammable, corrosive andtoxic chemical drums storage.

Smoking and other spark, flame generating item will bebanned from the Gate.

4 Solvents transfer from drum toDay tank/ reactor

Leakage, Spillagedue to Line rupture,Flange Gasketfailure, Fire,Explosion, Toxicrelease.

Solvent transfer by vacuum or by pump only. Static earthing will be provided. SS flexible hose / conductive hose will be used.

5 Solvent transfer from Day tank toreactor.

Leakage, Spillagedue to Line rupture,Flange Gasketfailure, Fire,Explosion, Toxicrelease.

Gravity transfer. Total quantity of day tank material will be charged in to

reactor at a time. NRV will be provided on day tank outlet line. Static earthing will be provided to storage tank. Double Jumpers will be provided to pipeline flanges.

TABLE: 7.5

Bromine Transportation, Unloading and handling Procedure :



SR.NO.

ACTIVITY TYPE OF POSSIBLEHAZARD

PROCEDURES.

1 Transportation of Bromineby ISO container

Leakage, Spillage, Toxicrelease

GPS will be installed in all the trucks and ISO container vehicle. Driver and assistant will be trained in using GPS. Open space separated from public highway and public

dwellings, where public does not normally pass. No passengersare allowed.

The crew shall know how to use fire-fighting appliances. The driver or driver's assistant may not open a package

containing bromine. Bromine receptacles are not to be checked with open flames. No smoking will be permitted around the transport unit or in the

vicinity of the vehicle during handling operations. The engine will be to be shut off during all handling operations

unless required to drive pumps, hoist, etc. Parking brakes are to be applied whenever parked. If the vehicle will be parked on a road at night or with poor

visibility, warning signs are to be placed 10 meters ahead of andbehind the vehicle.

TREM CARD provided to all transporters and trained fortransportation Emergency of Hazardous chemicals.

All trucks having 1 kg Sodium Thiosulfate bag. Training will be provided to driver and cleaner regarding the

safe driving, hazard of Bromine emergency handling, use ofSCBA sets and neutralizing agent.

SCBA set will be kept with ISO container truck. All the ISO container truck will be equipped with Global

Positioning system (GPS) and route will be predefined. Clear Hazard Identification symbol and emergency telephone

number will be displayed as per HAZCHEM CODE. Appropriate PPEs will be kept with Truck.

2 Bromine ISO container Leakage, Spillage, fire, Directly ISO container will be placed at storage area and



SR.NO.


PROCEDURES.

loading and handling atHemani site

explosion, toxic release connected with process tank. Wear recommended personal protective equipment during

connection of ISO container. Make sure the absorber unit will be working and capable of

handling vented bromine fumes. BE SURE THAT DRY AIR (DEW POINT -40"C) OR DRY

NITROGEN will be available in ample supply and its pressurewill be controlled below 3 atm. gauge.

Check that all the Iso-container valves are closed and blindflanges are in place.

Remove the blind flange above the red valve. Connect your pressure release line to the red valve outlet. Use a

new rubber gasket (use limit - 24 hours) to ensure tightconnection.

Open the red valve slowly and then the depressurizing valve, torelease any pressure which might have developed in the Iso-container.

Remove the blind flange above the yellow valve. Connect your line to the yellow valve outlet. Use a new rubber

gasket (use limit - 24 hours) to ensure tight connection. Open the yellow valve and all the valves in your liquid

unloading line. Close the depressurizing valve. Open the pressurizing valve, at first slowly (to check for

bromine leaks), then fully, to start bromine unloading. Use onlyenough pressure to lift the bromine to the high point in theunloading system.

NEVER EXCEED 3 ATM. PRESSURE. When air/nitrogen blows through the unloading line into your

storage tank, the Iso-container will be empty.



SR.NO.


PROCEDURES.

Close the pressurizing valve. Close the yellow valve and then all the other valves in your

liquid unloading line. Slowly open the depressurizing valve to release the air/nitrogen

pressure on the Iso-container to your absorber unit. Wait 5minutes.

Close the red valve and then the depressurizing valve. Cautiously disconnect your liquid unloading line from the

yellow valve of the Iso-container. Replace its blind flange,tightening all the bolts. Do not forget to reinstall the propergasket.

Disconnect your pressure release line from the red valve of theIso-container. Replace its blind flange, tightening all the bolts.Do not forget to reinstall the proper gasket.

If there has been a bromine spillage, wash it off the Iso-container with plenty of water to prevent corrosion. Smallbromine spills on the ground may be neutralized with a clearsoda ash or a sodium thiosulphate solution. Then dispose of in amanner approved by the local authorities.

Close the cover dome and pin it securely. Mark the Iso-container EMPTY (use erasable means). Bromine ISO tanks should be stored no closer than 10 meters

from human or animal consumable articles. Explosives andflammable materials should not be stored close to bromine.

There would be sufficient bromine storage tank capacity or anempty ISO tank to accommodate the transfer of bromine from aleaking container

Area where bromine will be used or stored will be enclosed sothat unauthorized persons and animals are prevented fromentering the area. Adequate lighting is provided to allowsufficient night surveillance. Surveillance will be provided 24



SR.NO.


PROCEDURES.

hours a day. Personnel escape routes will be clearly marked and it will be

maintained without any obstructions including adequately sizeddoors and windows.

Facilities like offices, eating, showering and changing rooms,will be located in up wind direction and remote from the areawhere bromine will be handled or stored. Provide an adequatesupply of clean water for washing and showers.

Emergency siren, telephone will be provided in storage area forthe reporting of accidents or emergency situations. Theemergency telephone numbers will be displayed at prominentlocations and it include the fire department, ambulance service,emergency response team, hospital and police.

A wind sock will be provided which will clearly visible from allpoints on the site and replaced as required. This will be requiredfor indicating wind strength and direction.

Emergency respirator equipment cabinets( Cupboard) will beinstalled not more than 30 meters or ten seconds walkingdistance from any location in the storage area.

Showers and eyewash fountains will be provided, clearlymarked, well lit and with unobstructed access.

Signs will be posted prominently at the site entrance andthroughout the installation with area maps showing accessways, hydrant locations, emergency showers, location ofemergency equipment and emergency telephone numbers.

All management and operating personnel involved in the use orhandling of bromine will undergo safety training, in addition tospecific task training.

Only experienced well-trained operators will be allowed toreceive and unload bromine receptacles.

The management will ensure that emergency response plans



SR.NO.


PROCEDURES.

have been made and coordinated with the emergency responselocal authorities.

Safety permit for hazardous material loading unloading will beprepared and implemented.

Fire hydrant system and water sprinkler system installed at tankfarm area.

TABLE: 7.6Chlorine Transportation, Unloading and handling Procedure:

SR.NO.


PROCEDURES.

1 Transportation of ChlorineTonners by road tanker

Leakage, Spillage, Toxicrelease

Training will be provided to driver and cleaner regarding thesafe driving, hazard of Chlorine emergency handling, use ofSCBA sets.

TREM card will kept with TL. SCBA set will be kept with TL. Instructions will be given not to stop Chlorine road truck in

populated area. Clear Hazard Identification symbol and emergency telephone

number will be displayed as per HAZCHEM CODE. Appropriate PPEs will be kept with TL.

2 Chlorine tonnersunloading at Hemani site

Leakage, Spillage, toxicrelease

Priority will be given to Tanker to immediately enter the storagepremises at site and will not be kept waiting near the gate or themain road.

Security person will check Licence, TREM CARD, Fireextinguisher condition; SCBA set condition, required PPEs asper SOP laid down.

3 Chlorine tonners storage Leakage, Spillage, Fire, SOP will be prepared for safe handling of Chlorine tonners.



SR.NO.


PROCEDURES.

shed Explosion, Toxic release. Chlorine Emergency Kit will be procured and kept ready atchlorine shed.

Chlorine Hood with blower will be provided with scrubbingarrangement.

Safety Shower and eye wash will be provided in Chlorine shedarea.

Tonner handling EOT crane will be installed in Chlorine shedarea for safe tonner handling.

Safety Valve will be provided on chlorine header line and it willbe connected to caustic scrubber.

SCBA sets will be kept ready at chlorine handling area. Safety valve will be provided on vaporizer header and outlet of

safety valve connected to scrubber. Flow and temperature controllers will be provided on process

line.4 Chlorine tonners connected

with headerLeakage, Spillage due toLine rupture, Toxicrelease.

Teflon or copper tube will be used for connection with header. Pressure gauge and safety valve will be provided on header line.

TABLE: 7.7Sodium Cyanide Transportation, Unloading and handling Procedure :

SR.NO.


PROCEDURES.

1 Transportation of SodiumCyanide by road truck

Leakage, Spillage, Toxicrelease in case of directcontact or ingestion

Close pack HDPE drums with seal. No hazard during transportation due to solid pallets.

2 Sodium Cyanide storageand handling safety

Leakage, Spillage, Toxicrelease in case of direct

Separate stored in locked room. Away from water sources.



SR.NO.


PROCEDURES.

contact or ingestion Total body protection suite will be provided to chargingoperator with air line respirator.

Safe operating (Charging) procedure will be prepared anddisplayed in process and storage area.

Total close process for charging and handling. Antodote kit for cyanide will be ketp ready in OHC. Training will be being provided to handle NACN, SCBA sets are available in handling area.



7.5.1 EVENT TREE ANALYSIS: STORAGE VESSEL FAILURE

Over Pressure Overfilling (level control fails Missile/ Bombexpansion of liquid, temp rise) Lightening attack Earthquake

( Heating due to radiation ) ( Failure of vents’ valves Spill Spill with Fireclogging of pipe lines)

Pool Evaporation Spill

Pool fire Toxic disp. VCEFlash Fire

Rupture ( Failure of Rupture ( Failure of welded Leak ( Corrosion Toxic disp Pool Fire/ welded joint valves joints valves/ nozzles flanges) cracks/ holes/ nozzles Flanges ) valves/flange joints, leaks)

Toxic dispersion

PoolSpill Spill Jet

Evaporation

Pool EvaporationPool Evaporation

Jet fire Pool Pool FirePool Fire Toxic disp. Pool fire Toxic disp.

Pool EvaporationToxic disp.

Toxic dispersion Toxic disp.Toxic dispersion Toxic dispersion

Pool Fire Toxic disp.



7.6 HAZARDOUS PROPERTIES OF THE CHEMICALS, COMPATIBILITIES AND SPECIAL HAZARD

TABLE: 7.8HAZARDOUS PROPERTIES OF THE CHEMICALS, COMPATIBILITIES AND SPECIAL HAZARD

SR.

NAME OFCHEMICAL

HAZARD

FLASHPOINT0 C

BP0 C

LEL%

UEL%

SP.GR. 20

0 C

VD SOLUBILIT

YWITHWATER at 20

0 C

NFPA

H FR

HAZARDOUS

COMBUSTIONPRODU

CT

TLVPPM

IDLHPPM

LC50mg/m

3

TARGET

ORGANCE

CARCINOGE

NICCHARACTERISTI

C

ANTIDOT

1.Benzyl chlorideCAS#100-44-7

H/F 67 179 1.1 14 1.1 4.4 NA 3 2 1 NA 110

ppm

LC50:Acute:1870mg/m

32hours[Rat].

Eyes,skin,

respirator

system

YES

Epikakesolution,activatedcharcoal,milkHomeopathy AntidoteBenzylChloride

2.Chlorine

CAS #7782-50-5T NF

Thelowestknownvalue is100°C

NA NA 1.424 0.62 Boils 3 0 0Toxic andirritating

gases1 10

1017ppmFor

human

Eyes,skin,

respiratory

system

NoMilk butterand milk ofmagnesia.

3.

Ammonia(Anhydrous)CAS # 7664-

41-7

C NF - 33.315.50

27

0.6819at -30

C(Water

)0.5970

Liq.608.

7kg/m3210

Insoluble

3 1 0 N A25

ppm300ppm

7040mg/m

3

Eyes,skin,

respiratory

system

NoSmellingEthanol or

Ether



SR.

NAME OFCHEMICAL

HAZARD

FLASHPOINT0 C

BP0 C

LEL%

UEL%

SP.GR. 20

0 C

VD SOLUBILIT

YWITHWATER at 20

0 C

NFPA

H FR

HAZARDOUS

COMBUSTIONPRODU

CT

TLVPPM

IDLHPPM

LC50mg/m

3

TARGET

ORGANCE

CARCINOGE

NICCHARACTERISTI

C

ANTIDOT

at 00C1 atm(Air1)

CGas0.77

1kg/m300C

4.

MethanolCAS# 67-56-1

F/T 10 54 5.4 44 0.792 1.1 Soluble 1 3 0Irritatingvapour

2006000LEL

64000ppm

for 4Hrat

Kidneys,

heart,centralnervou

ssystem, liver,eyes

No

10 mgdiazepamthroughinjectionActivatedCharcoal

5.Toluene

CAS # 108-88-3F 4.0 111 1.1 7.1 0.87 3.2 Insoluble 2 3 0

IrritatingVapour

generated50 2000

400ppmfor

24HrRat

Eyes,skin,

respiratory

system,

centralnervou

s

No

Diazem – 1mg/Kg.(Intravenous),

Epinephina,Efidrine



SR.

NAME OFCHEMICAL

HAZARD

FLASHPOINT0 C

BP0 C

LEL%

UEL%

SP.GR. 20

0 C

VD SOLUBILIT

YWITHWATER at 20

0 C

NFPA

H FR

HAZARDOUS

COMBUSTIONPRODU

CT

TLVPPM

IDLHPPM

LC50mg/m

3

TARGET

ORGANCE

CARCINOGE

NICCHARACTERISTI

C

ANTIDOT

system, liver,kidney

s

6.Chloroform

CAS # 7-66-3T NF 61.2 NF NF 1.49 4.1

Insoluble

2 0 0 N A10

ppm500ppm

47702mg/m4 hrsrat

Eyes,skin,

respiratory

system

YesAmyl nitriteor ammonia.

7.

DichloroMethane

(MDC, DCM )CAS#: 75-09-2

T N.F 39.814.0

22.0

1.325 2.9 20 g/ lit. 2 0 1

CO, CO2,Cocl2,

HCL (g)generated

50 NA

52gm/m

3inhalation

-rat

blood,centralnervou

ssystem

Yesno specificantidote.

8.Sodium cyanideNaCN CAS#143-33-9

H NFVeryhigh

NF NF 1.60 NA Soluble 3 0 0Irritating

vapor

5mg/m

3

25mg/m

3NA

Eye &Skin

No

MetheleneBlue orKelocynereinjection

9.Hydrochloricacid (15 - 33%)CAS #7647-01-0

T/C NA -84.9 NA NA 1.27 1.52 Soluble 3 0 1 HCL gas 5 50

1300ppm/30

mins

Eyes,skin,

respiratory

NoNo specificAntidote



SR.

NAME OFCHEMICAL

HAZARD

FLASHPOINT0 C

BP0 C

LEL%

UEL%

SP.GR. 20

0 C

VD SOLUBILIT

YWITHWATER at 20

0 C

NFPA

H FR

HAZARDOUS

COMBUSTIONPRODU

CT

TLVPPM

IDLHPPM

LC50mg/m

3

TARGET

ORGANCE

CARCINOGE

NICCHARACTERISTI

C

ANTIDOT

forhum

system

10.Sulfuric AcidCAS # 7664-93-9

C NA 340 NA NA 1.84 NAWater

reactive3 0 2

Noncombusti

ble

1mg/m3

15mg/m

3

510Rat

Skin,eyes,Lung,

No

SodiumHydro-Carbonate(4% Conc.),Milk, LimeJuice, Milkof Megnesia

11.

HydrochloricAcidHCLCAS#: 7647-01-0

C/T NF 108 NF NF1.12 -1.19

1.267

Soluble 3 0 1 N A5

ppm50

ppm

3124ppm

for 1hrat

Kidney, liver,mucou

smembranes,

respiratory

system, skin,eyesand

cardiovascularsystem

No

SodiumHydro-Carbonate(4% Conc.),

12. Methyl TCF 47 130 7.5 18.5 1.238 3.75 28 g/l 2 2 CO, CO2 NL NL 1 NA No No specific



SR.

NAME OFCHEMICAL

HAZARD

FLASHPOINT0 C

BP0 C

LEL%

UEL%

SP.GR. 20

0 C

VD SOLUBILIT

YWITHWATER at 20

0 C

NFPA

H FR

HAZARDOUS

COMBUSTIONPRODU

CT

TLVPPM

IDLHPPM

LC50mg/m

3

TARGET

ORGANCE

CARCINOGE

NICCHARACTERISTI

C

ANTIDOT

chloroacetate96-34-4

mg/m3

Antidote

13.Ammonia liquorCAS #1336-21-6 Toxic NF 36 16 25 0.9 1.2

Miscible 3 1 0Not

combustible

25300

2000ppm/4

-hr

Skin,Eye,

respiratory

system.

No

Wash withLactic Acid,ApplysoframycinSmellingEthanol orEther

14.BenzophenoneCAS#: 119-61-9

H NA 305.4 NA NA 1.11 NA Soluble 2 1 0CO, CO2

NL NLLD 50:

2895mg/kg

Eyes,skin,


15.

Soda ashSodiumCarbonate497-19-8

C/H N.A. N.A.N.A

.N.A

.NA NA

MISCIBLE

2 0 1

EmitsNa2Ofumeswhen

heated todecompos

iton

NA NA

Acute:2300mg/m

2hours[Rat].1200mg/m

2hours[Mous

e].

NANA No specific

antidote

16. Raney nickel T/F NA NA NA NA NA NA In 3 2 0 obnoxious 1 5 NA Skin. Yes No specific



SR.

NAME OFCHEMICAL

HAZARD

FLASHPOINT0 C

BP0 C

LEL%

UEL%

SP.GR. 20

0 C

VD SOLUBILIT

YWITHWATER at 20

0 C

NFPA

H FR

HAZARDOUS

COMBUSTIONPRODU

CT

TLVPPM

IDLHPPM

LC50mg/m

3

TARGET

ORGANCE

CARCINOGE

NICCHARACTERISTI

C

ANTIDOT

contactwithwater

releasesflammabl

e gas

W and toxicfumes ATE

> 20mg/l.

Nickelis

Group2B

carcinogen-

IARC

antidote

17.

Hydrogen GasCAS # 1333-74-0 F/E N.A.

-252.8°

C3.0 74 0.0696 NA

Solublein water

1 4 0Explosive

gas250ppm

NA

LC50>8000

00ppmrat

lungs,heart,upperrespira

torytract,

centralnervo

ussyste

m(CNS)


18.Iso butylalcoholCAS#78-83-1

T/F 32 107.9 1.610.9

0.802 NASolublein water

2 3 0Highly

Flammable

50ppm

1600ppm

LC500.5-

5.0g/kg(rat)

Eyes,skin,

respiratorysyste

NoNo specificantidote



SR.

NAME OFCHEMICAL

HAZARD

FLASHPOINT0 C

BP0 C

LEL%

UEL%

SP.GR. 20

0 C

VD SOLUBILIT

YWITHWATER at 20

0 C

NFPA

H FR

HAZARDOUS

COMBUSTIONPRODU

CT

TLVPPM

IDLHPPM

LC50mg/m

3

TARGET

ORGANCE

CARCINOGE

NICCHARACTERISTI

C

ANTIDOT

m,centralnervo

ussystem.

19.

ParaformaldehydeCAS#:30525-89-4

F/T 70 NA 7 73 1.46 1.03Partiallysoluble

3 2 0CO &CO2

NL NL

Dust-1070mg/m

4 hours[Rat].

Eyes,skin,

respiratory

system

NANo specificAntidote

20.Para-Xylene F 27 1381.1%

7.0%

0.861 3.66 Insoluble 2 3 0No

Pertinent100ppm

900ppm

NA NA NoNo specificantidote

21.

CuprousChlorideCAs.: 7758-89-6

H NF NF NA NA 4.4 NA NA 2 0 1 NF NA NA NAEyeAndSkin


22.HexaneCAS #110-54-3

F -7 68.7 1.2 7.7 0.659 3.0 Insoluble 1 3 0CO &CO2

500 1100

48000ppm

( Rat )4 h

Eyes,skin,

respiratory

system,

centralnervou

NoNo specificAntidot



SR.

NAME OFCHEMICAL

HAZARD

FLASHPOINT0 C

BP0 C

LEL%

UEL%

SP.GR. 20

0 C

VD SOLUBILIT

YWITHWATER at 20

0 C

NFPA

H FR

HAZARDOUS

COMBUSTIONPRODU

CT

TLVPPM

IDLHPPM

LC50mg/m

3

TARGET

ORGANCE

CARCINOGE

NICCHARACTERISTI

C

ANTIDOT

ssystem

,periphe

ralnervou

ssystem

23.Urea T NA NA NA NA 1.3232.07

EasilySoluble

2 1 0CO2,

CO,NOxNA N/A

4241mg/l

NA NONo specificAntidote

24.Nitric AcidCAS # 7697-37-2

C NF 121 NA NA 1.408 2.5 Soluble3 00

NA 2 225

260mg/m3/30M

Rat

Eyes,skin,

respiratory

system, teeth

Yes

SodiumHydro-Carbonate(4% Conc.),Milk, LimeJuice, Milkof Megnesia

25.

AluminumChloridealcl3CAS #7446-70-0

C/T NF NA NA NA 2.44 4.5 NA 3 0 2Toxicfumes

5ppm

100ppm

1274PPM

Eye ,Skin

No

2 to 5 gmthiosulphatein 5%sodium bicarbonatesolution in200 ml

26. Bromine C/T NF 58.78 NA NA 3.11 7.1 Soluble 3 0 0 Non 0.2 3.0 2600 Eye , No give milk,



SR.

NAME OFCHEMICAL

HAZARD

FLASHPOINT0 C

BP0 C

LEL%

UEL%

SP.GR. 20

0 C

VD SOLUBILIT

YWITHWATER at 20

0 C

NFPA

H FR

HAZARDOUS

COMBUSTIONPRODU

CT

TLVPPM

IDLHPPM

LC50mg/m

3

TARGET

ORGANCE

CARCINOGE

NICCHARACTERISTI

C

ANTIDOT

CAS #7726-95-6

in water combustible

ppm ppm mg/kg[Rat

Skin butter-milkor lemonjuice ormake asmall cottonball anddrench withethanol orethersolutiondrops andput it nearvictim’snose forsmell.Apply pureoxygen.

F = FIRE T = TOXIC C = CORROSIVE

E = EXPLOSIVE R = REACTIVE STEL = SHORT TERMEXPOSURE LIMITBP = BOILING POINT LEL = LOWER EXPLOSIVE LIMIT PPM =PARTS PER MILLION



UEL = UPPER EXPLOSIVE LIMIT SP.GR = SPECIFIC GRAVITY VD = VAPOURDENSITYER = EVAPORATION RATE H = HEALTH HAZARD CLASS F = FIREHAZARD CLASSR = REACTIVE HAZARD BR = BURNING RATE TLV =THRESHOLD LIMIT VALUENFPA =NATIONAL FIRE PROTECTION ASSOCIATION-usa N.A = NOT AVAILABLE N.L =NOTLISTED

EIA OF M/S. CHEMTECH INTERMEDIATES PVT LTD, GIDC NANDESARI,VADODARA


7.7 DETAILS OF OCCUPATIONAL HEALTH PROGRAM

i) To which chemicals, workers are exposed directly or indirectly.

Provided in Table No: 7.9 column B

ii) Whether these chemicals are within Threshold Limit Values (TLV)/Permissible Exposure Levels as per ACGIH recommendation.

Yes, regular Work place monitoring carried out and checked where it is in TLVlimit or not. If required control measures to be provided to control under TLVlimit.

iii) What measures company has taken to keep these chemicals withinPEL/TLV.

Measures to keep exposure below TLV/ PEL are provided in below table 3.11column D.

iv) How the workers are evaluated concerning their exposure to chemicalsduring preplacement and periodical medical monitoring.

Premedical examination and periodical medical examination is carried out oncein a year and record maintained in Form No-32 & 33

v) What are onsite and offsite emergency plan during chemical disaster.Onsite and offsite emergency plan provided in Table-7.9 column E

vi) Liver function tests (LFT) during pre-placement and periodical examination.

LFT will be done those workers who are working in process area and recordwill be maintained.

vii) Details of occupational health surveillance program.

• In process there is no any high noise, high heat stress and low levelillumination exposure to workers.

• Manual material handling only the causes of musculo-sketal disorders(MSD), backache, pain in minor and major joints, fatigue etc. followingmeasure have been taken to avoid above mentioned ill health effect toworkers.

• Below 25 kgs weight will be handled by a worker if required to do so.• Material handling lorry-cart, drum handling trolley, fork lift, stacker, etc.

will be used for material handling.• Training will be carried out for Manual material handling.• Ergonomics study will be carried out before commissioning of the plant

and correct material flow, Process flow of work place will be designed.

Following activities will be carried out for Occupational health of the workers.

• Treatment part (OPD) for both company and contractor employees.



• Occupational related problems will be studIed like ergonomic issues andcontrol measures

• Prevention part- Pre medical examination and periodical medicalexamination for operators, helpers, chemists.

• Profile active (Health Awareness programme.)



7.8 OCCUPATIONAL HEALTH IMPACT ON EMPLOYEES, CONTROL MEASURES, ACTION PLAN IF ACCIDENTOCCUR

TABLE: 7.9OCCUPATIONAL HEALTH IMPACT ON EMPLOYEES, CONTROL MEASURES, ACTION PLAN IF ACCIDENT OCCUR

Sr.No.

Chemical Occupational health impact onemployees

Measures to keepexposure below

TLV/ PEL

EMP for STEL & IDLH

A B C D E1. Bromine

CAS #7726-95-6

The substance may be toxic tokidneys, liver, cardiovascularsystem, central Nervous system(CNS), thyroid. Repeated orprolonged exposure to thesubstance can produce targetorgans damage.Repeated or prolonged contactwith spray mist may producechronic eye irritation and severeskin irritation. Repeated orprolonged exposure to spray mistmay produce respiratory tractirritation leading to frequentattacks of bronchial infection.Repeated exposure to a highlytoxic material may producegeneral deterioration of health byan accumulation in one or manyhuman organs.

Provide exhaustventilation or otherengineering controls tokeep the airborneconcentrations of vaporsbelow their respectivethreshold limit value.Ensure that eyewashstations and safetyshowers are proximal tothe work-station location

Corrosive liquid. Poisonous liquid. Stop leak if without risk.Absorb with DRY earth, sand or other non-combustiblematerial.Do not get water inside container. Do not touch spilledmaterial. Use water spray curtain to divert vapor drift. Usewater spray to reduce vapors. Prevent entry into sewers,basements or confined areas; dike if needed. Call for assistanceon disposal. Be careful that the product is not present at aconcentration level above TLV.

2. ChloroformCAS # 7-66-3

Potential Chronic Health Effects:CARCINOGENIC EFFECTS:Classified + (Proven.) by

Engineering Controls:Provide exhaustventilation or other

Absorb with an inert material and put the spilled material in anappropriate waste disposal. Be careful that theproduct is not present at a concentration level above TLV.



Sr.No.



TLV/ PEL

EMP for STEL & IDLH

NIOSH. Classified A3 (Provenfor animal.) by ACGIH, 2B(Possible for human.) by IARC.Classified 2 (Some evidence.) byNTP. MUTAGENIC EFFECTS:Mutagenic for mammaliansomatic cells. Mutagenic forbacteria and/or yeast.TERATOGENIC

engineering controls tokeep the airborneconcentrations of vaporsbelow their respectivethreshold limit value.Ensure that eyewashstations and safetyshowers are proximal tothe workstation location.Personal Protection:Splash goggles. Lab coat.Vapor respirator. Be sureto use anapproved/certifiedrespirator or Equivalent.Gloves.

Check TLV on the MSDS and with local authorities.

3. MethanolCAS# 67-56-1

The substance is toxic to blood,the reproductive system, liver,upper respiratory tract, skin,central nervous

Provide close process Flammable liquid. Keep away from heat. Keep away fromsources of ignition. Stop leak if without risk. Absorb withDRY earth, sand or other non-combustible material. Do nottouch spilled material. Prevent entry into sewers, basements orconfined areas; dike if needed.

4. PyridineCAS # 110 –86 - 1

Target organs: Liver, kidneys,nerves, Bone Marrow. Personswith pre-existing disorders maybe more susceptible. ThisProduct has been reported to be apossible carcinogen.Long-term exposure may causeliver, kidney or CNS damage.

Use process enclosure,local exhaust ventilation,or other engineeringcontrols to controlairborne levels belowrecommended exposurelimits. Facilities storing orutilizing this material

Absorb spill with inert material (e.g. vermiculite, sand orearth), then place in suitable container. Clean up spillsimmediately, observing precautions in the ProtectiveEquipment section. Remove all sources of ignition. Use aspark-proof tool. Provide ventilation. Prevent spreading ofvapors through sewers, ventilation systems and confined areas.Evacuate unnecessary personnel. Approach spill from upwind.Use water spray to cool and disperse vapors, protect personnel,



Sr.No.



TLV/ PEL

EMP for STEL & IDLH

Typical STEL 10 ppm. TypicalPEL 15 ppm.

should be equipped withan eyewash facility and asafety shower. Ventilationfans and other electricalservice must be non-sparking and have anexplosion-proof design.

and dilute spills to form nonflammable mixtures. Controlrunoff and isolate discharged material for proper disposal.

5. TolueneCAS # 108-88-3



6. HydrochloricAcid

Very hazardous in case of skincontact (corrosive, irritant,permeator), of eye contact(irritant, corrosive), of ingestion,. SlightlyHazardous in case of inhalation(lung sensitizer). Non-corrosivefor lungs. Liquid or spray mistmay produce tissue damageParticularly on mucousmembranes of eyes, mouth andrespiratory tract. Skin contactmay produce burns. Inhalation ofthe Spray mist may producesevere irritation of respiratorytraact, characterized bycoughing, choking, or shortness

Provide close process andscrubber on process ventand storage vent

Corrosive liquid. Poisonous liquid. Stop leak if without risk.Absorb with DRY earth, sand or other non-combustiblematerial.Do not get water inside container. Do not touch spilledmaterial. Use water spray curtain to divert vapor drift.



Sr.No.



TLV/ PEL

EMP for STEL & IDLH

of breath.Severe over-exposure can resultin death.

7. Sulfuric Acid Prolonged or repeated skincontact may cause dermatitis.Prolonged or repeated inhalationmay cause nosebleeds, nasalcongestion, erosion of the teeth,perforation of the nasal septum,chest pain and bronchitis.Prolonged or repeated eyecontact may cause conjunctivitis.Effects may be delayed. Workerschronically exposed to sulfuricacid mists may show variouslesions of the skin,tracheobronchitis, stomatitis,conjunctivitis, or gastritis.Occupational exposure to stronginorganic acid mists containingsulfuric acid is carcinogenic tohumans.

Facilities storing orutilizing this materialshould be equipped withan eyewash facility and asafety shower. Useadequate general or localexhaust ventilation tokeep airborneconcentrations below thepermissible exposurelimits. Use a corrosion-resistant ventilationsystem.

Clean up spills immediately, observing precautions in theProtective Equipment section. Carefully scoop up and placeinto appropriate disposal container. Provide ventilation. Do notget water inside containers. Cover with dry earth, dry sand, orother non-combustible material followed with plastic sheet tominimize spreading and contact with water.

8. HexaneCAS #110-54-3



9. Aluminiumchloride

The substance is toxic to lungs,mucous membranes. Repeated or

Use process enclosures,local exhaust ventilation,

Corrosive solid. Poisonous solid. Stop leak if without risk. Donot get water inside container. Do not touch spilled material.



Sr.No.



TLV/ PEL

EMP for STEL & IDLH

CAS#: 7446-70-0

prolonged exposure to thesubstance can produce targetorgans damage. Repeatedexposure of the eyes to a lowlevel of dust canproduce eye irritation. Repeatedskin exposure can produce localskin destruction, or dermatitis.Repeated inhalation of dust canproduce varying degree ofrespiratory irritation or lungdamage. Repeated exposure to ahighly toxic material mayproducegeneral deterioration of health byan accumulation in one or manyhuman organs.

or other engineeringcontrols to keep airbornelevels belowrecommendedexposure limits. If useroperations generate dust,fume or mist, useventilation to keepexposure to airbornecontaminants below theexposure limit.

Use water spray to reduce vapors. Prevent entry into sewers,basements or confined areas; dike if needed. Call for assistanceon disposal.

10. BenzylchlorideCAS#: 100-44-7

The substance is toxic tokidneys, lungs, the nervoussystem, liver, mucousmembranes. Repeated orprolonged exposure to thesubstance can produce targetorgans damage. Repeated orprolonged contact with spraymist may produce chronic eyeirritation and severe skinirritation. Repeated or prolongedexposure to spray mist may

Provide exhaustventilation or otherengineering controls tokeep the airborneconcentrations of vaporsbelow their respectivethreshold limit value.Ensure that eyewashstations and safetyshowers are proximal tothe work-station location.

Combustible material. Corrosive liquid. Keep away from heat.Keep away from sources of ignition. Stop leak if without risk.Absorb with DRY earth, sand or other non-combustiblematerial. Do not get water inside container. Do not touchspilled material. Use water spray curtain to divert vapor drift.Prevent entry into sewers, basements or confined areas; dike ifneeded.Call for assistance on disposal. Be careful that the product isnot present at a concentration level above TLV.



Sr.No.



TLV/ PEL

EMP for STEL & IDLH

produce respiratory tractirritation leading to frequentp. 2 attacks of bronchialinfection. Repeated exposure toa highly toxic material mayproduce general deterioration ofhealth by an accumulation in oneor many human organs.Repeated or prolongedinhalation of vapors may lead tochronic respiratory irritation.

11. CuprouschlorideCAS#: 7758-89-6

The substance is toxic tokidneys, lungs, liver, mucousmembranes. Repeated orprolonged exposure to thesubstance can produce targetorgans damage. Repeatedexposure of the eyes to a lowlevel of dust can produce eyeirritation. Repeated skinexposure can produce local skindestruction, or dermatitis.Repeated inhalation of dust canproduce varying degree ofrespiratory irritation or lungdamage. Repeated exposure toan highly toxic material mayproduce general deterioration ofhealth by an accumulation in one

Use process enclosures,local exhaust ventilation,or other engineeringcontrols to keep airbornelevels belowrecommended exposurelimits. If user operationsgenerate dust, fume ormist, use ventilation tokeep exposure to airbornecontaminantsbelow the exposure limit

Corrosive solid. Stop leak if without risk. Do not get waterinside container. Do not touch spilled material. Use waterspray to reduce vapors. Prevent entry into sewers, basementsor confined areas; dike if needed. Call for assistance ondisposal. Be careful that the product is not present at aconcentration level above TLV.



Sr.No.



TLV/ PEL

EMP for STEL & IDLH

or many human organs.12. Nitric acid

CAS#7697-37-2

The substance may be toxic tolungs, mucous membranes,upper respiratoryp. 2 tract, skin, eyes, teeth.Repeated or prolonged exposureto the substance can producetarget organs damage. Repeatedor prolonged contact with spraymist may produce chronic eyeirritation and severe skinirritation. Repeated or prolongedexposure to spray mist mayproduce respiratory tractirritation leading to frequentattacks of bronchial infection.

Provide exhaustventilation or otherengineering controls tokeep the airborneconcentrations of vaporsbelow their respectivethreshold limit value.Ensure that eyewashstations and safetyshowers are proximal tothe work-station location.

Corrosive liquid. Oxidizing material. Poisonous liquid. Stopleak if without risk. Absorb with DRY earth, sand or othernon-combustible material. Do not get water inside container.Avoid contact with a combustible material (wood, paper, oil,clothing...). Keep substance damp using water spray. Do nottouch spilled material. Use water spray curtain to divert vapourdrift. Use water spray to reduce vapors. Prevent entry intosewers, basements or confined areas; dike if needed. Call forassistance on disposal. Neutralize the residue with a dilutesolution of sodium carbonate. Be careful that the product is notpresent at a concentration level above TLV.

13. p-XyleneCAS#: 106-42-3

The substance is toxic to blood,kidneys, the nervoussystem, liver. Repeated orprolonged exposure to thesubstance can produce targetorgans damage.

Provide exhaustventilation or otherengineering controls tokeep the airborneconcentrations of vaporsbelow their respectivethreshold limits value.Ensure that eyewashstations and safetyshowers are proximal tothe work-station location.

Toxic flammable liquid, insoluble or very slightly soluble inwater. Keep away from heat. Keep away from sources ofignition.Stop leak if without risk. Absorb with DRY earth, sand orother non-combustible material. Do not get water insidecontainer.Do not touch spilled material. Prevent entry into sewers,basements or confined areas; dike if needed. Eliminate allignition sources. Call for assistance on disposal. Be carefulthat the product is not present at a concentration level aboveTLV.

14. ChlorineCAS #7782-

Toxic by inhalation. Irritating toeyes, respiratory system and

Use only with adequateventilation. Use process

Immediately contact emergency personnel. Keep unnecessarypersonnel away. Use suitable protective equipment. Eliminate



Sr.No.



TLV/ PEL

EMP for STEL & IDLH

50-5 skin. Very toxic to aquaticorganisms.

enclosures, local exhaustventilation orother engineering controlsto keep worker exposureto airborne contaminantsbelow anyrecommended or statutorylimits.

all ignition sources if safe to do so.Do not touch or walk through spilled material. Shut off gassupply if this can be done safely. Isolate area until gas hasdispersed.

15. SodiumCyanideCAS#: 143-33-9

The substance may be toxic toskin, eyes, central nervoussystem (CNS). Repeated orprolonged exposure to thesubstance can produce targetorgans damage. Repeatedexposure of the eyesto a low level of dust canproduce eye irritation. Repeatedskin exposure can produce localskin destruction, or dermatitis.Repeated inhalation of dust canproduce varying degree ofrespiratory irritation or lungdamage. Repeated exposure to ahighly toxic material mayproduce general deterioration ofhealth by an accumulation in oneor many human organs.

Use process enclosures,local exhaust ventilation,or other engineeringcontrols to keep airbornelevels belowrecommended exposurelimits. If user operationsgenerate dust, fume ormist, use ventilation tokeep exposure to airbornecontaminantsbelow the exposure limit.

Corrosive solid. Poisonous solid. Stop leak if without risk. Donot get water inside container. Do not touch spilled material.Use water spray to reduce vapors. Prevent entry into sewers,basements or confined areas; dike if needed. Eliminate allignition sources. Call for assistance on disposal. Be carefulthat the product is not present at a concentration level aboveTLV



7.8.1 LEAK DETECTION AND REPAIR (LDAR) PROGRAMLeak Detection and Repair (LDAR) is a program implemented to comply withenvironmental regulations for reducing the fugitive emissions of targeted chemicalsinto the environment. In addition to control fugitive emissions, LDAR Program alsohelps the industries to reduce unwanted losses of chemicals and thereby conservingenergy & increasing their profitability.

Following steps shall be followed for effective implementation of LDAR Program:1. Identification of volatile chemicals which may contribute in VOCs:

In proposed plant, following are the list of chemicals which may contribute inVOCs.

Bromine, Acetic acid, Methanol, Toluene, Isopropyl alcohol, Di methylsulphate, Hydrochloric Acid, Acetyl chloride, Sulfuric Acid, Acetone,Acetonitrile, Benzaldehyde, Liq. Ammonia (25 % Solution), Thionyl Chloride.

2. Identification of all the probable sources of leakage; such as valves, pumps,and connectors.List of the sources of probable leakage is as follows: Valves/Flanges Pump glands handling above chemicals Open vents from the tank top Pump seals Compressor seals Pressure relief devices Process drains LPDs (Low Point Drains) HPVs (High Point Vents)

A list of all such items shall be made and same shall be incorporated in thechecklist for LDAR.

3. Selection of appropriate method for leak detection:Considering the nature of the chemical; appropriate method shall be selected forleak detection of individual chemicals from the list given below: Visual Checks LEL meter VOC meter Gas Detector Chlroine Torch Ammonia torch Etc.

4. Scheduling and checklist for Leak Detection:All points shall be checked as per the checklist given below.

5. Methods for rectification of identified leaks:



For all identified leaks, closure shall be ensured with the help of maintenancedepartment and records for the same shall be maintained.



Checklist for implementation of LDAR Program to reduce emissions of VOCs.

NOTE: we have not addressed the recovery of solvents. You may prepare write up about maximizing the recovery of solvents toreduce emissions.

Records of leak detection have been maintained by client and are available at site.

Sr.No.

List ofSource ofleakage

Name ofChemical

Method ofleakcheck

FrequencyWeekly/Monthly /Quarterly

Checked on

Checkedby

Observations/Remarks

Leak to beattended by(Repair to bedone within 5working days)

Leakattended on

Closure Note



7.9 EXISTING FIRE PREVENTION & PROTECTION SYSTEM.

TABLE: 7.10EXISTING FIRE PREVENTION & PROTECTION SYSTEM

Department wise List of fireextinguishers with mapping ifavailable

Fire Extinguisher provided throughout the plant.Proposed fire extinguishers provided.

Fire hydrant system Fire hydrant system will be installed.

Fire and safety team Will be prepared and trained for the same activities.

Smoke detectors and gasdetectors

Smoke detectors and gas detectors (LEL % based) will beinstalled in drum storage area and tank area.

Nearest fire station GIDC fire station 1 km. away from the site and fire tenderreach time maximum 10 minutes

Fire prevention Flame proof electrical equipments provided in process andstorage area. Gas detectors will be provided in drum storagearea.

Environment control plan. Total close process adopted for process. Vent condenser andscrubber provided for toxic gas/vapour emission control.Loose handling of any chemicals will be restricted and spillcontrol plan will be prepared.

7.10 DO’S AND DON’T’S FOR STRENGTHENING HSE

DO’s

Wash affected part immediately with plenty of water. Take the patients affected by toxic vapour to well ventilated area. In case of vapor inhalation/gas poisoning, immediately render first aid to the

patient and then move the patient to First Aid Centre. In case of emergency everyone should try to reach at Assembly point. Move in

direction perpendicular to direction of gas leakage. In case of emergency all (except emergency staff) should reach at nearest

assembly point. In case of vapour inhalation/gas poisoning, immediately render first aid to the

patient and then move to First Aid Centre. Use ear plug/muff in high noise area. Work permit system to be followed before starting any hot work, vessel entry or

working at height. Barricade and mark hazardous/unsafe area Ensure use of safety belt while working at height. Electrical cables should be protected from water and from attack by corrosive

substances. Maintain good housing keeping, it will eliminate many unnecessary hazards. Protruding nail should be pulled out or bent over. All aisles, passage ways and stairways should be maintained, clean and

unobstructed. Employees must know the locations of fire extinguisher and fire exists.



During emergency be calm and do not get panicky.

DON’T’s

Smoking or carry cigarettes/bidis, match box, lighter, mobile phone or anyinstruments etc. in the plant/battery limit area. It is prohibited.

Unauthorized entry into battery limits of every plant is prohibited. Moving in the plant area without wearing safety helmet and safety shoes is not

permitted. Wearing of loose garments, ornaments etc. in the plant area. Cotton waste, paper, oil etc. should not be left in plant area. Do not follow shortcuts, use proper roads, pathways, wherever provided. Do not wear chappals or slippers in the plant. No automobile vehicle should be allowed to enter in the plant area without

muffler or exhaust. Chewing of tobacco, betel nut, chewing gum and other such items are not

allowed in any of process utility area.

7.11 HAZARD IDENTIFICATION

7.11.1 INTRODUCTION

Risk assessment process rests on identification of specific hazards, hazardousareas and areas vulnerable to effects of hazardous situations in facilitiesinvolved in processing and storage of chemicals.

In fact the very starting point of any such assessment is a detailed study ofmaterials handled & their physical / chemical / thermodynamic propertieswithin the complex at various stages of manufacturing activity. Such a detailedaccount of hazardous materials provides valuable database for identifyingmost hazardous materials, their behaviour under process conditions, and theirinventory in process as well as storage and hence helps in identifyingvulnerable areas within the complex.

Hazardous posed by particular installation or a particular activity can bebroadly classified as fire and explosive hazards and toxicity hazards. Whethera particular activity is fire and explosive hazardous or toxicity hazardousprimarily depends on the materials handled and their properties.

It will be from the above discussion that study of various materials handled isa prerequisite from any hazard identification process to be accurate. Based onthis study the hazard indices are calculated for subsequent categorization ofunits depending upon the degree of hazard they pose.

Identification of hazards is the most important step to improve the safety ofany plant. The hazard study is designed to identify the hazards in terms ofchemicals, inventories and vulnerable practices /operations.

The hazard evaluation procedures use as a first step by checklists and safetyreviews. Dow and Mond fire and explosion indices, which make use of past



experience to develop relative ranking of hazards, is also extensively used. Forpredictive hazard analysis, Hazard and Operability studies (HAZOP), Faulttree analysis, Event tree analysis, Maximum credible accident andconsequence analysis etc are employed.

7.11.2 IDENTIFICATION OF HAZARDOUS AREAS

Process plant is Batch process and multi utility base plant due to that at atime inventory of raw material at production area will be very less.

All raw material and finished product are stored warehouse in drums,Carboys and bags. Required material will be charged in process throughpump, drums in close circuit.

Batch size requirement chemicals will be charged in to day tank or reactorand empty drums will be sent back to drum shed for neutralization anddisposed off. Thus the inventory of the raw material in process area will belimited and for limited time.

Various raw materials used in the manufacturing processes are listed inchapter-2, Table-2.4 along with mode / type of storage & storage conditions.It can be readily seen that raw materials even though hazardous in nature,will be used in small quantities & storage quantities will also very low atprocess plant.

Drums will be stored in drum storage area as per petroleum rules. Maximumfive days running products raw material inventory will be kept in drumstorage area.

List of chemicals stored in larger quantities is provided in Table-7.4,hazardous properties are provided in Table-7.5 and Occupational healthimpact to employees and emergency action plan and its antidotes providedin Table 7.6

7.11.3 FAILURE FREQUENCIES

7.11.3.1 Hazardous material release scenarios can be broadly divided into 2 categories

I) Catastrophic failures which are of low frequency andII) ruptures and leaks which are of relatively high frequency.

Releases from failure of gaskets, seal, rupture in pipelines and vessels fall inthe second category whereas catastrophic failure of vessels and full borerupture of pipelines etc. fall into the first category.

7.11.3.2 Typical failure frequencies are given below

TABLE: 7.11TYPICAL FAILURE FREQUENCIES

Item Mode of failure Failure frequenciesAtmosphericstorage

Catastrophic failureSignificant leak

10-9 /yr10-5 /yr

Process Pipelines



< = 50 mm dia Full bore ruptureSignificant leak

8.8 x 10-7 /m.yr8.8 x 10-6 /m.yr

> 50 mm <=150mm dia Full bore ruptureSignificant leak

2.6 x 10-7 /m.yr5.3 x 10-6 /m.yr

< 150 mm dia Full bore ruptureSignificant leak

8.8 x 10-8 /m.yr2.6 x 10-6 /m.yr

Hoses Rupture 3.5 x 10-2 /m.yr

TABLE: 7.12ESTIMATED FREQUENCIES OF VAPOUR CLOUD EXPLOSION

TABLE: 7.13FAILURE RATES FOR PRESSURE STORAGE




8.8 x 10-7 /m.yr8.8 x 10-6 /m.yr


2.6 x 10-7 /m.yr5.3 x 10-6 /m.yr


8.8 x 10-8 /m.yr2.6 x 10-6 /m.yr







8.8 x 10-7 /m.yr8.8 x 10-6 /m.yr


2.6 x 10-7 /m.yr5.3 x 10-6 /m.yr


8.8 x 10-8 /m.yr2.6 x 10-6 /m.yr






Considering this, the risk analysis and consequences studies are concentrated onbelow area.

(a) Chlorine Tonner Storage area.(b) Bromine Bottle Storage area(c) Ammonia Cylinder Storage area(d) Hydrogen Cylinder Rack(e) Benzyl Chloride Storage Area(f) Drum Storage Area in Warehouse

7.12 RISK ASSESSMENT7.12.1 EFFECTS OF RELEASES OF HAZARDOUS SUBSTANCES

Hazardous substances may be released as a result of failures / catastrophes,causing possible damage to the surrounding area. In the following discussion,an account is taken of various effects of release of hazardous substances and theparameters to be determined for quantification of such damages.

In case of release of hazardous substances the damages will depend largely onsource strength. The strength of the source means the volume of the substancereleased. The release may be instantaneous or semi-continuous. In the case ofinstantaneous release, the strength of the source is given in kg and in semi-continuous release the strength of the source depends on the outflow time(kg/s.).

In order to fire the source strength, it is first necessary to determine the state ofa substance in a vessel. The physical properties, viz. Pressure and temperatureof the substance determine the phase of release. This may be gas, gascondensed to liquid and liquid in equilibrium with its vapour or solids.



















Instantaneous release will occur, for example, if a storage tank fails. Dependingon the storage conditions the following situations may occur.

The source strength is equal to the contents of the capacity of the storagesystem.

In the event of the instantaneous release of a liquid a pool of liquid will form.The evaporation can be calculated on the basis of this pool.

7.13 FIRE7.13.1JET FIRE

Jet fire causes damage due to the resulting heat radiation. The working levelheat radiation impact will vary widely depending on the angle of the flame tothe horizontal plane, which mainly depends on the location of the leak. Theflame direction was considered horizontal for consequence analysis of leaks andruptures from process equipment. Jet fire heat radiation impacts were estimatedfor the identified credible and worst case scenarios.

Upon accidental leakage, the pressurized fluid will disperse as a jet, initiallymoving forward in the spatial direction of the leak till the kinetic energy is lostand gravity slumping or lifting of the cloud occurs, dependent upon whether thefluid is heavier or lighter than air.

7.13.2POOL FIRE

In the event of the instantaneous release of a liquid a pool of liquid will form.The evaporation can be calculated on the basis of this pool.

The heat load on object outside a burning pool of liquid can be calculated withthe heat radiation model. This model uses average radiation intensity, which isdependent on the liquid. Account is also taken of the diameter-to-height ratio ofthe fire, which depends on the burning liquid. In addition, the heat load is alsoinfluenced by the following factors:

Distance from the fire

The relative humidity of the air (water vapour has a relatively high heat-absorbing capacity)

The orientation i.e. horizontal/vertical of the objective irradiated with respectto the fire.

7.13.3FLASH FIRE

The vapour / gas release from a pool would disperse under the influence of theprevailing wind; with material concentration in air reducing with distance. At aparticular location downwind, the concentration will drop below its lowerflammable level (LFL) value. If ignited within the flammable envelope, themass of the material available between the LFL and ½ LFL will be likely to



burn as a flash fire; rapidly spreading through the cloud from the point ofignition back to the source of release.

Although flash fires are generally low intensity transitory events, the burningvelocity is quite high and escape following ignition is not possible. Flash firesoften remain close to the ground, where most ignition sources are present. It isassumed that personnel caught inside a flash fire will not survive while thoseoutside suffer no significant harm. If other combustible material is presentwithin the flash fire it is also likely to ignite and a secondary fire could result.

7.14 EXPLOSION7.14.1 LATE EXPLOSION (UVCE)

The magnitude of the vapour cloud explosion is dependent on the size of the gascloud that has formed and the degree of congestion in the area, as thesedetermine the acceleration of the flame front.

The TNO GAMES model is used for modeling of vapour cloud explosions, asthe model incorporates the characteristics of the explosion, such as the type offuel, its reactivity, the effect of obstacles in the congested region, etc.Turbulence is the governing factor in blast generation, which could intensifycombustion to the level that will result in an explosion. Obstacles in the path ofvapour cloud or when the cloud finds a confined area, as under the bullets, oftencreate turbulence. Insignificant level of confinement will result in a flash fire.The VCE will result in overpressures.

It may be noted that VCEs have been responsible for very serious accidentsinvolving severe property damage and loss of lives. Vapour Cloud Explosionsin the open area with respect to Pure Methane is virtually impossible due totheir lower density.

7.14.2 Ball Fire / BLEVE

This happens during the burning of liquid, the bulk of which is initially overrich (i.e. above the upper flammable limit.). The whole cloud appears to be onfire as combustion is taking place at eddy boundaries where air is entrained (i.e.a propagating diffusion flame). The buoyancy of the hot combustion productsmay lift the cloud form the ground, subsequently forming a mushroom shapedcloud. Combustion rates are high and the hazard is primarily thermal.

7.15 MODES OF FAILURE

Liquid release due to catastrophic failure of storage vessel or road tanker. Liquid release through a hole/crack developed at welded joints/flanges /

nozzles / valves etc. Vapour release due to exposure of liquid to atmosphere in the above

scenarios. Gas release due to catastrophic failure of Ammonia cylinder or outlet

valve/line failure.



Event Causes

Tank on Fire/ - Catastrophic failure of tank + Ignition availabilityPool fire - Failure of liquid outlet line + Ignition availabilityFire Ball/BLEVE - Catastrophic failure of road tanker/ storage tankFlash Fire Vapour generation due to substrate and windUVCE Vapour cloud generation and about 15 % of

total vapour mass Above the UEL-LEL % Ignitionavailability

Toxic gas dispersion - Toxic Gas release due to catastrophic failure oftonner/bullet/Tanks and ignition not available within LEL- UEL

range.

Considering the quantity of storages & nature of Toxic nature and Flammablestorage, following scenarios were taken up for detailed analysis & safe distancescomputed:

Failure cases considered for consequence analysis are representative of worst-case scenarios. Probability of occurrence of such cases is negligible (less than 1x 10-6 per year) because of strict adherence to preventive maintenanceprocedures within the complex. General probabilities for various failure isprovided in Table-4.2, 4.3 and 4.4, but consequences of such cases can be grave& far reaching in case such systems fail during life history of the company.Hence such scenarios are considered for detailed analysis. It is to be notedhowever that such situations are not foreseeable or credible as long as sufficientmeasures are taken. Also, consequence analysis studies help us evaluateemergency planning measures of the Company.

7.16 IMPACT CRITERIA

Consequence assessment is conducted to understand the impact of identifiedscenarios in terms of Thermal radiation (Jet fire, Flash Fire), Explosion (vaporcloud explosion- UVCE). A range of potential consequences are assessed foreach of the release scenarios identified. This step identifies the fatalityprobability, based on hazard type and caused by each release case, to personnelat a range of distances.

Estimate of damage or impact caused due to thermal radiation, explosionoverpressure and toxic effects is generally based on the published literature onthe subject. The actual potential consequences from these likely impacts canthen be visualized by superimposing the damage effect zones on the proposedlayouts and identifying the elements within the project which might beadversely affected, should one or more hazards materialize in practice. Thedamage criteria used in the present study is described in the following sections.

7.17 DAMAGE CRITERIA FOR HEAT RADIATION

Damage effects vary with different scenarios. Calculations for various scenarios

are made for the above failure cases to quantify the resulting damages.



The results are translated in term of injuries and damages to exposed personnel,

equipment, building etc.

Tank on fire /Pool fire due to direct ignition source on tank or road tanker or

catastrophic failure or leakage or damage from pipeline of storage facilities or

road tanker unloading arm, can result in heat radiation causing burns to people

depending on thermal load and period of exposure.

All such damages have to be specified criteria for each such resultant effect, to

relate the quantifier damages in this manner, damage criteria are used for Heat

Radiation.

TABLE: 7.14PRACTICAL SIGNIFICANCE OF RADIATION INTENSITY

HeatRadiation(kW/m2)

Damage to Equipment Damage to People

1.2 Solar Heat at Noon

1.6 --- Minimum Level of pain threshold

2.0 PVC insulated cables damaged ---

4.0 --- Causes pain if duration is longer than20 seconds. Blistering is unlikely.

4.5 --- Blistering of skin

6.0 --- First degree burn

9.5 --- Pain threshold reached after 8 seconds.Second degree burns after 20 seconds.

12.0 --- Initiation of secondary fires

12.5 Minimum energy to ignitewood with a flame; Meltsplastic tubing.

First degree burns in ten seconds.1% Fatality in 20 sec,30% Fatality in 30 seconds.

16.0 --- Severe burns after 5 seconds.

21.2 --- 1% Fatality in 10 seconds, withprotection of clothing

25.0 Minimum energy to ignitewood at indefinitely longexposure without a flame.

100 % Fatality in 1 (one) minute.

27 -- Third degree burns (30secs)

30.0 Damage to plant & machinery --

37.5 Severe damage to plant 100 % Fatality



7.18 CONSEQUENCE ANALYSIS7.18.1 CONSEQUENCE ANALYSIS

In the risk analysis study, probable damages due to worst case scenarios werequantified and consequences were analyzed with object of emergency planning.Various measures taken by the company and findings of the study wereconsidered for deciding acceptability of risks.

7.18.2 THE CATASTROPHIC/ RUPTURE FAILURE AND MAXIMUMCREDIBLE LOSS SCENARIOS (MCLS) IDENTIFIED FOR PLANT BASEON ABOVE CRITERIA IS LISTED BELOW

TABLE: 7.15THE CATASTROPHIC/ RUPTURE FAILURE AND MAXIMUMCREDIBLE LOSS SCENARIOS (MCLS) IDENTIFIED FOR PLANT BASEON ABOVE CRITERIA IS LISTED BELOW

Sec. No. Scenario Description

StorageConditi

on(A/G or

U/G)

Material

Equipments

Capacit

yKL

/MT

OperatingPressure

Kg/cm2 &temperatu

re 0C

1Benzyl Chloride 20 KL

Storage Tank CatastrophicRupture

A/G

Benzyl

Chloride

Storage Tank

20KL

ATP1.1 Pool Fire1.2 Flash Fire

2Benzyl Chloride 20 KL

Storage Tank Short PipelineRupture

2.1 Pool Fire

3Chlorine 900 Kg Tonner

Catastrophic Rupture

A/GChlori

neTonner

900Kg

4-10Kg/cm2

3.1Maximum concentration

Footprint

4Chlorine 900 Kg Tonner 10mm Short pipeline Rupture


Footprint

5Chlorine 900 Kg TonnerVapor Leakage from line

Flange


Footprint

6Chlorine 900 Kg TonnerFixed Duration Release

6.1 Maximum concentration



Sec. No. Scenario Description

StorageConditi

on(A/G or

U/G)

Material

Equipments

Capacit

yKL

/MT

OperatingPressure

Kg/cm2 &temperatu

re 0C

Footprint

7Ammonia 40 Kg Cylinder

Catastrophic Rupture

A/GAmmonia

Cylinder

40Kg

8 Kg/cm2

7.1Maximum Concentration

Footprint


10 mm Short pipelineRupture


Footprint


Fixed Duration Release


Footprint

10Bromine 18 kg Glass BottleCrate Catastrophic Rupture

A/GBromi

ne

GlassBottleCrate

18Kg

ATP10.1

Maximum Concentrationfootprint

11Hydrogen Gas Cylinder

1100 M3 Rack CatastrophicRupture

A/GHydro

gen

GasCylind

erRack

1100

M3150 bar

11.1

Fire Ball

11.2

Flash Fire

11.3

Late Explosion worst case

12Hydrogen Gas Cylinder

1100 M3 Rack ShortPipeline Rupture

12.1

Jet Fire

12.2

Late Explosion worst case

13 Ware House Fire

A/G

Warehouse

Storage

DrumStorag

e

80KL

ATP13.1

Drum Storage - Pool Fire

13.2

Drum Storage - BLEVE



TABLE: 7.16CONSEQUENCE RESULTS DISTANCE IN METER

Sr.No.

Scenario Failure Case

Pool FireRadiation Intensity

( Kw / M2)

Flash Fire(ppm)

37.5 12.5 4.011000ppm

5500ppm

1Benzyl

Chloride 20 KLStorage TankCatastrophic

Rupture

CatastrophicRupture

5.88 15.02 26.22 NR 4.26

2Short

PipelineRupture

5.07 10.86 17.05 NR NR

Sr.No.


Maximum Concentration footprint(ppm)

1017ppm

LC-50Distance

500ppm

100ppm

10 ppmIDLH

Distance

3

Chlorine 900Kg Tonner

Catastrophic Rupture 200.3 260.5 478.1 2977

410 mm Short pipeline

Rupture84.10 144.9 381.5 1814

5Vapor Leakage from

line FlangeNR NR 193.52 1485

6Fixed Duration

Release163.1 234.2 491.2 850.3

Sr.No. Scenario Failure Case


1000ppm

500ppm

300ppm 25 ppm

7

Ammonia 40 KgCylinder

Catastrophic Rupture 100.1 129.4 155.8 1144

810 mm Short pipeline

Rupture122.4 222.5 299.5 609.8

9Fixed Duration

Release78.53 153.7 234.3 756.5

Sr.No.



1075ppm

500ppm

100ppm

3 ppmIDLH

Distance

10Bromine 18 kg

Glass BottleCrate

Catastrophic Rupture 12.82 16.07 37.47 329.58



Sr.No.

Scenario

FailureCase

FlashFire

(ppm)

Jet FireRadiationIntensity( Kw/ M2)

Late ExplosionWorth case

UVCE

Fire BallRadiationIntensity

( Kw / M2)40000ppm

20000ppm

37.5

12.5 4.0

0.2068bar

0.1379bar

0.02068bar

37.5

12.5 4.0

11Hydro

genGas

Cylinder

1100M3

Rack

Catastrophic

Rupture

85.20

129.4

NR

NR

NR268.

4327.

01385

170.5

297.5

512.9

12

ShortPipelin

eRupture

NR NRNR

7.97

10.07

24.56

26.10

51.41

NR NR NR

Sr.No.


Pool FireRadiation Intensity

( Kw/ M2)

Fire Ball / BLEVERadiation Intensity

( Kw/ M2)37.5 12.5 4.0 37.5 12.5 4.0

13Ware

House FireDrum Storage

Area Fire12.45 19.78 30.76 15.85 20.85 71.26



7.18.3 CONCLUSION

FLASH FIRE CASES

The highest damage distances for flash fire are for isolatable is Scenario ofHydrogen Gas Cylinder 1100 M3 Rack Catastrophic Rupture at 1.5F weathercondition. The maximum damage distance for Flash Fire is 85.20 meter (40000ppm) & 129.4 meter (20000 ppm) – 1.5F of whether condition. . UFL isdefined as burning zone, which means people caught within the burning zoneare exposed to a fatality rate of 100%.

JET FIRE

As can be seen from the results of the summary of the Quantitative RiskAnalysis study, the Fatality distance due to Scenario of Hydrogen Gas Cylinder1100 M3 Rack Short Pipeline Rupture of NR meter at 37.5 Kw/M2 , 7.97meter at 12.5 Kw/M2 and 10.07 Meter at 4.0 Kw/M2.

POOL FIRE

As can be seen from the results of the summary of the Quantitative RiskAnalysis study, the Fatality distance due to Scenario 11 Drum Storage AreaCatastrophic Rupture at dispersion of 23.1 meter at 37.5 Kw/M2, 40.0 meter at12.5 Kw/M2 and 70.0 Meter at 4.0 Kw/M2.

FIREBALL – BLEVE

As can be seen from the results of the summary of the Quantitative RiskAnalysis study, the Fatality distance due to Scenario 5.2 Mono Ethyl Amine 20KL Storage Tank Catastrophic Rupture at dispersion of 88.2 meter at 37.5Kw/M2, 172.1 meter at 12.5 Kw/M2 and 279.3 Meter at 4.0 Kw/M2.

LATE EXPLOSION WORTH CASE - UVCE

As can be seen from the results of the summary of the Quantitative RiskAnalysis study, the Fatality distance due to Scenario of Methyl Chloride (R-40)200 KL Storage Tank Catastrophic Rupture at 1.5F weather condition. Themaximum damage of 12.45 meter at 0.2068 bar, 19.78 meter at 0.1379 barand 30.76 meter at 0.02068 bar.

Fireball – BLEVE

As can be seen from the results of the summary of the Quantitative RiskAnalysis study, the Fatality distance due to Scenario of Hydrogen Gas Cylinder1100 M3 Rack Catastrophic Rupture at 1.5F weather condition. The maximumdamage Fire dispersion of 170.5 meter at 37.5 Kw/M2, 297.5 meter at 12.5Kw/M2 and 512.9 Meter at 4.0 Kw/M2.

Maximum concentration footprint



As can be seen from the results of the summary of the Quantitative RiskAnalysis study, the Fatality distance due to Scenario Chlorine 900 Kg TonnerCatastrophic Rupture toxic release dispersion of 200.3 meter at 1017 ppm(LC-50 Distance) , 260.5 meter at 500 ppm, 478.1 meter at 100 ppm and2977 meter at 10 ppm (IDLH Distance).

7.19 RISK REDUCTION MEASURES

7.19.1 RECOMMENDATIONS

From the Risk Analysis studies conducted, it would be observed that by and large, therisks are confined within the factory boundary walls in case of fire, explosion. In caseof toxic release scenarios it may be affect outside the factory premises. On siteemergency plan & preparedness plan is prepared and implemented to combat suchsituations. To minimize the consequential effects of the risk scenarios, following stepsare recommended.

Plant should meet provisions of the Manufacture, storage & Import ofHazardous Chemicals Rules, 1986 & the factories Act, 1948.

Process hazard analysis is carried out for existing products. Emergency handling facility like chlorine KIT, Hood, Blower for chlorine

available at site. Bromine handling procedure provided in report to beimplemented.

Fire water and sprinklers to be provided in plant premises. Emergency handling facilities to be maintained in tip top condition at all

time. Safe operating procedure to be prepared for hazardous process and material

handling process. Safety devices and control instruments to be calibrated once in a year. Proper colour work as per IS 2379 to plant pipeline and tank, equipments to

be done once in a six month to protect from corrosion. Preventive maintenance schedule to be prepared for all equipments. Permit to work system to be implemented 100 % for hazardous work in the

plant. Safety manual as per Gujarat Factories Rule-68 K & P and Public

awareness manual as per Gujarat Factories Rule 41 B & C needs to beprepared and distributed to all employees and nearby public.

Fire & Safety organization setup to be planed and implement for batterplant process safety.



7.19.2 COSEQUENCE CONTOURSFIGURE: 7.3Benzyl Chloride 20 KL Storage Tank Catastrophic Rupture - Flash Fire.

FIGURE: 7.4Benzyl Chloride 20 KL Storage Tank Short Pipeline Rupture – Pool Fire

FIGURE: 7.5Chlorine 900 Kg Tonner Catastrophic Rupture - Maximum concentrationFootprint



FIGURE: 7.6Chlorine 900 Kg Tonner 10 mm Short pipeline Rupture - Maximumconcentration Footprint

FIGURE: 7.7Chlorine 900 Kg Tonner Vapor Leakage from line Flange - Maximumconcentration Footprint



FIGURE: 7.8Chlorine 900 Kg Tonner Fixed Duration Release - Maximum concentrationFootprint

FIGURE: 7.9Ammonia 40 Kg Cylinder Catastrophic Rupture - Maximum concentrationFootprint



FIGURE: 7.10Ammonia 40 Kg Cylinder 10 mm Short pipeline Rupture - Maximumconcentration Footprint



FIGURE: 7.11Ammonia 40 Kg Cylinder Fixed Duration Release - Maximum concentrationFootprint

FIGURE: 7.12Bromine 18 kg Glass Bottle Crate Catastrophic Rupture - Maximumconcentration Footprint



FIGURE 7.13Hydrogen Gas Cylinder 1100 M3 Rack Catastrophic Rupture – Fire Ball

FIGURE: 7.14Hydrogen Gas Cylinder 1100 M3 Rack Catastrophic Rupture – Flash Fire



FIGURE: 7.15Hydrogen Gas Cylinder 1100 M3 Rack Catastrophic Rupture - LateExplosion worst case

FIGURE: 7.16Hydrogen Gas Cylinder 1100 M3 Rack Short Pipeline Rupture – Jet Fire



FIGURE: 7.17Hydrogen Gas Cylinder 1100 M3 Rack Short Pipeline Rupture – LateExplosion worst case

FIGURE: 7.18

Warehouse Drum 80 KL storage Catastrophic Rupture – Pool Fire



FIGURE: 7.19Warehouse Drum 80 KL storage Catastrophic Rupture – Fire Ball - BLEVE



7.20 SCENARIO BASED ON SITE AND OFF SITE EMERGENCY PLANTABLE NO: 7.17

POSSIBLE EMERGENCY: - DRUM SPILLAGE IN DRUM STORAGE AREA. (SPILL CONTROL PLAN)

Locatio

n

Scenario

considered

HazardConsequen

ce

PossibleCauses

Action to be taken Action by Remedial measures to preventrecurrence of such incident

(1) (2) (3) (4) (5) (6) (7)Drumstoragearea

Smallspillage

Largespillage

Toxicvapourexposure todrumhandlingoperators.

Fire in caseof ignitionsourceavailablewithin LEL-UEL %concentration

Drum puncheror damage,wrong storagemethod.

Find out leakage drum

Raised alarm immediately for warning thepeople if large spillage observed.

Do not entre in confined room if spillage inroom.

Do not touch any electrical switches in spillagearea.

Stop all hot work in this area.

Call fire and Safety department

Cordon the area.

Evacuate non essential persons from theaffected area immediately.

Inform the area in charge.

Incidentcontroller

IC

IC

IC anddepartmentteam

IC

Security team

Non essentialworkers

IC

IC

1. FLP type light fittings provided.2. Proper ventilation is available in

Drum storage area.3. Proper label and identification

board /stickers is provided in thestorage area.

4. Conductive drum pallets areprovided.

5. Drum handling trolley /stackers/fork lift are used fordrum handling.

6. Separate dispensing room withlocal exhaust and static earthingprovision is available.

7. Materials are stored as per itscompatibility study and separatearea is available for flammable,corrosive and toxic chemicaldrums storage.

8. Smoking and other spark, flamegenerating item are banned fromthe Gate.

9. NFPA labels are provided on



Try to control situation at department level withavailable resources with full PPEs.

Identify the spillage material and refer MSDSfor control plan.

Segregate leakage drum from the area.

Inform the Site main Controller (SMC) indetail.

Open all doors and windows in this area.

Take decision to Declare onsite emergency

Spill control and neutralization team membertry to control spread material in more area byabsorbing material and dry sand.

If material is toxic or any other flammable andtoxic chemical, special precautions needs to betaken as per chemical expert Key person guideline.

Do not spray water or Foam on spilled material.Do not drain spilled material in any trench.

Collect the spilled material in close containerand send for ETP for further neutralization ofthe residual contents.

IC

Dept. Toxiccontrol team

IC

Dept. Toxiccontrol team

SMC

Toxic/Spillcontrol team


Fire team



drums for hazard identificationof the chemicals.

10. Exhaust is provided atground level in drum storagearea.

11. Drum loading unloadingprocedures are prepared andimplemented.



Ensure search and rescue and causalities receiveattention.

Administer first aid to the victim.

Make arrangement to send injured person/s toHospital.

If off site emergency situation occur –Inform tofollowing agencies, Request for Mutual aiders,local authorities like – DISH office,Collectorate office, Disaster management cell,Police, fire brigade, nearby hospital, localGPCB office

Rescue team

First Aid team

Administrationteam.

SMC

TABLE: 7.18POSSIBLE EMERGENCY: - FIRE IN DRUM STORAGE AREA

Locatio

n

Scenario

considered

HazardConsequ

ence

PossibleCauses

Action to be taken Action by Remedial measures toprevent recurrence of

such incident

(1) (2) (3) (4) (5) (6) (7)Drumstoragearea

Smallspillage

Largespillage

Fire indrumstoragearea

BLEVEof drums

Drumleakageordamage,wrongstoragemethod.

Raise fire siren or shouting Fire…Fire….Fire…

Evacuate the area immediately.

Inform the area in charge.Inform IC in detail.

Call fire department immediately and help them for fire fighting.

First Observer

All employeesin this area

First observer

Department

1. FLP type light fittingsprovided.

2. Proper ventilation isavailable in Drumstorage area.

3. Proper label andidentification board/stickers is provided



Ignitionsourcelikeelectrical source,Frictionetc.

BLEVEdue toMetaldrumheat infire.

Try to control situation at department level with available resourceswith full PPEs.

If it is found uncontrollable condition by department level informSMC for onsite emergency situation.

Declare on site emergency if required.

Remove un burned drums from the site if possible without any risk.

Start fire hydrant system or water hose rill and spray water onuninvolved drums in fire for cooling purpose.

Use foam fire extinguishers for firefighting of fire.Do not enter in fire prone area.

If fire found uncontrollable condition call fire brigade and mutualaider for help.

In case of BLEVE fire, immediate evacuate the area up to 50meters of the area surrounding.All hazardous activates stop at site.

Inform nearby company to remove hazardous material or inventoryfrom the compound wall.

Ensure search and rescue and causalities receive attention.

Administer first aid to the victim.Make arrangement to send injured person/s to Hospital. And informvictim’ s family.

employeeIC

Department firefighting team.

IC

SMC

Rescue andevacuation teamFire team

Fire team

All teammember

SMC

All teammember

SMC and alldept. head.

SMC

in the storage area.4. Conductive drum

pallets are provided.5. Drum handling

trolley / stackers/forklift are used for drumhandling.

6. Separate dispensingroom with localexhaust and staticearthing provision isavailable.

7. Materials are storedas per itscompatibility studyand separate area isavailable forflammable, corrosiveand toxic chemicaldrums storage.

8. Smoking and otherspark, flamegenerating item arebanned from theGate.

9. NFPA labels areprovided on drumsfor hazardidentification of thechemicals.

10. Exhaust is providedat ground



If off site emergency situation occur –Inform to following agencies.

Request for Mutual aiders, local authorities like – DISH office,Collectorate office, Disaster management cell, Police, fire brigade,nearby hospital, local GPCB office

Rescue team

First Aid team

AdministrationteamSMC

level in drumstorage area.

11. Drum loadingunloadingprocedures areprepared andimplemented.

TABLE NO: 7.19

POSSIBLE EMERGENCY: - BROMINE BOTTLE DAMAGE SPILLAGE SCENARIO

Locatio

n

Scenario

considered

HazardConsequen

ce

PossibleCauses


(1) (2) (3) (4) (5) (6) (7)Bromine3 kgbottledamagespill

Spillpoolevaporative

Toxicfumesrelease indown winddirection atLC 50 ,IDLH &TLVconcentration

Health effectto nearbyvicinity people

Raised alarm immediately for warning thepeople.

Call the emergency response number (Areaincharge)


Try to control situation at department level withavailable resources.

First observer

IncidentController (IC)


IC

Department



1. As an immediate precautionary measure,isolate a bromine spill and leak area inall directions for at least 60 meters.

2. Consider taking steps to protect peopledownwind of the bromine spill throughevacuation. For daylight hours theprotection can extend up to 0.6 kmdownwind from the spill. During night-time the protection zone can extend upto 1.8 km.

3. Only trained chemical emergencyresponders should be allowed to cleanup the spill.

4. Professional responders should alwayswear correct personal protectiveequipment when dealing with abromine spill.

5. Neutralising chemicals should be insmall quantities incrementally as needed(i.e - do NOT dump large amounts ofneutralising chemicals onto spilledbromine all at once).

6. Wash the container afterwards using abrush and neutralizing solution followedby a water rinse.


Declare onsite emergency

Toxic controltrained team.


SMC

Toxic team

Fire and toxiccontrol team

Fire and toxic



Barricade and restrict movement in affectedarea.

Provide curtain in down wind direction torestrict dispersion.

Spray Dil. Ammonia solution on gas cloud ofbromine vapour

OR

Spread Sodium thio sulphate powder on liquidchlorine spillage.




If off site emergency situation occur –Inform tofollowing agencies

Request for Mutual aiders, local authorities like– DISH office, Collectorate office, Disastermanagement cell, Police, fire brigade, nearbyhospital, local GPCB office

control team


Rescue team

First aid team

First aid team

SMC



TABLE: 7.20

Possible Emergency:- Chlorine tonner catastrophic failure puff release scenario

Locatio

n

Scenario

considered

HazardConsequen

ce

PossibleCauses


(1) (2) (3) (4) (5) (6) (7)Chlorinetonnerstorageshed

Puffreleasefromchlorinetonner

Toxicrelease indown winddirection atLC 50 ,IDLH &TLVconcentration

Fatality tohuman up to________

Immediatedanger tolife andhealth(IDLH)Distance__________mi.e.

Over pressuredue to temp.increase

Reaction intonner withincompetitivematerial.

Evacuate the surrounding area up to _____ m infactory premises.




Inform the area incharge

Try to control situation at department levelwith available resources.



Start blower

Incidentcontroller (IC)

IC

IC


First observer


IC

SMC

Toxic team

Store tonner in dry and coolplace

Check tonner condition beforeunloading in our premises.

Hydrolic test certificate, testingdate and due date to be checkedat site.

NRV and reversed flow controlto be provided on header.

Distance to be kept between twotonners.

Blower with scrubber andpipeline to be providedsurrounding storage shed toabsorbed chlorine gas.

Chlorine gas detectors to beprovided in storage area.



Evacuationarea

Safedistance_________m

Barricade and restrict movement in affectedarea.

Provide Mayur curtain in down wind directionto restrict dispersion.

Spray Dil. Ammonia solution on gas cloud ofchlorine.

OR

Spread Sodium thiosulphate powder on liquidchlorine spillage.




If off site emergency situation occur –Inform tofollowing agenciesRequest for Mutual aiders, local authorities like– DISH office, Collectorate office, Disastermanagement cell, Police, fire brigade, nearbyhospital, local GPCB office

Security staff




Rescue team

First aid team

First aid team

SMC



TABLE: 7.21Possible Emergency: - Chlorine tonner catastrophic failure Point source release scenario

Locatio

n

Scenario

considered

HazardConsequen

ce

PossibleCauses


(1) (2) (3) (4) (5) (6) (7)Chlorinetonnerstorageshed

Pointsourcereleasefromchlorinetonnerliquid/Gasphasevalve

Toxicrelease indown winddirection atLC 50 ,IDLH &TLVconcentration

Fatality tohuman up to________

Immediatedanger tolife andhealth(IDLH)Distance__________mi.eEvacuationarea

Connectingtube 100 %leakage

Gas phase /liquid Valveleaking

Pipe lineleakage

Rupture ofpipeline

Evacuate the surrounding area up to _____ m infactory premises.

Inform the area incharge




Try to control situation at department levelwith available resources.



Start blower

Barricade and restrict movement in affected

Incidentcontroller (IC)

First observer

IC

IC



IC

SMC

Toxic team

Security staff

Store tonner in dry and coolplace

Check tonner condition beforeunloading in our premises.

Hydrolic test certificate, testingdate and due date to be checkedat site.

NRV and reversed flow controlto be provided on header.

Distance to be kept between twotonners.

Blower with scrubber andpipeline to be providedsurrounding storage shed toabsorbed chlorine gas.

Chlorine gas detectors to beprovided in storage area.



Safedistance_________m

area.

Applied chlorine kit to control leakage fromvalve

Provide Mayur curtain in down wind directionto restrict dispersion.

Spray Dil. Ammonia solution on gas cloud ofchlorine.ORSpread Sodium thiosulphate powder on liquidchlorine spillage.




If off site emergency situation occur –Inform tofollowing agenciesRequest for Mutual aiders, local authorities like– DISH office, Collectorate office, Disastermanagement cell, Police, fire brigade, nearbyhospital, local GPCB office

Toxic controlteam




Rescue team

First aid team

First aid team

SMC



TABLE: 7.22

Possible Emergency: - Major electrical fire in HT/LT panel, cable trench, cable tray, electrical equipments.Location

Scenarioconsidere

d

Hazard

Consequenc

e

Possible Causes Action to be taken Action by Remedial measures toprevent recurrence of

such incident

(1) (2) (3) (4) (5) (6) (7)Plantarea

Fire inpanel,cable,cabletrench,electricalequipments likemotor, etc.

Fire Electrocution andflashing due to shortcircuit or over load

Raise fire siren or shouting Fire…Fire….Fire… First observer 1. Safety measures takenat design level andfacilities installed asper requirements andelectrical load.

2. Double earthingprovided to allelectrical equipments.

3. Rubber met providednear electrical panelsand switches.

4. All safety measurestaken at design stage.

5. Magger test andearthing continuity testregularly carried outand log sheetmaintained.

6. All electricalhazardous conditionknown to all concern

Evacuate the area immediately. Non essentialworkers.

Inform the area in charge. Departmentemployee

Inform IC/ SHE Manager in detail. Departmentemployee

OFF electrical supply in fire porn area. Electrical head

Call fire department immediately and help themfor fire fighting.

DepartmentemployeeIC/ SHEManager

Try to control situation at department level withavailable resources with full PPEs.

Department firefighting team.

If it is found uncontrollable condition bydepartment level inform SMC for onsiteemergency situation.

IC/ SHEManager

Declare on site emergency if required. SMC



Start fire hydrant system and spray water on fire. Fire team dept.7. Appropriate fire

fighting arrangement isprovided to controlelectrical fire.

Do not enter in fire prone area. Due to toxic gasliberate in cable fire.

All teammember

Remove combustible and flammable materialfrom the fire site.

Rescue team

If fire found uncontrollable condition call firebrigade and mutual aider for help.

SMC

All hazardous activates stop at site. SMC and alldept. head


Rescue team

Administer first aid to the victim. First aid team

Make arrangement to send injured person/s toHospital. And inform victim’s family.

Administrationteam

If off site emergency situation occur –Inform tofollowing agencies.Request for Mutual aiders, local authorities like –DISH office, Collectorate office, Disastermanagement cell, Police, fire brigade, nearbyhospital, local GPCB office.

SMC



TABLE: 7.23Possible Emergency: - Leak from flanges, valves, during transfer from/to main tank.

Location

Scenarioconsider

ed

HazardConsequen

ce


such incident(1) (2) (3) (4) (5) (6) (7)

Pipelinenetwork

Spillage Fire,spillage,corrosion,burn effecton human.

Gasket failure,corrosion,impropermaintenance.

Detect the source of leakage. Maintenanceteam

Proper PMS systemprepared and implemented.

If the leakage is found significant then isolatebranch of line & stop the flow.

Maintenanceteam

Stop the loading /unloading operation in the Tank Maintenanceteam

Bring the portable fire extinguishers near to thearea of leakage

Maintenanceteam

Ensure operation of the fire pump Fire team

In case of major leakage follow action plan as perspill control plan.

-

TABLE: 7.24Possible Emergency: - Earth Quack

Location

Scenarioconsider

ed

HazardConsequen

ce


such incident(1) (2) (3) (4) (5) (6) (7)

Wholeplant

Earthquack

Building,structurecollapse,

Natural calamities Do not panic. Raise alarm. First observer Planning & Preparedness1. Constitute Emergency

Response TeamEvacuate building /plant immediately. All employees



groundshaking,

Landslides,Liquefaction,

surfacerupture

Avoid standing near to windows, external walls. All employees 2. Identify control centers3. Control centers to be

equipped with4. Communication

facilities5. Emergency vehicles/

equipment6. List of emergency

contacts & suppliers7. Medical facilities

Stand near the columns or duck under sturdyfurniture.

All employees

Assemble at emergency assembly point. All employees

Take head count HR dept. / SHE

Activate plant emergency plan as situationdemands.

SMC

Assess situation and initiate shut down of plants(if required)

SMC and planthead

Initiate search & rescue (if required) Rescue team

Provide first aid to victims. Remove casualtiesKey persons to report to site

First aid team

Assess damage Key personals

Undertake restorative measures & repairs Engg. Team

TABLE: 7.25Possible Emergency: - Floods:

Besides this, flooding of plants during monsoon due to clogging of storm water drains/ outlets may also take place. The plan to dealwith floods can be divided in following stages:

Location

Scenarioconsider

ed

HazardConsequen

ce

Possible Causes Action to be taken Action by Remedial measures to preventrecurrence of such incident

(1) (2) (3) (4) (5) (6) (7)Whol Floods Flash Natural calamities Stop all field activities. IC Check



eplant

Flooding,Flash ,

RiverFlooding,

BurnScars/Debris Flows,

Ice/DebrisJams,

Snowmelt, Dry Wash, Dam

Breaks/Levee Failure

Stop all permits to work. IC 1. All storm water drains & outlets arecleaned & de-choked.

Constitute2. Plant Emergency Response Team

comprising of (at least) one engineer,one HSE member, two operators &one Electrician.

3. Civil & Mechanical support team(including supply of spares).

Maintain4. Inventory of emergency items such as

torches, ropes, lines, wire, tarpaulins,plastic sheets, tool kits, duct tapes,assorted gears & sand bags etc.

5. Food stock, water, blankets & beddingand medicines for distribution.

Obtain & circulate6. Advance forecast warnings to be

continuously updated.7. Mobilize emergency response team8. Release non-essential personnel9. Initiate shut down of plants(s) if

required10. Audit plant safety measures11. Implement preventive & precautionary

measures especially12. Hot equipment to be cooled down.13. Exposed machinery & equipment to

be coated with grease.14. Open flames should be extinguished

Remain indoor observant to Detect any damage to equipment or

buildings. Detect development of unsafe

conditions. Maintain communication with

Emergency Control Center.

IC andemployees

Respond to emergency call

Audit plant area(s) for damageassessmentImplement fire preventive measuresUndertake restorative measures &repairsRestart the plant(s)

Engineeringteam



7.21 Possible Emergency: - Cyclonic Storms / Hurricane

Cyclonic storms/ hurricanes are intense depressions, which develop in tropical latitudes and are often the cause of very highwinds and seas. The wind blows around the center of a tropical storm in a spiral flow inward, anti-clockwise in NorthernHemisphere and clockwise in Southern Hemispheres. Plan for tackling cyclonic storm/ hurricane can be broadly divided infollowing stages:

TABLE: 7.26

Location

Scenarioconsider

ed

HazardConsequen

ce

PossibleCauses

Action to be taken Action by Remedial measures to prevent recurrenceof such incident

(1) (2) (3) (4) (5) (6) (7)Wholeplant

CyclonicStorms /Hurricane

storm surgeand stormtide, heavyrainfall andinlandflooding,

high winds, rip

currents, tornadoes

Naturalcalamities

Mobilize emergency response team IC / SMC 1. Inventory of emergency items such astorches, ropes, lines, wire, tarpaulins,plastic sheets, tool kits, duct tapes,assorted gears & sand bags etc.

2. Food stock, water, blankets & beddingand medicines for distribution.

3. Implement preventive & precautionarymeasures

Release non-essential personnel IC / SMC

Initiate shut down of plants(s) ifrequired

IC andemployees

Stop field activities.Stop all permits to work.

IC

Remain indoor observant to Detect any damage to equipment

or buildings. Detect development of unsafe

conditions.Maintain communication withEmergency Control Center.

Engineeringteam



TABLE: 7.27Possible Emergency: - Bomb Threat

All telephone calls and emails threatening harm to people or property, such as bomb threats, should be taken seriously.

Location

Scenarioconsider

ed

HazardConsequen

ce

PossibleCauses

Action to be taken Action by Remedial measures toprevent recurrence of

such incident(1) (2) (3) (4) (5) (6) (7)

Wholeplant

BombThreat

detonatean explosive or incendiarydevice tocause propertydamage,death orinjuries

If the threat is by EmailContact immediately your site Security & CrisisManagement Leader / EHS Leader or EmergencyResponse Team and report that you have received athreatening e-mail and also inform to global ITteam.

E-mail receiver 1. Security system isprovided.

2. CCTV camera providedin all areas of the plant.

3. Without photo ID noone can enter inpremises.

4. Vehicles are checked atmain gate thoroughlyfor suspicious materialduring entry of vehicle.

1. Be calm.2. Contact the C M Leader/EHS Manager/ IC/

Functional Leader if you have received the calland give all information regarding the call orEmail.

3. Evacuate immediately through the nearest exitafter hearing the alarm and announcement,

4. Shut down critical operation.5. Do not disturb any thing while evacuating.6. Follow evacuation procedure and reach the

designated assembly point.7. Do not run or dash.8. Keep the doors & windows open.

IC / SHEManager andemployees

WHAT TO DO IF YOU RECEIVE A BOMBTHREAT ON YOUR TELEPHONE.Contact immediately your site Security & CrisisManagement Leader / EHS Leader or Emergency



Response Team and report that you have received athreatening PhoneQuestion to Ask:1. when is it going to occur (or explode)? Where is

the harmful item (or bomb) right now?2. What kind of item (or bomb) is it?3. What does it look like?4. Why did you place the item (or bomb)?5. Where are you calling?

Call Recipient

Things to note:1. Apparent sex, age, and maturity of the caller.2. Peculiarities of voice or speech3. Speech impediment, foreign accent,

regional flavor, signs of intoxication,irrationality, and “pet phrases,” or theirmannerisms.

4. Listen for background noises

Call Recipient

What to do if… You observe SuspiciousBehavior:1. Description of the suspicious behavior.2. Description of person(s).3. Make/Year of vehicle (if applicable).4. Color of vehicle.5. License plate number and State.6. Time7. Vehicle’s location and/or direction of travel.8. Vehicle in restricted areas without proper

identification.9. Passengers taking photographs or video of any

part of the facility.

Observer

1. Inform Site Shift Manager & Security Observer/ Call



Recipient2. Inform all personnel to provide information

regarding any unidentified or suspiciousobjects/ persons

Observer/ CallRecipient

3. Intensify vigilance & patrolling Security head4. Initiate bomb search Security head5. If any suspicious object is detected, inform

Police Commissioner for arranging bombdisposal squad

SMC

6. Make arrangement to minimize effects SMC7. Make arrangement for evacuation SMC8. Liaise with police SMC9. If bomb recovered/ no untoward incident occurs

restore normalcy.SMC

If blast occurs1. Activate concerned plant(s) emergency plan –

tackle fire/ toxic leakage/ structural collapse etc.Assess damage.

2. Take restorative measures.3. Liaise with authorities (police, insurance etc.).

SMC



TABLE: 7.28Possible Emergency: - Industrial Unrest

Industrial relation between personnel and management may deteriorate because of any reason. Problems, which may arise dueto industrial unrest, include:

Dharna/ Strike/ Hunger strike Unofficial gatherings/ Gate meetings/ Forceful entryWork to rule/ Go slow/ Disobedience Gherao/ Rasta rookIntimidation & Use of force Support from local & criminal elementsSabotage

In such a scenario, to ensure smooth operation of plant(s), protection of lives and property, well-coordinated effort is neededfrom all concerned. Plan to deal with industrial unrest can be broadly divided in following stages:

TABLE: 7.29

Location

Scenarioconsidere

d

HazardConsequence

PossibleCauses


(1) (2) (3) (4) (5) (6) (7)Wholeplant

IndustrialUnrest

Unofficialgatherings/Gate meetings/Forceful entryGherao/ RastarookSupport fromlocal &criminalelements

IndustrialUnrest

Any employee noticing or heard about the CivilDisturbance immediately call EHS / Securitydepartment to give the information.

First victim

Don’t allow to enter any unknown person in thesite

Securityteam

Strengthen security at sensitive points Securityteam

Ensure protection lives & property Securityteam

Intensify vigilance & patrolling Securityteam



Assemble in designated Safe Assembly point. Allemployees

Brief to Site main controller and Crisismanagement Leader.

First victim

Join your group at assembly point and presentyourself for headcount to head count coordinator.

Allemployees

Communicate to ECC/Emergency team formissing or trapped employees.

Victim /IC

Give this information to site main controller/ EHSdept./ Manufacturing Head.

Victim /IC

Maintain law & order SMC

Ask help form nearest police station. SMC

Assess damage (if any) SMC

Restore normalcy SMC

TABLE: 7.30Possible Emergency: - Lighting strike in company

Location

Scenarioconsider

ed

HazardConsequen

ce


such incident(1) (2) (3) (4) (5) (6) (7)

Buildingroof

Lightingstrike incompany

Fire, burneffect onhuman.

Natural Immediate evacuate the affected area of the plant. All employees Proper PMS systemprepared and implemented.

In case of burn injury to any person, rescue thevictims immediately from the plant at any safelocation.

Departmentemergency teammember

In case of fire in the building/ plant follow fireemergency action plan.



TABLE: 7.31Possible Emergency: - Sodium Cyanide poisoning to worker.

Locatio

n

Scenario

considered

HazardConsequen

ce

PossibleCauses


(1) (2) (3) (4) (5) (6) (7)Sodiumcyanidedrumstoragearea

Toxiceffectdue tocyanidepoisoning toworkers

Fatality Injection ororal dose dueto contact withcyanide. Dustexposureduringchargingcyanide in torector.

Symptoms may be delay after 3 to6 hrs. ifexposure low.

Give first aid to victim. Apply Amyle Nitratesmell to victim by handkerchief. ApplyOxygen administration if he is breathing. Afterone minute repeat Amyle Nitrate treatment .This first aid treatment repeat till victim feelnormal.

Admit victim to hospital immediately.

Cyanide Antidote Kit keep with hospital forintravenous injection by doctor.

Apply Antidote injection

Antidote kit is kept in office in first aid centre.

Inform to statutory bodies.

First observeror victim.

Train firstaider forcyanide.

Administrationteam

First aid team

By doctoronly

SMC

SMC

1. Separate stored in lockedroom.

2. Away from water sources.3. Total body protection

suite is provided tocharging operator with airline respirator.

4. Safe operating( Charging)procedure is prepared anddisplayed in process andstorage area.

5. Total close process forcharging and handling.

6. Antidote kit for cyanideis kept ready in OHC.

7. Training is being providedto handle NACN,

8. SCBA sets are available inhandling area.

9. Operator having cuts andsores should not usecyanides.

10. If a li ttle poisoning,inhale cyanide antidote kit



(amyl nitrite, sodiumnitrite and sodiumthiosulfate) and oxygenfor 15-30 seconds as firstaid measures

11. Use sodium hypochlorite,calcium hypochloritesolution or potassiumpermanganate for washingbalance, glass apparatus,spatula, workplace and incase of spillage

12. Use Apron, eye protectingglass, Mask and glovesduring transferring, work-up and decomposition ofchemicals.

13. Issued quantity will beused fully for reactions.Cannot be stored in theprocess area

14. Separate Log Book forissuing above cyanidesand Manager has to signon the register



7.21 Details on various SOP to be prepared.

SR. No. EHS SOP1 Hot work permit2 Electrical isolation LOTO permit3 Confined space/ Vessel entry permit4 Working at height and excavation work permit5 PMS6 Accident investigation and reporting7 Training SOP8 Hazardous material handling and storage SOP9 Road tanker unloading procedure10 Medical examination11 PPES matrix12 Equipment testing and calibration SOP13 Management of change14 Drum handling procedure15 Fire protection system maintenance and record keeping16 Product vise BMR17 Safety manual for worker

Details of workers training before engaging work, periodical, in-house, outsideetc.,Safety Training provided to all workers as per Section 111A of the Factories Act.

Details on safety audit to be carried out and their compliance.Safety Audit conducted on 10.02.2018 and compliance report available.

Specific safety measures to be taken for general public living in the vicinity.Safety Manual prepared as per rule 41 B & C and distributed to all the nearbyemployees.

Detection of monitoring of VOC’s/Gases.Third party Work place monitoring report available in Form No- 37.

Details on volatile organic compounds (VOCs) from the plant operations andoccupational safety and health protection measures. Proposal for Leak Detectionand Repair (LDAR) program as per the CPCB guidelines.

LDAR Program



LDAR Program – APL shall be carrying out LDAR program as per sources ofLeakages

Following activities shall be carried out as part of LDAR

Monitoring of Solvent Losses Preventive Maintenance to prevent Leakages Immediate Corrections in case of Leakages

Monitoring of Solvent Losses

In warding, storage and consumption of solvents in various productsshall be measured through Level Transmitters and Load cells weighingsystems resp. The quantity at each stage shall be reconciled periodicallyto arrive at Losses.

Batch outputs shall be monitored and reconciled with quantity of inputraw materials added. Any variation beyond 5% shall be analysed indetail and action plan shall be prepared to reduce the variation.

Workplace VOC monitoring shall be carried out at the shop floor Periodic Leakage Audit at Plant

Preventive Maintenance to prevent Leakages

In order to prevent leakage from Pump, Seals, Valves etc, preventivemaintenance shall be carried out periodically as per plan. In case of anyrecurring problem, action plan shall be prepared or frequency shall berevised.

Sr.No.

Component Preventive Maintenanceschedule

1 Valves/flanges Quarterly2 Compressor seals Quarterly3 Pressure relief devices Yearly4 Pump seals with visible liquid dripping Daily5 Any component with visible leaks Weekly6 Any component after repair/

replacementWeekly

7 Pipeline Thickness Testing Yearly

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