mock drill oil bottling plant ban gal ores

8/3/2019 Mock Drill Oil Bottling Plant Ban Gal Ores

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Mock Exercise on Chemical(Industrial Disaster)

Indian Oil Corporation Ltd.

LPG Bottling Plant, Devanagunthi

Vijay Kumar C.

Sr. Plant Manager


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Profile of Devanagunthi LPG Bottling Plant

Plant is situated at Devanagunthi.

45 Km from Banglore Dist HQ.

Neighbouring Industries

1. IOCL (Terminal) 1.0 Km away2. BPCL (Terminal) 1.25 Km away

3. HPCL (Installation)- 1.5 Km away

4. Petronet MHB Limited-1.25 Km away


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Indane bottling plantLayout


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Major Activities

LPG receipt by rail and road,Storage, bottling & Despatch

Loading of LPG bullet trucks forAuto LPG Dispensing stations andother bottling plants


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Bulk LPG Receipt

Source of Receipt : Rail Wagons fromMangalore and

Hazira and road tankersfrom CPCL

Supply Area : Bangalore city,Peripheral marketsof Bangalore city


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LPG BOTTLING PLANT, DEVANAGUNTHI MAH INDUSTRY

Bottling Capacity

Existing : 138 TMTPA

Proposed: 232 TMTPA

Total Land Area : 93.35 ACRES

Green belt Area : 25 ACRES


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Bulk LPG Storage Facilities

Sphere 2 x 1400 MT

Bullets 2 x 100 MT

Bullet 1 x 150 MT

Additional Mounded 3 x 1200 MT

Bullets

Existing 3150 MT After Augumentation

6750MT

Existing


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By Road

12 nos. Tank lorry unloading bayswith unloading arms.

By Rail

Two spur full rake gantry unloadingfacility. Equipped to unload both

conventional and BTPGLN wagons.

Bulk Receipt Facilities


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Population in nearby VillagesSl. No. Name of the village Population

1 Kacharakanahalli 437

2 Dasarahalli 4583 Geddlapura 163

4 Dodda Donnasandra 1677

5 Kannekal 410

6 Makkanahalli 1465

7 Devalapura 446


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Material Safety DataIDENTITY OF MATERIAL :

Product Name LPG. Bottle gas,Liquefied

hydrocarbon gas.

UN No. 1075

Label / Class Red: Flammable

Liquid / 2.1Trade name LPG

Formula Mixture of

propane and

butane

HAZCHEM Code 2WE

PHYSICAL AND CHEMICAL PROPERTIES

Physical State Gas Boiling Point / Range , deg.

C

1 Vapor Pressure

at 65 deg. C,

16.9 kg/cm2

Appearance Colourless Melting / Freezing Point ,

deg. C

138

Odor Odorless/stanche

d

Vapor Density (Air =1) 1.5 to 2.0

Solubility in Water Insoluble Specific Gravity , 20 deg. C 0.53 to 0.57

Calorific Value

(Kcal / Kg.)11400 Dyn. Viscosity (PA.S 30

deg. C)

Molecular Weight.

FIRE AND EXPLOSIVE DATA

Explosivity Highly explosive Auto Ignition Temp. deg. C 405-450

Flammability Dangerous Explosive Limits , % 1.8 9.6

Extinguishing Media CO2, DCP. Water spray may be used to control and confine LPG fires.

Special Procedures Do not attempt o extinguish fire until leak has been shut off. For small fire use dry chemicals. Let large fires burn if not heating

the container. When exposed to heat and flame, containers may rupture due to BLEVE


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Risk Analysis

Based on three steps

What can go wrong?

(Hazard identification)

How often it can go wrong?

(Failure frequency)

What are the effects of consequences?

(Effect and damage calculations)


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MODES OF FAILURE OF

PRODUCT STORAGE VESSELS

Material and construction failures

Corrosion

Gasket failures


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PRINCIPAL HAZARDS - LPG

Flammability & Explosion

Jet Fire

Pool Fire

BLEVE

Flash Fire

UVCE

Asphyxia

Cold Burns

Metal brittleness due to Low temperature


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Consequences Analysis

Damages are caused due to

Heat radiation

Overpressure effect from explosions

Toxic effect


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Exposure time, heat radiation anddamage levels

Intensity of

radiation (Kw/

m2

Exposure

time in

Seconds

% Lethality

37.5 28 100% Lethality

12.5 28 1% Lethality /100 % first deg.burns4 28 1% first degree burns


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Damage distance for BLEVE

37.5 KW/m2 12.5 Kw/m2 4.0 KW/m2

HORTONSPHERE

1400 273 524 908 1830

Storage

Vessel

LPG in

MT

BLEVE

Radious(m)

Radiation distance in meters to


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Damage contour for catastrophic failure of 1400 MT sphere


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Zone AZone A 37.5 Kw/M2 524

M rad 100% lethality

(Plant personnel)


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Zone B

12.5 Kw/M2 908 M rad 1% lethal

(Kanekkal Village)

Zone - B


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Zone C

- 4.0 Kw/M2

- 1830 M

- First Degree burns(Kacharakanahalli, Dasarahalli,

Giddapura,Doddasandra)

Zone C


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Risk intensity

ZoneRadiation

(KW/M2)

Distance in

meter

Zone A 37.5 524 Plant Personnel 80

Zone B 12.5 908 Kanekal village 443

Kacharaknahalli 472

Dasarahalli 495

Gidlapura 176

Donnasandra 1811

Makanahalli 1582

Devalapura 482

Vagatta 1103

Neighboring

industries400

Affected population

Zone C 4 1830


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Gas Monitoring System

Air/Vapor Extraction System

Remote control Valve

Emergency Trip Button

Manual Call point

Quartzoid bulb detector.

Mitigation measures


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FIRE WATERSTORAGE TANKS

3 Nos. of 4000 KL capacity each

FIRE PUMPS

8 Nos. diesel driven waterpumps of 410 CUM/ Hr. capacity each.

JOCKY PUMPS

2 Nos. of 24 Cum /Hr.

Fire Fighting Facilities


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Ring main hydrant system

57 double hydrant points

46 water monitors 4 long range monitors coveringtruck Parking Area.

Auto sprinkler system forSheds

, TLD , Storage Vessels andTank Wagon Gantry.

Fire Fighting Facilities


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Carousel Inter locked with Vapour extractionsystem

Remote operated valves for LPG pipe lineinter locked with sprinkler system

LPG and Air compressors inter locked withcooling waterpumps.

Emergency trip buttons and Manual callstations at strategic points.

ROV closure ofStorage Vessel interlockedwith HLAs.

Additional Safety Features


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Detailed on-site emergencymanagementplanprepared andapproval obtained from Dept. ofFactories.

Emergency Response Drills(ERDs) are conducted twice in ayear.

Mock drills are conducted

every month & shortcomings areaddressed.

Mutual aid arrangement withneighbouring industries.

On-site Emergency Plan


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Mutual Aid

To Assist its neighbouring industries in responding to

emergencies that may occur either on-site or off-sites.

Member Roles and responsibilities

IOCL, Terminal Traffic control and smooth evacuation of trucks

BPC Terminal Assist the Rescue Team membersHPCL Installation Assist Auxilliary team members

PETRONET Assist Auxilliary team members

Mutual Aid agreemnt


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Fire Fighting Organisation Chart

FIRE COMBAT TEAM AUXILIARY TEAM RESCUE TEAM

Team In Charge: Floor Officer Team In Charge:

Manager (P)

Team In Charge: Asst.

Manager (F)

Alternate team Incharge: Officer

(Bulk Operations)

Alternate team Incharge: S&D

officer

Alternate team Incharge:

Accounts officer-II

Assisted by: Assisted by: Assisted by:

1. Tally operator 1 1. Dy. Manager (P) 1. A O - II2. Tally operator 2 2. Safety Officer 2. Sr. Assistant3. Segregation 1 3. Maintenance Officer4. Segregation 2 4. Maintenance operator 15. Pump House 1 5. Maintenance operator 26. TLD 6. Employees on Relief

7. Carousel Tare wt. 1 7. Security guard 3(Stores)

8.Carousel Tare wt. 2 8. Security guard 4

9. Evacuation (Gate 2)10. ICU11. Gantry operator 112. Gantry operator 213. Security guard 1(Main gate)

14. Security guard 2 (Maingate)

15. Security guard 3(Patrolling)

FIRE IN CHIEF: Sr. Plant ManagerAlternate FIRE IN CHIEF: Manager (P)


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Emergency Transport facility

Dedicated Vehicle for emergency

transportation is available round the clock.

Between 08.00 hr to 17.15 hr one more

vehicle also will be available.


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Shutting down procedure

Shutting down is done through the following

means:

Emergency trip Buttons & Manual Call

Point

Remote Control Valves

Quartzoid Bulb detector.


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On site Emergency Structure

The basic concep

t of thisp

lan is top

rovide a comp

rehensiveapproach for managing emergencies. Four elements of this

plan are

Prevention - incorporates all those activities that eleminate

theprobabilityof disaster occuring on-site.

Preparedness - includes all activities necessary to ensure

a high degree of readiness

Response- measures taken during an incident which

minimise damage to life and property.

Recovery includes those short and long-term activitiesthat return all systems to normal operations.


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Declaration of Emergency

Upon declaration of Emergency Sr.Plant Manager

makes initial assessment of incident and determine the need for

evacuation.

ensure that all personnel are accounted for.

ensure that outside agencies are communicated as per DMP asfollows:

Dy. Commisioner

Regional, State & Head Offices

Fire Dept

Law & Order

Revenue Dept

Local Panchayat

Railways

KPTCL

Medical Dept.


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Public Awareness Programs

Various programs being conductedFor creating public awareness to the

Neighboring villages.


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mock drill oil bottling plant ban gal ores

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