m/s. greentec chemicals pvt. ltd

M/s. GREENTEC CHEMICALS PVT. LTD. ENVIRONMENT IMPACT ASSESSMENT REPORT

Prepared By: Aqua-Air Environmental Engineers Pvt. Ltd., Surat 558

CHAPTER - 6

___________________________________________________________________________

RISK ASSESSMENT & DISASTER MANAGEMENT PLAN

In order to support the environment impact assessment and environment management

plan, following additional studies have been included in the report.

Risk assessment

Disaster Management Plan

On site and off site emergency action plan

Occupational Health and Safety Management System

6.1 RISK ASSESSMENT

6.1.1 INTRODUCTION

Hazard analysis involves the identification and quantification of the various hazards like

storage , handling & operations (unsafe conditions). On the other hand, risk assessment

deals with recognition and computation of risks, the equipment in the plant and personnel

are prone to, due to accidents resulting from the hazards present in the plant (operations)

Risk assessment follows an extensive hazard analysis. It involves the identification and

assessment of risks the neighboring populations are exposed to as a result of hazards

present. This requires a thorough knowledge of failure probability, credible accident

scenario, vulnerability of population etc. Much of this information is difficult to get or

generate. Consequently, the risk assessment is often confined to maximum credible

accident studies. It provides basis for what should be type and capacity of its on-site and off-

site emergency plan also what types of safety measures shall be required.

6.1.2 APPROACH TO THE STUDY

Risk involves the occurrence or potential occurrence of some accidents consisting of an

event or sequence of events. The risk assessment study covers the following:

Identification of potential hazard area;

Identification of representative failure cases;

Visualization of the resulting scenarios in terms of fire and explosion;



Assess the overall damage potential of the identified hazardous events and the

impact zones form the accidental scenarios;

Furnish the recommendations on the minimization of the worst accident possibilities

Preparation of Disaster Management Plan;

Emergency Plan, which includes Occupational and Health Safety Plan;

6.1.3 METHODOLOGY

Quantitative risk assessment (QRA) is a means of making a systematic assessment of the

risks from hazardous activities, and forming a rational evaluation of their significance, in

order to provide input to a decision-making process. The term ‘quantitative risk assessment’

is widely used, but strictly this refers to the purely numerical assessment of risks without

any evaluation of their significance. The study has been conducted based on the premises of

a traditional Quantitative Risk Assessment. The key components of a QRA are explained

below, and illustrated in Figure-6.1 and Figure-6.2.

FIGURE – 6.1

QRA METHODOLOGY



FIGURE–6.2

FLOW CHART FOR QUANTITATIVE RISK ASSESSMENT

Start Identify Risk Areas

Select a Risk Area

Identify Failure Cases

Select a Failure Cases

Identify Consequence Outcomes

Select Consequence Outcomes

Determine Frequency

Estimate Consequence

Record Frequency and Consequence in a summary Table

Have all Consequence outcomes been studied?

Have all failure cases been studied?

Have all risk areas been studied?

Draw Risk Contours Finish

Yes

Next Next



6.1.4 HAZARD IDENTIFICATION

Identification of hazards in the proposed project activity is of primary significance of the

analysis, and quantification. Hazard states the characteristics of system/plant/process that

presents potential for an accident. All the components of a system/plant/process need to be

thoroughly examined to assess their potential for initiating or propagating an unplanned

event/sequence of events, which can be termed as an accident.

6.1.4.1 IDENTIFICATION OF HAZARDOUS AREAS

The procedure for QRA starts with identification of major risk areas in the installation.

Operation carried out in specialty and agrochemical Industries usually come under certain

board, general categories. At M/s. Greentec Chemicals Pvt. Ltd., major risk areas are as

follows:

Bulk storage area for Raw Materials (explosive, toxic, Flammable & solvent) at ambient

temperature and atmospheric pressure.

Process Plant involving pumping, transportation, reactors, distillation, heating, cooling,

etc.

Bulk loading and unloading from storage tanks to road takers and vice versa.

6.1.4.2 IDENTIFICATION OF FAILURE CASES FOR HAZARDOUS AREAS

Release due to catastrophic failure of storage tanks or process vessels.

Spillage/Overflow & Leakage from storage tank

Rupture of connected pipe with storage tank or process vessels.

Continuous release at significant rates for long durations transfer pipelines caused by

sudden, major break of the pipeline.

Continuous release at low rate through small holes or cracks in piping and vessels, flange

leaks, and leakage from pump glands and similar seals.

It is to be noted that for Quantitative Risk Assessment, worst case scenarios has been

considered, though their frequency of occurrence is much lower than the cases of small

leaks.



6.1.4.3 MAJOR HAZARDOUS AREAS

The hazardous chemical storage area is shown in Figure-6.3. The major Hazardous chemicals

to be stored, transported, handled and utilized within the plot area are summarized in the

Table-6.1. Other hazards and control measures are summarized in Table-6.2. Facilities /

System for process safety, transportation, fire fighting system and emergency capabilities to

be adopted are stated below.



FIGURE-6.3

HAZARDOUS CHEMICAL STORAGE AREA

-



TABLE-6.1

STORAGE AND HANDLING DETAILS OF HAZARDOUS CHEMICALS

Quantity Name of the

Hazardous

Substance

(Mention

concentration

if any)

Maximum

that can

be stored

Actually

stored

(including

process &

handling)

Place of its

storage

State &

Operating

Pressure &

Temperature

Type of Hazard

Possible (fire,

explosion, toxic

release etc.)

Control measure provided

CHLORINE 36 MT 27 MT RM Storage

area 3

Liquefied

@ RT 10

kg/cm2

Toxic Release Online Gas Sensors, Pressure

Gauge, Emergency Kit, Caustic

Scrubbing System, SCBA Set

HYDROGEN 3000 KG 2000 KG RM Storage

area 3

Compressed

gas

Flammable Control Measures has been

taken as per license approved

by Dept. of Explosives.

Flameproof area, static

Earthing, fire fighting facility,

flame arrester, fenced area.

XYLENE 20 MT 15 MT RM Storage

area 2

Liquid Flammable Control Measures has been






TOLUENE 25 KL 17 KL Solvent Yard Liquid Fire Control Measures has been






METHANOL 35 KL 25 KL Solvent Yard

RM storage

3

Liquid Fire Control Measures has been






ETHANOL 30 KL 25 KL Solvent Yard

RM storage

3







HYDROCHLORIC

ACID

20 KL 10 KL RM Storage

1

Liquid Spillage/Leakage Bund Wall, scrubbers

CARBON

DISULPHIDE


1

Liquid Fire Bund wall, Earthing – bonding,

fire fighting facility, fencing.

CAUSTIC LYE

48 %


1

Liquid Spillage/Leakage Bund wall, Earthling – bonding,


ISOPROPYL

ALCOHOL


3






Hazardous

Substance

(Mention

concentration

if any)

Maximum

that can

be stored

Actually

stored

(including

process &

handling)

Place of its

storage

State &

Operating

Pressure &

Temperature

Type of Hazard

Possible (fire,

explosion, toxic

release etc.)


PHENOL 40 KL 25 KL RM Storage

2



NITRIC ACID 20 KL 15 KL RM tank

farm 1

Liquid Corrosive Bund wall, Earthing – bonding,


AMMONIA

SOLN. 22%

30 KL 20 KL RM tank

farm 2



AMMONIA GAS

CYLINDER

1000 Kg 700 Kg GTI plant

RM area

Compressed

gas







ETHYLENE

DIAMINE

300 KL 250 KL RM tank

farm 1







PCl3 150 KL 100 KL Intermediate

plant



METHYLENE

DICHLORIDE


2



ETHYLENE

DICHLORIDE


2



ACETIC

ANHYDRIDE


2







SULPHURIC

ACID

25 KL 20 KL RM tank

farm 1



DMPAT 100 KL 75 KL Intermediate

plant



BROMINE 15 MT 12 MT RM Storage

3



ETHYL ACETATE 25 KL 20 KL RM Storage

2







ACETONE

(DRUMS)

5 KL 4 KL RM storage

4







Hazardous

Substance

(Mention

concentration

if any)

Maximum

that can

be stored

Actually

stored

(including

process &

handling)

Place of its

storage

State &

Operating

Pressure &

Temperature

Type of Hazard

Possible (fire,

explosion, toxic

release etc.)





HEXANE 5 KL 4 KL RM storage

4







MONO CHLORO

ACETIC ACID


3



TETRA HYDRO

FURAN


4







DMS

(DRUMS)

5 MT 4 MT GTI plant RM

store



SULPHUR

LIQUID

30 KL 20 KL Intermediate

plant

Solid Corrosive Close room, flame proof

fittings, and proper ventilation.

4 NOx

(DRUMS)

27 MT 18 MT GTH plant

RM store

Liquid Spillage/leakage Bund wall, Earthing – bonding,


ZINC SULPHATE

SOLU 13%


farm 1



MNSO4

SOLUTION 27%


farm 1



SODIUM

METHOXIDE

(DRUMS)

4 MT 2 MT RM store 5 Solid Fire Close room, flame proof

fittings, and proper ventilation.

ACRYLONITRILE

(DRUMS)

8 MT 6 MT RM store 5 Liquid Fire Control Measures has been






TMP

(DRUMS)

15 MT 10 MT RM store 5 Liquid Spillage/leakage Bund wall, Earthing – bonding,


DIMETHYL

SULPHOXIDE

(DRUMS)

16 MT 12 MT RM store 5 Liquid Fire Control Measures has been









Hazardous

Substance

(Mention

concentration

if any)

Maximum

that can

be stored

Actually

stored

(including

process &

handling)

Place of its

storage

State &

Operating

Pressure &

Temperature

Type of Hazard

Possible (fire,

explosion, toxic

release etc.)


METHYL ISO

BUTYL KETONE

(DRUMS)

8 MT 5 MT RM storage

6







BUTYL

ALCOHOL

(DRUMS)


6



PHOSPHORUS

(DRUMS)

100 MT 80 MT RM store 4 Solid at

Room Temp.

Fire Bund wall, Earthing – bonding,


SOD CYANIDE

(DRUMS)


6

Solid Toxic Bund wall, Earthing – bonding,


CO2

(CYLINDER)


5

Compressed

gas







SO2

(CYLINDER)


5

Compressed

gas

Corrosive Control Measures has been






THIONYL

CHLORIDE

(DRUMS)


6

Liquid Toxic Bund wall, Earthing – bonding,


ORTHO

DICHLORO

BENZENE

(DRUMS)


6



DIMETHYL

FORMAMIDE

(DRUMS)


6







DI METHYL

AMINE

(DRUMS)


6

Liquid Fire & Toxic Bund wall, Earthing – bonding,


MONO METHYL

ACETO

ACTEMIDE

(DRUMS)


6






Hazardous

Substance

(Mention

concentration

if any)

Maximum

that can

be stored

Actually

stored

(including

process &

handling)

Place of its

storage

State &

Operating

Pressure &

Temperature

Type of Hazard

Possible (fire,

explosion, toxic

release etc.)


ANILINE

(DRUMS)


6



FORMIC ACID 20 MT 15 MT RM storage

2



SODIUM LIGNO

SULPHATE

(BAGS)

30

25 RM storage

6

Solid leakage No hazard

HMTA

(BAGS)

20 15 RM storage

6

Solid leakage No hazard



TABLE 6.2

OTHER HAZARDS AND CONTROL

Sr.

No.

Name of the possible

hazard or emergency Its sources & reasons

Its effects on persons,

property & environment In charge person

Place of

its effect Control measures provided

Name and

designation

1 2 3 4 5 6 7

1 BOILER

(1) Burning

(2) Physical injury

(3) Explosion

Over pressure in the boiler if

safety valve not working. Water

level indicator not working.

Low water level indicator fail.

High temp. System fails.

Minor/Major Injury Loss

of human life Loss of

property (Loss of Man /

Machine Material)

Utility Block Lower & Upper Level Indication System provision. Safety valves for

pressure control fixed temp. & pressure indicator provided. Blow down

& blowing system provided for cleaning tube and shell. Soft water

used. Inter locking provided on pumps, FD fan, ID fan. Periodical

checking & inspection maintenance done. Yearly inspection done by

Boiler Inspector

Engineering Services

2 ELECTRICITY

(1) Burning

(2). Fire

(3). Shock

Loose Contacts, Weak earthing

Short Circuit Improper

Insulation

Burning, Shock, Death Surrounding

the accident

area

Proper Earthing, Periodical Checking of joints, proper insulations of

Equipments, etc. Flame proof fitting in solvent storage area, bounding

and jumpers to all solvent barrier lines provided.

Electrical engineer

3 HOUSE KEEPING

(1). Physical

(2). Burning

(3) Fire

(4) Chemical Exposure

Bad House keeping Physical / Chemical

Thermal Burn Injury

(Major / Minor)

All Plant Proper Handling, regular cleaning, Proper placement of material (RIGHT

THING AT THE RIGHT PLACE)

Personnel depat

4 PIPE LINE LEAKAGES

Spillages etc.

(1) Corrosion

(2) Toxic gas release

Leaking of pipe line due to

corrosion, Loose contact etc.

Physical / Chemical

Thermal Burn Injury

(Major /

Minor)/Chemical

Exposure

Plant area Proper maintenance, Proper Selection of Material for pipe lines,

Immediate attention, NO SMOKING Boards displayed.

Concerned Plant In

Charge

5 Natural Gas Leaking of pipe line due to

corrosion

Leakage from flange joint

Loose earthing / Loose contact

etc.

Fire & explosion Plant area Proper maintenance, Proper Selection of Material for pipe lines,

Numetic test as per regulations

NO SMOKING Boards displayed.

Concerned Plant In

Charge



TABLE 6.3

HAZARDOUS PROPERTIES OF THE CHEMICALS, COMPATIBILITIES, SPECIAL HAZARD AND ANTIDOTES

SR. NAME OF

CHEMICAL

HAZARD FLASH

POINT 0

C

BP 0

C

LEL % UEL % SP.GR.

20 0

C

VD SOLUBILITY

WITH WATER

at 20 0 C

NFPA

H F R

HAZARDOUS

COMBUSTION

PRODUCT

TLV

/

TWA

IDLH

LC50

LD50

1. CHLORINE

CAS # 7782-50-5

T - -34.6 - - - 2.5 Reacts 4 0 0 When Heated, It Emits

Highly Toxic Fumes

0.5 ppm 10 ppm 293 ppm (Rat)

1 Hr

-

2. HYDROGEN

CAS# 1333-74-0

F - -253.15 4 74.5 - 0.07 Insoluble 0 4 2 - - - -

-

3. XYLENE

CAS#1330-20-7

F 24 138.5 1 7 0.864 3.7 Insoluble in

cold water, hot

water

2 3 0 Carbon Oxides (CO,

CO2)

- - 2119 5000 mg/kg

(Rat)

4. TOLUENE

CAS # 108-88-3

F 4 110.6 1.2 8 0.863 3.2 700 mg/L 2 3 0 Moderately Dangerous;

When Heated, Emits

Toxic Fumes Which Can

React Vigorously With

Oxidizing Materials

50 ppm 500 ppm 49 gm/m3

(Rat) 4Hr

636 mg/kg

(Rat)

5. METHANOL

CAS#67-56-1

F 12 64.5 6 36.5 0.7915 1.11 Easily soluble

in cold water,

hot water


CO2)

200 - 5628 64000

mg/kg

(Rat)

6. ETHANOL

CAS# 64-17-5

F 12.78 78.5 /

-114.1

3.3 19 0.789 1.59 Easily soluble

in cold water,

hot water


CO2)

1000 - 7060 20000

mg/kg

(Rat)

7. HYDROCHLORIC

ACID

CAS # 7647-01-0

C 11 -85.06 - - 1.19 1.25 Soluble 3 0 1 Non-Combustible,

Substance Itself Does

Not Burn But May

Decompose Upon

Heating To Produce

Corrosive And/Or Toxic

Fumes

5 ppm 50 ppm 4701 ppm

0.5 Hr [Rat]

-

8. CARBON

DISULPHIDE

CAS#75-15-0

F -30 46.3 1.3 50 1.2632 2.63 Very slightly

soluble in cold

water

3 3 0 - 10 ppm 500 2780 12500

mg/kg

(Rat)

9. CAUSTIC LYE 48 %

CAS#1310-73-2

C - 1388 - - 2.13 - Easily soluble

in cold water

3 0 2 Non - Flammable 2 (mg/m3) 250

mg/m3

500 -

10. ISOPROPYL

ALCOHOL

CAS # 67-63-0

F 12 82.4 2 12.7 0.785 2.1 Soluble 1 3 0 Fire May Produce

Irritating, Corrosive

And/Or Toxic Gases

400 ppm 2000

ppm

100000 mg/l

96 Hr

5045 gm/kg

[Rat]



SR. NAME OF

CHEMICAL

HAZARD FLASH

POINT 0

C

BP 0

C

LEL % UEL % SP.GR.

20 0

C

VD SOLUBILITY

WITH WATER

at 20 0 C

NFPA

H F R

HAZARDOUS

COMBUSTION

PRODUCT

TLV

/

TWA

IDLH

LC50

LD50

11 PHENOL

CAS#108-95-2

F 79 182 1.7 8.6 1.057 3.24 Soluble in cold

water,

Solubility in

water: 1g/15

ml water


CO2)

5 ppm 250 ppm 317 -

12

NITRIC ACID

CAS #7697-37-2

C - 121 - - 1.408 2.5 Easily soluble

in cold water,

hot water

3 0 0 Non Flammable 2 ppm 25 ppm - 244 ppm 0.5

hours [Rat]

13 AMMONIA SOLU22

%

CAS#1336-21-6

T & C - 38 - - 0.898 - Easily soluble

in cold water

3 0 0 Non Flammable 25 ppm - - 2000 ppm 4

hours [Rat]

14 AMMONIA GAS

CAS#7664-41-7

T & C - -33.4 - - - - Easily soluble

in cold water

3 0 0 Non Flammable 25 ppm 500 ppm - 2000 ppm 4

hours [Rat]

15 PCL3

CAS#7719-12-2

T & C - 76 - - 1.574 4.75 Insoluble in

water

3 0 2 Non Flammable 0.5 ppm 25 ppm 18 mg/kg [Rat] 50 ppm 4

hours

[Guinea pig]

16 METHYLEN

DICHLORIDE

CAS#75-09-2

T - 39.75 12 19 1.3266 2.93 Partially

soluble in cold

water


CO2), Halogenated

Compounds

50 - 1,600 52000

mg/kg

(Rat)

17 ETHYLEN

DICHLORIDE

CAS#107-06-2

F 13 83.5 6.2 15.6 1.2351 3.42 Very slightly

soluble in cold

water


CO2)

75 - 670 1414.2

mg/kg

(Rat)

18 ACETIC ANHYDRIDE

CAS#: 108-24-7

F T C 49 139.9 2.7 10.3 1.08 3.52 - 3 2 0 Carbon Oxides (CO,

CO2)

5 ppm 1,000

ppm

1780 mg/kg

[Rat]

-

19 DMPAT

CAS#17321-47-0

- - - - - - - - Carbon Monoxide,

Nitrogen Oxides, Sulfur

Oxides

- - - -

20 BROMINE

CAS#: 7726-95-6

T & C - 58.78 - - 3.11 7.1 Very slightly

soluble in cold

water

3 0 0 Non Flammable 0.1 ppm 10 ppm 2,600 ppm 240 ppm

21 ETHYL ACETATE

CAS#141-78-6

F -4.4 77 2.2 9 0.902 3.04 Soluble in cold

water, hot

water


CO2)

400 ppm 10,000

ppm

5620 mg/kg

[Rat]

45000 mg/m

3 hours

[Mouse]

22 ACETONE

CAS#67-64-1

F -20 56.2 2.6 12.8 0.79 2 Easily soluble

in cold water,

hot water


CO2)

500 - 5,800 44000

mg/kg

(Rat)

23 HEXANE F -22.5 68 1.15 7.5 0.66 2.97 Insoluble in 2 3 0 Carbon Oxides (CO, 500 - 25000 -



SR. NAME OF

CHEMICAL

HAZARD FLASH

POINT 0

C

BP 0

C

LEL % UEL % SP.GR.

20 0

C

VD SOLUBILITY

WITH WATER

at 20 0 C

NFPA

H F R

HAZARDOUS

COMBUSTION

PRODUCT

TLV

/

TWA

IDLH

LC50

LD50

CAS#110-54-3 cold water,

hot water

CO2)

24 MONO CHLORO

ACETIC ACID

CAS#: 79-11-8

T & C 150 189 8 - 1.4043 - Soluble in cold

water, hot

water


CO2), Halogenated

Compounds

0.05 ppm - 55 mg/kg

[Rat]

254.6 ppm 4

hour(s) [Rat]

25 TETRA HYDRO

FURAN

CAS#109-99-9

F & T -14.5 65 2 11.8 0.8892 2.5 Partially

soluble in cold

water.

Solubility in

water is 30%.


CO2)

200 ppm 2000

ppm

1650 mg/kg

[Rat]

21000 mg/m

3 hours [Rat]

26 DMS

CAS#77-78-1

T & C 83.3 - - - 1.3322 4.35 Partially

soluble in cold

water


CO2), Sulfur Oxides

(SO2, SO3)

1 ppm 10 ppm 205 mg/kg

[Rat]

45 ppm 4

hour(s) [Rat]

27 SULPHER

CAS#7704-34-9

C 207 445 - - Density:

2.07

- Insoluble in

cold water, hot

water

2 2 0 Sulfur Oxides (SO2, SO3) 5 ppm 100 ppm >8437 mg/kg

[Rat]

--

28 4 NOX

CAS#99-51-4

113 143 - - 1.139 - - - Carbon Oxides,

Nitrogen Oxides (NOx)

- - - -

29 ZNSO4 SOL 13%

CAS#7446-20-0

- - - - - - Soluble in

water. Water:

170 g/100ml

2 0 0 On Burning: Release Of

Toxic And Corrosive

Gases/Vapors (Sulphur

Oxides, Zinc Oxide) And

Formation Of Metallic

Fumes

- - - -

30 MNSO4 SOL 27 %

CAS#10034-96-5

- - 850 - - 2.95 - Easily soluble

in cold water,

hot water

2 0 0 - - 500

mg/m3

(as Mn)

- -

31 SOD METHOXIDE

CAS#124-41-4

F 33 - 7.3 36 1.1 1.1 Soluble in cold

water.

Decomposes/r

eacts in water


CO2)

10 mg/m3 -- 2037 mg/kg

[Rat]

--

32 ACRYLONITRILE

CAS#: 107-13-1

F & T -1.111 77.3 3.1 17 0.806 1.8 Very slightly

soluble in cold

water, hot

water


CO2)

1 ppm 85 ppm 78 mg/kg [Rat] 333 ppm 4

hours [Rat]



SR. NAME OF

CHEMICAL

HAZARD FLASH

POINT 0

C

BP 0

C

LEL % UEL % SP.GR.

20 0

C

VD SOLUBILITY

WITH WATER

at 20 0 C

NFPA

H F R

HAZARDOUS

COMBUSTION

PRODUCT

TLV

/

TWA

IDLH

LC50

LD50

33 TMP

CAS#512-56-1

T > 150 197 - - 1.210 -

1.215

g/cm3

- 1,000 g/l at 25

°C

Combustible. Fire may

cause evolution of:

oxides of phosphorus

- - - -

34 DIMETHYL

SULHOXIDE

CAS#67-68-5

T & F 89 189 2.6 42 1.1008 2.71 Soluble in cold

water, hot

water


CO2), Sulfur Oxides

(SO2, SO3)

- - 14500 -

35 BUTYL ALCHOL

CAS#: 71-36-3

F & T 28.9 117.7 1.4 11.2 0.81 2.55 Partially

soluble in cold

water, hot

water


CO2)

100 ppm 8,000

ppm

790 mg/kg

[Rat.]

3400 mg/kg

[Rabbit.]

36 SOD CYNIDE

CAS#: 143-33-9

T - 1496 - - 1.595 HCN

gas:

0.941

Soluble in cold

water

3 1 0 Some Metallic Oxides 5 mg/m3 25

mg/m3

6.44 mg/kg

[Rat]

10.4 mg/kg

[Rabbit]

37 SO2

CAS#7446-09-5

T & C - - - - - 1.5 Soluble in cold

water

3 0 0 - 2 ppm 100 ppm - 1260

ppm/4h

38 CO2

CAS#124-38-9

T - -78.5 - - - 1.53 Soluble in cold

water


CO2)

5000 ppm 40,000

ppm

- -

39 THIONYL CHLORIDE

CAS#: 7719-09-7

T - 76 - - 1.638 4.1 Insoluble in

cold water

3 0 2 - 1 ppm - - 500 ppm 1

hours [Rat]

40 ORTHOFICHLORO

BENZENE

CAS#: 95-50-1

F 66 2.2 9.2 1.3059 5.07 Very slightly

soluble in cold

water


CO2), Halogenated

Compounds

50 ppm 200 ppm - 500 mg/kg

[Rat]

41 DI METHYL

FORMAMIDE

CAS#68-12-2

F & T 57.77

8

153 2.2 15.2 0.949 2.51 Easily soluble

in cold water,

hot water


CO2), Nitrogen Oxides

(NO, NO2)

10 - 4720 9400 mg/kg

(Rat)

42 DIMETHYL AMINE

CAS#124-40-3

F -6.69 7 2.8 14.4 0.84 0.62 Easily soluble

in cold water


CO2)

- - 698 4540 mg/kg

(Rat)

43 TETRA HYDRO

FURAN

CAS#109-99-9

-14.5 65 2 11.8 0.8892 2.5 Partially

soluble in cold

water.

Solubility in

water is 30%


CO2)

200 ppm 2000

ppm

1650 mg/kg

[Rat]

21000 mg/m

3 hours [Rat]

44 MONO CHLORO

ACETIC ACID

CAS#: 79-11-8


water, hot

water


CO2), Halogenated

Compounds

0.05 ppm - 55 mg/kg

[Rat]

254.6 ppm 4

hour(s) [Rat]



SR. NAME OF

CHEMICAL

HAZARD FLASH

POINT 0

C

BP 0

C

LEL % UEL % SP.GR.

20 0

C

VD SOLUBILITY

WITH WATER

at 20 0 C

NFPA

H F R

HAZARDOUS

COMBUSTION

PRODUCT

TLV

/

TWA

IDLH

LC50

LD50

45

MONOMETHLL

ACETO ACETMIDE

CAS#5977-14-0

- - 139

140

- - Bulk

density 0.8

g/l at 20 °C

- - - Carbon Oxides,

Nitrogen Oxides (NOx)

- - - > 5,000

mg/kg

46 ANILINE

CAS#: 62-53-3

T & C 70 184.1 1.3 23 1.0216 3.22 Soluble in cold

water, hot

water



(NO, NO2)

5 ppm 100 ppm - 250 mg/kg

[Rat.]

47 FORMIC ACID

CAS# 64-18-6

F & T 69 100 18 57 1.21 1.59 Soluble in cold

water, hot

water


CO2)

5 ppm 30 ppm 6200 mg/m

0.25 hours

[Mouse]

700 mg/kg

[Mouse]

48 SOD

LIGHNOSULPHATE

CAS#: 8061-51-6

- - - - - - Easily soluble

in cold water,

hot water

2 1 0 - - - - 6030 mg/kg

[Mouse]

49 HMTA

CAS#100-97-0

F 250 - - - 1.331 4.9 Soluble in cold

water



(NO, NO2)

- - - 569 mg/kg

[Mouse]

50 NITRO BENZENE

CAS#: 98-95-3

T 87.78 210.8 1.8 - 1.2 4.25 Very slightly

soluble in cold

water



(NO, NO2)


[Mouse]

51 ANILINE

CAS#: 62-53-3

T & C 70 184.1 1.3 23 1.0216 3.22 Soluble in cold

water, hot

water



(NO, NO2)


[Rat.]

52 HYDROQUINONE

CAS#: 123-31-9

T & C 165 286 - - 1.33 3.81 Soluble in cold

water, hot

water


CO2)

2 mg/m3 50

mg/m3

- 320 mg/kg

[Rat.]

53 METHYL BROMIDE

CAS#: 74-95-3

T - 96.95 - - 2.497 6.05 Insoluble in

cold water, hot

water

2 0 0 - 20 ppm 250 ppm 3977.9 ppm 4

hour(s) [Rat]

108 mg/kg

[Rat]

54 ETHYL BROMIDE

CAS#: 74-96-4

F & T -10 38.04 6.75 11.25 1.45 3.76 Very slightly

soluble in cold

water, hot

water


CO2)

200 ppm 2000

ppm

8115 ppm 4

hour(s)

[Mouse]

1350 mg/kg

[Rat]

55 DETCL

CAS#2524-04-1

C 113 45 - - - - - - Carbon Oxides, Sulphur

Oxides, Oxides Of

Phosphorus, Hydrogen

Chloride Gas

- - - 1,340

mg/kg

(Rat)

56 HYDROGEN C - 108 - - 1.1 1.1 Easily soluble 3 0 1 - 1 ppm 75 ppm 2000 mg/m 4 2000 mg/kg



SR. NAME OF

CHEMICAL

HAZARD FLASH

POINT 0

C

BP 0

C

LEL % UEL % SP.GR.

20 0

C

VD SOLUBILITY

WITH WATER

at 20 0 C

NFPA

H F R

HAZARDOUS

COMBUSTION

PRODUCT

TLV

/

TWA

IDLH

LC50

LD50

PEROXIDE

CAS#7722-84-1

in cold water hours [Rat] [Mouse]

57 CHLORAL

CAS#: 302-17-0

75 96 - - 1.9081 - Easily soluble

in cold water


CO2), Halogenated

Compounds

- - - 479 mg/kg

[Rat]

58 ETHYL BROMIDE

CAS#: 74-96-4

F & T -10 38.04 6.75 11.25 1.45 3.76 Very slightly

soluble in cold

water, hot

water


CO2)

200 ppm 2000

ppm

8115 ppm 4

hour(s)

[Mouse]

1350 mg/kg

[Rat]

59 METHYL BROMIDE

CAS#: 74-95-3

T - 96.95 - - 2.497 6.05 Insoluble in

cold water, hot

water

2 0 0 - 20 ppm 250 ppm 3977.9 ppm 4

hour(s) [Rat]

108 mg/kg

[Rat]

60 MONO CHLORO

ACETIC ACID

CAS#: 79-11-8


water, hot

water


CO2), Halogenated

Compounds

0.05 ppm - 55 mg/kg

[Rat]

254.6 ppm 4

hour(s) [Rat]

61 HYDRAZINE HYDRIDE

(80%)

CAS#: 7803-57-8

C & T 72 113.5 4.7 - 1 1.1 Easily soluble

in cold water,

hot water

3 2 2 - - - 570 ppm 4

hour(s) [Rat]

129 mg/kg

[Rat]

62 OLEUM

CAS#: 8014-95-7

C - 45 - - 1.92 3.4 Easily soluble

in cold water

3 0 2 - 2 ppm - 510 mg/m 2

hours [Rat]

2140 mg/kg

[Rat.]

63 PHENYL HYDRAZINE

CAS#: 100-63-0

T 89 238 - - 1.099 3.7 Easily soluble

in cold water



(NO, NO2)


[Rat]

64 M CRESOL

CAS#: 108-39-4

F 86 202 1.1 - 1.034 3.72 Partially

soluble in cold

water Soluble

in about 40

parts water


CO2)

5 ppm 250 ppm 1100 mg/kg

[Rat]

242 mg/kg

[Rat]

65 NITROSYL

SULPHONIC ACID

(40%)

CAS#7782-78-7

F & C - > 100 - - - - Decomposes - Carbon Oxides (CO,


(NO, NO2)

- - 320 mg/m3 2140 mg/Kg

66 CYNO ACETIC ACID

CAS#: 3722-09-8

C 160 108 - - - - - 3 1 0 Carbon Oxides (CO,


- - - 1500 mg/kg

[Rat]



SR. NAME OF

CHEMICAL

HAZARD FLASH

POINT 0

C

BP 0

C

LEL % UEL % SP.GR.

20 0

C

VD SOLUBILITY

WITH WATER

at 20 0 C

NFPA

H F R

HAZARDOUS

COMBUSTION

PRODUCT

TLV

/

TWA

IDLH

LC50

LD50

(NO, NO2)

67 NPMIDA

CAS#5994-61-6

C - - - - - - - - Carbon Oxides,

Nitrogen Oxides (NOx),

Oxides Of Phosphorus

- - - -

68 BENZYL CHLORIDE

CAS#: 100-44-7

F & C 67.2 179 1.1 14 1.1 4.36 Insoluble in

cold water, hot

water


CO2), Halogenated

Compounds


[Rat.]

69 TCAC

CAS#: 76-03-9

C - 195.5 - - 1.6126 - Easily soluble

in cold water,

hot water,

Solubility in

water @ 25

deg. C: 1000

g/100 ml water

3 0 0 - 1 ppm - - -

F = FIRE T = TOXIC

E = Explosive R = REACTIVE

BP = BOILING POINT LEL = LOWER EXPLOSIVE LIMIT

UEL = UPPER EXPLOSIVE LIMIT SP.GR = SPECIFIC GRAVITY

VD = VAPOUR DENSITY ER = EVAPORATION RATE

H = HEALTH HAZARD CLASS F = FIRE HAZARD CLASS

R = REACTIVE HAZARD BR = BURNING RATE

TLV = THRESHOLD LIMIT VALUE PPM = PARTS PER MILLION

STEL = SHORT TERM EXPOSURE LIMIT NFPA = NATIONAL FIRE PROTECTION ASSOCIATION-USA

C = C



6.1.4.4 CONTROL MEASURES WHILE STORAGE OF HAZARDOUS CHEMICALS

For PESO Underground Storage Tank Farm:

Class A petroleum products will be received through road tanker and stored in

underground storage tank as per petroleum rules.

Tank farm will be constructed as per explosive department requirement and separation

distance will be maintained.

Static earthing provision will be made for road tanker as well as storage tank.

Flame arrestor with breather valve will be provided on vent line.

Road tanker unloading procedure will be prepared and implemented.

Fire load calculation will be done and as per fire load Hydrant System will be provided as

per NFPA std. and Fire extinguishers will be provided as per fire load calculation.

Spark arrestor will be provided to all vehicles in side premises.

Flame proof type equipment s and lighting will be provided.

Lightening arrestor will be provided on the top of chimney.

Trained and experience operator will be employed for tank farm area.

NFPA label (hazard identification) capacity and content will be displayed on storage tank.

Solvents will be transferred by pump only in plant area and day tank will be provided.

Overflow line will be return to the storage tank or Pump On-Off switch will be provided

near day tank in plant.

Jumpers will be provided on solvent handling pipe line flanges.

Flexible SS hose will be used for road tanker unloading purpose and other temp.

Connection.

For Above Ground Non PESO Storage Tank Farm:

SS storage tank provided as per IS code.

Dyke wall provided to storage tank.

Level gauge provided with low level high level auto cut-off provision.

Fire hydrant monitor with foam trolley facility provided.

FLP type pump provided.

Double static earthing provided to storage tank.

Double Jumper clip provided to all pipeline flanges.



Road tanker unloading procedure prepared and implemented.

Lightening arrestor, PPEs provided.

Safety shower, eye wash provided.

NFPA labeling system adopted for drums as well as storage tanks.

Safety Measures for Acid Storage Tank Area:

Storage tank will be stored away from the process plant.

Tanker unloading procedure will be prepared and implemented.

Caution note and emergency handling procedure will be displayed at unloading area and

trained all operators.

NFPA label will be provided.

Required PPEs like full body protection PVC apron, Hand gloves, gumboot, Respiratory

mask etc. will be provided to operator.

Neutralizing agent will be kept ready for tackle any emergency spillage.

Safety shower, eye wash with quenching unit will be provided in acid storage area.

Material will be handled in close condition in pipe line.

Dyke wall will be provided to all storage tanks, collection pit with valve provision.

Double drain valve will provided.

Level gauge will be provided on all storage tanks.

Safety permit for loading unloading of hazardous material will be prepared and

implemented.

TREM CARD will be provided to all transporters and will be trained for transportation

Emergency of Hazardous chemicals.

Fire hydrant system with jockey pump as per TAC norms will be installed.

Bromine Storage & Handling Safety

The amount of bromine in storage will be kept to a minimum.

Minimize the dispersal of bromine vapors by locating the storage area on low ground.

Low curbs or walls (called dikes), 200 mm high, will be provided to protect the area from

external flooding and to minimize the dispersal of bromine vapors. The minimum dyked

volume will be equivalent to the largest storage tank plus 10%.



Adequate size sump will be provided for collecting bromine spills and pump away

collected rainwater and fire-fighting water.

Floors will be of impervious construction, preferably concrete.

Bromine ISO tank should be stored no closer than 10 meters from human or animal

consumable articles. Explosives and flammable materials should not be stored close to

bromine.

There should be a strengthened approach way for emergency vehicles on two sides of

the installation.

Hoses will be PTFE with stainless steel braid covering and carbon steel flanges. Screwed

fittings will not used.

Provide lightning protection.

There would be sufficient bromine storage tank capacity or an empty ISO tank to

accommodate the transfer of bromine from a leaking container

Area where bromine will be used or stored will be enclosed so that unauthorized persons

and animals are prevented from entering the area. Adequate lighting will be provided to

allow sufficient night surveillance. Surveillance will be provided 24 hours a day.

Personnel escape routes will be clearly marked and it will be maintained without any

obstructions including adequately sized doors and windows.

Facilities like offices, eating, showering and changing rooms, will be located in up wind

direction and remote from the area where bromine is handled or stored. Provide an

adequate supply of clean water for washing and showers.

Emergency siren, telephone will be provided in storage area for the reporting of

accidents or emergency situations. The emergency telephone numbers will be displayed

at prominent locations 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 all points on the site and

replaced as required. This is required for indicating wind strength and direction.

Emergency respirator equipment cabinets (Cupboard) will be installed not more than 30

meters or ten seconds walking distance from any location in the storage area.

Showers and eyewash fountains will be provided, clearly marked, well lit and with

unobstructed access.



Signs will be 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.

All management and operating personnel involved in the use or handling of bromine will

undergo safety training, in addition to specific task training.

Only experienced well-trained operators will be allowed to receive and unload bromine

receptacles.

The management will ensure that emergency response plans have been made and

coordinated with the emergency response local authorities.

Bromine glass bottle capacity 2.5 litters and six bottles are stored in one packing box.

Bromine will be stored in dry and cool place and well ventilated area.

Safety permit for hazardous material loading unloading will be prepared and

implemented.

Fire hydrant system and water sprinkler system installed at tank farm area.

Safe Transportation Procedure to be adopted for Bromine ISO container

The driver and assistant driver of any vehicle transporting bromine should comply with the

following requirements:

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 passengers are 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 is permitted around the transport unit or in the vicinity of the vehicle during

handling operations.

The engine is 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 is parked on a road at night or with poor visibility, warning signs are to be

placed 10 meters ahead of and behind the vehicle.

TREM CARD provided to all transporters and trained for transportation Emergency of

Hazardous chemicals.

Following Personal Protective Equipments are to be made compulsory when handling

Bromine

American National Standards Institute (ANSI) approved chemical safety goggles at all

times when handling Br2.

Use a full face shield over eyewear.

Full body protection PVC suite

Eyewash fountains should be located in areas where bromine is handled, used or stored.

When in danger of contact with liquid bromine, wear an approved chemical resistant

suit.

Leather or other non-woven ANSI approved steel-toed shoes or Gum boot

Protective rubber boots should be worn over shoes for extra protection.

Have NIOSH approved respirators and self-contained breathing apparatus available.

Gloves: 100% Nitrile rubber gloves or Neoprene gloves

Safety Practices in the Work Area

We will inform our all employees of the potential hazards of contact with bromine and

train them in appropriate first-aid procedures.

Bromine handling areas will be clearly marked and restricted to qualified, trained

personnel only.

Ventilation

We will maintain bromine vapor concentration in the work area to less than 0.1 ppm

with adequate exhaust hoods, ventilation systems and scrubbers. Analyze air for proper

control.

Transfer or repackage bromine only in a controlled, closed environment.

Exhaust ventilating systems will be used in enclosed areas where bromine is handled.



Neutralization in Case of Spillage Leakage

Neutralization with sodium Bisulfite requires 3 moles of sodium hydroxide: 1 mole

sodium Bisulfite: 1 mole bromine.

Neutralization with sodium sulfite requires 2 moles sodium hydroxide: 1 mole sodium

sulfite: 1 mole bromine.

The weights and volumes specified include a 10% excess of sodium hydroxide and

sodium bisulfate or sodium sulfite.

Emergency Procedures

In case of bromine emergencies, follow recommended first aid and emergency response

procedures adopted

Transportation Emergencies

In emergency situations resulting from vehicle accidents:

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

Isolate the area.

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.

Call to the supplier

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 equipment must be worn.

Clear contaminated area of non-essential personnel and send them to assembly point.

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.”

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. Pour



hypo solution*, lime and water slurry or soda ash solution over the spill. Hypo-bromine

reactions produce hydrobromic acid.

Dry sodium thiosulphate and liquid bromine produce a violent reaction; do not mix them.

Using cold water, wash neutralized bromine into a sump for transfer to an approved

waste disposal facility where the waste can be processed.

Ventilate the area to remove the ammonium bromide and any bromine fumes. Scrub the

floors and equipment with soap and water.

First Aid Procedure

Immediate medical assistance is required if bromine is swallowed, inhaled or has

contacted the eyes or skin.

If bromine has been ingested, do not give anything by mouth. Seek medical attention

immediately. Do not induce vomiting.

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 and showing signs of respiratory distress, properly trained personnel should

administer oxygen.

For skin contact, the affected area must be flooded immediately with large amounts of

clean water from a safety shower or other 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 a minimum of 30 minutes. If possible, continue to wash the affected area

during transport to medical facilities. (Extended wash times of two hours or more have

proven beneficial.)

If bromine liquid or vapor contacts the eyes, they must be irrigated immediately with

large amounts of running water. Eye wash stations are preferable for irrigation. If one is

not available, a hose, water source with a liberal, gentle flow may be utilized. The eyelids

must be held apart during irrigation to ensure contact of water with all accessible tissues

of the eyes and lids. Eyes should be washed continuously for a minimum of 30 minutes. If



possible, continue flushing the eyes while transporting the employee to a physician. In all

cases of bromine injury, obtain immediate medical attention. Provide emergency

personnel with information about all materials used by the person and provide

appropriate information about bromine and first aid procedures.

For Drum Storage Area:

Some chemicals will be received at plant in drums by road truck and stored in a separate

drum storage area.

FLP type light fittings will be provided.

Proper ventilation will be provided in Godown.

Proper label and identification board /stickers will be 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 and toxic chemical drums storage.

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

For Chlorine:

Following steps will be adopted:

SOP will be prepared for safe handling of Chlorine tonners.

Chlorine Emergency Kit will be procured and kept ready at chlorine shed.

Chlorine Hood with blower will be provided with scrubbing arrangement.

Safety Shower and eye wash will be provided in Chlorine shed area.

Tonner handling EOT crane will be installed in Chlorine shed area for safe Tonner

handling.

Safety Valve will be provided on chlorine header line and it will be 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.

Hydrogenation Plant:

FLP type area will be provided.

Total enclosed process system.

Instrument & Plant Air System.

Nitrogen blanketing in Hydrogenation reactor.

Safety valve and Rupture disc provided on reactor.

Cooling Chilling and power alternative arrangement have been made on reactor.

Hydrogen and Nitrogen Cylinder bank away from the auto clave reactor.

PRV station with shut off valve, safety valve provision will be made for hydrogenation

reaction safety.

Before Hydrogen Gas charging in to reactor and after completion of reaction Nitrogen

flushing will be done.

Flame arrestor will be provided on vent line of reactor and it will be extended up to roof

level.

Open well ventilated and fragile roofs will be provided to on reactor.

Safe Catalyst charging method will be adopted.

SOP will be prepared and operators will be trained for the same.

Static earthing and electric earthing (Double) provided.

Rector vent extended out side the process area and flame arrestor provided on vent line.

Dumping vessel arrangement will be made.

Jumpers for static earthing on pipeline flanges of flammable chemical will be provided.

6.1.4.4.1 PRECAUTIONS DURING STORAGE AND TRANSPORTATION OF HAZARDOUS

CHEMICALS LIQUIDS

Always use the road tankers having authorization for transporting the said liquids.

Vendor will be asked to provide MSDS to Tanker Driver.

Tankers will have clearly marked identification of material being contained with

mentioning Safety Card.

Tanker/truck –Driver contact at gate & ensure meet all points as per Check List



Driver to have concerned Safety Officer’s contact details to contact him in case of

emergency.

Provide muffler on exhaust while entering tanker within premises.

Ensure Auto Earthling system Boss connection before starting any transferring.

SOP to cover routine checking of Tank farm area to be carried out for checking any

spillage / leakage.

Tanks will be inspected physically daily for having any visual abnormality.

Readings of Temperature & Pressure will be noted, recorded & reported immediately for

abnormality.

Safety instruments like rupture disc, safety valves will be checked at defined duration for

intakeness.

Scheduled testing of tanks to be done for thickness testing.

Tanks to be painted on regular interval defined as per laws to protect them from

atmospheric corrosion.

Barrels to be checked for proper fixing of bungs before sending it outside the premises.

Barrels to be monitored physically daily for developing any pressure or vacuum within it

on long storage.

Concerned persons will be trained properly to use spill kit in case of observing any

spillage inside warehouse.

SOLIDS

Vendor will be asked to provide MSDS to Truck Driver.

Driver to have concerned Safety Officer’s contact details to contact him in case of

emergency.

Provide muffler on exhaust while entering truck within premises.

SOP to cover routine checking of Bags & Containers for checking any damage.

Containers to be tested for safe racking & transportation.

Proper PPE to be used while handling the material & concerned persons to be trained for

usage of the same.

Concerned persons will be trained properly to use spill kit in case of observing any

spillage inside warehouse.



The major hazards in the M/s. Greentec Chemicals Pvt. Ltd. are described below.

Toxic hazard due to leakage of hazardous chemicals from storage tank.

Corrosive hazard due to leakage of chemicals from Carboys.

Electrical hazards due to the electrical major equipment/ machinery, operations,

welding, motors, and heavy lift devices, cabling, human intervention (short circuit

possibility), maintenance work (due to machinery breakdown etc.), plant lighting related

electrical hazards.

Possibility of human injury due to working with mechanical machines, manual handling

etc.

Possibility of injury during chemicals handled, during operations and due to intoxication.

Major dropped objects hazard due to large number of physical handling steps /

operations involved with crane/ overhead lifting/ hoisting equipment.

Fires in any part of the plant working areas – there is a possibility of rapid escalation if it

is not brought under control quickly.

Possibilities of fire hazards at transformers, switchgear and other electrical equipment

etc.



6.1.4.4.2 TRANSPORTATION, UNLOADING AND HANDLING PROCEDURE FOR HAZARDOUS

CHEMICALS

Transportation, Unloading and Handling Procedure for Solvents

SR.

NO.

ACTIVITY TYPE OF POSSIBLE

HAZARD

MITIGATION MEASURES

Leakage& Spillage

Check the source of leakage point.

Do not touch damaged containers or spilled material

unless wearing appropriate protective clothing.

Stop leak if you can do it without risk.

Fire & explosion Use water spray to reduce vapors; do not put water

directly on leak, spill area or inside container.

Keep combustibles (wood, paper, oil, etc.) away from

spilled material.

Auto earthling to be connect & ensure

1 Transportation of Solvents by

road tanker

Toxic release Isolate the area

Isolate the container

Training will be provided to driver and cleaner

regarding the safe driving, hazard of Flammable

chemicals, emergency handling.

TREM card will 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.

2 Road tanker unloading at tank

farm area

Leakage& Spillage





Auto earthling to be connect & ensure

Fire & explosion Use water spray to reduce vapors; do not put water



spilled material.

Toxic release Isolate the area



Isolate the area


Spray the water on leakage

Priority will be given to Tanker to immediately enter

the storage premises at site and will not be kept

waiting near the gate or the main road.

Security person will check License, TREM CARD, Fire

extinguisher condition; Antidote Kit, required PPEs as

per SOP laid down.

Store officer will take sample as per sampling SOP from

sampling point.



After approval of QC department unloading procedure

will be allowed 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.

All TL valves will be closed in TL.

Finally earthing connection and wheel stopper will be

removed.

Only day time unloading will be permitted.

Leakage& Spillage Check the source of leakage point.




Fire, Explosion Use water spray to reduce vapors; do not put water



spilled material.

3 Storage tank safety

Toxic release. Isolate the area



Isolate the area


Spray the water on leakage

SS storage tank will be provided as per IS 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.

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 Transfer from storage tank to

Day tank

Leakage& Spillage due to

Line rupture, Flange

Gasket 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 level will 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 Transfer from Day tank to

reactor.

Leakage, Spillage due to

Line rupture, Flange

Gasket 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.

Transportation, Unloading and handling procedure for Acrylonitrile (ACN)

SR.NO. ACTIVITY TYPE OF POSSIBLE

HAZARD

MITIGATION MEASURES

1 Road tanker filling

at Kandla /JNPT

/vendor port

& vendor factory

in tank farm area.

Spillage, toxic

release, fire,

explosion.

This activity falls under Kandla/jNPT Port Authority.

Following measures will be provided at Kandla/jNPT Tank

Lorry Filling (TLF) area.

Static earthing provision to Tank Lorry (TL) and

interlocking with filling pump.

Wheel stoppers to TL.

Automatic Charging by PLC based system with volume

measurement.

Flame arrestor/ spark arrestor on TL exhaust.

2 Transportation of

ACN by road

tanker

Leakage & Spillage

Fire, explosion,

Toxic release





Use water spray to reduce vapors; do not put water



spilled material.

Isolate the area


Training will be provided to driver and cleaner regarding

the safe driving, hazard of ACN, ACN emergency handling,

use of antidote kit administration.


Antidote Kit will be kept with TL.

SCBA set will be kept with TL.

Fire extinguishers will be kept with TL.

All the TL will be equipped with Global Positioning system

(GPS) and route will be predefined.

Flame arrestor will be provided to TL exhaust.

Instructions will be given not to stop ACN road tanker in

populated area.



CODE.




3 ACN tank Lorry

unloading at site

Leakage& Spillage,

Fire, explosion,

Toxic release








spilled material.

Isolate the area


Priority will be given to Tanker to immediately enter the

storage premises at site and will not be kept waiting near

the gate or the main road.


extinguisher condition; SCBA set condition, Antidote Kit,

required PPEs as per SOP laid down.


sampling point.

After approval of QC department unloading procedure will

be allowed be started.

Following precautions will be adopted during unloading by

Nitrogen pressure.


platform.


Tanker unloading procedure will be followed according to

check list and implemented.

Nitrogen hose connection will be done with TL nitrogen

inlet line for ACN transfer by Nitrogen pressure.

Flexible SS hose connection will be done at TL outlet line.

After connecting all hoses properly, check will be carried

out for leakage and then charging line valve will be

opened, followed by TL outlet line valve and finally

Nitrogen charging line valve will be opened gradually to

apply N2 pressure inside TL.

When TL is empty, first N2 pressure line valve will be

closed followed by TL outlet line valve and finally tank

charging line valve.


drained to a small underground storage tank, which will

be subsequently transferred by nitrogen pressure to the

main storage tank thus ensuring complete closed

conditions for ACN transfer from road tanker.

All TL valves will be closed keeping nitrogen blanketing in

TL.

Finally earthing connection and wheel stopper will be

removed.


Following precautions will be adopted during TL unloading



work by pump.

Wheel stopper will be provided to TL at unloading plate

form.


Tanker unloading procedure with check list will be

followed and implemented.

Flexible SS hose connection will be made to TL outlet line.

After connecting all hoses will be properly checked for any

leakages and then storage tank charging line valve will be

opened followed by TL outlet line valve and finally pump

will be started.

When TL is empty, stop the pump then tank charging line

valve is closed followed by TL outlet line valve.


drained to a small underground storage tank, which will

be subsequently transferred by nitrogen pressure to the

main storage tank thus ensuring complete closed

conditions for ACN transfer from road tanker.

All TL valves are closed and nitrogen blanketing in TL will

be provided.

Earthing connection and wheel stopper will be removed.


4 Storage tank

safety

Leakage &Spillage,

Fire, Explosion,

Toxic release








spilled material.

Isolate the area


SS storage tank will be provided as per IS 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.

Water sprinkler system will be provided to storage tank.

Fire hydrant monitor with foam attachment facility will be

provided.

Dumping / Drain 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 ACN handling

pipeline flanges.

5 ACN transfer from

storage tank to

Leakage, Spillage

due to Line

Double mechanical seal type FLP type pump will be

provided.



Day tank rupture, Flange

Gasket failure,

Fire, Explosion,

Toxic release.

Double on / off switch will provided at tank farm and

process area near day tank. Pump auto cut off with day

tank high level will 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.


Double Jumper clip will be provided to all ACN handling

pipeline.

Double static earthing will be provided to day tank.

6 ACN transfer from

Day tank to

reactor.

Leakage, Spillage

due to Line

rupture, Flange

Gasket failure,

Fire, Explosion,

Toxic release.

Gravity transfer.


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.

Bromine Transportation, Unloading and handling Procedure:


HAZARD

MITIGATION MEASURES

1 Transportation of

Bromine by ISO

container

Leakage, Spillage,

Toxic release

Leak check with ammonia torch and detect the leak point.

ELIMINATE all ignition sources (no smoking, flares, sparks

or flames in immediate area).




Prevent entry into waterways, sewers, basements or

confined areas.

Absorb or cover with dry earth, sand or other non-

combustible material and transfer to containers.

Do not get water inside containers.

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

passengers are 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 is permitted around the transport unit or in

the vicinity of the vehicle during handling operations.

The engine is 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 is parked on a road at night or with poor

visibility, warning signs are to be placed 10 meters ahead



of and behind the vehicle.

TREM CARD provided to all transporters and trained for

transportation Emergency of Hazardous chemicals.

All trucks having 1 kg Sodium Thiosulphate bag.


the safe driving, hazard of Bromine emergency handling,

use of SCBA 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.



CODE.

Appropriate PPEs will be kept with Truck.

3 Bromine ISO

container loading

and handling at

site

Leakage, Spillage,

toxic release


ELIMINATE all ignition sources (no smoking, flares, sparks

or flames in immediate area).





confined areas.




Directly ISO container will be placed at storage area and

connected with process tank.

Wear recommended personal protective equipment

during connection of ISO container.

Make sure the absorber unit is working and capable of

handling vented bromine fumes.

BE SURE THAT DRY AIR (DEW POINT -40"C) OR DRY

NITROGEN is available in ample supply and its pressure is

controlled below 3 atm. gauge.

Check that all the Iso-container valves are closed and blind

flanges 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

tight connection.

Open the red valve slowly and then the depressurizing

valve, to release 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

only enough pressure to lift the bromine to the high point

in the unloading system.

NEVER EXCEED 3 ATM. PRESSURE

When air/nitrogen blows through the unloading line into

your storage tank, the Iso-container is empty.

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 5 minutes.

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

proper gasket.

Disconnect your pressure release line from the red valve

of the Iso-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. Small

bromine spills on the ground may be neutralized with a

clear soda ash or a sodium thiosulphate solution. Then

dispose of in a manner 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 and flammable materials should not be stored

close to bromine.

There would be sufficient bromine storage tank capacity

or an empty ISO tank to accommodate the transfer of

bromine from a leaking container

Area where bromine will be used or stored will be

enclosed so that unauthorized persons and animals are

prevented from entering the area. Adequate lighting will

be provided to allow sufficient night surveillance.

Surveillance will be provided 24 hours a day.

Personnel escape routes will be clearly marked and it will

be maintained without any obstructions including

adequately sized doors and windows.

Facilities like offices, eating, showering and changing

rooms, will be located in up wind direction and remote

from the area where bromine is handled or stored.

Provide an adequate supply of clean water for washing

and showers.

Emergency siren, telephone will be provided in storage

area for the reporting of accidents or emergency

situations. The emergency telephone numbers will be



displayed at prominent locations 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

all points on the site and replaced as required. This is

required for indicating wind strength and direction.

Emergency respirator equipment cabinets (Cupboard) will

be installed not more than 30 meters or ten seconds

walking distance from any location in the storage area.

Showers and eyewash fountains will be provided, clearly

marked, well lit and with unobstructed access.

Signs will be 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.

All management and operating personnel involved in the

use or handling of bromine will undergo safety training, in

addition to specific task training.

Only experienced well-trained operators will be allowed to

receive and unload bromine receptacles.

The management will ensure that emergency response

plans have been made and coordinated with the

emergency response local authorities.

Safety permit for hazardous material loading unloading

will be prepared and implemented.

Fire hydrant system and water sprinkler system installed

at tank farm area.



Chlorine Transportation, Unloading and handling Procedure:


HAZARD

MITIGATION MEASURES

1 Transportation of

Chlorine Tonners

by road tanker

Leakage, Spillage,

Toxic release


ELIMINATE all ignition sources (no smoking, flares, sparks or

flames in immediate area).

Do not touch damaged containers or spilled material unless

wearing appropriate protective clothing.



confined areas.




Training will be provided to driver and cleaner regarding the

safe driving, hazard of Chlorine emergency handling, use of

SCBA sets.


SCBA set will be kept with TL.

Instructions will be given not to stop Chlorine road truck in

populated area.


telephone number will be displayed as per HAZCHEM CODE.


2 Chlorine tonners

unloading at site

Leakage, Spillage,

toxic release








confined areas.





storage premises at site and will not be kept waiting near

the gate or the main road.


extinguisher condition; SCBA set condition, required PPEs as

per SOP laid down.

3 Chlorine tonners

storage shed

Leakage, Spillage,

Toxic release.










confined areas.




SOP will be prepared for safe handling of Chlorine toners.

Chlorine Emergency Kit will be procured and kept ready at

chlorine shed.

Chlorine Hood with blower will be provided with scrubbing

arrangement.

Safety Shower and eye wash will be provided in Chlorine

shed area.

Tonner handling EOT crane will be installed in Chlorine shed

area for safe tonner handling.

Safety Valve will be provided on chlorine header line and it

will be connected to caustic scrubber.


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

header

Leakage, Spillage

due to Line

rupture, Toxic

release.








confined areas.




Teflon or copper tube will be used for connection with

header.

Pressure gauge and safety valve will be provided on header

line.

Transportation, Unloading and handling procedure for Phenol:


HAZARD

MITIGATION MEASURES

1 Transportation of

Phenol by road

tanker

Leakage, Spillage,

Toxic release


the safe driving, hazard of Flammable chemicals,

emergency handling, and use of SCBA sets

administration.


Instructions will be given not to stop road tanker in

populated area.



CODE.




Emergency telephone numbers list for OFF site

emergency agencies will be provided in TREM CARD.

2 Phenol Road tanker

unloading at site.

Leakage, Spillage,

toxic release, fire


storage premises at site and will not be kept waiting

near the gate or the main road.


extinguisher condition, required PPEs as per SOP laid

down.


sampling point.

After approval of QC department unloading procedure

will be allowed be started.



platform.

Tanker unloading procedure will be followed according

to check list and implemented.

Flexible hose connection will be done at TL outlet line

and checked for no leakage.

Every time rubber gasket will be changed.


drained to a small container, which will be subsequently

transferred to the main storage tank thus ensuring

complete closed conditions for transfer from road

tanker.

3 Phenol Storage

tank safety

Leakage, Spillage,

Toxic release.

Storage tank will be stored away from the process plant

in tank farm area.

Caution note and emergency handling procedure will be

displayed at unloading area and trained all operators.


Required PPEs like full body protection PVC apron, Hand

gloves, gumboot, Respiratory mask etc. will be provided

to operator.

Safety shower, eye wash with quenching unit will be

provided in acid storage area.


Dyke wall will be provided, collection pit with valve

provision.

Jacketed tank will be provided and steam heating will be

provided in jacket.


Level gauge will be provided on storage tank.

Safety permit for loading unloading of hazardous

material will be prepared and implemented.

Fire hydrant system with jockey pump as per TAC norms

will be installed.

4 Phenol transferred

from storage tank

to Day tank

Leakage, Spillage

due to Line

rupture, Flange

Double mechanical seal type pump will be provided.

Over flow will be provided for additional safety and it

will be connected to main storage tank.



Gasket failure,

Toxic release.


Flange Guard will be provided to all flanges.

5 Phenol transfer

from Day tank to

reactor.

Leakage, Spillage

due to Line

rupture, Flange

Gasket failure,

Toxic release.

Gravity transfer.

Double valve will be installed on day tank outlet line.


reactor at a time.

Flange guard will be provided to pipeline flanges.

6.1.5 CONSEQUENCE ANALYSIS

In a plant handling hazardous chemicals, the main hazard arises due to storage, handling &

use of these chemicals. If these chemicals are released into the atmosphere, they may cause

damage due to resulting fires or vapour clouds. Blast Overpressures depend upon the

reactivity class of material between two explosive limits.

Operating Parameters

Potential vapour release for the same material depends significantly on the operating

conditions. Especially for any liquefied gas, the operating conditions are very critical to

assess the damage potential. If we take up an example of ammonia, if it is stored at ambient

temperature, say 30oC, and then the vapour release potential of the inventory is much

higher as compared to the case if it is stored at 0oC.

Inventory

Inventory Analysis is commonly used in understanding the relative hazards and short listing

of release scenarios. Inventory plays an important role in regard to the potential hazard.

Larger the inventory of a vessel or a system, larger the quantity of potential release. The

potential vapour release (source strength) depends upon the quantity of liquid release, the

properties of the materials and the operating conditions (pressure, temperature). If all

these influencing parameters are combined into a matrix and vapour source strength

estimated for each release case, a ranking should become a credible exercise.

Loss of Containment

Plant inventory can get discharged to Environment due to Loss of Containment. Certain

features of materials to be handled at the plant need to the clearly understood to firstly list

out all significant release cases and then to short list release scenarios for a detailed



examination. Liquid release can be either instantaneous or continuous. Failure of a vessel

leading to an instantaneous outflow assumes the sudden appearance of such a major crack

that practically all of the contents above the crack shall be released in a very short time. The

more likely event is the case of liquid release from a hole in a pipe connected to the vessel.

The flow rate is depending on the size of the hole as well as on the pressure, which was

present, in front of the hole, prior to the accident. Such pressure is basically dependent on

the pressure in the vessel. The vaporisation of released liquid depends on the vapour

pressure and weather conditions. Such consideration and others have been kept in mind

both during the initial listing as well as during the short listing procedure. In the study,

Maximum Credible Loss accident methodology is to be used, therefore, the largest potential

hazard inventories have been considered for consequence estimation.

6.1.5.1 DAMAGE CRITERIA

In consequence analysis, use is made of a number of calculation models to estimate the

physical effects of an accident (spill of hazardous material) and to predict the damage

(lethality, injury, material destruction) of the effects. The calculations can roughly be divided

in three major groups:

a) Determination of the source strength parameters;

b) Determination of the consequential effects;

c) Determination of the damage or damage distances.

The basic physical effect models consist of the following.

Source strength parameters

* Calculation of the outflow of liquid, vapour or gas out of a vessel or a pipe, in case of

rupture. Also two-phase outflow can be calculated.

* Calculation, in case of liquid outflow, of the instantaneous flash evaporation and of

the dimensions of the remaining liquid pool.

* Calculation of the evaporation rate, as a function of volatility of the material, pool

dimensions and wind velocity.

* Source strength equals pump capacities, etc. in some cases.



Consequential effects

* Dispersion of gaseous material in the atmosphere as a function of source strength,

relative density of the gas, weather conditions and topographical situation of the

surrounding area.

* Intensity of heat radiation [in kW/ m2] due to a fire or a BLEVE, as a function of the

distance to the source.

* Energy of vapour cloud explosions [in N/m2], as a function of the distance to the

distance of the exploding cloud.

* Concentration of gaseous material in the atmosphere, due to the dispersion of

evaporated chemical. The latter can be either explosive or toxic.

It may be obvious, that the types of models that must be used in a specific risk study

strongly depend upon the type of material involved:

- Gas, vapour, liquid, solid

- Inflammable, explosive, toxic, toxic combustion products

- Stored at high/low temperatures or pressure

- Controlled outflow (pump capacity) or catastrophic failure?

Selection of Damage Criteria

The damage criteria give the relation between extent of the physical effects (exposure) and

the percentage of the people that will be killed or injured due to those effects. The

knowledge about these relations depends strongly on the nature of the exposure. For

instance, much more is known about the damage caused by heat radiation, than about the

damage due to toxic exposure, and for these toxic effects, the knowledge differs strongly

between different materials.

In Consequence Analysis studies, in principle three types of exposure to hazardous effects

are distinguished:

1. Heat radiation, from a jet, pool fire, a flash fire or a BLEVE.

2. Explosion

3. Toxic effects, from toxic materials or toxic combustion products.

In the next three paragraphs, the chosen damage criteria are given and explained.



Heat Radiation

The consequence caused by exposure to heat radiation is a function of:

The radiation energy onto the human body [kW/m2];

The exposure duration [sec];

The protection of the skin tissue (clothed or naked body).

The limits for 1% of the exposed people to be killed due to heat radiation, and for

second-degree burns are given in the table herein:

Damages to Human Life Due to Heat Radiation

Exposure

Duration

Radiation for

1% lethality

(KW/m2)

Radiation for 2nd

degree burns

(KW/m2)

Radiation for

first degree

burns (KW/m2)

10 Sec 21.2 16 12.5

30 Sec 9.3 7.0 4.0

Since in practical situations, only the own employees will be exposed to heat radiation in

case of a fire, it is reasonable to assume the protection by clothing. It can be assumed that

people would be able to find a cover or a shield against thermal radiation in 10 sec. time.

Furthermore, 100% lethality may be assumed for all people suffering from direct contact

with flames, such as the pool fire, a flash fire or a jet flame. The effects due to relatively

lesser incident radiation intensity are given below.

Effects Due To Incident Radiation Intensity

INCIDENT

RADIATION

KW/m2

TYPE OF DAMAGE

0.7 Equivalent to Solar Radiation

1.6 No discomfort for long exposure

4.0 Sufficient to cause pain within 20 sec. Blistering of skin (first degree burns are likely)

9.5 Pain threshold reached after 8 sec. second degree burns after 20 sec.

12.5 Minimum energy required for piloted ignition of wood, melting plastic tubing etc.



Explosion

In case of vapour cloud explosion, two physical effects may occur:

* a flash fire over the whole length of the explosive gas cloud;

* a blast wave, with typical peak overpressures circular around ignition source.

As explained above, 100% lethality is assumed for all people who are present within the

cloud proper.

For the blast wave, the lethality criterion is based on:

* A peak overpressure of 0.1 bar will cause serious damage to 10% of the

housing/structures.

* Falling fragments will kill one of each eight persons in the destroyed buildings.

The following damage criteria may be distinguished with respect to the peak overpressures

resulting from a blast wave:

Damage Due To Overpressures

Peak Overpressure Damage Type

0.83 bar Total Destruction

0.30 bar Heavy Damage

0.10 bar

0.03 bar

Moderate Damage

Significant Damage

0.01 bar Minor Damage

From this it may be concluded that p = 0.17 E+5 pa corresponds approximately with 1%

lethality. Furthermore it is assumed that everyone inside an area in which the peak

overpressure is greater than 0.17 E+ 5 pa will be wounded by mechanical damage. For the

gas cloud explosion this will be inside a circle with the ignition source as its centre.

Intoxication

The consequences from inhalation of a toxic vapour/gas are determined by the toxic dose.

This dose D is basically determined by:

- Concentration of the vapour in air;



- Exposure duration.

Furthermore, of course, the breathing rates of the victim, as well as the specific toxic

mechanism unto the metabolism play an important role.

The dose is defined as D = Cn.t, with:

C = concentration of the toxic vapour, in [ppm] or [mg/m3];

t = exposure duration, in [sec] or [min];

n = exponent, mostly > 1.0; this exponent takes into account the fact that a high

concentration over a short period results in more serious injury than a low

concentration over a relatively longer period of exposure. The value of n

should be greater than zero but less than 5.

The given definition for D only holds if the concentration is more or less constant over the

exposure time; this may be the case for a (semi) continuous source. In case of an

instantaneous source, the concentration varies with time; the dose D must be calculated

with an integral equation:

D = Cn.dt

For a number of toxic materials, so-called Vulnerability Models (V.M.) has been developed.

The general equation for a V.M. (probit function) is:

Pr = a + b.ln (Cn.t), with

Pr = probit number, being a representation of the percentage of people suffering

a certain kind of damage, for instance lethality

Pr = 2.67 means 1% of the population;

Pr = 5.00 means 50% of the population;

a and b material dependent numbers;

Cn.t = dose D, as explained above.

The values for a and b are mostly derived from experiments with animals; occasionally,

however, also human toxicity factors have been derived from accidents in past. In case only

animal experiments are available, the inhalation experiments with rats seem to be best

applicable for predicting the damage to people from acute intoxication. Although much



research in this field have been done over the past decades, only for a limited number of

toxic materials consequence models have been developed. Often only quite scarce

information is available to predict the damage from an acute toxic exposition. Data

transformation from oral intoxication data to inhalation toxicity criteria is sometimes

necessary. Generally, in safety evaluations pessimistic assumptions are applied in these

transformation calculations. The calculated damage (distance) may be regarded as a

maximum. For the purposes of a response to a major incident, the IDLH value level has been

chosen for the ‘wounded‘criteria. This type of injury will require medical attention.

6.1.5.2 MAXIMUM CREDIBLE LOSS ACCIDENT SCENARIOS

A Maximum Credible Accident (MCA) can be characterised as the worst credible accident. In

other words: an accident in an activity, resulting in the maximum consequence distance that

is still believed to be possible. A MCA-analysis does not include a quantification of the

probability of occurrence of the accident. Another aspect, in which the pessimistic approach

of MCA studies appears, is the atmospheric condition that is used for dispersion

calculations. As per the reference of the study, weather conditions having an average wind

speed of 2.05 m/s have been chosen.

The Maximum Credible Loss (MCL) scenarios have been developed for the Facility. The MCL

cases considered, attempt to include the worst “Credible” incidents- what constitutes a

credible incident is always subjective. Nevertheless, guidelines have evolved over the years

and based on basic engineering judgement, the cases have been found to be credible and

modelling for assessing vulnerability zones is prepared accordingly. Only catastrophic cases

have been considered and not partial or small failures (as is the case in Quantitative Risk

Assessment where contributions from low frequency - high outcome effect as well as high

frequency - low outcome events are distinguished). The objective of the study is emergency

planning, hence only holistic & conservative assumptions are used for obvious reasons.

Hence though the outcomes may look pessimistic, the planning for emergency concept

should be borne in mind whilst interpreting the results.



6.1.5.2.1 CONSEQUENCE ANALYSIS CALCULATIONS

The Consequence Analysis has been done for selected scenarios. This has been done for

weather conditions having wind speed 2.05 m/s. In Consequence Analysis, geographical

location of the source of potential release plays an important role. Consideration of a large

number of scenarios in the same geographical location serves little purpose if the dominant

scenario has been identified and duly considered.

6.1.5.2.2 SOFTWARE USED FOR CALCULATIONS

PHAST MICRO: Phast is the most comprehensive software available for performing Process

Hazard Analysis (PHA), Quantitative Risk Assessment (QRA) and Financial Risk Analysis (FRA).

Our extensively validated software for consequence and risk assessment is used by

governments and industry helping them to comply with local safety regulation and their

own corporate best practice. Phast contains all the discharge, dispersion, effects and risk

models you will need to accurately assess all your major hazards and associated risks. Phast

Consequence provides you with comprehensive hazard analysis facilities to examine the

progress of a potential incident from the initial release to its far-field effects.

TOXIC AND FLAMMABLE IMPACT

It calculates the initial discharge, as the material expands from its storage conditions to

atmospheric, through dispersion, as the material mixes with air and dilutes, and the

subsequent toxic or flammable effects. Phast includes a wide range of models for discharge

and dispersion as well as flammable, explosive and toxic effects.

DISCHARGE

Phast requires basic information about storage or process conditions and material

properties in order to perform discharge calculations

The software comes with an integrated material property database containing more

than 1,600 pre-defined pure component chemicals

Various discharge scenario options have been implemented to represent common

process failures, and model their behaviour. These include:

Leaks and line ruptures from long & short pipelines



Catastrophic ruptures

Relief valve and disc ruptures

Tank roof collapse

Vent from vapour spaces

In building release effects

DISPERSION

The dispersion models within Phast are able to model the following phenomena

Dispersion of gas, liquid and two-phase releases

Liquid droplet thermo dynamics calculations and liquid droplet rainout

Pool spreading and vaporization

Building wake dispersion effects for vapour releases

FLAMMABLE EFFECTS

For releases of flammable material Phast calculates

Radiation profiles and contours from a range of fire scenarios including pool fires,

flash fires, jet fires and fire balls, including cross-wind effects on a jet fire

Vapour Cloud Explosion modeling using industry standards models including the

TNO Multi-energy, Baker Strehlow Tang and TNT Equivalence models

Overpressure contours from Boiling Liquid Expanding Vapour Explosions

TOXIC EFFECTS

Graphs of toxic concentration profile

Indoor and outdoor toxic dose prediction

Reporting of distance to specific dose and concentration

Calculated exposure time and use as “averaging time” for passive dispersion effects

PHAST RISK

Phast Risk allows you to combine the flammable and toxic consequences from each

scenario in your QRA model with their likelihood to quantify the risk of fatalities. Phast Risk

allows you to take account of local population distribution, sources of ignition, land usage



and local prevailing weather conditions. It is designed to perform all the analysis, data

handling and results presentation elements of a QRA within a structured framework.

Phast Risk allows you to quickly identify major risk contributors so that time and efforts can

be directed to mitigating these highest risk activities. Based on effects calculations and

population vulnerabilities, Phast Risk can integrate over all scenarios and weather

conditions to estimate the total risk. The established individual and societal risk indicators

are predicted by Phast Risk across your facility and surrounding area using the classical QRA

methodology. Risk ranking reports can be produced at points of strategic importance to

show the relative influence of the various failure scenarios and their contribution to both

the individual and societal risk metrics.

A key benefit of Phast Risk is the ability to identify major risk contributors and differentiate

these from incidents with worst case consequences which might otherwise dominate the

safety reviews. Whilst medium scale incidents have lesser consequences, they may have a

higher frequency, which, when combined with their hazardous effects, generate a higher

level of risk. Time and effort directed to mitigating high consequence but often low

frequency events may not be well spent. Phast Risk helps you direct this effort more

effectively. Phast Risk also provides facilities to help you manage large quantities of input

data, including scenarios, parameters, wind roses, ignition and population, and combine

these in many ways. This is critical when looking at sensitivity analyses and assessing the

merits of a range of risk reduction measures.

Benefits

Facilitates cost reduction in terms of losses and insurance

Allows optimization of plant and process design

Assist in compliance with safety regulators

Enables quicker response to hazardous incidents

Improve engineer’s understanding of potential hazards

Regular software upgrades incorporate industry experience and expertise, and

advances in consequence modeling technology



6.1.5.2.3 SCENARIOS

TABLE – 6.4

POSSIBLE ACCIDENT SCENARIOS

Scenario MCL Scenario Pressure & Temp. Quantity

1 Release of Chlorine Liquefied

@ RT 10 kg/cm2

27 MT

2 Release of Hydrogen NTP 3000 Kg

3 Release of Xylene NTP 15 MT

4 Release of Toluene NTP 17 KL

5 Release of Methanol NTP 25 KL

6 Release of Ethanol NTP 25 KL

7 Release of Hydrochloric Acid NTP 10 KL

8 Release of Iso Propyl Alcohol NTP 12 KL

9 Release of Phenol NTP 25 KL

10 Release of Nitric Acid NTP 15 KL

11 Release of Liq. Ammonia NTP 700 kg

12 Release of Methylene Dichloride NTP 20 KL

13 Release of Ethylene Dichloride NTP 20 KL

14 Release of Acetic Anhydride NTP 40 KL

15 Release of Sulphuric Acid NTP 20 KL

16 Release of Bromine NTP 12 MT

17 Release of Ethyl Acetate NTP 20 KL

18 Release of Hexane NTP 4 KL

19 Release of THF NTP 4 KL

20 Release of CS2 NTP 150 KL

21 Release of EDA NTP 250 KL

22 Release of PCl3 @1kg/Cm2 N2 Pr 150 KL

23 Unconfined Pool Fire Simulations for Drum Storage

Area

NTP 200 Lit x 100

Drums



Scenario – 1 Release of Chlorine

This scenario considers release of Chlorine from Storage Tank:

Results indicate:

Puff Isopleth Simulation for Chlorine Tonner Catastrophic Failure

Scenario : PUFF DISPERSION

In put Data

Stored quantity 900 Kg X 30 Cylinders =27 MT

Instantaneous Puff Release quantity 900 Kgs.

Hazard Level Concentration (PPM) Ground level distance (Meter)

Lc50 1017 211

IDLH 10 856



Point source plume release for Chlorine toner liquid/ gas phase valve failure

Scenario : POINT SOURCE PLUME RELEASE

In put Data

Stored quantity 900 Kgs

Rate of release 1000 g/s

Hazard Level Concentration (PPM) Ground level distance (Meter)

Lc50 1017 166

IDLH 10 555

TWA/ TLV 1.00 1045



Measures to control and mitigate Emergency of Chlorine:

Evacuate the area in down wind direction:

For Chlorine evacuate area in down wind direction up to 0.4 km (400 meter) in small spillage and in case of

large spillage, evacuate the area in down wind direction 3.5 kms (3500 meters).

SOP will be prepared for safe handling of Chlorine tonners.

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

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

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.

Chlorine Gas detectors will be provided in Chlorine shed and near Header.

Scenario base On Site emergency Plan will be prepared.

Mitigation measures to control Emergency:

Chlorine Emergency Kit will be procured and kept ready at chlorine shed.

Chlorine Hood with blower will be provided with scrubbing arrangement.


Safety Shower and eye wash will be provided in Chlorine shed area.

Chlorine absorption system will be provided. In case of chlorine leakage in chlorine shed it will be suck

through blower and it will be scrubbed in Caustic scrubber.

Emergency siren and wind sock will be provided.

Tele Communication system and mobile phone will be used in case of emergency situations for

communication.

First Aid Boxes and Occupational health centre will be made at site.

Emergency organization and team will be prepared as per on site-Off site emergency planning.

Full body protection suite and other PPEs will be kept ready in ECC at site.

Emergency team will be prepared and trained for scenario base emergency. Like Toxic control team,

Fire control team, First aid team, Communication and general administration team, Medical team etc.

EMERGENCY RESPONSE

EMERGENCY RESPONSE

SPILL OR LEAK

· Fully encapsulating, vapor protective clothing should be worn for spills and leaks with no fire.

· Do not touch or walk through spilled material.

· Keep combustibles (wood, paper, oil, etc.) away from spilled material.

· Stop leak if you can do it without risk.

· Use water spray to reduce vapors or divert vapor cloud drift. Avoid allowing water runoff to contact spilled

material.



Scenario – 2 Release of Hydrogen

This scenario considers release of Hydrogen from Storage Tank:

Results indicate:

Scenario: Diffusion Jet Fire Simulation for 1.0 cm copper connecting pipe to PRV station

In put Data Results of Computations

Stored quantity Cylinder bank Max. IHR at flame centre height 52.49 Kw/m2

Gas Jet diameter 1 (cm) Flame centre height 63 meter

Gas velocity in the

leakage hole/ pipe

143463 m/s Maximum Flame width 12 meter

Wind speed 2.05 m/s Heat Flux 8.5 KW/ m2

Gas Density 0.067 kg/m3 Flame Surface Area 3778 m

2

Incident Intensity of Heat

Radiation ( IHR) at

ground level KW /m 2

IHR- Isopleth

Distance

( Meters )

Effect if IHR at Height of Simulation

37.5 8.3 Damage to process equipment. 100 % Fatal in 1 Min. 1 % fatal in 10

sec.

12.5 14.4 Min. to ignite wood (with flame contact). 1 % fatal in 1 min. 1st

deg.

burn in 10 sec.

4.0 25.4 Pain after 20 secs. Blistering unlikely.

Results

In the 8.3 meter radius area is considered as 100% fatality in 1 min.

In the 14.4 meter radius first degree burn in 10 sec.

In the 25.4 meter radius area will give pain after 20 seconds. Blistering unlikely.

Jet Fire

Red – 37.5 KW/m2

Yellow – 12.5 KW/m2

Green – 4 KW/m2



Over pressure / explosion for rupture of 1.0 cm copper pipe line of Hydrogen cylinder to PRV station

Results indicate:


Stored quantity Cylinder bank

Visible Flash Fire Height 0.52 m

Mass of Gas 1 kgs Visible Flash Fire Width 0.26 m

Heat of combustion 42267 KJ/Kg Duration of Flash-Fire in Sec. 2 sec

Fuel-Air volume ratio in Flash

fire cloud

0.600 Radius of fuel-air cloud mixture 4.19 m

Stochiometric Fuel-Air Mixture 00:29 Total energy release 283720 KJ

Wind speed 2.05 m/s Max. Heat Radiation from 1 m from Flash Fire 750 KW/ m2

Gas Density 0.067 kg/m3 Combustion efficiency 0.5


Radiation ( IHR) at ground

level KW /m 2

IHR- Isopleth

Distance

( Meters )


37.5 19 Damage to process equipment. 100 % Fatal in 1 Min. 1 % fatal in 10

sec.

12.5 32 Min. to ignite wood (with flame contact). 1 % fatal in 1 min. 1st

deg.

burn in 10 sec.

4.0 57 Pain after 20 secs. Blistering unlikely.

Results

In the 19 meter radius area is considered as 100% fatality in 1 min.

In the 32 meter radius first degree burn in 10 sec.

In the 57 meter radius area will give pain after 20 seconds. Blistering unlikely.

Red – 37.5 KW/m2


Green – 4 KW/m2



Scenario: 3 – Release of Xylene

Results indicate:

Input Data

Stored quantity 15 MT

Wind speed 2.05 m/s

Consequence Results

Radiation Effects

Radiation

Level

(KW/m2)

Distance (meter)

(Category 1.5/F)

Effect if IHR at Height of simulation

4 31.68 This level is sufficient to cause personnel if unable to reach cover within

20s; however blistering of the skin (second degree burn) is likely; 0: lethality

12.5 23.75 This level will cause extreme pain within 20 seconds and movement to a

safer place is instinctive. This level indicates around 6% fatality for 20

seconds exposure.

37.5 13.76 This level of radiation is assumed to give 100% fatality as outlined above.

Vapor Cloud Explosion

Radial

Distance (m)

Over Pressure

(psi)

Fatality lung

Rupture (%)

Eardrum

Rupture (%)

Structure

Damage (%)

Glass Rupture (%)

1.22 40.5 100.0 100.0 100.0 100.0

2.13 10.6 0.1 85.1 100.0 100.0

7.62 1.8 0.0 2.5 10.6 100.0

In case of Unconfined Vapor Cloud Explosion up to 1.22 meter is considered as 100% fatality and 100% ear drum

rupture radius.

In case of Unconfined Vapor Cloud Explosion up to 2.13 meter is considered as 100% structure damage and up to

7.62 meter 100% glass rupture area.

Flash Fire

Radiation

Level

(KW/m2)

Distance (meter)

(Category 1.5/F)


4 40 This level is sufficient to cause personnel if unable to reach cover within 20s;

however blistering of the skin (second degree burn) is likely; 0: lethality

12.5 24 This level will cause extreme pain within 20 seconds and movement to a


seconds exposure.

37.5 9 This level of radiation is assumed to give 100% fatality as outlined above.



Pool Fire Scenario: Flash Fire Scenario:

Red – 37.5 KW/m

2


Green – 4 KW/m2



Scenario – 4 Release of Toluene

This scenario considers release of Toluene from Storage Tank:

Results indicate:

Catastrophic Rupture

Input Data

Stored quantity - 17 KL

Wind speed - 2.05 m/s

Results indicate

Pool Fire Scenario

Radiation Level

(KW/m2)

Distance in meter Effect if IHR at Height of simulation

4 12.0 This level is sufficient to cause personnel if unable to

reach cover within 20s; however blistering of the skin

(second degree burn) is likely; 0: lethality

12.5 6.0 This level will cause extreme pain within 20 seconds and movement to

a safer place is instinctive. This level indicates around 6% fatality for

20 seconds exposure.

37.5 2.5 This level of radiation is assumed to give 100% fatality as outlined

above.


Radial

Distance (m)

Over Pressure

(psi)

Fatality lung

Rupture (%)

Eardrum

Rupture (%)

Structure

Damage (%)

Glass Rupture

(%)

4.7 36.2 100.0 100.0 100.0 100.0

5.1 8.9 0.0 77.0 100.0 100.0

8.7 2.0 0.0 3.1 14.5 100.0

Fireball Scenario

Fireball Radius: 8.13656 m

Radiation Level

(KW/m2)

Distance in meter Injury Type

37.50 6.5 100% Fatal

12.5 11.5 1st

Degree burn

4 18.5 Pain after 20secs.

Flash Fire

Radiation Level

(KW/m2)


37.5 7.0 100% Fatal

12.5 12.0 Pain after 20secs.


SAFETY PRECUASION:

- Flame proof pumping and other equipments will be provided.

- Transfer will be done in close process,

- Double Static earthling and Jumper clips will be provided on flanges,

- Hydrant system and Fire extinguishers will be provided.

- Automatic Sprinklers will be provided.

- Tanker unloading procedure will be made and followed.

- Dyke around the tank will be provided.



Pool Fire Fire Ball

Flash Fire

Green – 4 KW/m

2


Red – 37.5 KW/m2



Scenario – 5 Release of Methanol

Results indicate:


Input Data


Wind speed – 2.05 m/s

Results indicate

Pool Fire Scenario

Radiation Level

(KW/m2)

Distance in meter



20s; however blistering of the skin (second degree burn) is likely; 0: lethality



seconds exposure.



Radial Distance

(m)

Over Pressure

(psi)

Fatality lung

Rupture (%)

Eardrum

Rupture (%)

Structure

Damage (%)

Glass Rupture (%)

6.62 35.1 100.0 100.0 100.0 100.0

6.90 9.7 0.1 81.3 100.0 100.0

10.21 1.8 0.0 2.7 11.9 100.0


rupture radius.

In case of Unconfined Vapor Cloud Explosion up to 6.90 meter is considered as 100% structure damage and up to 10.21

meter 100% glass rupture area.

Results

37.5 KW/m2 IHR - In the 10.0 meter radius area is considered as 100% fatality in 1 min.

12.5 KW/m2 IHR - In the 18.0 meter radius first degree burn in 10 sec.

4 KW/m2 IHR - In the 24.0 meter radius area will give pain after 20 seconds. Blistering unlikely.

Fireball Scenario

Fireball Radius: 6.36 m

Fireball intensity of Heat Radiation (KW/m2) – 137.107

Fireball rate of Energy release (KJ/Sec)-69882.2

Fireball total energy released (KJ)- 98997.5

Fireball duration (Sec) – 1.40

Radiation Level

(KW/m2)


37.50 8 100% Fatal

12.5 14 1st

degree Burn

4 20 Pain after 20secs.

1.6 34 No Injury

Results






Pool Fire Flash Fire

Green – 4 KW/m2


Red – 37.5 KW/m2



Scenario – 6: Release of Ethanol

This scenario considers release of Ethanol from Storage Tank:

Input Data:

Storage capacity: 25 KL


Results indicate:

Dispersion modeled as passive plume/cloud at distance 37.93 m and time 63.36 s

Pool radius 16.73 m

Cloud center has reached the UFL concentration 0.19 fraction at distance 5.171 m and time 5.943 s

Cloud center has reached the LFL concentration 0.043 fraction at distance 5.728 m and time 6.363 s

Cloud center has touched down at distance 5.393 m and time 6.155 s

Pool Diameter 33.70 m

Flame Length 21.47 m

Burn Rate 21.01 kg/s

Maximum Pool Radius 16.85 m



Scenario – 7 Release of HCl This scenario considers release of HCl from Storage Tank:

Results indicate:

Spill Pool evaporation modules for HCl Storage Tank catastrophic failure Input Data



Results indicate

LC50 – 149 ppm 44.69 meter

IDLH – 5 ppm 1532.66 meter

TLV –0.75 ppm 2943.00 meter

Results

LC50 HUMAN (149 ppm) area up to 44.69 meter, Immediate danger to life and health (5 ppm )

concentration area up to 1532.66 meter and TWA (0.75 ppm ) area up to 2943 meter. Therefore 1532.66

meter area in wind direction is considered as evacuation area.



Measures to control and mitigate Emergency:

Measures to be taken to prevent such accident:

Priority will be given to Tanker to immediately enter the storage premises at site and will not be kept

waiting near the gate or the main road.

Security person will check License, TREM CARD, Fire extinguisher condition, required PPEs as per SOP laid

down.

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

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


Wheel stopper will be provided to TL at unloading platform.

Tanker unloading procedure will be followed according to check list and implemented.

Flexible hose connection will be done at TL outlet line and checked for no leakage.

Every time gasket will be changed.

The quantity remaining in the hose pipeline will be drained to a small container, which will be subsequently

transferred to the main storage tank thus ensuring complete closed conditions for transfer from road

tanker.

All TL valves will be closed.

Following precautions will be adopted Storage of such chemicals

Storage tank will be stored away from the process plant.

Tanker unloading procedure will be prepared and implemented.

Caution note and emergency handling procedure will be displayed at unloading area and trained all

operators.


Required PPEs like full body protection PVC apron, Hand gloves, gumboot, Respiratory mask etc. will be

provided to operator.

Neutralizing agent will be kept ready for tackle any emergency spillage.

Safety shower, eye wash with quenching unit will be provided in acid storage area.


Dyke wall will be provided to all storage tanks, collection pit with valve provision.


Level gauge will be provided on all storage tanks.

Safety permit for loading unloading of hazardous material will be prepared and implemented.

TREM CARD will be provided to all transporters and will be trained for transportation Emergency of

Hazardous chemicals.

Fire hydrant system with jockey pump as per TAC norms will be installed.

Mitigation measures to control Emergency:

Safety Shower and eye wash will be provided away from the tank and unloading station.

Sand bags/ buckets will be provided near tank area.

Neutralizing medium (Lime and dry sand) will be kept ready near tank farm.

Emergency siren and wind sock will be provided.

Tele Communication system and mobile phone will be used in case of emergency situations for

communication.

First Aid Boxes and Occupational health centre will be made at site.

Emergency organization and team will be prepared.

Full body protection suite and other PPEs will be kept ready in ECC at site.

Emergency team will be prepared and trained for scenario base emergency. Like Toxic control team, Fire

control team, First aid team, communication and general administration team, Medical team etc.



EMERGENCY RESPONSE

SPILL OR LEAK

· Do not touch damaged containers or spilled material unless wearing appropriate protective clothing.


· Use water spray to reduce vapors; do not put water directly on leak, spill area or inside container.

· Keep combustibles (wood, paper, oil, etc.) away from spilled material.

Small Spill

· Cover with DRY earth, DRY sand or other non-combustible material followed with plastic sheet to minimize

spreading or contact with rain.

· Use clean non-sparking tools to collect material and place it into loosely covered plastic containers for later

disposal.

· Prevent entry into waterways, sewers, basements or confined areas.



Scenario - 8 Release of IPA

This scenario considers release of IPA from Storage Tank:

Results indicate:


Input Data



Results indicate

Pool Fire Scenario

Radiation

Level (KW/m2)

Distance in meter


4 62.0 This level is sufficient to cause personnel if unable to reach cover within 20s;




seconds exposure.



Radial

Distance (m)

Over Pressure

(psi)

Fatality lung

Rupture (%)

Eardrum

Rupture (%)

Structure

Damage (%)

Glass Rupture (%)

6.50 36.7 100.0 100.0 100.0 100.0

6.83 8.4 0.0 73.3 100.0 100.0

10.02 1.9 0.0 2.8 12.8 100.0


rupture radius.

In case of Unconfined Vapor Cloud Explosion up to 6.83 meter is considered as 100% structure damage and up to

10.02 meter 100% glass rupture area.

Results


12.5 KW/m2 IHR -In the 40.0 meter radius first degree burn in 10 sec.

4 KW/m2 IHR -In the 62.0 meter radius area will give pain after 20 seconds. Blistering unlikely.



Fireball Scenario

Fireball Radius: 6.36m

Fireball intensity of Heat Radiation (KW/m2) – 134.186

Fireball rate of Energy release (KJ/Sec)- 68393.6

Fireball total energy released (KJ)- 96888.6

Fireball duration (Sec) – 1.40

Radiation Level

(KW/m2)


100.20 7.0 100% Fatal

37.5 11.0 100% Fatal

12.5 19.0 1st

degree Burn



1.54 59.0 No Injury

Results






Cloud Footprint

Maximum Concentration



Pool Fire Fire Ball

Green – 4 KW/m2


Red – 37.5 KW/m2



Scenario – 9 Release of Phenol This scenario considers release of Phenol from Storage Tank:

Results indicate:

Scenario : POOL FIRE


Stored quantity 25 KL Max. IHR at flame centre height 63 Kw/m2

Pool diameter 10 (m) Flame centre height 15.6 meter

Pool liquid depth 2.8 (m) Maximum Flame width 14.6 meter

Wind speed 2.05 m/s Mass burning rate liquid 7.9 kg/ m2/min.

Liquid Density 1006 kg/m3 Flame burnout time 120 Mims.


Radiation ( IHR) at

ground level KW /m 2

IHR- Isopleth

Distance

( Meters )


37.5 5.45 Damage to process equipment. 100 % Fatal in 1 Min. 1 % fatal in 10

sec.

12.5 9.4 Min. to ignite wood (with flame contact). 1 % fatal in 1 min. 1 st deg.

burn in 10 sec.

4.0 16.6 Pain after 20 secs. Blistering unlikely.

Results

In the 5.45 meter radius area is considered as 100% fatality in 1 min.

In the 9.4 meter radius first degree burn in 10 sec.

In the 16.6 meter radius area will give pain after 20 seconds. Blistering unlikely.

Pool Fire

Green – 4 KW/m

2


Red – 37.5 KW/m2



Scenario 10: Release of Nitric Acid


Input Data

Stored quantity – 15 KL


Vapor Density (Air=1) – 2.5

Results indicate

TLV – 4 ppm

Cloud Footprint:

Maximum Concentration:



Safety measures:

In case of contact with eyes, immediately flush eyes with plenty of water for at least 15 minutes. Cold

water may be used. Get medical attention immediately.

In case of contact with skin, immediately flush skin with plenty of water for at least 15 minutes while

removing contaminated clothing and shoes. Cover the irritated skin with an emollient. Cold water

may be used. Wash clothing before reuse. Thoroughly clean shoes before reuse. Get medical

attention immediately.

Wash with a disinfectant soap and cover the contaminated skin with an anti-bacterial cream. Get

medical attention.

If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give

oxygen. Get medical attention immediately.

Evacuate the victim to a safe area as soon as possible.



Scenario – 11: Release of Liq. Ammonia

Basis: Catastrophic Rupture unloading arm (4”) of road tanker and Resultant Pool Fire due to static charge.

Basic Input Data

Stored quantity 15 KL

Wind speed 1.62 m/s

Consequence Results

Radiation

Level

(KW/m2)

Distance (meter)

(Category 1.5/F)



20s; however blistering of the skin (second degree burn) is likely;

0: lethality

12.5 NR This level will cause extreme pain within 20 seconds and movement to a


seconds exposure.

37.5 NR This level of radiation is assumed to give 100% fatality as outlined above.

Fireball Radius 8.70 m

Cloud Footprint




Pool Fire

Green – 4 KW/m2



Scenario – 12: Release of MDC MDC Tank Catastrophic Failure

Input Data



Results indicate

Pool Vapor Flow Rate – 26.8 kg/s

Pool Diameter – 72.76m

Cloud edge has reached the UFL concentration 0.191 fraction at distance 4.794 m and time 13.28s

Cloud edge has reached the LFL concentration 0.159 fraction at distance 10.1 m and time 20.86s

Cloud center has touched down at distance 0.1397 m and time 1.397s

Droplet totally evaporate at cloud centerline distance 0.2754 m

Dispersion modeled as passive plume/cloud at distance 167.5m and time 186.4s



Scenario – 13 Release of EDC

This scenario considers release of EDC from Storage Tank:

Results indicate:


Input Data



Pool Fire Scenario

Radiation Level

(KW/m2)

Distance in

meter


4 70.91 This level is sufficient to cause personnel if unable to reach

cover within 20s; however blistering of the skin (second

degree burn) is likely; 0: lethality



seconds exposure.


Dispersion

Release Rate 1000 gms/sec. (assumption)

Hazard Level Concentration (ppm) Distance (meter)

LC50 1414.2 23.61

IDLH 300 48.93

TWA/ TLV 75 115

SAFETY PRECUASION:

- Flame proof pumping and other equipments will be provided.

- Transfer will be done in close process,

- Double Static earthling and Jumper clips will be provided on flanges,

- Hydrant system and Fire extinguishers will be provided.

- Automatic Sprinklers will be provided.

- Tanker unloading procedure will be made and followed..

- Dyke around the tank will be provided.



DISPERSION ISOPLETH FOR EDC TANK CATASTROPHIC FAILURE



Pool Fire

Green – 4 KW/m2


Red – 37.5 KW/m2



Scenario-14 Release of Acetic Anhydride

Basic Input Data


Wind speed 2.05 m/s

Radiation Effects

Radiation Level

(KW/m2)

Distance (meter)

(Category 1.5/F)




12.5 22.0 This level will cause extreme pain within 20 seconds and movement to a safer

place is instinctive. This level indicates around 6% fatality for 20 seconds

exposure.

37.5 NR This level of radiation is assumed to give 100% fatality as outlined above.

Results:-

Maximum Pool Radius is 21.8 m.

NR – Not Reached



Cloud Footprint




Intensity Radiation for Pool Fire

Green – 4 KW/m2




Scenario – 15 Release of Sulfuric Acid

This scenario considers release of Sulfuric Acid from Storage Tank:

Results indicate:

Spill pool evaporation module for Sulphuric Acid due to Catastrophic Rupture of 40 KL Storage Tank

Input Data



Failure Mode: Catastrophic failure of 4” bottom nozzle and loss of containment

Density ( Air) – 1840 kg/m3

Release rate: 1000 g/s

Results indicate

LC50 – 510 mg/m3 38.26 meter

IDLH – 15 mg/m3 528.56 meter

TLV –1 mg/m3 792.29 meter

Results:-

LC50 HUMAN (510 mg/m3) area is up to 38.26 meter,

IDLH (15 mg/m3) concentration area is up to 528.56 meter and

TLV (1 mg/m3) area is up to 792.29 meter.

Therefore, 528.56 meter area in wind direction is considered as evacuation area.



Scenario:



MITIGATION MEASURES FOR SULPHURIC ACID LEAKAGE:

Isolate the source if possible without risk.

If leakage is small, dilute with water and mop up, or absorb with an inert dry material and place in an

appropriate waste disposal container. If necessary: Neutralize the residue with a dilute solution of

sodium carbonate.

Absorb with DRY earth, sand or other non-combustible material.

Do not get water inside container. Do not touch spilled material. Use water spray curtain to divert

vapor drift.

Prevent entry into sewers, basements or confined areas.

Neutralize the residue with a dilute solution of sodium carbonate.

PREVENTIVE MEASURES TO AVOID SULPHURIC ACID LEAKAGE:

A dike will be provided to accommodate the full quantity in tank.

Periodic testing of storage tank will be done by competent person.

Provide exhaust ventilation or other engineering controls to keep the airborne concentrations of

vapors below their respective TLVs. Storage tank vent is connected to scrubber system.

Flange guard provided to prevent splash of material.

Level interlock

Keep container dry. Never add water to this product.

In case of insufficient ventilation, wear suitable respiratory equipment. If ingested, seek medical

advice immediately and show the container or the label.

Avoid contact with skin and eyes. Keep away from incompatibles such as oxidizing agents, organic

materials, metals, alkalis, moisture.

Storage: Keep container tightly closed. Keep container in a cool, well-ventilated area.

While handling always use face shield. Full suit. Vapor respirator. Be sure to use an approved/certified

respirator or equivalent.

Ensure that eyewash stations and safety showers are proximal to the work-station location.



Scenario – 16 Release of Bromine

This scenario considers release of Bromine from Storage Tank:

Results indicate:

Spill Pool Evaporation for Bromine 8 KL day tank catastrophic failure

Scenario : Puff release

Input Data Results of Computations

Stored quantity 12 MT

Evaporation rate 1500 g/s

End point

(meter)

LC50 Human 1075 ppm 50

IDLH value 3.0 ppm 1418

Results

LC50 HUMAN (1075 ppm) area up to 50 meter, IDLH (Immediate danger to life and health)

concentration (3.0 ppm) area up to 1418 meter and TWA (0.1 PPM) area.




Input Data

Stored quantity - 12 MT


Results indicate (Puff Release)

LC50 – 1075 ppm 27.50

IDLH – 3 ppm 292.84

TLV – 0.1 ppm 787.33

Safety Precaution:

Preventive maintenance of FLT. Train and license driver will be employed to drive FLT.

Limit switch, interlock will be provided, Apron, Hand gloves, gumboot, helmet, goggles will be provided.

Apron, Hand gloves, gumboot, helmet, goggles will be provided.



Measures to control and mitigate Emergency of Bromine:

Bromine emergencies:

Transportation Emergencies

Evacuate the area in down wind direction:

For Bromine evacuate area in down wind direction up to 0.6 km ( 600 meter) in small

Spillage and in case of large spillage, evacuate the area in down wind direction 3.1 kms (3100 meters).

In 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 supplier.

5. Seek immediate medical assistance for those injured and follow recommended first aid procedures.

Leaking Containers

6. When handling a leaking bottle personal protective clothing, goggles and NIOSH approved self contained

breathing equipment must be worn.

7. Clear contaminated area of non-essential personnel and send them to assembly point.

8. 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.”

9. 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.

10. Pour hypo solution*, lime and water slurry or soda ash solution over the spill. Hypo-bromine reactions

produce hydrobromic acid.

11. Dry sodium thiosulfate and liquid bromine produce a violent reaction; do not mix them.

12. Using cold water, wash neutralized bromine into a sump for transfer to an approved waste disposal facility

where the waste can be processed.

13. Ventilate the area to remove the ammonium bromide and any bromine fumes. Scrub the floors and

equipment with soap and water.

First Aid Procedure

14. Immediate medical assistance is required if bromine is swallowed, inhaled or has contacted the eyes or

skin.

15. If bromine has been ingested, do not give anything by mouth. Seek medical attention immediately. Do not

induce vomiting.

16. 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 and showing signs of respiratory distress, properly trained personnel

should administer oxygen.

17. For skin contact, the affected area must be flooded immediately with large amounts of clean water from a

safety shower or other 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 a minimum of 30 minutes. If possible, continue to wash the affected

area during transport to medical facilities. (Extended wash times of two hours or more have proven beneficial.)

18. If bromine liquid or vapor contacts the eyes, they must be irrigated immediately with large amounts of

running water. Eye wash stations are preferable for irrigation. If one is not available, a hose, water source with

a liberal, gentle flow may be utilized. The eyelids must be held apart during irrigation to ensure contact of

water with all accessible tissues of the eyes and lids. Eyes should be washed continuously for a minimum of 30

minutes. If possible, continue flushing the eyes while transporting the employee to a physician. In all cases of

bromine injury, obtain immediate medical attention. Provide emergency personnel with information about all

materials used by the person and provide appropriate information about bromine and first aid procedures.

EMERGENCY RESPONSE

ELIMINATE all ignition sources (no smoking, flares, sparks or flames in immediate area).

· Do not touch damaged containers or spilled material unless wearing appropriate protective clothing.


· Prevent entry into waterways, sewers, basements or confined areas.

· Absorb or cover with dry earth, sand or other non-combustible material and transfer to containers.

· Do not get water inside containers.



Scenario - 17: Release of Ethyl Acetate

Basis: Catastrophic Rupture unloading arm (4”) of road tanker and Resultant Pool Fire due to static charge.

Basic Input Data


Wind speed 2.05 m/s

Consequence Results

Radiation

Level

(KW/m2)

Distance (meter)

(Category 1.5/F)



20s; however blistering of the skin (second degree burn) is likely;

0: lethality



seconds exposure.


Max. Pool Radius 18.32

Cloud Footprint




Pool Fire

Green – 4 KW/m2


Red – 37.5 KW/m2



Scenario – 18 Release of Hexane

This scenario considers release of Hexane from Storage Tank:

Results indicate:


Input Data



Density ( Air) – 869 kg/m3

Pool Fire Scenario

Radiation Level

(KW/m2)

Distance in meter






seconds exposure.


Pool diameter – 2.35 m

Maximum Flame width – 4.12 m

Results




Pool Fire

Green – 4 KW/m2


Red – 37.5 KW/m2



Scenario 19: Release of Tetrahydrofuran

Results indicate:

Input Data





Scenario – 20 Release of Carbon Disulphide

This scenario considers release of CS2 from Storage Tank:

Results indicate:


Input Data



Pool Fire Scenario

Radiation Level

(KW/m2)

Distance in meter






seconds exposure.


Maximum Pool Radius – 45.68 m

Results






Pool Fire

Green – 4 KW/m2


Red – 37.5 KW/m2



Scenario – 21 Release of Ethylene Diamine

This scenario considers release of EDA from Storage Tank:

Results indicate:


Input Data



Pool Fire Scenario

Radiation Level

(KW/m2)

Distance in meter






seconds exposure.



Results






Pool Fire

Green – 4 KW/m2


Red – 37.5 KW/m2



Scenario – 22 Release of Phosphorus Trichloride

This scenario considers release of PCl3 from Storage Tank:


Input Data



Results indicate:




Scenario - 24 Unconfined Pool Fire Simulations for Drum Storage Area


Input Data

Stored quantity - 200 Lit (200 lit X 100 drums)


Results indicate

Pool Fire Scenario

Radiation Level

(KW/m2)

Distance in meter






seconds exposure.


Fire Ball Scenario

Radiation Level

(KW/m2)



12.5 42.5 1st

degree Burn

37.50 25.0 100% Fatal

MITIGATION MEASURES:

Isolate the source if possible without risk.

If leakage is small, dilute with water and mop up, or absorb with an inert dry material and place in an

appropriate waste disposal container. If necessary: Neutralize the residue with a dilute solution of

sodium carbonate.

Absorb with DRY earth, sand or other non-combustible material.

Do not get water inside container. Do not touch spilled material. Use water spray curtain to divert

vapor drift.

Use water spray to reduce vapors.

Prevent entry into sewers, basements or confined areas.

Neutralize the residue with a dilute solution of sodium carbonate.

Trained man power for fire fighting /toxic resale

PREVENTIVE MEASURES:

A dyke will be provided to accommodate the full quantity stored in all the drums.

Drums will be stored in designated area.

Provide exhaust ventilation or other engineering controls to keep the airborne concentrations of

vapors below their respective TLVs.

Never add water to this product.

In case of insufficient ventilation, wear suitable respiratory equipment. If ingested, seek medical

advice immediately and show the container or the label.

Avoid contact with skin and eyes. Keep away from incompatibles such as oxidizing agents, organic

materials, metals, alkalis, moisture.

Storage: Keep container tightly closed. Keep container in a cool, well-ventilated area.

While handling always use face shield. Full suit. Vapor respirator. Be sure to use an approved/certified


Ensure that eyewash stations and safety showers are proximal to the work-station location.

Mock drills –Regularly

Display of Hazards & how to controll



Pool Fire Fire Ball

Green – 4 KW/m2


Red – 37.5 KW/m2



6.1.6 RISK ASSESSMENT SUMMARY

From the Risk Assessment studies conducted, it would be observed that by and

large, the risks are confined within the factory boundary walls.

Based on these studies company has been proposed to plan its facility sitting as well

as location of operator cabin, open area, etc.

Company has to increase awareness programme in the surrounding vicinity and

educate people for safe evacuation at the time of toxic release.

A HAZOP study to be carried out for all product plant and storage facilities.

Induction safety course to be prepared and trained all new employees before

starting duties in plant.

Ensure periodically process safety knowledge & equipment safety provision

6.1.6.1 PROCESS SAFETY

Safety measures to be adopted from the design stage.

Safety Valve and pressure gauge are to be provided on reactor and its jacket (if jacket is

provided).

Utility like Chilling, cooling, vacuum, steaming and its alternative are to be provided to

control reaction parameters in a safe manner.

Free Fall of any flammable material in the vessel is to be avoided.

Static earthing provision is to be made at design stage to all solvent handling

equipments, reactors, vessels & powder handling equipments.

Any reaction upsets will be confined to the reaction vessel itself.

All emergency valves and switches and emergency handling facilities are to be easily

assessable.

Further all the vessels are to be examined & will be examined periodically by a

recognized competent person under the Gujarat Factory Rules.

All the vessels and equipments are to be earthed appropriately and protected against

Static Electricity. Also for draining in drums proper earthing facilities is to be provided.

Exothermic/Run away reaction- to be provide Knock out tank & double safety &

interlocks

Materials shall be transferred by pumping through pipeline or by vacuum from drums.



All solvents and flammable material storage tanks shall be stored away from the

process plant and required quantity of material is to be charged in reactor by pump.

Jumpers are to be provided on all solvent handling pipeline flanges.

Caution note, safety posters, stickers, periodic training & Updation in safety and

emergency preparedness plan shall be displayed and conducted.

Flame proof light fittings will be installed in the plant.

All the Plant Personnel shall be provided with Personal Protection

Equipments to protect against any adverse health effect during operations, leakage,

spillages or splash. PPE like Helmets, Safety Shoes, Safety Glasses, Acid-Alkali Proof

Gloves etc. are to be provided to the employees.

All employees shall be given and updated in Safety aspects through periodic training in

safety.

Material Safety Data Sheets of Raw Materials & Products will be readily available that

the shop floor.

6.1.6.2 FOR HAZARDOUS STORAGE TANK FARM

Tank farm shall be constructed as per explosive department requirement and separation

distance will be maintained.

Tanks shall be located and marked in designated area of hazardous chemical storage.

Static earthing provision shall be made for road tanker as well as storage tank.

Tanks of proper MOC shall be selected.

Flame arrestor with breather valve shall be provided on vent line.

Road tanker unloading procedure /Check list to be implemented.

Fire load calculation shall be done and as per fire load Hydrant System will be provided

as per NFPA std. and Fire extinguishers shall be provided as per fire load calculation.

Spark arrestor shall be provided to all vehicles in side premises.

Flame proof type equipments and lighting shall be provided.

Lightening arrestor shall be provided on the top of chimney.

Trained and experience operator shall be employed for tank farm area.

NFPA label (hazard identification) capacity and content shall be displayed on storage

tank.



Solvents shall be transferred by pump only in plant area and day tank shall be provided.

Overflow line returns to the storage tank or Pump On-Off switch shall be provided near

day tank in plant.

Jumpers shall be provided on solvent handling pipe line flanges.

Flexible SS hose shall be used for road tanker unloading purpose and other temperature

connection.

All tanks shall be uniformly tagged.

Level indicator shall be provided in tanks.

Dyke shall be provided.

Industrial type electric fittings shall be provided.

Adequate fire fighting equipments shall be provided.

Anti corrosive paint shall be done.

Safety instruction board shall be displayed.

6.1.6.2 FOR DRUM/CARBOY STORAGE AREA

Some chemicals shall be received at plant in drums/Carboys by road truck and stored in a

drum/Carboy storage area.

FLP type light fittings shall be provided.

Proper ventilation shall be provided in godown.

Proper label and identification board /stickers shall be provided in the storage area.

Conductive drum pallets shall be provided.

Drum handling trolley /stackers/fork lift shall be used for drum handling.

Separate dispensing room with local exhaust and static earthing provision shall be made.

Materials shall be stored as per its compatibility study and separate area will be made for

flammable, corrosive and toxic chemical drums storage.

Smoking and other spark, flame generating item shall be banned from the Gate.



6.1.6.3 TRANSPORTATION

Road tanker unloading procedure shall be in place and is implemented for safe

unloading of road tanker.

Static earthing provision shall be made for tanker unloading.

Earthed Flexible Steel hose shall be used for solvent unloading from the road tanker.

Fixed pipelines with pumps shall be provided for solvent transfer up to Day

tanks/reactors.

Double mechanical seal type pumps shall be installed.

NRV provision shall be made on all pump discharge line.

Dry run /High temperature protection to be provided.

6.1.7 OTHER RISK REDUCTION OPPORTUNITIES

The following opportunities are to be considered as a potential means of reducing identified

risks during the detailed design phase:

Buildings and plants structures shall be designed for cyclone floods and seismic

events to prevent structural collapse and integrity of weather (water) proofing for

storage of goods;

Provision for adequate water capacity to supply fire protection systems and critical

process water;

Isolate people from load carrying/mechanical handling systems, vehicle traffic and

storage and stacks locations;

6.1.8 RECOMMENDATIONS FOR ALARP

The following actions shall be particularly recommended to be implemented in order to

ensure ALARP (As Low As reasonably practical) performance in the operation: Maintain and

ensure effectiveness of all the safety measures, among others through the following actions:



Raw Material Storage Area

- The raw material storage area should be declared as a prohibited area and should be

provided having at least two exits, “No Smoking” and “Prohibited Area” display

boards, as applicable should be provided at site.

- Regular inspection of tanks/drums/carboys containing raw material to be done to

take care.

- Periodic site inspection should be carried out to ensure that there is no leakage from

any of the drums in the ware house.

- Fire hydrant system needs to be provided in storage area as per TAC standards.

- Smoke detector and fire alarm systems need to be provided.

- Provision of fire doors in ware house area.

Fire access for Tank Farm area and Ware Houses

- Fire access roads should be provided to storage area. The storage tanks/area should

have suitable fire protection and fire fighting facility.

The following features are also important for the project by taking the layout into

consideration:-

Hinged doors swing outward in an explosion.

Window panes (if installed) shall be shatterproof or plastic in frame.

Floors, walls and ceilings are to be designed and installed to limit the generation and

accumulation of static electricity.

All doors must be fire resistant. Floors, walls and ceilings shall be designed for at

least 2 h of fire resistance.

Walls or partitions shall be continuous from floor to ceiling, and securely anchored.

Integrity of the wall should be ensured i.e. blast wall not to be broken or drilled as

that can leads to weak spots.

The building shall be constructed of non-combustible materials, on a substantial

frame.

Restrained deflagration vent panels shall be present.

There shall be adequate ventilation, and any heating in rooms is limited to steam,

hot water, or other indirect means.



Electrical Safety for Whole Facility

Electrical Safety: All cables and electric fittings shall be constructed, installed,

protected, operated and maintained in such a manner so as to prevent risk of open

sparking.

6.1.9 FIRE FIGHTING SYSTEM

M/s. Greentec chemicals Pvt. Ltd., Management has taken into consideration fire

prevention measures at the project planning and during plant commissioning stage to avoid

any outbreak of fire. But looking to the hazardous nature of process and the chemicals that

are to be handled and processed, the chances of outbreak of fire cannot be totally ignored.

Hence to tackle such a situation a good well laid fire protection system will be provided in

the factory. Details of fire fighting are given in Table 6.5.



TABLE 6.5

FACILITIES FOR FIRE FIGHTING

Fire Extinguisher Type Fire Fire Hydrant Valve Branch Mech Sprinkler Wind First

DCP (Kgs) Foam CO2 (Kgs) Sand

Safety

SCBA ELBA Hose FEH Single Foam system Sock Aid

Plant/Location

5 6 10 9ltr 2 4.5 22.5 Bucket Shower SET SET Reel Hydrant

Fire

Hose Short TP FB

5x

Water

cum

Foam

Monitor ltr Box

Fire Pump

House 1 1 2 4 1 2 1800

Fungicide Plan 1 1 6 4 20 4 1 10 1 10 2 500 4 2 2

Insecticide

plant 1 1 6 4 10 2 1 10 1 10 2 500 4

1 1

Intermediate

plant 1 1 6 4 12 2 1 10 1 10 2 500 4

1 1

Herbicide

plant 1 1 6 4 15 2 1 1 1 10 2 500 4

1 1

Solvent Yard 1 4 2 8 4 4 7 2 1 1 200

Tank farm 1 1 1 1 1 4 1 4 4 3 2 1 2 1 1

ETP 6 1 3 2 2 4 1

R&D 1 1 1 1 2 2 2 2 1

QC Lab 1 1 2 2 1 2 1 1 1 1 1

QC UPS Room 1 1

Utility 1 3 4 4 8 1 1

Finished

product

Area(WH)

3 2 2 4 2 1

1

Compressor

room 2 1 1 1 1

1

Panel

room(nr.toilet) 1 1 1 2 1

LFR 1

Canteen 2 1 2 1 1

ADM 1 1 2 1 2 1 1 1

Main Gate

(Security) 5 3 2 2 1 2 4

1 1



Fire Extinguisher Type Fire Fire Hydrant Valve Branch Mech Sprinkler Wind First

DCP (Kgs) Foam CO2 (Kgs) Sand

Safety

SCBA ELBA Hose FEH Single Foam system Sock Aid

Plant/Location

5 6 10 9ltr 2 4.5 22.5 Bucket Shower SET SET Reel Hydrant

Fire

Hose Short TP FB

5x

Water

cum

Foam

Monitor ltr Box

Ambulance 2 1

Store 8 3 4 4 2 4 1 1 2 4 1 1

OHC 1 2 1

Power House 1 1 3 1 2

R&M

Workshop 1

1

Explosive tank

fram 2 2 1 2 2 4 1 1 200 1

Fabrication

workshop 2 1

Stand by Fire

Pump House 1 1 1 2 2

19 20 15 19 9 45 13

54 4 67 12 33 4 23 3

Total 124 35 11 18 7 54 50 87 30 11 3200 20 9 18

Main and Alternative water storage cap. : 1000 KL

Single Hydrant Point (Jet Type) : 33 No.

Water Monitor fixed : 11 No.

Water Monitor Trolley Mounted : 02 No.

Water Monitor lifting height : Water/Foam throws 45 to 60 meters at an angle of 30’ in still air. Water/Foam flow

1750 to 2600 LPM.

No. of Fire Sand Storage : 35 No. Fire sand bucket



DETAILS OF FIRE HYDRANT PUMPS

SR.

NO.

NAME OF EQUIPMENT CAPACITY/

QUANTITY

DISCHARGE TAG.NO. LOCATION MAKE

1 Water Reserve Tank 1000 KL Fire Pump House FWS/01 Fire Pump house RCC

2 Jockey Pump 12.5 HP 10.8 m3/hr JP-01 Fire Pump house Kirloskar

3 Main Pump 75 HP 171 m3/hr MP-01 Fire Pump house Kirloskar

4 Diesel Pump 92 HP 171 m3/hr DP-01 Fire Pump house Kirloskar

5 D-watering pump 12.5 HP - DWP-01 Fire Pump house -

6 Diesel Tank 200 Liter - - Fire Pump House -

Other fire fighting facilities proposed to be installed at site:

Fire load calculation shall be carried out and Fire Extinguishers at different locations

shall be provided (as mentioned in above table) as per the TAC guidelines.

Working staff shall be given training to operate DCP and CO2 extinguishers.

Fire Hydrant Network shall be installed as per the calculated requirement for fire

fighting.

A main fire pump with a capacity of 50 m3/hr @ 10 Bar/cm2 is to be installed.

A stand-by diesel pump with equal capacity (50 M3/Hr @ 10 Bar/cm2) is to be

installed. This pump will be used for fire fighting in case of power failure.

A fire water reservoir with holding capacity of 300 m3 of water shall be provided.

First Aid Training will be imparted to employees by designated first aid trainers.

6.2 DISASTER MANAGEMENT PLAN

M/s. Greentec Chemicals Pvt. Ltd. shall develop the emergency management system to

tackle the emergency situation, apart from its emergency management system. The detail of

disaster management system is discussed in the following section.

6.2.1 DEFINING THE NATURE OF EMERGENCY

6.2.1.1 LEVEL OF EMERGENCY CAN BE CLASSIFIED IN THREE CATEGORIES.

LEVEL - 1:

The leakage or emergency, which is confinable within the plant, premises. It may be due to -

a) Small fire in the plant

b) Low toxic gas release for short duration.

c) Collapsing of equipment that do not affect out side premises.



LEVEL - 2:

The emergency, which is confinable within the factory premises. It may arise due to -

a) Major fire inside the factory premises.

b) Medium scale explosion confined to the factory premises.

c) Heavy toxic / flammable gas leakage for short duration.

LEVEL - 3:

The emergency, which is not confinable within the factory premises and general public in

the vicinity likely to be affected. It may arise due to -

a) Explosion of high magnitude affecting the adjacent area

b) Heavy / Profuse leakage of toxic / flammable gases for a long duration.

6.2.2 OBJECTIVES OF EMERGENCY MANAGEMENT SYSTEM

The objectives of the emergency management system are summarized as under.

To identify and assess types of emergencies due to different types of hazards.

To work out plan with all provisions to handle emergencies and safeguard employees

and people in the vicinity of the factory.

To provide for emergency preparedness and the periodical rehearsal of the plan.

To plan mode of proper communication and actions to be followed in the event of

emergency.

To keep all necessary information with respect to hazard/accident control and

emergency contacts in one document for easy and speedy reference.

To inform employees, general public and the authorities about the hazards/risk if any

and the role to be played by them in the event of emergency.

To control and contain the accident.

To effect rescue and treatment of casualties.

To inform and help relatives of casualties.

To secure rehabilitation of affected area and restore normalcy.

To provide information to media and government agencies.

To preserve record, equipment etc. for investigating cause of emergency.

To be ready for “mutual aid” if need arises to help neighboring units.



6.2.3 STRUCTURE OF EMERGENCY MANAGEMENT SYSTEM

M/s. Greentec Chemicals Pvt. Ltd. shall develop an emergency management team. The

management structure includes the following personnel’s;

Incident Controllers and Deputy Incident Controllers

Site Main Controllers

Key Personnel’s

Essential Workers

Assembly points

Emergency control center

Fire control arrangements

Medical arrangements

Other arrangements

6.2.3.1 INCIDENT CONTROLLER AND DEPUTY INCIDENT CONTROLLER

His primary duty is to take charge at the scene of the incident. In the initial stages he may be

required to take decision involving the operation of the other plants or to stop or continue

any process and operation of the other plants or to stop or continue any process and to take

technical decision to control the incident. Therefore he should be fully knowledgeable for

this purpose. He is a factory Manager. Appointed such person for all shifts including

holidays. Any one incident controller must be available at any time. Fixed their duties that

way. The duty is appointed to take the charge of incident controller if he is not available due

to any reason. He is equally competent. The incident controllers have adequate means of

communicating with the emergency control center by telephone or runner.

His responsibilities/duties are as follows:

1. Immediately being aware of the emergency and its location, he will proceed to the

scene. On arrival he wills.

2. Assess the scale of emergency and decide if a major emergency exist or is likely. On

his decision, he will activate the on site plan and if necessary the off site emergency

plan.



3. Assume the duties of the site Main Controller pending the latter’s arrival for this

purpose he will depute his Deputy Incident Controller on the scene and he will go to

the control center. Particularly he will:

3.1. Direct the spitting down and evacuation of plant and areas likely to be

affected the emergency.

3.2. Ensure that the outside emergency services, including mutual aid, have been

called in.

3.3. Ensure that key personnel have been called in.

4. Direct all operations with in the affected area with the following properties.

4.1. Secure the safety of personnel.

4.2. Minimize damage to plant, property and the environment.

4.3. Minimize loss of material.

5. Direct rescue and fire fighting operations until the arrival of the outside fire bridged,

when he will relinquish control to the head of the Fire Bridged.

6. Search for casualties.

7. Evacuate non-essential workers to the assembly points.

8. Set up a communications point and establish/telephone/messenger contact as

appropriates with the emergency control center.

9. Give advice and information as required to the head of the Fire Bridged and other

emergency services.

10. Brief the site main controller and keep informed of developments.

11. Preserve evidences that will be necessary for subsequent inquiry in to the cause of

the emergency and concluding preventive measures.

6.2.3.2 SITE MAIN CONTROLLER

He has overall responsibilities for directing operations and calling outside help form

Emergency Control center. As he is required to take decisions by collaboration between the

senior manager at the site (works) and the senior officers of the outside services, he is the

senior manager or top execute.

His responsibilities / duties are as follows:

Immediately being aware of the emergency, he will go to the Emergency Control Room. On

arrival he will-



Relieve the Incident Controller of responsibility for overall main control.

On consultation with the Incident Controller decide whether major emergency exist

and on declaration of a major emergency, ensure that the outside emergency

services and mutual help are called, the off-site plan activated and if necessary,

nearby factories and population are informed.

Ensure that the key personnel are called in.

Exercise direct operational control of those parts of the works outside the affected

area.

Continually review and assess possible developments to determine the most

probable course of events.

Direst the safe close down and evacuation of plants in consultation with the Indirect

Controller and key personnel. If necessary, arrange for evacuation of neighboring

population.

Ensure that consulates are receiving adequate attention. Arrange for hospitalization

of victims and additional help if required. Ensure that the relatives are advised.

Inform and liaise with the Chief Officer of the Fire and Police Services, District

Emergency Authority and with the Factory Inspectorate and experts on health and

safety. Provide advice on possible effects on areas outside the factory.

In the case of prolonged emergencies involving risk to outside areas by wind blown

materials, contact the local meteorological office to receive early notification of

impending changes in weather conditions.

Ensure the accounting for personnel and rescue of missing persons.

Control traffic movement within the factory.

Arrange for a chronological record of the emergency to be maintained.

Where the emergency is prolonged, arrange for the relief of personnel and the

provision of catering facilities.

Issue authorized statements to the news media. Where necessary, inform Head

office.

Ensure that proper consideration is given to the preservation of evidence. Arrange

for photographs / video.



Control rehabilitation of affected areas and victims on causation of the emergency.

Do not restart the plant unless. It is ensured safe to start and cleared by the

authorities.

6.2.3.3 KEY PERSONNELS

Other key personnel are required to provide to and implement the decisions made by the

Site Main Controller in the light of information received on the developing situation at the

emergency. Such key personnel will include the senior managers responsible for safety,

security, gas and spill control, pollution control, Communication system including telephone,

wireless, messengers etc, medical services, transport, engineering, production, technical

services (including utilities, laboratories) stores and personnel (including welfare, canteen,

shelters etc).

As necessary, they will decide the actions needed to shutdown plants, evacuate personnel,

carry out emergency engineering work, arrange for supplies of equipment, utilities ( fuel

water, power etc ) carry out atmospheric tests, provide catering facilities, liaise with police,

fire brigade, emergency planning authority, factory Inspectorate, hospitals, neighboring

industries and population, assembly points, outside shelters, mutual aid centers, relatives of

casualties, press and so on, under the direction of the Site Main Controller. At the

declaration of a major emergency, all key personnel and others called in to assist shall

report to the Emergency Control Center. They shall be available at any time on duty or on

call on off – duty or holiday.

6.2.3.4 ESSENTIAL WORKERS

A taskforce of essential trained workers (expert teams) will be available to get the work

done by the incident control and the site main controller. Such work will include:

Fire righting, gas leak and spill control till a fire Brigade takes the charge.

To help to the Fire brigade and mutual aid teams. It is so required.

Shutting down plant and making it safe.

Emergency engineering work e.g. Isolating equipment, materials, process, providing

temporary by-pass lines, safe transfer of material, urgent repairing or replacement,

electrical work etc.



Provision of emergency power, water, lighting, instruments, equipments, materials

etc.

Movement of equipment, special vehicle and transport to or from the scene of the

incident.

Search, evacuation, rescue and welfare.

First-aid and medical help.

Moving tankers or other vehicles from area of risk.

Carrying out atmospheric test and pollution control.

Assistance at casualty’s reception areas to record details of casualties.

Assistance at communication center to handle out going and incoming calls and to

act as messengers if necessary.

Manning of works entrances in liaison with the police to direct emergence vehicles

entering the work, to control traffic leaving the works and turn away or make

alternative safe arrangements for visitors, contractors and other traffic arriving at

the works.

Informing surrounding factories and the public risk directed by the Site Main

Controller.

Any special help required.

6.2.3.5 ASSEMABLY POINT

In affected and vulnerable plants, all non-essential workers (who are not assigned any

emergency duty) shall evacuate the area and report to a specified assembly point. Each

assembly point will be clearly marked by a conspicuous notice and provided with an

identification number e.g. ASSEMBLY POINT -1. Mark such points permanently for the notice

of people.

Each assembly point is sited in a safe place, well away from areas of risk and least affected

by the down wind direction. More than one assembly point is needed (1) to ensure that

employees do not have to approach the affected area to reach the point. (2) In case any

assembly point lies in the path of wind-blown harmful materials, e.g. toxic gas.

Each assembly point is manned by a nominated person(s) to record the names and

departments of those reporting there.



SAFE ASSEMBLY POINTS

IDENTIFICATION

Sr.No. OF THE

ASSEMBLY

POINT

LOCATION ACCOMMODATION

CAPACITY

1 Nr HR /

ADMN

Garden

Approx 100 People

2 Near boiler

house

Gate 3

(emergency

gate)

Approx 100 People

6.2.3.6 EMERGENCY CONTROL CENTER

The Emergency Control Center (or Room) is the place from which the operations to handle

the emergency are directed and co-ordinate. It will be attended by the site Main Controller,

key personnel and senior officers of the Fire, police, factory Inspectorate, and district

authorities and emergency services. The Center is equipped to receive and transmit

information and directions from and to the incident controller and areas of the works as

well as outside. Have equipment for logging the development of the incident of the assist

the controllers to determine any necessary action. In addition to the means of

communication, the center is equipped with relevant data and equipment, which will assist

those meaning the center to be conversant with the developing situation and enable them

to plan accordingly. It is sited in an area of minimum risk and close to a road to allow for

ready access by a radio-equipped vehicle for use it other systems fails or extra

communication facilities are needed.

The center is therefore containing:

1. An adequate number of external telephones.

2. An adequate number of external telephones.

3. Wireless Set.

4. Plans of the factory to show :

(a) Areas of large inventories of hazardous materials including tanks, reactors, drums

and compressed gas cylinders.



(b) Sources of sirens and safety equipments including fire, expansion, spill and gas

controls.

(c) Stocks of other fire extinguishing materials.

(d) The firewater system and additional sources of water.

(e) Site entrances and road system, updated at the time of the emergency to indicate

any road that is impassable.

(f) Assembly points, shelters, lunchroom and canteen.

(g) Casualty treatment centers first aid centers.

(h) Location of the factory in relation to the surrounding community (Annexure-2).

5. Nominal roll of employees, work permits, gate entries and documents for head count or

access to this information. Employee’s blood group information and address is

prepared and kept on Record.

Note pads, pens, pencils, rubbers, and stationary to record all messages received

and sent by whatsoever means.

More copies of this on –site and off- Site Emergency plan i.e. updated full text

including all Annexure. From this, some vehicle and messengers (runners) will be

kept ready at the center.

Troche, umbrella, rain – coats, and some extra sets of gas detectors explosive

meters and personal protective equipments.

Fire and Toxicity Control Arrangements:

Medical Arrangements:

A good organization should have, depending on size of the factory, its own ambulance room

or occupational health center or dispensary or hospital for medical. Names of surrounding

factories for mutual aid, list also the names and address of the surrounding hospital, nursing

homes, dispensaries etc. and give their details

6. Transport and Evacuation Arrangements:

In Major emergency, it will be necessary to evacuate personnel from affected areas and, as

a precautionary measure, to further evacuate non essential workers from areas likely to be

affected should the emergency escalate.



We have separate evacuation alarm, which can be beard in 3 km radius. So that the people

be ready for evacuation. On evacuation, employee will be directed to predetermine

assembly points already explained earlier. If they are required to be evacuated outside the

factory and it a remote place, their transportation will be necessary which vehicles will be

required. At remote shelters their care and welfare will also be required. The safe

authorized passages / routes for escape is decided and marked by arrow in the plans as

explained in the details of emergency control Center.

Emergency Control Centre

Location of the centre: (1) Main ADM - Office ( 8.30 am to 5.00 pm ) (2). Main Gate Office after 5.00 pm

Telephone Nos. of the Centre Internal 4414 / 4446 Internal 4412 / 4403

External : 2676 : 247028 /

247283/247161

External : 2676 :247283/247161,

326606

Its period of operation Sr. No. Item kept in the centre see

(1) to (10)

Number or

quantity

Persons who will handle /

operate this item Last Present

Notes

1 2 3 4 5 6 7

01 phone & 1 Communication facility

02 Wireless

2 Safety Cupboard with some

PPE

1

3 Fire Extinguishers 2

4 Copy of On-Site Emergency

Plan

1

5 List of trained First Aider 1

6 Address & Telephone

Number of Key Personnel

1

7 Address & Telephone

Number outside Agencies &

Factories

1

8 Ambulance Van 1

9 Emergency Siren system 1

10 Emergency Light 1

Site Main controller /

Incident Controller

Security Officer , First Aid

Trained Persons & Time Keeper

Operation

During Mock

Drill



6.2.3.7 FIRE CONTROL ARRANGEMENTS

6.2.3.7.1 FIRE FIGHTING, GAS LEAK CONTROL AND RESCUE OPERATION

A) Role of Manager (Fire and Safety) / Shift In-Charge (Fire & Safety)

1. Incident Controller will be the only person to direct the fire fighting and Emergency

operation.

2. Keep the constant touch with the SMC / In charge - EHS.

3. Direct the crew members to the scene of emergency and arrange replenishment of

Manpower / equipment / extinguishing media etc.

B) Role of EHS Representative:

1. On being notified about the location of fire/ gas leakage immediately proceed to the help.

2. Decide his line of action in consultation with Incident controller and take appropriate

measures to handle the emergency.

3. Assessing the severity of the incident immediately report to emergency controller about

the gravity of the situation.

4. He will assess the extra requirement required if any from the neighboring industry.

C) Fire crew members

1. On hearing fire alarm, emergency siren they shall immediately report to control room

and proceed to the scene of emergency and work under the direction of IC/ Dy IC.

2. The personal availability at the scene of incident to be made optimize.



FIRE & TOXICITY CONTROL ARRANGEMENT

Fire Water :- Total Quantity - 500 M3 + Stand by 200 M

3

No. of Sprinklers : 02 Nos

No. of Monitors : 02 Fixed , 02 Trolley

Fixed Portable

Other

source &

capacity

No. of

hydrant

points

No. of

pumps,

type &

capacity

No. of

hose

reels &

total

length

No. of

fire

tenders

and

capacity Lifting

height Pressure

Lifting

height Pressure

Alternate

power

arrangement

1 2 3 4 5 6 7 8 9 10

10 meter 7

Kg/Cm2

- -

Own

Bore

well

45 Jockey,

Electrical

driven,

Diesel

pump

capacity

7 kg/hr

80 Nos.

of 15

mtrs cap

-

1 Nos DG Set

Dry Powder Type Foam Type Water Jet Products Other

Extinguishers

Personal Protective Equipment

No. of portable No. of portable Respiratory Non- respiratory Type of powder

& total quantity Extingui-

shes

Tonners

Type of

foam &

total

quantity

Exting. Tonners

No. of

size of

blankets

Other jet

products,

quantity

Type Number of

Quantity Type Nos. Type Nos.

12 13 14 15 16 17 18 19 20 21 22 23 24 25

1. DCP Powder 5

kg Cap. 10 kg

Cap.

Extinguishers

2. 150 kgs

storage

40 nos - AFFF

Compounds

1400 Ltrs

Carbo

25 nos - - - Co2 45 nos Self Contained

airline

breathing

apparatus

oxygen kit

Dust mask

7

10

2

150

Cartridge

Helmet

Gumboo

ts

Goggles

Appron

Chemical

Suits

Face

shield

50

100

50

50

20

15

15



6.2.3.8 MEDICAL SERVICES

The roles of Medical officers are as follows;

(a) He will contact immediately to the SMC/IC.

(b) He will render necessary treatment, at Occupational Health Center.

(c) He will arrange for Hospitalization and Treatment at outside hospitals, if required.

(d) He will mobilize in getting the services of External medical agencies, other Para –

medical services etc. and transportation services etc.

(e) He will arrange for extra medical assistance/antidotes, from out, if required.

(f) He will arrange for first-aid trained volunteers for necessary help.

(g) He will liaise with the Government Health Authorities for treatment of the affected

persons nearby.

6.2.3.9 OTHER ARRANGEMENTS

Other arrangements include external transport, cranes, generator sets to supply emergency

power, environment monitoring equipment, rescue items etc. when available resources do

not meet the requirement.

STANDARD OPERATING PROCEDURE (EMERGENCY)

As soon as emergency alarm is heard, all essential workers shall report to IC or SMC.

They shall carefully listen to the instructions given by IC or SMC

According to the type of emergency/accident, they shall get equipped with PPE/Fire

fighting equipment and devices.

The runner among the workers shall inform SMC/IC and key personnel if they are not at

site.

The messenger amongst the workers shall deliver messages to nearby units as per the

instructions of SMC/IC.

The in-charge of medical arrangements shall prepare first-aid and other required

facilities for the injured.

The other essential workers shall try to control the emergency as per the instructions

given to IC.



IC would keep SMC informed about the status of control measures being taken at the

site and ask for other requirements e.g. Mutual aid, equipment etc., if he find necessary.

SMC would co-ordinate with outside agencies regarding control measures being taken,

need for external help, evacuation, medical treatment etc.



MEDICAL ARRANGMENTS

First aid Centers / Ambulance Room / OHC / Hospital Ambulance van or alternante arrangement

In charge person

Residence Sr.

No.

Name &

Location

Telex-

hone

Number Name &

Designation Phone Address

Facilities &

Equipments

Antidotes

avail-able

First

aiders

avail-

able

Accommodation Place of

availability Capacity

Facilities

in the

van

Driver’s

Name &

address

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 OHC -

Greentec

Chemicals

Pvt Ltd

Medical

Assistant

- Premises 01

Ambulance

Van 01 Bed,

Oxygen

Cyl.,

Structure,

Artificial

breathing

apt,

Balance, B P

Meter,

Yes Yes ,

Trained

First

Aider

Available

round

the clock

Yes Main Gate

OHC

building

6 Oxygen

kit, First

Aid bod,

Structure

Driver

available

at Main

Gate



6.3 COMMMUNICATION SYSTEM

After the assessment of risk & their possible environmental impact and after making an

organization for the preparedness to control the emergency, the next most essential step is to

make us ready for Communication at the time of emergency. Communication System is a

Crucial Factor while handling emergency.

Company will have quick & effective Communication System through which, any situation,

which can lead to emergency, can be informed or known to.

i. All working inside the plant.

ii. Key Personnel outside during normal working hours & during off-duty hours.

iii. Outside emergency services, Statutory and Local Authorities and

iv. Neighboring facilities and public leaving in vicinity.

Each and every section, Plant & Department of the Factory shall be connected by internal

telephones. External Phone at Office and Residence and Mobile shall be also available with

Key Personnel and top executive of the factory. Hot lines shall be provided with mutual aid

Partner through the Emergency Control Center. The Communication System begins with

raising the alarm declaring the emergency, Telephone messages and Procedure to

communicate the emergency to other persons & General Public.

6.3.1 RAISING THE ALARM

As soon as incident takes place inside the factory and is noticed by someone, the first step is

to raise the nearest manual emergency bell to alert the nearby people. Next, he/she

informs the security persons to raise the emergency siren located at the factory gate. The

security personnel sound the siren, raising and lowering the sound three times in a 10

second “ON”, 5 second “OFF” sequence. After emergency is over “CLEAR SIREN”, 30

seconds. All the security employees shall be trained for operating the siren to announcing

the emergency. In case of power failure, manual bell shall be also provided.

The alarm sound informs the I.C and the S.M.C that an emergency has been created and

emergency organization is to be activated. The I.C. rushes to the site and takes charge of

the scene.



ALARMS & SIRENS

Plant wise alarm points Sound difference if any Sr.

No.

Plant / Dept./ Location Sr. No

.of

Its place

of

Type of

the

Its period

The alarm

(signal)

Type of Type of

alarm

Duration

of

Type of

sound

1 2 3 4 5 6 7 8 9 10 11 12 13

1 At the

Main

gate

- - 1 At

Security

Gate

Electric Once in a

week/Every

Monday at

10-30 AM

Whole

complex

and

surrounding

area

Fire, Toxic,

Emergency

Release All

clear

2 Fungicide

plant

- - 1 Fungicide

plant

Electric Once in a

week/Every

Monday at

10-30 AM

Entire

Factory

Fire, Toxic,

Emergency

Release All

clear

As per attached siren code

# Public Announcement System Available at ECC / Main Gate for emergency communication and speakers are available in factory premises

as well as offices for fast communication.

.



6.3.2 DECLARING THE MAJOR EMERGENCY

Major emergency has to be declared after sufficient and through check because the

declaration of major emergency puts many agencies on action and it may disturb the

running system, which may be Costly at, time or its Consequence may be Serious. Therefore

major emergency must not be decided on whims or immature judgment or without proper

thought. Looking to all the above, we will have taken care to nominate the persons who can

declare the emergency; we will have selected them on the basis of their knowledge &

experience. These persons will be technically qualified and experienced. They shall advice

the Incident Controller or Site Main Controller regarding the type of emergency. On being

convinced, the Site Main Controller or Incident Controller shall declare an ON-SITE

emergency. The decision about major emergency shall be taken as early as possible and

without wasting time so that control action can be started immediately.

6.3.3 TELEPHONE MESSAGES

After hearing the emergency alarm and during emergency or even while just receiving the

emergency message on phone, Telephone operator should be precise, sharp, attentive and

quick in receiving and noting the message and subsequently effective in further

Communication A form to record emergency telephone calls shall be available with

telephone operator or Person available in Emergency Control Center, who has to record

such calls during emergency. Telephonic messages shall be given out by the telephone

operator to Site main Controller and key personnel as per the instructions of the Incident

Controller. Telephonic messages shall also be given to authorities and external agencies to

describe the type of emergency. All details of emergency shall be collected/delivered

according to this format shall available with the telephone operator.

6.3.4 COMMUNICATION OF EMERGENCY & STATUTORY INFORMATION

6.3.4.1 COMMUNICATION OF EMERGENCY

An effective system to communicate emergency shall be available.

Inside the factory i.e. workers including key personnel and essential workers, on duty &

inside during normal working hours.

To key personnel and essential workers not on duty and outside during normal working

hours.



To the outside emergency services and the Government authorities.

To the neighboring factory & the General Public in the vicinity.

a) Information to Workers

All personnel inside the factory shall be informed by the sounding of the siren or in case of

electricity by ringing the bell.

b) To key personnel outside during normal working hours

The key personnel outside the factory premises shall be informed as per the need by

external telephones or runners.

c) To the outside Emergency Services and the Authorities

Once the emergency is declared, it is essential that the outside emergency services should

be informed in the shortest possible time. Responsibilities shall be fixed as per the

Incident/Emergency Command structure/plan to contact outside agencies for help and to

communicate to the all the Government and other Authorities such as Fire Brigade, Police,

District Emergency Authorities, Factory Inspectorate & Hospital etc. In case of major

emergency, outside agencies like mutual aid, hospitals, policies, Factory Inspector, Collector,

Fire-brigade etc. shall be informed by telephone or by sending special messenger from

emergency control center.

d) To neighboring factories and the General Public

A major emergency will affect areas outside the works and it is essential that neighboring

factory and General Public, should be informed to enable them to take prompt action to

protect their own workers and to take whatever measures may be possible to prevent

further escalation of the emergency due to effects on their own installations, at the same

time, they may be able to provide assistance as part of a prearranged mutual aid plan.

Further responsibilities shall be fixed to inform the neighboring factories and the General

Public leaving in the vicinity. The neighboring units shall be informed about an emergency

through external telephones or runners. The general public shall be informed about an

emergency using loudspeaker on scooter or rickshaw or car. Help from police shall be

sought if required.



6.3.4.2 STATUTORY INFORMATION

a) Information to Workers

Set of Statutory information regarding types of hazards and their prevention and control as

directed in the Factories Act shall be prepared by the unit. This information shall be printed

in the local language and given in the form of booklet to all workers including contract

workers.

b) To the outside emergency services and authorities

Statutory information in the form of booklet shall be given to outside emergency services

and authorities.

c) To neighboring firms and the general public

Statutory information in the form of booklet will be given to neighboring units and the

general public of the villages in the vicinity of the unit.

6.4 ACTION ON SITE

The activities related to emergency time activities shall be divided into two parts. These are

Pre-emergency activities

Post-emergency Activities

6.4.1 PRE-EMERGENCY ACTIVITIES

6.4.1.1 INTERNAL SAFETY SURVEY

A safety committee shall be constituted as per Factories Act. The nominated members of

the committee shall be assigned the responsibility to conduct safety survey once in a month

before safety meeting. The internal safety survey includes –

Identify various hazards in the factory

Check whether protective equipments are in sound working condition

Check various safety installations located at various plants for proper working

Check sprinklers, showers, etc. in all plants

Suggest extra modifications/ requirements to make systems more reliable

Check presence of toxic gases by the help of dragger tube

Frequency of Internal Safety Survey: Once in a month



6.4.1.2 THIRD PARTY SURVEY

A safety survey shall be carried out once in a year by an external agency. It shall include –

Inspection of building, structures for strength and stability

Identify and study the hazards inside individual plants and within the factory

premises.

Check safety system for its adequacy.

Suggest modifications or additions in the operating practices and safety system, if

necessary.

Frequency of Third Party Safety Survey: Once in a year

6.4.1.3 PRESSURE VESSEL TESTING/ EXAMINATION

To prepare list of pressure vessels in the plant with details of operating conditions

and manufacturing details.

To carry out preventive maintenance of valves & fittings on all pressure vessels

(valves, pipelines, pressure gauge, temperature recorders and emergency vent lines)

To arrange for testing and examination of all pressure vessels as per the rules of

Factories Act by govt. certified competent person on due date.

To maintain record of testing and certificates issued by competent person and make

them available to Factory Inspector at the time of inspection.

Frequency of Pressure Vessel Testing / Examination: Twice in a year

6.4.1.4 NON-DESTRUCTIVE TESTING (NDT)

To prepare list of equipment and pipelines in the plant which require NDT as per the

rules of Factories Act?

To arrange for Non-Destructive Testing (NDT) as per the rules under Factories Act by

govt. certified competent person on due dates.

To maintain record of testing and certificates issued by competent person and make

them available to Factory Inspector at the time of inspection.

Frequency of Non-Destructive Testing : Once in a year



6.4.1.5 SAFETY RELIEF VALVES TESTING

To prepare list of Safety Relief Valves installed on various equipment and pipelines in

the unit along with detailed specifications.

To prepare schedule for testing and calibration as per the rules under Factories Act

by govt. certified agencies on due dates.

To maintain record of testing and certificates and mark dates of testing and

calibration on the valves.

To carry out repairs/replacement as suggesting by the testing authority.

Frequency : Twice in a year

6.4.1.6 FIRE SYSTEM TESTING

To prepare list of various fire-fighting equipment (Fire Extinguishers, etc.) installed at

various locations in the unit along with detailed specifications.

To prepare schedule for testing of all these equipment and check operability

To maintain record of testing and mark dates of testing on the equipment.

To carry out repairs/replacement of defective equipment

Frequency: Once in a month

6.4.1.7 MUTUAL AID SCHEME

To prepare Mutual Aid Scheme and enter into agreement with the neighboring units

for getting or extending help during emergency

To appoint coordinator for follow-up under mutual Aid Scheme

To review the scheme once in a year with coordinators of neighboring units w.r.t.

scope of help, type of aid, contact persons, etc.

To include the scheme in mock drills

6.4.1.8 MOCK-DRILLS

To conduct minor mock drills to train employees about their role / duties during

emergency

To refresh training to the employees for fire fighting, spill control, use of personal

protective equipments etc.



To check whether various members of emergency control committee remember

their role / duties properly and to find out the faults and points of improvement in

their performance.

To check whether the various equipment for emergency control are operating

satisfactorily and find and rectify the draw-backs if any.

To conduct major mock-drills with permission from the authorities

Mock drills shall be regularly conducted in our unit by our Emergency Control Organization

and the findings are compiled to analyze whether employees are familiarized with the

emergency control procedures and what sort of training is required to be given.

6.4.1.9 SAFETY TRAINING

To organize regular training for the employees for handling of safety equipment, use of

personal protective equipment, first-aid, etc. by internal/external faculty, as well as by

sending persons outside to attend safety programs etc. The topics covered in safety

training will be –

Training on fire fighting

Training on spill control

Training on toxic release control

Training on good housekeeping

Training on use of PPE

The records of the training programs shall be maintained by the Safety Committee. New

topics will be included in the safety training programs year by year to upgrade safety

knowledge among the workers.

Frequency: Once in a year

6.4.1.10 PERSONAL PROTECTIVE EQUIPMENT

To procure adequate number of personal protective equipment (aprons, hand

gloves, safety goggles, helmets, nose masks, safety belts, gas cartridges, self-

breathing apparatus, safety shoes etc.) suitable for plant operations and maintain

records of use.

To have proper system for issuing the PPE and disposal of used PPE



To train the workers about proper use of PPE.

To check the fresh air blowers provided at confined spaces for fresh air to workers.

6.4.1.11 COMMUNICATION

To maintain internal/external telephones in working order

To check alarms / siren / loudspeakers for workability

To provide manual emergency bells at various location for use during power failure

To periodically check wind cock for wind direction

To check lightning arrestors installed at different locations for physical condition and

proper earthing connection.

6.4.1.12 EMERGENCY LIGHTS

To keep sufficient number of emergency torch/ batteries in ECC as well as at the

production site

To maintain the three DG sets available in the factory as stand-by for power failure.

The D.G. sets are set to start functioning within two minutes of failure of electricity.

6.4.1.13 EMERGENCY CONTROL ROOM

It is necessary to maintain the Emergency Control Room and keep it equipped with all

necessary items, documents, telecommunication systems, PPE etc. required in case of an

emergency.

6.4.1.14 ASSEMBLY POINTS

To fix assembly points in the factory for non-essential workers

To fix assembly points for plant emergency staff and coordinators

To maintain record of no. of workers gathered at the assembly points at the time of

emergency. The Safety Committee shall nominate a person for this duty.

6.4.1.15 LIAISON WITH STATE AUTHORITIES

To liaison with civil authorities, local hospitals, Fire-Brigade, Collector, factories

Inspector, Police, etc regarding emergency activities and need for external aid.



To keep the details regarding name, address & telephone numbers of various govt.

authorities and neighboring units available and update the details from time to time.

To inform about Mock-drill in advance and if required conduct mock-drill in presence

of any of these authorities.

To submit report of Mock-drill conducted and the out comings with photograph to

Factories Inspector.

6.4.1.16 HOSPITAL FACILITIES

To equip Occupational Health Centre with First-Aid and medicines

To keep Health records (esp. blood-group records) of all employees

To liaison with hospitals in the area of the unit

To keep list of blood donors ready for reference

To update arrangements with neighboring units for emergency first aid.

6.4.1.17 OUTSIDE SHELTER

To reserve space in nearby schools/hospitals/buildings for temporary shelter during

emergency

To arrange for clothing, food, medicine in temporary shelter

6.4.1.18 STATUTORY INFORMATION

Statutory Information about chemicals handled in the unit, manufacturing process, the

hazards in the unit, methods of prevention and control, first aid measures etc. shall be given

to

- Workers

- Public and Neighboring units

- Government authorities & outside emergency services

6.4.1.19 PROTECTIVE DEVICES & ENGINEERING MAINTENANCE

Installation of safety valve and pressure gauges on vessels used for high pressure

operations.



Installation of temperature indicators on reactors, temperature switch or alarm at

critical reactors

Maintenance of cooling water systems and pumps. To keep standby pump at cooling

tower.

Installation of overhead water tank for emergency. To keep it filled and regular

cleaning of the same

Periodic cleaning of heat transfer surfaces (jacket, reactors, shell & tube heat

exchangers, boilers)

To keep minimum inventory of hazardous materials with records

To maintain good housekeeping and ensure safety compliance

6.4.1.20 LIST OF SUPPLIERS OF SAFETY EQUIPMENT

To prepare and preserve list of suppliers of safety equipment e.g. first aid box,

medicines, fire extinguishers, PPE, communication, self breathing apparatus, chlorine

kit, etc.

To check all supplies every three months

To update the list and keep it ready-to-refer location in the plant as well as at ECC

6.4.1.21 FIRE PREVENTION PLAN

List of major work-place fire hazards

Potential ignition sources

Sparks from electrical fitting / motors

Sparks from welding operations

Ignition system of boiler house

Sparks from static electricity

Fire prevention & control measures

Use of flameproof electrical fittings and electric motors wherever necessary

No welding shall be done anywhere in the plant without prior permission from safety

officer and necessary precautions from in charge of the area.

Ignition system of boiler should be provided with guard

All vessels and pipeline should be properly earthed to prevent static electricity



The vent lines of all vessels and tanks holding flammable materials should be

provided with flame arrestors

Fire extinguishers shall be provided at all critical locations in the unit

6.4.2 POST EMERGENCY ACTIVITIES

These activities are to be carried out after an emergency is over so as to establish the cause

of the emergency and decide the measures to be taken to prevent its re-occurrence. These

activities are –

1. Collection of records of accident, injury, damage to property, buildings, equipment,

material and loss of production

2. Conducting enquiries and concluding preventive measures

3. Making insurance claim for the materialistic loss / damage

4. Implementation of enquiry report’s recommendations

5. Rehabilitation of affected persons within and outside the plant

6. Restarting the plant and normalizing the operations.

6.4.3 EMERGENCY TIME ACTIVITIES

The probable emergency situation that can arise in the unit and the corresponding control

actions are describes below.

6.4.3.1 FLAMMABLE RELEASES

Source / Incident – Fire involving spilled combustible material near or in flammable storage

areas

Control action –

1. Any one who notices fire shall sound emergency alarm.

2. SMC/IC who is at site, shall immediately rush to the scene and assess the situation.

For fire due to spillage of combustible material, he activates the on-site plan as -

He cuts off electric supply to that area and evacuates all the persons to safe

assembly points.

He calls in DIC (if DIC is not present there) and asks essential workers to fight fire

with dry chemical / CO2 fire extinguisher or sand.



He inform fire brigade telling them in briefly about kind of fire and type of

extinguishers required

He informs mutual aid teams and asks for necessary help.

He arranges first-aid / hospitalization for the affected persons.

Fire officer on reaching the site, takes charge of the fire-fighting operations

Mutual aid teams shall be asked for help in the form of first-aid, transport etc.

If fire is growing, fire officer informs IC who alerts neighboring units and through

SMC gets more fire-fighting help.

Fire fighting shall be continued till fire is fully overcome

After extinguishing fire, fire officer cools the entire area with water spray and checks

that no re-ignition shall be likely. After that, he declares the area safe.

IC tells essential workers to sound all clear

The incident shall be recorded

SMC arranges to inform families / relatives of injured / dead.

SMC issues authorized statement to press / media.

SMC informs Factories Inspector about the incident and related information

6.4.3.2 TOXIC RELEASES

Source / Incident – Pressure release due to failure of

- Stuffing box gland packing

- Pressure release valve

- Vessel / pipeline failure

- Cylinder/tank/drum leakages like Cl2/Bromine/Thinonyl chloride

Control action –

1. Any one who notices the release shall sound emergency alarm.

2. Leakage - kits /minimum stock /spare tank

2. SMC/IC who is at site, shall immediately rush to the scene and assess the situation.

For toxic release from a reactor, he activates the on-site plan as -

He evacuates all the persons to safe assembly point.



He calls in DIC (if DIC is not present there) and asks essential workers to wear self-

breathing apparatus and if the reaction is exothermic, start cooling water flow in the

reactor jacket and cool the reactor as soon as possible.

The essential workers stop all the charging pumps of that reactor and the nearby

reactors.

He informs mutual aid teams and asks for necessary help.

He arranges first-aid / hospitalization for the affected persons.

Mutual aid teams shall be asked for help in the form of first-aid, transport etc.

When the leak stops and the air shall clear of toxic release, IC tells essential workers

to sound all clear.

The vessel / rupture disc/gland packing will be attended by maintenance

department.

The incident shall be recorded

SMC arranges to inform families / relatives of injured / dead.

SMC issues authorized statement to press / media.

SMC informs Factories Inspector about the incident and related information

6.4.3.3 CHEMICAL SPILL

Most of the storage tanks shall be located in Storage Tank Yards. Dyke walls of sufficient size

will be connected around the tank yard. Neutralizing material shall be kept nearby. For

dilution, water connection will be provided on all sides of tank farms. Sand buckets shall be

provided for covering spillage of flammable / corrosive materials.

6.4.4 EVACUATION & TRANSPORTATION

All non-essential workers shall be evacuated from incident area and adjacent areas to safe

assembly points. Assembly points shall be clearly marked and assembly point in-charge will

also be designated. The assembly point in-charge will be a well-trained supervisor who shall

keep record of persons arriving at the assembly point and direct them for proper gathering.

He shall also inform the ECC about the persons gathered at the assembly point. Those in

need of medical treatment shall be transported to first-aid center / hospital as the case may

be. In case of major emergency all non-essential workers shall be transported to temporary

shelter.



6.4.5 SAFE CLOSE-DOWN

As per the instructions from IC or SMC, some parts or full of the plant shall be closed down

by the essential workers. The procedure for safe shut-down and start-up will be given in

safety manual given to all workers.

6.4.6 USE OF MUTUAL AID

Mutual aid from neighboring units shall be called up as and when required. The aid shall be

taken under the supervision of SMC.

6.4.7 HELP OF EXTERNAL AUTHORIES

Outside authorities such as Police, District Emergency Authority (DEA), Factory Inspector,

Disaster Management Centre, GIDC officer, Industries Association, Regional Pollution

Control Board, nearby hospitals etc. shall be informed of the on-site and off-site emergency

plans and called in as per need.

6.4.8 MEDICAL TREATMENT

Injured workers shall be located and given prompt first-aid by essential workers and key

personnel. Those requiring medical treatment shall be taken to the hospital / outside

medical center.

6.4.9 ACCOUNTING FOR PERSONNEL

Through daily muster rolls and with the help of shift-in-charge the head count shall be

undertaken to find out whether persons are missing and if so immediate search shall be

carried out to locate them. The list shall include company employees, contract workers as

well as visitors. Help from local authority or fire-brigade shall be taken if required. This list

shall be kept with time keeper / security officer at any time and shall be used to account for

personnel. Injured shall be taken to hospitals and their families/relatives shall be informed

Casualties would be identified, their families and local authority shall be informed.

6.4.10 ACCESS TO RECORDS

In order to inform families/relatives of injured/dead, a up-to-date list of names and

addresses of all the workers is maintained in addition to the muster roll where shift-wise



attendance is marked. Such list includes health records. This list will be available at the ECC

and one such copy shall be available at our head office.

6.4.11 PUBLIC RELATIONS

Our General Manager shall be the only nominated person to issue administrative statement

about the accident or emergency to news/media. No other person shall divulge any

information to any news / media person.

6.4.12 REHABILITATION

In case of Toxic release or chemical spillage, Senior Fire Brigade Officer would ensure that

the incident area shall be safe and cleaned up of all mess. Then only, he would allow people

to re-enter the location. In case of fire, the Senior Fire-Brigade Officer shall ensure that the

area is cooled down and there are no chances of re-ignition. IC shall arrange for clean-up of

the area and then only people shall be allowed to re-enter the area for work. Even when all

clear has been given, great care shall be taken when re-entering affected areas and no work

in connection with the salvage, collection of evidence or start up shall be taken up until a

thorough examination of the area has been carried out. The statutory powers of the

Factory Inspector shall be kept in mind before any evidence is disturbed. Particular care

shall be taken to avoid the introduction of possible sources of ignition, such as diesel

engines, hand or power operated tools, flame cutting equipment, etc. until it has been

established that no flammable materials are present where they could be ignited.

6.5 OFF – SITE EMERGENCY PLAN

6.5.1 NEED OF THE OFF – SITE EMERGENCY PLAN

An off-site emergency plan is prepared to deal with those incidents which have the potential

to harm persons or the environment outside the boundary of the factory premises. A major

accident, major emergency and disaster may affect areas outside the plant. An explosion

can scatter debris over wide areas and its effects of blasts can cover considerable distances.

Wind can spread burning fumes of toxic gases. Thus the events like these described above

can affect outside areas and combating them needs an Off-site Emergency plan.

Envisaging such a rare incident, an off-site emergency plan should be drawn up for the

following purpose.



1. To provide basic information about the risk and environmental impact assessment

related to the unit to local / district authorities, police, fire-brigade, surrounding

units, and the general public. To appraise them of consequences and the protection

/ prevention measures and control actions and to seek their help to communicate

with public in case of a major emergency. The information from all industries shall

enable district authorities to educate public about what could go wrong, and to train

them of measures to be taken as an individual.

2. To enable district authorities to prepare the off-site emergency plan (contingency)

for the district or particular area and to organize rehearsals and initiate actions

learnt from these incidents.

Our Emergency Plan shall be made after considering the all possible effects of incidents on

the neighboring population and the remedial measures will be devised in consultation with

the local authorities and emergency services.

6.5.2 STRUCTURE OF THE OFF-SITE EMERGENCY PLAN

Organization Details of :

Command Structure, Co – Ordination arrangements, warning systems,

implementation procedures, emergency control centers.

Name & appointments of :

Incident Controller, Site Main Controller, their deputies and other key personnel.

Communication Identification of personnel involved, communication center, call signs, network, lists

of key telephone numbers.

Specialized emergency

equipment

Details of availability and location of :

Heavy lifting gear, bulldozer, specialized fire fighting equipments, fire boats.

Specialized Knowledge Details of specialized bodies, firms and people upon whom it may be necessary to

call, egg, people or firms with specialized chemical knowledge, laboratories.

Voluntary Organizations Details of organizers, telephone numbers, resources, etc.

Chemical Information Details of the hazardous substances stored or processed on each site and a summary

of the risks associated with them. (HAZCHEM details).

Meteorological

Information’s

Arrangements for obtaining details of weather conditions prevailing at the time and

for weather forecasts.

Humanitarian

arrangements

Transport, evacuation centers, emergency feeding, treatment of injured – first aid,

ambulance, temporary mortuaries.

Public Information Arrangements for

(a) Dealing with the media, press and office.

(b) Informing relatives etc.

Assessment Arrangements for

(a) Collecting information on the cause of the emergency appointment of a

historian.

(b) Reviewing the efficiency and effectiveness of all aspects of the emergency

plan.



6.5.3 ROLE OF FACTORY MANAGEMENT

The Off-Site emergency Plans are dovetail so that the emergency services shall be

summoned at the appropriate time and shall be provided with accurate information and a

correct assessment of the situation. The responsibility for this is with the Site Main

Controller. The Site Main Controller shall provide a copy of our On-Site and Off-Site

Emergency Plan to the District authorities, the Factories Inspectorate and the Emergency

Services, so that on the basis of information and such authorities can make their emergency

preparedness plan to formulate and execute the District / Area off Site Emergency Plan.

Further on the advice of the authorities we can also modify our plan to make our plan more

effective and perfect.

6.5.4 ROLE OF EMERGENCY CO-ORDINATION OFFICER (ECO)

The various emergency services will be co-ordinated by the Emergency Co-ordination officer

(ECO), who will likely to be a Collector. The ECO will liaise closely with the Site Main

Controller. The Emergency Control Centre of the factory can be utilized by the ECO to keep

liaison with the Site Main Controller.

6.5.5 ROLE OF THE FIRE AUTHORITIES

The control of fire is normally the responsibility of the senior fire officer who would take

over the handling of fire from the IC on arrival at the site.

The senior fire brigade officer may also have similar responsibility for other events

such as explosion and toxic releases. Fire authority having major hazard units in the

area shall- Familiarize themselves with the location and site of all stages of

flammable materials, water and foam supply points, fire fighting equipment.

Act as observer of an on-site exercise involving only site personnel

6.5.6 ROLE OF THE HEALTH AUTHORITIES

Health authorities, including Doctors, Surgeons, Hospitals, and Ambulances so on, have a

vital part to play following a Major Accident and they should form an integral part of any

emergency plan. In case of major fires, injuries will be the result of the effects of thermal

radiation to a varying degree, and the knowledge and experience to handle this type of

injuries cases may be generally available in most of the hospitals. But in case of major toxic



releases, the effects vary according to the chemical, which has leaked, and it is important for

health authorities that might be involved in dealing with the aftermath of a toxic release to

be familiar with the treatment appropriate to such casualties. Major Off-Site incidents are

likely to require medical equipment and facilities additional to those available locally and a

Medical 'Mutual Aid' scheme should exist to enable the assistance of neighboring

authorities to be obtained in the event of an emergency.

6.5.7 ROLE OF TELEPHONE DEPARTMENT

The communication system between the factory and the various above role-playing

authorities must be effective. The ineffective public telephone system will not be useful in

emergency. Therefore, telephone department should maintain the phones and if required

temporary telephone connection may be provided to various above authorities to deal the

emergency.

6.5.8 ROLE OF POLICE AND EVACUATION AUTHORITIES

To protect life and property

To control traffic movement

To inform people to remain indoors or evacuate

To carry-out evacuation

To identify dead, deal with casualties and inform relatives of dead or injured.

For evacuation, the following criteria are useful:

a) In case of major fire, only houses close to fire and in the direction of smoke need

evacuation

b) If fire is escalating and in turn threatening a store of hazardous material, it is

necessary to evacuate people nearby if time is available; otherwise they should be

informed to keep themselves indoor and shield from the fire.

c) For release of toxic gases, limited evacuation may be appropriate in downwind

direction with windows closed and provides good protection. Toxic gases which are

hazardous down to much lower concentration cover a long distance. This factor

must be considered while deciding upon the need and extent of evacuation.



6.5.9 ROLE OF THE MUTUAL-AID AGENCIES

Mutual-aid arrangements shall be made in areas of fire & toxicity control, medical and

transport & evacuation. All partners of mutual-aid shall extend all possible help in these

areas.



6.6 OCCUPATIONAL HEALTH AND SAFETY

For large industries, where multifarious activities are involved during construction, erection,

testing, commissioning, operation and maintenance; the men, materials and machines are

the basic inputs. Along with the boons, industrialization generally brings several problems

like occupational health and safety. The industrial planner, therefore, has to properly plan

and take steps to minimize the impacts of industrialization and to ensure appropriate

occupational health and safety including fire plans. All these activities again may be

classified under construction and erection, and operation and maintenance.

6.6.1 OCCUPATIONAL HEALTH

Occupational health needs attention both during construction & erection and operation &

maintenance phases. However, the problem varies both in magnitude and variety in the

above phases.

6.6.1.1 CONSTRUCTION AND ERECTION

The occupational health problems envisaged at this stage can mainly be due to

constructional accident and noise. To overcome these hazards, in addition to arrangements

to reduce it within TLV's, necessary protective equipments shall be supplied to workers.

6.6.1.2 OPERATION AND MAINTENANCE

The problem of occupational health, in the operation and maintenance phase is primarily

due to noise which could affect consultation. The necessary personal protective equipments

will be given to all the workers. The working personnel shall be given the following

appropriate personnel protective equipments.

Industrial Safety Helmet;

Face shield

Zero power plain goggles with cut type filters on both ends;

Zero power goggles with cut type filters on both sides and blue color glasses;

Welders equipment for eye and face protection;

Cylindrical type earplug;

Ear muffs;



Canister Gas mask;

Self contained breathing apparatus;

Leather apron;

Aluminized fiber glass fix proximity suit with hood and gloves;

Boiler suit;

Safety belt/line man's safety belt;

Leather hand gloves;

Asbestos hand gloves;

Acid/Alkali proof rubberized hand gloves;

Canvas cum leather hand gloves with leather palm;

Lead hand glove;

Electrically tested electrical resistance hand gloves; and

Industrial safety shoes with steel toe.

6.6.1.3 HOSPITAL FACILITIES

It is proposed that client will make formal agreements with nearby hospital having facilities

to attend fire and toxic effect cases for attending the affected persons in the emergency

arising out of accidents, if any.

6.6.1.4 FACTORY MEDICAL OFFICER

A qualified doctor will be appointed as FMO on retainer ship basis. Apart from him,

Paramedical Staff will be employed.

6.6.1.5 PROPOSED FACILITY TO BE MADE AVAILABLE AT OHC

One Room is proposed to be provided to be operated as OHC. The centre will be equipped

with following medical equipments:—

1. Examination Table

2 Dressing Tables For performing Dressing

3. Glucometer For measurement of Blood Sugar

4 Vision chart To evaluate vision acuity

5. Nebuliser For relieving coughs & Breathing Difficulty



6. Infra red light for relieving muscular pain

7. Suction machine For cleaning airway

8. Autoclave machine For sterilizing cotton &dressing material

9. Weighing Machine For measuring body weight

10. Medical Oxygen Cylinder kit

11. Sphygmomanometer To measure blood pressure

12. Refrigerator To preserve medicines

13. Thermometer

OHC (OCCUPATION HEALTH CENTRE)

Item Quantity

First aid boxes 15 Nos

Stretchers 03 Nos

Ambulance 01 No + other vehicles

Availability of Doctors/nurses 02 Nos FMO & (01 Medical Asst.)

Availability of medicines/antidotes Yes , All relevant chemicals

Dr Consulting room 13 * 13 sq ft area

No. of beds in Medical Room 02 Nos ( 27 * 13 sq ft area )

Details of other facilities/equipment OHC related all medical facility &

Mutual Aid facility,

Medical Oxygen cylinders – 03 Nos

Freeze – 01 no

Nebuliser – 01 no

Dressing equipments

Peak flow meter – 01 no

B. P. Meter

Ambush bag

Digital thermometer

Medical Examination Every six month as per Hazardous process

Annually as details examination

Medical record keeping As per GFR Form – 32 & From – 33

6.6.1.6 AMBULANCE VAN

An ambulance van is proposed to be made available 24 hours at Fire Station.

6.6.1.7 FIRST AID BOX

First Aid Boxes are proposed to be made available at the different location in the plant,

Training to be given to employees for First Aid.



FIRST AID BOX (LIST OF MEDICINES)

SR.

NO.

NAME OF MEDICINE

1 Tab. Crocin

2 Eno Powder

3 Iodine Tincture

4 Savlon / Dettol

5 Tube Soframycin

6 Tube Burnol

7 Eye drop –Locula 10% / Gentamacin

8 Bandage roll

9 Cotton

6.6.1.8 PERIODIC MEDICAL EXAMINATION

It is proposed that client will ensure that…

(1) Workers employed shall be medically examined by a qualified medical practitioner/

Factory Medical Officer, in the following manner:

(a) Once in a period of 6 months, to ascertain physical fitness of the person to do the

particular job;

(b) Once in a period of 6 months, to ascertain the health status of all the workers in

respect of occupational health hazards to which they are exposed and in cases where

in the opinion of the Factory Medical Officer it is necessary to do so at a shorter

interval in respect of any workers;

© In periodic and pre-medical examinations, various parameters will be checked. Viz.,

LIVER FUNCRION TESTS, Chest X-rays, Audiometry, Spirometry, Vision testing (Far &

Near vision, color vision and any other ocular defect) ECG and other parameters as will

be found necessary as per the opinion of Factory Medical officer.

(2) No person shall be employed for the first time without a certificate of granted by the

Factory Medical Officer.



6.6.1.9 EMP FOR THE OCCUPATIONAL SAFETY & HEALTH HAZARDS SO THAT SUCH

EXPOSURE CAN BE KEPT WITHIN PERMISSIBLE EXPOSURE LEVEL (PEL)/THRESHOLD

LEVEL VALUE (TLV) SO AS TO PROTECT HEALTH OF WORKERS

1. It is proposed to formulate and implement an EMP for Occupational Safety and

Health with following aims…

To keep air-borne concentration of toxic and hazardous chemicals below PEL

and TLV.

Protect general health of workers likely to be exposed to such chemicals

Providing training, guidelines, resources and facilities to concerned

department for occupational health hazards.

Permanent changes to workplace procedures or work location to be done if it

is found necessary on the basis of findings from workplace Monitoring Plan.

2. It is proposed that this EMP be formulated on the guidelines issued by Bureau of

Indian Standards on OH&S Management Systems: IS 18001:2000 Occupational

Health and Safety Management Systems

3. Proposed EMP will be incorporated in Standard Operating Procedure also.

4. The proposed EMP will also include measure to keep air-born concentration of

toxic and hazardous chemicals below its PEL and TLV, like…

a. Leak Surveys

b. Separate storage for toxic chemicals

c. Exhaust Ventilation

d. Proper illumination

e. On-line detectors toxic chemicals

f. Close processes to avoid spills and exposures

g. Atomization of process operations to hazards of manual handling of

chemicals

h. Supply of proper PPEs like Air mask, Berating canisters, SCBA sets, On-line

breathing apparatus at the places where there is possibility of presence of

toxic chemicals

i. Decontamination procedure for empty drums and carboys.

j. Regular maintenance program for pumps, equipment, instruments handling

toxic and corrosive chemicals

k. Display of warning boards

l. Training to persons handling toxic and corrosive chemicals



5. Workplace Monitoring Plan

It is proposed that a Workplace Monitoring Plan to be prepared & implemented in

consultation with FMO and industrial hygienists.

Each workplace must be evaluated to identify potential hazards from toxic

substances or harmful physical agents. Air-borne concentration of toxic chemicals

will be measured and record will be kept.

The current state-of-the-art exposure measurement model is as follows: For

purposes of measuring worker exposure across a single shift it is sufficient t o place a

reasonably accurate exposure measuring device on the worker , within t he worker ’s

breathing zone, and have it operate for nearly the full shift. Client has been proposed

to study the exposure data when the plant is operative.

6. Health Evaluation of Workers

1. It is proposed that management will device a plan to check and evaluate the

exposure specific health status evaluation of workers

2. Workers will be checked for physical fitness with special reference to the possible

health hazards likely to be present where he/she is being expected to work before

being employed for that purpose. Basic examinations like Liver Function tests, chest

x ray, Audiometry, Spirometry Vision testing (Far & Near vision, color vision and any

other ocular defect) ECG, etc. will be carried out. However, the parameters and

frequency of such examination will be decided in consultation with Factory Medical

Officer and Industrial Hygienists.

3. While in work, all the workers will be periodically examined for the health with

specific reference to the hazards which they are likely to be exposed to during work.

Health evaluation will be carried out considering the bodily functions likely to be

affected during work. The parameters and frequency of such examination will be

decided in consultation with Factory Medical Officer and Industrial Hygienists. Plan

of monthly and yearly report of the health status of workers with special reference to

Occupational Health and Safety.



Occupational health impact on employees, control measures, action plan if accident occur Sr.

No.

Chemical Occupational health impact

on

Employees

EMP/Measures to keep

exposure below

TLV/ PEL

EMP for STEL & IDLH

1 Acetonitrile

Potential Acute Health

Effects: skin contact

(irritant), of eye contact

(irritant), Potential Chronic

Health Effects: The

substance is toxic to blood,

kidneys, lungs, liver, mucous

membranes, gastrointestinal

tract, upper respiratory

tract, skin, eyes, central

nervous system (CNS). The

substance may be toxic to

the reproductive system.

Closed system, ventilation,

explosion-proof electrical

equipment and lighting. Do

NOT use compressed air for

filling, discharging, or

handling

Ventilation. Remove all ignition sources.

Collect leaking liquid in sealable containers.

Absorb remaining liquid in dry sand or inert

absorbent and remove to safe place. Do NOT wash

away into sewer. Personal protection: complete

protective clothing including self contained

breathing apparatus

2 Bromine May be fatal if inhaled.

Highly toxic by inhalation,

ingestion or skin contact.

Causes severe burns.

Lachrymator. Typical TLV 0.1

ppm. Typical STEL 0.3 ppm.

The substance is toxic to

mucous membranes. The


kidneys, liver, cardiovascular

system, central nervous

system (CNS), thyroid

Provide exhaust ventilation

or other engineering

controls to keep the

airborne concentrations of

vapors below their

respective threshold limit

value. Ensure that eyewash

stations and safety showers

are proximal to the work-

station location. Personal

Protection: Face shield. Full

suit. Vapor respirator. Be

sure to use an

approved/certified


Gloves. Boots.

Small Spill: Absorb with an inert material and put

the spilled material in an appropriate waste

disposal.

Large Spill: Corrosive liquid. Poisonous liquid. Stop

leak if without risk. Absorb with DRY earth, sand or

other non-combustible material. Do not get water

inside container. Do not touch spilled material.

Use water spray curtain to divert vapor drift. Use

water spray to reduce vapors. Prevent entry into

sewers, basements or confined areas; dyke if

needed. Call for assistance on disposal. Be careful

that the product is not present at a concentration

level above TLV.

3 Ethyl Alcohol 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 from sources of ignition. Stop leak if without

risk. Absorb with DRY earth, sand or other non-

combustible material. Do not touch spilled

material. Prevent entry into sewers, basements or

confined areas; dyke if needed.

4 Dimethyl

formamide(DMF)


kidneys, liver, central

nervous system (CNS). The


blood, the nervous system.

Repeated or prolonged

exposure to the substance

can produce target organs

damage.


or

other engineering controls

to

Keep the airborne

concentrations of vapors

below their respective

threshold limit value.

Ensure that eyewash



station location.

Flammable liquid. Keep away from heat. Keep






5 Hydrochloric

Acid

Very hazardous in case of

skin contact (corrosive,

irritant, permeator), of eye

contact (irritant, corrosive),

of ingestion, Slightly

Provide close process and

scrubber on process vent

and

storage vent

Corrosive liquid. Poisonous liquid. Stop leak if

without risk. Absorb with DRY earth, sand or other

non-combustible material. Do not get water inside

container. Do not touch spilled material. Use

water spray curtain to divert vapor drift.



hazardous in case of

inhalation (lung sensitizer).

Non-corrosive for lungs.

Liquid or spray mist may

produce tissue damage

particularly on mucous

membranes of eyes, mouth

and respiratory tract. Skin

contact may produce burns.

Inhalation of the spray mist

may produce severe

irritation of respiratory tract,

characterized by coughing,

choking, or shortness of

breath. Severe over-

exposure can result in death.

6 Hexane The substance is toxic to




central nervous







7 Isopropyl alcohol The substance is toxic to




central nervous







8 Methanol The substance is toxic to




central nervous







9 Liq. Ammonia Very hazardous in case of

skin contact (corrosive,

irritant, permeator),

Inhalation of the spray mist

may produce severe

irritation

of respiratory tract,

characterized by coughing,

choking, or shortness of

breath. Severe overexposure

can result in death. The

substance is toxic to upper

respiratory tract





vapors below their





station location.

Dilute with water and mop up, or absorb with an

inert dry material and place in an appropriate

waste disposal container. If necessary: Neutralize

the residue with a dilute solution of acetic acid.

Corrosive liquid. Poisonous liquid. Stop leak if

without risk. Absorb with DRY earth, sand or other

non-combustible material.

Do not get water inside container. Do not touch

spilled material. Use water spray curtain to divert

vapor drift. Use water spray to reduce vapors.

Prevent entry into sewers, basements or confined

areas; dyke if needed. Call for assistance on

disposal. Neutralize the residue with a dilute

solution of acetic acid.

10 Methylene

Chloride

CARCINOGENIC EFFECTS:

Classified + (Proven.) by

OSHA. The substance is toxic

to lungs, the nervous

system, liver, mucous

membranes, central nervous

system (CNS).





vapors below their




Absorb with an inert material and put the spilled

material in an appropriate waste disposal. Be

careful that the product is not present at a

concentration level above TLV



are proximal to the

workstation location.

Personal Protection:

11 Thionyl Chloride Corrosive. Extremely

destructive to tissues of the

mucous membranes and

upper respiratory tract.

Symptoms may include

burning sensation, coughing,

wheezing, and laryngitis,

shortness of breath,

headache, nausea and

vomiting. Inhalation may be

fatal as a result of spasm

inflammation and edema of

the larynx and bronchi,

chemical pneumonitis and

pulmonary edema.

Use process enclosure, local

exhaust ventilation, or


to control airborne levels

below recommended

exposure limits. Facilities

storing or utilizing this

material should be

equipped with an eyewash

facility and a safety shower.

Use only under a chemical

fume hood.

Do not contact with water. Ventilate area of leak

or spill. Wear appropriate personal protective

equipment as specified in Section 8. Isolate hazard

area. Keep unnecessary and unprotected

personnel from entering. Contain and recover

liquid when possible. Neutralize with alkaline

material (soda ash, lime), then absorb with an

inert material (e. g., vermiculite, dry sand, earth),

and place in a chemical waste container. Do not

use combustible materials, such as saw dust. Do

not flush to sewer.

12 Toluene The substance is toxic to




central nervous







13 Sulfuric Acid Prolonged or repeated skin

contact may cause

dermatitis. Prolonged or

repeated inhalation may

cause nosebleeds, nasal

congestion, erosion of the

teeth, perforation of the

nasal septum, chest pain and

bronchitis

Facilities storing or utilizing

this material should be

equipped with an eyewash

facility and a safety shower.

Use adequate general or

local exhaust ventilation to

keep airborne

concentrations below the

permissible exposure limits.

Use a corrosion-resistant

ventilation system.

Clean up spills immediately, observing precautions

in the Protective Equipment section. Carefully

scoop up and place into appropriate disposal

container. Provide ventilation. Do not get water

inside containers. Cover with dry earth, dry sand,

or other noncombustible material followed with

plastic sheet to minimize spreading and contact

with water.

14 EDC/ (1,2-

Dichloroethane)


lungs, the nervous system,

liver, mucous membranes.




damage. Repeated or

prolonged contact with

spray mist may produce

chronic eye irritation and

severe skin

Irritation. Repeated or

prolonged exposure to spray

mist may produce

respiratory tract irritation

leading to frequent attacks

of bronchial infection.





vapors below their





station location.

Flammable liquid. 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-combustible material. Do not

get water inside container. Do not touch spilled

material. Use water spray curtain to divert vapor

drift. Prevent entry into sewers, basements or

confined areas; dyke if needed. Eliminate all

ignition sources. Call for assistance on disposal. Be


concentration level above TLV.

15 Nitric acid The substance may be toxic

to lungs, mucous

membranes, upper

respiratory p. 2 tract, skin,





Corrosive liquid. Oxidizing material. Poisonous

liquid. Stop leak if without risk. Absorb with DRY

earth, sand or other noncombustible material. Do

not get water inside container. Avoid contact with



eyes, and teeth. Repeated or

prolonged exposure to the

substance can produce

target organs damage.


contact with spray mist may

produce chronic eye

irritation and severe skin

irritation. Repeated or

prolonged exposure to spray

mist may produce

respiratory tract irritation

leading to frequent attacks

of bronchial infection.

vapors below their





station location.

a combustible material (wood, paper, oil,

clothing...). Keep substances damp using water

spray. Do not touch spilled material. Use water

spray curtain to divert vapor drift. Use water spray

to reduce vapors. Prevent entry into sewers,

basements or confined areas; dyke if needed. Call

for assistance on disposal. Neutralize the residue

with a dilute solution of sodium carbonate. Be


concentration level above TLV.

16 Xylene The substance is toxic to

blood, kidneys, the nervous

system, liver. Repeated or

prolonged exposure to the

substance can produce

target organs damage.





vapors below their





station location.

Toxic flammable liquid, insoluble or very slightly

soluble in water. Keep away from heat. Keep away

from sources of ignition. Stop leak if without risk.

Absorb with DRY earth, sand or other non-

combustible material. Do not get water inside

container. Do not touch spilled material. Prevent

entry into sewers, basements or confined areas;

dyke if needed. Eliminate all ignition sources. Call

for assistance on disposal. Be careful that the

product is not present at a concentration level

above TLV.

17 Phenol The substance may be toxic

to kidneys, liver, central

nervous system (CNS).




damage. Repeated p. 2

exposure of the eyes to a

low level of dust can

produce eye irritation.

Repeated skin exposure can

produce local skin

destruction, or dermatitis.

Repeated inhalation of dust

can produce varying degree

of respiratory irritation or

lung damage. Repeated

exposure to a highly toxic

material may produce

general deterioration of

health by an accumulation in

one or many human organs.

Use process enclosures,

local exhaust ventilation, or


to keep airborne levels

below recommended

exposure limits. If user

operations generate dust,

fume or mist, use

ventilation to keep

exposure to airborne

contaminants below the

exposure limit.

Corrosive solid. Stop leak if without risk. Do not

get water inside container. Do not touch spilled

material. Use water spray to reduce vapors.

Prevent entry into sewers, basements or confined

areas; dyke if needed. Eliminate all ignition

sources. Call for assistance on disposal. Be careful

that the product is not present at a concentration

level above TLV.

18 Chlorine Toxic by inhalation. Irritating

to eyes, respiratory system

and skin. Very toxic to

aquatic organisms.

Use only with adequate

ventilation. Use process

enclosures, local exhaust

ventilation or other

engineering controls to

keep worker exposure to

airborne contaminants

below any recommended or

statutory limits.

Immediately contact emergency personnel. Keep

unnecessary personnel away. Use suitable

protective equipment. Eliminate all ignition

sources if safe to do so. Do not touch or walk

through spilled material. Shut off gas supply if this

can be done safely. Isolate area until gas has

dispersed.



6.6.1.10 TRAINING AND EDUCATION OF EMPLOYEES AND PERSONAL PROTECTIVE

EQUIPMENTS

Safety awareness training programmes are arranged regularly through safety department

and safety-training programmes are also arranged for workers & staff working in the factory

premises. External faculties are also invited the lectures on the matter of safety in a

practical manner understandable to the workers & staff.

M/s. Paushak Ltd. gives training on the following subjects;

Accident Prevention Technique

Basic fire fighting

Use of Respiration PPE

Handling of Hazardous chemicals

Use of chlorine kit

First Aid program

Breathing Apparatus practical Programme

General safety regulation

Permit to work system

Electrical safety

HAZOP study

On site emergency plan training

MSDS Awareness

SHE SOP’s

Once in a month workmen for different plant are grouped together & practical classes are

held to train them how to operate various types of fire extinguisher to wear the mask, SCBA

apparatus, use of cylinder handling kits. Usefulness of each part of the chlorine kits is also

explained. Fire dill is also conducted regularly. Personal protective equipment such as safety

shoes, safety goggles, hand gloves, gum boots, safety helmet have been given to each

workers & staff. Provided seven nos. of SCBA set with standby extra cylinders in entire

premises, Airline mask provided in each plant. All type of PPE are kept in all related area, we

check them regularly. Fire hydrant points & eye wash showers have been installed at various

places and at various floors of the plant building. They have been instructed how to use.

Maintaining plant as per GFR guidelines.



6.6.1.11 MEDICAL SURVEILLANCE PROGRAM

Pre-employment Medical Check Up

1. Chest X-ray

2. Cardiogram

3. Audiometry

4. Hematological Examination:- CBC, SGOT, SGPT, Cholesterol, Blood Sugar etc

5. Urine Examination

6. Vision test

7. Colour blindness test

8. Lung function test- Spirometry

Periodical Medical Check up

1. Lung Function test

2. Cardiogram

3. Audiometry

4. Hematological Examination

5. Urine examination

6. Vision test

7. Colour blindness test

8. Biomarker in Blood & Urine

6.6.2 SAFETY PLAN

Safety of both men and materials during construction and operation phases is of concern.

Safety plan shall be prepared and implemented in the proposed project activity. The

preparedness of an industry for the occurrence of possible disasters is known as emergency

plan. The disaster in the plant is possible due to collapse of structures and fire/explosion etc.

The proposed expansion project would formulate safety policy keeping in view the

safety requirement during construction, operation, maintenance phases, with the

following regulations:

To allocate sufficient resources to maintain safe and healthy conditions of work;

To take steps to ensure that all known safety factors are taken into account in the

design, construction, operation and maintenance of plants, machinery and

equipment;

To ensure that adequate safety instructions are given to all employees;

To provide wherever necessary protective equipment, safety appliances and clothing

and to ensure their proper use;

To inform employees about materials, equipment or processes used in their work

which are known to be potentially hazardous to health or safety;



To keep all operations and methods of work under regular review for making

necessary changes from the point of view of safety in the light of experience and up

to date knowledge;

To provide appropriate facilities for first aid and prompt treatment of injuries and

illness at work;

To provide appropriate instruction, training, retraining and supervision to employees

in health and safety, first aid and to ensure that adequate publicity is given to these

matters;

To ensure proper implementation of fire prevention methods and an appropriate fire

fighting service together with training facilities for personnel involved in this service;

To organize collection, analysis and presentation of data on accident, sickness and

incident involving people injury or injury to health with a view to taking corrective,

remedial and preventive action;

To promote through the established machinery, joint consultation in health and

safety matters to ensure effective participation by all employees;

To publish/notify regulations, instructions and notices in the common language of

employees;

To prepare separate safety rules for each type of occupation/processes involved in a

plant; and

To ensure regular safety inspection by a competent person at suitable intervals of all

buildings, equipments, work places and operations.

6.6.3 SAFETY ORGANIZATION

Construction and Erection Phase

A qualified and experienced safety officer shall be appointed. The responsibilities of the

safety officer include identification of the hazardous conditions and unsafe acts of workers

and advice on corrective actions, conduct safety audit, organize training programs and

provide professional expert advice on various issues related to occupational safety and

health. He is also responsible to ensure compliance of Safety Rules/ Statutory Provisions.

Operation and Maintenance Phase

When the construction is completed the posting of safety officers shall be in accordance

with the requirement of Factories Act and their duties and responsibilities shall be as

defined there of.



6.6.4 SAFETY CIRCLE

In order to fully develop the capabilities of the employees in identification of hazardous

processes and improving safety and health, safety circles would be constituted in each area

of work. The circle would consist of about five to six employees from that area. The circle

normally shall meet for about an hour every week.

6.6.5 SAFETY TRAINING

Safety training shall be provided by the Safety Officers with the assistance of faculty

members called from Professional Safety Institutions and Universities. In addition to regular

employees, limited contractor labors shall also be provided safety training. To create safety

awareness safety films shall be shown to workers and leaflets shall be distributed.

Some precautions and remedial measures proposed to be adopted to prevent fires are:

Compartmentalization of cable galleries, use of proper sealing techniques of cable

passages and crevices in all directions would help in localizing and identifying the

area of occurrence of fire as well as ensure effective automatic and manual fire

fighting operations;

Spread of fire in horizontal direction would be checked by providing fire stops for

cable shafts;

Reliable and dependable type of fire detection system with proper zoning and

interlocks for alarms are effective protection methods for conveyor galleries;

Housekeeping of high standard helps in eliminating the causes of fire and regular fire

watching system strengthens fire prevention and fire fighting; and

Proper fire watching by all concerned would be ensured.

6.6.6 HEALTH AND SAFETY MONITORING PLAN

The health of all employees shall be periodically monitored for early detection of any

ailment due to exposure to heat and noise.



6.7 TRAINING, REHERASAL & RECORDS

6.7.1 NEED OF TRAINNING & REHEARASAL

Training is important in order to –

Teach worker’s how to handle chemicals safely, how to act as a runner/messenger, how

to use PPE, how to start and shut down the plant, how to carry out emergency repairs

etc.

Teach one to be a safe and alert worker.

Rehearsal is essential for -

Explaining and making key personnel and essential workers aware of their role in

case of an emergency.

Testing the emergency procedure, emergency arrangements and ability of all

involved with it to grasp the procedure and implement the same.

Testing the effectiveness of communication system including the alternative

arrangement in case of failure.

Testing the speed of mobilization of resources, search, rescue and treatment of

casualties, emergency isolation and shut down.

Detecting the shortcomings in the emergency plan and incorporating remedial

measures.

Allowing professional emergency services to test their parts of the plan and testing

co-ordination.

Building confidence in workers which is helpful in facing real situations.

Training shall be given to regular employees and contract personnel also. Effective and

latest teaching aids will be used to train workers and supervisory staff. Such training courses

shall be conducted once in a year and co-ordination with offsite personnel shall be sought

during such training. Records will be maintained for training.

6.7.2 SOME CHECK POINTS

Following points can be checked at the time of training/assessing the adequacy of the

Emergency Plan.

Does the plan cover the range of incidents that can realistically be anticipated?



Have the consequences of the various incidents considered been adequately assessed?

Are there sufficient resources in terms of personnel and equipment on the site to carry

out the Emergency Plan for the various incidents in conjunction with the public

emergency services?

Have the time scales been assesses correctly?

Is there a logical sequence of actions for each person given a role in the plan? Whether

key personnel, especially the nominated incident controllers, consulted in the

preparation of the plan?

Is there 24 hours cover, to take account of absences due to sickness and holidays,

minimum shift manning, operator only periods, silent hours, shutdown periods, only

security personnel being present, or for unmanned sites etc.?

Is there satisfactory co-operation with the local emergency services and district

emergency planning officers?

At sites where an off-site plan to protect people and the environment outside the site in

the event of an incident is appropriate what is the procedure for initiating the off-site

plan and is this satisfactory?

6.7.3 RECORDS AND UPDATING THE PLAN

All records of On-Site and Off-Site Emergency Plan and modifications by experience and

suggestion, the rehearsals and conclusions of such plans and the enquiries shall be well

maintained and preserved. The necessary data bank shall be also maintained for the utility

of industries and others. New information and the deficiencies identified during the

rehearsal is reviewed and incorporated in the document for continual up dating of the plan

and such information shall be communicated to the concerned authorities.

6.8 HAZOP STUDY

6.8.1 OBJECTIVE

For identifying cause and the consequences of perceived mal operations of equipment and

associated operator interfaces in the context of the complete system. It accommodates the

status of recognized design standards and codes of practice but rightly questions the

relevance of these in specific circumstances where hazards may remain undetected.



6.8.2 PURPOSE OF HAZOP

It emphasizes upon the operating integrity of a system, thereby leading methodically to

most potential and detectable deviations which could conceivably arise in the course of

normal operating routine

- including "start-up” and "shut-down" procedures

- as well as steady-state operations.

It is important to remember at all times that HAZOP is an identifying technique and not

intended as a means of solving problems nor is the method intended to be used solely as an

undisciplined means of searching for hazardous scenarios.

6.8.3 FEATURES OF HAZOP STUDY

Subsystems of interest line and valve, etc

Equipment, Vessels

Modes of operation Normal operation

Start -up mode

Shutdown mode

Maintenance /construction / inspection mode

Trigger events Human failure

Equipment /instrument/component failure

Supply failure

Emergency environment event

Other causes of abnormal operation, including

instrument disturbance

Effects within plant Changes in chemical conditions

Changes in inventory

Change in chemical physical conditions

Hazardous conditions Release of material

Changes in material hazard characteristics

Operating limit reached

Energy source exposed etc.

Corrective actions Change of process design

Change of operating limits

Change of system reliability

Improvement of material containment

Change control system

Add/remove materials

How would hazardous During normal operation

Conditions detected? Upon human failure

Upon component failure

In other circumstances

Contingency actions Improve isolation

Improve protection



6.8.4 HAZOP STUDY PROCEDURE

• Procedure in HAZOP study consists of examining the process and instrumentation (P&I)

line diagram, process line by process line.

• A list of guide words is used to generate deviations from normal operation

corresponding to all conceivable possibilities.

• Guide words covering every parameter relevant to the system under review i.e. flow

rate and quality, pressure, temperature, viscosity, components etc.

• Flowchart for application of HAZOP is shown in figure.



HAZOP STUDY FLOW CHART



GUIDE WORDS

NONE No forward flow when there should be

MORE More of any parameter than there should be, e.g. more

flow, more pressure, more temperature, etc.

LESS As above, but "less of" in each instance

PART System composition difference from what it should be

MORE THAN More "components" present than there should be for

example, extra phase, impurities

OTHER What needs to happen other than normal operation, e.g.

start up, shutdown, maintenance?

NONE e.g., NO FLOW caused by blockage; pump failure; valve

closed or jammed: leak: valve open; suction vessel empty;

delivery side over - pressurized: vapor lock; control failure

REVERSE e.g., REVERSE FLOW caused by pump failure: NRV failure or

wrongly inserted; wrong routing; delivery over pressured;

back- siphoning; pump reversed

MORE OF e.g., MORE FLOW caused by reduced delivery head ; surging

; suction pressurized ; controller failure ; valve stuck open

leak ; incorrect instrument reading.

MORE OF MORE TEMPERATURE, pressure caused by external fires;

blockage ; shot spots; loss of control ; foaming; gas release;

reaction; explosion; valve closed; loss of level in heater; sun.

LESS OF e.g., LESS FLOW caused by pump failure; leak; scale in

delivery; partial blockage ; sediments ; poor suction head;

process turndown.

LESS e.g., low temperature, pressure caused by Heat loss;

vaporization; ambient conditions; rain; imbalance of input

and output; sealing; blocked vent.

PART OF Change in composition high or low concentration of mixture;

additional reactions in reactor or other location; feed

change.

MORE THAN Impurities or extra phase Ingress of contaminants such as

air, water, lube oils; corrosion products; presence of other

process materials due to internal leakage ; failure of

isolation ; start-up features.

OTHER Activities other than normal operation start-up and

shutdown of plant ; testing and inspection ; sampling ;

maintenance; activating catalyst; removing blockage or scale

; corrosion; process emergency ; safety procedures activated

; failure of power, fuel, steam , air, water or inert gas;

emissions and lack of compatibility with other emission and

effluents.



6.8.5 PROCESS HAZARD AND ITS CONTROL

In charge Person

Sr.

No.

Name of the

Plant,

Department and

Operation.

Name of

hazardous

process and

operation.

Materials in the

process /

Operation with

their quantity.

Name of the

vessel and its

location.

Operating

parameters :

pressure,

temperature

etc.

Type of hazards

possible

(exothermic, run

away, pressure

release, fire,

explosion etc.)

Control measure provided Name &

Designation

Telephone

number

1 2 3 4 5 6 7 8 9 10

1 GTF Plant D14 reaction

SPD

RVD

EDA -2.4 mt

CS2- 7 mt

12 mt height

Storage tank 1

900 mmwc

Temp 40to

428c

sPD 290*c

Pressure

Fire in SPD

PLC control

As per temp limit

operation stop

new new

2

GTI plant Isomerization

Acetylation

ANF

SFD

DMPAT 7 mt

AC20 4.5 mt

Ethyl acetate -15

mt

12 mt height

18 mt

24 mt

Storage tank 2

50to 55*C

kg/cm2

100*c steam

temp

RUN away

Fire in SFD

PLC control

As per temp limit

operation stop

new new

3 Intermediate

plant

PCL3 rxn

PScl3 rxn

Monoester

Di ester

Pcl3 -50 mt

Sulpher-20 mt

Methanol-30 mtl

Liq amm -20 mt

6 mt height

12 mt height

18 mt

24 mt

Storage tank 4

115 *C

10 to 15*c

Highly

exothermic

& explosionn

PLC control

As per temp limit

operation stop

new new

4 GTH plant Hydrogenation

Nitration

Chemical &

thermal

denitratuioin

Hydrogenation

mass =34 mt

Nitration

mass=30 mt

Chemical de

nitration mass=5

mt

Acetone

Heptane

EDC

Auto calve

Nitration

Chemical

denitartion

Thermal de

nitration

Dissolution

purification

95 to 100*c Safety valve

Temp controller

At

Hydrogenation&

nitration stage

PLC control

As per temp limit

operation stop

Hydrogen sensor

new new

5 Chlorine &

hydrogen

handling

Cl2 tank farm

Hydrogen trolley

Cl2 tank farm 10

mt

Hydrogen trolley-

1200 m3

Ground level RT Scrubbing system Cl2 & Hydrogen sensor new new

5 Tank farm &

material handling

Tanker unloading

C2s =100 mt

EDA =200 mt

Mnso4 =500 mt

Znso4=100 mt

Clye=200 mt

Ground level RT Over flow

Static generation

Leakages from

piping /Valve

Smell from Vent

Earthing

Safety valve

Thickness

Dyke valve

Check list

Flame arrestor /breather

valve

Scrubber

sensor

new new

3 Process control &

equipment safety

system

Over pressure

High Temp

Instrument

failure

PLC failure

On equipment

& plant

RT Explosion

Fire

Human error

Safety valve /RD/BPRV

inspection

Instrument calibration

PLC healthy

New new



6.8.6 PLANNING FOR HAZOP

• Safety procedures documents

• Relief/venting philosophy

• Chemical involved

• Piping specifications

• Carry out the study

• Record the results

• Follow-up of actions noted

1. Final report contains resolution of all recommended actions.

2. Must appoint someone as leader to check progress of action.

3. Team may meet again if answers to questions do not simply lead to an action.

4. Team may meet again if significant design changes in interim report.

m/s. greentec chemicals pvt. ltd

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