m/s. sabari chemicals pvt. ltd. - …environmentclearance.nic.in/writereaddata/formb/ec/... ·...

1

M/s. Sabari Chemicals Pvt. Ltd.

Vaibhu Safety Consultants Risk Assessment Study August ‐2015

M/S. Sabari Chemicals Pvt. Ltd.

Plot no. A2/236 in GIDC, Nandesari ‐ 391340, Dist. Vadodara

RISK ASSESSMENT STUDY For Existing and Proposed Fine chemicals Manufacturing Unit

Augast‐2015

PREPARED BY

VAIBHU SAFETY CONSULTANTS FF 10-11, Akshat Complex, Nr. Reliance petrol pump,

High Tension road, Subhanpura, Vadodara-390023

Phone: 9825756467 / 898004562(M)/ 0265-2395798(O) Email: [email protected]

[email protected] Web site: www.vaibhusafety.com

2

M/s.M/s.M/s.M/s. Sabari Chemicals Pvt. Ltd.

Vaibhu Safety Consultants Risk Assessment Study August -2015

CONTENTSCONTENTSCONTENTSCONTENTS

SECTION NO.SECTION NO.SECTION NO.SECTION NO.

PARTICULARPARTICULARPARTICULARPARTICULAR

PAGE PAGE PAGE PAGE

NO.NO.NO.NO.

SUB SECTIONSUB SECTIONSUB SECTIONSUB SECTION

1 Executive Summary

4

2 Objectives, Philosophy and methodology of Risk assessment

5

3 Introduction of the unit

7

3.1 Company Introduction

7

3.2 Details of Unit

7

3.3 Project setting

8

3.4 Organizational setup

11

3.5 List Of product

12

3.6 List of Raw material

13

3.7 Hazardous material storage and handling safety

14

3.8 Transportation, Loading and handling procedure for hazardous

chemicals

17

3.9 Hazardous Properties Of The Chemicals, Compatibilities And

Special Hazard

22

3.10 Occupational Health Impact on Employees, Control measures,

action plan If accident occur and its antidotes.

27

3.12 Brief Description of process plant 33

4 Hazard identification 34

4.0 Introduction 34

4.1 DOW’s Fire and Explosion Index 34

4.2 Identification of Hazardous area 35

4.3 Failure Frequency 35

5 Risk Assessment 37

5.1 Effects of Release of Hazardous Substances 37

5.2 Tank on Fire / Pool Fire 37

5.3 Fire Ball 38

5.4 UVCE 38

5.5 Dispersion cases 38

5.6 Identification of High Risk Areas 38

5.7 Modes of Failure 38

5.8 Damage Criteria for heat radiation 39

6 Consequence Analysis 41

6.1 Consequence Analysis 41

Scenario-1 Unconfined pool fire for Drum Storage Area 42

Scenario-2 BLEVE Simulation for Drums storage Area 44

3

M/s.M/s.M/s.M/s. Sabari Chemicals Pvt. Ltd.

Vaibhu Safety Consultants Risk Assessment Study August -2015

Scenario-3 Spill pool evaporation for thionyl chloride drum catastrophic

failure

46

6.2 Detail regarding consequences analysis table 51

6.3 Conclusions 51

7 Risk Reduction Measures 53

8 Onsite – Offsite Emergency plan 54

4



SECTION I

EXECUTIVE SUMMARY

Executive Summary

1.1 M/s. Sabari Chemicals Pvt. Ltd. is an existing Chemical Unit located on plot no. A2/236 in

GIDC, Nandesari, a designated Chemical Zone, Dist. Vadodara. The unit started

manufacturing of fine chemicals.

1.2 Experts from Vaibhu Safety Consultants visited the site on 05.08.2015 and subsequently

inspection of site as per site plan and the environs along with collection of relevant

information about the proposed installation and the operations of the plant. Also a

detailed discussion was held on various aspects including storage facilities, process safety

and emergency preparedness with the officers of the company.

1.3 Petroleum product like Toluene, Hexane, Trimethylamine etc., are received in drums

through road truck and stored in Raw material store Drum storage area as per petroleum

storage requirements. Other chemicals like sulfuric avid HCL are to be stored in above

ground tank in tank farm area. All safety measures are provided at design level and

foolproof safety features are provided.

1.4 Sodium cyanide received in drums in pallets Solid form and stored in dedicated cyanide

storage area in lock and key as per poison act requirements.Storage and handling safety

measures are provided in the subsequent chapters.

1.5 Some flammable/combustible/ Toxic liquid/solid chemicals will be received in drums or

bags or in carboys and are stored in warehous as per its incompatibility and other

properties like flammable, toxic, corrosive and reactive.

1.6 Based on the data furnished and the study of the installation, certain hazards have been

identified and their consequences are modeled mathematically using HAMSGAP software.

Mapping of various scenario are with hazardous distances and safe distances are drawn

on site plan for easy understanding of the consequences of the accident/ incident.

1.7 The study indicates that possible hazards associated with the plant are confined to a

Drum storage area b Thionyl Chloride drum storage. c Sodium cyanide storage and

handling area. Various hazardous scenarios have been identified for Risk Assessment and

the consequences modeled.

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

1.9 Conclusion Based on the

1 Risk Analysis study and information regarding the layout plan and safety systems.

2 Discussions with company officials,

5



SECTION II

OBJECTIVE, PHILOSOPHY AND METHODOLOGY OF RISK ASSESSMENT 2.1 Objective :

The main objectives of the Risk Assessment RA study is to determine damage due to major hazards having damage potential to life & property and provide a scientific basis to assess safety level of the facility. The principle objective of this study was to identify major risks in the manufacture of specialty fine chemicals and storage of hazardous chemical at site and to evaluate on‐site & off‐site consequences of identified hazard scenarios. Pointers are then given for effective mitigation of hazards in terms of suggestions for effective disaster management, suggesting minimum preventive and protective measures & change of practices to ensure safety.

2.2 PHILOSOPHY :

This report is limited to the following: Identification of major risk areas. Hazard identification/Identification of failure cases Consequential analysis of probable risks / failure cases

o Evaluation of heat radiation & pressure wave profiles for identified failure cases

o Risk assessment on the basic of the above evaluation & risk acceptability o Minimum preventive & protective measures to be taken to minimize risks to

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

2.3 Methodology

The procedure used for carrying out the Quantitative Risk Assessment Study is outlined below:‐ Identify Credible Loss Scenarios for the facility under the study by discussion with M/s. Sabari Chemicals Pvt. Ltd., Simulate loss Scenarios to determine the vulnerable zones for toxic dispersion, pool fire, Tank on fire Thermal Radiation , Flash fire, Explosion over pressure Vapour cloud Explosion, Ball fire using software packages HAMSGAP. Suggest mitigating measures to reduce the damage, considering all aspects of the facilities. The flowchart of the methodology for the present study is shown in following page.

SV

Typewriter

6



RISK ASSESSMENT STUDY METHODOLOGY FLOWCHART

START

FACILITY, PROCESS AND METEOROLOGICAL DATA COLLECTION

LISTING OUT OF HAZARDOUS OPERATIONS & STORAGE DETAILS

DEFINING OF PARAMETERS FOR EACH OF CHEMICALS & EACH OF HAZARDS

IDENTIFICATION OF FAILURE SCENARIOS & QUANTIFICATION OF PROBABLE HAZARDS ASSOCIATED WITH THEM

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

SIMULATION OF SELECTED CASES FOR CONSEQUENCE MODELING

PREPARATION OF SUMMERY OF CONSEQUENCE RESULTS

EVALUATION OF POTENTIAL RISK TO THE SURROUNDING POPULATION

DISCUSSION & RECOMMENDATION OF MITIGATIVE / REMEDIAL MEASURES

END

7



SECTION III

INTRODUCTION OF THE UNIT

3.1 COMPANY INTRODUCTION

M/s. Sabari Chemicals Pvt. Ltd. is an existing Chemical Unit located on plot No. A2/236 in GIDC, Nandesari, a designated Chemical Zone, Dist. Vadodara. The total area of the plot is 3000 sq mts. for its production activities.

3.2 DETAILS OF UNITS TABLE: 3.1

Sr. No.

Particulars

1. Full Name & Address of Unit Sabari Chemicals Pvt. Ltd. Plot no. A2/236 in GIDC, Nandesari ‐ 391340, Dist. Vadodara, Gujarat

2. Telephone No. Fax Number: Email ID :

265‐2840429, 2840885 265‐[email protected]@yahoo.com

3. Month & Year of Establishment 19834. Full name & Address and phone

number of the occupierMr. Mohan NairMr. Vinodbhai Nair

5. Full name & Address and phone number of the Factory manager

Mr. Jayantibhai Patel

6. License & Approval:‐Factory Inspectorate No. 079585

Valid up to :‐ 31.12.2016 GPCB/PCB consent AWH:‐ 47992

Valid upto: 17/02/2017 Solid waste Disposal NECL Member ship Explosive licence No : N.A.

Poison Licence 233/887 T/M Sodium cyanide

7. Man Power Proposed : 54 company employee 12 Contractor labour 5 security

8. No. Of shift & Shift timingGeneral First Second Third

9.00 a.m. to 05.00 p.m. 7.00 a.m. to 15.00 p.m. 15.00 p.m. to 23.00 p.m. 23.00 p.m. to 7.00 a.m.

9. Power connection 125 KVA10. TFH 4 lacs Kcal Gas fired

2 lacs wood fired11. Boiler Non IBR small industrial boiler 600 kgs 4

kgs/cm2 12. Chilled Water Plant 40 TR Freon gas

8



13. Cooling Tower 2 nos. 200 TR X 2 Nos. No standby pump

14. Effluent Treatment Plant Yes, 42000 Lit/ Day 15. OHC facilities / First Aid facilities First Aid facilities available 16. List of emergency facilities 1. SCBA sets‐ 02 nos. To be procure

2. First Aid Box –1 no. 3. Stretcher – 01 no.

17. Environs Nearest Facilities 22°24'49.68"N,73° 5'52.10"E

1. Railway Station Nandesari~1 km 2. Police Station Chhani Police Station~3 km 3. Fire Station GIDC Fire Station~1 km 4. Air Port Vadodara~20 Km 5. Hospitals Nearby Deepak Medical Foundation,

Nandesari~1km 6. Hospital all emergency facilities

available at hospitalESIC , Gorva, Vadodara~8 km

18. Total Land at PlantLand Breakup Details Area ( sq mts)

Administrative Building 225

Production Plant 742

Utilities 150

Raw Material and Finished Good Storage 147

ETP 122

Road and Parking 450

Greenbelt 350

Area for expansion 814

Total 3000

19. DG Set 125 KVA20. Water Storage and source GIDC water supply 21. Fire Hydrant details With drawing Hydrant system will be installed 22. Fire water source GIDC water supply 23. Fire Water Reservoir capacity : M3 20 K X 2 Nos. tank O/H

10 KL O/H24. Department wise List of fire

extinguishers with mapping if available

18 Nos. of fire extinguishers

3.3 PROJECT SETTING:

The unit is located in GIDC, Nandesari about 17 kms North of Vadodara. GIDC, Nandesari is equipped with a common Effluent Treatment Plant running on the latest technology of Hydrodynamic cavitations and Electro‐Oxidation. The facility for disposal of Hazardous waste by landfill and Plasma gasification is also available at GIDC, Nandesari. Latitude : 22°24'49.68"N, Longitude: 73° 5'52.10"E Proposal site is shown as Figure 1.1. & Plot plan is shown in figure 1.2.

9



Figure No. 1.1: GIDC, Nandesari Layout Plan

10



Figure 1.2 Plant location on Nadesari GIDC Map

11



Figure 1.3 Plant layout

3.4 SAFETY ORGANIZATIONAL SET UP

Advise Company of safety legislation & updates, safety awareness, carry out safety audits, update safety policy, provide training when required, to provide investigations and reports for any accidents.

Directors

Factory manager ( GM) (Safety Manager)

Safety Committee member

12



3.5 LIST OF PRODUCTS:‐ TABLE: 3.2

Sr. No. Name of ProductExisting Quantity MT/Month

Total Quantity after expansion MT/Month

1 Benzyl Acetate 20 50

2 Benzyl Benzoate 20 50

3 Benzyl Alcohol 20 50

4 Benzyl Cyanide 20 50

5 Phenyl Acetic Acid 20 50

6 Benzyl Salicylate 20 50

7 Naphthalene Acetic Acid Tech and Sodium Salt 5 30

8 Sodium Acetate 6 0

9 Sodium Benzoate 6 0

10 Para Methoxy Phenyl Aceto nitrile 0 50

11 Para Methoxy Phenyl Acetic Acid 0 10

12 Naphthalene Acetamide 0 10

13 Dibenzyl Ether High boiler of Benzyl Alcohol

0 30

14 High boiler of Benzyl Benzoate 0 10

15 High boiler of Benzyl Acetate 0 15

16 Trading Repacking

0 150 Benzyl Acetone

1 Acetyl Naphthalene

Benzyl Acetate

13



3.6 LIST OF RAW MATERIALS TABLE: 3.3

SR.NO. Raw Materials Existing Qty

MT/MonthProposed Qty MT/Month

Stored In MOC

1. Benzyl Chloride 83.08 207.70 Tank / Drum HDPE

2. Benzyl Cyanide 21.30 53.25 Drum HDPE

3. Beta Napthol 0.00 10.00 Bags HDPE

4. Catalyst 0.56 1.40 Drum Fiber

5. Caustic Lye 15.25 88.33 Tank / Drum MS

6. HCl 24.00 60.00 Tank / Drum HDPE

7. Liq. Ammonia 0.00 19.00 Carbuoy HDPE

8. MCA 0.00 13.54 Bags HDPE

9. Napthalene Acetic Acid

6.00 36.00 Drum Fiber

10. N‐Hexane 0.00 14.00 Drum HDPE

11. Para Anisyl Alcohol

0.00 54.55 Drum HDPE

12. Paraformaldehyde 1.65 9.90 Bags HDPE

13. Refined Naphthalene

6.65 39.90 Bags HDPE

14. Soda Ash 13.73 35.78 Bags HDPE

15. Sodium Acetate 1.27 3.18 Bags HDPE

16. Sodium Benzoate 15.50 38.75 Bags HDPE

17. Sodium Cyanide 12.11 39.62 Drum MS

18. Sulfuric Acid 1.75 10.50 Tank MS

19. Thionyl Chloride 0.00 10.50 Drum HDPE

20. Toulene 0.00 85.54 Drum HDPE

21. Trimethyl Amine 0.13 0.75 Drum HDPE

22. Zinc Chloride 0.25 1.47 Bags HDPE

14



3.7 DETAILS OF STORAGE OF HAZARDOUS MATERIALS IN BULK & CONTROL MEASURES

TABLE: 3.4

SR. NO.

NAME OF HAZAR‐DOUS

SUBSTANCE

MAX. STORAGE CAP. Qty.

MT

PLACEOF IT’S STORAGE

OPERATING PRESSURE AND TEMP.

TYPE OF HAZARD

PRECAUTION TO BE TAKEN DURING

STORAGE

1. Toulene 200 kg. X 50 Nos.HDPE drums 10 MT

Drum storage area

ATPAmbient

Fire Provided in Point No: 3.7.1

2. N‐Hexane 200 kg. X 20 Nos.HDPE

drums 4 MT

Drum storage area

ATPAmbient


3. Trimethyl Amine

200 kg. X 2Nos HDPE drums 0.3 MT

Drum storage area

ATPAmbient


4. Benzyl Chloride

200 kg. X 125 Nos HDPE drums 25 MT

Drum storage area

ATPAmbient

Toxic / Fire

Provided in Point No: 3.7.1

5. Benzyl Cyanide

200 kg. X 25 Nos HDPE

drums 5 MT

Drum storage area

ATPAmbient

Toxic / Fire


6. Napthlene Acetic Acid

200 kg. X 20 Nos Fiber

drums 4 MT

Drum storage area

ATPAmbient


7. Para Anisyl Alcohol

200 kg. X 50 Nos HDPE drums 10 MT

Drum storage area

ATPAmbient


8. Beta Napthol 25 kg X 40 1 MT

R.M. Store ATPAmbient

Toxic / Fire


9. Caustic Lye 50 kg X 40 Nos. bags 20

MT


Corrosive Provided in Point No: 3.7.2

10. Liq. Ammonia

35 Ltr. Carboys 1MT


Corrosive/Toxic


15



11. MCA 25 kg X 80 bags 2MT


Toxic Provided in Point No: 3.7.2

12. Paraformaldehyde

25 kg X 12 bags 3MT



13. Refined Naphthalene

25 kg X 400bags 10 MT



14. Soda Ash 50 kg X 200bags 10 MT



15. Sodium Acetate

25 kg X 120 bags

3MT



16. Sodium Benzoate

25 kg X 400bags 10 MT



17. Zinc Chloride

25 kg X 12 bags 0.3 MT



18. Sulfuric Acid 5 MT MS tank

Tank area ATPAmbient


19. HCl 18 MT in tank

Tank area AmbientATP

Corrosive

20. Thionyl Chloride

200 kg X 15 Nos. MS

drums 3MT

Drum storage area

ATPAmbient

Corrosive/ Toxic


21. Sodium Cyanide

25 kg X 320 drums 10 MT

Separate Cyanide storage room

with lock & Key

ATPAmbient

Toxic /Poison


22. Catalyst 0.6 fiber drum

Designated area

with lock & Key

ATPAmbient

Pyrophoric substance


16



TOR: 30 PRECAUTION TO BE TAKEN DURING STORAGE 3.7.1 For Drum Storage area :

1. FLP type l ight f itt ings provided. 2. Proper ventilation is available in Drum storage area. 3. Proper label and identif ication board /stickers is provided in the

storage area. 4. Conductive drum pallets are provided. 5. Drum handling trolley / stackers/fork l i ft are used for drum handling. 6. Separate dispensing room with local exhaust and static earthing

provision is available. 7. Materials are stored as per its compatibil ity study and separate area

is available for f lammable, corrosive and toxic chemical drums storage.

8. Smoking and other spark, f lame generating item are banned from the Gate.

9. NFPA labels are provided on drums for hazard identif ication of the chemicals .

10. Exhaust is provided at ground level in drum storage area. 11. Drum loading unloading procedures are prepared and implemented.

3.7.2 For WareHouse Safety Measures:

1. FLP type l ight f itt ings are provided. 2. Proper ventilation is available in godown. 3. Proper label and identif ication board /stickers are provided in the

storage area. 4. Pallets are provided for material bag storage. 5. Material handling trolley / stackers/fork l i ft are used. 6. Materials are stored as per its compatibil ity study and separate area

is available for f lammable, corrosive and toxic chemical storage. 7. Smoking and other spark, f lame generating item are banned from the

Gate. 3.7.3 Safety Measures for Sulfuric acid and HCL

1. Storage tank are stored away from the process plant. 2 . Tanker unloading procedure is prepared and implemented. 3. Caution note and emergency handling procedure is displayed at

unloading area and trained all operators . 4 . NFPA label is provided on tank. 5. Required PPEs l ike ful l body protection PVC apron, Hand gloves,

gumboot, Respiratory mask etc . are provided to operator. 6. Neutralizing agent is kept ready for tackle any emergency spil lage. 7 . Safety shower, eye wash with quenching unit is instal led in acid

storage area. 8. Material is being handled in c lose condition in pipe l ine. 9. Dyke wall is provided to al l storage tanks, collection pit with valve

provision. 10. Double drain valves are provided. 11. Level gauge is provided on all storage tanks.

17



3.7.4 Safety Measures for Sodium Cyanide

1 . Separate stored in locked room. 2. Away from water sources . 3. Total body protection suite is provided to charging operator with air

l ine respirator. 4. Safe operating Charging procedure is prepared and displayed in

process and storage area. 5. Total c lose process for charging and handling. 6. Antidote kit for cyanide is kept ready in OHC. 7. Training is being provided to handle NACN, 8. SCBA sets are available in handling area. 9. Operator having cuts and sores should not use cyanides. 10. If a l i tt le poisoning, inhale cyanide antidote kit amyl nitrite, sodium

nitrite and sodium thiosulfate and oxygen for 15‐30 seconds as f irst aid measures

11. Use sodium hypochlorite, calcium hypochlorite solution or potassium permanganate for washing balance, glass apparatus, spatula, workplace and in case of spil lage

12. Use Apron, eye protecting glass, Mask and gloves during transferring, work‐up and decomposition of chemicals .

13. Issued quantity wil l be used fully for reactions. Can not be stored in the process area

14. Separate Log Book for issuing above cyanides and Manager has to sign on the register

TOR‐ 30 PRECAUTION TO BE TAKEN DURING TRANSPORTATION OF HAZARDOUS CHEMICALS 3.8 Transportation , Unloading and handling procedure 3.8.1 Sodium Cyanide Transportation, Unloading and handling Procedure :

SR.NO. ACTIVITY TYPE OF POSSIBLE HAZARD

PROCEDURES.

1 Transportation of Sodium Cyanide by road truck

Leakage, Spillage, Toxic release in case of direct contact or ingestion

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

2 NACN storage and handling safety

Leakage, Spillage, Toxic release in case of direct contact or ingestion

Separate stored in locked room. Away from water sources. Total body protection suite will be provided to charging operator with air line respirator.

Safe operating Charging procedure will be prepared and displayed in process and storage area.

Total close process for charging and handling.

Antodote kit for cyanide will be ketp ready in OHC.

Training is being provided to handle NACN,

SCBA sets are available in handling area.

18



3.8.2 Transportation , Unloading and handling procedure for Acids:

SR.NO.

ACTIVITY TYPE OF POSSIBLE HAZARD

CONTROL MEASURES AND HANDLING PROCEDURES.

1 Transportation of Acids by road tanker

Leakage, Spillage, Toxic release

Training will be provided to driver and cleaner regarding the safe driving, hazard of Flammable chemicals, emergency handling, use of SCBA sets administration.

TREM card will kept with TL. SCBA set will be kept with TL. 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. Emergency telephone numbers list of OFF site emergency agencies will be provided in TREM CARD

2 Acids Road tanker unloading at site.

Leakage, Spillage, toxic release

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, SCBA set 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.

Following precautions will be adopted during unloading 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 rubber 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 in TL.3 Acids Storage tank

safety Leakage, Spillage, Toxic release.

Storage tank will be stored away from the process plant.

Tanker unloading procedure will be prepared and implemented.

Caution note and emergency handling

19



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.

4 Acids transferred from storage tank to Day tank

Leakage, Spillage due to Line rupture, Flange Gasket failure, Toxic release.

Double mechanical seal 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. Flange Guard will be provided to all flanges.

5 Acids 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.

Total quantity of day tank material will be charged in to reactor at a time.

NRV will be provided on day tank outlet line.Flange guard will be provided to pipeline flanges.

20



3.8.3 Drums Transportation , Unloading and handling procedure SR.NO. ACTIVITY TYPE OF

POSSIBLE HAZARD

PROCEDURES.

1 Transportation of drums Leakage, Spillage, fire, explosion, Toxic release

Training will be provided to driver and cleaner regarding the safe driving, hazard of Flammable chemicals, emergency handling, use of SCBA sets.

TREM card will kept with TL. SCBA set will be kept with TL. Fire extinguishers will be kept with TL. Flame arrestor will be provided to TL exhaust.

Instructions will be given not to stop road tanker in populated area.

Clear Hazard Identification symbol and emergency telephone number will be displayed as per HAZCHEM CODE.

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

Spillage, fire, explosion, toxic release

Priority will be given to truck 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 Licence, TREM CARD, Fire extinguisher condition, SCBA set 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.

Only day time unloading will be permitted.

3 Godown/warehouse safety

Leakage, Spillage, Fire, Explosion, Toxic release.

FLP type light fittings will be provided. Proper ventilation will be provided in godown.

Proper label and identification board /stickers will be 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

21



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.

4 Solvents transfer from drum to Day tank/ reactor

Leakage, Spillage due to Line rupture, Flange Gasket failure, Fire, Explosion, Toxic release.

Solvent transfer by vacuum or by pump only.

Static earthing will be provided. SS flexible hose / conductive hose will be used.

5 Solvent transfer from Day tank 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.

SV

Typewriter

22



TOR : 34 MATERIAL SAFETY DATA SHEETS : 3.9 HAZARDOUS PROPERTIES OF THE CHEMICALS, COMPATIBILITIES AND SPECIAL HAZARD

Table‐3.5

Sr. No.

NAME OF CHEMICAL HAZARD

FLASH POINT

0C

BP 0C

LEL % UEL % SP.GR.200 C

VD SOLUBILITY WITH

WATER at 200 C

NFPAH F R

HAZARDOUS COMBUSTION PRODUCT

TLVPPM

IDLHPPM

LC50mg/m3

TARGETORGANS

CARCINOGENIC CHARACTERIS

TIC

ANTIDOT

1. Benzyl Acetate CAS#140‐11‐4

T/F

93.33 206 NA NA‐ 1.04 5.1 Insoluble 2 2 0 CO, CO2. 10ppm

‐ 245.8 hours cat .

Brain. CNS, Eyes, skin, Respiratory system

No No specific antidote

2. Benzyl Benzoate CAS#: 120‐51‐4

H 147.8 323.5 NA NA 1.118 7.31 Insoluble 1 1 0 CO, CO2. NL NL NA Eyes, skin, Respiratory system

NA No specific antidote

3. Benzyl Alcohol CAS#: 100‐51‐6

H 93 205.3 NA NA 1.04 3.72 Soluble 1 1 0 CO, CO2 5.5 ppm

NL NA liver, centralNervous

system CNS .

No No Specific Antidote

4. Benzyl cyanide CAS#: 140‐29‐4

C 101 233 1.1 14 1.02 N.A. Insoluble 3 1 0 N.A. 30.0 mg/m3

NL 430 mg/m3/2h HL‐RAT

NA No No Specific Antidote

5. Phenyl Acetic Acid PAA CAS#: 103‐82‐2

C/F 100 265.5 NA N.A. 1.081 N.A. Soluble 1 1 0 toxic to lungs, mucous membranes

10 ppm,

50 ppm N.A. NA No No Specific Antidote

6. Benzyl Salicylate CAS# 118‐58‐1

137 300 NA NA 1.170 7.9 SlightlySoluble

0 1 0 release of irritating gases and vapors, CO, CO2

NL NL NA NA NA No Specific Antidote

7. Sodium Acetate CAS#127‐09‐3

T NF NF NA NA NA NA Soluble 1 1 0 Not combustible NL NL NA Eyes, skin No No specific antidote

8. Sodium Benzoate CAS # 532‐32‐1

T NA NA NA NA 1.44 4.97 Soluble 2 1 0 irritating fumes,CO, CO2

NL NL NA blood, the reproductive system, liver, central nervous

system

ClassifiedPOSSIBLE teretogen;

No Specific Antidote

9. Para Methoxy Phenyl Aceto nitrile CAS# 104‐47‐2

T 117 286‐287 1.2 9.4 1.081 NA SlightlySoluble

3 0 0 CO, CO2, NOx,Hydrogen cyanidehydrocyanic acid

5Mg/m3

25Mg/m3

NA NA No No Specific Antidote

SV

Typewriter

23



10. Para Methoxy Phenyl Acetic Acid CAS# 104‐01‐8

H NA 140 NA NA NA NA Partiallysoluble

2 0 0 irritating gases and vapors, CO, CO2.

NL NL NA NA No No Specific Antidote

11. Naphthalene Acetamide CAS# 86‐86‐2

C NA NA NA NA NA NA NA NA COx, NOx. NL NL NA NA No No Specific Antidote

12. Dibenzyl Ether CAS# 103‐50‐4 High boiler of Benzyl Alcohol

H 135 298 NA NA 1.040 6.8 Insoluble 2 1 0 CO, CO2 NL NL NA NA No No Specific Antidote

13. Benzyl Acetone F 98 235 NA NA 9890 g/cm3

5.11 NA 1 1 0 CO, CO2, irritating and toxic fumes and gases

NL NL NA NA No No Specific Antidote

14. 1 Acetyl Naphthalene CAS# 941‐98‐0

H 110 302 NA NA 1.119 NA 2 0 0 CO, CO2 NL NL NA NA No No Specific Antidote

15. Benzyl chloride CAS#100‐44‐7

T 67 179 1.1 14 1.1 4.4 Reactive with water

3 2 1 Toxic vapour HCL 1ppm

10 ppm 1870 mg/m3 2 hours Rat .

Eyes, skin, respirator system

YES No Specific Antidote

16. Beta Napthol CAS # 135‐19‐3

H 153 285 NA NA 1.22 4.98 Very slightly soluble

2 1 0 CO, CO2 NL NL NA lungs, mucous membranes

No No Specific Antidote

17. Caustic Lye CAS # 1310‐73‐2

C NA NA NA NA 2.13 NA Soluble 3 0 1 Non combustible 2 mg/m3

200 mg/m3

2300 mg/m3 for 2H Rat

Eyes, skin, respiratory system

No Sodium Hydro‐Carbonate 4% Conc. , Milk, Lime Juice, Milk of Magnesia

18. Hydrochloric Acid HCL

C/T NF 108 NF NF 1.12 -1.19

1.267 Soluble 3 0 1 N A 5 ppm 50 ppm

3124 ppm for 1h rat

No Sodium Hydro-Carbonate (4%

Conc.),

Hydrochloric Acid HCL

19. Ammonia liquor CAS #1336-21-6

Toxic - 36 16 25 0.9 1.2 Miscible

3 1 0

Not combustible 25

300 2000 ppm/4-hr

No Wash with Lactic Acid,

Apply soframycin Smelling

Ethanol or Ether

Ammonia liquor CAS #1336-21-6

20. Mono Chloro acetic acid CAS#: 79‐11‐8

C/T 150 189 8 1.58 NA Soluble 3 1 0 CO,CO2,halogenated compounds.

NA NA 254.6 ppm 4 hour s Rat .

NA NA No Specific Antidote

21. Napthalene Acetic Acid CAS# 86‐87‐3

C NA NA NA NA NA NA NA 2 0 0 COx NL NL NA NA NA No Specific Antidote

24



22. Hexane CAS #110‐54‐3

F ‐7 68.7 1.2 7.7 0.659 3.0 Insoluble 1 3 0 CO & CO2 500 1100 48000 ppm Rat 4 h

Eyes, skin, respiratory system, central nervous system,

peripheral nervous system

No No specific Antidot

23. Para Anisyl Alcohol CAS# 105‐13‐5

H 113 259 NA NA 1.108 NA NA 1 1 0 COx NL NL NA Irritating to eyes, respiratory system and skin.

NA No specific Antidot

24. Paraformaldehyde CAS#:30525‐89‐4

F/T 70 NA 7 73 1.46 1.03 Partially soluble

3 2 0 CO & CO2 NL NL Dust‐1070mg/m 4 hours Rat .

Eyes, skin, respiratory system

NA No specific Antidot

25. Naphthalene CAS # 91‐20‐3

T 190 218 0.9 5.9 1.145 NA Moltennaphthalene spatters and foams in

contact with water.

2 2 0 TOXIC VAPOUR 10 250 1780mg/kg

No. No specific Antidote

26. Soda ash Sodium Carbonate 497‐19‐8

C/H NA NA NA NA NA NA MISCIBLE 2 0 1 Emits Na2O fumes when heated to decompositon

NA NA Acute: 2300 mg/m 2 hours Rat . 1200 mg/m 2 hours Mouse .

NA NA No specific antidote

27. Sodium Acetate CAS#127‐09‐3

T NA NA NA NA NA NA MISCIBLE 1 0 0 Not combustible NA NA NA Skin, eye and respiratory Effect,

Harmful by skin

absorption, Skin

sensitizer

NO No specific Antidote

25



28. Sodium Benzoate CAS# 532‐32‐1

H NA NA NA NA NA 4.97 Easily soluble 2 1 0 CO, CO2 NA NA NA blood, the reproductive system, liver, central nervous

system

NA;

Classified as TERATOGEN

IC & DEVELOPME

NTAL TOXICANT for both, male & female.

No specific Antidote

29. Sodium cyanide CAS #143‐33‐9

NA Very high

NA NA 1.60 NA Soluble 3 0 0 Irritating vapor 5 mg/m3

25 mg/m3

NA Eyes, skin, respiratory system

No Methelene Blue or

Kelocynere injection

30. Sulfuric Acid CAS # 7664‐93‐9

C NA 340 NA NA 1.84 NA Water reactive

3 0 2 Non combustible 1 mg/m3

15 mg/m3

510 Rat Eyes, skin, respiratory system, teeth

No Sodium Hydro‐

Carbonate 4% Conc. , Milk, Lime Juice, Milk of Megnesia

31. Thionyl Chloride CAS # 771909‐7

T NA 76 1.64 4.6 NA NA Water reactive

4 0 2 sulfur dioxide, sulfur chloride

1 ppm Not determined

500 ppm for 1 Hr Rat

NA No natural oil and one table

spoon sodium or magnesium sulphate with one glass of water.

32. Toluene CAS # 108‐88‐3

F 4.0 111 1.1 7.1 0.87 3.2 Insoluble 2 3 0 Irritating Vapour generated

50 2000 400 ppm for 24Hr Rat

Eyes, skin, respiratory system, central nervous

system, liver, kidneys

No Diazem – 1 mg/Kg. Intrave

nous , Epinephina, Efidrine

33. Trimethylamine TMA CAS#: 75‐50‐3

T/F ‐6.15 2.9 2.0 11.6 0.633 2.0 Insoluble 3 4 0 NP 5 NL 2000 1 hrRat

Respiratory system, eyes, skin, mucous membranes

No Not available

34. Zinc Chloride CAS No.:7646‐85‐7

T NA 732 NA NA 2.907 4.7 423G/100G 3 0 0 Non Flame able 1 mg/m3

NA 2000rat

Liver , kidney NO No specific Antidote

26



F FIRE T TOXIC C CORROSIVE E EXPLOSIVE R REACTIVE STEL SHORT TERM EXPOSURE LIMIT BP BOILING POINT LEL LOWER EXPLOSIVE LIMIT PPM PARTS PER MILLION 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 NFPA NATIONAL FIRE PROTECTION ASSOCIATION‐usa N.A NOT AVAILABLE N.L NOT LISTED

27



TOR: 37 3.10 Details of occupational health program.

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

Provided in Table No: 3.8 column B

ii Whether these chemicals are within Threshold Limit Values TLV / Permissible ExposureLevels as per ACGIH recommendation.

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

iii What measures company has taken to keep these chemicals within PEL/TLV.

Measures to keep exposure below TLV/ PEL are provided in below table 3.6 column D.

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

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

v What are onsite and offsite emergency plan during chemical disaster.

Onsite and offsite emergency plan provided in Table‐3.6 column E

vi Liver function tests LFT during pre‐placement and periodical examination.

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

vii Details of occupational health surveillance program.

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

• Manual material handling only the causes of musculo‐sketal disorders MSD , backache, pain in minor and major joints, fatigue etc. following measure have been taken to avoid above mentioned ill health effect to workers.

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

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

material flow, Process flow of work place will be designed. Following activities will be carried out for Occupational health of the workers.

• Treatment part OPD for both company and contractor employees. • Occupational related problems will be studded like ergonomic issues and control measures • Prevention part‐ Pre medical examination and periodical medical examination for

operators, helpers, chemists. • Profile active Health Awareness programme.

28



3.11 Occupational health impact on employees, control measures, action plan if accident occur

Table‐3.6 Sr. No. Chemical Occupational health impact on

employeesMeasures to keep exposure

below TLV/ PELEMP for STEL & IDLH

A

B C D E

1 Hexane CAS #110‐54‐3

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 confinedareas; dike if needed.

2 Hydrochloric Acid

Very hazardous in case of skin contact corrosive, irritant, permeator , of eye contact irritant, corrosive , of ingestion, . Slightly 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.

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.

3 Liq. Ammonia 25 % Solution

Very hazardous in case of skin contact corrosive, irritant,

Provide exhaust ventilation or other engineering controls to

Dilute with water and mop up, or absorb with an inert dry material and place in an appropriate waste

29



permeator , 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. The substance is toxic to upper respiratory tract

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.

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; dike if needed. Call for assistance on disposal. Neutralize the residue with a dilute solution of acetic acid.

4 Thionyl Chloride CAS # 771909‐7

Corrosive. Extremely destructive to tissues of the mucous membranes and upper respiratory tract. Symptoms may include burning sensation, coughing, wheezing, 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 5pulmonary edema. Prolonged or repeated exposure may cause conjunctivitis, dermatitis, rhinitis, and pneumonitis.

Use process enclosure, local exhaust ventilation, or other engineering controls 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!

5 Toluene CAS # 108‐88‐3

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 confinedareas; dike if needed.

30



6 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. Prolonged or repeated eye contact may cause conjunctivitis. Effects may be delayed. Workers chronically exposed to sulfuric acid mists may show various lesions of the skin, tracheobronchitis, stomatitis, conjunctivitis, or gastritis. Occupational exposure to strong inorganic acid mists containing sulfuric acid is carcinogenic to humans.

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 non‐combustible material followed with plastic sheet to minimize spreading and contact with water.

7 Zinc chloride CAS#: 7646‐85‐7

The substance may be toxic to kidneys, pancreas. Repeated or prolonged exposure to the substance can produce target organs damage. Repeated 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.

Use process enclosures, local exhaust ventilation, or other engineering controls 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; dike if needed. Call for assistance on disposal. Be careful that the product is not present at a concentration level above TLV

8 Paraformaldehyde CAS#: 30525‐89‐4

The substance p. 2 is toxic to mucous membranes. Repeated or

Use process enclosures, local exhaust ventilation, or other

Flammable solid. Corrosive solid. Stop leak if without risk. Do not get water inside container. Do not touch

31



prolonged exposure to the substance can produce target organs damage. Repeated 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 manyhuman organs

engineering controls 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.

spilled material. Use water spray curtain to divert vapor drift. Use water spray to reduce vapors. Prevent entry into sewers, basements or confined areas; dike if needed. Eliminate all ignition sources. Call for assistance on disposal.

9 Benzyl Acetate CAS#: 140‐11‐4

The substance may be toxic to central nervoussystem CNS . Repeated or prolonged exposure to the substance can produce target organs damage.

Provide exhaust ventilation or other engineering controls to keep the airborne oncentrations of vapors below their respective threshold limit value. Ensure that eyewash stations and safety showers are proximal to the work‐station location.

Combustible material. Keep away from heat. Keep away from sources of ignition. Stop leak if without risk. Finish cleaning by spreading water on the contaminated surface and allow to evacuate through the sanitary system. Be careful that the product is not present at a concentration level above TLV.

10 Benzyl chloride CAS#: 100‐44‐7

The substance is toxicto kidneys, lungs, the nervous system, liver, mucous membranes. Repeated or prolonged exposure to the substance can produce target organs 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

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.

Combustible material. Corrosive liquid. Keep away from heat. Keep away from sources of ignition. Stop leak if without risk. Absorb with DRY earth, sand or other non‐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; dike if needed. Call for assistance on disposal. Be careful that the product is not present at a concentration level above

32



respiratory tract irritation leading to frequent p. 2 attacks of bronchial infection. Repeated exposure to a highly toxic material may produce general deterioration of health by an accumulation in one or many human organs. Repeated or prolonged inhalation of vapors may lead to chronic respiratory irritation.

TLV.

11 Mono Chloro Acetic Acid

CAS # 79‐11‐8

Repeated exposure of theeyes 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 an p. 2 highly toxic material may produce general deterioration of health by an accumulation in one or many human organs. Repeated or prolonged inhalation of dust may lead to chronic respiratory irritation.


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; dike if needed. Eliminate all ignition sources. Call for assistance on disposal. Neutralize the residue with a dilute solution of sodium carbonate.

12 Naphthalene CAS#: 91‐20‐3

The substance is toxic to blood, kidneys, the nervous system, the reproductive system, liver, mucous membranes, gastrointestinal tract, upper respiratory tract, central nervous system CNS . Repeated or prolonged exposure to the substance can produce

Use process enclosures, local exhaust ventilation, or other engineering controls to keep airborne levels below recommended exposure limits. If user operations generate dust, fume or mist, use ventilation to keep

Flammable solid. Stop leak if without risk. Do not touch spilled material. Use water spray curtain to divert vapor drift. Prevent entry into sewers, basements or confined areas; dike 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. Check TLV on the MSDS and with local authorities.

33



target organs damage. Repeated exposure to an highly toxic material may produce general deterioration of health by an accumulation in one or many human organs.

exposure to airborne contaminants below the exposure limit.

13 Benzyl alcohol CAS#: 100‐51‐6

The substance may be toxic to liver, central nervous system CNS . Repeated or prolonged exposure to the substance can produce target organs damage.

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.

Combustible material. Keep away from heat. Keep away from sources of ignition. Stop leak if without risk. Finish cleaning by spreading water on the contaminated surface and allow to evacuate through the sanitary system. Be careful that the product is not present at a concentration level above TLV.

14 Sodium Cyanide CAS#: 143‐33‐9

The substance may be toxic to skin, eyes, central nervous system CNS . Repeated or prolonged exposure to the substance can produce target organs damage. Repeated 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.


Corrosive solid. Poisonous 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; dike 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

3.12 Process description and flow chart :‐ provided in EIA report Chapter ‐ 2

34



SECTION IV

HAZARD IDENTIFICATION

4.0 INTRODUCTION

Risk assessment process rests on identification of specific hazards, hazardous areas and areas vulnerable to effects of hazardous situations in facilities involved in processing and storage of chemicals. In fact the very starting point of any such assessment is a detailed study of materials handled & their physical / chemical / thermodynamic properties within the complex at various stages of manufacturing activity. Such a detailed account of hazardous materials provides valuable database for identifying most hazardous materials, their behaviour under process conditions, and their inventory in process as well as storage and hence helps in identifying vulnerable areas within the complex. Hazardous posed by particular installation or a particular activity can be broadly classified as fire and explosive hazards and toxicity hazards. Whether a particular activity is fire and explosive hazardous or toxicity hazardous primarily depends on the materials handled and their properties. It will be from the above discussion that study of various materials handled is a prerequisite from any hazard identification process to be accurate. Based on this study the hazard indices are calculated for subsequent categorization of units depending upon the degree of hazard they pose. Identification of hazards is the most important step to improve the safety of any plant. The hazard study is designed to identify the hazards in terms of chemicals, inventories and vulnerable practices /operations.

The hazard evaluation procedures use as a first step by checklists and safety reviews. Dow and Mond fire and explosion indices, which make use of past experience to develop relative ranking of hazards, is also extensively used. For predictive hazard analysis, Hazard and Operability studies HAZOP , Fault tree analysis, Event tree analysis, Maximum credible accident and consequence analysis etc are employed.

4.1 Dow’s fire and Explosion Index F & EI

TABLE‐ 4.1

Sr No

Material stored

Nh

Nf

Nr

MF

GPH SPH FEI Degree of Hazard

Radius of Exp. ft.

Th Ts TI Degree of Hazard

1. Toluene 0 3 0 16 2.55 3 122.4 Intermediate

106 125 50 11.4 Severe

2. Hexane 1 3 0 16 2.55 2.03 82.82 Moderate 75 50 50 5.6 Light

3. Thionyl Chloride

4 0 2 24 2.5 1.4 76 19 Moderate 325 125 22.0 Severe

35



Nh NFPA Health rating GPH General Process Hazard Nf NFPA Fire rating SPH Special Process Hazard Nr NFPA Reactive rating FEI Fire Explosion Index MF Material Fctor Th Penalty Factor Ts Penalty for Toxicity TI Toxicity Index

4.2 Identification of Hazardous Areas:

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

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

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

Various raw materials used in the manufacturing processes are listed in Table‐3.3 in Section‐3 along with mode / type of storage & storage conditions. It can be readily seen that raw materials even though hazardous in nature, will be used in small quantities & storage quantities will also very low at process plant.

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

List of chemicals stored in larger quantities is provided in Table‐3.4, hazardous properties are provided in Table‐3.5 and Occupational health impact to employees and emergency action plan and its antidotes provided in Table 3.6

4.3 Failure Frequencies 4.5.1 Hazardous material release scenarios can be broadly divided into 2 categories

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

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

4.5.2 Typical failure frequencies are given below:‐

TABLE‐4.2

Item Mode of failure Failure frequencies Atmospheric storage

Catastrophic failure Significant leak

10‐9 /yr 10‐5 /yr

Process Pipelines 50 mm dia Full bore rupture

Significant leak 8.8 x 10‐7 /m.yr 8.8 x 10‐6 /m.yr

50 mm 150mm dia Full bore rupture Significant leak

2.6 x 10‐7 /m.yr 5.3 x 10‐6 /m.yr

150 mm dia Full bore rupture Significant leak

8.8 x 10‐8 /m.yr 2.6 x 10‐6 /m.yr

Hoses Rupture 3.5 x 10‐2 /m.yr TABLE‐4.3

36



TABLE‐4.4

Considering this, the risk analysis and consequences studies are concentrated on Below area. a Drum storage area b Thionyl Chloride drum storage area.

SV

Typewriter

37



SECTION V

RISK ASSESSMENT 5.1 Effects Of Releases Of Hazardous Substances

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

In case of release of hazardous substances the damages wil l depend largely on source strength. The strength of the source means the volume of the substance released. The release may be instantaneous or semi‐continuous. In the case of instantaneous release, the strength of the source is given in kg and in semi‐continuous release the strength of the source depends on the outflow time kg/s. . In order to f ire the source strength, i t is f irst necessary to determine the state of a substance in a vessel . The physical properties, viz . Pressure and temperature of the substance determine the phase of release. This may be gas, gas condensed to l iquid and l iquid in equil ibrium with its vapour or solids . Instantaneous release will occur, for example, i f a storage tank fai ls . Depending on the storage conditions the fol lowing situations may occur. The source strength is equal to the contents of the capacity of the storage system. In the event of the instantaneous release of a l iquid a pool of l iquid wil l form. The evaporation can be calculated on the basis of this pool .

5.2 Tank On Fire/ Pool Fire In the event of the instantaneous release of a l iquid a pool of l iquid wil l form. The evaporation can be calculated on the basis of this pool . The heat load on object outside a burning pool of l iquid can be calculated with the heat radiation model . This model uses average radiation intensity, which is dependent on the l iquid. Account is also taken of the diameter‐to‐height ratio of the fire, which depends on the burning l iquid. In addition, the heat load is also influenced by the following factors:

Distance from the f ire The relative humidity of the air water vapour has a relatively high heat‐

absorbing capacity The orientation i .e . horizontal/vertical of the objective irradiated with

respect to the f ire.

SV

Typewriter

38



5.3 Fire Ball/ BLEVE This happens during the burning of liquid, the bulk of which is initially over rich i.e. above the upper flammable limit. . The whole cloud appears to be on fire as combustion is taking place at eddy boundaries where air is entrained i.e. a propagating diffusion flame . The buoyancy of the hot combustion products may lift the cloud form the ground, subsequently forming a mushroom shaped cloud. Combustion rates are high and the hazard is primarily thermal.

5.4 “UVCE”

UVCE stands for unconfined vapour cloud explosion. The clouds of solvent vapour mix with air within flammability limit 3.0 % to 11 % may cause propagating flames when ignited. In certain cases flame may take place within seconds. The thermal radiation intensity is severe depending on the total mass of vapour in cloud and may cause secondary fire. When the flame travels very fast, it explodes causing high over pressure or blast effect, resulting in heavy damage at considerable distance from the release point. Such explosion is called UVCE Unconfined Vapour Cloud Explosion and is most common cause of such industrial accident.

5.5 DISPERSION CASES :

5.5.1 PLUMES : Plumes are continuous release of hazardous gases and vapours. Smoke from a chimney is an example. Plumes can cause FIRES AND EXPLOSIONS as secondary scenarios .

5.5.2 PUFFS : Puffs are instantaneous release of hazardous gases and vapours. Puffs can give rise to FIRE BALLS and vapour cloud explosions VCE . A special case of vapour cloud explosion is the Boiling Liquid Evaporating Vapour Explosion BLEVE .

5.5.3 SPILLS POOL:

Spil ls are l iquid pools created by leaking l iquid chemicals . Spil ls cause evaporation and dispersal of toxic gases and if the spil led l iquid is f lammable, then it can catch f ire creating a pool f ire also the vapours can cause explosion.

5.6 Identification of High Risk Areas :

1. Under ground storage tank farm area, road truck unloading area 2. Above ground tank farm area 3. Drum storage area 4. Methylamine gas cylinder storage area. 5. Oleum storage tank area.

5.7 Modes of Failure: Liquid release due to catastrophic failure of storage vessel or road tanker.

SV

Typewriter

39



Liquid release through a hole/crack developed at welded joints/flanges / nozzles / valves etc.

Vapour release due to exposure of liquid to atmosphere in the above scenarios. Gas release due to catastrophic failure of Ammonia cylinder or outlet valve/line failure.

Event Causes Tank on Fire/ ‐ Catastrophic failure of tank Ignition availability Pool fire ‐ Failure of liquid outlet line Ignition availability Fire Ball/ ‐ Catastrophic failure of road tanker/ storage tank Flash Fire Vapour generation due to substrate and wind UVCE Vapour cloud generation and about 15 % of

total vapour mass Above the UEL‐LEL % Ignition availability Toxic gas dispersion ‐ Toxic Gas release due to catastrophic failure of tonner/bullet/ Tanks and ignition not available within LEL‐ UEL range. Considering the quantity of storages & nature of Toxic nature and Flammable storage, following scenarios were taken up for detailed analysis & safe distances computed : Catastrophic failure of road tanker of Isobutylene, n‐Hexane, Toluene, Methanol, etc. and

presence of ignition source poses heat radiation hazards to nearby areas. Dispersion of vapour up to LC‐50 Fatal , Immediate Danger to Life and Health IDLH

and TLV Threshold Limit Value concentration Dispersion of vapour to toxic end points

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

5.8 Damage Criteria For Heat Radiation:

Damage effects vary with different scenarios. Calculations for various scenarios are made for the above fai lure cases to quantify the resulting damages. The results are translated in term of injuries and damages to exposed personnel , equipment, building etc . Tank on f ire /Pool fire due to direct ignition source on tank or road tanker or catastrophic fai lure or leakage or damage from pipeline of storage facil it ies or road tanker unloading arm, can result in heat radiation causing burns to people depending on thermal load and period of exposure.

Al l such damages have to be specif ied criteria for each such resultant effect , to relate the quantifier damages in this manner, damage criteria are used for Heat Radiation.

40



TABLE 5.3

DAMAGE CRITERIA – HEAT RADIATION

Heat Radiation Incident Flux KW/m2 Damage 38 100% lethality, heavy damage to tanks 37.5 100% lethality, heavy damage to equipment. 25 50% lethality, nonpiloted ignition 14 Damage to normal buildings 12.5 1% lethality, piloted ignition 12 Damage to vegetation 6 Burns escape routes 4.5 Not lethal, 1st degree burns 3 1st degree burns possible personnel only in emergency allowed 2 Feeling of discomfort1.5 No discomfort even after long exposure

41



SECTION VI

CONSEQUENCE ANALYSIS 6.1 Consequence analysis.

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

6.1.1 Maximum Credible loss scenarios MCLS

MCLS assume maximum inventory of hazardous chemicals and worst weather condition prevail ing at the t ime of fai lure. Further, no credit is given for the safety features provided in the facil ity to determine maximum possible damage from the scenario selected. In reality , leakage of hazardous chemical wil l be smaller in magnitude. Also the leakage wil l be detected immediately by plant operating staff then initiate various mitigation measures to prevent any disastrous situation. The maximum credible loss Scenarios MCLS identified for plant base on above criteria are listed below:

Table‐6.1

Scenario No.

Loss of containment Scenario

Failure Mode Consequence

1 Fire in drum storage area. Drum spillage Unconfined Pool fire.2 Fire in drum storage area. Due to fire domino

effect BLEVE in drum

3 Thionyl Chloride Drum catastrophic failure

Catastrophic failure Spill pool evaporation dispersion and its LC 50, IDLH & TLV concentration distances.

6.1.2 Weather Data: Average wind speed : 3 to 6 m / sec. Average Ambient Temperature : 35 deg. c . Average Humidity : 60 % Atmospheric Stabil ity : D & F

6.1.3 Assumption :

6.1.3.1 Basic assumptions for drum storage area

Drum Fire i f direct ignition on road tanker. Drum storage area f ire due to heat effect and domino effect .

42



Heat Radiation Damage

37.5 100% lethality, heavy damage to equipment. 12.5 1% lethality, piloted ignition 4.5 Not lethal, 1st degree burns 1.6 No discomfort even after long exposure

6.1.3.2 Basic assumptions for Thionyl chloride Drum catastrophic failure

We have calculated fol lowing hazardous distance for the above mentioned scenarios.

Fatality LC‐50 Immediate danger to l i fe and health IDLH concentration area TWA/TLV concentration distance Meters

MCA Scenario ‐1 Unconfined Pool Fire Simulation for Drum Storage Area.

TABLE – 1Unconfined Pool Fire for Drum Storage Area

Scenario : UNCONFINED POOL FIREIn put Data Results of Computations

Stored quantity 20 KL Max. IHR at flame centre height 143.48 Kw/m2

Pool diameter 25 m Flame centre height 21.60 meterPool liquid depth 0.01 m Maximum Flame width 21.59 meterWind speed 6 m/s Mass burning rate liquid 5.02 kg/ m2/min.Liquid Density 867 kg/m3 Flame burnout time 1.66 Hrs.

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 23.1 Damage to process equipment. 100 % Fatal in 1 Min. 1 % fatal in 10 sec.

25.0 28.3 Min. to ignite wood without flame contact . 100 % fatal in 1 Min. Significant injury in 10 sec.

12.5 40 Min. to ignite wood with flame contact . 1 % fatal in 1 min. 1 st deg. burn in 10 sec.

4.0 70.7 Pain after 20 secs. Blistering unlikely.

1.6 111.8 No discomfort even on long exposure.

Results In the 23.1 meter radius area is considered as 100 % fatality in 1 min. and first degree burn in 10

sec. In the 40 meter radius first degree burn in 10 sec. In the 70.7 meter radius area will give pain after 20 seconds. Blistering unlikely. In the 111.8 meter radius area is considered as safe area and no discomfiture even on long

exposure.

43



44



MCA Scenario – 2 BLEVE simulation for Drums Storage

TABLE – 2BLEVE simulation for Drums Storage

Scenario : BLEVEIn put Data Results of Computations

Stored quantity 20 Kl Fire Ball radius 11.17 meter Mass of vapour 80 Kgs. Fire ball Intensity of Heat

radiation 186.59 Kw /m 2

Heat of combustion 40550 Kj/Kg Fire Ball rate of energy release

292486 Kj/ sec.

Wind speed 6 m/s Fire‐ Ball total energy release

1.333e 006 Kj

Liquid Density 867 kg/m3 Fire ball duration 4.56 sec.

Incident Intensity of Heat Radiation

IHR at ground level KW /m 2

IHR‐ Isopleth Distance Meters

Damage effects

37.5 25 100 % Fatal . Min. to ignite wood without flame contact

25.0 30 Min. to ignite wood without flame contact . Significant injury.

12.5 42.5 Min. to ignite wood with flame contact . 1 st deg. burn .

4.0 76 Pain after 20 secs. Blistering unlikely.

1.6 120 No discomfort even on long exposure.

Results In the 25 meter radius area is considered as 100% fatality in 1 min. In 42.5 meter radius area is considered as 1st deg. Burn in 10 sec. and 1 % fatal in 1 minute. In the 76 meter radius area will give pain after 20 seconds. Blistering unlikely. In the 120 meter radius area is considered as safe area and no discomfiture even on long

exposure.

SV

Typewriter

45



46



Scenario-3 Spill pool Evaporation for Thionyl Chloride Drum catastrophic failure

TABLE –L FOR THIONYL CHLORIDE Scenario : Spill pool Evaporation

In put Data Results of Computations Stored quantity 200 ltrs Max. ground level conc. 4895 ppm(SO2)

1630ppm(HCL) Rate of release 37 g/s Dist. of maxi. ground level

conc. 67 meter

Molecular weight 119 Wind speed 3.0 / 6.0 m/s Density ( Air) 1.64kg/m3

Hazard Level Concentration

(PPM) D weather condition

(Meter) F weather condition

(Meter) LC50( As HCL gas) 3940 - -

IDLH ( As HCL gas) 50 94.72 327.21

TWA/ TLV ( As HCL gas) 5 376.12 1409.14

LC50( As SO2 gas) 5784 - -

IDLH ( As SO2 gas) 100 35 132

TWA/ TLV ( As SO2 gas) 2 445 1697

47



48



49



50



51



6.2 Detail regarding consequences analysis table

TABLE ‐ 6.3 For Fire simulations Type of failure considered Spill

quantity consideration Max. Credible loss scenario in KL.

Heat Intensity KW/ M2

37.5 12.5 4.0

MCA Scenario ‐1 Unconfined Pool Fire Simulation for Drum Storage Area

25 23.1 40.0 70.7

MCA Scenario–2 BLEVE simulation for Drums Storage

25 25.0 42.5 76.0

TABLE ‐ 6.4 For Toxic gas dispersion simulations

Type of failure considered

Spill quantity

consideration Max.

Credible loss scenario in

MT.

Evaporation RateGrm. / Sec.

LC50 Distance in meter

IDLH Distance in meter

TLV Distance in meter

Scenario-12 Spill pool Evaporation for Thionyl Chloride Drum catastrophic failure

200 ltrs 36.8 as HCL gas D weather condition

- 94.72 376

36.8 as HCL gas F weather condition

- 327.21 1409

36.8 as SO2 gas D weather condition

- 35.51 445

36.8 as SO2 gas F weather condition

- 132.4 1697

6.3 Conclusions

The appended table 6.3 and 6.4 summarizes the consequences of the various Scenarios analyzed under this study. As can be seen from the results of the summary of the Quantitative Risk Analysis study, the Total damage and Fatality zone due to Fire & Explosion up to 25 meters in worst case scenario. First degree burn zone up to 42.5 meter. Within the manufacturing processes, no major hazards are for seen due to minimal storage in process area.

SV

Typewriter

52



Due to Thionyl Chloride release scenario 50 % lethality distance up to plant premises in case of TC drum loss containment. Evacuation Zone up to 327 meter can be considered in wind direction. On site emergency preparedness plan will be prepared as per risk assessment findings. Emergency control facilities and resources will be plan and rehearsal / Mock‐ Drill to be conducted regularly to combat emergency in minimum time.

53



SECTION VII

RISK REDUCTION MEASURES

7.1 Recommendations 7.1.1 From the Risk Analysis studies conducted, it would be observed that by and large, the risks

are confined within the factory boundary walls in case of fire, explosion and spillage of chemicals. On site emergency plan & preparedness plan to be prepared and implemented to combat such situations. To minimize the consequential effects of the risk scenarios, following steps are recommended.

Plant should meet provisions of the Manufacture, storage & Import of Hazardous

Chemicals Rules, 1986 & the factories Act, 1948. Fire hydrant system needs to be installed as per NFPA / GFR 66 A Norms in plant and

buildings. Process hazard analysis and HAZOP study to be conducted for each process and

recommendation to be implemented. HSE management system to be implemented. Induction course for HSE to be implemented at very initial stage of the plant employees

recruitment. Periodic On Site Emergency Mock Drills and occasional Off Site Emergency Mock Drills to

be conducted, so those staffs are trained and are in a state of preparedness to tackle any emergency.

Emergency handling facilities to be maintained in tip top condition at all time. Safe operating procedure to be prepared for hazardous process and material handling

process. Local call points LCP and smoke detectors to be provided in godown/ware house,

office building, drum storage area etc. Safety devices and control instruments to be calibrated once in a year. Proper colour work as per IS 2379 to plant pipeline and tank, equipments to be done

once in a six month to protect from corrosion. Preventive maintenance schedule to be prepared for all equipments. Permit to work system to be implemented 100 % for hazardous work in the plant. Safety manual as per Gujarat Factories Rule‐68 K & P and Public awareness manual as

per Gujarat Factories Rule 41 B & C needs to be prepared and distributed to all employees and nearby public.

Emergency siren to be provided in all plant to declare emergency. Fire & Safety organization setup to be planed and implement for batter plant process

safety. Static earthing interlocking with pump facility to be provided for drum unloading area to

avoid static hazard during tanker unloading work.

SV

Typewriter

54



SECTION VIII

SCENARIO BASED ON SITE AND OFF SITE EMERGENCY PLAN

8.1 Possible Emergency :‐ Drum Spillage in drum storage area. Spill Control Plan

Location

Scenario consider

ed

Hazard Consequence

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

1 2 3 4 5 6 7Drum storage area

Small spillage Large spillage

Toxic vapour exposure to drum handling operators. Fire incase of ignisource available within LEL‐UEL % concentration

Drum puncher or damage, wrong storage method.

Find out leakage drum

Raised alarm immediately for warning the people if large spillage observed. Do not entre in confined room if spillage in room. Do not touch any electrical switches in spillage area. Stop all hot work in this area. Call fire and Safety department Cordon the area. Evacuate non essential persons from the affected area immediately. Inform the area incharge. Try to control situation at department level with available resources with full PPEs.

Incident controller IC IC IC IC and department team IC Security team Non essential workers IC IC

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

in Drum storage area. 3. Proper label and identification

board /stickers is provided in the storage area.

4. Conductive drum pallets are provided.

5. Drum handling trolley / stackers/fork lift are used for drum handling.

6. Separate dispensing room with local exhaust and static earthing provision is available.

7. Materials are stored as per its compatibility study and separate area is available for flammable, corrosive and toxic chemical drums storage.

8. Smoking and other spark, flame generating item are banned from the Gate.

55



Identify the spillage material and refer MSDS for control plan. Segregate leakage drum from the area. Inform the Site main Controller SMC in detail. Open all doors and windows in this area. Take decision to Declare onsite emergency Spill control and neutralization team member try to control spread material in more area by absorbing material and dry sand. If material is toxic like ACN or any other flammable and toxic chemical, special precautions needs to be taken as per chemical expert Key person guide line. Do not spray water or Foam on spilled material. Do not drain spilled material in any trench. Collect the spilled material in close container and send for ETP for further neutralization of the residual contents. Ensure search and rescue and causalities receive attention. Administer first aid to the victim.

Make arrangement to send injured person/s to

IC

Dept. Toxic control team IC Dept. Toxic control team SMC Toxic/Spill control team Toxic/Spill control team Fire team Toxic/Spill control team Toxic/Spill control team Rescue team First Aid team

Administration

9. NFPA labels are provided on drums for hazard identification of the chemicals.

10. Exhaust is provided at ground level in drum storage area.

11. Drum loading unloading procedures are prepared and implemented.

56



Hospital.

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

team.

SMC

Drum storage area


Fire in drum storage area BLEVE of drums

Drum leakage or damage, wrong storage method. Ignition sorce like electrical source , Friction etc. BLEVE due to Metal drum heat in fire.

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

Evacuate the area immediately. Inform the area incharge. Inform IC in detail. Call fire department immediately and help them for fire fighting. Try to control situation at department level with available resources with full PPEs. If it is found uncontrollable condition by department level inform SMC for onsite emergency situation. Declare on site emergency if required. Remove un burned drums from the site if possible without any risk. Start fire hydrant system or water hose rill and spray water on uninvolved drums in fire for cooling purpose.

First Observer

All employees in this area First observer Department employee IC Department fire fighting team. IC SMC Rescue and evacuation team Fire team

57



Use foam fire extinguishers for firefighting of solvent fire. Do not enter in fire prone area. If fire found uncontrollable condition call fire brigade and mutual aider for help. In case of BLEVE fire, immediate evacuate the area up to 50 meters of the area surrounding. All hazardous activates stop at site. Inform nearby company to remove hazardous material or inventory from the compound wall. Ensure search and rescue and causalities receive attention. Administer first aid to the victim. Make arrangement to send injured person/s to Hospital. And inform victim’s family. If off site emergency situation occur –Inform to following agencies. Request for Mutual aiders, local authorities like – DISH office, Collectorate office, Disaster management cell, Police, fire brigade, nearby hospital, local GPCB office.

Fire team

All team member SMC All team member SMC and all dept. head. SMC Rescue team First Aid team Administration team SMC

58



8.2 Possible Emergency :‐ Fire in drum storage area

Location

Scenario consider

ed

Hazard Consequence




Fire in drum storage area BLEVE of drums

Drum leakage or damage, wrong storage method. Ignition sorce like electrical source , Friction etc. BLEVE due to Metal drum heat in fire.

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

Evacuate the area immediately. Inform the area incharge. Inform IC in detail. Call fire department immediately and help them for fire fighting. Try to control situation at department level with available resources with full PPEs. If it is found uncontrollable condition by department level inform SMC for onsite emergency situation. Declare on site emergency if required. Remove un burned drums from the site if possible without any risk. Start fire hydrant system or water hose rill and spray water on uninvolved drums in fire for cooling purpose. Use foam fire extinguishers for firefighting of solvent fire.

First Observer

All employees in this area First observer Department employee IC Department fire fighting team. IC SMC Rescue and evacuation team Fire team Fire team

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

in Drum storage area. 3. Proper label and identification

board /stickers is provided in the storage area.

4. Conductive drum pallets are provided.


6. Separate dispensing room with local exhaust and static earthing provision is available.

7. Materials are stored as per its compatibility study and separate area is available for flammable, corrosive and toxic chemical drums storage.

8. Smoking and other spark, flame generating item are banned from the Gate.


10. Exhaust is provided at ground

59



Do not enter in fire prone area. If fire found uncontrollable condition call fire brigade and mutual aider for help. In case of BLEVE fire, immediate evacuate the area up to 50 meters of the area surrounding. All hazardous activates stop at site. Inform nearby company to remove hazardous material or inventory from the compound wall. Ensure search and rescue and causalities receive attention. Administer first aid to the victim. Make arrangement to send injured person/s to Hospital. And inform victim’s family. If off site emergency situation occur –Inform to following agencies. Request for Mutual aiders, local authorities like – DISH office, Collectorate office, Disaster management cell, Police, fire brigade, nearby hospital, local GPCB office.

All team member SMC All team member SMC and all dept. head. SMC Rescue team First Aid team Administration team SMC

level in drum storage area.11. Drum loading unloading

procedures are prepared and implemented.

60



8.3 Possible Emergency :‐ Thionyl Chloride drum spillage . Thionyl Chloride Spill Control Plan

Location

Scenario consider

ed

Hazard Consequence




Toxic vapour exposure Evacuate area in down wind direction up to 327 meter

Drum damage, punctured, wrong storage method.

Raise siren or shouting for help

Evacuate the area immediately. Inform the area incharge. Inform Incident controller IC in detail. Call toxic control team Try to control situation at department level with available resources with full PPEs. And respiratory system. If it is found uncontrollable condition by department level inform SMC for onsite emergency situation. Declare on site emergency if required. Inform nearby company to evacuate area in down wind direction. Coedon the area Do not entre in this area without respiratory protection and full body protection suite.

First observer

All employees in down wind direction. First observer Area incharge Shift incharge IC Area incharge Shift incharge IC SMC SMC Security team All team members

1. Check for leakage all drums properly while unloading from truck.

2. If found any spillage first search for leakage drum.

3. Store separate from water source or reactive chemical drums.

4. Proper ventilation is available in Drum storage area.

5. Proper label and identification board /stickers is provided in the storage area.

6. Drum containment provision to be made.


8. Drum loading procedure to be prepared.

9. TC handling safety training to be provided to all operators.


11. Exhaust is provided at ground

61



Find out leakage drum. Remove spilled drum from the area in open place. Stop leakage if possible by drum position change. Transfer material from drum in a new drum by barrel pump or by gravity. Neutralize spilled drum by soda ash or soda lime powder . Spilled area to be covered and spray with soda ash or soda lime. Keep as it is for 1 ‐2 hrs. for neutralizing the TC. Collect the powder in close container and send ETP for safe disposal. Never use water for cleaning of TC spilled area. TC is water reactive chemical. It will generate SO2 and HCL fumes and will create white fumes cloud in down wind direction. Ensure search and rescue and causalities receive attention. Administer first aid to the victim. In open air place. Make arrangement to send injured person/s to Hospital. And inform victim’s family.

Toxic control team Toxic control team Toxic control team Toxic control team Toxic control team Toxic control team Toxic control team All team members Rescue team Fire team Administration team.

level in drum storage area.12. Drum loading unloading

procedures are prepared and implemented.

62



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

SMC

63



8.4 Possible Emergency :‐ Sodium Cyanide poisoning to worker.

Location

Scenario consider

ed

Hazard Consequence


1 2 3 4 5 6 7Sodium cyanide drum storage area

Toxic effect due to cyanide poisoning to workers

Fatality Injection or oral dose due to contact with cyanide. Dust exposure during charging cyanide in to rector.

Symptoms may be delay after 3 to6 hrs. if exposure low. Give first aid to victim. Apply Amyle Nitrate smell to victim by handkerchief. Apply Oxygen administration if he is breathing. After one minute repeat Amyle Nitrate treatment . This first aid treatment repeat till victim feel normal. Admit victim to hospital immediately. Cyanide Antidote Kit keep with hospital for intravenous injection by doctor. Apply Antidote injection Antidote kit is kept in office in first aid centre. Inform to statutory bodies.

siirviir miiT\ a\nT&-Di\T *kTnii\ upiyii\gi krviini& r&ti: sii@ pi`Wimi *kTmiI riKi\li Rmiili ni& ciir giL& viiL& tyiir biid ti\mii a\miiEli niiETX\T ni& bii\Tlini\ mi#k& fr&Wi& ciir giL& viiL& bii\Tli

First observer or victim. Train first aider for cyanide. Administration team First aid team By doctor only SMC SMC

15. Separate stored in locked room.

16. Away from water sources . 17. Total body protection suite is

provided to charging operator with air l ine respirator.

18. Safe operating Charging procedure is prepared and displayed in process and storage area.

19. Total c lose process for charging and handling.

20. Antidote kit for cyanide is kept ready in OHC.

21. Training is being provided to handle NACN,

22. SCBA sets are avai lable in handling area .

23. Operator having cuts and sores should not use cyanides .

24. I f a l i t t le poisoning, inhale cyanide antidote ki t amyl ni tri te , sodium ni tri te and sodium thiosulfate and oxygen for 15‐30 seconds as f irst a id measures

25. Use sodium hypochlori te , calcium hypochlori te

64



tii\D& niiKi& ti\ Rmiilini\ a\k viir si#>giiLi\ tyiir biid ai\ksi&jni aipii\ ani\ a\k mi&ni&T biid fr&Wi& Rmiili si#>giiLi\ ani\ fr&Wi& ai\ksi&jni aipii\ aimi jyiI si#Gi& miiNisi nii\miPli k>D&Sini miI nii aivi\ tyii si#Gi& krtii rhi\ . miiNsini\ hi\spi&TlimiI liE jti& viKiti\ a\*k`lii\niiETXiEli a\nT&-Di\T *kT siiWi\ liE jivi ani\ hi\spi&Tli miI hijr Di\kTrni\ ti\ *kT aipivi& jRr& C\ j\Wi& ti\ *kTni& middWi& Di\kTr siirviir kr& Sik\. nii\>Gi: · a\nT&-Di\T *kT ai\*fsi mii ani\ siih\bini& ai\*fsimii riKiviimii aivi\li& C\. ·

solution or potassium permanganate for washing balance , glass apparatus , spatula , workplace and in case of spi l lage

26. Use Apron, eye protecting glass , Mask and gloves during transferring, work‐up and decomposition of chemicals .

27. Issued quantity wil l be used ful ly for reactions. Can not be stored in the process area

28. Separate Log Book for issuing above cyanides and Manager has to sign on the register

m/s. sabari chemicals pvt. ltd. - …environmentclearance.nic.in/writereaddata/formb/ec/... ·...

Documents