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Risk Assessment Prepared by Shriji EHS Management Services for Ice Make Refrigeration Pvt. Ltd.

ICE MAKE REFRIGERATION PVT.LTD

Survey No. 226-227 , Dantali Industrial Estate ,

Gota - Vadsar Road , At. Dantali

Taluka-Kalol

Dist-Gandhinagar

Risk Assessment

(December - 2015)

Prepared By

Shriji EHS Management Services


Preface

The Management of ICE MAKE REFRIGERATION PVT.LTD. Survey no.226-227 , Dantali

Industrial Estate , Ta. Kalol , Dist. Gandhinagar has entrusted me for the task of preparing

Risk Assessment Report for their expansion project work. Accordingly, we have prepared

Risk Assessment Report for any emerging out of storage, use and handling of hazardous

chemicals to be used in the plant area.

The factory is expanding their activities and production capacities. As a part of Environment

Clearance and EMP, Risk to be reviewed for worst case scenario , MCA ( Maximum

Credible Accident Scenario Analysis ) before expansion activity and to be addressed

properly with Safety Management System to avoid any incident.

The factory is storing, using hazardous chemicals and hence it falls under category

‘Hazardous Process’ i-e section (2cb) of factories Act. Hence management has decided to

prepare Risk Assessment Report regarding hazards and measures to be taken in case of

any emergency while operating the plant.

We have tried fully to prepare the plan to estimate Risk Associated with activity and

proposed mitigation and control measures to cope up with any worst condition or situation by

handling or storage of chemicals , in case.

We are thankful to Mr. Rajendra Patel , whole Time Director, Mr. Hienbhai Patel for their co-

operation for preparation of plan.

We sure the RA Report will be useful to the management in effective operation of Safety

Management System.

Place : Ahmedabad

Date : 12/12/2015

Gopal Shah

Shriji EHS Management Services


Contents 1. INTRODUCTION .............................................................................................................................................. 6

1.1 Identification of Project and Project Proponent ................................................................................ 6

1.2 Nature of the Project .......................................................................................................................... 6

1.3 Need of the Project and it’s important to the country and or region: ............................................... 6

1.4 Demand Supply gap: ........................................................................................................................... 6

The ample market is available and demand is not yet tapped by the supply side as the demand is newly

generated for the refrigeration equipment in the market for the special application. ................................. 6

1.5 Employment Generation ......................................................................................................................... 6

2.PROJECT DESCRIPTION ....................................................................................................................................... 7

2.1Type of Project and interlinked and interdependent Project, if any ........................................................ 7

2.2 Location: ................................................................................................................................................... 7

2.3 Details of alternate site and the basis of selecting the proposed site. .................................................... 7

2.4 Size of magnitude of the Operations........................................................................................................ 7

Table 1: List of Product with capacity (existing and proposed) .................................................................... 7

Table – 2 - The Raw Materials Consumption details (existing and proposed) ............................................... 7

2.5 Process Description .................................................................................................................................. 7

3.GLOSSARY AND TERMS USED IN RISK ASSESSMENT ........................................................................................... 9

4. RISK ASSESSMENT ............................................................................................................................................ 11

4.1 Introduction ................................................................................................................................................ 11

4.2 Objectives of the Study: ............................................................................................................................. 11

4. 3.1. HAZARD IDENTIFICATION: ................................................................................................................ 12

A. Project Hazards: ........................................................................................................................................... 12

B. Operation Hazards: ...................................................................................................................................... 12

4.3.1.1Storage Hazard: ..................................................................................................................................... 13

Causes ............................................................................................................................................................... 14

4.3.1.2 Fire Hazard : ..................................................................................................................................... 14

4.3.1.3 Electrical Hazard : ............................................................................................................................. 14

4.3.1.4 Mechanical Hazard : ......................................................................................................................... 14

4.3.1.5 Material Handling : ........................................................................................................................... 15

4.3.1.6 Toxic Hazards : ................................................................................................................................. 15

4.3.1.7 Explosion Hazards : .......................................................................................................................... 15

4.3.1.8 Corrosion Hazards : .......................................................................................................................... 15

4.3.1.9 Hazards due to structure fall : .......................................................................................................... 15

4.3.1.10 Fall Hazards / Working at Height: ................................................................................................... 15


4.3.1.11 Hazards due to Natural Disaster: ................................................................................................... 15

4.3.1.12 Hazards due to Bad House keeping : .............................................................................................. 16

4.3.1.13 Hazards due to Bad illumination: ................................................................................................... 16

4.3.1.14 Hazards due to Bad ventilation / confined space : ........................................................................ 16

4.3.1.15 Hazards at tank farm area: ............................................................................................................. 16

4.3.1.16 Hazards at switch yard area: .......................................................................................................... 16

4.3.2 Risk Assessment & Hazard Mitigation Measures. ............................................................................... 16

4.3.2.1 Risk Analysis ..................................................................................................................................... 16

4.4 Worst Case Scenario: .................................................................................................................................. 18

4.5 Consequence Analysis: ............................................................................................................................... 18

4.6 Maximum Credible Accident ( MCA ) ......................................................................................................... 22

4.6.1 Release of Polyol ................................................................................................................................. 26

4.7 – Preventive control Measures to avoid/Control Worst Case Scenario and MCA ( Maximum Credible

Accident ) Scenario .............................................................................................................................................. 29

4.7 RISK ASSESSMENT BY 3X3 MATRIX ............................................................................................................. 29

4.7.1 Types of Accidents likely to be happen during Construction, Operation phase and Waste disposal

phase of Expansion Project. ......................................................................................................................... 29

4.7.2 Health Effects (including occupational diseases or poisoning ) likely to be happen during

Construction, Operation phase and Waste disposal phase of Expansion Project. ...................................... 32

4.7.3. Accident Record (Accidents during last five years) ............................................................................ 32

4.7.4 Occupational Diseases Record ( during last five years ) .................................................................... 32

4.8 PREVENTIVE AND CONTROL MEASURES: ................................................................................................... 32

4.8.1 General Recommendations for Storages: ........................................................................................... 32

4.8.2 Do’s and Don’t’s for Handling of Chemicals, Material Handling, Fire Prevention and Housekeeping

are as under: ................................................................................................................................................. 34

4.8.3 Recommendations for Polyol , MDI & Diesel Storage and Handling : ................................................ 38

4.8.4 CONTROL MEASURES THROUGH SAFETY MANAGEMENT SYSTEM: ................................................... 42

4.8.4.1 Factory Layout: ................................................................................................................................. 43

4.8.4.2 Medical Services: .............................................................................................................................. 43

4.8.4.3 Safety Services: ................................................................................................................................. 43

4.8.4..4 Engineering Services:....................................................................................................................... 44

4.8.4.5 Mitigation Measures during Manufacturing Activity: ...................................................................... 44

4.9 The salient features of the Storage & Handling of Hazardous Materials. ................................................. 45

ANNEXURE 2: Hazardous Characteristics and toxicity of raw materials and products and proposed measures

to control it. ......................................................................................................................................................... 47

TABLE A: IMPORTANT CHARACTERISTICS OF HAZARDOUS MATERIALS ........................................................... 50


4.9 OCCUPATIONAL HEALTH AND SAFETY MANAGEMENT SYSTEM: .............................................................. 54

Annexure – A - MSDS ........................................................................................................................................... 57

Tris (2-chloro-1-methylethyl) phosphate ......................................................................................................... 57

2. Diphenyl Methane Di-isocyanate (MDI) ................................................................................................... 57


1. INTRODUCTION

1.1 Identification of Project and Project Proponent

M/s. ICE MAKE REFRIGERATION PVT.LTD. Survey no.226-227 , Dantali Industrial Estate , Ta. Kalol , Dist. Gandhinagar proposes for the expansion of the expansion of the existing manufacturing capacity of industrial and commercial refrigeration equipment using PUF.

1.2 Nature of the Project

The Expansion project is of manufacturing of industrial and commercial refrigeration equipment using PUF .

1.3 Need of the Project and it’s important to the country and or region:

The market for the refrigeration unit is potential in the country. The existing unit proposes the expansion based on the future requirement. M/s. ICE MAKE REFRIGERATION PVT.LTD. Survey no.226-227 , Dantali Industrial Estate , Ta. Kalol, Dist. Gandhinagar proposes for the expansion of the expansion of the existing manufacturing capacity of industrial and commercial refrigeration equipment using PUF.

1.4 Demand Supply gap:

The ample market is available and demand is not yet tapped by the supply side as the demand is newly generated for the refrigeration equipment in the market for the special application.

1.5 Employment Generation

There will be 15-25 labours and contractor required for the construction phase we are having existing setup for infrastructure as well as of existing manufacturing set up. The unit will employ 120 no. of direct labours, staff and contractor’s labours and indirect employment after the expansion.

Image 1: Showing the plot in Dantali Industrial Estate , Kalol , Dist. Gandhinagar


2.PROJECT DESCRIPTION

2.1Type of Project and interlinked and interdependent Project, if any

Proposed project is manufacturing of Refrigeration equipment using PUF.

2.2 Location:

The unit is, located at Survey no.226-227, Dantali Industrial Estate, Ta. Kalol , Dist. Gandhinagar , image -1 shows , its location.

2.3 Details of alternate site and the basis of selecting the proposed site.

The existing unit is located in Survey no.226-227 , Dantali Industrial Estate , Ta. Kalol , Dist. Gandhinagar , had obtained approvals from GPCB. The location attracts the various advantages including manufacturing refrigeration equipment at one location for two plots . So alternative site selection criteria will not be attracted and is not exercised by Propjet Proponent.

2.4 Size of magnitude of the Operations.

The Product name and capacities are shown here in table 1.

Table 1: List of Product with capacity (existing and proposed)

Product name Existing capacity,

Unit/month

Proposed expansion

in Unit/month

Total capacity in

Unit/month

All type of Commercial &

Industrial Refrigeration

Equipment using PUF

200 nos. 1000 nos. 1200 nos.

Table – 2 - The Raw Materials Consumption details (existing and proposed)

Raw material Existing

(kg/Month)

Expansion

(kg/Month) Total (kg/Month)

Polyol (1,1-dichloro-1-

fluoroethane (HCFC –

141b)

Tris (2-chloro-1-

methylethyl)

phosphate)

- 26,400 26,400

Diphenyl Methane Di-

isocyanate (MDI) - 34,200 34,200

2.5 Process Description

The process description for the each product with batch size and raw materials consumption are addressed for each proposed product, as Annexure – A.


Annexure – Factory layout of ICE MAKE – Dantali Industrial Estate


3.GLOSSARY AND TERMS USED IN RISK ASSESSMENT

The common terms used in risk assessment and disaster management are elaborated as below.

Safety:

It is the state of being relatively free from harm, danger, injury and damage. It means protection of

environment including man, money and material.

Accident

Accident is an unplanned event, which has a probability of causing personal injury or property

damage or both.

Disaster

Disaster is defined as a catastrophic situation that cause damage, economic disruptions , loss of

human life and deterioration of health and health services on a scale sufficient to warrant an

extraordinary response from outside the affected are or community. Disasters occasioned by man

are factory fir explosions and release of toxic gases or chemical substances etc.

Emergency

Emergency is defined as a situation where the demand exceeds the resources. This highlights the

typical nature of emergency. It will be after experience that enough is not enough in emergency

situations. Situations of this nature are avoidable but it is not possible to them always.

Emergency preparedness

Emergency preparedness is one of the key activities in the overall management. Preparedness,

though largely dependent upon the response capability of the person engaged in direct action, will

require support from others in the organization before, during and after emergency.

Hazard

Hazard is defined as a physical situation, which may cause human injury, damage to property or the

environment or some combination of these criteria.

Hazardous process

Hazardous process is defined as any process or activity in relation to an industry, which may cause

impairment to the health of the persons engaged or connected therewith or which may result in

pollution of general environment.


Hazardous substance

Hazardous substance means any preparation, which by reason of its chemical or physico-chemical

properties or handling is liable to cause harm to human beings other living creatures, plants, micro-

organisms, property or the environment.

Risk

Risk is defined as a likelihood of an undesired event (accident, injury or death) occurring within a

specified period or under specified circumstances. This may be either a frequency or a probability

depending on the circumstances.

Risk is an expression of possible loss over a specific period or number of operational cycles. It may be

indicated by the probability of accident times, the damage in terms of cost, life or operating units.

Major Accident Hazard (MAH) Installation:

As per the rule2 of the Manufacture, Storage, Import of Hazardous Chemicals Amendment Rules,

2000 (MSIHCAR,2000) , MAH means isolated storage and industrial activity at a site handling

(including transport through carrier or pipeline) of hazardous chemicals equal to or in excess of the

threshold quantities specified in column 3 of schedule 2 and 3 respectively.

Environment:

It includes water, air, and land and the inter-relationship, which exists among and between water, air

and land and human being, other living creatures, plants, organisms and property.

Environment Pollutant:

The substance means any solid, liquid, gaseous substance, noise, which may present in exceed

quantity tend to be injurious to environment called pollutant.


4. RISK ASSESSMENT

4.1 Introduction

It is essential to apply modern approaches to safety practices based on good design, management

and operational control. It is essential to identify potential hazards while assessing design and

development proposals which handle hazardous materials. Risk assessment techniques have been

recognized as an important tool for integrating and internalizing safety in plant operation and

production sequencing. So the risk assessment is mandatory for all new projects process industries

dealing with hazardous chemicals and severe operating conditions.

Risk is associated with the frequency of failure and consequence effect. Predicting such situations

and evaluation of risk is essential to take appropriate preventive measures. The major concern of the

assessment is to identify the activities falling in a matrix of high & low frequencies at which the

failures occur and the degree of its impact. The high frequency, low impact activities can be managed

by regular maintenance i.e., Leak detection and repair (LDAR) programmes. Whereas, the low

frequency, high impact activities (accidents) are of major concern in terms of risk assessment. As the

frequency is low, often the required precautions are not realized or maintained. However, the risk

assessment identifies the areas of major concerns which require additional preventive measures,

likely consequence distances considering domino effects, which will give the possible casualties and

ecological loss in case of accidents. These magnitudes demand the attention for preventive and

disaster management plans (DMPs). Thus is an essential tool to ensure safety of operations.

In the below sections, identifications of various hazardous, probable risks in the storage and handling

of hazardous materials are addressed which gives a broad identification of risks involved in proposed

manufacturing plant. The Disaster Management Plan is prepared considering the hazard and risk

involved in proposed manufacturing activity.

4.2 Objectives of the Study:

1) Assessing risk levels due to operations,

2) Evaluation for corrosive, toxic, flammable and combustible liquids and solids.

3) Identification of the risk mitigation measures to bring the potential risk within acceptable range,

4) To suggest general safety improvement measures for the facility.

5) To identify emergency scenarios and suggest mitigation measures.

6) To prepare disaster management plan.


Present study has been carried out to assess the risk involved in the proposed project. The study

specifically focuses on the followings:

1. Hazard Identification.

2. Risk Assessment & Hazard Mitigation Measures.

3. The salient features of the Storage &Handling of Hazardous Materials.

4. Occupational health and Safety Management System.

5. Disaster Management Plan.

4. 3.1. HAZARD IDENTIFICATION:

Risk is a probability that damage to life, health and/or the environment. Risk will occur as a result of

the hazard.

Hazard is an inherent property of a substance, agent, and source of energy or situation having

potential of causing undesirable consequences.

A. Project Hazards:

During project activity, establishment of building structure, material handling, handling of

mechanical equipment’s, working at height, handling of heavy materials etc.

B. Operation Hazards:

Handling and use of different hazardous chemicals, process operations involving high temperature,

high pressure, etc.

The probable hazards in the M/s. ICE MAKE REFRIGERATION Pvt. Ltd. are listed & described below.

Fire hazard due to leakage of chemicals like Polyol, MDI, etc.

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

motors, 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 .

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

The following are the various hazards considered during proposed expansion project.


1. Storage Hazard 2. Fire Hazard 3. Electrical Hazard 4. Mechanical Hazard 5. Material Handling 6. Toxic Gas Release Hazards 7. Explosion Hazards 8. Corrosion Hazards 9. Hazards due to structure fall 10. Fall Hazards / Working at Height 11. Hazards due to Natural Disaster 12. Hazards due to Bad House keeping 13. Hazards due to Bad illumination 14. Hazards due to Bad ventilation / confined space 15. Hazards at tank farm area 16. Hazards at switch yard area

4.3.1.1Storage Hazard:

The following chemicals are used and stored at M/s. ICE MAKE REFRIGERATION Pvt. Ltd. List of

Hazardous Chemicals to be used

No. Hazardous Chemical

name Falling under category of MSIHC Rules

Threshold

Quantity

in MT

Storage

Quantity

details

1 Polyol

1,1-dichloro-1-

fluoroethane (HCFC –

141b)

Tris (2-chloro-1-

methylethyl)

phosphate

Schedule 1 Part – 1 (a) Toxic chemicals

category 2 Highly toxic: LD50 >2000

mg/kg


category 2 Highly toxic: LD50 >5000

mg/kg


category 2 Highly toxic: LC50 >4.6 mg/l

- 16 MT

2 Diphenyl Methane Di-

isocyanate (MDI)

Sr. No. 109 of Group-2 Toxic Substance in

Schedule 3 Part I &Schedule 1 Part – 1 (a)

Toxic chemicals category 1 Extremely toxic:

LC50 0.49 mg/l

20 T for

rule 5,7-

9,13-15

18 MT


Types of Risk Associated With Different Types of Chemicals

Sr.

No.

Type of

Chemical

Name

Causes

1. Toxic

Chemicals

MDI

Polyol

Form vapor clouds or fumes having lower concentration are hazardous

then the flammable component. Organic solvents are toxic in nature.

4.3.1.2 Fire Hazard :

The condition of events like spillage and leakage of flammable material could leads to fire.

Equipment failures, presence of open flame or spark in the area, static charge accumulation, open

live cables and reaction between incompatible materials are some of the reasons which lead to the

occurrence of fire.

It should be clearly understood that when a liquid is used having flash point below or close to the

normal ambient temperature, it could lead to fire in suitable circumstances, liberate a sufficient

quantity of vapor to give rise to flammable mixtures with air.

The M/s. ICE MAKE REFRIGERATION Pvt. Ltd. uses Flammable chemicals (MDI , Polyol etc.). All

flammable liquid materials having very less inventory are to be stored in drums, whereas rest will be

stored in storage tanks having dykewall around them.

4.3.1.3 Electrical Hazard :

The circumstances of short circuit of wiring during operation of any electrical appliances, loose wiring

and static electricity could lead to electric as well as fire hazard.

HAZARDS DUE TO ELECTRIC SHORT CIRCUIT

Electric short circuit is possible because of any one or more of the following reasons :

(a) Loose wiring.

(b) Faulty equipment.

(c) Lack of earthing

(d) Choking

(e) Overheating.

Proper earthing, periodical checking of contacts, proper insulation of equipment, flame proof fitting

in solvent area, electrician to be provided

4.3.1.4 Mechanical Hazard :

The following mechanical hazards are considered during proposed project:

Handling of cranes, trolleys, construction machineries, dryers.

Handling of mechanical equipment’s like, drilling, shovel, forklift, etc.

Handling of raw material, MS sheet, and various mechanical accessories.


4.3.1.5 Material Handling :

Hazards in Manual as well as Mechanical handling of materials are identified as the chances of

accident due to loading, unloading and transportation of material.

4.3.1.6 Toxic Hazards :

The condition of ingestion, absorption and/or inhalation of toxic substances leads to toxic hazard.

The M/s. ICE MAKE REFRIGERATION Pvt. Ltd. Should have adequate provision of safety along with

personal protective equipment. Protective equipment’s like breathing apparatus, gloves, safety

glasses, etc. and emergency kit should be provided at various locations of the installation.

4.3.1.7 Explosion Hazards :

Release of energy in a rapid and uncontrolled manner gives rise to explosion. Identified locations

having explosion hazards are in solvent tank farm and storage area.

4.3.1.8 Corrosion Hazards :

Corrosion is a chemical reaction taking place at the surface of metal. Chemicals have their typical

hazard when it comes in contact with human tissues. Corrosive substances in contact with skin will

produce chemical burns, deep ulceration and dermatitis. This has also adverse effects on weakening

the strength of material in contact. At M/s. ICE MAKE REFRIGERATION Pvt. Ltd. Such type of

corrosive chemicals usage is very less or negligible.

4.3.1.9 Hazards due to structure fall :

Structural collapse is possible because of any one or more of the following reasons:

(a) Corrosion.

(b) Old structure.

(c) Heavy load.

(d) Extensive vibration.

(e) Heavy stress on structure.

To avoid the above, regular checking will be done by a competent authority in above case, if major

emergency may arise suddenly, the outside emergency services can be utilized.

4.3.1.10 Fall Hazards / Working at Height:

Falling from height is possible any where in the plant when workman is working at height without

safety belt.

Safety belt, helmet, safety platform will be provided at the time of work supervised.

4.3.1.11 Hazards due to Natural Disaster:

Earth quake, lightening, flood , sabotage --Lightening arrester, fire fighting equipment and PPEs

make ready, mutual aid, on site / off-site emergency plan to be activated.


4.3.1.12 Hazards due to Bad House keeping :

Minor or major injury is possible due to bad house keeping.

Proper handling, regular cleaning, proper placement of material should be observed in plant.

4.3.1.13 Hazards due to Bad illumination:

Due to bad illumination, proper vision may not be possible at working area, storage area, which has

potentiality to lead slip, fall, injury due to stuck with object etc. so ensure proper lighting facility at

each working area.

4.3.1.14 Hazards due to Bad ventilation / confined space :

Due to bad ventilation, respiratory problem due to presence of chemical vapor may happen, so

ensure proper ventilation and availability of fresh air at work place. Ensure proper cleaning of vessel

and availability of air by natural or artificial way, when required to work at confined space.

4.3.1.15 Hazards at tank farm area:

Due to lack of knowledge or awareness, smoking, heat or any other means possibility of fire or

release of chemicals may happen. Ensure provision of display Do’s and don’ts in local language at

storage area as well as availability of required proper Personal Protective Equipment’s, and person to

be trained properly.

4.3.1.16 Hazards at switch yard area:

Due to lack of knowledge or awareness, smoking, heat or any other means possibility of fire may

happen. Ensure provision of display Do’s and don’ts in local language at switch yard area as well as

availability of required proper Personal Protective Equipment’s, and person to be trained properly.

4.3.2 Risk Assessment & Hazard Mitigation Measures. Risk is the likely hood of an undesired event (i.e. accident, injury or death) occurring with a specified

period or under specified circumstances. It may be either a frequency or a probability depending on

the circumstances.

4.3.2.1 Risk Analysis

Risk Analysis is a technique that provides advanced identification of hazards, analysis, assessment, and control and management methods to identify the potential for such incidents and to evaluate risk reduction and control strategies. It identifies those areas where operation, engineering or management systems can be modified, and assessment of hazards and risk provide vital information to Risk Management.

LIMITATIONS OF RISK ASSESSMENT PLAN


The risk assessment study has following limitations.-

(a) Non-availability of norms for our Country. (b) Non-availability of correct analysis data. (c) High cost for getting expertise from foreign developed Countries. (d) Lack of expertise in our Country. (e) Difficulty of checking the final results with experiments. (f) Non-availability of past accident data about damages. (g) Complexity and laboriousness of the techniques. (h) Non-availability of acceptable criteria.

Risk analysis is a complex exercise and can be carried out to various depths. In order to satisfy the

scope the study has been divided into three phases as described herewith. The study has been

concentrated on identified hazardous chemicals presently being used as well to be used in proposed

products manufacturing.

Phase-I: Hazard Identification

Hazard identification is an essential first step in risk analysis. Identification of hazard is of vital

significance in the analysis, quantification and cost effective control of accident involving chemicals.

Identification of hazard comprises the following action:

Collection of relevant information for the proposed facility

Computation of hazard indices for screening of vulnerable units

The technique employed for hazard identification is MCA analysis, MCA stand for maximum credible

accident or in other words an accident with maximum damage distance which is believed to be

probable.

MCA analysis does not include quantification of the probability of occurrence of an accident. In

practice, the selection of accident scenario for MCA analysis is carried out on the basis of engineering

judgment and expertise in the field of risk analysis especially in accident analysis. Process

information study and relevant data would help in identification of hazard prone section of the plant.

Inventory analysis and fire and explosion and toxicity index and material, storage and transportation

of hazardous chemical rules of Government of India (GOI Rules -2000) are also the methods used in

hazard identification. Release of chemicals in the atmosphere from the storage section is studied by

building scenarios on the basis of properties of chemicals and consequence are calculated in terms of

damage distance. This study helps in plotting the damage contours on the detailed plot plan of the

unit in order to visualize the magnitude of occurrence of particular event.

Phase-II: Risk assessment and evaluation

Hazard prone areas are critically examined with an accent of quantification of hazard and it’s

evaluation with recourse to consequence analysis.


The accidental release scenario for the escape of hazardous chemicals have been visualized by

studying the process parameters such as properties of chemicals, operating condition etc. ranking of

each unit in hazard prone section is done based on fire and explosion index and toxicity index and

inventory analysis. The damage distance due to different accidental scenarios and over pressure has

been calculated to determine the area extent of damage.

Phase-III: Risk Mitigation Measures

The risk mitigation measures have been suggested based on MCA analysis for catastrophic failure.

The mitigation measures mainly consider the implementation of safety measures to improve the

safety aspects and risk factor as well as to reduce the consequence due to accidental release of

hazardous chemicals.

Based on risk and mitigation measures, the chances of occurrence of accidental release would be

significantly minimized.

Due to non-availability of failure rate data, reliability rate, gas dispersion rate, suitability of Industry

for Indian environment, acceptable criteria for risk to public and environment etc. the complete Risk

Assessment is not possible.

4.4 Worst Case Scenario:

In worst case scenario conditions, For projection of maximum effects due to release of chemicals is

considered by considering maximum amount of chemical leakage or at sudden release of all the

chemicals within a minute time, in the atmosphere, with considering meteorological data for

projection of probable loss of chemicals, release of fumes, vapor and area covered, number of

persons affected.

It is projection at project stage, to take preventive measures to avoid such type of incidents, at actual

level. It is also useful for training and awareness for company employee and surrounding village or

nearby people by giving proper information in prior, to take care of emergency in real condition.

4.5 Consequence Analysis:

In consequence analysis, numbers of calculation models are used to estimate the physical effects of

an accident (spill of hazardous material) and to predict the damage (lethality, injury, material

destruction) of the effects. These calculations can be roughly divided in to three major groups:

Determination of the source strength parameters.

Determination of the consequential effects.

Determination of the damage or damage distances.

The basic physical effect models consist of the following features.

A) Source Strength Parameters:

Calculation of the outflow of liquid, vapor 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.

B) 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 vapor 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, vapor, liquid, solid.

Inflammable, explosive, toxic, toxic combustion products.

Stored at high/low temperatures or pressure.

Controlled outflow (pump capacity) or catastrophic failure.

C) 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.

1) 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 1st 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.

2) Explosion :

In case of vapor 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 0.1bar 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 Moderate Damage

0.03 bar 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 center.

3) Intoxication :

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

This dose D is basically determined by:

Concentration of the vapor 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 vapor, 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.

4.6 Maximum Credible Accident ( MCA )

In any plant, the various hazards arise due to improper storage& handling of hazardous chemicals. If

these chemicals are released into the atmosphere, they may cause damage due to resulting fires or

vapor clouds. The following are the important factors which can lead to the consequences of hazard.

A) Operating Parameters :

Potential vapor 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, i.e. if we take up an example of ammonia, if it is stored at ambient temperature, say 30oC,

and then the vapor release potential of the inventory is much higher as compared to the case if it is

stored at 0oC.

B) 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 vapor 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 vapor source strength estimated for each release case, a ranking should become a

credible exercise.

C) 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 will depend 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 vaporization of released liquid depends on the vapor

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.

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 3.0 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 judgment, the cases have been found to be credible and modeling 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.

Consequence Analysis Calculations:

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

conditions having wind speed 3.0m/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.

Software Used for Calculations :

ALOHA (Areal Locations of Hazardous Atmospheres): Aloha is a computer program designed

especially for use by people responding to chemical accidents, as well as for emergency planning and

training. ALOHA can predict the rates at which chemical vapors may escape into the atmosphere

from broken gas pipes, leaking tanks, and evaporating puddles. It can then predict how a hazardous

gas cloud might disperse in the atmosphere after an accidental chemical release.

ALOHA is an air dispersion model, which you can use as a tool for predicting the movement and

dispersion of gases. It predicts pollutant concentrations downwind from the source of a spill, taking

into consideration the physical characteristics of the spilled material. ALOHA also accounts for some

of the physical characteristics of the release site, weather conditions, and the circumstances of the


release. Like many computer programs, it can solve problems rapidly and provide results in a

graphic, easy-to-use format. This can be helpful during an emergency response or planning for such a

response.

ALOHA provides output as amount of chemical discharged from the source as well as its

concentration in air it takes in to account different levels of concentrations for a specified chemical.

Different concentration levels are given below:

ERPG 1:It is the maximum airborne concentration below which it is believed that nearly all

individuals could be exposed for up to 1 hour without experiencing other than mild transient adverse

health effects or perceiving a clearly defined, objectionable odor.

ERPG 2: It is the maximum airborne concentration below which it is believed that nearly all

individuals could be exposed for up to 1 hour without experiencing or developing irreversible or

other serious health effects or symptoms which could impair an individual's ability to take protective

action.

ERPG 3: It is the maximum airborne concentration below which it is believed that nearly all

individuals could be exposed for up to 1 hour without experiencing or developing life-threatening

health effects.

IDLH: The Immediately Dangerous to Life or Health (IDLH) level. A chemical's IDLH is an estimate of

the maximum concentration in the air to which a healthy worker could be exposed without suffering

permanent or escape-impairing health effects.

Scenario:

Possible Accident Scenarios at M/s. ICE MAKE REFRIGERATION Pvt. Ltd.

Scenario* MCL Pressure Temp. Qty.

1 Release of Polyol Ambient Ambient 225

liters

Worst Case Scenario

Scenario MCL Red

Zone,meter

Orange

Zone, meter

Yellow

Zone, meter Remarks

1 Release of Polyol 82 114 155

Detailed Summary of Results:

Detailed Results of the consequence analysis of above-mentioned scenarios have been given below:


4.6.1 Release of Polyol

This scenario considers release of Polyol from Polyol Storage Drum :

TEXT SUMMARY OF MODEL FROM ALOHA® 5.4 :

Site Data :

Location : M/s. ICE MAKE REFRIGERATION Pvt. Ltd. Dantali Industrial Estate , Dist. Gandhinagar

Building Air Exchanges Per Hour : 0.75 (unsheltered single storied)

Time : October 17, 2015 1159 hours ST (user specified)

Chemical Data :

Chemical Name: Polyol ,MolecularWeight: 116.95 g/mol

AEGL-1: 1000 ppm AEGL-2: 1700ppm AEGL-3: 3000 ppm

Ambient Boiling Point: 30.3 °C

Atmospheric Data : (Manual Input of Data)

Wind: 3 meters/second from NE at 3 meters

Ground Roughness: open country Cloud Cover: 5 tenths

Air Temperature: 27°C Stability Class: C

No Inversion Height Relative Humidity: 50%

Source Strength :

Direct Source :225 liters ,Source Height : 0.0 m

Release Duration : 1 minutes

Release Rate : 4.61 kilograms/sec

Total Amount Released :277.0 kilograms


Result :

Estimated maximum distance is 155 m from the source of release from the Drum

source, which is within factory premises. Persons handled will be trained accordingly.

Preventative Measures:

Some of the preventative measures that will be undertaken to avoid the occurrence of this type of

incident include:

Handling by trained experienced personnel only.

Stored in a tightly closed container in a shaded area.

Use of safe operating procedures for handling.

Chemical to be stored under adequate safe conditions.

Area will be barricaded, only authorized person entry, no smoking board, DCP type fire

extinguisher to be provided.

Probable affected person will be aware/educate about probable hazard risk and response in

case of emergency. First-Aid facility will be provided with trained person availability and all


required contents.

Flameproof electrical fittings will be used at chemical storage area.

Equipment’s containing the material will be grounded to prevent static electricity.

Onsite emergency plan will be prepared and mock drill will be carried out.

Safety sign board displaying Do’s and Don’ts at work place and storage area in local language,

MSDS will be made available.

Proper and effective Personal Protective Equipment’s will be provided.

Highly controlled and closely monitored operations.

Remedial Actions and Recommendations:

• Spare tank provided to transfer the material in case of leak.

• Stock of dry sand & lime is kept near the storage area,

• Provision of Respiratory protective equipment & personal protective equipment,

• Safety shower & eye wash unit installed.

• Strict supervision while unloading, regular testing & inspection of tanks

Evacuate the affected area.


4.7 – Preventive control Measures to avoid/Control Worst Case Scenario and

MCA ( Maximum Credible Accident ) Scenario

We have considered or assumed worst case scenario modeling for preparedness of Emergency

situation only.

Polyol will be stored at isolated storage area , so there will not be any possibility of seepage and

will be stored with provision of Dyke wall facility and emergency storage tank, and necessary

precautions.

Polyol

• Spare tank provided to transfer the material in case of leak. • Stock of dry sand & lime is kept near the storage area, • Provision of Respiratory protective equipment’s & personal protective equipment’s, • Safety shower & eye wash unit installed. • Strict supervision while unloading, regular testing & inspection of tanks

4.7 RISK ASSESSMENT BY 3X3 MATRIX

4.7.1 Types of Accidents likely to be happen during Construction, Operation phase and Waste disposal phase of Expansion Project.

Sr.

No.

Potential

Hazard

Sub

Hazard

Risk Assessment Control Measures

Severity Probability Risk

1. Injury due

to forklift

Body

Injury

Serious Highly

Unlikely

Moderate 1. Proper maintenance of forklift shall be done.

2. Container

fall from

forklift &

material

spillage

Eye

Contact

Serious Highly

Unlikely

Moderate 1. Proper personnel protective equipment like gloves, goggles, apron, helmet, gumboot etc. will be provided.

2. Inert material (e.g., vermiculite, dry sand or earth) will be provided which can absorb the chemicals leaked or spilled.

3. Eye washer &

Skin

contact

Moderate Unlikely Moderate

Inhalation Minor Highly

Unlikely

Minor

Slip & Fall Serious Highly

Unlikely

Moderate

3. Leakage

from

Eye

contact

Serious Highly

Unlikely

Moderate


container Inhalation Minor Unlikely Minor shower will be provided.

Skin

contact

Minor Highly

Unlikely

Minor

4. Electrical

shock

circuit

Fire, Injury

& Loss of

property

Serious Highly

Unlikely

Major 1. Proper enclosure of Electrical equipments with earthing will be provided.

5. Fall from

height

Injury Serious Highly

Unlikely

Major 1. Provide training to the workers and employee to handle the worst scenario.

2. Providing Working plateform and Safety Harness

6 Fire Fire Serious Highly

Unlikely

Moderate 1.Provide training to the workers and employee to handle the worst scenario. 2.Use spark-proof equipment during handling. 3. Fire Fighting system and trained worker

Toxic Liquids

a) Name of the Chemicals associated with the risk: Polyol , MDI

b) Type of Associated Activity: Handling, storage and process

c) Type of Storage: Carboys/Drums/MS, Glass Bottle, under ground storage tank


Sr.

No.

Potential

Hazard

Sub

Hazard

Risk Assessment Control Measures

Severity Probability Risk

1. Drum/

Carboys Falling

From Palette

from height or

loading

/unloading

material to

tank via pump

Injury Moderate Unlikely Moderate 1. Proper personnel protective equipment like gloves, goggles, apron, helmet, gumboot etc. will be provided.


3. Good quality palate should be used.

Spillage Moderate Unlikely Minor

2. Leakage from

drums/carboys

Eye

contact

Serious Unlikely Moderate 1. Proper personnel protective equipment like gloves, goggles, apron, helmet, gumboot etc. will be provided.


Inhalation

of vapour


Skin

contact


3. Escape of

Vapor from

during

handling

Inhalation

of Vapor

Minor Likely Moderate 1. Proper ventilation should be provided to allow escaping the vapor fumes.

2. Flameproof Electrical equipment & safety gadgets like fire extinguisher should be provided.

Fire Serious Highly

unlikely

Moderate

4. Injury due to

Forklift

Body

Injury

Serious Highly

Unlikely

Moderate 1. Proper maintenance of forklift shall be done.

Risk assessed is found “MODERATE” and “TOLERABLE”, hence it has been considered that the effect of

incident for said services is restricted within the premises. However, necessary control measures will be

provided.


4.7.2 Health Effects (including occupational diseases or poisoning ) likely to be happen during Construction, Operation phase and Waste disposal phase of Expansion Project.

During construction phase, manpower will be arranged locally, si they used to reside at their nearby

premises, so water will be available and sanitary facility will be also available.

During operation phase and disposal phase, fresh drinking water facility is available at company

premises, sanitary facility is also available at premises, and First-Aid center is also available at

premises and tie up with other doctors on need basis to cope up with any type of emergency.

4.7.3. Accident Record (Accidents during last five years)

As such no previous accidents records are available, but will manage to maintain accidents record

now onwards. But from available information, no such major accidents were reported; only two

minor incidents were reported, of cut injury.

4.7.4 Occupational Diseases Record ( during last five years )

No such incident recorded.

4.8 PREVENTIVE AND CONTROL MEASURES:

4.8.1 General Recommendations for Storages:

Main Risk prevailing at storage tank is Fire, Following measures shall be ensured for prevention/

control of fire at storage tanks.

Availability of water supply

Foam system

First aid appliances

Secondary containment for the storage of hazardous chemicals.

Toxic and flammable gas leak detection , alarm and control system

Critical switches and alarm should be always kept in line.

Fire extinguishers should be tested periodically and should be always kept in operational

mode.

Fire detectors should be installed near those points which handle large amount of explosive

material and operate under high temperature and pressure.

Shut off and isolation valves should be easily approachable in emergencies.

Surrounding population (includes all strata of society) should be made aware of the safety

precautions to be taken in the event of any mishap within the plant. This can effectively be

done by conducting the training programs.

A wind direction pointer should also be installed at storage site, so that in an emergency the

wind direction can be directly seen and downwind population can be cautioned.


The fire protection equipment shall be kept in good operating condition at all time and fire

fighting system should be periodically tested for proper functioning and logged for record and

corrective actions.

Fire alarm system

Fire exit for escape

Persons to be trained for handling any type of emergencies.

Persons to be trained for use of fire extinguisher, fire control system.

First –Aid training to be provided to every employee, and necessary first –aid facility with anti

dotes to be kept ready.

Alternate power availability ( D.G.Set )

Provision of railing for height area , with toe guard

Earthing provision , for flange joint

Provision of proper heat insulation

Noise Control facility , or PPEs

Interlock system for storage tanks and vessels

Machine guarding


4.8.2 Do’s and Don’t’s for Handling of Chemicals, Material Handling, Fire Prevention and Housekeeping are as under:


4.8.3 Recommendations for Polyol , MDI & Diesel Storage and Handling :

Handling and Storage :

Prior to working, person has to be trained on its proper handling and storage.

A regulated, marked area should be established.

It must be stored to avoid contact with even small amounts of incompatible substances.

Store in tightly closed containers in a cool well-ventilated area away from Heat, Sparks, or

Sunlight.

Sources of ignition such as smoking and open flames are prohibited.

Use only non-sparking tools and equipment, especially when opening and closing containers.

Wherever required, use explosion-proof electrical equipment and fittings.

Hazards cannot be eliminated totally in any activity. They can be only controlled and at the most can

be minimized. Risk associated with any activity is directly proportional to the hazard control

procedures and arrangements.

Spill, Leak and Emergencies:

Restrict person not wearing protective equipment from area of spill or leak until clean-up is

complete.

Do not touch the spilled material; stop the leak if it is possible to do so without risk.

Notify safety personnel.

Remove all sources of heat and ignition.

Ventilate the area of the spill or leak.

Trips and alarms for any leakage or spillage

Fire Hazards:

Fight a fire from an explosion-resistant location. Use dry chemical, CO2, water spray, or foam

extinguishers.

If employees are expected to fight fires, they must be trained and equipped as per statutory

guidelines.

Ways of Reducing Exposure :

Post hazard and warning information in the work area.

As part of an ongoing education and training effort communicate all information on the

health and safety hazards of all used chemicals at work place in local language, to potentially

exposed workers.

Fire Fighting Measures:

These materials are delivered, stored, and used at temperatures above their flash point.

Avoid all naked flames, sparks, cigarettes etc.

In case of fire immediately alert the fire brigade.

Ensure an escape path is always available from any fire.


If gas has ignited, do not attempt to extinguish, but stop gas flow and allow burning out. Use

water spray to cool heat-exposed containers, and to protect surrounding areas and

personnel.

Every precaution must be taken to keep containers cool to avoid the possibility of a boiling

liquid expanding vapor explosion (BLEVE).

Control and Prevention of Fire:

Fire Fighting Arrangements:

The Premises shall be provided with fire system and various types of portable fire

extinguishers namely Dry Chemical Powder type, Foam type and CO2 type, to face any

emergency arising due to the occurrence of fire.

FIRE SYSTEM

The fire system should be installed as per Authority guidelines.

FIRE EXTINGUISHERS

Sufficient number of fire extinguishers should be installed in the unit as per Indian Standards

and as per Factories Act.

The following steps shall be considered to prevent fire consequences during any stage of

material handling, operation or any other unexpected leakage.

Proper earthling connections for the all the equipment, i.e. lines and similar operations will

be given.

All the electrical connections will do with flameproof fittings.

Fire system & various types (DCP, CO2) of fire extinguisher will be installed as per Indian

standards.

Detail study will be carried out for finding all the source of ignition while handling the

flammable materials.

All the pipelines will be providing suitable earthing to handle static charges safely.

Only SS braided hose will be used for safe transferring of flammable materials.

Utmost care will be taken to avoid source of spark or shifting of cylinders, when flammable

materials transferring are on.

The storage area will have barbed wire fencing with a main gate.

The storage tanks will be provided with flame arrester.

The approval will be taken from concerning authority for storage, handling and use of

hazardous materials.

Extinguishing Media :

A) Large fire:

Product flow must be stopped and container cooled by water spray. Water fog should be

used to assist approach to the source of the fire. Large fires should only be fought by the Fire

Brigade.


B) Small fire :

Dry Powder.

Do not use water or foam.

Special Protective Equipment for Fire Fighters :

In confined spaces use self-contained breathing apparatus

Hazardous Combustion Products.

Incomplete combustion may form carbon monoxide.

A) Immediate Emergency Action :

Clear people away from the area to a safe place.

Do not operate electrical equipment unless flameproof.

Summon the emergency services.

Treat or refer casualties if necessary.

B) In case of Fire :

Stop Product flow.

Use dry powder or carbon dioxide extinguishers.

Cool containers exposed to fire by using water / fog spray.

C) In case of Spillage :

If Safe:

Extinguish all naked lights – Avoid making sparks.

Position firefighting equipment.

Try to stop flow of liquid product.

Cover drains and disperse vapor with water spray.

Prevention and Control of Electrical Hazard:

All electrical installation shall be as per The Indian Electricity Act, 1910 The Indian Electricity

Rules, 1956.

The ELCB will be installed for human safety as and when required.

Prevention/Mitigation/Control of Mechanical Hazard :

All the installation shall be as per the related standards and codes.

All the rotating parts will be guarded properly.

The following general precautions should be taken during the project – Construction and

operational stages.

Regular testing of equipments as per Form No. 9, 10, 11 of Factory Act.

Plants should be designed as partly R.C.C and Steel Structure.


Precautions duringMaterial Handling:

A) Precaution during Manual Handling–

Adult worker will be appointed. For carrying weight, carrying capacity will be considered for lifting

weight. Child and Female worker will be avoided for such type of job.

B) Precaution during Mechanical Handling -

All tools and tackles used for material handling should be inspected, checked and maintained by

qualified person.

The records in Form No. 10 containing particulars of examination specifying safe working load should

be maintained.

Solvents will be stored and handled as per PESO guideline .The certified engineers test the safety

valves every year for their efficiency. The records of certificates are maintained.

Precautions during Toxic Gas Release/Explosion Hazards/Corrosion Hazards:

As there are toxic, corrosive and explosive natures chemicals are used, some precautions are

suggested as below.

A) Preventative Measures :

Some of the preventative measures being undertaken to avoid the occurrence of this type of

incident include:

Regular testing and inspection of tanks (mechanical, electrical, earthing etc.).

Regular maintenance

Provision for remote switches for remote cut-off.

Compatibility of material will be checked before storage.

Proper control system like, level indicator, pressure gauge, temperature indicator, dyke wall

will be ensured.

Anti corrosive paints at regular interval during maintenance of plant / shut down.

Training to person handling chemicals.

Ensure proper and sufficient Personal Protective Equipments are available.

B) Storage and Handling of Hazardous Chemicals :

The properties of the important materials and the safety precautions to be taken to prevent an

accident are as per Material Safety Data Sheet of each chemical used.

The details of storage of Hazardous Chemicals along with measures taken during storage are

prescribed in following paragraphs.

C) Health & Safety Measures :

M/s. ICE MAKE REFRIGERATION Pvt. Ltd. Dantali Industrial Estate , Dist. Gandhinagar is handling

hazardous chemicals and to take care of employee’s health, : M/s. ICE MAKE REFRIGERATION Pvt.


Ltd. has adopted practice of preventive and predictive maintenance looking to the nature of

hazardous chemicals being handled / processed. All the equipments in the plant areas are being

inspected / tested by an outside agency.

4.8.4 CONTROL MEASURES THROUGH SAFETY MANAGEMENT SYSTEM:

The various safety equipments like breathing apparatus and critical instrumentation provided on

various equipments are inspected and tested frequently to ensure their operability all the time.

Besides, all the first aid fire fighting devices are also inspected, tested and maintained by a

competent third party and kept all the time in ready to use condition.

Health of all the employees in plant area is being regularly monitored by outside physician. If any

abnormality is found necessary treatment is also being given time to time. Necessary history cards,

records are also being maintained which is up-dated time to time.

Some of the safety measures carried out by Industries to ensure prevention of occupational hazards

is delineated below.

Toxic gas or LEL detectors with alarm and automatic fire fighting systems should be made

available.

Tanks and all pump motors are earthed.

Independent dykes have been provided for hazardous chemicals storage to contain leakages.

Floors of the dyke area have impervious finish.

Housekeeping of the plant is as per prescribed norms. Floors, platforms, staircases, passages are

kept free of any obstruction.

All hazardous operations are explained to the workers. They are periodically trained on the

hazardous processes.

Only authorized persons are allowed inside the plant.

All instrument and safety devices are checked and calibrated during installation. They are also

calibrated, checked at a frequent interval. Calibration records are maintained.

All electrical equipments are installed as per prescribed standards.

All the equipments of the plant are periodically tested as per standard and results are

documented. All equipments undergo preventive maintenance schedule.

The area is fenced to isolate the same from all other departments.

Proper Earthing is provided to each tank. Also earthing is taken care during solvent transfer from

tanker into the underground vessel.

Flameproof pumps & motors are provided for solvent transfer.

Pressure gauge is provided on each tank. The solvents are stored at normal temperature and

pressure.

D.G. Sets are also available which can supply power in case of grid power failure.

Fire extinguishers are installed at different locations within premises.

Adequate ventilation arrangement has been is provided for safe and better working in the plant

as per the standard.


Process, equipments, plant involving serious fire hazards are designed as per prescribed

guideline.

Sufficient access for firefighting is existing in the plant

Protection against lightning is taken care in the plant.

Precaution against ignition has been taken.

Flammable liquids are stored in tank farm adequate safety measures are provided in tank farm

the area.

General Precaution to mitigate hazard following should be considered.

1) Factory Layout

2) Medical services

3) Safety services

4) Engineering services

4.8.4.1 Factory Layout:

All plant building up to 4.5 mt. levels will have two-exit route connected by approach roads from

plants. Storage tanks of hazardous chemicals will be located away in an isolated area called tank farm

area.

4.8.4.2 Medical Services:

Planned to avail the services of Nearby Hospital. In addition arrangements should be made for

emergency vehicle. List of Anti dotes should be available.

Medical Checkups :

The services of nearby Hospital for pre-employment medical examination should be availed. To

arrange render medical assistance during any emergency.

A detailed bi- annual medical check-up of the employees will also be carried out to detect any

symptoms of health hazards. Records of all these medical checkups should be properly

maintained.

First Aid Boxes :

First aid boxes should be provided at proper place, which will regularly inspect and maintained.

4.8.4.3 Safety Services:

Safety department should be looked after by Manager. Planning, organizing, directing, placement,

inspections and implementation of the company s safety aspects and strategy are the Key Result

Areas of the safety dept. in the safety related activities of the company.

List of safety appliances should be available with safety dept:

Self Contained Breathing Apparatus

Canister type gas masks

Dust masks

Safety Goggles

Helmets

Acid / Alkali proof hand gloves


Safety Shoes

Face Shield

Apron

Rope ladders

4.8.4..4 Engineering Services:

Engineering services comprise mechanical, electrical, civil and instrumentation areas. They play a

vital role in emergencies arising from material spillages fire or explosion. Mechanical maintenance

group possess all equipments like chain pulley blocks, wire ropes, tools and tackles, which will

require in handling any emergency situations.

The following are the various methods for mitigation of hazards :

A) Maintenance and inspection schedules,

Regular maintenance and preventive maintenance should be carried out as per schedule. The high-

pressure storage tank thickness should be tested by the outside agency after every six months. The

crane system will also tested by the competent person after every 6 months.

B) Description of responsibility for plant safety,

Safety committee should be form which comprises of senior persons with officers & workers from

each field. This committee should be meet minimum once in every three months. The points raised

in the committee should be implemented based on the evaluation.

C) Work permits system

The meaning of work permit is the permit or approval for the work other than the manufacturing

process or routine manufacturing jobs.

This is one type of accident prevention technique. The main objectives of the permit systems are as

follows,

To ensure the safe working place

To ensure that all necessary precautions are taken

To prevent the human error

To prevent the unsafe condition

To prevent the incidents / accidents

To give information to the plant personnel

To make the hazardous operations smooth and tension free

The various work permits should be introduced according to the requirement.

4.8.4.5 Mitigation Measures during Manufacturing Activity:

The key strategy for managing the potential risks associated during manufacturing activity will be the

development and implementation of the following actions, policies and procedures.


Facilities and Resources:

Chemical storage facilities to comply with relevant legislation, standards, building codes as well as

codes of practice with regard provision of ventilation and separation requirements;

Sufficient quantities of spill response equipment for containing and cleaning up chemical and fuel

spills; and

Fire equipment to comply with relevant legislation, standards, building codes as well as codes of

practice.

Management Policies, Plans &Procedures:

Incident Reporting Policy

Fire Action Plan (including preventative measures)

Environmental Management Plan

Maintenance Schedule

Spill Response Procedures

Training:

Chemical storage (separation and ventilation requirements), handling (reading labels, MSDS etc)

and response (spill containment and clean up);

Oil spill containment and clean-up;

Fire safety (identifying and managing fire risks and suppression techniques);

Incident reporting

Operation of equipment

Maintenance:

Inspect and maintain equipments as per legal requirements (fire equipment), the maintenance

schedule (machinery, facilities vehicles and tools) and documented procedures (spill response

equipment and chemical stores); and

The routine inspection and monitoring of equipments.

4.9 The salient features of the Storage & Handling of Hazardous Materials.

In Factory lay out plan, we have shown the place where the raw materials including hazardous

substances are stored.

The complete details regarding hazardous raw material, are given in the following tables. Where as

the complete details regarding material identification, their use, hazardous ingredients of material,

physical data for material, fire and explosion hazard of material, reactivity data, toxicological

properties of material, personal protective method and first aid measures is given in the enclosed

Annexure – (MSDS).

Release of explosive and flammable chemicals and may create emergency if proper precautionary

measures are not taken.


Details of Storage of all chemicals are as under:

Polyol / MDI

• Spare tank provided to transfer the material in case of leak.

• Stock of dry sand & lime is kept near the storage area,

• Provision of Respiratory protective equipments& personal protective equipments,

• Safety shower & eye wash unit installed.

• Strict supervision while unloading, regular testing & inspection of tanks


ANNEXURE 2: Hazardous Characteristics and toxicity of raw materials and products and

proposed measures to control it.

No Products and Raw Materials Hazards Identification Exposure Control

1 MDI

Inhalation Harmful by inhalation, May cause

sensitization by inhalation,

Danger of serious damage to

health by prolonged exposure

through inhalation.

Respiratory

Protection

Respirators

Skin Contact Limited evidence of a skin contact.

Skin Protection Gloves,

Eye Contact Irritation, Eye Protection Safety goggles

Ingestion Limited evidence of a carcinogenic effect.

Ventilation

requirements

Provide local exhaust

2 Polyol ,

. Carcinogenicity: This product and its constituents are not listed as carcinogens by IARC, NTP or regulated as carcinogens by OSHA at this time.

Inhalation Nausea, irritation of digestive track. Irritation of respiratory system.,

Airborne aerosols or vapors from heated material may cause severe respiratory system irritation.

Gas Mask

Skin Contact Rash, redness, may cause severe skin irritation, may cause allergic skin reactions in some individuals. Slightly toxic by skin absorption , Constant exposure to skin may cause chronic dermatitis. Other chronic effects are unknown.

Avoid direct contact , hand gloves


Eye Contact Redness and irritation, may cause severe eye irritation

Safety goggles

Ingestion May cause irritation of gastrointestinal track and nausea.

Hand gloves , cleaning facility

No Exposure Source Control Measures

1 Respiratory Protection Wear NIOSH approved Respirator

2 Skin Protection Gloves, Flame retardant antistatic protective clothing

3 Eye Protection Dust proof goggles

4 Engineering Controls Provide local exhaust, dust collection system

5 Specific Hygiene Measures Washing after handling the material and before eating,

drinking. No smoking. Routinely wash work clothing and

protective equipment to remove contaminants


PPE Matrix as on today

- Above are the existing and proposed PPE distribution list based on hazards exposure.

No. Department Identified

Contaminant

No. of

exposed

workers

PPE provided to each workers

1 Production ---- 30 Dust Masks , Safety Goggles and Safety shoes

2 New Production MDI , Polyol 4 Dust mask, Safety Goggles , Apron , Safety Gloves

3 Boiler SPM 6 Helmet , Dust Masks , Safety Goggles , Safety Shoes , Safety Gloves , Apron

4 Cutting ,

finishing

RSPM 10 Helmets , Dust Masks , Safety Goggles , Safety Gloves , Safety Shoes

5 ETP RSPM 1 Helmet , Dust Masks , Safety Shoes , Safety Gloves , Safety Goggles

6 Laboratory Formaldehyde 2 Dust Masks , Safety Gloves , Apron, Safety Goggles , Safety Shoes

7 Office Staff Formaldehyde 20 Dust Masks


TABLE A: IMPORTANT CHARACTERISTICS OF HAZARDOUS MATERIALS

No. Hazardous

Chemical

name

Stored

Qty. ,

MT

Hazard Rating

System

Type of Hazard/Risk

Involved

Persons Affected

Control Measures

1 Polyol (

Toxic and

flammable

Liquid )

(1) 16 Threshold Limit Value: Not established by ACGIH or OSHA HMIS HEALTH 1, FIRE 1, REACTIVITY 0 Flash Point 350oF (175oC) TCC.

Toxic when contact

with skin

Cause Burns

Toxic , if swallowed

Irritating to skin ,

eys and respiratory

system

Flammable

Operators , Technicians

Supervisors

Maintenance

People

Nearby

Working/residing

People

Dyke provision to storage tank

Display of Safety Board @ Tank

Availability of First-Aid Kit

Availability of SCBA

Use of Safety shoes, Safety goggles, Safety goggles

while handlling

Spare tank provided to transfer the material in case

of leak. Stock of dry sand & lime is kept near the

storage area, provision of Respiratory protective

equipments & personal protective equipments,

Safety shower & eye wash unit installed. Strict

supervision while unloading, regular testing &

inspection of tank

2 MDI

( Corrosive

liquid and

non

flammable )

18

Assessment of acute toxicity: Virtually nontoxic after a single ingestion. Virtually nontoxic after a single skin contact. Of moderate toxicity after short-term inhalation.

Highly flammable

Toxic when contact

with skin

Toxic by inhalation

Toxic , if swallowed

Danger of very

serious irreversible

effects

Operators , Technicians

Supervisors

Maintenance

People

Nearby

Working/residing

Keep away source of ignition.

Dyke provision to storage tank

Display of Safety Board @ Tank

Provision of ventilation

Availability og First-Aid Kit

Availability of SCBA

Availability of Fire Extinguisher and Fire Hydrant

system

Use of Safety shoes, Safety goggles, Safety goggles

while handlling

Frequent inspections, nosmoking–spark– ignition


LD50 rat (oral): > 10,000 mg/kg LC50 rat (by inhalation): approx. 0.493 mg/l 4 h LD50 rabbit (dermal): > 10,000 mg/kg

Non-flammable

People on Open flame in the vicinity &

Provided Hose pipe with sufficient length to Fight

fire from distance.

Safe operating practices are introduced

Dry sand near tank to contain leak.

Spare tanks/drums provided

Project status ‐ Tick mark [√] (a) New [], (b) Expansion [√], (c) Project mix [ ]

Sr. No.

Full name of product

State : Solid, Liquid or Gas

No of container and size

Main properties (refer MSDS, Sch‐9 of MSIHC Rules)

No MT B.P. °C

F.P. °C

LEL

UEL %

LC50

mg/kg

LD50

mg/kg -oral

LD50 mg/L -dermal

Specific Gravity (Water =

1)

Vapor Density (Air = 1)

1 2 3 4 5 6 7 8 9 10 11 12

1. Polyol Liquid 0.2 x 80

16MT > 150 °C 160°C

LEL – 5.6

UEL – 17.7

--- >2000

and > 5000

1.11 N.A.

2. MDI Liquid 0.2 x 90

18MT

200 °C > 204 °C

N.A. 0.493 >10,000 1.22 8.5


The Material Safety Data Sheets of the important hazardous material are attached as Annexure - A.

Sr.

No

Dist. in meter

Environment

(neighbor ing

factory,

residential

colony, village

etc)

Population with composition Possible consequence & Assessment Types of control

Day time Night time Risk assessment measures

Healthy

Vuln

erab

le

Total Health

y

Vuln

erab

le

Total Type of

risk &

effect

possible

Dura

tion of

risk

No.of

people,

property

may be

affected

Frequ

ency of

the

hazard

Accept

able

criteria

Available

in the

factory

Required

from

outside

1 50 Own premises 10 0 10 5 0 5 Small

leak of

MDI ,

Polyol

Fire –

very less

possibilit

y .

10

Mts

05 person

may be

affected,

Property

not affect

Not

recorde

d so far

Not

recorde

d so far

NIL

but care is

required.

NIL

but care is

required

Fire

extinguish

er

Sand

Bags

Fire

brigade

Mansa

2 100 Own premises 50 5 55 30 2 32

3 500 Estate /Public

road

300 40 340 150 20 170

5 1 k.m. Whole Estate/

Dantli village

1000 400 1400 1000 200 1200

5 2 k.m. Dantali village 7000 800 7800 3000 200 3200


4.9 OCCUPATIONAL HEALTH AND SAFETY MANAGEMENT SYSTEM:

M/s. ICE MAKE REFRIGERATION Pvt. Ltd. Dantali Industrial Estate , Dist. Gandhinagar is

committed towards the Health and Safety of workers and provided a facility of pre medical

and regular medical check-up of employees for detecting any kind of adverse effect on the

health of employee due to the chemical or work place condition and providing opportunity

to improve the working condition.

The workers exposed to fugitive emission will be provided with some protective devices like

dust mask to prevent respiratory disorders. The workers exposed to higher noise level will

be provided with ear muffs/ ear plugs.

The protective devices will be provided to the employees handling hazardous substances.

Proper handling of the hazardous chemicals and the maintenance of Material Safety Data

Sheet (MSDS) will be followed to ensure safety within the plant area.

Drinking water supply for the employees will be provided by the project proponent and the

standard of the drinking water will be per WHO guidelines. Proper sanitary facilities will be

made available by the project proponent so that employees do not suffer from any health

ailments.

The employees will be made aware of general sanitary practices. Periodical training

programme to inform the employees about their task, associated risk, and safe-working

practices will be undertaken.

Training will also include information on accident prevention, proper control and

maintenance of equipment and safe material handling practices.

A regular monitoring of the Occupational Health and Safety will reduce the chances of

accidents hence all the records of job related accidents and illness should be maintained as

per the requirements of factory act. This information will be reviewed and evaluated to

improve the effectiveness of Environmental Health and Safety programme.

The following occupational measures will be adopted:

The workers will be provided with personal protective equipment’s such as gloves,

goggles, safety shoes, helmets and dust masks.

Periodic medical checkup of the workers for audiometric, blood tests, physical

examination, etc. as per applicable rules.

First aid medical facility will be made available at the site and medical kit will be made

available at strategic location and plant personnel will be trained for first aid medical

treatment.

Dispensary and medical facility is available in the nearby GIDC area and that will be

utilized in the case of emergency. However. The company will appoint one doctor for

further consultation and treatment in case of emergency.


Plan will be made and sufficient fund will be allocated to ensure the occupational

health & safety of all contract and casual workers.

Details of exposure specific health status evaluation of worker , if required. workers'

health will be evaluated by pre designed format, chest x rays, Audiometry,

Spirometry, Vision testing (Far & Near vision, colour vision and any other ocular

defect) ECG, during pre placement and periodical examinations by qualified prson.

Details of existing Occupational & Safety Hazards – As there is no any such chemical

hazards, involved. Only material handling and mechanical and electrical hazards

involved , which is covered under existing health hazards and illness , as per OHSAS

requirement.

Exposure levels of hazards and whether they are within Permissible Exposure level

(PEL). If these are not within PEL, what measures the company has adopted to keep

them within PEL so that health of the workers can be preserved – Work place

monitoring is carried out to check exposure level as per Factory Act , Form no.37 ,

and will also be carried out after expansion.

Annual report of heath status of workers with special reference to Occupational

Health and Safety, submitted to Factory inspector office in prescribed format.


Annexure – A

MSDS

Of

Hazardous

Chemicals


Annexure – A - MSDS

1. Polyol

1,1-dichloro-1-fluoroethane (HCFC – 141b)

Tris (2-chloro-1-methylethyl) phosphate

2. Diphenyl Methane Di-isocyanate (MDI)


Material Safety Data Sheet – Polyol 1. PRODUCT AND COMPANY IDENTIFICATION Manufacturers Name: Development Associates, Inc. Emergency Phone No: Chemtrec (800) 424-9300 24 Hour Product Name: Z7500 Part A Chemical Family/Name: Polyesterglycol,Polypropyleneglycol, and additive mixture.

2. COMPOSITION / INGREDIENT INFORMATION Component CAS # % Exposure limits(source) Polyester polyol trade secret 40-60 none(5) Polyether polyol trade secret 40-60 none(5) Additive Mixture trade secret 0-5 none(5) Source of Exposure Limit Data: 1 ACGIH Threshold Limit Values 2. Federal OSHA Permissible exposure limit 3. DA Exposure Guidelines 4. Chemical Manufacturer Recommended Guidelines 5. None Established

3. HAZARDS IDENTIFICATION HMIS HEALTH 1, FIRE 1, REACTIVITY 0 Threshold Limit Value: Not established by ACGIH or OSHA Routes of Entry: At room temperature by skin absorption or ingestion. If heated or atomized by inhalation. Signs and Symptoms of Exposure: Eyes: Redness and irritation. Skin: Rash, redness Ingestion: Nausea, irritation of digestive track. Inhalation: Irritation of respiratory system. Acute Effects of Overexposure: Eye Contact: May cause severe eye irritation. Ingestion: May cause irritation of gastrointestinal track and nausea. Skin Contact: May cause severe skin irritation. May cause allergic skin reactions in some individuals. Skin Absorption: Slightly toxic by skin absorption. Inhalation: Airborne aerosols or vapors from heated material may cause severe respiratory system irritation. Chronic Effects of Exposure: Constant exposure to skin may cause chronic dermatitis. Other chronic effects are unknown. Conditions Aggravated by Exposure: Respiratory ailments, dermatitis, other conditions unknown. Carcinogenicity: This product and its constituents are not listed as carcinogens by IARC, NTP or regulated as carcinogens by OSHA at this time. Routes of Entry: At room temperature primary routes are ingestion or skin absorption. If the material is heated or atomized the vapors or aerosol may cause exposure via inhalation.

4. FIRST AID MEASURES Emergency and First Aid Procedures: Eyes: Irrigate w/flowing water immediately and continuously for 15 minutes. Obtain medical attention. Swallowing: Give water or milk. Do not induce vomiting. Call a physician. DO NOT GIVE ANYTHING BY MOUTH TO AN UNCONSCIOUS PERSON. Skin Contact: Remove contaminated clothing wash before reusing. Wash affected area well with soap and water. Consult physician. Inhalation: Remove to fresh air. Obtain medical attention.


5. FIRE AND EXPLOSION DATA Flash Point 350oF (175oC)TCC. Flammable Limits in Air % Volume Upper: n/d Lower: n/d Extinguishing Media: Foam, CO2, or Dry Chemical Unusual Fire and Explosion Hazards: Do not breathe smoke when burning. Irritating and or toxic vapors and gasses when burned. Special Fire Fighting Procedures: Fire fighters should wear full emergency equipment including selfcontained breathing apparatus. Do not direct solid stream of water or foam into hot, burning pools, this may cause frothing and increase fire intensity.

6. ACCIDENTAL RELEASE MEASURES Steps to be Taken in Case Material is Released or Spilled: Contain spills with dams of absorbent material such as Zip Zorb. Absorb material and shovel into drums. Use appropriate safety equipment. Do Not flush to sewers.

7. HANDLING AND STORAGE Precautions to be Taken in Storage and Handling: Avoid skin and eye contact. Avoid breathing vapors if generated. Exercise reasonable care and cleanliness. Storage Temperatures 25-500C (77-1220F). Condition material to 30-600C (86-1400F) before using. Mix well under dry atmosphere before using.

8. EXPOSURE CONTROLS/PERSONAL PROTECTION Eye Protection: Adequate eye protection as required to prevent contact during handling. i.e. Safety glasses, splash goggles, face shield. Skin Protection: Rubber Gloves, aprons and other protective clothing as required to prevent contact. Remove any contaminated clothing and wash before use. Routinely wash hands, arms and face with soap and water after handling. Do not smoke or eat until hands and face have been washed. Ventilation and Respiratory Protection: Good room ventilation is required. General mechanical ventilation is normally satisfactory. Use organic vapor respirator or supplied air respirator where supplemental protection is needed. Follow OSHA regulations when using personal protective equipment. Other: Eye wash, safety shower.

9. PHYSICAL AND CHEMICAL PROPERTIES Appearance clear liquid Color slight yellow tint Odor mild Boiling Range decomposes over 150oC. Melting Point super cools, sets to glass <10oC. Evaporation Rate(BuAcet=1) not volatile Vapor Density (air=1) n/a Weight per Gallon 8.9 Specific Gravity 1.07 Solubility in Water(%) very slight Percent Volatile negligible

10. STABILITY AND REACTIVITY Stability Stable Conditions to Avoid High heat (over 225oF) Incompatibility (materials to avoid) Oxidizing materials. Hazardous Polymerization Will not occur. Hazardous Decomposition Products By fire: CO2, CO, partially decomposed hydrocarbons, other undetermined irritating and or toxic fumes or vapors.


11. TOXICOLOGICAL INFORMATION Polyether polyol: Skin rabbit LD50: >2000 mg/kg; dermal rat LD50: >2000 mg/kg; ingestion oral rat LD50: >2000 mg/kg.

12. ECOLOGICAL INFORMATION Data unavailable

13. DISPOSAL CONSIDERATIONS Waste Disposal Method: If discarded in its purchased form, this product is not hazardous waste either by listing or by characteristic. However, processing, use or contamination of this product may change its hazardous waste status. Under RCRA, it is the responsibility of the product user to determine, at the time of disposal, whether a material is a hazardous waste. State and local disposal regulations may differ from federal disposal regulations. Dispose in accordance with all federal, state, and local waste disposal laws and regulations. Incineration is the preferred method.

14. TRANSPORT D.O.T. Shipping Name none Technical Shipping Name Z7500 Part A Polyol, Plastic Related Material D.O.T. Hazard Class not regulated UN/NA Number none NMFC Item Plastic material liquid, NMFC-156240 Class 60

15. REGULATORY All components of this mixture are listed in the TSCA inventory. For details on regulatory requirements you should contact the appropriate agency in your state.

16. OTHER This data is offered in good faith as typical values and not as a product specification. The information in this data sheet was compiled from information supplied by the vendors of the components of this compound. No warranty, either expressed or implied is hereby made. The recommended industrial hygiene and safe handling procedures are believed to be generally applicable. However, each user should review these recommendations in the specific context of the intended use and determine whether they are appropriate. The information on this data sheet is only to assist in the safe handling of this material, and may contain trade secrets which may not be divulged to anyone except the users of this material and health care and hygiene professionals as required for its safe use. No license or permission to infringe any patent or breach any trade secret is given.


Safety data sheet – MDI Product: ISOCYANATE B1001

1. Substance/preparation and company identification

ISOCYANATE B1001 Use: Chemical Manufacturer/supplier: BASF India Ltd 1st Floor, VIBGYOR Towers, Plot No. C – 62, ‘G’ Block, Bandra Kurla Complex, Mumbai – 400051, INDIA Telephone: +91 22 6661-8000 Telefax number: +91 22 6758-2753 Emergency information: International emergency number: Telephone: +49 180 2273-112

2. Composition/information on ingredients Chemical nature P-MDI (Content (W/W): 100 %) CAS Number: 9016-87-9

3. Hazard identification Harmful by inhalation. Irritating to eyes, respiratory system and skin. Limited evidence of a carcinogenic effect. May cause sensitization by inhalation and skin contact. Harmful: Danger of serious damage to health by prolonged exposure through inhalation.

4. First-Aid Measures General advice: Immediately remove contaminated clothing. If inhaled: Keep patient calm, remove to fresh air, seek medical attention. On skin contact: After contact with skin, wash immediately with plenty of water. Consult a doctor if skin irritation persists. On contact with eyes: Immediately wash affected eyes for at least 15 minutes under running water with eyelids held open, consult an eye specialist. On ingestion: Immediately rinse mouth and then drink plenty of water, do not induce vomiting, seek medical attention. Note to physician: Symptoms: tightness in the chest, coughing, difficulty breathing Hazards: Symptoms can appear later. Information on: Diphenylmethane-4,4'-diisocyanate (MDI) Hazards: Respiratory sensitization may result in allergic (asthma-like) signs in the lower respiratory tract including wheezing, shortness of breath and difficulty breathing, the onset of which may be delayed. Repeated inhalation of high concentrations may cause lung damage, including reduced lung function, which may be permanent. Substances eliciting lower respiratory tract irritation may worsen the asthma-like reactions that may be produced by product exposures. Treatment: Treat according to symptoms (decontamination, vital functions), no known specific antidote, administer corticosteroid dose aerosol to prevent pulmonary odema.

5. Fire-Fighting Measures Suitable extinguishing media: dry powder, carbon dioxide, alcohol-resistant foam, water spray Specific hazards: carbon dioxide, carbon monoxide, hydrogen cyanide, nitrogen oxides, isocyanate The substances/groups of substances mentioned can be released in case of fire.


Special protective equipment: Wear self-contained breathing apparatus and chemical-protective clothing. Further information: Keep containers cool by spraying with water if exposed to fire. Dispose of fire debris and contaminated extinguishing water in accordance with official regulations.

6. Accidental Release Measures Personal precautions: Use personal protective clothing. Ensure adequate ventilation. Use breathing apparatus if exposed to vapours/dust/aerosol. Environmental precautions: Do not empty into drains. Do not discharge into the subsoil/soil. Methods for cleaning up or taking up: For large amounts: Pump off product. For residues: Pick up with absorbent material (e.g. sand, sawdust, general-purpose binder). Dispose of absorbed material in accordance with regulations. Neutralize with a solution of 5 - 10 % Sodium carbonate, 0,2 - 2 % detergents and 90 - 95 % water.

7. Handling and Storage Handling Provide suitable exhaust ventilation at the processing machines. Ensure thorough ventilation of stores and work areas. Avoid aerosol formation. When handling heated product, vapours of the product should be ventilated, and respiratory protection used. Wear respiratory protection when spraying. Danger of bursting when sealed gastight. Protect against moisture. Products freshly manufactured from isocyanates can contain incompletely reacted isocyanates and other dangerous substances. Clean up contamination as soon as they occur. Provide basic employee training to prevent/minimize exposures. Storage Keep away from water. Segregate from foods and animal feeds. Segregate from acids and bases. Suitable materials for containers: carbon steel (iron), High density polyethylene (HDPE), Low density polyethylene (LDPE), tin (tinplate), Stainless steel 1.4301 (V2) Further information on storage conditions: Keep container tightly closed in a cool, well-ventilated place. Protect against moisture. Formation of CO2 and build up of pressure possible. Danger of bursting when sealed gastight.

8. Exposure controls and personal protection Components with occupational exposure limits Diphenylmethane-4,4'-diisocyanate (MDI), 101-68-8; Personal protective equipment Respiratory protection: Respiratory protection in case of vapour/aerosol release. Combination filter for gases/vapours of organic compounds and solid and liquid particles (f.e. EN 14387 Type A-P2) Hand protection: Chemical resistant protective gloves (EN 374) Suitable materials also with prolonged, direct contact (Recommended: Protective index 6, corresponding > 480 minutes of permeation time according to EN 374): butyl rubber (butyl) - 0.7 mm coating thickness nitrile rubber (NBR) - 0.4 mm coating thickness chloroprene rubber (CR) - 0.5 mm coating thickness Unsuitable materials polyvinylchloride (PVC) - 0.7 mm coating thickness Polyethylene-Laminate (PE laminate) - ca. 0.1 mm coating thickness Eye protection: Safety glasses with side-shields (frame goggles) (e.g. EN 166) Body protection: safety shoes (e.g. according to EN 20346) General safety and hygiene measures: Do not breathe vapour/spray. With products freshly manufactured from isocyanates body protection


and chemical resistant protective gloves is recommended. Wearing of closed work clothing is required additionally to the stated personal protection equipment. No eating, drinking, smoking or tobacco use at the place of work. Take off immediately all contaminated clothing. Hands and/or face should be washed before breaks and at the end of the shift. At the end of the shift the skin should be cleaned and skin-care agents applied.

9. Physical and Chemical Properties Form: liquid Colour: brown Odour: earthy, musty pH value: not applicable Melting point: < 0 °C Boiling point: 200 °C (1,013 mbar) Flash point: > 204 °C Flammability: not flammable Lower explosion limit: For liquids not relevant for classification and labelling., The lower explosion point may be 5 – 15 °C below the flash point. Upper explosion limit: For liquids not relevant for classification and labelling. Ignition temperature: > 600 °C Explosion hazard: not explosive Vapour pressure: < 0.01 Pa (25 °C) Density: 1.22 g/cm3 (25 °C) Relative density: approx. 1.22 (20 °C) Relative vapour density (air): 8.5 (20 °C) Solubility in water: Reacts with water., hydrolyzes Miscibility with water: Reacts with water. Partitioning coefficient n-octanol/water (log Pow): not applicable Viscosity, dynamic: 100 - 250 mPa.s (25 °C) Other Information: If necessary, information on other physical and chemical parameters is indicated in this section.

10. Stability and Reactivity Conditions to avoid: Temperature: < 15 °C Avoid moisture. Thermal decomposition: > 230 °C Substances to avoid: acids, alcohols, amines, water, Alkalines Corrosion to metals: No corrosive effect on metal. Hazardous reactions: Reacts with water, with formation of carbon dioxide. Risk of bursting. Reacts with substances which contain active hydrogen. No hazardous decomposition products if stored and handled as prescribed/indicated.

11. Toxicological Information Acute toxicity Assessment of acute toxicity: Virtually nontoxic after a single ingestion. Virtually nontoxic after a single skin contact. Of moderate toxicity after short-term inhalation. LD50 rat (oral): > 10,000 mg/kg LC50 rat (by inhalation): approx. 0.493 mg/l 4 h LD50 rabbit (dermal): > 10,000 mg/kg

Irritation Assessment of irritating effects: Eye contact causes irritation. Skin contact causes irritation. Primary skin irritation: Irritant. Primary irritations of the mucous membrane: Irritant.


Assessment other acute effects Assessment other acute effects: Causes temporary irritation of the respiratory tract.

Sensitization Assessment of sensitization: The substance may cause sensitization of the respiratory tract. Sensitization after skin contact possible.

Repeated dose toxicity Assessment of repeated dose toxicity: The substance may cause damage to the lung even after repeated inhalation of low doses, as shown in animal studies.

Genetic toxicity Assessment of mutagenicity: The substance was mutagenic in various test systems with microorganisms and cell cultures; however, these results could not be confirmed in tests with mammals.

Carcinogenicity Assessment of carcinogenicity: Indication of possible carcinogenic effect in animal tests. However, the relevance of this result for humans is unclear. The substance was tested in form of respirable aerosols.

Reproductive toxicity Assessment of reproduction toxicity: Repeated inhalative uptake of the substance did not cause damage to the reproductive organs.

Developmental toxicity Assessment of teratogenicity: Animal studies gave no indication of a developmental toxic effect at doses that were not toxic to the parental animals.

Experiences in humans coughing, dyspnea, tightness in the chest, temporary influenzal symptoms: Can severely irritate the eyes and respiratory tract depending upon the concentration.

12. Ecological Information Ecotoxicity Assessment of aquatic toxicity: There is a high probability that the product is not acutely harmful to aquatic organisms. No toxic effects occur within the range of solubility. Toxicity to fish: LC0 (96 h) > 1,000 mg/l, Fish (other) Aquatic invertebrates: EC0 (24 h) > 500 mg/l, daphnia (other) Aquatic plants: EC0 (72 h) 1,640 mg/l, Scenedesmus subspicatus (OECD Guideline 201)

Mobility Assessment transport between environmental compartments: Adsorption to solid soil phase is not expected.

Persistence and degradability Assessment biodegradation and elimination (H2O): Poorly biodegradable. Elimination information: < 10 % BOD of the ThOD (28 d) (OECD Guideline 302 C) (aerobic, activated sludge) Under test conditions no biodegradation observed.

Bioaccumulation potential Assessment bioaccumulation potential: Does not significantly accumulate in organisms. Bioaccumulation potential: Accumulation in organisms is not to be expected.

Other adverse effects Adsorbable organically-bound halogen (AOX): This product contains no organically-bound halogen.

Additional information


Other ecotoxicological advice: Do not release untreated into natural waters. Do not allow to enter soil, waterways or waste water channels.

13. Disposal Considerations Incinerate in suitable incineration plant, observing local authority regulations. Dispose of isocyanate waste in dry containers and never mix together with other wastes (reaction, dangerous pressure build up). Contaminated packaging: Contaminated packaging should be emptied as far as possible; then it can be passed on for recycling after being thoroughly cleaned.

14. Transport Information Domestic transport: Not classified as a dangerous good under transport regulations Sea transport IMDG Not classified as a dangerous good under transport regulations Air transport IATA/ICAO Not classified as a dangerous good under transport regulations

15. Regulatory Information Regulations of the European union (Labelling) Regulation 1272/2008/EC on classification, labelling and packaging of substances and mixtures, amending and repealing Directives 67/548/EEC and 1999/45/EC, and amending Regulation 1907/2006/EC: Hazard symbol(s) Xn Harmful. R-phrase(s) R20 Harmful by inhalation. R36/37/38 Irritating to eyes, respiratory system and skin. R40 Limited evidence of a carcinogenic effect. R42/43 May cause sensitization by inhalation and skin contact. R48/20 Harmful: Danger of serious damage to health by prolonged exposure through inhalation. S-phrase(s) S23.3 Do not breathe vapour/spray. S36/37 Wear suitable protective clothing and gloves. S45 In case of accident or if you feel unwell, seek medical advice immediately (show the label where possible). Hazard determining component(s) for labelling: P-MDI Other regulations If other regulatory information applies that is not already provided elsewhere in this safety data sheet, then it is described in this subsection.

16. Other Information Recommended use: polyurethane component, industrial chemicals Vertical lines in the left hand margin indicate an amendment from the previous version. The data contained in this safety data sheet are based on our current knowledge and experience and describe the product only with regard to safety requirements. The data do not describe the product's properties (product specification). Neither should any agreed property nor the suitability of the product for any specific purpose be deduced from the data contained in the safety data sheet. It is the responsibility of the recipient of the product to ensure any proprietary rights and existing laws and legislation are observed.

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