Annexure-5.2 M/s. La Chandra Pharma Lab Pvt....

Risk Assessment Study S- 1 February-2015

Annexure-5.2

M/s. La Chandra Pharma Lab Pvt. Ltd.

RISK ASSESSMENT STUDY


1 Executive Summary

S-4

2 Objectives, Philosophy and methodology of Risk assessment

S-6

3 Introduction of the unit

S-8

3.1 Company Introduction

S-8

3.2 Details of Unit

S-8

3.3 Project setting

S-9

3.4 Organizational setup

S-11

3.5 List of product

S-11

3.6 List of Raw material

S-11

3.7 Storage details of hazardous materials and control measures

S-13

3.8 Hazardous material storage and handling safety

S-14

3.9 Transportation, Loading and handling procedure for hazardous chemicals

S-16

3.10 Hazardous Properties Of The Chemicals, Compatibilities And Special Hazard

S-20

3.11 Occupational Health Impact on Employees, Control measures, action plan If accident occur and its antidotes.

S-24

3.12 Brief Description of process plant S-29

4 Hazard identification

S-30

4.1 DOW’s Fire and Explosion Index

S-31

4.2 Identification of Hazardous area

S-31

4.3 Failure Frequency

S-32

4.4 Evaluation of Process areas

S-33

5 Risk Assessment

S-35


5.1 Effects of Release of Hazardous Substances

S-35

5.2 Tank on Fire / Pool Fire

S-35

5.3 Fire Ball

S-36

5.4 UVCE

S-36

5.5 Dispersion cases

S-36

5.6 Identification of High Risk Areas

S-36

5.7 Modes of Failure

S-37

5.8 Damage Criteria for heat radiation

S-37

6 Consequence Analysis

S-39

6.1 Consequence Analysis

S-39

Scenario-1 Unconfined pool fire due to Loss of containment in Ethyl Alcohol/Methanol Road tanker.

S-41

Scenario-2 Unconfined pool fire Simulation for Drum Storage Area.

S-44

Scenario-3 BLEVE Simulation for Drums storge.

S-46

Scenario-4 Diffusion jet fire simulation for 1.0 Cm Copper connecting pipe to PRV station.

S-48

Scenario-5 Over pressure / explosion for rupture of 1.0 Cm Copper pipe line of Hydrogen cylinder to PRV station.

S-50

6.2 Detail regarding consequences analysis table

S-52

6.3 Conclusions

S-52

7 Risk Reduction Measures

S-53

8 Disaster Management plan

S-54


intends to produce an Active Pharmacuetical Ingradiates Manufacturing Unit, which is to be set-up at Survey No. 64/P2/P2, Banas Farm, Deesa-Chitrasani Highway, Village: Vaghrol, Taluka: Dantiwada, District: Banaskantha, Gujarat. 1.1 Experts from our organization visited the site on 20.11.2014 and subsequently inspection of

site as per site plan and the environs along with collection of relevant information about the proposed installation and the operations of the plant. Also a detailed discussion was held on various aspects including storage facilities, process safety and emergency preparedness with the officers of the company.

1.2 Petroleum product like Ethanol, Methanol will be received through road tanker and will be stored in PESO approved under ground storage tank farm area as per Petroleum Act and Rules. All safety measures will be provided at design level and foolproof safety features will be provided.

1.3 Some flammable/combustible/ Toxic liquid/solid chemicals will be received in drums or bags or in carboys and it will be stored in drum storage area and in RM store as per its incompatibility and other properties like flammable, toxic, corrosive and reactive.

1.4 Based on the data furnished and the study of the installation, certain hazards have been identified and their consequences are modeled mathematically using HAMSGAP software. Mapping of various scenario are with hazardous distances and safe distances are drawn on site plan for easy understanding of the consequences of the accident/ incident.

1.5 The study indicates that possible hazards associated with the plant are confined to (a) Petroleum storage tank farm area, road truck unloading area (b) Drum storage area (c) Hydrogen cylinder skid and hydrogenation reaction shed. Various hazardous scenarios have been identified for Risk Assessment and the consequences modeled.

1.6 The results of the analysis have been summarized in the table appended. 1.7 It is observed from the summary that the consequences of hazards associated with any

possible spills / leaks for catastrophic failure of storage tanks, road tanker release scenarios would be of large in nature and would be taken care of with the proposed emergency facilities and manpower employed.

1.8 The possibility of occurrence of such hazards and their effects could be further reduced by implementing the suggestions made in this report.

1.9 Catastrophic failure of storage tanks, road tanker or Hydrogen gas leakage, resulting in major disaster due to fire, explosion is very unlikely events barring gross neglect of time tested safety standards and procedures set up by the industry.


1.10 The possibility of occurrence of major disaster due to fire, explosion and toxic release and mishaps are considered very remote.

1.11 However considering the potential for major hazards, however remote they may be, associated with storage area, some suggestions are made in the subsequent chapters for further improvement in the areas of safety, environmental impact, Emergency facilities and emergency preparedness plan.

1.12 Conclusion Based on the 1) Risk Analysis study and information regarding the layout plan and safety systems. 2) Discussions with company officials,


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

This report is limited to the following:-

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

o Evaluation of heat radiation & pressure wave profiles for identified failure cases o Risk assessment on the basic of the above evaluation & risk acceptability o Minimum preventive & protective measures to be taken to minimize risks to

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

The procedure used for carrying out the Quantitative Risk Assessment Study is outlined below:- Identify Credible Loss Scenarios for the facility under the study by discussion with

Simulate loss Scenarios to determine the vulnerable zones for toxic dispersion, pool fire, Tank on fire (Thermal Radiation ), Flash fire, Explosion over pressure (Vapour cloud Explosion, Ball fire using software packages HAMSGAP. Suggest mitigating measures to reduce the damage, considering all aspects of the facilities. The flowchart of the methodology for the present study is shown in following page.


START

FACILITY, PROCESS AND METEOROLOGICAL DATA COLLECTION

LISTING OUT OF HAZARDOUS OPERATIONS & STORAGE DETAILS

DEFINING OF PARAMETERS FOR EACH OF CHEMICALS & EACH OF HAZARDS

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

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

SIMULATION OF SELECTED CASES FOR CONSEQUENCE MODELING

PREPARATION OF SUMMERY OF CONSEQUENCE RESULTS

EVALUATION OF POTENTIAL RISK TO THE SURROUNDING POPULATION

DISCUSSION & RECOMMENDATION OF MITIGATIVE / REMEDIAL MEASURES

END


intends to produce an Active Pharmacuetical Ingradiates Manufacturing Unit, which is to be set-up at Survey No. 64/P2/P2, Banas Farm, Deesa-Chitrasani Highway, Village: Vaghrol, Taluka: Dantiwada, District: Banaskantha, Gujarat.

1. Full Name & Address of Unit Survey No. 64/P2/P2, Banas Farm, Deesa-Chitrasani Highway, Village: Vaghrol, Taluka: Dantiwada, District: Banaskantha, Gujarat.

2. Telephone No. Fax Number: Email ID :

Mobile No.: 09099028738 E-mail: [email protected]

3. Month & Year of Establishment It is a proposed unit. 4. Full name & Address and phone

number of the occupier The Board of directors of the company consists of the following directors. 1. Mr. Priyvrat Gadhvi 2. Mr. Edwin Straessle 3. Mr. Kevin Straessle Address: As above

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

Mr. Priyvrat Gadhvi (Managing Director) Address: As above

6. Environs (Nearest Facilities) Latitude: 24°17'5.01"N Longitude: 72°21'2.87"E

7. Total Land at Plant 10186 sq.m.

8. Power connection Source: Uttar Gujarat Vij Company Limited (UGVCL) Connected Load: 100 kW

9. DG Set 50 Kva


intends to produce an Agro/Chemical intermediate which is to be set-up at No. 64/P2/P2, Banas Farm, Deesa-Chitrasani Highway, Village: Vaghrol, Taluka: Dantiwada, District: Banaskantha, Gujarat.

Latitude: 24°17'5.01"N Longitude: 72°21'2.87"E



1 16-Dehydro Pregnenolone Acetate 1.0

2 Pregnenolone 1.0

3 Progesterone 0.833

4 Estradiol-1 0.833

5 Testosterone 0.833

1 16–Dehydro Pregnenolone Acetate Solid 46 Fibre drum 2.3 MT

2 Ethanol* Liquid U.G tank S.S. 118 kl

3 Raney Nickel Solid 20 Plastic carboy 9.6 MT

4 Methanol* Liquid U.G tank / 46 drums

S.S tank / HDPE drum 9.2 kl

5 Potassium Carbonate Solid 10 Corrugated drum 0.5 MT

6 Toluene* Liquid 117 HDPE drum 23.2 kl

7 Aluminium Isopropoxide Solid 51 Fibre drum 2.5 MT

General Manager

(Operations)

Environment, Health & Safety Manager

Production Manager

Safety Officer

ETP In-Charge

Shift In-Charge


8 Sulphuric Acid* Liquid 18 Plastic carboy 0.5 kl 9 Hydrogen* Gas 92 Cylinder 4.6 MT

10 Activated Charcoal Solid 20 Corrugated drum 0.5 MT

11 Diosgenin Solid 59 Corrugated drum 3 MT

12 Acetic Anhydride* Liquid 26 Plastic drum 1.3 kl 13 Acetonitrile* liquid 118 Plastic drum 23.5 kl

14 Tetraethyl Ammonium Iodide Solid 01 Plastic carboy 0.02 MT

15 Potassium Permanganate Solid 22 HDPE

Container 1.1 MT

16 Glacial Acetic Acid* Liquid 98 Plastic drum 19.5 kl 17 Petroleum Ether Liquid 95 Plastic carboy 2.4 kl

18 Estrone Solid 19 Corrugated drum 0.9 MT

19 Sodium Borohydride Solid 03 M.S. container 0.06 MT

20 Sodium Hydroxide* Solid 02 HDPE container 0.1 MT

21 Acetone* Liquid 99 Plastic drum 19.8 kl 22 Argon Gas Gas 25 Cylinder 1 MT

23 Androstenedione Solid 20 Corrugated drum 1 MT

24 Triethylorthoformate Liquid 05 Plastic drum 1 MT 25 Triethylamine Liquid 04 Plastic carboy 0.1 kl 26 Methylene Dichloride Liquid 13 Plastic drum 2.5 kl 27 Hydrochloric Acid Liquid 17 Plastic carboy 0.4 kl

28 Sodium Bicarbonate Solid 10 HDPE container 0.5 MT

29 4 – AD (Androst-4-Ene-3,17-Dione) Solid 40 Fiber Drum 2 MT

30 Dimethyl Sulphoxide Liquid 33 Plastic drum 6.6 kl 31 Sodium Methoxide Solid 30 Fiber Drum 1.5 MT

32 Acetylene* in DMF (Dimethyl Formamide)

Gas in Liquid 32 Plastic Carboy 0.8 kl

33 CuSO4.5H2O* / Alumina Solid 14 Corrugated

Drum 0.7 MT

34 1,4 – Dioxane Liquid 144 Plastic Drum 28.8 kl

35 Methane Sulphonic Acid Liquid 3 Plastic Carboy 66 l

36 Celite Solid 42 Fiber Drum 2.1 MT


37 Trifluoromethane Sulphonic Acid Liquid 2 Plastic Carboy 42 l

38 10% Pd on Activated Carbon Solid 10 HDPE

Container 0.5 MT

39 Hantzsch Ester Solid 52 Fiber Drum 2.6 MT 40 Silica Gel Liquid 95 Plastic Drum 19 kl

41 Ethyl Acetate* / Hexane* Liquid U.G. Tank /

3000 Plastic Drum 600 kl

3.7 DETAILS OF STORAGE OF HAZARDOUS MATERIALS IN BULK &

CONTROL MEASURES: TABLE: 3.4

1 Ethanol 118 KL U/G storage tank ATP Ambient

Fire Provided below separately for Under ground storage area

2 Methanol 9.2 KL U/G storage tank ATP Ambient

Fire Do

3 Toluene 23.4 KL Drum storage area

ATP Ambient

Fire Provided below separately as per Drum stoage shed

4 Acetone 19.8 KL Drum storage area

ATP Ambient


5 Acetonitrile 23.5 KL Drum storage area

ATP Ambient

Fire/ Toxic

Provided below separately as per Drum stoage shed

6 Petroleum Ether 2.4 KL Drum storage area

ATP Ambient


7 Acetic Anhydride 1.3 KL Drum storage area

ATP Ambient


8 Glacial Acetic Acid 19.5KL Drum storage area

ATP Ambient



9 Triethylamine 0.1 KL Drum storage area

ATP Ambient


10 Methylene Dichloride

2.5 KL Drum storage area

ATP Ambient


11 Sulphuric Acid 0.5 KL Acid storage area ATP Ambient

Corrosive Provided below separately

12 Hydrochloric Acid 0.4 KL Acid storage area ATP Ambient

Corrosive Provided below separately

13 Hydrogen 4.6 MT Hydrogen cylinder skid

200 kg/cm2 Ambient

Fire & Explosion

Provided below

14 Acetylene in DMF (Dimethyl Formamide)

0.8 kl 32 Plastic Carboy

ATP Ambient

Fire Provided below separately

15 CuSO4.5H2O 0.7 MT

14 Corrugated

Drum

ATP Ambient Solid

Provided below separately

16 Ethyl Acetate / Hexane 600 kl

U.G. Tank / 3000Plastic

Drum

ATP Ambient Liquid

Provided below separately

1. Clas s A p etroleum products wil l be received through road t anker and stor ed in underground stor age tan k as per pet roleum rules.

2. Tank farm will be construct ed as per explosive depart ment requirement and sep aration di st ance wil l b e maint ained.

3. St atic eart hing provision wil l be made for road t ank er as well as st orage tank.

4. Flam e arrest or with breat her valve wil l be p rovided on vent l ine. 5. Road t anker u nloading procedure wil l be p repared and imp lemented . 6. Fire load calculation wil l be done and as per fire load Hydrant System

will be provided as p er NFPA st d. and Fire extinguisher s wil l be provided as per fire load calculation.

7. Spark arrest or wil l be p rovided to a l l vehic les in side premi ses . 8. Flam e proof type equipmen t s and l ight ing wil l be provided. 9. Light ening arrest or wil l be provided on the t op of chimney. 10. Trained and exp erience operat or wil l be employed for tan k farm area. 11. NFPA label (hazard ident ification ) capacity and content wil l be

displayed on stor age tan k. 12. Solvents wil l b e transferr ed by p ump only in plant area and day tank

wil l be provided. Overflow l ine wil l be ret urn to t he st orage tank or Pump On-Off switch wil l be provided near day tank in plant.

13. Jumpers wil l be provided on so lven t h andling pipe l ine f lan ges. 14. Flexible SS hose wil l be used for road tanker unload in g purpos e and

oth er t emp.connect ion.


Some chemicals wil l b e received at plant in dru ms by road truck an d st ored in a separate drum storage ar ea.

1. FLP type l ight fit tings wil l be p rovided . 2. Proper ventilat ion wil l be provided in godown. 3. Proper label and identification board /st ickers wil l be provided in the

st orage area. 4. Conduct ive drum pallets wil l be provided. 5. Drum hand ling t rolley / stackers/f ork l if t wil l be used for drum

handling. 6. Sep arate di spensing room with local exhaust and static earthing

provisi on wil l be made. 7. Materi als wil l be st ored as per it s compati bil it y st udy and separat e area

wil l be made for flammab le, corrosiv e and toxic chemi cal drums stor age . 8. Smoking and other spark, flame generating it em will be banned from the

Gate.

1. Caut ion note and emergency f irst aid measur es wil l be displayed and train for th e same to al l employees.

2. Carboyes wil l b e st ored away fr om the proces s plant . 3. Caut ion note and emergen cy handling procedu re wil l be d isplayed at

unload ing area and t rained all operat ors. 4. NFPA label wil l be provided. 5. Required PPEs l ik e full body protection PVC apron, Hand glov es,

gumboot , Respiratory mask et c. wil l be p rovided t o oper ator. 6. Neutralizing agent wil l be kept ready for tackle any emer gen cy spil lage . 7. Safety shower, eye wash with quench ing unit wil l be provided in acid

stor age area .

1 FLP t yp e area wil l be provided. 2 Total en closed process syst em. 3 Instrument & Plant Air System. 4 Nit rogen blanket ing in Hydrogen ation reactor. 5 Safety valve and Rupt ure disc provided on reactor. 6 Cooling Chil l ing and power alt ernative arrangement have bee n m ade

on reactor. 7 Hydrogen and Nit rogen Cylinder bank away fr om t he autoclave

reactor. 8 PRV st ation with sh ut of f valve , safet y valv e provision wil l be made for

hydrogen ation react ion safety. 9 Before Hydrogen G as chargin g in to react or and aft er completion of

reaction Nitrogen flu shing wil l be done. 10 Flam e arrest or wil l b e provided on vent l ine of reactor and it wil l be

ext ended up to roof level . 11 Open well vent ilated and fragile roof wil l be provided to on r eactor. 12 Safe C ataly st charging method wil l be adop te d. 13 SOP will be prepared and operat ors wil l be trained for the s ame. 14 St atic earthing and elect ric earth ing (D ouble) provided.


15 Rector vent extended out side th e process area and f lame arrestor provided on vent l ine.

16 Dumping vess el arr angement wil l be made. 17 Ju mpers for st atic eart hing on pipeline f langes of f lam mable chemical

wil l be provid ed.

Hydrogen road skid will be received by road and skid will be stored away from process plant.

PRV station provided with shut off valve and safety valve . Flame proof light fitting installed. Static earthing and electric earthing (Double) provided. Jumpers for static earthing on pipeline flanges of flammable chemical will be

provided. Non sparking tools will be used for hydrogen line fitting.

1 Transportation by road tanker

Leakage, Spillage, fire, explosion, Toxic release

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

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

exhaust. Instructions will be given not to stop road

tanker in populated area. Clear Hazard Identification symbol and

emergency telephone number will be displayed as per HAZCHEM CODE.

Appropriate PPEs will be kept with TL. 2 Road tanker unloading

at site. Leakage, Spillage, fire, explosion, toxic release

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

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

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

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

Wheel stopper will be provided to TL at


unloading platform. Static earthing will be provided to road

tanker. Tanker unloading procedure will be

followed according to check list and implemented.

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

The quantity remaining in the hose pipeline will be drained to a small underground storage tank, which will be subsequently transferred by nitrogen pressure to the main storage tank thus ensuring complete closed conditions for transfer from road tanker.

All TL valves will be closed in TL. Finally earthing connection and wheel

stopper will be removed. Only day time unloading will be

permitted. 3 Storage tank safety Leakage, Spillage,

Fire, Explosion, Toxic release.

SS storage tank will be provided as per IS code.

Dyke wall will be provided to storage tank.

Level transmitter will be provided with low level high level auto cut-off provision.

Vent will be connected to water trap and vent of water trap will be provided with flame arrestor.

Water sprinkler system will be provided to storage tank.

Fire hydrant monitor with foam attachment facility will be provided.

Dumping / Drain vessel/alternate vessel will be provided to collect dyke wall spillage material.

FLP type pump will be provided. Nitrogen blanketing will be provided to

storage tank. Double static earthing will be provided to

storage tank. Double Jumper clip will be provided to all

Solvent handling pipeline flanges.

4 Transfer from storage tank to Day tank

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

Double mechanical seal type FLP type pump will be provided.

Double on / off switch will provided at tank farm and process area near day tank. Pump auto cut off with day tank high level will be provided.

Flame arrestor will be provided on day tank vent.

Over flow will be provided for additional safety and it will be connected to main storage tank.

NRV will be provided on pump discharge line.

Double Jumper clip will be provided to all solvent handling pipeline.


Double static earthing will be provided to day tank.

5 Transfer from Day tank to reactor.


Gravity transfer. Total quantity of day tank material will be

charged in to reactor at a time. NRV will be provided on day tank outlet

line. Static earthing will be provided to storage

tank. Double Jumpers will be provided to

pipeline flanges.

SR.NO.

1 Transportation of Solvents drums

Leakage, Spillage, fire, explosion, Toxic release

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

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

exhaust. Instructions will be given not to stop

road tanker in populated area. Clear Hazard Identification symbol and

emergency telephone number will be displayed as per HAZCHEM CODE.

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

Spillage, fire, explosion, toxic release

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

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

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

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

Wheel stopper will be provided to TL at unloading platform.

Only day time unloading will be permitted.

3 Godown/warehouse safety

Leakage, Spillage, Fire, Explosion, Toxic release.

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

godown. Proper label and identification board

/stickers will be provided in the storage area.

Conductive drum pallets will be provided.


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

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

Materials will be stored as per its compatibility study and separate area will be made for flammable, corrosive and toxic chemical drums storage.

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

4 Solvents transfer from drum to Day tank/ reactor


Solvent transfer by vacuum or by pump only.

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

used.

5 Solvent transfer from Day tank to reactor.


Gravity transfer. Total quantity of day tank material will

be charged in to reactor at a time. NRV will be provided on day tank outlet

line. Static earthing will be provided to

storage tank. Double Jumpers will be provided to

pipeline flanges.


1. Ethyl Alcohol CAS # 64–17-5

F 55 78.3 3.3 19 0.790 1.6 Soluble 0 3 0 CO & CO2 1000 ppm

3300 ppm

20000

ppm for

10H rat

Eyes, Respiratory System, Skin.lever, kidneys.

No 2 gm sodium bi carbonate in 250 ml water, Diazepam 10 mg through

injection 2. Methanol

CAS# 67-56-1 F/T 10 54 5.4 44 0.792 1.1 Soluble 1 3 0 Irritating

vapour 200 6000

LEL 6400

0 ppm for 4H rat

Eyes, Respiratory System,

Skin.

No 10 mg diazepam through injection Activated Charcoal

3. Toluene CAS # 108-88-3

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

generated

50ppm 2000 ppm

400 ppm for

24Hr Rat

Eyes, skin, respiratory

system, central

nervous

No Diazem – 1 mg/Kg.(Intrav

enous), Epinephina,

Efidrine 4. Acetone

CAS# 67-64-1 99 F - 20 56 2.15 13.0 0.791 2.00 Soluble 1 3 0 Irritating

vapour 750 25000

LEL N.L. Eyes, skin,

respirator system.

No 10 mg diazepam through injection

5. Acetonitrile CAS #75-05-8

T/F 42 81.6 4.4 16 0.787 1.4 Soluble 2 3 1 Toxic vapor are generated

2.7 40 ppm

4000 ppm

eyes, skin, nervous system

No Cyanide Kit

6. Petroleum Ether CAS # 8000-05-9

T/F -40 30 1.1 5.9 0.75 2.6 Insoluble 1 4 0 Toxic vapor are generated

400 ppm

1100 ppm

3400 ppm for 4H rat

Eyes, skin. No Water

7. Acetic Anhydride CAS No.108-24-7

F/T 49 140 2.7 10.3 1.05 3.5 Slightly soluble

3 2 1 Emits toxic fumes

5 ppm 200 ppm

1780

mg/m3

Eyes, skin, respiratory system

No milk butter and milk of

magnesia.


8. Triethylamine (TEA) CAS #121-44-8

T/F 20 89.5 1.2 8.0 0.729 3.5 Insoluble 2 3 0 Irritating vapour

10 ppm

1000 ppm

570 mg/k

g Rabbi

t.

Heart, liver,

kidneys, skin, eyes. Cardiovasc

ular system.

No water/ milk

9. Mthylene Dichloride (MDC) CAS#75-09-2

T N.F 39.8 14 22.0 1.325 2.9 Insoluble 2 0 1 CO, CO2, Cocl2, HCL (g) generated

50 ppm 2300 ppm

N.L. Eyes, skin, lungs.

No No specific antidote

10. Sulfuric Acid CAS # 7664-93-9

C NF 340 NA NA 1.84 NA Water reactive

3 0 2 Sulphur Dioxide,

SO2,and toxic fumes

1 mg/m

3

15 mg/m3

510 mg/m

3 Rat


system,

No Sodium Hydro-

Carbonate (4% Conc.), Milk, Lime

Juice, Milk of Megnesia

11. Hydrochloric Acid HCL CAS # 7647-01-0

C/T NF 108 NF NF 1.12 -1.19

1.267

Water reactive

3 0 1

Non combustible

5 ppm

50 ppm

3124 ppm for 1h rat

Respiratory system,

gastrointestinal

system, teeth, eyes,

No Sodium Hydro-

Carbonate (4% Conc.),

12. Hydrogen Gas CAS # 1333-74-0

F/E N.A. -2.8°C 3.0 74 0.0696 NA Soluble in water

1 4 0 Explosive gas 250 ppm

- LC50 >800000 ppm rat

lungs, heart, upper respiratory tract, central nervous system (CNS)

No No specific Antidote

13. Argon CAS#740-37-1

Asphyxiate

N.A. -185.9 N.A. N.A. 0.103 1.66 N.A. 0 0 0 N.A. N.L. N.L. N.L. Eyes, blood, skin


14. Raney Nickel CAS#7440-02-0

T/F N.A. 2730 N.A. N.A N.A 8.90 Insoluble 4 2 1 Toxic Fumes 1.5 mg/m3

10 mg/m3

LC50 > 10 mg/m

3 (Rat)

Respiratory system,

gastrointestinal

system, teeth, eyes,

No No specific Antidote.


15. Activated Charcoal CAS#7440-44-0

F NA NA NA NA 3.51 NA Insoluble 1 3 0 CO, CO2 2 mg/m3

NL NL Mucuous membrane

s, eyes, respirator

system.

No No Specific Antidote


T/F 42 81.6 4.4 16 0.787 1.4 Soluble 2 3 1 Toxic vapor are generated

2.7 PPM

40 ppm 4000 ppm


system

No Cyanide Kit

17. Dimethyl formamide(DM F)CAS #68-12-2

T/F 136 153 2.2 15.2 0.950 2.51 Soluble 1 2 0 Irritating vapor 10 ppm 500 - Eyes, skin, respiratory

system

No Calcium Gluconate 10 ml in 10% solution

through injection 18. Ethyl Acetate

CAS # 141-78-6 F -4.0 77.0 2.0 11.5 0.902 3.0 1 ml/10ml

water 1 3 0 Irritating Vapour - 400 200

gm/m3


system

No Not available

19. Hexane CAS #110-54-3

F -7 68.7 1.2 7.7 0.659 3.0 - 1 3 0 CO & CO2 50 ppm 5000 ppm

- Eyes, skin, respiratory

system

No No specific Antidot

20. Dimethyl Sulfoxide T 95 189 3.0 63.0 1.101 2.71 Soluble 1 1 0 SO2, Fomaldehyde,

Me. Mercaptan

N.L. N.L. N.A. No No specific antidote

21. Sodium methoxide CAS #124-41-4

Fire & explosi

on

60.55 300 7.3 36 0.996 1.3 3 4 3 200 6000 ppm N.L. N.L. N.L. Respiratory system, gastrointes

tinal system,

eyes, skin

NO No specific antidote

22. DMF(di methyl formamide) CAS#68-12-2

F 42.7 NA 2.2 15.2 1.018 2.51

Insoluble in

water 0.1

mg/mL at 64° F

2 2 0 Highly flammable

10 ppm

500 ppm

Rat LC50 (inhalatio

n) 2485 mg/k

g

Liver, Kidney, Central nervous system,

Cardiovascular

system., Blood


23. Sodium Bicarbonate CAS#497-19-8

T NF 100 NA NA 1.06 0.62

Soluble in water

1 0 0 Not combustible

10 mg/m

3

- N.L. glands in stomach

No No specific antidote.


24. Dichloro Methane (MDC, DCM )

T N.F 39.8 14.0 22.0 1.325 2.9 20 g/ lit. 2 0 1 CO, CO2, Cocl2, HCL (g) generated

50 N.L. N.L. Respiratory system, gastrointes

tinal system,

eyes, skin

No No specific antidote

25. Hantzsch

T N.F 39.8 14.0 22.0 1.325 2.9 20 g/ lit. 2 0 1 CO, CO2, Cocl2, HCL (g) generated

50 N.L. N.L. N.L. No No specific antidote

F = FIRE T = TOXIC C = CORROSIVE E = EXPLOSIVE R = REACTIVE STEL = SHORT TERM EXPOSURE LIMIT BP = BOILING POINT LEL = LOWER EXPLOSIVE LIMIT PPM = PARTS PER MILLION UEL = UPPER EXPLOSIVE LIMIT SP.GR = SPECIFIC GRAVITY VD = VAPOUR DENSITY ER = EVAPORATION RATE H = HEALTH HAZARD CLASS F = FIRE HAZARD CLASS R = REACTIVE HAZARD BR = BURNING RATE TLV = THRESHOLD LIMIT VALUE NFPA =NATIONAL FIRE PROTECTION ASSOCIATION-usa N.A = NOT AVAILABLE N.L =NOT LISTED


1. Toluene Toxic if swallowed. Toxic in contact with skin. Toxic if inhaled. Suspected of causing genetic defects. Suspected of causing cancer. May cause damage to organs through prolonged or repeated exposure. Toxic to aquatic life with long lasting effects.

Appropriate engineering controls Avoid contact with skin, eyes and clothing. Wash hands before breaks and immediately after handling the product.

CALL Emergency Response Telephone Number on Shipping Paper first. If Shipping Paper not available or no answer, refer to appropriate telephone number listed on the inside back cover. · As an immediate precautionary measure, isolate spill or leak area for at least 50 meters (150 feet) in all directions. · Keep unauthorized personnel away. · Stay upwind. · Keep out of low areas. · Ventilate closed spaces before entering. EVACUATION Large Spill · Consider initial downwind evacuation for at least 300 meters (1000 feet). Fire · If tank, rail car or tank truck is involved in a fire, ISOLATE for 800 meters (1/2 mile) in all directions; also, consider initial evacuation for 800 meters (1/2 mile) in all directions. Fire CAUTION: All these products have a very low flash point: Use of water spray when fighting fire may be inefficient. Small Fire · Dry chemical, CO2, water spray or regular foam. Large Fire · Water spray, fog or regular foam. · Do not use straight streams. · Move containers from fire area if you can do it without risk. Fire involving Tanks or Car/Trailer Loads · Fight fire from maximum distance or use unmanned hose holders or monitor nozzles. · Cool containers with flooding quantities of water until well after fire is out.


· Withdraw immediately in case of rising sound from venting safety devices or discoloration of tank. · ALWAYS stay away from tanks engulfed in fire. · For massive fire, use unmanned hose holders or monitor nozzles; if this is impossible, withdraw from area and let fire burn. SPILL OR LEAK · ELIMINATE all ignition sources (no smoking, flares, sparks or flames in immediate area). · All equipment used when handling the product must be grounded. · Do not touch or walk through spilled material. · Stop leak if you can do it without risk. · Prevent entry into waterways, sewers, basements or confined areas. · A vapor suppressing foam may be used to reduce vapors. · Absorb or cover with dry earth, sand or other non-combustible material and transfer to containers. · Use clean non-sparking tools to collect absorbed material. Large Spill · Dike far ahead of liquid spill for later disposal. · Water spray may reduce vapor; but may not prevent ignition in closed spaces.

2. Acetic Acid CAS No. 64-19-7

Chronic respiratory disease due to long term exposure inhalation Skin disease due to skin contact

Process enclosure, Local exhaust, General dilution ventilation, Personal protective equipments

Remove victim from the spillage location into fresh air area. Small spillage control absorb on paper towel. Large spillage – Evacuate area and stop source of ignition. Dilute with water and collect washed out water in tank and neutralize it in safe manner.


3. Acetic anhydride CAS No.108-24-7



Remove victim from the spillage location into fresh air area. Small spillage control absorb on paper towel. Large spillage – Evacuate area and stop source of ignition. Dilute with water and collect washed out water in tank and neutralize it in safe manner.

4. Hydrochloric Acid

Very hazardous in case of skin contact (corrosive, irritant, parameter), of eye contact (irritant, corrosive), of ingestion, . Slightly hazardous in case of inhalation (lung sensitizer). Non-corrosive for lungs. Liquid or spray mist may produce tissue damage particularly on mucous membranes of eyes, mouth and respiratory tract. Skin contact may produce burns. Inhalation of the spray mist may produce severe irritation of respiratory tract, characterized by coughing, choking, or shortness of breath. Severe over-exposure can result in death.

Provide close process and scrubber on process vent and storage vent

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

5. Acetone CAS# 67-64-1 99



Prevent ignition, stop leak and ventilate the area. Contain spilled liquid with sand or earth. DO NOT use combustible materials such as sawdust. Use appropriate personal protective


equipment


Potential Acute Health Effects: skin contact (irritant), of eye contact (irritant), Potential Chronic Health Effects: The substance is toxic to blood, kidneys, lungs, liver, mucous membranes, gastrointestinal tract, upper respiratory tract, skin, eyes, central nervous system (CNS). The substance may be toxic to the reproductive system.

Closed system, ventilation, explosion-proof electrical equipment and lighting. Do NOT use compressed air for filling, discharging, or handling.

Ventilation. Remove all ignition sources. Collect leaking liquid in sealable containers. Absorb remaining liquid in dry sand or inert absorbent and remove to safe place. Do NOT wash away into sewer. Personal protection: complete protective clothing including self-contained breathing apparatus

7. Ethyl Alcohol CAS # 64–17-5

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

Provide close process Flammable liquid. Keep away from heat. Keep away from sources of ignition. Stop leak if without risk. Absorb with DRY earth, sand or other non-combustible material. Do not touch spilled material. Prevent entry into sewers, basements or confined areas; dike if needed.

8. Hexane CAS #110-54-3




9. Methanol CAS#: 67-56-1

The substance is toxic to eyes. The substance may be toxic to blood, kidneys, liver, brain, peripheral nervous system, upper respiratory tract, skin, central nervous system (CNS), optic nerve. Repeated or prolonged exposure to the substance can produce target organs damage. Repeated exposure to a highly toxic material may produce general deterioration of health by an accumulation in one or many human organs.

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

Flammable liquid. Poisonous liquid. Keep away from heat. Keep away from sources of ignition. Stop leak if without risk. Absorb with DRY earth, sand or other non-combustible material. Do not get water inside container. Do not touch spilled material. Use water spray to reduce vapors. Prevent entry into sewers, basements or confined areas; dike if needed. Call for assistance on disposal. Be careful that the product is not present at a concentration level above TLV.

10. Sulfuric Acid

Prolonged or repeated skin contact may cause dermatitis. Prolonged or repeated inhalation may cause nosebleeds, nasal congestion, erosion of the teeth, perforation of the nasal septum, chest pain and bronchitis. Prolonged or repeated eye contact may cause conjunctivitis. Effects may be delayed. Workers chronically exposed to sulfuric acid mists may show various lesions of the skin, tracheobronchitis, stomatitis, conjunctivitis, or gastritis. Occupational exposure to strong inorganic acid mists containing sulfuric acid is carcinogenic to humans.

Facilities storing or utilizing this material should be equipped with an eyewash facility and a safety shower. Use adequate general or local exhaust ventilation to keep airborne concentrations below the permissible exposure limits. Use a corrosion-resistant ventilation system.

Clean up spills immediately, observing precautions in the Protective Equipment section. Carefully scoop up and place into appropriate disposal container. Provide ventilation. Do not get water inside containers. Cover with dry earth, dry sand, or other non-combustible material followed with plastic sheet to minimize spreading and contact with water.


11. Dimethyl formamide(DM F)CAS #68-12-2

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

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

Flammable liquid. Keep away from heat. Keep away from sources of ignition. Stop leak if without risk. Absorb with DRY earth, sand or other non-combustible material. Do not touch spilled material. Prevent entry into sewers, basements or confined areas; dike if needed.

12. Ethyl Acetate CAS # 141-78-6



Process details are provided in EIA report.


Risk assessment process rests on identification of specific hazards, hazardous areas and areas vulnerable to effects of hazardous situations in facilities involved in processing and storage of chemicals. In fact the very starting point of any such assessment is a detailed study of materials handled & their physical / chemical / thermodynamic properties within the complex at various stages of manufacturing activity. Such a detailed account of hazardous materials provides valuable database for identifying most hazardous materials, their behaviour under process conditions, and their inventory in process as well as storage and hence helps in identifying vulnerable areas within the complex. Hazardous posed by particular installation or a particular activity can be broadly classified as fire and explosive hazards and toxicity hazards. Whether a particular activity is fire and explosive hazardous or toxicity hazardous primarily depends on the materials handled and their properties. It will be from the above discussion that study of various materials handled is a prerequisite from any hazard identification process to be accurate. Based on this study the hazard indices are calculated for subsequent categorization of units depending upon the degree of hazard they pose. In a Agro/chemical Intermidiates Products Manufacturing Unit main hazard handling of hazardous chemicals like, solvents, corrosive and toxic chemicals, HSD as a fuel in Boiler and DG Sets, the primary concern has always been, fire and explosion prevention and control as these are the main hazard posed by such unit. This concern has grown through the loss of life, property and materials experienced after experienced after major disasters, which have occurred over the years. Identification of hazards is the most important step to improve the safety of any plant. The hazard study is designed to identify the hazards in terms of chemicals, inventories and vulnerable practices /operations.

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


1. Acetic Acid 2 2 1 14 2.2 3.08 95 Intermediate 27.84 125 125 15.7 Severe 2. Hydrogen 0 4 0 21 3.0 2.29 144 Heavy 120 - - - - 3. Sulfuric

acid 1 3 0 24 2.85 1.5 102.6 Intermediate 87 250 125 20.06 Severe

4. Toluene 0 3 0 16 2.55 3 122.4 Intermediate 106 125 50 11.4 Severe

5. Acetic anhydride

2 2 1 14 2.2 3.08 95 Intermediate 27.84 125 125 15.7 Severe

6. Acetone 1 3 0 16 2.55 2.3 93.84 Moderate 75 125 50 9.2 Moderate

7. Methanol 1 3 0 16 2.55 2.35 95.88 Moderate 78 50 50 5.3 Light

8. Ethanol 0 3 0 16 3.20 1.54 117.25 Intermediate 100 00 50 5.3 Light

9. Aceto Nitrile

2 3 0 16 2.55 2.35 95.88 Moderate 78 50 50 5.3 Light

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

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

All raw material and finished product will be stored in tank farm area and drum storage Shed. Required material will be charged in process through pump, drums in close circuit.

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

Hydrolisis and Hydrogination both Reactions are exothermic reaction and autoclave reaction at high pressure.

Hydrogen reaction area will be segregated from the other process and storage area. Various raw materials used in the manufacturing processes are listed in Table-3.3 in

Section-3 along with mode / type of storage & storage conditions. It can be readily seen that raw materials even though hazardous in nature, will be used in small quantities & storage quantities will also very low at process plant.

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

Hydrogen gas will be used in hydrogenation process and road skid will be used for process and it will be directly connected to PRV station.

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


Hazardous material release scenarios can be broadly divided into 2 categories

(I) Catastrophic failures which are of low frequency and (II) Ruptures and leaks which are of relatively high frequency.

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

Atmospheric storage

Catastrophic failure Significant leak

10-9 /yr 10-5 /yr

Process Pipelines < = 50 mm dia Full bore rupture

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

> 50 mm <=150mm dia Full bore rupture Significant leak

2.6 x 10-7 /m.yr 5.3 x 10-6 /m.yr

< 150 mm dia Full bore rupture Significant leak

8.8 x 10-8 /m.yr 2.6 x 10-6 /m.yr

Hoses Rupture 3.5 x 10-2 /m.yr


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

All raw material and finished product will be stored in tank farm area and drum storage Shed. Required material will be charged in process through pump, drums in close circuit.

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

Hydrolisis and Hydrogination both Reactions are exothermic reaction and autoclave reaction at high pressure.

Hydrogen reaction area will be segregated from the other process and storage area. Various raw materials used in the manufacturing processes are listed in Table-3.3 in

Section-3 along with mode / type of storage & storage conditions. It can be readily seen that raw materials even though hazardous in nature, will be used in small quantities & storage quantities will also very low at process plant.

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

Hydrogen gas will be used in hydrogenation process and road skid will be used for process and it will be directly connected to PRV station.

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


Considering this, the risk analysis and consequences studies are concentrated on Below area. (a) Under ground storage tank farm area, road truck unloading area (b) Drum storage area (c) Hydrogen cylinder and hydrogenation reaction shed


Hazardous subst ances may be released as a result of failures / cat astroph es, cau sin g possible damage to the surroundin g area. In the fol lowin g discussion , an account is tak en of vari ous ef fect s of releas e of hazard ou s substances and the p arameter s t o be d etermined for q uantif icat ion of such damages.

In case of rel ease of hazardou s substances the damages wil l depend largely on source st rength. The strengt h of t he sou rce mean s t he volume of t he substance released. The release may be instantaneous or semi -continuou s. In the case of instant aneous r elease, the strength of the source i s giv en in kg and in semi-continuou s release t he stre ngt h of t he source depends on t he out flow t ime (k g/s.). In order to f ire t he source st rength , it is first necessary to deter mine the stat e of a subst ance in a vessel . The physical propert ies, viz . Pressure and temperature of th e su bst ance det ermine t he phase of re lease. Th is may be gas, gas cond ensed t o l iquid and l iquid in eq uil ibrium with it s vapou r or solids. Instant aneous release wil l occur, for example, if a st orage tank fails. Depen ding on the st orage cond itions the fo llowin g sit uation s may occur . Th e source st rength i s equal t o the cont ents of t he capacit y of t he st orage system. In t he event of th e instant aneou s release of a l iquid a pool of l iquid wil l form. Th e evaporat ion can be calculated on the basis of this p ool .

In t he event of th e instant aneou s release of a l iquid a pool of l iquid wil l form. The ev aporati on can b e calculated on the basi s of this pool . Th e heat load on object outside a burning pool of l iquid can be calculated wit h t he heat radiat ion model . This model uses average radiat ion int ensity, which is d ependent on t he l iqu id. Account is als o t ak en of the diamet er -to-heigh t ratio of t he f ire , which dep ends on t he b urning l iquid. In addition, t he heat load i s a lso inf luenced by th e followin g fact ors:

Dist an ce f rom t he fire The relative humidit y of t he air (wat er vapour has a relatively high heat -

absorbing capacity) The orientation i . e. horizont al/vert ical of the objective irrad iat ed with

respect to the fir e.


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

UVCE stands for unconfined 36apour cloud explosion. The clouds of solvent vapour mix with air (within flammability limit 3.0 % to 11 %) may cause propagating flames when ignited. In certain cases flame may take place within seconds. The thermal radiation intensity is severe depending on the total mass of vapour in cloud and may cause secondary fire. When the flame travels very fast, it explodes causing high over pressure or blast effect, resulting in heavy damage at considerable distance from the release point. Such explosion is called UVCE (Unconfined Vapor Cloud Explosion) and is most common cause of such industrial accident.

Plumes are cont inuous release of hazardou s gases and vapour s. Sm oke from a chimney is an example. Plumes can cause FIRES AND EXPLO SIONS as secondary scenarios.

Puf fs are instantan eous release of hazardous gases and vapours. Puffs can give ri se to FIRE BALLS and vapour cloud explosions (VCE). A special case of vapour cloud explosion is the B oil ing Liquid Evaporat ing Vap our Explosion (BLEVE).

Spil ls are l iquid pools created by leaking l iquid chemicals. Spil ls caus e evaporation and dispersal of t oxic gases and if the spil led l iquid is flammable , then it can catch fire creat ing a pool fire a lso t he vapours can cau se explosion.

1. Under ground Storage tank farm area, road truck unloading area 2. Drum storage area. 3. Hydrogen cylinder skid and hydrogenation reaction shed.


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

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

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

total vapour mass Above the UEL-LEL % Ignition availability Toxic gas dispersion - Toxic Gas release due to catastrophic failure of tonner/bullet/ Tanks and ignition not available within LEL- UEL range. Considering the quantity of storages & nature of Toxic nature and Flammable storage, following scenarios were taken up for detailed analysis & safe distances computed : Catastrophic failure of road tanker of Ethyl Alcohol, Methanol and presence of ignition source poses heat radiation hazards to nearby areas. Failure cases considered for consequence analysis are representative of worst-case scenarios. Probability of occurrence of such cases is negligible (less than 1 x 10-6 per year) because of strict adherence to preventive maintenance procedures within the complex. General probabilities for various failure is provided in Table-4.2, 4.3 and 4.4, but consequences of such cases can be grave & far reaching in case such systems fail during life history of the company. Hence such scenarios are considered for detailed analysis. It is to be noted however that such situations are not foreseeable or credible as long as sufficient measures are taken. Also, consequence analysis studies help us evaluate emergency planning measures of the Company.

Damage effect s vary with dif ferent scenarios. Calcu lations for various scenarios are m ade for t he ab ove failure cases to quant ify th e resulting damages. Th e results are t ranslated in ter m of injuries an d damages to exposed person nel , equip ment, building etc. Tank on f ire /P ool fire due t o direct ignit ion source on t ank or road tank er or catastrophic failure or leakage or damage fr om pipelin e of storage facil ities or road tan ker unloading arm, can result in heat radiation causing burns t o people depending on t hermal load and period of exposure.


All such damages have t o b e specifi ed criteria for each su ch resultant ef fect, to relat e t he quantif ier damages in t his manner, damage criteria are used for Heat Radiat ion.

38 100% lethality, heavy damage to tanks 37.5 100% lethality, heavy damage to equipment. 25 50% lethality, nonpiloted ignition 14 Damage to normal buildings 12.5 1% lethality, piloted ignition 12 Damage to vegetation 6 Burns (escape routes) 4.5 Not lethal, 1st degree burns 3 1st degree burns possible (personnel only in emergency allowed) 2 Feeling of discomfort 1.5 No discomfort even after long exposure


In the risk analysis stu dy, probable damages du e to worst case s cen arios wer e quant ified and consequences were analyzed with object of em ergency plannin g. Variou s measures tak en by the company and f indings of t he study wer e con sidered for deciding accept abil it y of risks.

MCLS as su me maximum invent ory of hazar dous chemicals and wor st weather cond ition prevail ing at t he t ime of failure. Further, n o credit is giv en for t he safet y feat ures provided in the facil ity t o determine maxi mum possible damage from t he scenario selected. In real ity, leakage of hazardou s chemical wil l be smaller in magnit ud e. Also t he leakage wil l be d etected immediat ely by plant operating staff th en initiat e various mit igation measures to prevent any disast rous situat ion.

1. Loss of containment in Ethyl Alcohol, Methanol road tanker.

Unloading arm 100 % failure.

and immediate Ignition.

Unconfined Pool fire.

2. storage area. Drum failure Fire in drum storage.

3. storage area. Drum failure BLEVE in drum.

4. Catastrophic failure of Hydrogen pipe line rupture.

Random failure Jet fire.

5. Catastrophic failure of Hydrogen pipe line rupture.

Random failure Flash Fire (Explosion).

Average win d sp eed : 6 m / sec . Average Ambient Temperature : 35 deg. c. Average Humidity : 60 %


100 % failure of Unloading arm i s consid ered for 10 KL road tanker whil e unloading wor k. Tot al mat erial drain wi l l spread on f loor. Immediat e ignition wil l give unconf ined pool f ire.

Drum Fir e if direct i gnition on road tanke r. Drum st orage area fire d ue to heat ef fect and domino ef fect .

Hydrogen cylinder Pipeline to PRV station l ine damage and hydrogen gas release and it wil l be exploid due to an y ignition source. Following scenarios can b e possible.

Jet fire Explosion ( Over pressure) We have calculat ed following hazardous distance for the above

mentioned scen arios. Intensit y of H eat Radiat ion ( IHR) at groun d level (KW /m 2 )


Scenario : UNCONFINED POOL FIRE

In put Data Stored quantity 10 KL Pool diameter 35.6(m) Pool liquid depth 0.01 (m) Wind speed 6 m/s Liquid Density 790 kg/m3

Incident Intensity of

Heat Radiation ( IHR) at ground level KW /m

2

IHR- Isopleth Distance

( Meters )

Effect if IHR at Height of Simulation

37.5 19.2 Damage to process equipment. 100 % Fatal in 1 Min. 1 % fatal in 10 sec.

25.0 23.5 Min. to ignite wood ( without flame contact ). 100 % fatal in 1 Min. Significant injury in 10 sec.

12.5 33.2 Min. to ignite wood (with flame contact). 1 % fatal in 1 min. 1 st deg. burn in 10 sec.

4.0 58.6 Pain after 20 secs. Blistering unlikely.

1.6 92.7 No discomfort even on long exposure.

In the 19.2 meter radius area is considered as 100% fatality in 1 min. In the 33.2 meter radius first degree burn in 10 sec. In the 58.6 meter radius area will give pain after 20 seconds. Blistering unlikely.


Measures to control and mitigate Emergency of road tanker accident:

Measures to be taken to prevent such accident:

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

2. TREM card will kept with TL. 3. SCBA set will be kept with TL. 4. Fire extinguishers will be kept with TL. 5. Flame arrestor will be provided to TL exhaust. 6. Instructions will be given not to stop road tanker in populated area. 7. Clear Hazard Identification symbol and emergency telephone number will be

displayed as per HAZCHEM CODE. 8. Appropriate PPEs will be kept with TL.

1. Off site emergency agency telephone provided in TRM CARD. 2. Fire extinguishers are provided in TL. 3. Training provided to control such emergency to driver and cleaner. 4. Evacuate the area up to 200 meters in all direction.


5. In case of leakage from valve road tanker should be deriver away from the populated area.

6. Call to police, fire brigade, Users company and supplier company.

EMERGENCY RESPONSE Fire CAUTION: All these products have a very low flash point: Use of water spray when fighting fire may be inefficient. CAUTION: For mixtures containing alcohol or polar solvent, alcohol-resistant foam may be more effective. Small Fire Dry chemical, CO2, water spray or regular foam. Large Fire Water spray, fog or regular foam. Use water spray or fog; do not use straight streams. Move containers from fire area if you can do it without risk. Fire involving Tanks or Car/Trailer Loads Fight fire from maximum distance or use unmanned hose holders or monitor nozzles.

Cool containers with flooding quantities of water until well after fire is out. Withdraw immediately in case of rising sound from venting safety devices or

discoloration of tank.

ALWAYS stay away from tanks engulfed in fire.

For massive fire, use unmanned hose holders or monitor nozzles; if this is impossible, withdraw from area and let fire burn.

SPILL OR LEAK

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

All equipment used when handling the product must be grounded. Do not touch or walk through spilled material. Stop leak if you can do it without risk. Prevent entry into waterways, sewers, basements or confined areas. A vapor suppressing foam may be used to reduce vapors. Absorb or cover with dry earth, sand or other non-combustible material and

transfer to containers. Use clean non-sparking tools to collect absorbed material.

Dike far ahead of liquid spill for later disposal. Water spray may reduce vapor; but may not prevent ignition in closed spaces.


20 KL 143.48 Kw/m2 25(m) 21.60 meter 0.01 (m) 21.59 meter 6 m/s 5.02 kg/ m2/min. 867 kg/m3 1.66 Hrs.

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

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

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

70.7 Pain after 20 secs. Blistering unlikely.

111.8 No discomfort even on long exposure.

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

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

exposure.



20 KL 11.17 meter 80 Kgs. 186.59 Kw /m 2

40550 Kj/Kg 292486 Kj/ sec.

6 m/s 1.333e + 006 Kj

867 kg/m3 4.56 sec.

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

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

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

4.0 76 Pain after 20 secs. Blistering unlikely.

1.6 120 No discomfort even on long exposure.

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

exposure.



515 M3 52.49 Kw/m2

1 cm 6.3 meter 143463 m/s 1.2 meter

3 m/s 8.5 Kw/ m2 0.067kg/m3 37.78 m2

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

10.2 Min. to ignite wood ( without flame contact ). 100 % fatal in 1 Min. Significant injury in 10 sec.

14.4 Min. to ignite wood (with flame contact). 1 % fatal in 1 min. 1 st deg. burn in 10 sec.

25.4 Pain after 20 secs. Blistering unlikely.

40.1 No discomfort even on long exposure.

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

around gas receiving and handling equipment, the damage to equipment is likely to be very heavy.

In the 10.2 meter radius area it is also considered as 100 % fatality in 1 min. and 1 % fatal in 10 sec.

In the 14.4 meter radius area is considered as 1 % fatality in 1 min. and first degree burn in 10 sec.

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

In the 40.1 meter radius area is considered as safe area and no discomfiture even on long exposure.



7 m3 0.52meter 1 kgs 0.26 meter 42267 Kj/kg 2 sec. 0.600 4.19 meter

0029 283720 Kj

6.0 m/s 750 Kw/ m2

0.067 kg/m3 0.5

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

24 Min. to ignite wood ( without flame contact ). 100 % fatal in 1 Min. Significant injury in 10 sec.

32 Min. to ignite wood (with flame contact). 1 % fatal in 1 min. 1 st deg. burn in 10 sec.

57 Pain after 20 secs. Blistering unlikely.

89 No discomfort even on long exposure.

Results

In the 19 meter radius is considered as 100 % fatality in 1 min. area and around gas receiving and handling equipment, the damage to equipment is likely to be very heavy.

In the 24 meter radius area it is also considered as 100 % fatality in 1 min. and 1 % fatal in 10 sec.

In the 32 meter radius area is considered as 1 % fatality in 1 min. and first degree burn in 10 sec.

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

In the 89 meter radius area is considered as safe area and no discomfiture even on long exposure.



MCA Scenario –1 Unconfined pool fire due to Loss of containment in Methanol/ Toluene road tanker

10 26 41.1 72.6

MCA Scenario -2 Unconfined Pool Fire Simulation for Drum Storage Area.

20 23.1 40.0 70.7

MCA Scenario – 3 BLEVE simulation for Drums Storage

20 25.0 42.5 76.0

7 m3. 8.3 14.4 25.4

1 kgs 19 32 57

The appended table 6.3 summarizes the consequences of the various Scenarios analyzed under this study. As can be seen from the results of the summary of the Quantitative Risk Analysis study, the Total damage and Fatality zone due to Fire & Explosion up to 26 meters in worst case scenario. First degree burn zone up to 42 meter. Within the manufacturing processes, no major hazards are for seen due to minimal storage in process area. On site emergency preparedness plan will be prepared as per risk assessment findings. Emergency control facilities and resources will be plan and rehearsal / Mock- Drill to be conducted regularly to combat emergency in minimum time.


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

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

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

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

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

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

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

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

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

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

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

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

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

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

safety. Static earthing interlocking with pump facility to be provided in tank farm area to avoid

static hazard during tanker unloading work. Plant process safety recommendations provided in relavent section of the report should

be complied at plant comissining stage.


An onsite emergency in the industries involving hazardous processes or in hazardous installations is one situation that has potential to cause serious injury or loss of life. It may cause extensive damage to property and serious disruption in the work area and usually, the effects are confined to factory or in several departments of factory, premise. An emergency begins when operator at the plant or in charge of storage cannot cope up with a potentially hazardous incident, which may turn into an emergency.

A quick and effective response at during an emergency can have tremendous significance on whether the situation is controlled with little loss or it turns into a major emergency. Therefore, purpose an emergency plan is to provide basic guidance to the personnel for effectively combating such situations to minimize loss of life, damage to property and loss of property. An objective of Emergency Planning is to maximize the resource utilisation and combined efforts towards emergency operations are as follows. :

To increase thinking accuracy and to reduce thinking time. To localize the emergency and if possible eliminates it. To minimize the effects of accident on people and property. To take correct remedial measures in the quickest time possible to contain the incident

and control it with minimum damage. To prevent spreading of the damage in the other sections. To mobilize the internal resources and utilize them in the most effective way To arrange rescue and treatment of causalities.

To keep the required emergency equipment in stock at right places and ensure the

working condition. To keep the concerned personnel fully trained in the use of emergency equipment. To give immediate warning tooth surrounding localities in case of an emergency situation

arising. To mobilize transport and medical treatment of the injured. To get help from the local community and government officials to supplement manpower

and resources. To provide information to media & Government agencies, Preserving records, evidence of

situation for subsequent emergency etc.


This OSEP is prepared for industrial emergencies like fires, explosions, toxic releases, and asphyxia and does not cover natural calamities and societal disturbances related emergencies (like strikes, bomb threats, civil commission’s etc.)

The important elements to be considered in plan are

Emergency organization Emergency Facilities. Roles and Responsibilities of Key Personnel and Essential Employee. Communications during Emergency Emergency Shutdown of Plant & Control of situation. Rescue Transport & Rehabilitation. Developing Important Information.

The consideration in preparing Emergency Plan will be included the following steps:

Identification and assessment of hazards and risks. Identifying, appointment of personnel & Assignment of Responsibilities. Identification and equipping Emergency Control Centre. Identifying Assembly, Rescue points Medical Facilities. Formulation of plan and of emergency sources. Training, Rehearsal & Evaluation. Action on Site.

Earlier, a detailed Hazard Analysis and Risk Assessment was carried out on hazards and their likely locations and consequences are estimated following the standard procedure. However the causing factors for above discussed end results may be different and causing factors are not discussed in this plan.

Emergencies that may be likely at bulk fuel storage area, process plant, cylinder storage area, and drum storage shed, and autoclave reactor area. There are chances of fire and explosive only.

Other risks are earthquake, lightning, sabotage, bombing etc., which are usually, not in the purview of management control.

Plant organization is enclosed. Based on the plant organization, which includes shift organization, an Emergency Organization is constituted towards achieving objectives of this emergency plan.


Plant Manager is designated as Overall in Charge and is the Site Controller. The following are designated as Incident Controllers for respective areas under their control. Shift in charge Engineer (Plant Operations) is designated at Incident Controller for all areas of plant.

It is a location, where all key personnel like Site Controller, Incident Controller etc. can assemble in the event of onset of emergency and carry on various duties assigned to them. Plant Manager’s Office is designated as Emergency Control Centre. It has P&T telephone as well as internal telephones, ECC is accessible from plant located considerably away from process plant, Storage’s and on evaluation of other locations, Plant Manager’s Room find merit from the distance point of view, communication etc.

The following facilities and information would be made available at the ECC

Latest copy of Onsite Emergency Plan and off sites Emergency Plan (as provided by

District Emergency Authority). Intercom Telephone. P&T Telephone. Telephone directories (Internal, P&T) Factory Layout, Site Plan Plans indicating locations of hazardous inventories, sources of safety equipment, hydrant

layout, location of pump house, road plan, assembly points, vulnerable zones, escape routes.

Hazard chart. Emergency shut-down procedures. Nominal roll of employees. List and address of key personnel List and address of Emergency coordinators. List and address of first aides, List and address of first aid fire fighting employees, List and address of qualified Trained persons.

Internal hydrant system Portable extinguishers

These systems are proposed to protect the plant by means of different fire protection facilities and consist of


Hydrant system for exterior as well as internal protection of various buildings/areas of the plant.

Portable extinguishers and hand appliances for extinguishing small fires in different areas of the plant.

Water cum foam monitor to be provided in bulk fuel storage area. Fire water pumps. Two (2) independent motor driven pumps each of sufficient capacity and head are

proposed for the hydrant systems which is capable to extinguish Fire or cooling purpose.

Adequate number of fire hydrants and monitors will be provided at various locations in and around the buildings and other plant areas. The hydrants will be provided on a network of hydrant mains drawing water from the hydrant pump, which starts automatically due to drop of pressure in the event of operating the hydrant valves. We are suggesting you to go for TAC approved hydrant system for foolproof safety and benefit from fire policy premium.

The objective of the emergency escape is to escape from the hazardous locations, to the nearest assembly point or the other safe zone, for rescue and evacuation.

Assembly point is location, where, persons unconnected with emergency operations would proceed and await for rescue operation.

Wind socks for knowing wind direction indication would be provided at a suitable location to visible from many locations. It is proposed to install windsocks at plant and Administration Building so as to be visible from different locations in the plant.

Emergency Ambulance would be stationed at the Administration Office and round the clock-driver would be made available for emergency transportation of injured etc. However, the other vehicles of the company also would be available for emergency services.

There are two kinds of communication system provided.

(a) Regular P&T phones with intercom facility. (b) Mobile phone

The emergency would be communicated by operating electrical siren for continuously for five minutes with high and low pitch mode.


Priority of Emergency Protection.

Life safety Preservation of property Restoration of the normalcy

While necessary facilities are available and are updated from time to time, sometimes, it may be necessary to seek external assistance; it may be from the neighboring factories or from the State Government as the case may be.

Inspite of detailed training, it may be necessary to try out whether, the OSEP works out and will there be any difficulties in execution of such plan. In order to evaluate the plan and see whether the plan meets the objectives of the OSEP, occasional mock drills are contemplated. Before undertaking the drill, it would be very much necessary to give adequate training to all staff members and also information about possible mock drill. After few pre-informed mock drills, few UN-informed mock drills would be taken. All this is to familiarize the employees with the concept and procedures and to see their response. These scheduled and unscheduled mock drills would be conducted during shift change, public holidays, in night shift etc. To improve preparedness once in 6 months and performance is evaluated and Site Controller maintains the record. Incident Controller (IC ) coordinates this activity.

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