9.0 risk assessment & on site/off site emergency...

REIA of Kusa Chemicals Pvt. Ltd. S. No. 126/1,2,3, Godhra-Halol Highway, Vi: Popatpura, Ta: Godhra, Di:

Panchmahal, Gujarat

Chapter 9 Additional Studies

Prepared By: ECO-CARE SOLUTIONS, Vadodara,

September - 2014

197

9.0 RISK ASSESSMENT & ON SITE/OFF SITE EMERGENCY PLAN

Risk Assessment (RA) is a method that has proven its value as an all-round tool for

improving the safety standards prevalent in every hazardous industry. With advancements in

in-built and inherent safety systems, accident rates have come down, but still persist at

un-acceptable levels for newer technology and new process plants. Risk Assessment is a

structured safety assessment tool designed for high hazard industries such as chemical,

petrochemical, pesticides, pharmaceuticals etc., supplementing other safety system tool such

as HAZOP, safety audit, and regular incident analysis to identify the potential for incidents

(near-miss, unsafe conditions) and to evaluate the necessary control measures.

9.1 OBJECTIVE

The main objective of the Risk Assessment study is to determine damage due to major

hazards having damage potential to life and property and provide a scientific basis to assess

safety level of the facility.

The secondary objective is to identify major risk in manufacture of chemicals, storage of

chemicals and provide control though assessment. To prepare on- site, off site, disaster

management plan for control of hazards.

9.2 PHILOSOPHY

The main philosophy of risk assessment is to find out the real cause of accident and then

based on it to suggest appropriate remedial measures to prevent its recurrence. To find out

unsafe action negligence, omission or personal fault.

Software used for calculation- 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 sources 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


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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 provide output as amount of chemical discharged from the source as well as its

concentration in air it takes into account different levels of concentrations for a specified

chemical.

9.3 METHODOLOGY

Design data, built in safety systems to be provided are studied. Discussions are held with

officials. Safety related individual system is discussed.

Hazard identification exercise is conducted taking into consideration of materials, material

handling methods, operating procedures, built in safety in reactors, operating parameters

and safety measures to be taken in proposed plant. Few areas like process building, storage

of hazardous chemicals, to evaluate safety systems in the event of any abnormalities

occurring. Containment failure scenario related to storage area is considered for hazard

Analysis and consequences of such containment failures are considered in detail. Thus, this

study is mainly oriented towards actual risks rather than chronic risks.

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

been identified and their consequences are modeled mathematically using ALOHA

software.

9.4 PROJECT SETTING

The site is located at S. No.126/1,2,3, Godhra-Halol Highway, Vi: Popatpura, Ta: Godhra,

Di: Panchmahal. Other locational details are as follows:

The site is located:

o Approximately 10.0 km South of Godhra Town

o The site is on State Highway (Halol-Godhra).

o Geographical Location & Area of the Premises are displayed below:

o Latitude : 22° 42’ 50.57” N Longitude: 73° 34’ 49.17"E

o The total area of the site is 132905.63 m2.


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9.5 ORGANOGRAM OF THE COMPANY

DIRECTOR

UNIT HEAD

PRODUCTIO MANAGER

MAINTENANCE

ENGINEERSHIFT EXECUTIVE

ELECTRICAL

ENGINEERSTORE

SUPERVISOR

OPERATORS

HELPERS


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9.6 DETAILS OF STORAGE OF RAW MATERIALS/HAZ. MATERIALS

SR.NO

RAW MATERIALS

STATE

Mol. Formula

Mol.

Weight

Storage MOC

Storage

Capacity

No. of containe

r

Total

Quantity of

Storage

MT MT

1 MINERAL OIL LIQUI

D - - TANK SS 20 KL 5 100 KL

2

DIETHYLENE GLYCOL

LIQUI

D C4H10O3 106

DRUM

S

HDP

E 200 KG 50 10

3 DIETHANOLAMINE

LIQUID C4H11NO2 105

DRUMS

HDPE 200 KG 50 10

4

ETHYLENE OXIDE

GAS, LIQUI

D C2H4O 44 TANKS SS 7 KL 2 14 KL

5

2-

ETHYLHEXANOL

LIQUI

D 4R-OH 100

DRUM

S

HDP

E 200 KG 25 5

6 ETHYL ACRYLATE

LIQUID

CH₂CHCO₂CH₂C

H₃ 940 DRUM

S HDP

E 200 KG 25 5

7

FATTY ALCOHOL 16,18 SOLID R-CO-R - BAGS

HDP

E 25 KG 800 20

8

FATTY ALCOHOL

12, 14 LIQUI

D R-CO-R - TANK SS 15 KL 2 30 KL

9 METHACRYLIC ACID

LIQUID C4H6O2 86 TANK SS 15 KL 1 15 KL

10

METHYL METHACRYLATE

LIQUID C5H8O2 100 TANK SS 15 KL 1 15 KL

11 CASTOR OIL

LIQUID R-CO-R 910 TANK SS 10 KL 1 10 KL

12 NONYL PHENOL

LIQUID C9H19C6H4OH 220 TANK SS 15 KL 1 15 KL

13 OELIC ACID

LIQUI

D C18H34O2 282 TANK SS 15 KL 2 30 KL

14

PHOSPROUS PENTASUL SOLID P2S5 222

DRUMS

HDPE 300 KG 10 3

15 PHENOL SOLID C6H50H 94 TANK SS 15KL 1 15 KL

16 SOYA OIL

LIQUI

D R-CO-R - TANK SS 10 KL 1 10 KL

17 TOLUENE

LIQUID C6H5CH3 92 TANK SS 10 KL 1 10 KL

18 ZINC OXIDE SOLID ZnO 39 BAGS 50 KG 80 4

19 DIISOBUTYLENE Liquid C8H17 112.21 TANK SS 10 KL 1 10 KL

20 NONENE Liquid C9H18 126.24 TANK SS 10 KL 1 10KL

21

α-METHYL

STYRENE Liquid C9H10 118.18

DRUM

S

HDP

E 200 KG 25 5

22 STYRENE

Liquid C8H8 104 TANK SS 10 KL 1 10 KL

23 PHENOL Solid at

R.T C6H6O 94 TANK SS 20 KL 1 20 KL


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SR.NO

RAW MATERIALS

STATE

Mol. Formula

Mol. Weight

Storage

MOC

Storage Capacity

No. of containe

r

Total Quantit

y of

Storage

MT MT

26 P- CRESOL

Solid C7H8O 108.1 DRUM

S HDP

E 200 KG 50 10

27 MIX XYLENOL

Solid C7H10O 110 DRUM

S HDP

E 200 KG 25 5

28

BUTYLENE

OXIDE Liquid C4H8O 72 TANK SS 5 KL 1 5 KL

31 CATALYST

32 1) CLAY

Solid Clay - BAGS HDP

E 25 KG 120 3

33 2) ALCL3

Solid AlCl3 133.34

DRUM

S

HDP

E 25 KG 40 1

34

FORMALDEHYDE Liquid

CH2O+H2

O 30 DRUM

S HDP

E 200 KG 50 10

35 FO Liquid - - TANK SS 10 1 10KL

36 CHLORINE

GAS Cl2 70 Tonner

s MS 900 KG 3 2.7


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9.7 DETAILS OF STORAGE OF PRODUCTS

SR.NO

PRODUCTS STATE Mol. Formula

Mol.

Weight

Storage

MOC

Storage

Capacity

No. of container & size

Total

Quantity of

Storage

MT MT

1 Oil Additives Liquid

-( R-CO-R)n -

DRUMS

HDPE 200 KG 50 10

2 Emulsifer

Liquid (CH2CH2O)n

H - DRUM

S HDP

E 200 KG 50 10

3 Monomer

Liquid -

-

DRUM

S

HDP

E 200 KG 50 10

4

Zinc Di Alkyl Di

Thio Phosphate (ZDDP) Liquid

((RO)2PSS)2Zn

- DRUM

S HDP

E 200 KG 50 10

5 POLYAMIDES Solid(powde

r) -

- DRUM

S HDP

E 200 KG 25 5

6

ACRYLIC

EMULSION Liquid

(C5H8O2)n

(C4H6O2)n -

DRUM

S

HDP

E 200 KG 25 5

7

PIBSA(Polyisobutyle

ne Succenic Anhydride) Liquid

- -

DRUMS

HDPE 200 KG 25 5

8

Mix of Di Octyl

Mono Tri Octyl Di Phenyl Amine Liquid

C8H17(C12H11

N) 208

DRUM

S

HDP

E 200 KG

9

Mix of Di, Tri, Mono Octyl Phenyl-a-

Naphtalamine Liquid

C8H17(C16H13

N) 332

DRUMS

HDPE 200 KG

10

Mix of Mono, Di, Tri

Nonylated Diphenyl Amine Liquid

C9H18(C12H11

N) 295

DRUM

S

HDP

E 200 KG

50 10

11

Styrene Diphenyl

Amine Liquid

C8H8(C12H11N

) 273

DRUM

S

HDP

E 200 KG

12

Methyl Styrene

Diphenyl Amine Liquid

C9H10(C12H11

N) 287 DRUM

S HDP

E 200 KG

13 Nonylated p-Cresol

Liquid C9H18(C7H8O)

234

DRUM

S

HDP

E 200 KG

14 Styrenated Phenol

Liquid C8H8(C6H6O)

198

DRUM

S

HDP

E 200 KG

15 Tetra Methyl Bisphenol-F Liquid

(C7H9O)CH 122

DRUMS

HDPE 200 KG


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9.8 PROPERTIES OF HAZARDOUS CHEMICALS AS PER MSIHC RULES

Sr.

No

Full name Of the raw

materials

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

B.P. °C

F.P. °C

LEL

UEL %

TLV ppm

or mg/m

3

LD50

mg/Kg LC50 mg/l

Specific

Gravity (water

=1)

Vapor

density (air=1)

Odour

threshold ppm or

mg/m3

Chemical

Class (As per MSIHC

Rules)

1. Di isobutylene 102 - - - - 0.708 - - Flammable

2. Nonene 150 26 0.9 - -- 0.73 4.35 -- Flammable

3. α-methyle

styrene 165.

4 44(CC) 52 (OC)

1.9 100 ppm

4500 mg/kg

0.909 4.1 50 ppm Flammable

4. Styrene 145.

2

31.1CC)

36.7(OC)

1.1/6.

1

50

ppm 316 mg/kg 0.906 3.59 0.1 ppm Flammable

5. Phenol 182 79(CC)

85(OC)

1.7/8.

5 5 ppm 317/125 1.057 3.24 0.48 ppm

Flammable, Toxic,

Hazardous

6. Butylene oxide 63 -17 -- --

50 mg/kg/

1000 ppm/7 hr

0.837 2.2 - Flammable

7. Formaldehyde

37% 98

50(CC)

60(OC) 6/36.5

0.3

ppm 100 mg/kg 1.08 1.03 10 ppm Flammable

8. Ethylene Oxide 10.4 -20 3/100 1 ppm --/72

mg/kg - 1.52 - Flammable

9. Methacrylic

Acid 163

77(CC)

1.6/8.1

20 ppm

1250 mg/kg

1.015 2.97 - Flammable

10. Toluene 110.

6

4.4(CC) 16(OC)

1.1/7.

1

200

ppm

--/50

mg/kg 0.8636 3.1 1.6 ppm Flammable

11. FO 339 54

1.3/7.

5 100 ppm

-- 0.83 - <0.16 ppm Flammable

12. Coal-Anthrasite -- -- -- 10

ppm -- 2-3 - - --

13. Chlorine -35 -- -- 0.5 ppm

293 ppm/1 hr

-- 2.49 0.01 ppm combustible

Note: CC: Close Cup, OC: Open Cup, N.A.: Not Available


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9.9 OCCUPATIONAL HEALTH SURVEILLANCE PROGRAMME

Health surveillance is the monitoring of a person’s health to identify changes in health status

due to occupational exposure to a hazardous substance. It includes biological monitoring.

Ideally, the avoidance of work-related diseases should be achieved by the prevention or

controlling exposures to hazardous substances in the workplace. Where a process cannot be

designed or maintained to eliminate the risk of exposure, it may be necessary for workers to

undergo health surveillance.

9.9.1 AIMS OF HEALTH SURVEILLANCE

• Identify those at increased risk

Health surveillance is used to identify workers who have an increased risk of developing an

occupational disease. For example, people who have asthma are at increased risk of being

severely affected if exposed to potent respiratory irritants such as chlorine.

• Compliance with regulations

Health surveillance is sometimes required by laws and codes of practice (for example, a

worker exposed to lead in battery manufacture or a spray-painter exposed to isocyanates in

two-pack paints). Each state or territory has regulations containing a schedule of hazardous

substances for which health surveillance is mandated.

• Early detection

The major purpose of health surveillance is to detect adverse health effects at an early stage

so that the worker may be protected from further injury, either by control of the process or by

removal from exposure.

• Evaluating effectiveness of control measures

Health surveillance is not a control measure in itself and should not be the sole means of

determining whether control measures are effective. However, it can provide useful

information on the effectiveness of safe working practices.

• Epidemiology and disease


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Health surveillance can be used to evaluate the health experiences of groups of workers

exposed to specific hazardous agents or working within a particular industry.

Workers should be made aware that health surveillance is sometimes necessary to ensure

their ongoing health. Health surveillance is often used in addition to workplace monitoring.

Workplace monitoring will only indicate the potential for exposure of workers to a hazardous

substance. It can never be an indication of the actual amount of substance absorbed or the

effect on the body of absorbing the hazardous substance.

When a toxic substance (such as an industrial chemical) is present in the environment, it

contaminates air, water, food, or surfaces in contact with the skin: environmental monitoring

evaluates the amount of toxic agent in these media.

As a result of absorption, distribution, metabolism, and excretion, a certain internal dose of

the toxic agent (the net amount of a pollutant absorbed in or passed through the organism

over a specific time interval) is effectively delivered to the body and becomes detectable in

body fluids.

Subsequent interaction with a receptor in the critical organ (the organ which, under specific

conditions of exposure, exhibits the first or the most important adverse effect) leads to

biochemical and cellular events. Both the internal dose and the elicited biochemical and

cellular effects may be measured through biological monitoring.

• Mission

The overall mission of the Occupational Health Surveillance Program is to promote the

health, safety and quality of life of working people will be achieved:

9.9.2 SURVEILLANCE PROGRAM CAN BE IMPROVED BY FOLLOWING

ACTION

• Pre-placement examination and periodic examination must be carried out at workplace.

• Emergency/exposure examination and test should be carried out. Examination is based on

irritation, sensitization of skin, respiratory system, eye , shortness of breath.

• Maintain the work profile and medical history of employee/workers.

• Pulmonary function test must be carried out in case handling of formaldehyde.

• Written medical opinion must be maintained by industry.


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• Examination must be certify by qualified medical practitioners

9.9.3 OCCUPATIONAL HEALTH PROGRAMME

• The health & physical hazards caused due to toxic, irritant, corrosive, flammable materials. All

chemicals are within Threshold Limit Value as per ACGIH.

• Monitoring of occupational hazards like noise, ventilation, chemical exposure etc. will be

carried out regularly and its record will be maintained.

• Good housekeeping, use of PPE, Engineering controls, Enclosure processes, scrubber system,

display of safety boards, SOP of loading / unloading, local exhaust ventilation, safety shower

etc. are important safety measures have taken to keep these chemicals within TLV.

• Appropriate personal protective equipment will be provided & ensure the usage of them.

• Workers will be trained on safe material handling of hazardous chemicals.

• Prepare & display the safe operating procedure for hazardous chemicals storage, handling &

transporting or using.

• Periodical medical examination of the workers & Liver Function Testes will be done.

• Register (form no.37) for work place air monitoring will be done.

• Employee training and education will be carried out.

• Control the noise at source by substitution, isolation, segregation, barriers etc.

• Local Exhaust ventilation and scrubber should be installed where it is required to reduce

fumes, vapors, temperature and heat stress.

• Reduce the level of physical activity by sharing workload with other or by using mechanical

means.

• Pre-employment medical checkup and periodically medical examination will be done.

• Emergency /exposure examination and test should be carried out. Examination is based on

irritation, sensitization of skin, respiratory system, eye, shortness of breath

• Test must be carried out as per handling of chemicals as per OSHA guideline.

• Check the previous medical opinion of worker/employee as well as history.

• Safety showers is being placed within premises.


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9.9.4 MEASURES TO KEEP CHEMICALS WITHIN PEL/TLV.

• Process should be carried out in isolated area or closed system.

• Dilution ventilation/local exhaust ventilation system should be provided.

• Chemical handled by competent person

• MSDS of hazardous substance must be maintained by company.

• Quantity of substance should kept to absolute minimal.

• Flame proof electric fitting should be provided.

• Safety devices like temp. Control and pressure control must be provided to vessel

• Labeling and sign board should be provided.

• Fire fighting, sprinkling system and emergency exit should be provided.

• PPE must be used during handling of chemicals.

9.9.5 PRECAUTIONS DURING STORAGE & TRANSPORTATION OF

HAZARDOUS CHEMICALS

For Storage:

• Storage shall be in cool, dry well-ventilated location away from any area where the fire

hazard may be acute.

• Outside or detached storage shall be done for solvents storage and separate from

incompatible.

• Storage and use area shall be No smoking area.

• Use non-sparking type tools and equipment, including explosion proof ventilation.

• Dyke wall shall be provided to all storage tanks.

• Fire hydrant system has been installed and Mock drill is regularly conducted..

• Safety shower and eye washer shall be installed near storage area.

• Flame proof light fitting shall be provided at flammable storage area.

• Sprinkler system shall be installed at flammable material storage area.

• Earthing / bonding shall be provided for static charges.

• Level gauge and level measurement instrument shall be provided on material storage tank.

• Lightening arrestor on all chimney and building shall be provided.

• Safety permit system shall be followed for loading, unloading of hazardous chemical.


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• Fencing, caution note, hazardous identification board should be provided.

• Only authorized person shall be permitted in storage tank area and register will be

maintained.

• Quantity should be kept to minimum.

For Transportation:

• Solvent shall be received by road tanker and stored in above ground storage tank in

separated bulk storage area.

• Loading and unloading procedure shall be prepared for material received through road

tanker.

• Earthing/bonding shall be provided for static charges.

• Container shall be bonded and grounded for transfer to avoid static sparks.

• Flexible steel hose shall be used for unloading from the road tanker.

• Flame proof electric motor shall be used during loading/unloading.

• NRV shall be provided on pump discharge line.

• Fixed pipeline with pumps shall be provided for transfer to vessel.

• TERM CARD will be provided to all transporters and shall be trained for transportation

Emergency of hazardous chemicals.

• Personal Protective Equipment (safety goggles, hand gloves, apron, masks, gum boots etc.)

shall be provided.

Step if a spill Occurs:

• Stop or reduce the release of material , if it can be done safely.

• If there are noxious vapors, evacuate and notify supervisor or emergency coordinator.

• Eliminate all sources of ignition.

• Evacuate all person not wearing protective equipment from the area of the spill or leak until

cleanup is complete.

• Notify supervisor or emergency coordinator of the spill.

• Do not walk through spilled product. Avoid skin contact and inhalation.

• Stay upwind and keep out of low lying area.

• For large spills and fires , immediately call your fire department.

• Earthing/bonding shall be provided for static charges.

• Container shall be bonded and grounded for transfer to avoid static sparks.

Following emergency equipment shall be present on site.


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• Fire extinguishers

• Industrial first aid kit

• Safety Shower.

• Emergency shower

• Ample supply of potable water for washing as well as for drinking purpose.

• Emergency communication devices, such as mobile phone, or two way radios

• Vehicle suitable for emergency transport

9.10 RISK ASSESSMENT FOR STORAGE CHEMICALS

The worst case scenario of chemical release has been tabulated below

TABLE 9.1 WORST CASE SCENARIO OF CHEMICAL

Sr.No. Short description

of scenario

Chemical

involved

Type of

Risk

Probability Concentration Damage

Distance from

source

1 Release from

damage of Phenol

tank ( 20 KL)

Phenol Toxic

effect

Very

unlikely

15 ppm

23 ppm

200 ppm

1.6 Km

1.2 Km

339 meter

2 Release from

damage of Toluene storage tank

(10 KL)

Toluene Thermal

Radiation from pool

fire

Very

unlikely

2 kw/sqm

5 kw/sqm 10 kw/sqm

137 meter

95 meter 73 meter

3 Release from

damage of chlorine

tonner

( 900 kg)

chlorine Toxic

effect

Very

unlikely

0.5 ppm

2 ppm

20 ppm

2.4 Km

1.2 Km

343 meter

4 Release from

damage of Ethylene oxide

storage tank

(7 KL)

Ethylene

oxide

Toxic

effect

Very

unlikely

45 ppm

200 ppm

3.8 Km

2.0 Km


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9.10.1 SCENARIO 1: PHENOL

LOCATION: KUSA CHEMICALS, INDIA

TIME: FEBRUARY 14, 2014 20:00 HOURS

CHEMICAL DATA:

CHEMICAL NAME: PHENOL

MOLECULAR WEIGHT: 94.11 G/MOL

AEGL-1 (60 MIN): 15 PPM


AEGL-3 (60 MIN): N/A

IDLH: 250 PPM

LEL: 1.7 PPM

UEL: 8.6 PPM

AMBIENT BOILING POINT: 182.0° C

VAPOR PRESSURE AT AMBIENT TEMPERATURE: 0.032 ATM

AMBIENT SATURATION CONCENTRATION: 31,731 PPM OR 3.17%

ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)

WIND: 5 METERS/SECOND FROM N AT 3 METERS

GROUND ROUGHNESS: OPEN COUNTRY

CLOUD COVER: 3 TENTHS

AIR TEMPERATURE: 25° C

STABILITY CLASS: D

NO INVERSION HEIGHT

RELATIVE HUMIDITY: 52%

SOURCE STRENGTH:

DIRECT SOURCE: 320 KILOGRAMS/MIN

SOURCE HEIGHT: 0


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RELEASE DURATION: 60 MINUTES

RELEASE RATE: 320 KILOGRAMS/MIN

TOTAL AMOUNT RELEASED: 19,200 KILOGRAMS

THREAT ZONE:

MODEL RUN: GAUSSIAN

RED : 339 METERS --- (200 PPM = ERPG-3)

ORANGE: 1.2 KILOMETERS --- (23 PPM = AEGL-2 (60 MIN))

YELLOW: 1.6 KILOMETERS --- (15 PPM = AEGL-1 (60 MIN))


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9.10.2 SCENARIO 2: TOLUENE


TIME: FEBRUARY 14, 2014 20:45

CHEMICAL DATA:

CHEMICAL NAME: TOLUENE





IDLH: 500 PPM

LEL: 11000 PPM

UEL: 71000 PPM


VAPOR PRESSURE AT AMBIENT TEMPERATURE: 0.038 ATM

AMBIENT SATURATION CONCENTRATION: 37,542 PPM OR 3.75%



GROUND ROUGHNESS: OPEN COUNTRY C

LOUD COVER: 3 TENTHS


STABILITY CLASS: D

NO INVERSION HEIGHT


SOURCE STRENGTH:

LEAK FROM HOLE IN VERTICAL CYLINDRICAL TANK

FLAMMABLE CHEMICAL IS BURNING AS IT ESCAPES FROM TANK


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TANK DIAMETER: 2 METERS

TANK LENGTH: 3 METERS

TANK VOLUME: 9,425 LITERS

TANK CONTAINS LIQUID

INTERNAL TEMPERATURE: 25° C

CHEMICAL MASS IN TANK: 8.57 TONS

TANK IS 95% FULL

CIRCULAR OPENING DIAMETER: 1 FEET

OPENING IS 2 FEET FROM TANK BOTTOM

MAX FLAME LENGTH: 34 METERS

BURN DURATION: 5 MINUTES

MAX BURN RATE: 2,970 KILOGRAMS/MIN

TOTAL AMOUNT BURNED: 6,168 KILOGRAMS

NOTE: THE CHEMICAL ESCAPED AS A LIQUID AND FORMED A BURNING PUDDLE.

THE PUDDLE SPREAD TO A DIAMETER OF 28 METERS.


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THREAT ZONE:

THREAT MODELED: THERMAL RADIATION FROM POOL FIRE

RED : 73 METERS --- (10.0 KW/ (SQ M) = POTENTIALLY LETHAL WITHIN 60

SEC)

ORANGE: 95 METERS --- (5.0 KW/ (SQ M) = 2ND DEGREE BURNS WITHIN 60

SEC)

YELLOW: 137 METERS --- (2.0 KW/ (SQ M) = PAIN WITHIN 60 SEC)


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9.10.3 SCENARIO 3: CHLORINE



CHEMICAL DATA:

CHEMICAL NAME: CHLORINE


AEGL-1 (60 MIN): 0.5 PPM



IDLH: 10 PPM

AMBIENT BOILING POINT: -34.0° C

VAPOR PRESSURE AT AMBIENT TEMPERATURE: GREATER THAN 1 ATM

AMBIENT SATURATION CONCENTRATION: 1,000,000 PPM OR 100.0%






STABILITY CLASS: D

NO INVERSION HEIGHT


SOURCE STRENGTH:

DIRECT SOURCE: 8 LITERS/MIN

SOURCE HEIGHT: 0

SOURCE STATE: LIQUID

SOURCE TEMPERATURE: EQUAL TO AMBIENT


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RELEASE DURATION: 60 MINUTES

RELEASE RATE: 11.2 KILOGRAMS/MIN

TOTAL AMOUNT RELEASED: 669 KILOGRAMS

THREAT ZONE:

MODEL RUN: HEAVY GAS

RED : 343 METERS --- (20 PPM = AEGL-3 [60 MIN])

ORANGE: 1.2 KILOMETERS --- (2 PPM = AEGL-2 [60 MIN])

YELLOW: 2.4 KILOMETERS --- (0.5 PPM = AEGL-1 [60 MIN])


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9.10.4 SCENARIO 4: ETHYLENE OXIDE


BUILDING AIR EXCHANGES PER HOUR: 1 (USER SPECIFIED)


CHEMICAL DATA:

CHEMICAL NAME: ETHYLENE OXIDE


AEGL-1 (60 MIN): N/A



IDLH: 800 PPM

LEL: 30000 PPM

UEL: 1000000 PPM

CARCINOGENIC RISK - SEE CAMEO CHEMICALS


VAPOR PRESSURE AT AMBIENT TEMPERATURE: GREATER THAN 1 ATM

AMBIENT SATURATION CONCENTRATION: 1,000,000 PPM OR 100.0%






STABILITY CLASS: D

NO INVERSION HEIGHT



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SOURCE STRENGTH:

LEAK FROM HOLE IN HORIZONTAL CYLINDRICAL TANK

FLAMMABLE CHEMICAL ESCAPING FROM TANK (NOT BURNING)

TANK DIAMETER: 1.8 METERS

TANK LENGTH: 2.8 METERS

TANK VOLUME: 7,125 LITERS

TANK CONTAINS LIQUID

INTERNAL TEMPERATURE: 25° C

CHEMICAL MASS IN TANK: 6.50 TONS

TANK IS 95% FULL

CIRCULAR OPENING DIAMETER: 1 FEET

OPENING IS 1 FEET FROM TANK BOTTOM

RELEASE DURATION: 1 MINUTE

MAX AVERAGE SUSTAINED RELEASE RATE: 96.3 KILOGRAMS/SEC

(AVERAGED OVER A MINUTE OR MORE)

TOTAL AMOUNT RELEASED: 5,779 KILOGRAMS

NOTE: THE CHEMICAL ESCAPED AS A MIXTURE OF GAS AND AEROSOL (TWO

PHASE FLOW).

THREAT ZONE:

MODEL RUN: HEAVY GAS

RED : 2.0 KILOMETERS --- (200 PPM = AEGL-3 [60 MIN])

ORANGE: 3.8 KILOMETERS --- (45 PPM = AEGL-2 [60 MIN])

YELLOW: NO RECOMMENDED LOC VALUE --- (N/A = AEGL-1 [60 MIN])


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9.11 ACTION PLAN FOR HANDLING & SAFETY SYSTEM

• Wind indicator should be provided at the highest level of the plant to know the wind

direction.

• Sprinkler system for the flammable material tanks (over ground tanks only) may be

provided as knock on effect in case of fire is possible.

• Containment dykes with proper sloping and collection sumps should be provided so that

any spillages in the bulk storage and other handling areas shall not stagnate and shall be

quickly lead away to a safe distance from the source of leakage. This reduces the risk of

any major fire on the bulk storages and the risk to the environment shall be minimized/

eliminated.

• Inspection of the storage tanks as per prefixed inspection schedule for thickness

measurement, joint and weld efficiency etc.

• Provision of flameproof electrical fittings / equipment’s.

• Proper maintenance of earth pits & Regular check of Resistance.

• Strict compliance of security procedures like issue of identity badges for outsiders, gate

passes system for vehicles, checking of spark arrestors fitted to the tank lorries etc.

• Strict enforcement of no smoking.

• Periodic training and refresher courses to train the staff in safety fire fighting.

• Employee training and education will be carried out.

• Emergency drills should be carried out periodically to ensure preparedness must continue.

• Many operations involve use of highly toxic/flammable materials and these needs to be

documented as SOPs. These must be made and kept updated on priority.

• Extensive training on use of Self Contained Breathing apparatus (SCBAs) must be

ensured for emergency control.

• Many of the raw materials used for resin are either toxic or flammable. It is therefore

important to ensure that these materials are stored in closed, well ventilated totally safe

areas. A fire alarm system (heat and smoke detection) should be provided for the storage

area where the material is stored as toxic fumes arise on combustion.

• Loose drums of waste materials, often solvent laden, must be removed from the working

areas and close watch kept.

• Proper Earthing needs to be provided through plug type systems or through the

agitators/liquid.


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• Ventilation should be provided for any enclosed are where hydrocarbon or toxic vapors

may accumulate. Several such areas were noticed- these may be surveyed and tackled

accordingly.

• All personnel should be trained in handling emergency situations and should be apprised

of their role in handling emergency situation and to ensure adequacy of the emergency

procedures simulated exercise should be carried out. This was found wanting.

• Flame arrestor should be provided.

• Adequate number of caution boards highlighting the hazards of chemicals should be

provided at critical locations.

• The health & physical hazards caused due to toxic, irritant, corrosive, flammable materials.

All chemicals are within Threshold Limit Value as per ACGIH.

• Monitoring of occupational hazards like noise, ventilation, chemical exposure etc. will be

carried out regularly and its record will be maintained.

• Good housekeeping, use of PPE, Engineering controls, Enclosure processes, scrubber

system, display of safety boards, SOP of loading / unloading, local exhaust ventilation,

safety shower etc. are important safety measures have taken to keep these chemicals

within TLV.

• Appropriate personal protective equipment will be provided & ensure the usage of them.

• Workers will be trained on safe material handling of hazardous chemicals.

• Prepare & display the safe operating procedure for hazardous chemicals storage, handling &

transporting or using.

• Local Exhaust ventilation and scrubber should be installed where it is required to reduce

fumes, vapors, temperature and heat stress.

• Reduce the level of physical activity by sharing workload with other or by using mechanical

means.


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� FOLLOWING FIRE SAFETY DEVICES WILL BE PROVIDED TO PROTECT FROM ANY

MALFUNCTIONING OF PLANT EQUIPMENTS. FOLLOWING FIRE PROTECTION SYSTEMS WILL

BE PROVIDED.

• Water storage of adequate capacity to meet the requirements of water for firefighting

purposes.

• Fire hydrants and sprinkler system, Diesel driven pumps and headers to supply water to

fire hydrant network.

• Adequate Portable fire extinguishers, sand bucket, wheeled fire & safety equipment

should be provided at the required places.

• Equipment required for personal safety like blankets, gloves, apron, gum boots, face mask

helmets, safety belts, first aid boxes etc. are provided. Proximity suits and self-contained

breathing apparatus to be provided.

9.12 ON SITE EMERGENCY PLAN& OFF SITE EMERGENCY PLAN

9.12.1 OBJECTIVES

The overall objectives of are:

• To control the situation and if possible eliminate as quickly as possible.

• To avoid confusion/panic and to attend the emergency with clear-cut line of action.

• To minimize the loss of property to the plant as well as to our neighborhood.

• To safe guard the non-affected areas.

• To alert the neighborhood.

• To arrange head-count and rescue operations.

• Treatment of the injured.

• To safeguard others by timely evacuation.

• To prevent any cascade of emergencies.

9.12.2 EMERGENCY

An emergency is the situation, which has potential to cause a large-scale damage or

destruction to life or property or Environment or combination of these within or outside the

factory. Therefore it is essential to have a laid down procedure to meet emergency

systematically.

In any industry, emergency can arise at any moment and this depends on the type of:


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• Structure

• Raw materials

• Machines

• Nearby Industries

• Location of the Industry etc.

9.12.3 TYPES OF EMERGENCY:

The "Emergency" specified in this plan will refer to occurrence of one or more of the

following natural/manmade events.

• Fire

• Explosion

• Release of Toxic Gas/Vapour

• Spillage of flammable liquid /gas

• Deliberate Sabotage, Terrorism, Air Raid etc.

• Natural Calamities: - Lightening, Storm, Earthquake, Flood etc.

• Collapsing of structure

• Overturning of tanker containing flammable / toxic substances.

9.12.4 NATURE OF EMERGENCY

If there is any emergency in part of the plant / work place / industry due to any

reason, the area which may be affected due to the emergency can be divided in the

following two natures

Nature – I (On Site Emergency)

Effects remain limited to plants / industry boundary.

Nature – II (Off Site Emergency)

Effect spread to neighboring industry / population.

9.13 OFF SITE EMERGENCY

Events likely to endanger the human lives, plant and equipment within the factory and also

in the neighborhood and is not possible to control with the resources available within the

factory.


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Requires mobilization of outside resources from Local / District Authorities such as

Hospital Facilities, Civil Defense, District Magistrate, Police, Army, Air Force, and other

agencies (may be called into control and contain the emergency).

A. Functions of the State Crisis Group

The State Crisis Groups shall –

• Review all district off-site emergency plans in the State with a view to examine its

adequacy in accordance with the Manufacture, Storage and Import of Hazardous

Chemical, Rules and forward a report to the Central Crisis Group once in three months;

• Assist the State Government in managing chemical accidents at a site;

• Assist the State Government in the planning, preparedness and mitigation of major

chemical accidents at a site in the State;

• Continuously monitor the post accident situation arising out of a major chemical

accident in the State and forward a report to the Central Crisis Group;

• Review the progress report submitted by the District Crisis Groups;

• Respond to queries addressed to it by the District Crisis Groups; and

• Publish a list of experts and officials in the State who are concerned with the

management of chemical accidents.

B. Functions of the District Crisis Group

The District Crisis Group shall –

Assist the preparation of the district off-site emergency plan;

• Review all the on-site emergency plans prepared by the occupier of Major Accident

Hazards installation for the preparation of the district off-site emergency plan;

• Assist the district administration in the management of chemical accidents at a site lying

within the district;

• Continuously monitor every chemical accident;

• Ensure continuous information flow from the district to the Centre and State Crisis

Group regarding accident situation and mitigation efforts;

• Forward a report of the chemical accident within fifteen days to the State Crisis Group;


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and

• Conduct at least one full scale mock-drill of a chemical accident at a site each year and

forward a report of the strength and the weakness of the plan to the State Crisis Group.

C. Functions of the Local Crisis Group

The Local Crisis Group shall -

• Prepare local emergency plan for the industrial pocket;

• Ensure dovetailing of the local emergency plan with the district off-site emergency

plan;

Train personnel involved in chemical accident management;

• Educate the population likely to be affected in a chemical accident about the

remedies and existing preparedness in the area;

• Conduct at least one full scale mock-drill of a chemical accident at a site every six

months and forward a report to the District Crisis Group; and

• Respond to all public inquiries on the subject.

The Off-site Emergency Plan shall be contains up-to-date details of outside emergency services and resources such as Fire Services, Hospitals, Police etc. with telephone number.

a. Police Department.

b. Revenue Department.

c. Fire Brigade.

d. Medical Department.

e. Municipality.

f. Gram Panchayat.

g. Railway Department.

h. Telephone Department.

i. Factory Department.

j. Electricity Department.

k. Pollution Control Department.

l. Explosive Department.

m. Press and Media.


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9.14 ON SITE EMERGENCY

Events likely to endanger human lives, plant and equipment, and is beyond the control of

shift personnel and facilities available in the plant.

Requires mobilization of additional resources of other plant / department to handle the

emergency.

Require help under mutual aid scheme for fire fighting and rescue operation from nearby

industries.

9.14.1 DEFINITION:

Environment as defined u/s 2(a) of the environment Protection Act includes water, air and

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

human beings, other living creatures, plants, micro organism and property.

Environment pollutant defined by the same Act as any solid, liquid or gaseous substances

present in such concentration as may be tend to injurious to atmosphere.

Hazardous substance is also defined by the same Act and hazardous process is defined by

sec.2 (cb) of the Factories Act. 1948.

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

environment or any combination of these criteria.

Chemical Hazard is a hazard due to chemical (including it’s storage, process, handling etc.)

and it is realized by fire, explosion, toxicity, corrosivity, radiation etc.

Risk is a likelihood of an undesired event (i.e. accident, injury or death) occurring within a

specified period or under specified circumstances.

Individual risk is the frequency at which any individual may be expected to sustain a given

level of harm from the realization of specific hazards.

Social risk is a measure of chances of a number of people being effected by a single event or

set of events and is often presented as f/n curves (i.e. frequency v/s number of people

effected)


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The on-site emergency plan will deal with measures to prevent and control emergencies

affecting public and the environment outside the premises. The manufacturer should provide

the necessary information on the nature, extent and likely effects of such incidents.

Disaster is a catastrophic situation in which the day-to-day patterns of life are, in many

instances, suddenly disrupted and people are plunged into helplessness and suffering and as a

result need protection, clothing, shelter, medical and social care and other necessities of life,

such as: -

• Disasters resulting from natural phenomenon like earthquake, volcanic eruptions,

storm, surges, cyclones, tropical storms, floods, landslides, forest fires and massive

insect infestation. Also in this group, violent draught which will cause a creeping

disaster leading to famine, disease and death must be included.

• Second group includes disastrous events occasioned by man, or by man’s impact

upon the environment, such as armed conflict, industrial accidents, factory fires,

explosion and escape of toxic gases or chemical substances, river pollution, mining

and other structural collapses; air, sea, rail and road transport accidents, aircraft

crashes, collision of vehicles carrying inflammable liquids, oil, spills at sea, and dam

failures.

9.14.2 ACCIDENT:

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

damage or both. It may result in physical harm (injury or disease) to person (s), damage to

property, loss to the company, a near miss or any combination of the effect.

A Major accident is a sudden, unexpected, unplanned event, resulting from uncontrolled

developments during and industrial activity, which causes or has a potential to cause

• Serious adverse effects immediate or delayed (death, injuries, poisoning or

hospitalization) to a number of people inside the installations and/ or to persons

outside the establishment.

• Significant damage may be caused to crops, plants or animals or significant

contamination of land waters or air.

• An emergency intervention outside the establishment (evacuation of local

population, stopping of local traffic).

• Any combination of above.


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9.14.3 MEDICAL HELP:

First Aid Boxes have been provided at various strategic locations. Requisite number

employees are trained about First Aid, Liaison with nearest hospitals.

9.14.4 COMMUNICATION SYSTEM:

• Alarm Raising for Emergency by blowing the sirens installed

• The siren will be used for raising the emergency alarm and also for all clear signals.

• Emergency Siren: The wailing alarm will be sounded intermittently at fixed interval of 30

seconds for a period of two minutes in case of emergency, such alarm will signify the

employees that an emergency has occurred and that the emergency services should be put

into operation.

• Incident Controller after assessing the situation will declare that emergency is over. Till the

Incident Controller issues the declaration, all the leaders will adhere to the task and be

present at the prescribed location.

• All clear signal will be sounded through continuous siren for 1 minute. Even after the

emergency is over a skeleton staff of the Rescue/Evacuation Team will be available at the

site of emergency for at least 30 minutes to ensure that the situation is absolutely free from

danger.

• After the emergency is over, all the team leaders should meet at the Emergency Control

Center and each team leader should submit a report to the Incident Controller about team

performance and other details observed.

• In addition to the above systems, internal telephones, P.A.System, Mobile telephones,

Computer System etc. will be used for communication.

• If situation is beyond the control, the external agencies will be informed accordingly and

asked for the help. Direct telephone, cell phone or messengers / runners may achieve this.

9.14.5 ASSEMBLY POINT:

In case of emergency some locations are considered as Assembly Points. Depending on the

wind direction and location of emergency, Assembly Point will be declared. The employees

should run across the wind direction and not against the wind direction.


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Depending upon the location of the emergency the Incident Controller will fix the Assembly

Point and Officer will announce the location of the Assembly Point. Employee’s attendance,

visitors and contractors workmen register will be made available at the Assembly Point for

head count.

EMERGENCY CONTROL CENTER:

Factory Manager Office will be declared as an Emergency control center. Emergency control

center is facilities with:

• Address and Telephone numbers of the Factory Inspectorate, Gujarat Pollution Control

Board, Police, Fire Brigade, Hospitals and OEP Team Members

• Plant layout-indicating storage of hazardous materials, layout of fire

Hydrants/extinguishers, entrances/exits, roads etc.

• Portable P.A. System, Manual Siren, flood lights, Torches, Pickaxe, Saw, Nylon Ropes.

• Fire Blankets / Fire Proximity Suit, Breathing Apparatus, First Aid Box etc.

• List of employees with address, telephone number, blood group etc.

• Material Safety Data Sheets of all chemicals handled.

9.14.6 WIND SOCKS:

Wind direction will be determined with the help of installed windsocks.

9.14.7 MOCK DRILL:

Mock drills are carried out regularly to familiarize the staff with their roles, fire protection

equipment/system installed in the plant and use of personnel protective equipment. Senior

officials monitor this and shortcomings are thoroughly studied and necessary corrective

measures are taken.

PROCEDURES FOR MOCK DRILLS

• Inform all the employees about mock drills and the signal to be given.

• Fix the date and location of the emergency for mock drills.

• Mock drills will be monitored by observers.

• Raise the siren for emergency.


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• After hearing the siren the Incident Controller, Site Controller, Officers and Team Members

should actuate the “On-site Emergency Plan”.

PROCEDURE ON NOTICING AN EMERGENCY

• If anybody notices any situation, which may lead to a disaster, should be immediately

inform the Shift In-charge / site controller / Incident Controller / Fire & Safety Supervisor /

Security.

• Take charge of the situation as Incident Controller.

• Rush to the site of emergency to get the correct picture and then to Emergency Control

Center for speedy control over the situation by making an arrangement for raising the alarm.

• On arrival of Team members, he shall assign duties as required and activate the On-Site

Emergency Plan.

• Ensure safety of the plant and the personnel in the plant. He will make an assessment of the

emergency and decide on external assistance.

• Communicate and Coordinate among the Incidents Controller/ Site Controller/ Factory

manager/ fire safety supervisor etc. and will be the final authority on all matters related with

management of emergency such as:

• Fire fighting.

• Welfare and rescue operations.

• Arrange for Civil/Mechanical/Electrical work during emergency.

• Transport.

9.14.8 INCIDENT CONTROLLER / SITE CONTROLLER:

Rush immediately to the scene of the fire/emergency, select and set out appropriate

fire/emergency equipment. He will take the below mentioned actions at the earliest

opportunity, if the fire/emergency is not controlled.

He will

• Call the security personnel from their residences for additional manpower if

required.

• Regulate entry and exit of personal required for controlling the fire/emergency.

• Restrict exit of personal required for controlling the fire/emergency.


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• Arrange for Personnel Protective Equipment required for the emergency.

• Call, the local Fire Brigade, Police in case of necessity in consultation with the

Incident Controller.

• Arrange transport facilities for removal of causalities to dispensary / hospital.

• Take responsibility of law and order.

• Keep detailed records of the incident and progress of operations to fight the emergency.

9.14.9 FACTORY MANAGER:

He will rush to the Emergency Control Centre and collect the information from the Incident

Controller. Further he will,

• Announce the location of the Assembly Point after getting information from Incident

Controller / site controller.

• Take the list of persons to be communicated internally and externally.

• Maintain liaison with the press, government agencies i.e. Police, Fire Brigade etc.

and the neighborhood regarding the emergency under instructions from Incident

Controller.

• Courteously Receive officers from the State Government or neighbors to the

Administration Block only and inform to Incident Controller that they can be taken

care off.

• Take all the steps required for the welfare such as providing tea, snacks, emergency

temporary Medical Center in consultation with the incident controller/site controller.

• Disclose all the necessary information in the plant and media so as to avoid rumors

and confusion.

• Also be responsible for the head counts at the Assembly Points.

9.14.10 FIRE & SAFETY SUPERVISOR/ SHIFT INCHARGE& S ECURITY:

• Proceed to the scene; establish contact with firemen and incident controller to

supplement efforts in fire fighting.

• Assist in searching casualties and help to remove them to the medical center.

• Organize outside assistance in fire fighting and rescue operations if required.

• Mobilize personal protective equipment and safety appliances and assist personnel

handling emergency in using them.


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• Keep and check on any new development of unsafe situation and report the same to

Site Main Controller.

• Collect and preserve evidence to facilitate future inquiries.

• Effectively cordon off the emergency area and will prevent unauthorized people

entering the scene.

• Permit the Fire tenders or Ambulance requisitioned by Incident Controller to the

plant.

• Ensure that vehicles and trolleys are sent out of the plant premises.

• Ensure that all the employees are conducted out of plant and assembled at Assembly

Point.

• Control Traffic Movement.

• Remove tankers, tanker drivers outside.

• Entry of unauthorized public to be prevented.

• Arrange for vehicles for shifting casualties and essential workers to safe assembly

points.

9.14.11 ENGINEERING/ OPERATION & MAINTENANCE:

• Ensure the safety of the remaining part of the plant.

• Take necessary steps for plant shutdown in consultation with the site controller.

• Ensure that an Operator is immediately available at the Water Pump House for fire

fighting.

• Mobilize with necessary tools and tackles to handle any repair work on an

emergency basis.


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9.15 MSDS – MATERIAL SAFETY DATA SHEET

A material safety data sheet has information on using and storing hazardous substances safely.

It must state:

• a hazardous substances product name

• the chemical name of certain ingredients which also have a generic name

• the chemical and physical properties of the hazardous substance

• health hazard information

• precautions for safe use and handling

• manufacturer or importer’s name, address and telephone number

How to use MSDS

• identify the hazards associated with a hazardous substance

• check that all hazardous substances are being used in the manner intended

• decide whether any improvements should be made to control methods or procedures

• Identify necessary control measures before the introduction of a new hazardous substance.

• Decide whether workplace monitoring or health surveillance should be done.

9.0 risk assessment & on site/off site emergency...

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