Download - CHAPTER - 7 ADDITIONAL STUDIES
CHAPTER - 7
ADDITIONAL
STUDIES
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-148
Report No. 1718A058
CHAPTER – 7
ADDITIONAL STUDIES
7.1 PUBLIC HEARING
Public hearing is applicable for the proposed unit as stipulated in ToR Letter No: IA-J-11011/517/2017-IA-
II(I) Dated: 9/12/2017 issued by MoEF. Public hearing was conducted on 25th
May 2018, at Palsana, Surat
and MOM of public hearing, issues raised and commitments made by the project proponent during public
hearing with action plan in tabular chart Annexure- XLII.
7.2 GENERAL
M/s. Spectrum Dyes & Chemicals Private Limited was incorporated in the year 1989 for manufacturing Disperse Dyes. Spectrum has a fully integrated installed plant for manufacturing Disperse dyes and
Intermediates and is the second largest disperse dyestuff manufacturing company in India. Spectrum has a
strong customer base. Besides the local Surat market, the company is selling its products all across India and
abroad. Spectrum follows stringent quality controls in the manufacturing process and sourcing of all the raw materials.
These products are manufactured in compliance to the international standards acceptable in Dyes and Intermediates industry. Spectrums’ Research & Development Department is equipped with the latest equipments. In a proactive measure, experienced scientists continually research on improvements in existing
products and processes as well as innovation for higher efficiency and newer products. One such step is to
improve technologies to minimize impact on environment.
7.3 RISK ASSESSMENT AND DISASTER MANAGEMENT PLAN AND OBJECTIVE
Industrial accidents results in great personal and financial loss. Managing these accidental risks in today’s
environment is the concern of every industry, because either real or perceived incidents can quickly jeopardize
the financial viability of a business. Many facilities involve various manufacturing processes that have the
potential for accidents which may be catastrophic to the plant, work force, environment, or public. The main
objective of risk assessment study is to propose a comprehensive but simple approach to carry out risk
analysis and conducting feasibility studies for industries and planning and management of industrial prototype
hazard analysis study. It is essential to achieve and maintain high standards of plant integrity through good
design, management and operational controls. However, accidents do occur and these can cause serious injury
to employees or to the public, and damage to property. Most disastrous events like the Bhopal tragedy have
emphasized the need to address both on-site and off-site safety. The public concern at such events invariably
leads to call for additional control at national and international levels. It is against this background that the
various Section and Rules under the Environment Protection Act, 1986, the Factories Act, 1948 and other
Acts specify the requirements for a safe and reliable working of an industry. These require carrying out
various studies and analysis to assess and mitigate hazards prevalent in the factory in line with the above goal
of safe and reliable working.
The main objectives of the Risk Assessment Studies are :
1. To define and assess emergencies, including risk hazard assessment.
2. To control and contain incidents.
3. To safeguard employees and people residing in vicinity of the company.
4. To minimize damage to property and environment through appropriate installed mitigating procedures.
5. To be ready for mutual aid if need arise to help neighboring units. Normal jurisdiction of an OEP (ON-
SITE EMERGENCY PLAN) is to control events in own premises only. When it comes to the mutual
aid it requires catering to Mutual Aid Partners also.
The study includes predictions of the WORST CASE SCENARIO (catastrophic failure) and MAXIMUM
CREDIBLE ACCIDENT SCENARIO along with damage distances and preparedness plan for effectively
combating such situations. The report also discusses and demarcates the vulnerable zones.
No plan is complete or total of its requirements and its scope of improvement is a continuous process. Hence,
the Risk Assessment Report is to be reviewed and updated as and when:
• Any expansion, alteration, or extension of the plant is planned / implemented
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-149
Report No. 1718A058
• An incident has occurred and been dealt with, based on feedback gathered on any shortcomings in the
handling of the situation
• Any feedback is received from the users of the report
Risk Assessment is therefore defined as a continuous and integrated process of identification, evaluation, and
measurement of risks, along with their potential impact on the organization.
7.4 TOOLS & SOFTWARE USED FOR CALCULATIONS
7.4.1 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 one can use as a tool for predicting the movement and dispersion of
gases. It predicts pollutant concentrations downwind from the source of a spill, taking into consideration the physical characteristics of the spilled material. ALOHA also accounts for some of the physical characteristics of the release site, weather conditions, and the circumstances of the release. Like many computer programs, it
can solve problems rapidly and provide results in a graphic, easy-to-use format. This can be helpful during an
emergency response or planning for such a response.
ALOHA provides output as amount of chemical discharged from the source as well as its concentration in air it takes in to account different levels of concentrations for a specified chemical. Different concentration levels
are given below:
ERPG 1: is the maximum airborne concentration below which it is believed that nearly all individuals could
be exposed for up to 1 hour without experiencing other than mild transient adverse health effects or perceiving a clearly defined, objectionable odor.
ERPG 2: is the maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 hour without experiencing or developing irreversible or other serious health effects or
symptoms which could impair an individual's ability to take protective action.
ERPG 3: is the maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 hour without experiencing or developing life-threatening health effects.
IDLH: The Immediately Dangerous to Life or Health (IDLH) level. A chemical's IDLH is an estimate of the maximum concentration in the air to which
7.5 ELEMENTS OF THE RH STUDY
7.5.1 ELABORATED QUALITATIVE & QUANTITATIVE RISK ASSESSMENT
(METHODOLOGY)
Identification, analysis and assessment of hazard and risk are very useful in providing information to risk management. It provides basis for what should be the type and capacity of its, on-site and off-site emergency
plans. Risk analysis is carried out considering storage and handling of various hazardous raw materials,
manufacturing process and storage of hazardous finished goods.
7.5.2 TOXIC EFFECTS OF CHEMICAL SUBSTANCES. WHAT ARE THE LIMITS? Toxic chemicals are substances that may cause harm to an individual if it enters the body. Toxic chemicals
may enter the body in different ways. These ways are called the route of exposure. The most common route of exposure is through inhalation (breathing it into the lungs). Another common route of entry is through skin
contact. Some chemicals can easily pass through unprotected skin and enter the body. Ingestion is another, less common, route of exposure in the workplace. Ingestion often occurs accidentally through poor hygiene practices. Below shows Toxicity limits by enters the body in different ways.
SR.
NO TOXICITY
ORAL
TOXICITY
LD50(MG/KG)
DERMAL
TOXICITY
LD50(MG/KG)
INHALATION
TOXICITY
LC50(MG/L)
1. Extremely toxic > 5 <40 < 0.5
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-150
Report No. 1718A058
2. Highly toxic >5-50 >40-200 < 0.5 - 2.0
3. Toxic >50-200 > 200-1000 >2-10
7.5.3 ASSESSMENT OF FLAMMABILITY & EXPLOSIVE PROPERTIES.
FLAMMABLE CHEMICALS: what law interprets and gives limits. (1) Flammable gases: Gases which at 20
oC and at standard pressure of 101.3KPa are :-
(a) Ignitable when in a mixture of 13 percent or less by volume with air, or;
(b) Have a flammable range with air of at least 12 percentage points regardless of the lower flammable limits.
Note: The flammability shall be determined by tests or by calculation in accordance with methods
adopted by International Standards Organization ISO Number 10156 of 1990 or by Bureau of Indian Standard ISI Number 1446 of 1985.
(2) Extremely flammable liquids: Chemicals which have flash point lower than or equal to 23oC and
boiling point less than 35oC.
(a) Very highly flammable liquids: Chemicals which have a flash point lower than or equal to
23oC and initial boiling point higher than 35oC.
(b) Highly flammable liquids : Chemicals which have a flash point lower than or equal to 60oC
but higher than 23oC.
(c) Flammable liquids : Chemicals which have a flash point higher than 60oC but lower than
90oC.
(3) Explosives: Explosives mean a solid or liquid or pyrotechnic substance (or a mixture of substances) or
an article.
(a) Which is in itself capable by chemical reaction of producing gas at such a temperature and pressure and at such a speed as to cause damage to the surroundings?
(b) Which is designed to produce an effect by heat, light, sound, gas or smoke or a combination of these as the result of non-detonative self sustaining exothermic chemical reaction?
7.5.3.1 TOXIC HAZARDS OF SUBSTANCES Toxic substances affect in three ways by ingestion, absorption & inhalation. Adequate provision of safety
along with personal protective equipment will be made; emergency kit shall be provided at various locations of the installation.
Intoxication – Analytical Analysis. The consequences from inhalation of a toxic vapour/gas are determined by the toxic dose.
This dose D is basically determined by:
- Concentration of the vapour in air; - Exposure duration.
Furthermore, of course, the breathing rates of the victim, as well as the specific toxic mechanism unto the metabolism play an important role.
The dose is defined as D = Cn
.t, with: C = concentration of the toxic vapour, in [ppm] or [mg/m3];
t = exposure duration, in [sec] or [min]; n = exponent, mostly > 1.0; this exponent takes into account the fact that a high concentration
over a short period results in more serious injury than a low concentration over a relatively
longer period of exposure. The value of n should be greater than zero but less than 5. The given definition for D only holds if the concentration is more or less constant over the exposure time; this
may be the case for a (semi) continuous source. In case of an instantaneous source, the concentration varies
with time; the dose D must be calculated with an integral equation:
D = Cn.dt
For a number of toxic materials, so-called Vulnerability Models (V.M.) have been developed. The general equation for a V.M. (probit function) is:
Pr = a + b.ln (Cn.t), with
Pr = probit number, being a representation of the percentage of people suffering a certain kind of damage, for instance lethality
Pr = 2.67 means 1% of the population;
Pr = 5.00 means 50% of the population; a and b material dependent numbers; Cn.t = dose D, as explained above.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-151
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The values for a and b are mostly derived from experiments with animals; occasionally, however, also human
toxicity factors have been derived from accidents in past. In case only animal experiments are available, the
inhalation experiments with rats seem to be best applicable for predicting the damage to people from acute intoxication. Although much research in this field have been done over the past decades, only for a limited number of toxic materials consequence models have been developed. Often only quite scarce information is
available to predict the damage from an acute toxic exposition. Data transformation from oral intoxication data to inhalation toxicity criteria is sometimes necessary. Generally, in safety evaluations pessimistic
assumptions are applied in these transformation calculations. The calculated damage (distance) may be
regarded as a maximum. For the purposes of a response to a major incident, the IDLH value level has been
chosen for the ‘wounded‘ criteria. This type of injury will require medical attention.
7.5.3.2 FLAMMABILITY HAZARDS OF SUBSTANCES Since the Stone Age term 'fire' is associated with fear. Fire destroys everything when not controlled. It is very dangerous if occurs in uncontrolled manner. It should be clearly understood that when a liquid is used having
flash point (Beginning of transformation phase from liquid to vapor) below the normal ambient temperature, it
could, in suitable circumstances, liberate a sufficient quantity of vapor to give rise to flammable mixtures with air. Any source of ignition will transform the vapor to fire.
Heat Radiation – Analytical Analysis Parameters. The consequence caused by exposure to heat radiation is a function of:
The radiation energy onto the human body [kW/m2
];
The exposure duration [sec];
The protection of the skin tissue (clothed or naked body).
The limits for 1% of the exposed people to be killed due to heat radiation, and for second-degree burns are given in the table herein:
Damages to Human Life Due to Heat Radiation
Exposure
Duration
Radiation for 1%
lethality (kW/m2)
Radiation for 2nd
degree burns(kW/m2)
Radiation for first
degree burns, (kW/m2)
10 Sec 21.2 16 12.5
30 Sec 9.3 7.0 4.0
Since in practical situations, only the own employees will be exposed to heat radiation in case of a fire, it is reasonable to assume the protection by clothing. It can be assumed that people would be able to find a cover or a shield against thermal radiation in 10 sec. time. Furthermore, 100% lethality may be assumed for all
people suffering from direct contact with flames, such as the pool fire, a flash fire or a jet flame. The effects
due to relatively lesser incident radiation intensity are given below.
Effects Due To Incident Radiation Intensity
INCIDENT RADIATION –
kW/m2
TYPE OF DAMAGE
0.7 Equivalent to Solar Radiation
1.6 No discomfort for long exposure
4.0 Sufficient to cause pain within 20 sec. Blistering of skin (first degree burns are likely)
9.5 Pain threshold reached after 8 sec. second degree burns after 20 sec.
12.5 Minimum energy required for piloted ignition of wood, melting plastic tubing etc.
7.5.3.3 EXPLOSION HAZARDS Release of energy in a rapid and uncontrolled manner gives rise to explosion. Explosion is very dangerous
because it has the potential to spread the flammable material and fire on low flammable substances also. This
effect of spreading fire instantaneously at different installations due to explosion is called “DOMINO EFFECT”.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
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Explosion –Analytical Analysis Parameters In case of vapour cloud explosion, two physical effects may occur:
* A flash fire over the whole length of the explosive gas cloud;
* A blast wave, with typical peak overpressures circular around ignition source. As explained above, 100% lethality is assumed for all people who are present within the cloud proper. For the blast wave, the lethality criterion is based on:
* A peak overpressure of 0.1 bar will cause serious damage to 10% of the housing/structures. * Falling fragments will kill one of each eight persons in the destroyed buildings.
The following damage criteria may be distinguished with respect to the peak overpressures resulting from a
blast wave:
Damage Due To Overpressures
PEAK OVERPRESSURE DAMAGE TYPE
0.83 bar Total Destruction
0.30 bar Heavy Damage
0.10 bar
0.03 bar
Moderate Damage
Significant Damage
0.01 bar Minor Damage
From this it may be concluded that p = 0.17 E+5 pa corresponds approximately with 1% lethality.
Furthermore it is assumed that everyone inside an area in which the peak overpressure is greater than 0.17 E+
5 pas will be wounded by mechanical damage. For the gas cloud explosion this will be inside a circle with the ignition source as its centre.
7.5.3.4 CORROSION HAZARDS Corrosion is a chemical reaction-taking place at the surface of metal. It is also the effects of tissue damage
caused to human beings when contacted accidentally. All substances pH 0-5 & 8.0-12.0 are corrosive. Most
corrosive substances will produce chemical burns, while certain chemical substances produce deep ulceration. The effect will be for internal organs also when the fumes are inhaled/ ingested. Other damages are, has a detailing effect on skin and may cause dermatitis.
On contact with metals, corrosive substances will oxidize the load bearing columns, beams and truss structure
and bring down the stability factor of the buildings.
7.5.3.5 REACTIVITY HAZARDS Reactivity is a property of causing a violent chemical reaction when TWO OR MORE compatible materials coming in contact. The resulting impetus shall release energy in the form of heat, detonation, vapors/gases.
The criteria of avoiding reactivity type hazards is to follow the REACTIVITY MATRIX for storing materials.
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Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
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INCOMPATIBLE STORAGE RECOMMENDATIONS.
CHEMICAL
SEGREGATION BY CHEMICAL
GROUP
CLASS 1 2 3 4 5 6
EXPLOSIVES 1
1.0
EXPLOSIVE
SEGREGATE
FROM
SEGREGAT
E FROM
SEGREGAT
E FROM
SEGREGAT
E FROM
SEGREGAT
E FROM
SEGREGAT
E FROM
SEGREGATE FROM SEGREGA
E FROM
FLAMMABLE LIQUIDS
2
SEGREGATE
FROM
KEEP
APART KEEP APART
KEEP
APART
FLAMMABL
E SOLIDS 3
READILY
COMBUSTIBLE
SEGREGAT
E FROM
KEEP
APART
KEEP APART
SPONTENEOUSL
Y COMBUSTIBLE
SEGREGATE
FROM
SEGREGATE
FROM
KEEP
APART KEEP APART
KEEP
APART
DANGEROUS
WHEN WET
SEGREGATE
FROM
SEGREGATE
FROM
OXIDIZING
SUBSTANCE
S
4
OXIDIZING
SUBSTANCE
SEGREGAT
E FROM
SEGREGAT
E FROM KEEP APART
KEEP
APART
ORGANIC
PEROXIDE
SEGREGATE
FROM
SEGREGATE
FROM
KEEP
APART
KEEP APART KEEP
APART
TOXIC
SUBSTANCE
S
5
SEGREGATE
FROM
KEEP
APART
KEEP
APART
KEEP
APART
KEEP
APART
KEEP
APART
SEGREGATE
FROM
KEEP
APART
KEEP
APART
KEEP
APART
KEEP
APART
KEEP
APART
CORROSIVE
SUBSTANCE
S
6
SEGREGATE
FROM
KEEP
APART
KEEP
APART
KEEP
APART
KEEP
APART
KEEP
APART
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-154
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7.6 STORAGE AND HANDLING OF HAZARDOUS MATERIALS
Both hazardous and non-hazardous materials generated within the project facility shall be temporarily
accommodated in designated storage units within the project facility built/made in line with the safety, health
and environmental standards.
Size of these temporary units would depend on the quantity and type of hazardous waste materials with
appropriate storage capacities placed in the project facility in compliance with the Hazardous Waste
Management and Handling Rules. Each unit in the facility should have fire hydrant system to handle fire
hazards.
A. LIQUID RAW MATERIALS A.1 IN STORAGE TANKS - Stored in multiple units of same chemical when the quantity is very large in
a tank-farm.
A.2 IN STORAGE TANKS - Stored in a single tank, with other material tanks in a tank –farm. (Mixed
materials tank-farm.
A.3 IN STORAGE TANKS - Specific material stored in A TANK / TANKS in a tank-farm demarcated
and isolated storage ,Licensed and separated with minimum safe distances.
A.4 IN STORAGE SHEDS- Separate storage sheds made for storing specifically raw materials in drums and carboys.
B. SOLID RAW MATERIALS B.1 IN SILOS - Large quantities of powder / Granules are stored in silos. The handling of materials
are done pneumatically. The quantity dispatch in terms of weight are measured with the provision of load cells.
B.2 IN BAGS & - Solid raw materials are received in bags and boxes are stored in closed sheds as per
the BOXES compatibility norms.
C. GASEOUS RAW MATERIALS C.1 IN TONNERS & GAS CYLINDERS.- Flammable and toxic raw materials are stored in demarcated
and isolated storage in Licensed premises.
C.2 IN PIPELINES - Received in pipelines up to the unit and parameters processed in the skid for end
use.
All the above systems of storage are practiced in M/s. SPECTRUM DYES&CHEMICALS PVT.LTD.
Materials that are employed in different processes of Spectrum Dyes & Chemicals Pvt. Ltd., Palsana, Surat
plant, together with their hazardous characteristics are listed in following table 7.1.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
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TABLE 7.1 PHYSIO-CHEMICAL PARAMETERS OF HAZ-CHEM: RAW MATERIALS IN TANKFARMS HAZARDOUS CHEMICALS USED IN M/S.
SPECTRUM DYES & CHEMICALS PVT. LTD, PALSANA, SURAT.
HAZARD PARAMETERS CHART.- RAW MATERIALS IN TANKFARMS.- HAZARD PARAMETERS
HIGHLY FLAMMABLE HIGHLY TOXIC
S.NO NAME TPQ LIQUID/
VAPOR
TANK
FARM/
YES/NO
NFPA
LABEL
F-H-R-O
VD LEL
UEL%
F.P
°C B.P °C
TLV
ppm/mg/m³
IDLH
ppm/mg/m³ CAS. NO UN NO
1 Acetic acid 55 L YES 2-3-0-X 2.07 5,0
16.0 40.0 118 5 50 64-19-7 2789
2 Acetic
anhydride 18 L YES 2-3-1-X 3.52
2.7
10.3 49.0 139 0.5 200 108-24-7 1715
3 Acetone 33 L YES 3-1-0-x 2 2.6
12.8 -19 56.0 200 NA 67-64-1 1090
4 Acrylonitrile 13 L YES 3-4-2-X 1.9 3 17 0 77.3 107-13-1 1093
5 Ammonia 25% 9 L YES 0-2-0-X 0.62 NA NA 100 25 300 7766-41-7 1760
6 Aniline Oil 12 L YES 2-3-0-x 3.22 1.3
25 70 184.1 2 100 62-53-3 1547
7 Caustic soda
Lye 48% 40 L YES 0-3-1-X 0.62 NA NA NA 2mg/m3 NA 1310-73-2 1824
8 DMF 75 L YES 2-2-0-X 2.51 2.2
15.2 67 156 2 500 68-12-2 2265
9 Formaldehyde 32 L YES 2-3-2-x 1.06 6
36.5 56-63 NA 1 20 50-00-0 1198
10 Hydrochlo ric
acid 87 L YES 0-3-1-x 1.267 NA NA 110 5 NA 7647-01-0 1789
11 Methanol 34 L YES 3-1-0-x 1.1 5.5
36.5 11.1 64.5 200 6000 67-56-1 1230
12 Oleum 23% 152 L YES 0-3-2-X 2.76 NA NA 142 0.2mg/m³1 NA 8014-95-7 1831
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
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13 O-Phosphoric
acid 42 L YES 0-3-0-x 3.4 NA NA 158 1mg/m3 NA 7664-38-2 1805
14 Liquid Phenol
94% 19 L YES 2-3-0-x 3.2
1.7
8.6 79 100 6.3 250 108-95-2 2821
15 Sulphuric acid 206 L YES 0-3-2-w 3.4 NA NA 554 1mg/m3 15mg/ m3 7664-93-9 1830
16 NSL 30 L YES NA NA NA NA NA 1.2mg/m³ NA 7782-78 -7 2308
LIST OF HAZARDOUS LIQUID CHEMICALS STORED IN DRUMS AND CARBOYS- HAZARD PARAMETERS
S.NO NAME TPQ/M LIQUID/ VAPOR
TANK
FARM/
YES/NO
NFPA
LABEL
F-H-R-O
VD LEL UEL%
F.P °C
B.P °C TLV ppm IDLH CAS. NO UN NO
1 TOULENE 10 L NO 3-2-0-X 3.14 1.27
7.1 4.4 110.5 50 500 108-88-3 1294
2 BROMINE 6 L NO 0--3-0-0X 5.5 X X 59.4 0.033 3 7726-95 -6 1744
3 BENZOYL
CHLORIDE 36 L NO 2-3-2-W 4.8
1.2
4.9 162 387 X X
4 HYDROGEN
PEROXIDE 5 L NO 0-3-1-0X X X NA 150 10 75 7722-84 -1 2014
5. ALLYL
CHLORIDE 30 L NO 3-3-1-X 2.64
3.3
11.2 3.8 45 2.8 250 107-105 -1 1100
LIST OF HAZARDOUS COMPRESSED GAS STORED IN TANKS & TONNERS
1
ETHYL
CHLORIDE
(EC)
45 GAS
COMP. TONNER 4-2-0-X 2.22
3.8
15.4
(-)
14.4 12.2 300 3800 75-00-3 1037
2 ETHYLENE
OXIDE (EO) 7.5
GAS
COMP. TANK 4-3-3-X 1.49
3
100 -20 10.7 5 800 75-21-8 1040
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
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LIST OF HAZARDOUS SOLID CHEMICALS STORED IN DRUMS –HAZARD PARAMETERS
S.NO NAME TPQ/M SOLID TANK FARM/ YES/NO
NFPA LABEL F-H-R-O
VD LEL
UEL% F.P °C B.P °C
TLV
ppm IDLH CAS. NO UN NO
1 Caustic soda
flakes 13 YES NO x x x x x 0.5mg/m3 10 mg/m3 1310-73-2 1823
2 Copper cyanide 5 YES NO NA x x x x 21mg/m3 NA 544-92-3 1587
3 Sodium cyanide e 5 Y NO 0-3-0-X x x x x 4mg/m³ 25mg/m³ 143-33-9 1689
4 Zinc cyanide 5 Y NO 0-3-0-X X X X x 14mg/m³ x 557-21-1 1713
5 Hydroquinone 1 Y NO 1-2-0-X x x 168 287 3.0 mg/
m³ NA 123-31-9 1713
6 Naphthalene 250 Y NO 2-2-X-0 4.4 0.9 5.9 87.7 218 15 250 91-20-3 1334
7 Iodine 0.05 Y NO X x x x 185 0.1 2 7553-56-2 3495
8 Para nitrile
Aniline 36 Y NO 1-3-2-X 4.8 X 390 637 9mg/m3
300
mg/m³ 100=01-6 1661
9 P Chloro Aniline 30 y NO NA 4.41 2.2
- 113 232
6.1 mg /
m3 NA 106-47-8 2018
TPQ - THRESHOLD PLANNED QUANTITY, FP – FLASH POINT, BP – BOILNG POINT, VD – VAPOR DENSITY , SG- SPECIFIC GRAVITY, LEL/UEL – EXPLOSIVE LIMITS, TLV – THRESHOD
LIMIT VALUE , IDLH – IMME. DANGER TO LIFE & HEALTH, NFPA –HAZARD PARAMETERS LABEL
TABLE 7.2 STORAGE HAZARDS & MITIGATION MEASURES (QUANTITIES AND TOXICOLOGICAL DATA):
Sr.
No.
Name of
the
Hazardous
Substance
No. of
Container
with
Quantity.
(MT)*
Place of
its
Storage
State and
operating
Pressure&
Temp.
Types of hazards
Possible
(Fire,
Explosion on,
Toxic
Release
, Spill etc.)
Control Measures Provided
1 2 3 6 7 8 9
1 Acetic
Acid
25 MT + 35
MT
EO
RM
Liquid,
Pr. & Temp.
Fire,
Corrosive,
1) Dyke wall having sufficient size is provided.
2) Tank, valve, pipeline are checked and maintain, in good condition.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-158
Report No. 1718A058
2 St. Tank
SS 316
Tank
Farm
Atm. Toxic 3) All Gaskets are checked periodically & being replaced by new one if found defective.
4) Joints are checked regularly for any Leakages.
5) Adequate PPEs are kept to handle the Hazard.
6) ISI Portable fire extinguisher & Hydrant line is provided.
7) Sufficient amount of sand/soil are kept to control any spillage. 8) Flame proof fitting provided.
9) Eye washer cum shower is provided near Tank-farm area.
10) Level indicator provided.
11) Spark arrester are installed on all vehicles inside the premises.
12) SCBA set, Canister mask and airline mask is provided.
13) Earthing& bonding on Tanks is provided.
14) Vent line dipped in water is provided.
15) Tanks kept on sound foundation.
2 Acetic
Anhydride
18 MT
1 Tank
SS 316
EO RM
Tank
Farm
Liquid,
Pr. &
Temp.
Atm.
Fire,
Corrosive
1) Dyke wall having sufficient size is provided.
2) Tank, valve, pipeline are checked and maintain, in good condition.
3) All Gaskets are checked periodically & being replaced by new one if found defective. 4) Joints are checked regularly for any Leakages.
5) Adequate PPEs are kept to handle the Hazard.
6) ISI Portable fire extinguisher & Hydrant line is provided.
7) Sufficient amount of sand are kept to control any spillage.
8) Flame proof fitting provided.
9) Eye washer cum shower is provided near Tank-farm area.
10) Level indicator provided.
11) Spark arrester are installed on all vehicles inside the premises.
12) SCBA set, Canister mask and airline mask is provided.
13) Earthing& bonding on Tanks is provided.
14) Vent line dipped in water is provided.
15) Tanks kept on sound foundation.
3 Acetone 33 MT
1 Tank
M S
Methanol
Tank
Farm
Area
U/ G
Liquid,
Pr. &
Temp.
Atm.
Fire 1) Separate storage Tank.
2) Flame proof fittings provided.
3) Fire hydrant & extinguishers provided.
4) Sufficient amount of sand are kept.
5) Apron, Hand gloves, gumboot, helmet, goggles provided
4 Acrylonitr
ile
13 MT
1 Tank
Acrylon
itrile
Tank
Liquid,
Under N2
Blanketing,
Explosive,
Toxic
1) Tank, valve, pipeline are checked and maintained, in good condition.
2) All Gaskets are checked periodically & if being replaced by new one if found defective.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-159
Report No. 1718A058
M S Farm
Area
U/ G
pressure 0.1
Kg/Cm2 &
Temp.
Atm.
3) Joints are checked regularly for any Leakages.
4) ISI Portable fire extinguishers are provided.
5) Sufficient amount of sand are kept to control any spillage 6) Flame proof fitting
provided.
7) Vent line dipped in water is provided.
8) Proper Earthing& Bonding provided. Earth pit resistance is checked on regular basis and records are maintained.
9) Flame arrester with breather valve is provided on the vent line.
10) Apron, Hand gloves, gumboot, goggles and helmet provided.
11) NRV provided on Tanks.
12) Trained operators are employed to handle the Acrylonitrile under the supervision of
Chemist.
13) Eye washer & shower are provided near the Tank farm area 14) Tank is kept on RCC foundation.
15) Good ventilation in the area. 16) Area declared as “NO SMOKING ZONE”.
17) All vehicles are allowed to enter in the premises after installing spark arrester on
exhaust pipe.
5 Liquor
Ammonia
– 25 %
9 MT
1 Tank
M S
NKS/
M.N.
LIQUI
D T F
A
Liquid,
Pr. &
Temp.
Atm.
Toxic,
Corrosive
1) Dyke wall of sufficient size is provided.
2) Tank, valve, pipeline are checked and maintain, in good condition.
3) All Gaskets are checked periodically & being replaced by new one if found defective.
4) Joints are checked regularly for any Leakages.
5) Adequate PPE is kept to handle the Hazard.
6) ISI Portable fire extinguisher is provided.
7) Sufficient amount of sand are kept to control any spillage.
8) Flame proof fitting provided.
9) Eye washer cum shower is provided near Tank-farm area.
10) Level indicator provided.
11) Spark arrester are installed on all vehicles inside the premises.
12) SCBA set, Canister mask and airline mask is provided.
13) Vent line dipped in water is provided.
14) RCC foundation is provided.
15) Sprinkler system provided
6 Aniline
Oil
12 MT
1 Tank
M S
EO RM
Tank
Farm
Liquid,
Pr. &
Temp.
Atm.
Fire, Toxic 1) Dyke wall of sufficient size is provided.
2) Tank, valve, pipeline are checked and maintain, in good condition 3) All Gaskets are checked periodically & being replaced by new one if found defective.
4) Joints are checked regularly for any Leakages.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-160
Report No. 1718A058
5) Apron, Hand gloves, gumboot, goggles and helmet provided.
6) ISI Portable fire extinguisher & Hydrant line is provided.
7) Sufficient amount of sand are kept to control any spillage.
8) Flame proof fitting provided.
9) Eye washer cum shower is provided near Tank-farm area.
10) Level indicator provided.
11) Spark arrester are installed on all vehicles inside the premises.
12) SCBA set, Canister mask and airline mask is provided.
13) Earthing& bonding on Tanks is provided.
14) Vent line dipped in water is provided.
7 A S C
Acetanilide
SULFONY
L
Chloride
5.4 MT
0.050 X 108
Bags
RM
Store
Solid,
PR. &
Temp.
Atm.
Flammable 1) Separ ate place provided in store
2) Flame proof fittings provided
3) Fire hydrant & extinguishers provided
4) Apron , Hand gloves, gumboot, helmet , goggles provided
8 Benzene
Sulphonyl
Chloride
6 MT
0.250 x 24
M S
DRUM
RM
Store
Liquid,
Pr. &
Temp.
Atm.
Corrosive 1) Separate place provided in store.
2) Flame proof fittings provided
3) Fire hydrant & extinguishers provided
4) Sufficient amount of sand are kept
5) Apron, Hand gloves, gumboot, helmet, goggles provided
9 Benzoyl
Chloride
36 MT
0.250X 144
P P
DRUM
RM
Store
Liquid,
Pr. &
Temp.
Atm.
Toxic 1) Separate place provided in store 2) Flame proof fittings provided.
3) Fire hydrant & extinguishers provided.
4) Sufficient amount of sand are kept.
5) Apron, Hand gloves, gumboot, helmet, goggles provided
10 Benzyl
chloride
7.920
MT0.220 X
36
Drums
RM
Store
Liquid ,
Pr. &
Temp
Atm.
Corrosive
&
Toxic
1) Separate place provided in store
2) Fire hydrant & extinguishers provided
3) Apron , Hand gloves, gumboot, helmet, goggles & Gas mask provided
11 Bromine 6 MT
3 KG X
In
Bromin
e
Liquid,
Pr. &
Temp.
Toxic,
Corrosive
1) Separate place provided in store.
2) Flame proof fittings provided.
3) Fire hydrant & extinguishers provided.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-161
Report No. 1718A058
2000
Bottles
Store
Area
Atm. 4) Sufficient amount of sand are kept.
5) Apron, Hand gloves, gumboot, helmet, goggles provided.
12 Caustic
soda
Flakes
13 MT
0.050 X
260
Bags
RM Store Solid,
Pr. &
Temp.
Atm.
Toxic,
Corrosive
1) Separate place provided in store 2) Fire hydrant & extinguishers provided.
3) Sufficient amount of sand are kept.
4) Apron, Hand gloves, gumboot, helmet, and goggles provided.
13 Caustic
Soda Lye
48%
68 MT
40 MT
1 Tank
M S
28 MT
1 TANK
MS
N K S
TFA
EO RM
TFA
Liquid,
Pr. &
Temp.
Atm.
Toxic,
Corrosive
1) Dyke wall of sufficient size is provided.
2) Tank, valve, pipeline are checked and maintain, in good condition.
3) All Gaskets are checked periodically & being replaced by new one if found defective.
4) Joints are checked regularly for any Leakages.
5) Apron, Hand gloves, gumboot, goggles and helmet provided. 6) ISI Portable fire extinguisher & Hydrant line is provided.
7) Sufficient amount of sand are kept to control any spillage
8) Eye washer cum shower is provided near Tank-farm area
9) Level indicator provided
10) Vent line provided at sufficient height
14 Copper
Cyanide
0.050 x
120
M S
DRUM
RM
Store
Powder,
Pr. &
Temp.
Atm.
Toxic 1) Separate storage room with lock & key arrangement is provided.
2) Fire hydrant & extinguishers provided.
3) Apron, Hand gloves, gumboot, helmet, goggles provided.
4) No acid handling nearby storage area.
15 D 129 3.6 MT
0.150 X 48
M S Drum
RM
Store
Liquid ,
Pr.& Temp
Atm.
Corrosive 1) Separate place provided in store
2) Flame proof fittings provided
3) Fire hydrant
4) Sufficient amount of sand are kept 5) Apron , Hand gloves, gumboot, helmet , goggles provided
16 D E S 17 MT
1 Tank
M S
N K S
Tank
Farm
Area
Liquid ,
Pr. & Temp
Atm.
Toxic 1) Dyke wall of sufficient capacity provided.
2) Tank, valve, pipeline are checked and maintain, in good condition.
3) Apron, Hand gloves, gumboot, goggles, canister gas mask and helmet provided.
4) ISI Portable fire extinguisher is provided.
5) Sufficient amount of sand are kept to control any spillage.
6) Eye washer cum shower is provided near Tank farm area. 7) Level indicator provided
8) RCC foundation is provided.
17 DMF 9.6 MT
RM Liquid,
Pr.
Fire 1)Tank, Valve, pipeline , joint leakage checked & maintain in good condition
through preventive maintenance
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-162
Report No. 1718A058
M S
Drum
0.190 x 80
MS Tank
U/G
34 MT
&
A/G
30 M.T.
Store
&
U/G
Tank
farm
area
&Temp.
Atm.
2) Fire extinguishers & fire Hydrant line are provided.
3) Flame proof electrical fittings/ installation provided
4) Proper earthing, Bonding & flange to flange jump ring is provided.
5) Flame arrester provided on vent line
6) CCE approved Separate Storage area with door having locking arrangement is provided.
7) Spark arresters are installed on all vehicles inside the premises.
8) Apron, Hand gloves, gumboot, goggles & helmet provided.
9) Trained operator employed
10) Eye washer & shower provided
11) Tank's thickness measured on regular interval 12) Good ventilation provided in the
area. 13) Mayura water curtain,3% AFFF solution & Foam gun available
18 Dispersant
B/
REAX
89L
35 MT
0.025 X
1400
Bags
RM
Store
Liquid ,
Pr. & Temp
Atm.
Toxic, Fire 1) Separate place provided in store
2) Flame proof fittings provided
3) Fire hydrant & extinguishers provided
4) Sufficient amount of sand are kept
5) Apron , Hand gloves, gumboot, helmet , goggles provided
19 Ethylene
Oxide
15.8 MT
2 Tanks
M S + S S
E.O.
Tank
Yard
Liquid,
Temp.
2oC-
8oC and
under N2
Blanketing
,
Pr.-3.5
Kg/Cm2
Fire,
Toxic, &
Explosion
1) Dyke wall having sufficient size - filled with sufficient water is provided.
2) Tank, valve, pipeline are checked and maintain, in good condition through preventive
maintenance.
3) All Gaskets are checked periodically & if found, defective are replaced by new one,
under preventive maintenance schedule.
4) Joints are checked regularly to detect any leakage under preventive maintenance schedule
5) ISI Portable fire extinguisher & Fire Hydrant line is provided.
6) Flame proof electrical fittings / installation provided.
7) Proper earthing, bonding & flange to flange jump ring is provided. Earth pit resistance
is checked on regular basis and records are maintained
8) Sprinkler System is provided.
9) 1 No. Water monitor is provided.
10) Double Safety valve installed on each Tank. Vent line of safety valve is connected
with water pit.
11) Excess flow checks valve and NRV Provided on EO transfer line.
12) EO are always stored under Inert Gas (N2) atmosphere Blanketing
13) All vehicles are allowed to enter in the premises after installing spark arrester on
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-163
Report No. 1718A058
exhaust pipe.
14) Brine cooling system provided and alternative arrangement of child water-cooling system is also provided to maintain temperature bellow 10
oc.
15) Double Temp. & Pressure Indicator provided and maintained good condition.
16) Magnetic level indicator provided.
17) Apron, Hand gloves, gumboot, goggles and helmet provided.
18) Trained operators are employed to handle EO under the supervision of Chemist.
19) Eye washer & shower provided near EO storage and handling area. 20) Tank’s
thickness measured on regular interval.
21) One Tank out of two Tanks is always kept empty for emergency purpose. 22) RCC foundation provided.
23) Railing with toe guard provided and maintained.
24) Water pit provided and maintain. Vent line connected to water pit.
25) Logbook is maintained for pressure and temperature & to verify quantity on regular
basis.
26) Good ventilation in the area.
27) Lighting arrestor is provided at the roof of tank yard. 29) Area declared as “NO
SMOKING ZONE”.
30) Auto Earthing system installed for EO Tanker Unloading.
31) Mayura water curtain,3% AFFF solution & Foam gun for any type of serious Emergency
32) Emergency Alarm System is installed at 1st & 2nd floor
20 ET 87 3.6 MT
0.150 x 24
M S Drum
RM
Store
Liquid,
Pr.
&Temp. Atm.
Fire &
Corrosive
1) Separate place provided in store
2) Flame proof fittings provided
3) Fire hydrant & extinguishers provided.
4) Sufficient amount of sand are kept.
5)Apron , Hand gloves , gumboot , helmet & goggles provided.
21 Formaldeh
yde 37%
35 MT
1 Tank
MS
NKS
TFA
Liquid,
Pr. &
Temp.
Atm.
Fire, Toxic 1) Dyke wall is provided.
2) Dyke wall of sufficient size is provided.
3) Tank, valve, pipeline are checked and maintain, in good condition.
4) Apron, Hand gloves, gumboot, goggles and helmet provided. 5) ISI Portable fire extinguishers & Hydrant line is provided.
8) Sufficient amount of sand are kept to control any spillage.
9) Eye washer cum shower is provided near Tank-farm area.
10) Level indicator provided.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-164
Report No. 1718A058
22 H R D
(n Hexayl
Bromide)
19.2
MT
0.200 X 96
M S Drum
RM
Store
Liquid ,
Pr. & Temp
Atm.
Hygro
scopeopic
1) Separate place provided in store
2) Flame proof fittings provided
3) Fire hydrant & extinguishers provided
4) Sufficient amount of sand/soil are kept
5) Apron , Hand gloves, gumboot, helmet , goggles provided
23 Hydrochlor
ic Acid
63 MT
2 Tanks
PP
40 MT
23MT
NEW
DD – 1
TFA
DD – 2
TFA
Liquid,
Pr. &
Temp.
Atm.
Toxic,
Corrosive
1) Dyke wall will be provided.
2) Dyke wall of sufficient size will be provided in DD1 TFA.
3) Tank, valve, pipeline are checked and maintain, in good condition.
4) Apron, Hand gloves, gumboot, goggles and helmet provided.
5) ISI Portable fire extinguisher is provided.
6) Separate storage area are provided.
7) Scrubber system provided
24 Hydro
quinone
1 M T
0.025 x 40
Bags
RM
Store
Powder,
Pr. &
Temp.
Atm.
Toxic, 1) Separate place provided in store
2) Fire hydrant & extinguishers provided.
3) Apron, Hand gloves, gumboot, helmet, and goggles provided.
25 Hydrogen 2 Cylinder
Near
Engg.
Worksh
op
Area
Gas,
Under
pressure
150
Kg/Cm2
& Temp. Atm.
Explosive 1) Apron, Hand gloves, gumboot, goggles & helmet provided
2) ISI Portable fire extinguisher & Hydrant line is provided. 3) Flame proof fitting provided.
4) Sufficient Nos. of SCBA sets & 2 No. of Air line mask.
5) Preventive maintenance on regular basis.
6) Cylinder will be stored and used under Shed to protect from direct sun light.
26 Hydrogen
Peroxide
6.0 MT
0.050X120
Carboys
PP
RM Store Liquid,
Pr. &
Temp.
Atm.
Toxic,
Corrosive
1) Separate place provided in store
2) Flame proof fittings provided.
3) Fire hydrant & extinguishers provided.
4) Sufficient amount of sand are kept.
5) Apron, Hand gloves, gumboot, helmet, and goggles provided.
27 Iodine 0.050
0.050 x 1
RM
Store
Solid,
Pr. &
Toxic, 1) Separate place provided in store
2) Fire hydrant & extinguishers provided.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-165
Report No. 1718A058
Corr. Box Temp.
Atm.
3) Apron, Hand gloves, gumboot, helmet, and goggles provided.
28 Malano
Nitrile
19.2 MT
0.200 X 96 Drum
MS
RM
Store
Solid,
Pr. &
Temp.
Atm.
Toxic 1) Separate place provided in store
2) Flame proof fittings provided.
3) Fire hydrant & extinguishers provided.
4) Sufficient amount of sand/soil are kept.
5) Apron, Hand gloves, gumboot, helmet, goggles provided
29 M E A
70%
Mono
Ethyl
Amine
70%
14.4 MT
0.150 X 96
M S
Drum
RM
Store
Liquid ,
Pr. &
Temp
Atm.
Toxic, Fire 1) Separate place provided in store
2) Flame proof fittings provided
3) Fire hydrant & extinguishers provided
4) Sufficient amount of sand are kept
5) Apron , Hand gloves, gumboot, helmet , goggles provided
30 Methanol 34 MT
1 Tank
M S
Methanol
Tank
Yard
Area.
Liquid,
Pr. &
Temp.
Atm.
Fire &
Explosion
1) Tank, valve, pipeline are checked and maintain, in good condition through preventive maintenance.
2) Joints are checked regularly to detect any Leakage.
3) ISI Portable fire extinguishers & Fire Hydrant line are provided. 4) Flame proof electrical fittings / installation provided.
5) Proper Earthing, Bonding & flange-to-flange jump ring is provided. 6) Flame arrester provided on vent line.
7) CCE approved Separate Storage area with door having locking arrangement.
8) Spark arrester are installed on all vehicles in side the premises. 9) Apron, Hand gloves, gumboot, goggles and helmet provided.
10) Trained operator employed.
11) Eye washer & shower provided.
12) Good ventilation in the area.
13) Tanks are kept under RCC dyke.
14)Mayura water curtain,3% AFFF solution & Foam gun for any type of serious
Emergency
31 Mono
Ethyl
Aniline
10 MT
1 Tank
M S
E.O.
R M
Tank
Yard
Liquid,
Pr. &
Temp.
Atm.
Toxic 1) Dyke wall of sufficient size is provided.
2) Tank, valve, pipeline are checked and maintain, in good condition.
3) All Gaskets are checked periodically & being replaced by new one if found defective.
4) Joints are checked regularly for any Leakages.
5) Apron, Hand gloves, gumboot, goggles and helmet provided.
6) ISI Portable fire extinguishers & Hydrant line are provided.
7) Sufficient amount of sand are kept to control any spillage.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-166
Report No. 1718A058
8) Flame proof fitting provided.
9) Eye washer cum shower is provided near Tank-farm area.
10) Level indicator provided.
11) Spark arrester are installed on all vehicles inside the premises.
12) SCBA set, Canister mask and airline mask is provided.
13) Earthing& bonding on Tanks is provided.
32 M.M.A. 40%
Mono
Methyl
Amine
8.160 MT
0.170 x
48
Drum
MS
RM
Store
Liquid,
Pr. &
Temp.
Atm.
Fire, Toxic 1) Separate place provided in store 2) Flame proof fittings provided. 3) Fire hydrant & extinguishers provided.
4) Sufficient amount of sand are kept.
5) Apron, Hand gloves, gumboot, helmet, goggles provided
33 MSC
MethaneSulphonyl
Chloride
21 MT
0.250x84 MS Drums
RM
Store
Liquid,
Pr. &
Temp
Atm.
Corrosive,
Toxic
1) Separate place provided in store
2) Fire hydrant & extinguishers provided.
3) Sufficient amount of sand are kept.
4) Apron, Hand gloves, gumboot , helmet & goggles provided.
34 MNBA
Mono N
Butyl
Amine
14.4 MT
0.150 X 96
M S Drum
RM
Store
Liquid,
Pr.
&Temp
Atm.
Fire,
Toxic
Corrosive
1) Separate storage godown
2) Flame proof fittings provided
3) Fire hydrant & extinguishers provided.
4) Sufficient amount of sand are kept.
5) Apron , Hand gloves , gumboot , helmet & goggles provided.
35 M 108 1.8 MT
0.200 X 9
P P Drum
RM
Store
Liquid ,
Pr. & Temp
Atm.
Flammable 1) Separate place provided in store
2) Flame proof fittings provided
3) Fire hydrant & extinguishers provided
4) Apron , Hand gloves, gumboot, helmet , goggles provided
36 Naphthalen
e
250 MT
0.025 X 10000
Bags
Naphthal
e
ne
Godown
RM Store
Solid, PR.
& Temp.
Atm.
Toxic,
Flammable
1) Separate storage godown
2) Flame proof fittings provided
3) Fire hydrant & extinguishers provided
4) Apron , Hand gloves, gumboot, helmet , goggles & cartridge mask for organic vapour
provided
37 N S A
35%
98 MT
52 MT
DD2
Acid
Liquid ,
Pr. & Temp
Atm.
Corrosive
Acidic
1) Dyke wall of sufficient size is provided.
2) Tank, valve, pipeline are checked and maintain, in good condition.
3) Apron, Hand gloves, gumboot, goggles and helmet are provided.
4) ISI Portable fire extinguisher.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-167
Report No. 1718A058
1 Tank
S S
+
46 MT
1 Tank
S S
TFA
MONO
AZO
TFA
5) Sufficient amount of sand are kept to control any spillage.
6) Eye washer cum shower is provided near Tank-farm area.
7) Level indicator provided.
8) SCBA set, Canister mask and airline mask is provided.
9) Vent line dipped in H2So4 are provided.
10) RCC foundation is provided.
38 Oleum
23%
86 MT
2 Tanks
MS
40 MT
+
48 MT
NKS
TFA
MONO
AZO
TFA
Liquid,
Pr. & Temp.
Atm.
Toxic,
Corrosive
1) Dyke wall of sufficient size is provided.
2) Tank, valve, pipeline are checked and maintain, in good condition. 3) Apron, Hand gloves, gumboot, goggles and helmet are provided.
4) ISI Portable fire extinguisher.
5) Sufficient amount of sand are kept to control any spillage.
6) Eye washer cum shower is provided near Tank-farm area.
7) Level indicator provided.
8) SCBA set, Canister mask and airline mask is provided.
9) Vent line dipped in H2So4 are provided.
10) RCC foundation will be provided.
39 Ortho
Phosphori
c Acid
25 MT
1 Tank
SS 316
JARRY
CANS
1.5 MT X
8
12 MT
DYTOL
DF
TFA
RM
Store
Liquid,
Pr. &
Temp.
Atm.
Corrosive 1) Dyke wall will be provided.
2) Dyke wall of sufficient size is provided.
3) Tank, valve, pipeline are checked and maintain, in good condition.
4) Apron, Hand gloves, gumboot, goggles and helmet provided.
5) ISI Portable fire extinguisher & Hydrant line is provided.
6) Separate storage area will be provided.
7) Sufficient amount of sand are kept to control any spillage.
8) Eye washer cum shower is provided near Tank-farm area.
9) Level indicator provided.
10) RCC foundation will be provided.
40 Para Nitro
Aniline
36 MT
0.025 x
1440 Bags
RM
Store
Solid,
Pr. &
Temp.
Atm.
Fire, Toxic 1) Separate place provided in store
2) Fire hydrant & extinguishers provided.
3) Apron, Hand gloves, gumboot, helmet, and goggles provided.
41 Para
Chloro
Aniline
7 MT
0.050 x 140
Bags
RM
Store
Solid,
Pr. &
Temp.
Atm.
Fire 1) Separate place provided in store
2) Fire hydrant & extinguishers provided.
3) Apron, Hand gloves, gumboot, helmet, goggles provided
42 P C O N A 9 MT RM Solid, Corrosive 1) Separate place provided in store
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
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Para
Chloro
Ortho
Nitro
Aniline
0.025 X 360
Bags
Store PR.
& Temp.
Atm.
2) Apron, Hand gloves, gumboot, helmet, cartridge mask, goggles provided.
43 Phenol
90%
Liquid
37 MT
1 Tank
M S
NKS
Tank
Farm
Area.
Liquid,
Pr. &
Temp.
Atm.
Fire, Toxic 1) Dyke wall of sufficient size is provided.
2) Tank, valve, pipeline are checked and maintain, in good condition.
3) Apron, Hand gloves, gumboot, goggles and helmet provided.
4) ISI Portable fire extinguisher & Hydrant line is provided
5) Flameproof electrical connection will be provided.
6) Separate storage area will be provided.
7) Sufficient amount of sand are kept to control any spillage
8) Eye washer cum shower is provided near Tank-farm area.
9) Level indicator provided.
44 Phosphoro
us Oxy
Chloride
15 MT
0.050 X
300
PP Carboys
RM
Store
Liquid,
Pr. &
Temp.
Atm.
Toxic 1) Separate storage godown.
2) Flame proof fittings provided.
3) Fire hydrant & extinguishers provided.
4) Sufficient amount of sand/soil are kept.
5) Apron, Hand gloves, gumboot, helmet, goggles provided
45 Piperidine 2.112 MT
0.176 x 12
PP Drum
RM
Store
Liquid,
Pr. &
Temp.
Atm.
Corrosive 1) Separate place provided in store
2) Flame proof fittings provided.
3) Fire hydrant & extinguishers provided.
4) Sufficient amount of sand are kept.
5) Apron, Hand gloves, gumboot, helmet, and goggles provided.
46 Pyridine 0.200
MT
0.200 x 1
PP DRUM
RM
Store
Liquid,
Pr. &
Temp.
Atm.
Fire, Toxic 1) Separate place provided in store
2) Flame proof fittings provided.
3) Fire hydrant & extinguishers provided.
4) Sufficient amount of sand are kept.
5) Apron, Hand gloves, gumboot, helmet, and goggles provided.
47 PC0808 4.8 MT
0.200 X 24
PP Drum
RM
Store
Liquid,
Pr.
&Tem
p Atm.
Fire
Toxic
1) Separate place provided in store
2) Flame proof fittings provided
3) Fire hydrant & extinguishers provided.
4) Sufficient amount of sand are kept.
5) Apron, Hand gloves, gumboot, helmet & goggles provided.
48 P N B C 0.520 RM Solid, Corrosive 1) Separate place provided in store
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
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Report No. 1718A058
P Nitro
BenzoyL
Chloride
MT
0.065 X
8
Carboys
Store PR.
& Temp.
Atm.
2) Apron, Hand gloves, gumboot , helmet , cartridge mask , goggles provided.
49 Propionic
Acid
2.4 MT
0.200 X 12
M S Drum
New
RM
Store
Liquid ,
Pr. & Temp
Atm
Flammable 1) Separate place provided in store
2) Flame proof fittings provided
3) Fire hydrant & extinguishers provided
4) Apron , Hand gloves, gumboot, helmet , goggles provided
50 Propionic
Anhydride
2.4 MT
0.200 X 12
M S Drum
New
RM
Store
Liquid ,
Pr. & Temp
Atm
Flammable 1) Separate storage godown
2) Flame proof fittings provided
3) Fire hydrant & extinguishers provided
4) Apron , Hand gloves, gumboot, helmet , goggles provided
51 Sodium
Cyanide
10 MT
0.050 x
200
M S
DRUM
RM
Store
Solid,
Pr. &
Temp.
Atm.
Toxic 1) Separate storage room with lock & key arrangement is provided. 2) Fire hydrant & extinguishers provided.
3) Apron, Hand gloves, gumboot, helmet, and goggles provided.
4) No acid handling nearby storage area.
52 Sodium
Hydro
Sulphite
3 MT
120 X 2 5
M S Drum
RM
Store
Solid,
PR.
& Temp.
Atm.
Combustible 1) Keep in a separate place which should be clean , dry &dark place
2) Flame proof fittings provided
3) Fire hydrant & extinguishers provided
4) SCBA Set & Fire Suit should be provided
53 Solvent 87 7.2 MT
0.160 X 45
M S Drum
New
RM
Store
Liquid ,
Pr. & Temp
Atm.
Flammable 1) Separate storage godown
2) Flame proof fittings provided
3) Fire hydrant & extinguishers provided
4) Apron , Hand gloves, gumboot, helmet , goggles provided
54 Sulfuric
Acid 98%
100
MT
1 Tank
M S
46 MT
+
54 MT
MONO
AZO
TFA
DD 2
Acid
TFA
Liquid,
Pr. & Temp.
Atm.
Corrosive,
Toxic
1) Dyke wall sufficient capacity is provided.
2) Tank, valve, pipeline are checked and maintain, in good condition.
3) Apron, Hand gloves, gumboot, goggles and helmet provided.
4) ISI Portable fire extinguisher is provided.
5) Sufficient amount of sand are kept to control any spillage.
6) Eye washer cum shower is provided near Tank-farm area.
7) Level indicator provided
8) Vent line dipped in H2So4 will be provided.
19) RCC foundation will be provided.
55 Sulfamic 15 MT New Solid, Corrosive 1) Separate place provided in store
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
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Report No. 1718A058
Acid 0.050X360
Bags
RM
Store
PR.
& Temp.
Atm.
Hygro
scopic
2) Apron, Hand gloves , gumboot , helmet , cartage mask , goggles provided.
56 Sulfuryl
Chloride
5 MT
0.100 X 50
Carboy
RM
Store
Liquid ,
Pr. &
Temp
Atm.
Corrosive & Toxic
1) Separate place provided in store
2) Fire hydrant & extinguishers provided
3) Apron , Hand gloves, gumboot, helmet, goggles & Gas mask provided
57 T C A 2 MT
0.050 X 40
Bags
New
RM
Store
Solid,
PR.
& Temp.
Atm.
Corrosive
Hygroscopic
1) Separate place provided in store
2) Apron, Hand gloves, gumboot , helmet , cartage mask , goggles provided.
58 Zinc
Cyanide
4 MT
0.030 x 133
M S Drum
RM
Store
Solid,
Pr. &
Temp.
Atm.
Toxic 1) Separate storage room with lock & key arrangement is provided.
2) Fire hydrant & extinguishers provided.
3) Apron, Hand gloves, gumboot, helmet, and goggles provided.
4) No acid handling nearby storage area .
59 3 AC 3 MT
0.050 x 60
P P Drum
New
RM
Store
Liquid ,
Pr. & Temp
Atm.
Flammable
Liquid
1) Separate place provided in store
2) Flame proof fittings provided
3) Fire hydrant & extinguishers provided
4) Apron , Hand gloves, gumboot, helmet , goggles provided
60 3 M P A
3 Methoxy
Propyl
Amine
3.96 MT
0.165 X 24
M S Drum
New
RM
Store
Liquid ,
Pr. & Temp
Atm.
Flammable
Liquid
1) Separate space provided in store
2) Flame proof fittings provided
3) Fire hydrant & extinguishers provided
4) Apron, Hand gloves, gumboot, helmet , goggles provided
61 2 Amino
Thio
Phenol
2.640 MT
0.220 X 12
Drums
RM
Store
Liquid ,
Pr. & Temp
Atm.
Corrosive 1) Separate place provided in store
2) Apron, Hand gloves, gumboot, helmet, cartridge mask, goggles provided.
62 2 Ethyl
Hexa
Amine
0.8 MT
0.160 M.T.
X 5 Drums
RM
Store
Liquid ,
Pr. & Temp
Atm
Corrosive
Flammable
1) Separate place provided in store
2) Flame proof fittings provided
3) Fire hydrant & extinguishers provided
4) Apron , Hand gloves, gumboot, helmet , goggles provided
63 3:4
Di chloro
Aniline
6 MT
0.050 M.T.
X 120 Bags.
RM
Store
Solid, Pr.
& Temp
Atm.
Toxic 1) Separate place provided in store
2) Fire hydrant & extinguishers provided
3) Apron , Hand gloves, gumboot, helmet, goggles & Dust mask provided
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-171
Report No. 1718A058
TABLE 7.3 PROCESS HAZARD & MITIGATION MEASURES:
Sr.
No.
Name of
Plant,
Dept.
or place
Name of the
Hazardous
Process and
Operation
Materials in the
process /operation
with their
quantity.
Name of the
Vessel and its
Location
Operating
Parameter
- pressure,
temp., flow etc.
Types of hazards
Possible
(Fire, Explosion,
Toxic Release,
Spill etc.)
Control Measures Provided
1
BROMIDE
PLANT
1) Sulphonation
2) Condensation
TK - 28
OLEUM -6000 Kgs
H2SO4
DMF
Pocl3
MS- 5,6,7
NGL - 1,2,3
GL – 4,5,6
CT – 1 to CT - 3
FP-1 to FP-3
P = ATM
T = 90OC
Toxic Release
Corrosive
Spill
1) Temp. Gauge Are Provided
2) Scrubber Unit Provided
3) All Required PPEs Are Provided
4) Fire Extinguishers Are Provided
5) Fire Hydrant Points Are Provided. 6) Sand & Lime Drums Are Kept On Each
Floor 7) Emergency Alarm System Is Provided
2
SOLVENT
- 1
PLANT
1) Cyanation
2) Condensation
3) Oxidative
Bromination
METAL
CYANIDE - 190
Kgs
METHANOL -
1500
Kgs
MONO AZO DYE
DMF
SS - 1,2,3,4
SS - 5,6,7,8,9
NUTSCHE
SS – 1 to 9
P = ATM
T = 110OC
Toxic Sludge
Fire
1) Toxic Sludge Collect. Detoxified and Solvent recover In Recovery Plant.
2) All Electrical Gadgets are provided. 3) Scrubber Unit Provided.
4) Spark Arrester are Provided on The Vent
Line.
5) All Required PPEs are provided 6) Fire Extinguishers Are Provided
7) Fire Hydrant Point are provided
8) Sand & Lime Drums are kept on each Floor
3 SOLVENT
- 2
PLANT
Condensation SD – 31
POCL3
DMF
METHANOL
SS – 1 TO 12
GL- I TO 6
P = ATM
T = RM to 90OC
Toxic
Sludge
Fire
Toxic
1) Toxic sludge collect. detoxified and
Solvent recover in recovery plant.
2) All electrical gadgets are provided.
3) Scrubber unit provided.
4) Spark arrester are provided on the vent line.
5) all required PPEs are provided
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-172
Report No. 1718A058
Sr-30
Sludge
Fire
6) Fire extinguishers are provided
7) Fire hydrant point are provided
8) sand & lime drums are kept on each floor
4
AQ-1
PLANT
Bromination
Condensation
METHANOL -
2000
Kgs
BROMINE - 330
Kgs
POCl3,, EC, SOL-
87,
A.ACID, HCL,
H2SO4
ACETIC
ANHYDRIDE,
H2O2
ST-1 to ST-10
CT-1 to CT-4
FP-1 to FP-4
P = ATM
T = 50oC - 120OC
Toxic release,
Corrosive,
spill
1) Temp.gauges are provided.
2) Scrubber unit are provided.
3) all require PPE's are provided 4) Safety valves are provided.
5) Fire extinguishers are provided.
6) Fire hydrant points are provided. 7) sand & lime drums are kept on each floor 8) emergency alarm system is provided
5
AQ-2
PLANT
Condensation
MSC,BSC,
HAC
MAA-
ESTER,ECA
CAME,MMA,
METHYL AMINE,
ETHYL AMINE,
BUTYL AMINE,
3 METHOXY
PROPILE AMINE
ST –1 to ST-10
CT-1
P = 1-2 Kg/Cm2
T = 90oC
Toxic release,
Corrosive,
spill
1) Temp.gauges are provided.
2) Scrubber unit are provided.
3) All require PPE's are provided 4) Safety valves are provided.
5) Fire extinguishers are provided.
9) Fire hydrant points are provided. 10) sand & lime drums are kept on each
floor
11) Emergency alarm system is provided.
6
RECOVERY
1, 2& 3
PLANT
1) Distillation
2) Vacuum
Distillation
METHENOL
DM
AQ-1
ST – 11,12
SOLVENT – 2
SS - 8
P=ATM
T = 65OC
P=ATM
T = 110OC
Toxic Sludge,
Fire
1) All electric gadgets are flame proof.
2) Fire extinguishers are provided.
3) Water Ejectors are provided.
4) Spark arrestors are provided on the vent line.
5) All require PPE’s are provided.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-173
Report No. 1718A058
SOLVENT – 3
RC – 101,102
P=ATM
T = 180OC
6) Fire hydrant points are provided.
7) sand & lime drums are kept on each floor
8) Emergency alarm system is provided
7
DD-1
PLANT
(DISPERSE
DYES)
Diazotization
HCL
NaNO2
SODIUM
ACETATE
AMINES
DYTOL DF
OPA
ACETIC ACID
DV – 1 TO 11
CR – 1 TO 8
CT – 1 TO 8
FP - 1TO 8
CFP – 1 TO 8
ST – 1 TO 7
HV – 1 TO 11
PADDLE
DRYER – 1
TRAY DRYER
– 4 TO 8
P=ATM
T = <5OC
Toxic
Exothermic
1) All required PPE’s are provided.
2) Scrubber unit are provided.
3) Fire extinguishers are provided.
4) Temperature indicators are provided. 5) Fire hydrant points are provided.
6) sand & lime drums are kept on each floor
8
DD-2
PLANT
(DISPERSE
DYES)
Diazotization
H2SO4
HCL
NSA
NaNO2
SODIUM
ACETATE
DYTOL DF
OPA
ACETIC ACID
MSGL 1 TO 12
CT - 1 TO 7
SL – 1 TO 7
FP – 1 TO 7
P=ATM
T = <5OC
Toxic
Exothermic
1) All required PPE’s are provided. 2) Scrubber unit are provided.
3) Fire extinguishers are provided.
4) Temperature indicators are provided.
5) Fire hydrant points are provided. 6) sand & lime drums are kept on each floor
9 NKS
(DISPERSI
1) Naphthalene
Melting
NAPTHALENE, M
N LIQUID.
MELTERS
1,2,3
P=ATM
T = <80O
C
Toxic
1) All required PPE’s are provided.
2) Temperature indicator & pressure gauge is
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-174
Report No. 1718A058
NG
AGE)&
MAA
PLANT
2) Sulphonation
3) Condensation
4) Nutralisation
5) Filtration
6) Condensation
MAA PLANT
:-
7) Des
Condensation
8) Acetylation
9) Filtration
10) Bromination
OLEUM / H2SO4
FORMALDEHYD
E
CAUSTIC LYE
PHENOL
FORMALDEHYD
E
CAUSTIC LYE
DI ETHYL
SULPHATE
MPDA, META
TOLUDINE
N HSXYAL
BROMIDE
H2SO4,HCL,AMI
NE,
BROMINE,H2O2
3rd
FLOOR
R - 109,110 ,111
2nd
FLOOR
R -
103,104,108,113
1st FLOOR
R -
101,102,105,112
1st
FLOOR
FP - 1, FP - 2,
FP - 3,
FP - 6
R - 106,107
1st
FLOOR
R - 122
1st
FLOOR
R - 117,
118,119,120,
121,122
ANF,FP - 4,
FP - 5
R – 119
P=ATM
T =<150OC
P= < 2.0
Kg/Cm2
T =<135OC
T = <60OC
P= < 3.5
Kg/Cm2
T=< 150OC
P=ATM
T = <100OC
P=ATM
T = 10OC
P = ATM
T = 30OC
Exothermic
Exothermic
Pressure
Release
Toxic
Toxic
Exothermic
Toxic
Toxic
Exothermic
Toxic
provided.
3) Safety valves are provided.
4) Pressure reducing valve are provided.
5) Vent line dip in water provided.
6) Alternate cooling arrangement is
provided
7) All required PPE’s are provided
8) Fire extinguishers are provided
9) Fire hydrant points are provided. 10) Sand & lime drums are kept on each floor.
10 EO PLANT
ETHYLEN
E
OXIDE
PLANT
Ethoxylatioin
Acetylation
Condensation
Filtration
EO,AMA,MAA,M
T,
MCA,ACN,MEMT
,MEA
ACETIC
ANHYDRIDE
1st FLOOR
R - 1 TO 9
GROUND
FLOOR
NUTSCHE - 1
TO 3
P= 3.5
Kg/Cm2
T = <
120OC
Explosive
Fire
Toxic
Exothermic
Pressure
1) All required PPE’s are provided.
2) Temp & pressure gauges are provided.
3) Safety valves are provided.
4) Vent line dip in water provided.
5) Alternate cooling arrangement is
Provided.
5) Fire extinguishers are provided. 6) Fire hydrant points are provided.
7) Emergency alarm system is provided
8) Sand & lime drums are kept on each floor.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-175
Report No. 1718A058
ACETIC ACID
ANILINE OIL
ALLYL
CHLORIDE
BENZYL
CHLORIDE
CAUSTIC LYE
9) Sprinkler system is
provided in plant.
11 FORMULA
TION
- 1 PLANT
Grinding
Milling
Spray Drying
DYTOL - DF
NKS
TKS / TKM
OPA
ACETIC ACID
REAX 89 L
HEDP
SPD - 4
2nd
FLOOR
PV - 1 TO 16
HOMO - 6,
HV12A,12B,12C
HV - 1B
G FLOOR
SM -
1AB,2AB,3AB,
4AB
SM- 5AB
6AB,7AB,8AB,
9AB,10AB
SM - 11,12
SM -
13AB,14AB,15
AB,16AB
FT BOX – 1 TO
3
ALL AT
FORM - 1
SPD - 3,5
HV - 1,2,3,4 2nd
FLOOR
ALL AT NKS
P=ATM
T = <50OC
1) All required PPE’s are provided. 2) Temp. Gauges are provided.
3) Fire extinguishers are provided
4) Fire hydrant points are provided.
5) Sand & lime drums are kept on each floor.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-176
Report No. 1718A058
SIDE
12 FORMULA
TION
- 2 PLANT
Grinding
Milling
Spray Drying
DYTOL – DF
NKS
TKS
OPA
ACETIC ACID
SPRAY
DRYER - 6,7,8
TANK – 1 TO4
1st FLOOR
SM -
1AB,2AB,3AB,
4AB,
5AB,6AB
FILTER BOX -
1,2,3,4
2nd FLOOR
TURBO-
1,SMV-1 TO 6
MRV-1,2,3
CV 1TO 6
EXV-1,2,3
G FLOOR AT
DD - 2
MR-1A,B,C
MR2A,B,C,D
MR - 3A,B,C
MR -
4A,B,C,D,E
1) All required PPE’s are provided.
2) Temp. Gauges are provided.
3) Fire extinguishers are provided.
4) Fire hydrant points are provided. 5) Sand & lime drums are on kept on each
floor.
13
PT P
PLANT
&
AMINO
PLANT
Amination
&
Reduction
EFFLUENT
WATER
8, 50,000 LITS.
LIME - 700 MT
FERRIOUS
SULPHATE 80
MT
LIQ. AMMONIA
QUNIZILINE
HYDRO
NT – 1&2
EQUILIZER
TANK
1000KL
AMINO
PLANT
AR-
101,102,103,104
DISTILATION
R - 101 TO 103
P=ATM
T = <50OC
P= 3.0 Kg/Cm2
T= 70OC
Fire
Toxic
1) All required PPE’s are provided.
2) Temp. Gauges are provided.
3) Fire extinguishers are provided.
4) Fire hydrant points are provided.
5) Sand & lime drums are kept on each floor.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-177
Report No. 1718A058
DISTILATION
C-101, R-105
FILTER
PRESS
AFT-102
AR - 106
14 SOLVENT
– 3
PLANT
Chlorosulfonatio
n
&
Condensation
ODCB
SULPHURYL
CHLORIDE
LEUCO
VIOLET 28
PHENOL
POTASSIUM
CARBONATE
R – 102 to R -
108
FP – 2 / FP – 3
P=ATM
T = 50OC
to
80OC
P=ATM
T = RT to
180OC
Toxic
Release
Corrosive
Spill
1) All required PPE’s are provided.
2) Temp & pressure gauges are provided.
3) Fire extinguishers are provided. 4) Fire hydrant points are provided.
5) Sand & lime drums are kept on each floor.
6) Emergency alarm system is provided.
15 MONO
AZO
Diazotization
Coupling
Bromination
NSA, H2SO4,
WEAK AMINE,
DBPNA, DCPNA,
SD – 12,
SD - 7
SV – 1 to DV –
6
CT – 1 to CT –
4
FP – 1 to FP - 4
P=ATM
T = 80OC
Toxic
Release
Corrosive
Spill
1) All required PPE’s are provided.
2) Temp & pressure gauges are provided.
3) Fire extinguishers are provided.
4) Fire hydrant points are provided. 5) Sand & lime drums are kept on each floor.
6) Emergency alarm system is provided.
The major anticipated hazards in the SDCL are described below.
Electrical hazards due to the electrical major equipment/ machinery, operations, welding, motors, heavy lift devices, cabling, human intervention (short circuit
possibility), maintenance work (due to machinery breakdown etc.), plant lighting related electrical hazards.
Possibility of human injury due to working with mechanical machines, manual handling etc.
Possibility of injury during chemicals handled, during operations and due to intoxication
Major dropped objects hazard due to large number of physical handling steps / operations involved with crane/ overhead lifting/ hoisting equipment.
Fires in any part of the plant working areas; there is a possibility of rapid escalation if it is not brought under control quickly.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-178
Report No. 1718A058
TABLE 7.4 GENERAL HAZARDS AND ITS CONTROL
S.
NO
HAZARD
EMERGENCY
POSSIBLE
REASON
RISK/
IMPACT
CONTROL MEASURES
AVAILABLE/REQUIRED
1 Hazardous gases
exposure Failure of equipment
Toxicity
poisoning
Application of gas masks
advised
2 High temperature
contact
Slips,
Falls,
Burn injuries Application of aprons, gloves
and facemasks advised.
3 High noise Hearing impairment Inability in
communication application of ear plugs advised
4 Fire, explosion Unforeseen material
in wastes
Physical injuries,
loss of equipment,
Application of fire
extinguishers, fire hydrant
system advised
5 Movement of
vehicles Accidental impacts
Physical injuries,
damage to
equipment
Speed limit of vehicles and
routes for plying to be fixed.
6 Electrical hazards Contacts/overloads Flash fires,
electrocutions
Application of hand gloves,
face mask, safety shoes advised.
7 Scaffold failure Insufficient props Physical injuries Application of props and
leveling of scaffold
8 No work permits No proper work
procedures/controls
Failures, physical
injuries
Implementation of a work
permit system.
SAFETY MEASURES FOR TRANSPORTING OF HAZARDOUS CHEMICALS:
Transporter to be provided with transport emergency card (TREM) with detailed instructions in case
of accident and/or emergency situation;
Driver & cleaner to be provided training to handle the emergency situation;
Transport vehicle will be equipped with fire fighting gadgets;
SAFETY MEASURES FOR STORING AND HANDLING OF HAZARDOUS CHEMICALS:
All the hazardous chemicals are provided with Safety instruction sheets.
All the user departments are provided with the sheets and regular training imparted to the employees.
Visuals are also displayed to understand the do’s and don’ts of the chemicals.
The monitoring of implementations is done through safety inspections. (Near Miss incidents)
A model safety instruction sheet is given below for scrutiny.
Continued…….
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat (EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
SUBSTANCE: ETHYLENE OXIDE.
SAFETY INSTRUCTIONS – HAZCHEM: ETHYLENE OXIDE (EO) CAS NO: 75-21-8
COMPANY: SPECTRUM DYES &CHEMICALS PVT.LTD. DATE: 02.07.2017
WORKING AREA: EO
RESPONSIBLE PERSON: Mr. HUSMUKH PATEL SIGNATURE :
HAZARD TO HUMAN HEALTH AND THE ENVIRONMENT
FLAMMABLE LIQUID/GAS : Extremely flammable liquid and vapor. Freely soluble in water. Gas is heavier
than air. Chemically unstable. Kept in liquefied state under Nitrogen pressure at lower temperatures. (-5°C)
FP = (-57) °C BP= 10.5 °C LEL = 2.6 % VD = 1.925kg/cm2 at 15°C ,VP = 2.1 bar at 30°C, Auto
Ignition Temp. = 435°C Density of liquid = 0.8866 kg/l. Explosion group = II B TWA = 1.0 ppm
HEALTH: Acute and Chronic health hazards form the substance. Lowest inhalation concentration causing
toxic effects is 1.44 mg/l for 4 hours. It is a strong skin irritant. Neurological disorders and even death have
been reported. Confirmed carcinogen.
REACTIVITY : The auto ignition temperature may be as low as 140° C in presence of rust. Rapid compression
of the vapor with air causes explosion. Ethylene oxide vapor may be initiated into explosive decomposition
in the absence of air. Metal fittings containing magnesium, copper or silver should be avoided. Tends to
polymerize spontaneously due to impurities & application of heat.
Avoid spills and process water in drains. This substance is Eco toxic.
PROTECTIVE MEASURES AND RULES OF CONDUCT
Provision of good ventilation in the working area.
Avoid inhalation of vapor or cold mist. Stay upwind and uphill. Deny entry.
Avoid contact with skin and eyes. In case of contact wash skin and eyes with water.
Store liquefying the gas and cooling to (-5°C). Protect it from heat and heat loss.
Fill in a designated labeled container/vessel.
Evacuate downwind areas for large release of HAZCHEM.
When on large releases, notify the fire and health officials and pollution control agencies.
Avoid long term spills un-cleaned. Vapor formation will result in ignition and flashbacks.
Empty the containers as soon as they are taken for process applications.
Restricted entry. Entry only to authorized personnel.
CONDUCT IN CASE OF DANGER
Suitable dry extinguishing media. Dry extinguishing powder, dry sand.
The flammable gases are highly toxic. Use appropriate gas masks/SCBA set during fire fighting.
Provide sprinkler system, FFF Foam system, fire hydrant system for mitigating fires.
Use water spray to cool and dilute the gas leakages.
In case of large fire use copious amount of water to fight fire.
Use appropriately the fire suits / Proximity suits/ depending on the intensity of the situations.
In any case personal safety shall be the guiding point during fire fighting.
Avoid fire prone liquids and gases entering closed enclosures/ drains. The substance is hazardous to aquatic
environment.
FIRST-AID
EMERGENCY
INHALATION: Remove the casualty from the hazardous area and take him to the fresh air. Arrange medical treatment.
SKIN: Remove the contaminated clothing. Immediately cleanse the affected skin areas with soap under running water.
If irritation persists arrange for medical treatment.
EYES: Rinse the affected eyes with widely spread lids for 10 minutes with running water. Take him to an eye doctor.
SWALLOING: Rinse the mouth and spit the fluids out. If the person is conscious, make him to drink copious amounts of
liquids. Arrange medical treatment.
PROPER DISPOSAL
Carefully absorb the spilled liquid, place into sealed containers, and send to the competent authority for proper
disposal. If the quantity is small dissolve it with plenty of water and dispose it off.
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7.7 TRANSPORTATION
All the raw materials and finished are transported through by road only.
7.8 RISK ASSESSMENT AND CONSEQUENCE ANALYSIS
In a plant handling hazardous chemicals, the main hazard arises due to storage, handling and use of these
chemicals. If these chemicals are released into the atmosphere, they may cause damage due to resulting fires
or vapour clouds.
Operating Parameters: Potential vapour release for the same material depends significantly on the operating
conditions. Especially for any liquefied gas, the operating conditions are very critical to assess the damage
potential.
Inventory: Inventory Analysis is commonly used in understanding the relative hazards and short listing of
release scenarios. Inventory plays an important role in regard to the potential hazard. The potential vapour
release (source strength) depends upon the quantity of liquid release, the properties of the materials and the
operating conditions (pressure, temperature).
Loss of Containment: Plant inventory can get discharged to Environment due to Loss of Containment.
Certain features of materials to be handled at the plant need to the clearly understood to firstly list out all
significant release cases and then to short list release scenarios for a detailed examination. Liquid release can
be either instantaneous or continuous. Failure of a vessel leading to an instantaneous outflow assumes the
sudden appearance of such a major crack that practically all of the contents above the crack have to released in
a very short time.
7.8.1 SELECTION OF INCIDENTS AND CONSEQUENCE CALCULATIONS
The Consequence Analysis has been done for selected scenarios. This has been done for weather conditions
having wind speed 1.2 m/s. In Consequence Analysis, geographical location of the source of potential release
plays an important role. Consideration of a large number of scenarios in the same geographical location serves
little purpose if the dominant scenario has been identified and duly considered.
7.8.2 MAXIMUM CREDIBLE LOSS ACCIDENT SCENARIOS
A Maximum Credible Accident (MCA) can be characterised as the worst credible accident. In other words: an
accident in an activity, resulting in the maximum consequence distance that is still believed to be possible. A
MCA-analysis does not include a quantification of the probability of occurrence of the accident. Another
aspect, in which the pessimistic approach of MCA studies appears, is the atmospheric condition that is used
for dispersion calculations. The Maximum Credible Loss (MCL) scenarios have been developed for the
Facility. The MCL cases considered, attempt to include the worst “Credible” incidents- what constitutes a
credible incident is always subjective. Nevertheless, guidelines have evolved over the years and based on
basic engineering judgement, the cases have been found to be credible and modelling for assessing
vulnerability zones is prepared accordingly. Only catastrophic cases have been considered and not partial or
small failures (as is the case in Quantitative Risk Assessment where contributions from low frequency-high
outcome effect as well as high frequency - low outcome events are distinguished). The objective of the study
is emergency planning, hence only holistic and conservative assumptions are used for obvious reasons. Hence
though the outcomes may look pessimistic, the planning for emergency concept should be borne in mind
whilst interpreting the results.
7.8.3 SCENARIOS (VULNERABILITY AREA IDENTIFICATION)
Identification of risks is done qualitatively and quantitatively through the selection of hazardous substances
and by studying process, to arrive at possible failures and their inherent causes. Probability of risk occurrence
is also ascertained in order to determine the MAXIMUM CREDIBLE ACCIDENT SCENARIO and the
WORST CASE SCENARIO. Hazardous substances have been identified as follows considering the applicable
criteria laid down under the Chemical Accident (Emergency Planning, Preparedness and Response) Rules,
1996, as well as other relevant guidelines.
The handling, processing, and storage of Hazardous chemicals were analyzed and the risks as shown in Table
7.1 had been identified. The risks are then analyzed quantitatively in terms of probability, and severity. The
risks have also been rated according to the matrix R = Probability x Severity.
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Based on generally accepted definitions, the MAXIMUM CREDIBLE ACCIDENT SCENARIO (MCAS)
indicates most likely or possible accident scenario, taking into account the effect of existing control measures
also.
Possible accident scenarios at SDCL are given in following table 7.5
TABLE 7.5 POSSIBLE ACCIDENT SCENARIOS
S.
No Source Scenarios
Failure
Mechanism
RISK
Consequences Probability
¹
Severity 2
Risk
Rating3
1
FIRE IN OUTSIDE
SURFACE OF
ETHYLENE OXIDE STORAGE TANK DUE TO LEAKAGE
FROM THE TANK
(WORST CASE SCENARIO)
WELD CRACK ON THE WELD
SEAMS OF STORAGE TANK.
BIG FIRE, BLEVE, DOMINO
EFFECTS OF FIRE IN OTHER
AREAS OF THE
PREMISES.
2 5 10
2
ETHYLENE OXIDE LEAKAGE FROM
THE TANKER UNLOADING HOSE
PIPE CONNECTION. FLAMMABLE VAPOURS
ENGULFING THE
AREA.
LEAKAGE FROM THE
UNLOADING HOSE PIPE JOINTS.
FIRE ACCIDENTS AND PHYSICAL INJURIES TO THE
OPERATING PEOPLE IN THE
PLANT. DAMAGE
TO PLANT AND EQUIPMENT.
2 4 8
3
LEAKAGE IN THE
UNDERGROUND METHANOL TANK. OUT FLOWN
MATERIAL EMITS
FLAMMABLE
VAPOUR.
STORAGE TANK WELD
JOINT CRACK.
METHANOL VAPOURS ARE HIGHLY
FLAMMABLE. LIKELYHOOD OF
FLAMMABILITY.
DUMPING ARRANGEMENT IN OTHER
TANKS TO
MITIGATE EMERGENCY.
2 4 8
4
OVERFLOW OF
METHANOL FROM
THE RECEIVER IN THE PLANT.
FLAMMABLE
VAPOURS INSIDE THE PLANT PREMISES.
(MAXIMUM
CREDIBLE
ACCIDENT
SCENARIO)
OVERFLOW
RETURN LINE
NOT AVAILABLE. OVER FLOWN
METHANOL
SPILLS ON THE PLANT
FLOOR AND
PROCESS EQUIPMENT
POSSIBILITY OF MOJOR FIRE
2 4 8
5
OLEUM STORAGE TANK INFLOW LINE
VALVE LEAKAGE.
INFLOW LINE DIPPED IN THE
STORAGE
MATERIAL.
VALVE SEAT
ERODED AND LEAKED.
OULEUM FUMES SPREAD IN THE
FACTORY
PREMISES AND THE NEARBY
NATIONAL
HIGHWAY.
3 3 9
6 OVERTURNING OF FORKLIFT WHILE
CARRYING
WHILE TURNING
ROUND A
BREAKAGE OF BOTTLES AND
LIBERATION OF 3 3 9
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BROMINE BOTTLE
CRATES.
CORNER FORKLIFT
OVERTURNED.
THICK BROMINE TOXIC VAPORS
END LEGEND
1PROBABILITY: 2SEVERITY: 3RISK RATING:
1 – HIGHLY UNLIKELY 1 – EXTREMELY MILD PROBABILITY x SEVERITY
2 – UNLIKELY 2 – MILD
3 – SOMEWHAT LIKELY 3 – MODERATE 4 – LIKELY 4 – SEVERE
5 – VERY LIKELY 5 – MOST SEVERE
There are more numbers of TOXIC SEVERITY SCENARIO RISKS from the following chemicals,
(OLEUM, ACETIC ACID, ACETIC ANHYDRIDE, HCL, H2SO4, NSA, ANILINE) , on the Bulk
storage and transfer of chemicals.
There are VERY HIGHLY FLAMMABLE GASES in compressed form (ETHYLENE OXIDE,
ETHYL CHLORIDE), very highly flammable liquids ( METHANOL, DMF, ACRYLONITRILE,
ACETONE)
The worst case scenario is also well within the reach of fire protection/mitigation measures, planned for
installation.
Fire protection/ control / mitigation measures are fully incorporated.
7.8.4 VULNERABILITY ANALYSIS A vulnerability analysis is carried out on the MAXIMUM CREDIBLE ACCIDENT SCENARIO and the WORST CASE SCENARIO. The analysis is carried out using the help of sophisticated computer
software which provides the zone of influence as well as the geographical risk contours. The
calculations are complex in nature, and various parameters are defined to assist the software in simulating the risk contours. The parameters include details such as the size of the leakages / holes,
quantity of materials released, duration of the release, weather and geographical conditions. The
simulations are generated under standard operating conditions. Data given in the reports and manuals are taken as correct information.
The weather conditions are taken as per Table 7.6 for all simulations.
TABLE 7.6 WEATHER CONDITIONS
PARAMETERS CONDITION D CONDITION F
Wind Speed 10.0 m/s 3.0 m/s
Wind Direction 225° true at 3 m 45° true at 3 m
Pasquill Stability D F
Ground Roughness Open country Open country
Air Temperature (°C) 32 25
Surface temperature 32 25
Relative Humidity 75% 50%
Cloud Cover 70% 50%
7.8.4.1 MAXIMUM CREDIBLE ACCIDENT SCENARIO The MAXIMUM CREDIBLE ACCIDENT SCENARIO was analyzed based on flammable vapor and toxic
vapor risks. The ALOHA simulation software was used to obtain the risk contours and the zone of influence,
as well as levels of risk associated with each zone. The calculations performed are based on Unified Dispersion Modeling and provide the foot prints of hazardous chemical dispersion and the distances of critical concentrations for flammability and toxicity. The
model considers a three stage method as given in the following illustration:
POOL SPREADING AND VAPORIZATION The release containing liquid droplets forms a pool. Any
evaporation from this pool will contribute to the dispersing pool.
Evaporation
↓
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DISPERSION The vapor cloud disperses in the atmosphere until it has
reached harmless concentration.
Calculation of the concentration profile of the cloud ↓
FLAMMABILITY AND TOXICITY
The results of the ALOHA simulation as well as the parameters used for carrying out the simulations is given
below. Downwind concentrations of chemicals are shown.
7.8.4.2 The latitude for Surat - Palsana, Surat, Gujarat, India is:
Latitude DMS: 21°5'7.09" N
Longitude DMS: 72°56'30.69" E
7.8.5 WORST CASE SCENARIO:
TABLE 7.7 WORST CASE SCENARIOS SIMULATION FOR WEATHER CONDITIONS ‘D’, ‘F’
PARAMETERS RISK
THREAT
ZONES
‘D’
THREAT
ZONES
‘F’
PSI
AFFECTED
POPULATION
THREAT AT
POINT:
DW:50M,
CW30M
ETHYLENE OXIDE (BLAST
FORCE IN THE
TANKS)
BLEVE
14 m 19 m 8.0 Employees in the plant shall assemble at safe
Assembly points. The
Assembly points shall
be located in UPWIND
SIDE. Minor damages
are possible in the
works premises. No off
site emergency
foreseen.
‘D’Stability:0.676
psi.
‘F’ Stability :
1.04 psi
20m 27 m 3.5
44 m 61 m 1.0
7.8.5.1 DISPERSION CALCULATIONS:
1) Fire in outside Surface of Ethylene Oxide Storage Tank due to leakage from The Tank.
(WORST CASE SCENARIO)
Ethylene Oxide – 3 m/s, Stability Condition: “F”
SITE DATA:
Location: PALSANA, SURAT,GUJARAT, INDIA
Building Air Exchanges Per Hour: 12 (user specified) Time: January 9, 2018 1342 hours ST (using
computer's clock)
CHEMICAL DATA:
Chemical Name: ETHYLENE OXIDE
Molecular Weight: 44.05 g/mol AEGL-1 (60 min):
N/A AEGL-2 (60
min): 45 ppm AEGL-3 (60 min): 200 ppm IDLH: 800 ppm LEL: 30000 ppm
UEL: 1000000 ppm
Carcinogenic risk - see CAMEO
Chemicals
Scenario:
Fire in outside Surface Of Ethylene Oxide Storage Tank
due to leakage from the tank.
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Ambient Boiling Point: 10.5° C
Vapor Pressure at Ambient Temperature: greater than 1 atm Ambient Saturation Concentration:
1,000,000 ppm or 100.0%
ATMOSPHERIC DATA: (MANUAL
INPUT OF DATA)
Wind: 3 meters/second from 45° true at 3 meters
Ground Roughness: open country
Cloud Cover: 5 tenths
Air Temperature: 25° C
Stability Class: F (user override)
No Inversion Height
Relative Humidity: 50%
SOURCE STRENGTH:
Direct Source: 2000 kilograms/hr
Source Height: 0
Release Duration: 60 minutes Release Rate: 33.3 kilograms/min
Total Amount Released: 2,000 kilograms
Note: This chemical may flash boil and/or result in two phase flow.
THREAT ZONE:
Threat Modeled: Overpressure (blast force) from vapor cloud explosion
Type of Ignition: ignited by spark or flame
Level of Congestion: congested
Model Run: Heavy Gas
Red : 19 meters --- (8.0 psi = destruction of buildings)
Orange: 27 meters --- (3.5 psi = serious injury likely) Yellow: 61 meters --- (1.0 psi = shatters glass)
THREAT AT POINT: Overpressure Estimate at the point:
Downwind: 50 meters Off Centerline: 30 meters
Overpressure: 1.04 psi
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Ethylene Oxide– 10 m/s, Stability Condition: “D”
SITE DATA:
Location: PALSANA, SURAT,GUJARAT, INDIA Building Air Exchanges Per Hour: 12 (user
specified)
Time: January 9, 2018 1342 hours ST (using computer's clock)
CHEMICAL DATA:
Chemical Name: ETHYLENE OXIDE
Molecular Weight: 44.05 g/mol AEGL-1 (60 min):
N/A AEGL-2 (60 min): 45 ppm AEGL-3 (60 min): 200 ppm
IDLH: 800 ppm LEL: 30000 ppm
UEL: 1000000 ppm
Carcinogenic risk - see CAMEO
Chemicals
Ambient Boiling Point: 10.5° C
Vapor Pressure at Ambient Temperature: greater
than 1 atm Ambient Saturation Concentration: 1,000,000 ppm or 100.0%
ATMOSPHERIC DATA:
Wind: 10 meters/second from 225° true at 3 meters
Ground Roughness: open country Cloud Cover: 7 tenths
Air Temperature: 32° C Stability Class: D
No Inversion Height Relative Humidity: 75%
SOURCE STRENGTH:
Direct Source: 2000 kilograms/hr
Source Height: 0
Release Duration: 60 minutes Release Rate: 33.3 kilograms/min
Total Amount Released: 2,000 kilograms
Note: This chemical may flash boil and/or result in two phase flow.
Scenario:
Fire in outside Surface Of Ethylene Oxide Storage Tank
due to leakage from the tank.
THREAT ZONE:
Threat Modeled: Overpressure (blast force) from vapor
cloud explosion
Type of Ignition: ignited by spark or flame
Level of Congestion: congested
Model Run: Heavy Gas
Red : 14 meters --- (8.0 psi = destruction of buildings)
Orange: 20 meters --- (3.5 psi = serious injury likely)
Yellow: 44 meters --- (1.0 psi = shatters glass)
THREAT AT POINT:
Overpressure Estimate at the point:
Downwind: 50 meters
Off Centerline: 30 meters
Overpressure: 0.676 psi
Discussion / Interpretation:
• Ethylene Oxide is stored under the nitrogen pressure due to its highly reactive & explosive nature.
• Here, we have considered the Fire in outside Surface of Ethylene Oxide Storage Tank due to
leakage from the tank.
• Analysis shows, The maximum overpressure (8.0 psi = destruction of buildings) is experienced up to
19 meter & 14 meter from the source for stability class 3F & 10D respectively.
• EO should be handled with care & control measures shall be regularly checked & maintained.
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7.8.5.2 MAXIMUM CREDIBLE ACCIDENT SCENARIO (MCAS) :
TABLE 7.8 MAXIMUM CREDIBLE ACCIDENT SCENARIO (MCAS) SIMULATION FOR
WEATHER CONDITIONS ‘D’, ‘F’
PARAMETERS
–RELAESE OF
GAS
RISK
THREAT
ZONES
‘D’ in ‘m’
THREAT
ZONES
‘F ’in
‘m ‘
PPM/
PSI ACTIONS TO REDUCE
SEVERITY
THREAT
AT
POINT:
DW 10M,
CW 5 M
ETHYLLENE
OXIDE: Storage
tank Failure (Flammable area
vapor cloud)
FLAM MABLE
Vapor Cloud
10 NA
18000 Cover the spilled liquid
with sand. Dilute the
liquid pool with 1:25
ration water
No
significant
effect. XX NA XX
30 NA 3000
METHANOL:
storage tank
failure .(Flammable area
vapor cloud)
FLAM MABLE Vapor
Cloud
11 NA 43080
Cover the spilled liquid
with sand. Use PPEs.
No
significant
effect.
xx NA XX
28 NA 7180
METHANOL: Pipeline Transfer failure.
(Flammable area
vapor cloud)
FLAM
MABLE
Vapor Cloud
27 NA 43080
Cover the spilled liquid
with sand. Use PPEs.
No
significant
effect.
XX NA XX
97 NA 7180
OLEUM :
Leakage from the inlet filling line valve(Toxic
cloud effect)
Toxic Vapor Cloud
<1O NA 160mg
m3
Cover the spilled liquid
with sand. Then apply
neutralizers (Soda ash/
Lime) over the sand. The
toxic effect will be
reduced to 10%.Use
PPEs.
No
significant
effect.
11 NA xx
80 NA
xx
BROMINE:
Forklift capsizing
and bottles broken. (Toxic
cloud effect)
Toxic
Vapor Cloud
27 NA 8.5 All the crates shall be
placed in a open container
to avoid fall and
breakage.
No
significant
effect.
164 NA 0.24
486 NA 0.033
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1) Ethylene Oxide: Storage tank failure (Flammable area vapor cloud)
(MAXIMUM CREDIBLE ACCIDENT SCENARIO)
Ethylene Oxide – 3 m/s, Stability Condition: ‘D’
SITE DATA:
Location: PALSANA, SURAT,GUJARAT,
INDIA
Building Air Exchanges Per Hour: 12 (user specified) Time: January 9, 2018 1503 hours ST
(using computer's clock)
CHEMICAL DATA:
Chemical Name: ETHYLENE OXIDE
Molecular Weight: 44.05 g/mol AEGL-1 (60 min): N/A
AEGL-2 (60 min): 45 ppm AEGL-3 (60 min): 200 ppm
IDLH: 800 ppm LEL: 30000 ppm
UEL: 1000000 ppm Carcinogenic risk - see CAMEO
Chemicals
Ambient Boiling Point: 10.5° C
Vapor Pressure at Ambient Temperature:
greater than 1 atm
Ambient Saturation Concentration:
1,000,000 ppm or 100.0%
ATMOSPHERIC DATA:
Wind: 10 meters/second from 225° true
at 3 meters
Ground Roughness: open country Cloud
Cover: 7 tenths
Air Temperature: 32° C
Stability Class: D
No Inversion Height
Relative Humidity: 75%
SOURCE STRENGTH:
Evaporating Puddle (Note: chemical is
flammable)
Puddle Diameter: 3 meters Puddle Mass: 500 kilograms
Ground Type: Default soil Ground Temperature: 32° C Initial Puddle Temperature: 10.5° C
Release Duration: ALOHA limited the
duration to 1 hour
Max Average Sustained Release Rate: 29.8 kilograms/min (averaged over a minute or
more) Total Amount Released: 321 kilograms
Scenario:
Storage tank failure (Flammable area vapor cloud)
THREAT ZONE: Threat Modeled: Flammable Area of Vapor Cloud
Model Run: Gaussian
Red : less than 10 meters(10.9 yards) --- (18000 ppm = 60% LEL = Flame Pockets)
Note: Threat zone was not drawn because effects of near-field patchiness make dispersion predictions less reliable for short distances.
Yellow: 30 meters --- (3000 ppm = 10% LEL)
Note: Threat zone was not drawn because effects of near-field patchiness make dispersion predictions less
reliable for short distances.
THREAT AT POINT: Concentration Estimates at the point: Downwind: 10 meters
Off Centerline: 5 meters
Note: Concentration not drawn because there is no
significant concentration at the point selected.
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2) Methanol: Storage tank failure (Flammable area vapor cloud)
(MAXIMUM CREDIBLE ACCIDENT SCENARIO)
METHANOL – 10 m/s, Stability Condition: ‘D’
SITE DATA:
Location: PALSANA, SURAT,GUJARAT,
INDIA
Building Air Exchanges Per Hour: 12 (user
specified) Time: January 9, 2018 1503 hours ST
(using computer's clock)
CHEMICAL DATA:
Chemical Name: METHANOL Molecular Weight: 32.04 g/mol
AEGL-1 (60 min): 530 ppm
AEGL-2 (60 min): 2100 ppm AEGL-3 (60 min): 7200 ppm
IDLH: 6000 ppm
LEL: 71800 ppm UEL: 365000 ppm
Ambient Boiling Point: 64.7° C
Vapor Pressure at Ambient temperature: 0.24 atm
Ambient Saturation Concentration: 237,713
ppm or 23.8%
ATMOSPHERIC DATA:
Wind: 10 meters/second from 225° true
at 3 meters
Ground Roughness: open country Cloud
Cover: 7 tenths
Air Temperature: 32° C
Stability Class: D
No Inversion Height
Relative Humidity: 75%
SOURCE STRENGTH:
Direct Source: 2000 kilograms/hr
Source Height: 0
Release Duration: 60 minutes Release Rate: 33.3 kilograms/min
Total Amount Released: 2,000 kilograms
Scenario:
Storage tank failure (Flammable area vapor cloud)
THREAT ZONE: Threat Modeled: Flammable Area of Vapor Cloud Model Run: Gaussian
Red: 11 meters --- (43080 ppm = 60% LEL = Flame Pockets)
Note: Threat zone was not drawn because effects of
near-field patchiness make dispersion predictions less
reliable for short distances.
Yellow: 28 meters --- (7180 ppm = 10% LEL)
Note: Threat zone was not drawn because effects of
near-field patchiness make dispersion predictions less
reliable for short distances.
THREAT AT POINT: Concentration Estimates at the point:
Downwind: 10 meters Off Centerline: 5 meters
Note: Concentration not drawn because there is no
significant concentration at the point selected.
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3) METHANOL: Pipeline Transfer failure (Flammable area vapor cloud)
(MAXIMUM CREDIBLE ACCIDENT SCENARIO)
METHANOL – 10 m/s, Stability Condition: ‘D’
SITE DATA:
Location: PALSANA, SURAT,GUJARAT, INDIA Building Air Exchanges Per Hour: 12 (user
specified) Time: January 9, 2018 1503 hours ST
(using computer's clock)
CHEMICAL DATA:
Chemical Name: METHANOL Molecular Weight: 32.04 g/mol
AEGL-1 (60 min): 530 ppm AEGL-2 (60 min): 2100 ppm AEGL-3 (60 min): 7200 ppm
IDLH: 6000 ppm
LEL: 71800 ppm
UEL: 365000 ppm Ambient Boiling Point: 64.7° C Vapor Pressure at Ambient temperature: 0.24
atm Ambient Saturation Concentration: 237,713
ppm or 23.8%
ATMOSPHERIC DATA:
Wind: 10 meters/second from 225° true
at 3 meters
Ground Roughness: open country Cloud
Cover: 7 tenths
Air Temperature: 32° C
Stability Class: D
No Inversion Height
Relative Humidity: 75%
SOURCE STRENGTH:
Direct Source: 200 kilograms/min Source Height: 15
Release Duration: 60 minutes Release Rate: 200 kilograms/min
Total Amount Released: 12,000 kilograms
Scenario:
Pipeline Transfer failure (Flammable area vapor cloud)
THREAT ZONE:
Threat Modeled: Flammable Area of Vapor Cloud
Model Run: Heavy Gas Red: 27 meters --- (43080 ppm = 60% LEL = Flame
Pockets)
Note: Threat zone was not drawn because effects of
near-field patchiness make dispersion predictions less
reliable for short distances.
Yellow: 97 meters --- (7180 ppm = 10% LEL)
THREAT AT POINT: Concentration Estimates at the point:
Downwind: 10 meters
Off Centerline: 5 meters Max Concentration: Outdoor:1.89 ppm Indoor:1.89 ppm
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4) OLEUM: Leakage from the inlet filling line valve (Toxic cloud effect)
(MAXIMUM CREDIBLE ACCIDENT SCENARIO)
OLEUM – 10 m/s, Stability Condition: ‘D’
SITE DATA:
Location: PALSANA, SURAT,GUJARAT, INDIA Building Air Exchanges Per Hour: 12 (user
specified) Time: January 9, 2018 1503 hours ST
(using computer's clock)
CHEMICAL DATA:
Warning: OLEUM can react with water and/or water vapor. This can affect the
evaporation rate and downwind dispersion. ALOHA cannot accurately predict the air hazard if this substance comes in contact with
water.
Chemical Name: OLEUM
Solution Strength: 23% (by weight) Ambient Boiling Point: 131.6° C Partial Pressure at Ambient Temperature:
0.0035 atm Ambient Saturation Concentration: 3,535
ppm or 0.35%
Hazardous Component: SULFUR TRIOXIDE Molecular Weight: 80.06 g/mol
AEGL-1 (60 min): 0.2 mg/(cu m)
AEGL-2 (60 min): 8.7 mg/(cu m) AEGL-3 (60 min): 160 mg/(cu m)
ATMOSPHERIC DATA:
Wind: 10 meters/second from 225° true
at 3 meters
Ground Roughness: open country Cloud
Cover: 7 tenths
Air Temperature: 32° C
Stability Class: D
No Inversion Height
Relative Humidity: 75%
SOURCE STRENGTH:
Evaporating Puddle: Puddle Diameter: 1 meters
Puddle Mass: 200 kilograms
Ground Type: Concrete Ground Temperature: 32° C Initial Puddle Temperature: Ground
temperature Release Duration: ALOHA limited the
duration to 1 hour
Max Average Sustained Release Rate: 10.8
grams/min (averaged over a minute or more) Total Amount Hazardous Component
Released: 642 grams
Scenario:
Leakage from the inlet filling line valve (Toxic cloud effect)
THREAT ZONE:
Model Run: Gaussian Red: less than 10 meters (10.9 yards) --- (160 mg/(cu m)
= AEGL-3 (60 min))
Note: Threat zone was not drawn because effects of
near-field patchiness make dispersion predictions less
reliable for short distances. Orange: 11 meters --- (8.7 mg/(cu m) = AEGL-2 (60 min))
Note: Threat zone was not drawn because effects of
near-field patchiness make dispersion predictions less
reliable for short distances.
Yellow: 80 meters --- (0.2 mg/(cu m) = AEGL-1 (60 min))
THREAT AT POINT: Concentration Estimates at the point: Downwind: 10 meters
Off Centerline: 5 meters Max Concentration: Outdoor:1.89 ppm Indoor:1.89 ppm
Note: Concentration not drawn because there is no
significant concentration at the point selected.
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05) BROMINE: Forklift capsizing and bottles broken. (Toxic cloud effect)
(MAXIMUM CREDIBLE ACCIDENT SCENARIO)
BROMINE – 10 m/s, Stability Condition: ‘D’
SITE DATA:
Location: PALSANA, SURAT,GUJARAT, INDIA Building Air Exchanges Per Hour: 12 (user
specified) Time: January 9, 2018 1617 hours ST
(using computer's clock)
CHEMICAL DATA:
Chemical Name: BROMINE Molecular Weight: 159.81 g/mol
AEGL-1 (60 min): 0.033 ppm AEGL-2 (60 min): 0.24 ppm AEGL-3 (60 min): 8.5 ppm
IDLH: 3 ppm
Ambient Boiling Point: 58.7° C
Vapor Pressure at Ambient Temperature: 0.38 atm Ambient Saturation Concentration: 376,061
ppm or 37.6%
ATMOSPHERIC DATA:
Wind: 10 meters/second from 225° true at 3 meters Ground Roughness: open country Cloud
Cover: 7 tenths
Air Temperature: 32° C Stability Class: D
No Inversion Height Relative Humidity: 75%
SOURCE STRENGTH:
Direct Source: 20 kilograms/hr Source Height: 0
Release Duration: 60 minutes Release Rate: 333 grams/min
Total Amount Released: 20.0 kilograms
Scenario:
Leakage from the inlet filling line valve (Toxic cloud effect)
THREAT ZONE:
Model Run: Gaussian
Red : 27 meters --- (8.5 ppm = AEGL-3 (60 min))
Note: Threat zone was not drawn because effects of
near-field patchiness make dispersion predictions less
reliable for short distances.
Orange: 164 meters --- (0.24 ppm = AEGL-2 (60 min))
Yellow: 486 meters --- (0.033 ppm = AEGL-1 (60 min))
THREAT AT POINT: Concentration Estimates at the point:
Downwind: 10 meters
Off Centerline: 5 meters
Note: Concentration not drawn because there is no
significant concentration at the point selected.
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7.8.6 RISK ASSESSMENT AND MITIGATION MEASURES
RISK ASSESSMENT MITIGATION MEASURE & ITS MANAGEMENT
FORMALDEHYDE, PHENOL, AQUOUS AMMONIA are
highly toxic Materials.
Whenever there is spillage on the ground the pool has to be immediately covered with sand and neutralizers like SODA ASH/LIME shall be
spread on the spillage. 90% of the potential harm will be reduced.
FORMALDEHYDE , PHENOL, AMMONIA,OLEM in the gaseous form are very dangerous.
All the chemicals are both
flammable and highly toxic.
Leaks have to be isolated by closing the control valves SWIFTLY. No
body shall stay in the down wind direction. SCBA set shall be used and skilled manpower shall be used to control the effects of these chemicals.
METHANOL, ACETONE,
ACRYLONITRILE,
ETHYLENE OXIDE, ETHYL CHLORIDE are highly flammable chemical with low flash point and
boiling point. These chemicals are a potential source of major fires.
The storage area shall be well protected from any ignitable substances.
All the electrical fittings shall be flameproof. Only qualified /trained
persons shall be used to operate in the tank farm. The tank farm shall be
monitored all the 365 days including nights. Major accident scenarios have to be planned and MOCK DRILLS conducted.
Unsafe practices in the Tank-Farm
areas
All the storage tanks facilities shall have dumping arrangements
planned for reducing the severity during emergencies.
Dumping arrangement is a spare tank facility kept empty and ready to
receive the chemical from the tank with an emergency.
Quantity requirement of
Formaldehyde and Methanol are
very high.
It is preferable to have tanks with medium capacity (more in number) in
the tank farm.
Toxic Chemicals tank farm It shall be separated from flammable chemical tank farm. They have to
be separated by at least 15m away.
Rise in Exothermic reaction
temperature in Reaction vessels.
The cooling arrangements for the Reaction vessels shall be with standby
system. This will control the rise in Exothermic reaction temperatures.
There shall be also two Temperature indicators for monitoring temperature rise in the Reaction vessels.
In case of pressure reactors where
the pressures of operations are greater than atmospheric pressure, the overrun of exothermic reactions
control is very critical.
In addition to the safety devices, there must be arrangement to dislodge
the reaction mass through the bottom discharge valve. There shall be a provision of remote controlled discharge valves for the purpose.
7.8.7 SPECIFIC GUIDELINES FOR HANDLING OF HAZARDOUS CHEMICALS 7.8.7.1 SPECIFIC GUIDELINES FOR ETHYLENE OXIDE:
Guideline for Potential Hazards: Health & Safety • TOXIC; may be fatal if inhaled or absorbed through skin.
• Contact with gas or liquefied gas may cause burns, severe injury and/or frostbite.
• Fire will produce irritating, corrosive and/or toxic gases.
• Runoff from fire control may cause pollution.
• Flammable; may be ignited by heat, sparks or flames.
• May form explosive mixtures with air.
• Those substances designated with a (P) may polymerize explosively when heated or involved in a fire.
• Vapors from liquefied gas are initially heavier than air and spread along ground.
• Vapors may travel to source of ignition and flash back.
• Some of these materials may react violently with water.
• Cylinders exposed to fire may vent and release toxic and flammable gas through pressure relief
devices.
• Containers may explode when heated.
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• Ruptured cylinders may rocket.
• Runoff may create fire or explosion hazard.
• 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 100 meters (330 feet) in
all directions.
• Keep unauthorized personnel away.
• Stay upwind.
• Many gases are heavier than air and will spread along ground and collect in low or confined areas
(sewers, basements, tanks).
• Keep out of low areas.
• Ventilate closed spaces before entering.
• Wear positive pressure self-contained breathing apparatus (SCBA).
• Wear chemical protective clothing that is specifically recommended by the manufacturer. It may
provide little or no thermal protection.
• Structural firefighters' protective clothing provides limited protection in fire situations ONLY; it is not
effective in spill situations where direct contact with the substance is possible.
Guideline for Emergency Response: Fire
• DO NOT EXTINGUISH A LEAKING GAS FIRE UNLESS LEAK CAN BE STOPPED. Dry
chemical, CO2, water spray or alcohol-resistant foam.
Large Fire
• Water spray, fog or alcohol-resistant foam.
• FOR CHLOROSILANES, DO NOT USE WATER; use AFFF alcohol-resistant medium expansion
foam.
• Move containers from fire area if you can do it without risk.
• Damaged cylinders should be handled only by specialists.
Fire involving Tanks
• 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.
• Do not direct water at source of leak or safety devices; icing may occur.
• Withdraw immediately in case of rising sound from venting safety devices or discoloration of tank.
• ALWAYS stay away from tanks engulfed in fire.
• ELIMINATE all ignition sources (no smoking, flares, sparks or flames in immediate area).
• All equipment used when handling the product must be grounded.
• Fully encapsulating, vapor protective clothing should be worn for spills and leaks with no fire.
• Do not touch or walk through spilled material.
• Stop leak if you can do it without risk.
• Do not direct water at spill or source of leak.
• Use water spray to reduce vapors or divert vapor cloud drift. Avoid allowing water runoff to contact
spilled material.
• FOR CHLOROSILANES, use AFFF alcohol-resistant medium expansion foam to reduce vapors.
• If possible, turn leaking containers so that gas escapes rather than liquid.
• Prevent entry into waterways, sewers, basements or confined areas.
• Isolate area until gas has dispersed.
• Move victim to fresh air. • Call 911 or emergency medical service.
• Give artificial respiration if victim is not breathing.
• Do not use mouth-to-mouth method if victim ingested or inhaled the substance; give artificial
respiration with the aid of a pocket mask equipped with a one-way valve or other proper
respiratory medical device.
• Administer oxygen if breathing is difficult.
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• Remove and isolate contaminated clothing and shoes.
• In case of contact with substance, immediately flush skin or eyes with running water for at least 20
minutes.
• In case of contact with liquefied gas, thaw frosted parts with lukewarm water.
• In case of burns, immediately cool affected skin for as long as possible with cold water. Do not
remove clothing if adhering to skin.
• Keep victim warm and quiet.
• Keep victim under observation.
• Effects of contact or inhalation may be delayed.
• Ensure that medical personnel are aware of the material(s) involved and take precautions to protect
themselves.
7.8.7.2 SPECIFIC GUIDELINES FOR CYANIDES: Cyanides – Hazards - Curatives. Cyanides are considered to be one of the highly poisonous chemicals. It can produce severe undesirable health
effects when in direct contact with them. The write up highlights how much we are prepared for handling it. Any fresh suggestions on SAFETY ENHANSEMENT are welcome. Cyanides are supplied as white crystalline solid, lump solid or in powder form. Cyanides are deadly human
poison by ingestion, Toxic by skin absorption through open wounds, Toxic by ingestion, and by inhalation of
dust.
In M/s. Spectrum Dyes & Chemicals Pvt. Ltd, PALSANA. We use sodium Cyanide, Copper Cyanide and Zinc Cyanide in the Cyanation process. Sodium Cyanide is supplied in the form of tablets coated with soda ash, while the copper cyanide and zinc cyanide are supplied in the powder form.
This paper was discussed with Mr.Hardutt singh Tarar, Mr.K.B.Vishwakarma, Mr. Milind Joshi, Mr. Balbirsingh and all their suggestions incorporated.
PRECAUTIONS AT PROPDUCTION UNITS: The supply of cyanides is done in thick metal containers, the lids in sealed condition. The cyanide materials
are supplied in 25kgs, 30kgs and 50kgs tins. Inside the containers the cyanide material is again packed in thick
polythene bags sealed after packing. The packing is usually good and no accidents reported by damage of containers. The average consumption of cyanides in our company is 100 metal tins in each category.
1. All the Cyanides when accidentally come in contact with Acids (Even diluted acids) will puff out
copious amount of hydrogen cyanide gas which is a deadly poisonous gas associated with flammability.
2. Whenever there is a spillage of cyanides in the liquid form they have to be neutralized with
ALKALINE FERROUS SULPHATE solution. The neutralization process will prevent the
generation of hydrogen cyanide gas, hence will reduce the risk of poisoning and fire. 3. The cyanation process begins with addition of sodium cyanide in DMF liquid already charged inside
the reaction vessel. Addition of sodium cyanide tablets are done only when the DMF is tested alkaline. The mixture is stirred for 12-14 hrs prior to the addition of MONOAZODYE solutions.
4. Similarly the addition of copper cyanide and zinc cyanide is done in DMF when the vessel is taken on
vacuum. Due to vacuum the cyanide powders does not spill outside or spread. Designated PPEs are
used during cyanides handling. 5. In our company the CYANIDE material is used for almost 25 years and there is no damage of cyanide
containers during handling. This is due to clear demarcation of responsibility. All the handling and
manipulations are done by designated employees who are well trained for the purpose. 6. After the transfer of cyanide material the containers are washed with ferrous sulphate solution and
disposed off.
7. Throughout the period of association with cyanides, wearing of the designated PPEs are made
mandatory. 8. The track record of cyanide operations is good in M/s. Spectrum Dyes & Chemicals Pvt Ltd,
PALSANA. For the past 25 years there is no single incident on CYANIDE handling and usage. These
chemicals are handled by ONLY SOLVENT-1 group.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat (EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
PRECAUTIONS AT OHC:
CYANIDES anti dote kit is kept in Occupational Health Centre. They contain SODIUM NITRITE – INJECTION, SODIUM THIOSULPHATE-INJECTION., AMYL NITRITE –inhalant. Shift Nurses are well
aware of the procedure during emergencies.
MATERIAL SAFETY DATA SHEET (MSDS) An extract of the MATERIAL SAFETY DATA SHEET (MSDS) is given for Cyanides used in
M/s. Spectrum Dyes & Chemicals Pvt Ltd, PALSANA. This will give a ready reference and actions to be
taken during emergencies. 1. Sodium Cyanide
2. Copper Cyanide
3. Zinc Cyanide
1.SODIUM CYANIDE
CAS Number UN/NA Number DOT Hazard Label CHRIS Code
143-33-9 1689 Poison SCN
NFPA 704
Diamond Hazard Value Description
0 3
0
Health 3 Can cause serious or permanent injury.
Flammability 0 Will not burn under typical fire conditions.
Instability 0 Normally stable, even under fire conditions.
Special Source: (NFPA, 2010)
General Description
A white crystalline solid, lump solid or powder. A deadly human poison by ingestion Toxic by skin absorption through open wounds, by ingestion, and by inhalation of dust.
Reactivity Alerts : Water-Reactive
Air & Water Reactions
Soluble in water. Slowly decomposed by water and very rapidly by acids to give off hydrogen cyanide, a flammable poison gas. Based on a scenario where the chemical is spilled into an excess of water (at least 5 fold excess of water), half of the maximum theoretical yield of Hydrogen Cyanide gas will be created in 12
minutes.
Fire Hazard
Sodium cyanide is not combustible itself, but contact with acids releases highly flammable hydrogen cyanide
gas. Fire may produce irritating or poisonous gases. Runoff from fire control water may give off poisonous
gases. Container may explode in the heat of fire. Avoid strong oxidizers such as nitrates and chlorates; acids and acid salts. Avoid contact with acids. Aqueous solutions rapidly decompose.
Health Hazard
Super toxic; probable oral lethal dose in humans is less than 5 mg/kg or a taste (less than 7 drops) for a 70 kg (150 lb.) person. Sodium cyanide is poisonous and may be fatal if inhaled, swallowed or absorbed through the
skin. Contact with sodium cyanide may cause burns to skin and eyes. Individuals with chronic diseases of the kidneys, respiratory tract, skin, or thyroid are at greater risk of developing toxic cyanide effects.
Reactivity Profile
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SODIUM CYANIDE produces deadly and flammable hydrogen cyanide gas upon contact with acids, even
very weak acids, e.g., carbon dioxide dissolved in water (soda pop). Reacts violently with fluorine,
magnesium, nitric acid, nitrates and nitrites Incompatible with strong oxidizing agents.
Belongs to the Following Reactive Group(s) : Cyanides, Inorganic
First Aid
Headache, vertigo (dizziness), agitation, and giddiness may be followed by combative behavior, dilated and
unreactive pupils, convulsions, paralysis, and coma. Sodium cyanide is irritating to the skin and mucous membranes. Lacrimation (tearing) and a burning sensation of the mouth and throat are common. Increased
salivation, nausea, and vomiting are often seen.
Emergency Life-Support Procedures: Acute exposure to sodium cyanide may require decontamination and life support for the victims. All exposed persons should be transported to a health care facility as quickly as
possible. Emergency personnel should wear protective clothing appropriate to the type and degree of
contamination. Air-purifying or supplied-air respiratory equipment should also be worn as necessary. Rescue vehicles should carry supplies such as plastic sheeting and disposable plastic bags to assist in preventing
spread of contamination.
INHALATION EXPOSURE: 1. Move victims to fresh air. Emergency personnel should avoid self-exposure to sodium cyanide.
2. Evaluate vital signs including pulse and respiratory rate, and note any trauma. If no pulse is detected, provide CPR. If not breathing, provide artificial respiration. IMMEDIATELY begin administering 100% oxygen to all victims. Monitor victims for respiratory distress. Warning: To prevent self-poisoning, avoid
mouth-to-mouth breathing; use a forced-oxygen mask. Direct oral contact with sodium cyanide-contaminated
persons or their gastric contents may result in self-poisoning. 3. RUSH to a health care facility!
DERMAL/EYE EXPOSURE: 1. Remove victims from exposure. Emergency personnel should avoid self- exposure to sodium cyanide.
2. Evaluate vital signs including pulse and respiratory rate, and note any trauma. If no pulse is detected,
provide CPR. If not breathing, provide artificial respiration. IMMEDIATELY begin administering 100%
oxygen to all victims. Monitor victims for respiratory distress. Warning: To prevent self-poisoning, avoid mouth-to-mouth breathing; use a forced-oxygen mask. Direct oral contact with sodium cyanide-contaminated
persons or their gastric contents may result in self-poisoning. 3. RUSH to a health care facility! 4. Remove contaminated clothing as soon as possible.
5. If eye exposure has occurred, eyes must be flushed with lukewarm water for at least 15 minutes.
6. Wash exposed skin areas twice with soap and water.
INGESTION EXPOSURE: 1. Evaluate vital signs including pulse and respiratory rate, and note any trauma. If no pulse is detected,
provide CPR. If not breathing, provide artificial respiration. IMMEDIATELY begin administering 100% oxygen to all victims. Monitor victims for respiratory distress. Warning: To prevent self-poisoning, avoid mouth-to-mouth breathing; use a forced-oxygen mask. Direct oral contact with sodium cyanide-contaminated
persons or their gastric contents may result in self-poisoning. 2. RUSH to a health care facility!
3. DO NOT induce vomiting. Ipecac is not recommended for ingestion of sodium cyanide.
4. Obtain authorization and/or further instructions from the local hospital for administration of an antidote or
performance of other invasive procedures. 5. Activated charcoal may be administered if victims are conscious and alert. Use 15 to 30 g for children, 50
to 100 g for adults, with 125 to 250 ml of water.
Exposure Period AEGL-1* AEGL-2 AEGL-3
30 minutes 5 mg/m3 20 mg/m3 42 mg/m3
IDLH (Immediate Danger to Life and Health) : 25 mg/m3
Permissible Exposure Limit (PEL) : 8 hours 2 mg/m3
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat (EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
2. COPPER CYANIDE
CAS Number UN/NA Number DOT Hazard Label CHRIS Code
544-92-3 1587 Poison CCY
NFPA 704
General Description
A green powder. Insoluble in water. Toxic by skin absorption, through open wounds, by ingestion, and by inhalation of hydrogen cyanide that arises from slight decomposition. Produces toxic oxides of nitrogen in fires.
Hazards:
Reactivity Alerts: None
Air & Water Reactions : Insoluble in water.
Fire Hazard
Non combustible. Special Hazards of Combustion Products: Toxic hydrogen cyanide gas may form in fires.
Health Hazard
Following severe exposure to dust, symptoms of cyanide poisoning may develop (see ingestion). Ingestion causes anxiety, confusion, dizziness, sudden loss of consciousness, odor of bitter almonds on breath or in
vomits, rapid weak pulse, convulsions, and paralysis. Contact with eyes causes irritation. Air & Water Reactions : Insoluble in water.
Fire Hazard
Non combustible. However mixed during combustion can release poisonous hydrogen cyanide gas.
Health Hazard
Following severe exposure to dust, symptoms of cyanide poisoning may develop (ingestion). anxiety,
confusion, dizziness, sudden loss of consciousness, odor of bitter almonds on breath or in vomits, rapid weak pulse, convulsions, and paralysis. Contact with eyes causes irritation.
Reactivity Profile
COPPER CYANIDE is decomposed by acids to give off hydrogen cyanide, a flammable poisonous gas. Tends to explosive instability. Capable of violent oxidation under certain condition: fusion with metal
chlorates, per-chlorates, nitrates or nitrites can cause explosions. Reacts with incandescence with magnesium.
COPPER CYANIDE is decomposed by acids to give off hydrogen cyanide, a flammable poisonous gas. Tends to explosive instability. Capable of violent oxidation under certain condition: Fusion with metal
chlorates, per-chlorates, nitrates or nitrites can cause explosions. Reacts with incandescence with magnesium
Belongs to the Following Reactive Group(s): Cyanides, Inorganic.
First Aid EYES: First check the victim for contact lenses and remove if present. Flush victim's eyes with water or
normal saline solution for 20 to 30 minutes while simultaneously calling a hospital or poison control center.
Do not put any ointments, oils, or medication in the victim's eyes without specific instructions from a
physician. IMMEDIATELY transport the victim after flushing eyes to a hospital even if no symptoms (such as redness or irritation) develop.
SKIN: IMMEDIATELY flood affected skin with water while removing and isolating all contaminated clothing. Gently wash all affected skin areas thoroughly with soap and water. If symptoms such as redness or
irritation develop, IMMEDIATELY call a physician and be prepared to transport the victim to a hospital for
treatment.
INHALATION: IMMEDIATELY leave the contaminated area; take deep breaths of fresh air.
IMMEDIATELY call a physician and be prepared to transport the victim to a hospital even if no symptoms
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat (EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
(such as wheezing, coughing, shortness of breath, or burning in the mouth, throat, or chest) develop. Provide
proper respiratory protection to rescuers entering an unknown atmosphere. Whenever possible, Self-Contained
Breathing Apparatus (SCBA) should be used; if not available, use a level of protection greater than or equal to that advised under Protective Clothing.
INGESTION: CYANIDES ARE EXTREMELY TOXIC AND FAST-ACTING POISONS. Even though the
induction of vomiting is not usually recommended outside of a physician's care if the victim is conscious and not convulsing, it may be worth the risk if cyanide has been ingested. Ipecac syrup or salt water may be used
to induce vomiting in such an emergency. IMMEDIATELY call a hospital or poison control center and transport the victim to a hospital. If the victim is convulsing or unconscious, do not give anything by mouth,
assure that the victim's airway is open and lay the victim on his/her side with the head lower than the body. DO NOT INDUCE VOMITING. IMMEDIATELY transport the victim to a hospital.
IDLH(Immediate Danger to Life and Health): Data unavailable
3. ZINC CYANIDE
CAS Number UN/NA Number DOT Hazard Label CHRIS Code
557-21-1 1713 Poison ZCN
NFPA 704
Diamond Hazard Value Description
0
3
0
Health 3 Can cause serious or permanent injury.
Flammability 0 Will not burn under typical fire conditions.
Instability 0 Normally stable, even under fire conditions.
Special (NFPA, 2010)
General Description: A white powder. Insoluble in water. Toxic by inhalation (dust and the hydrogen cyanide from slight
decomposition) and by ingestion. Produces toxic oxides of nitrogen in fires. Used in medicine, in metal
plating, and in chemical analysis.
Hazards:
Reactivity Alerts : None Air & Water Reactions : Insoluble in water.
Fire Hazard Non-combustible, substance itself does not burn but may decompose upon heating to produce corrosive and/or toxic fumes. Containers may explode when heated.
Health Hazard EYES: Causes eye burns. SKIN: Irritation. INGESTION OR INHALATION: A bitter, acrid burning taste is sometimes noted followed by a feeling of constriction or numbness in the throat. Salivation and nausea are not
unusual, but vomiting is rare. Anxiety, confusion, vertigo, giddiness and often a sensation of stiffness in the
lower jaw.
Reactivity Profile ZINC CYANIDE is decomposed by acids to give off hydrogen cyanide, a flammable poisonous gas. Tends
to explosive instability. Capable of violent oxidation under certain condition; fusion with metal chlorates, per chlorates, nitrates or nitrites can cause explosions. Reacts incandescence (Glow) with magnesium.
First Aid EYES: First check the victim for contact lenses and remove if present. Flush victim's eyes with water or
normal saline solution for 20 to 30 minutes while simultaneously calling a hospital or poison control center. Do not put any ointments, oils, or medication in the victim's eyes without specific instructions from a
physician. IMMEDIATELY transport the victim after flushing eyes to a hospital even if no symptoms (such as redness or irritation) develop.
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SKIN: IMMEDIATELY flood affected skin with water while removing and isolating all contaminated
clothing. Gently wash all affected skin areas thoroughly with soap and water. If symptoms such as redness or
irritation develop, IMMEDIATELY call a physician and be prepared to transport the victim to a hospital for treatment.
INHALATION: IMMEDIATELY leaves the contaminated area; take deep breaths of fresh air. IMMEDIATELY call a physician and be prepared to transport the victim to a hospital even if no symptoms
(such as wheezing, coughing, shortness of breath, or burning in the mouth, throat, or chest) develop. Provide
proper respiratory protection to rescuers entering an unknown atmosphere. Whenever possible, Self-Contained
Breathing Apparatus (SCBA) should be used; if not available, use a level of protection greater than or equal to that advised under Protective Clothing.
INGESTION: CYANIDES ARE EXTREMELY TOXIC AND FAST-ACTING POISONS. Even though the induction of vomiting is not usually recommended outside of a physician's care if the victim is conscious and
not convulsing, it may be worth the risk if a cyanide has been ingested. Ipecac syrup or salt water may be used
to induce vomiting in such an emergency. IMMEDIATELY call a hospital or poison control center and transport the victim to a hospital. If the victim is convulsing or unconscious, do not give anything by mouth,
assure that the victim's airway is open and lay the victim on his/her side with the head lower than the body.
DO NOT INDUCE VOMITING. IMMEDIATELY transport the victim to a hospital
IDLH: Not available.
7.9 DISASTER MANAGEMENT PLAN
7.9.1 INTRODUCTION: The term ‘Disaster’ owes its origin to the French word ‘desastre’, which is a combination of two words ‘des’
meaning bad and ‘aster’ meaning star. Thus, the term ‘disaster’ refers to ‘Bad or Evil Star’. In earlier days
disasters were considered to be an outcome or outburst of some unfavorable star.
Ideally, a disaster may be defined as “an event concentrated in time and space which threatens a society or a relative self sufficient subdivision of a society with major unwanted consequences as a result of the collapse
of precautions which had hitherto been culturally accepted as adequate”.
Disaster according to the Disaster Management Act, 2005 means “a catastrophe, mishap, calamity or grave
occurrence in any area, arising from natural or man made causes or by accident or negligence which results in substantial loss of life or human suffering or damage to, and destruction of property, or damage to, or
degradation of, environment, and is of such a nature or magnitude as to be beyond the coping capacity of the
community of the affected area”;
Disasters are extreme events which cause great loss to life and property. They pose a serious threat to the
normal life as well as the process of development and strike with sudden violence, tearing bodies, destroying lives and structures and throwing apart families. Natural disasters, which are both sudden and powerful,
damage national economy and cause hardships to a large section of the population. They are the single largest concern for most of the nations as they take a heavy toll of human life, destroy belongings and infrastructure and have far reaching economic and social consequences for communities. Thus, the impact of disasters on
human life is multi – dimensional, affecting it in all aspects- domestic, social, economic etc.,
Disaster Management Act:
The DM Act, 2005 provides for the requisite institutional mechanism for drawing up and monitoring the implementation of the DM Plans ensuring measures by various wings of government for prevention and
mitigation effects of disasters and for undertaking a holistic coordinated and prompt response to any disaster situation. The Act seeks to institutionalize the mechanisms at the national, state and district levels to plan,
prepare and ensure a swift response to both natural calamities and man-made disasters/accidents IN THREE LEVELS.
1. NATIONAL LEVEL
2. STATE LEVEL
3. DISTRICT LEVEL (In a state) - Local level in a district
Types of Disasters: Generally, disasters are of two types – Natural and Manmade. Based on the devastation, these are further
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classified into major/minor natural disaster and major/minor man-made disasters. Some of the disasters
are listed below:
Major natural disasters: Flood
Cyclone Drought,
Earth quake
Minor natural disasters: Cold wave
Thunderstorms Heat waves Mud slides
Storm
Major man-made disaster: Setting of fires Epidemic Deforestation
Wars
Pollution due to prawn cultivation
Industrial disaster/ crisis
Chemical disaster/pollution.
Minor man-made disaster: Road / train accidents, riots Food poisoning Environmental pollution
Industrial hazards are threats to people, and life-support systems that arise from the mass production of goods
and services. When these threats exceed human coping capabilities, or the absorptive capacities of environmental systems, they give rise to industrial disasters.
Industrial hazards can occur at any stage in the production process, including extraction, processing,
manufacture, transportation, storage, use, and disposal. Losses generally involve the release of damaging substances (e.g. chemicals, radioactivity, and genetic materials) or damaging levels of energy from industrial facilities or equipment into surrounding environments.
The growth of chemical industries has led to an increase in the risk of occurrence of incidents associated with hazardous chemicals (HAZCHEM). A chemical industry that incorporates the best principles of safety can
largely prevent such incidents. Common causes for chemical accidents are deficiencies in safety
management systems and human errors, or they may occur as a consequence of natural calamities or sabotage activities. Chemical accidents result in fire, explosion and/or toxic release.
The nature of chemical agents and their concentration during exposure ultimately decides the toxicity and damaging effects on living organisms in the form of symptoms and signs like irreversible pain, suffering, and
death. Meteorological conditions such as wind speed, wind direction, height of inversion layer, stability class,
etc., also play an important role by affecting the dispersion pattern of toxic gas clouds.
The Bhopal Gas tragedy of 1984—the worst chemical disaster in history, where over 2000 people died due to the accidental release of the toxic gas Methyl Iso-cyanate, is still fresh in our memories. Such accidents are
significant in terms of injuries, pain, suffering, loss of lives, damage to property and environment. A small
accident occurring at the local level may be a prior warning signal for an impending disaster. Chemical disasters, though low in frequency, have the potential to cause significant immediate or long-term damage.
DISASTER MANAGEMENT IS WITH THE GUIDELINES OF
1. ON –SITE EMEGENCY PLAN - prepared by the plant
2. OFF-SITE EMERGENCY PLAN- Prepared by DDMA
ON-SITE EMERGENCY: Disaster within the premises of the PLANT / FACTORY describes the action scenarios, complying with a documented Plan, to manage and eliminate the Disaster by the Plant personnel.
OFF-SITE EMERGENCY: Disaster spilled outside the factory premises, describes the action scenarios,
complying with a documented plan to manage and eliminate the disaster, by both the plant personnel and District Disaster Management Authorities. This plan will be prepared by DDMA seeking the details from plant authorities.
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7.9.2 GLOSSARY: TERMS AND INTERPRETATIONS:
DISASTER: “means a catastrophe, mishap, calamity or grave occurrence in any area, arising from natural or man-made causes, or by accident or negligence which results in substantial loss of life & sufferings or damage & destruction of property, or damage & degradation of environmental systems, and is of such a
magnitude as to be, beyond the coping capacity of the community of the affected area”;
MANAGEMENT: “means a group of employees unifying to mitigate the undesirable effects of a disaster,
controlling and eliminating its effects fully to bring back to erstwhile normal operating conditions.”
EMERGENCY: “an undesirable state of events of LOSS, beyond the coping capacity of the designated
operating personnel of the plant”.
PLAN: “means set of activities laid in series, arrangements made in advance with internal trained personnel & external agencies, to perform them in a systematic way to mitigate, control and eliminate an EMERGENCY”
ON-SITE EMERGENCY: “means an EMERGENCY SITUATION – Radiation, Toxicity, impact on environment , confined to the plant premises” to cause LOSS.
OFF-SITE EMERGENCY: “means an adverse EMERGENCY SITUATION- Radiation, Toxicity, impact
on environment, spilling outside the plant premises to cause LOSS.
LOSS: “means - ill health to people, destruction to property, stoppage of plant operations, forced layoff to
employees, increased debt burden of loans on purchase of plant & machinery, good will loss, loss of employee’s confidence level, impact on environmental systems which supports life in the area. (Loss of greenery, loss of cattle, and loss of aquatic life, land and water pollution and ……..)
EMERGENCY CONTROL ROOM: “means designated room for the “INCIDENT CONTROLLER” to
perform his role on mitigating, controlling, eliminating the emergency and bring the plant back to normal
working environment.” INCIDENT CONTROLLER (IC): “means a designated person, vested with OVERALL responsibility &
authority to mitigate, control and eliminate emergency and put the plant in normal working condition.”It
includes controlling the entire operations as a team leader and reporting to TOP MANAGEMENT/ OWNERS of the plant. Normally this position is given to the plant CEO or NO.1 POSITION HOLDER of the plant.
ACCIDENT SITE CONTROLLER (ASC): “means a designated person, vested with overall responsibility to mitigate, control and eliminate emergency from the designated site / sites inside the plant premises. He
mitigates, controls, and eliminates the actual accident which has later become an emergency. (Engineering
team, Rescue & Relief team, Fire fighting team, and other miscellaneous services will report to him.)”.
Normally this position is held by CONCERNED PLANT HEAD.
RESCUE & RELIEF HEAD (RRH): “means a designated person, who will perform rescue operations, take relief measures to the injured, co-ordinates with Liaison officer. Rescue operations in the entire plant being a big operation he will have a fairly big team to perform this operation.” This position is given to the HEAD -
CIVIL DEPARTMENT.
ENGINEERING HEAD (EH): “means a designated person, who will advice operations to save damages to Plant & Machinery, operations to mitigate and control processes, performs safe shutdown operations, safely operating the utility services (Electricity, Instrument air, various water systems, waste water systems,). This
position is given to the HEAD - MAINTENANCE (MECHANICAL, UTILITY, ELECTRICAL & INSTRUMENTATION).
LAISION HEAD (LH): “means a person authorized by INCIDENT CONTROLLER for coordinating the external resources & services. He interacts with INCIDENT CONTROLLER, and communicates to mainly District Disaster Management Authorities. He receives the requirements from IC, analyses and coveys the
same to his SPOKES PERSON, who in turn, contacts the concerned external agency, and gets the required
external resources sought.”
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SPOKES PERSON: “means a person authorized by LAISION HEAD to contact and arrange for external
resources / help (like district administration-collector, commissioner of police, commissioner of labor, Factory
Inspectorate, Health inspector, Fire Brigade Head, Local panchayat head, District transport officer……etc”).
KEY EMERGENCY PERSONNEL: “means employees, who take responsibilities and take positions to mitigate, control and eliminate EMERGENCY. They report to their respective team HEADS. During the
entire course of EMERGENCY these personnel will be inside the plant to perform above operations. They will note down the REAL performance of operations carried out, analyze the gaps in the performance and
discuss the same in the post emergency feedback meeting.”
NON-EMERGENCY PERSONNEL: “means employees, visitors, contractors and other outsiders required to be evacuated from the factory premises on “declaration of emergency”.
SAFETY MATERIALS: “means additional materials, tools, PPEs and appliances required for use during EMERGENCY operations by the persons inside the factory.” Also the additional safety materials required to
be provided to district administration in the event of an OFF SITE EMERGENCY”.
EMERGENCY PLAN: “means an authorized document (preconceived, discussed and agreed methodology
of operations and responsibilities) having clear cut action scenarios without aberrations, to be performed by
key emergency personnel, during MOCK DRILLS or REAL EMERGENCY situations.”
SITE PLAN: “means a print copy of the layout of the plant / factory displaying the locations of different
buildings, facilities, storage locations, roads, referred for easy communication and action during EMERGENCY.
AREA PLAN: “means plan showing the area e.g., JOLWA INDUSTRIAL AREA to scale. Useful for
assessing the affected area in the event of an OFF-SITE EMERGENCY and preparations for evacuation of people till the emergency is over.
TOXICITY: “ means - Toxicity is, the degree to which a substance can damage an organism. Three types of toxicity are 1. CHEMICAL, 2. BIOLOGICAL, 3. PHYSICAL. The entry routes for damage of the organism are 1. INHALATION, 2. INGESTION, 3. SKIN ABSORPTION. Isolation from the source of
origination is the effective way of safe guard. The degree of toxicity is given by the Threshold Limit Value
(TLV), Immediate Danger to Life & Health (IDLH).
FLAMMABILITY: “means- Flammability is, as how easily matter will burn or ignite, causing FIRE or COMBUSTION.” The degree of flammability is determined by the explosion limits of the hazardous
chemical, and its quantity & calorific value determines the “thermal radiation flux” liberated on combustion.
SPOT FIRE: “means fire liberated from a point or line opening of a container due to leakage of a flammable
gas.” FLASH POINT/ FIRE POINT: - “the flash point of a volatile liquid is the lowest temperature at which it
can vaporize to form an ignitable mixture in air”. The fire point, a higher temperature, is defined as the temperature at which the vapor continues to burn after being ignited.
THRESHOLD LIMIT VALUE: “means -The threshold limit value (TLV) of a chemical substance, is a
level to which it is believed, a worker can be exposed day after day, for a working lifetime without adverse health effects.” It is expressed in ppm or mg/kg of body weight.
TRESHOLD QUANTITY: “means the highest quantity of a HAZCHEM (in m³ or MT) of liquid or solid stored in a manufacturing unit storage area (In one or more vessels) at any point of time throughout the year,
above which certain regulatory compliance's are required.
SCENARIO: “means the mathematically arrived “virtual physical effects” of an accident, for the input conditions given.” It is presented in the form of a x-y graph.
DISPERSION: “means the spread of any flammable combustible vapor or toxic cloud of vapor, in the atmosphere for a given set of wind speed and atmospheric stability conditions.”
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DISPERSION FOOT PRINTS: “means graphical mapping of the dispersion clouds in the x-y-z coordinates
with respect to distance traveled and over a said period of time.
THERMAL RADIATION FLUX: “means the amount of thermal energy released by a flammable cloud of vapor in the atmosphere on a unit area, and its radiation effects, at a particular distance in the hazardous zone.
SAFE ZONE: “means a safe limit of TOXIC VAPOUR CLOUD existing in an area where there is no damage to human beings or environment when they live in a free exposed condition for an hour or more.
“Means a safe limit of THERMAL RADIATION FLUX existing in an area, where there is no damage to
human beings or environment when they live in a free exposed condition.”
EMERGENCY SIREN: “means a siren with a blowing range of 1 km radius, all around the source, and
capable of giving long and short variances sound for a period of minimum 3 minutes.”
ALL CLEAR SIREN: “means a siren with a blowing range of 1km radius, all around the source, and capable
of giving a continuous non-variant sound for 5 minutes.”
7.9.3 ORGANISATION SET UP:
PLAN: 1. Approved ON-SITE, OFF-SITE EMERGENCY plans shall be available with OH&S Head.
2. All plant personnel have to be trained on the Emergency Plans.
3. Rescue members have to be additionally trained as per the TEAM responsibility.
4. Mock drills have to be performed once in every 6 Months. The drills shall be witnessed by DISH
officials OR Senior management members of same group of Industries. The EXTERNAL
OBSERVERS concept in MOCKDRILLS will improve the quality of drills.
5. All the improvements suggested in the Mock Drills have to be implemented through a MOM.
6. The reports of MOCKDRILLS have to be sent to DISH officials as a record.
7. A list of Risk Scenarios has to be identified and listed for performing the Mock Drills at periodic
intervals.
7.9.4 TEAMS FITMENT PLAN:
S.NO TEAM TEAM LEADERS
1 INCIDENT CONTROLLER SENIOR MANAGEMENT PERSON
2 ACCIDENT SITE CONTROLLER
IN CHARGE OF ACCIDENT PLANT
SR. SUPERVISOR /CHEMIST
(II SHIFT & III SHIFT)
3 LIAISON HEAD HOD -HR
4 ENGINEERING TEAM
SENIOR MANAGEMENT PERSONNEL FROM
PROJECTS, DESIGN , MAINTENANCE
5 RESCUE &RELIEF TEAM SENIOR MANAGEMENT PERSONNEL FROM
PERSONNEL, ACCOUNTS
6 FIRE TEAM SAFETY PERSONNEL
7 MEDICAL TEAM OHC PERSONNEL
8 SECURITY TEAM SECURITY OFFICERS SECURITY GUARDS
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat (EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
ORGANISATIONAL SET UP FOR EMERGENCY:
7.9.5 RESPONSIBILITIES OF KEY EMERGENCY PERSONNEL / TEAMS: INCIDENT CONTROLLER – RESPONSIBILITIES
The head of the PLANT will be normally the Incident Controller(IC). Ensures the emergency is
properly dealt with, eliminated and normal operating conditions are restored as soon as possible.
Ensures all the managers and officers of the plant are included as “key emergency personnel.”
Ensures the On-site Emergency Plan is prepared, and general training is given to all the employees of
the plant. On-site Emergency Plan is submitted to Department of Industrial safety & Health for review.
Ensures Mock drills (Virtual Emergency) are conducted quarterly in different shifts as per the provisions of On-Site Emergency plan.
Ensures one or two District disaster management Authority (DDMA) personnel are invited to
participate in the mock-drills.
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Ensures On site Emergency Plan is revised, based on the Mock-drill feed backs, till he is satisfied,
that the plan is acceptable to all key emergency personnel.
To officiate a person responsible to co-ordinate with District Disaster Management Authorities to prepare OFF-SITE EMERGENCY PLAN for the plant. The LIASION HEAD may be the appropriate
person for the same.
Ensure the fire fighting system, safety materials required for use during real emergency, and first-aid
medical facilities, are in order by review of documents, inspections and trials.
Ensures to name the alternate key emergency personnel IC, ASC, LH, EH, RRH in case the
emergency is reported after general shift hours .The key emergency personnel will take positions as
soon as possible and replace the alternate team. (Mock drills conducted in II & III shifts will give
necessary guidance to select the personnel)
ON DECLARATION OF REAL EMERGENCY
Soon after hearing the emergency from the Main gate security or SMS –Emergency, INCIDENT
CONTROLLER rushes to ECC.
He takes control on all operations to deal with the EMERGENCY from ECC.
He ensures all the team leaders are in their respective positions of operation, soon after ordering to
blow the emergency siren.
On the advices of ASC, LH, EH, RRH analyzes the actual situation at periodic intervals and declares
OFF-SITE EMERGENCY if required.
He ensures through Liaison Head, external emergency services are informed and called for help in
time.
Take periodic rounds to provide guidance and help to team leaders for effectively discharging their
duties. Notes down the short comings in the operations.
Once the Risk is eliminated completely as declared by ACCIDENT SITE CONTROLLER, he orders
to blow “All clear siren”.
He calls a FEED BACK meeting at ECC. All the key emergency personnel are to attend the meeting
and participate in the deliberations.
He CO-ORDINARES with department heads to normalize the plant for regular production activities
and support services.
ACCIDENT SITE CONTROLLER - RESPONSIBILITIES
Coordinates with ENGG TEAM, FIRE TEAM, RESCUE &RELIEF TEAM to mitigate emergency
conditions’
Ensures to finally eliminate the Emergency condition completely inside the plant.
Ensures after eliminating emergency the area/s worked, are kept clean for normal operations.
Ensures the required number of teams and personnel are kept ready for eliminating the emergency.
Ensures all required materials, equipment and resources are available for eliminating the emergency.
Is requested and brought in time.
Ensures right information is given to IC at periodic intervals.
ON DECLARATION OF REAL EMERGENCY
Soon after hearing the emergency siren or SMS Emergency, ACCIDENT SITE CONTROLLER rushes and takes control of the site inside the plant, which created an emergency situation.
He assesses the risk, computes the requirements of teams, the requirement of key emergency
personnel for each team, requirement of reserve teams in case the risk spreads, and orders them to
take their positions.
He assesses the complete scenario, and decides whether to declare OFF-SITE EMERGENCY and
informs to IC accordingly.
Ensures all the requirements for fighting the Emergency is available to eliminate the emergency at the
shortest possible time.
Ensures all requirements of external resources are informed in time to LIAISON TEAM.
He takes regular rounds and gives necessary guidance and help to teams to deal with emergency.
He applies strategies, and tries all possible permutations & combinations to LIMIT the Emergency as ON-SITE EMERGENCY.
Ensures all the key emergency personnel, are operating strictly complying safety parameters.
Gives constant feedback on the Emergency situation, and post his requirements to IC.
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He ensures emergency conditions are completely eliminated, areas are cleared, and informs to IC for
blowing all clear siren.
Notes down the short comings in the operations performed for eliminating the emergency, during his rounds.
LIAISON HEAD - RESPONSIBILITIES
Head – HR department is nominated as Liaison Head.
ENSURES district disaster administration authorities are informed about the declaration of emergency
and constantly keeps in touch with them. Informs the actions initiated by district administration
officials to IC.
Ensures local in habitations are well informed and measures taken for their safety.
Ensures the external resource help is given in time to ASC.
Ensures the medical assistance for the injured, in nearby Hospitals, and transport for non-emergency
personnel movement.
Ensures constant dialogue with nearby industries and arranges all possible help through district
administration.
Ensures proper gate security is maintained for preventing outside persons unauthorized entry inside
the industry.
ON DECLARATION OF REAL EMERGENCY
Soon after hearing the emergency siren or SMS Emergency, Liaison Head rushes to main gate.
Briefly informs the district administration of the Emergency situation and the help required.
Informs the Fire Brigade for fire tenders and transport department for buses to evacuate the non
emergency employees.
Informs the nearby industries about the impact and precautions to be taken by them. On request
distribute chemical masks for the employees inside factory.
Takes periodic rounds of the affected areas and studies the situation. Notes down the points of
concern of the Egg. Team, Fire mitigation Team, Rescue & Relief teams.
Asks his spokes person to meet the nearby village head and brief the actions taken for the safety of the
people of that village.
Keeps the district administration informed about the latest situation and the help required.
ENGINEERING TEAM- RESPONSIBILITIES
Engineering team head is nominated from Maintenance Department.
Mechanical, Electrical & Instrumentation & Utility Maintenance Head will be the team leaders.
Ensures the Plant & Machinery inside the plant are protected from damages.
Isolates EB power and takes essential operations on standby power.
Ensures the plant with minimum required illumination to carryout emergency operations.
Ensures the systematic stoppage of plant and machinery to cause minimum LOSS, and pave way for
easy restart conditions.
Ensures isolation of systems which can otherwise raise the risk level of emergency.
Ensures the semi finished products on the process line are protected from unwanted reactions and
prevent it from becoming a waste.
Ensures all the machines are in shut- off condition.
Ensures the unaffected storage locations are well protected, using the built in safety protection
systems.
ON DECLARATION OF REAL EMERGENCY
Soon after hearing the emergency siren or SMS - emergency, Engineering Heads rushes and takes
control of his key personnel to deal with the conditions of emergency.
Associates with the site controller wherever he demands help in controlling the emergency.
Isolates EB power and takes the unit on standby power.
Provides minimum illumination required for the control of emergency operations throughout the
plant.
Puts off all running equipment and shuts off the continuous process plant following emergency shut-
down procedures.
Ensures unwanted chemicals are drained off the reactor vessels, heat exchangers and other systems as
the plant demands.
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Keeps the waste water treatment plant running to clear off the excess load on the system?
In the Tank storage farms take appropriate actions like – draining the Hazchem in the dyke,
transferring from one vessel to another standby vessel, additional cooling arrangements of the equipment wherever required.
RESCUE AND RELIEF TEAM – RESPONSIBILITIES
On receiving information from SMS emergency rushes to accident site and coordinates activities with
ASC.
Group the team members and inform all non-emergency personnel to assemble at assembly points
(Assembly points are located near main security gate).
Subdivide the group and perform intensive search operation at all location to find out the injured.
Make arrangements to transport to injured on stretcher to the medical team stationed at medical
center.
Search for the missing person given in the list by LH. Give periodic feedback to ASC.
ON DECLARATION OF REAL EMERGENCY
Soon after hearing the emergency siren or SMS - emergency, Rescue and Relief Team Head rushes
to accident site.
Associates with the accident site controller wherever he demands help in controlling the emergency.
Makes arrangements to search employees, contract persons and visitors missing in the HEAD
COUNT.
Search teams go all around the plant to search for the missing persons in the head count.
FIRE TEAM – RESPONSIBILITIES Fire Team head is nominated from Safety Department.
Fire Team consists of Key emergency personnel from safety Department, First aid centre, process department and security departments.
He ensures all electrical systems are isolated except emergency lighting systems.
He ensures all the fuel /heating systems are isolated from both the ends of flow.
He ensures required numbers of fire mitigation equipment are fully operational. He ensures all fire fighting persons are performing the operations safe.
He ensures all external help required is informed to ASC in time.
He ensures the water resources are fully operational. He ensures smooth co-ordination with external Fire Mitigation Agencies.
ON DECLARATION OF REAL EMERGENCY 1. Soon after hearing the emergency siren or SMS Emergency FIRE Team Head rushes to Accident site
and takes Instructions from ASC.
2. He plans with ASC and EH to isolate systems prior to start of fire extinguishing operations. 3. He takes note of wind direction and proper ventilation systems prior to start of fire fighting.
4. He ensures the required number of fire fighting teams is kept for fire fighting and preventing fire
spreading.
5. He ensures appropriate extinguishing systems are optimally used for controlling the situation. 6. He ensures wherever inert gases are used for controlling the fire, safe systems of operations are
adopted.
7. He ensures personal safety is given utmost importance. 8. After ensuring complete extinguishment reports to ASC.
9. He ensures complete clean up operations are performed prior to allowing persons for inspection.
SECURITY TEAM – RESPONSIBILITIES
Security Team head is nominated from Security Department. Security Team reports to Liaison Head. It is divided into three divisions
a. Gate security Team b. Team to associate fire team
c. Team to perform inside factory security and cordoning operations.
He ensures overall assistance is given to all teams. He ensures non emergency persons are guided to Assembly points.
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He ensures traffic regulation inside the plant is done to the requirement.
He ensures gate security team protects all inside plant persons. Records the in time of key emergency
personnel.
Stops all persons/ vehicular movements as soon as Emergency Call is received. Allows DDMA vehicles , emergency service vehicles and guides them properly. He ensures all instructions given by Liaison Head are strictly followed.
ON DECLARATION OF REAL EMERGENCY a. Soon after hearing the emergency call OR SMS-emergency, Security Team Head rushes and takes
Instructions from LH.
b. He plans his persons for various operations and assigns a security supervisor for the same.
c. He takes note of wind direction and guides the persons to Assembly point/s.
d. He controls the gate operations and records the movement of vehicles and persons after the declaration of emergency.
e. He interacts with LH and performs his instructions.
MEDICAL TEAM – RESPONSIBILITIES Medical Team head is nominated from OHS Department. He ensures the ambulance and one male nurse is kept in the accident site. Ensures CPR is given to unconscious persons in the accident site.
Depending on the requirement requests LH for additional ambulances.
He ensures proper prearrangements are done at nearby hospitals for treatment of injured. Keeps records of injured persons and monitor the progress of injured regularly.
ON DECLARATION OF REAL EMERGENCY a. Soon after hearing the emergency call OR SMS - emergency, Medical Team Head rushes and takes
Instructions from LH. b. He will be stationed in OHS centre and monitor the medical needs of the injured.
c. He will ensure the required medicine, fire blankets, first aid boxes, and other essentials are kept ready for the injured persons.
d. One additional ambulance will always be kept at OHC depending on the emergency conditions.
He will have constant interactions with LH on the medical treatment to injured persons
7.9.6 COMMUNICATION SYSTEM:
Communication will be exchanged mainly from team to team or person to person using
Mobile cell phones, Group SMS for Key emergency personnel. Land line phones wherever available. Designated intercom cell phones.
Public Address system installed in offices & Plants.
FIRST - INCIDENT INFORMATION: The first incident information about, informing an incident/accident will be given by an employee, who has seen the incident. He will give the information to the main Security Main Gate/ Fire Room, giving his identity
in full.
The security officer on duty/ Safety Person on duty, who receives the information informs to their Heads. Both the fire team lead by safety supervisor/ security persons will rush to incident site immediately for
mitigating the emergency. The Head of Safety/Security passes information by flashing SMS message (Template) to all the KEY EMERGENCY PERSONNEL by group SMS using Mobile Cell phone. For easy
sending, each group is recommended to have 10 persons. The person informed is requested to REPLY positively.
By this system all the Key members of the emergency will be officially informed about the emergency. Their replies will confirm their receipt. The replies shall be as concise as ‘YES’.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-209
Report No. 1718A058
7.9.6.1 INCIDENT CONTROLLERS
Sr.
No.
Shifts Incident Controller's Runner's
Name & Designation Qualification
Place of availability Phone No.
Name & Designation
Place of
availability
in Plant
Phone
No. In the
Factory
(Plant)
Residence
Address In the
Factory Residence
1 2 3 4 5 6 7 8 9 10 11
2 First
&
General
1) HardattSinghTarar B.A. Form - 2 347 9924903599 1) Hithart Pathak ADM
Building
310
2) K.B. Vishwakarma M.Sc. ADM Building 224 9879323596 2) Sanjay Patil AQ 245
3) Mukesh Patel B.E.Che DD - 1 324 9824724340 3) JanakMaisuriya DD - 1 258
4) Hasamukh Patel B.Sc. EO 362 9825376478 4) Snehal Patel EO 363
5) Mukesh Patel B.E.Che NKS 324 9824724340 5) Sanjay Rathod NKS 319
6) Mukesh Patel B.E.Che MAA 324 9824724340 6) Naresh Tandel MAA 266
7) Yogesh Sonani M.Sc. DD – 2 353 9825242182 7) Rajesh Patel DD – 2 352
8) Yogesh Sonani M.Sc. DD – 2 353 9825242182 8) EknathSonawane Form - 2 341/349
9) K.B. Vishwakarma M.Sc. ADM Building 224 9879323596 9) RajendraPrajapati Solv - 2 336
10) K.B. Vishwakarma M.Sc. ADM Building 224 9879323596 10) RasikSutariya Solv - 3 366
11) K.B. Vishwakarma M.Sc. ADM Building 224 9879323596 11) S Chandran Mono Azo 297
12) K.B. Vishwakarma M.Sc. ADM Building 224 9879323596 12) Rajendra Patel AQ- 2 251
13) K.B. Vishwakarma M.Sc. ADM Building 224 9879323596 13) Rajesh Patel AQ - 1 389
14) S K Jha M.Sc. PTP 231 9714999336 14) Vipul Patel PTP 339
15) S K Jha M.Sc. PTP 231 9714999336 15) Vipul Patel AMINO 365
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-210
Report No. 1718A058
Sr.
No.
Shifts Incident Controller's Runner's
Name & Designation Qualification
Place of availability Phone No.
Name &
Designation
Place of
availability
in Plant
Phone No. In the
Factory
(Plant)
Residence
Address In the
Factory Residence
1 2 3 4 5 6 7 8 9 10 11
2 Second 1) Shift Executive Min. B. Sc. DD - 1 374 1) Shift Executive DD - 1 374/262
2) Shift Executive AQ 274 2) Shift Executive AQ 251
3) Shift Executive Form - 1 259 3) Shift Executive Form - 1 235
4) Shift Executive NKS/MAA 319/266 4) Shift Executive NKS/MAA 319/266
5) Shift Executive EO 263 5) Shift Executive EO 263
6) Shift Executive DD - 2 358 6) Shift Executive DD - 2 358
7) Shift Executive Form - 2 349/348 7) Shift Executive Form - 2 349/348
8) Shift Executive Sol - 2 264 8) Shift Executive Sol - 2 264/334
9) Shift Executive Sol – 3 368 9) Shift Executive Sol – 3 368
10) Shift Executive ETP /PTP 218 10) Shift Executive ETP /PTP 218
11) Shift Executive Mono Azo 292 11) Shift Executive Mono Azo 292
12) Shift Executive AQ - 2 251 12) Shift Executive AQ - 2 251
13) Shift Executive AQ – 1 389/390 13) Shift Executive AQ - 1 390
14) Shift Executive AMINO 218 / 339 14) Shift Executive AMINO 365
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-211
Report No. 1718A058
Sr.
No.
Shifts Incident Controller's Runner's
Name & Designation Qualification
Place of availability Phone No.
Name &
Designation
Place of
availabilit y
in Plant
Phone No. In the
Factory
(Plant)
Residence
Address In the
Facto ry Residence
1 2 3 4 5 6 7 8 9 10 11
3 Third 1) Shift Executive Min. B. Sc. DD - 1 374 1) Shift Executive DD - 1 374/262
2) Shift Executive AQ 274 2) Shift Executive AQ 251
3) Shift Executive Form - 1 259 3) Shift Executive Form - 1 235
4) Shift Executive NKS/MAA 319/266 4) Shift Executive NKS/MAA 319/266
5) Shift Executive EO 263 5) Shift Executive EO 263
6) Shift Executive DD - 2 358 6) Shift Executive DD - 2 358
7) Shift Executive Form - 2 349/348 7) Shift Executive Form - 2 349/348
8) Shift Executive Sol - 2 264 8) Shift Executive Sol - 2 264/334
9) Shift Executive Sol – 3 368 9) Shift Executive Sol – 3 368
10) Shift Executive ETP /PTP 218 10) Shift Executive ETP /PTP 218
11) Shift Executive Mono Azo 292 11) Shift Executive Mono Azo 292
12) Shift Executive AQ - 2 251 12) Shift Executive AQ - 2 251
13) Shift Executive AQ – 1 389/390 13) Shift Executive AQ - 1 390
14) Shift Executive AMINO 218 / 339 14) Shift Executive AMINO 365
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-212
Report No. 1718A058
NOTE:–
1. If IC is not available, for deputy IC see 7.3
2. The shift may change but the person will be available against each shift.
3. Prepare 2 to 3 IC even if there is only one or two shifts
Sr.
No.
Shifts Incident Controller's Runner's
Name & Designation Qualification
Place of availability Phone No.
Name &
Designation
Place of
availabilit y
in Plant
Phone No. In the
Factory
(Plant)
Residence Address In the
Factory Residence
1 2 3 4 5 6 7 8 9 10 11
4
Holiday
1) JanakMaisuriya Min. B. Sc. DD - 1 258 1) Devang Desai DD - 1 377
2) Sanjay Patil AQ 245 2) Rajendra Patel AQ 251
3) Paresh Mistry Form - 1 259 3) Mukesh Patel Form - 1 235
4) Sanjay Rathod NKS/MAA 319 4) Naresh Tandel NKS/MAA 266
5) Snehal Patel EO 362 5) Dharmesh Mehta EO 363
6) Rajesh Patel DD - 2 352 6) Rakesh Patel DD - 2 358
7) EknathSonawane Form - 2 341 7) Kamlesh Patel Form - 2 349/348
8) RajendraPrajapati Sol - 2 363 8) Rakesh Desai Sol - 2 364
9) RasikSutariya Sol – 3 366 9) DhavalThakor Sol-3 366/368
10) Vipul Patel ETP /PTP 218/339 10)Dilip Mistry ETP /PTP 218/339
11) Vinod Sonwane Mono Azo 297 11) Rajendra Mono Azo 292
12) Rajendra Patel AQ - 2 251 12) Ajay Mishra AQ - 2 251
13) Vinod Sonwane AQ – 1 389/390 13) R I PATEL AQ - 1 390
14) Dilip Mistry AMINO 218 / 339 14) Pavan Mishra AMINO 365
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-213
Report No. 1718A058
7.9.6.2 DEPUTY INCIDENT CONTROLLERS:
Shifts
Sr. No.
(Any one shall
be
available in
each
shift & on
holidays on
call)
Deputy Incident Controller's Persons to be called if IC & Dy. IC both are
not available
Name & Designation Qualifi
cation
Place of availability Phone No.
Name & Designation
Place of
availability
In
Plant Phone No. In the
Factory
Residence
Address
In the
Factory Residence
1 2 3 4 5 6 7 8 9 10 11
First &
General
1 1) Sanjay Patil B.Sc. AQ 245 1) RajendraPatel AQ - 1 251
2) JanakMaisuria M.Sc. DD - 1 258 2) Gunvant Tank DD - 1 258
3) Snehal Patel B.Sc EO 362 3) Kirit Desai EO 363
4) Naresh Tandel B.Sc MAA 266 4) PrafulRathod MAA 266
5) Sanjay Rathod B.Sc NKS 319 5) Sakir Patel NKS 319
6) Rajesh Patel B.Sc DD - 2 352 6) Chhotu Ram DD - 2 358
7) Kamlesh Patel B.Sc Form - 2 341 7) Bhudhu ram Form - 2 349
8) Paresh Mistry B.Sc Form - 1 259 8) Mukesh Patel Form - 1 235
9) RajendraPrajapati M. Sc. Solv - 2 336 9) Rakesh Desai Solv - 2 336
10) RasikSutariya B. Sc. Solv - 3 366 10) DhavalThakor Solv - 3 368
11) S Chandran M. Sc Mono Azo 297 11) Rajendra Mono Azo 292
12) Dilip Mistry B.Sc. ETP/PTP 218/339 12) BALVANT ETP / PTP 218/339
13) Vipul Patel B. Sc. Amino 218/365 13) Balvent Amino 218/365
14) Rajesh Patel B. Sc. AQ - 1 389 14) Vinod Sonwane AQ - 1 390
15) Rajendra Patel B. Sc. AQ - 2 251 15) Ajay Mishra AQ - 2 279
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-214
Report No. 1718A058
Shifts
Sr. No.
(Any one
shall be
available in
each
shift & on
holidays on
call)
Deputy Incident Controller's Persons to be called if IC & Dy. IC both
are not available
Name & Designation Qualifi
cation
Place of availability Phone No.
Name & Designation
Place of availability
In
Plant Phone No. In the
Factory
Residence
Address
In the
Factory Residence
1 2 3 4 5 6 7 8 9 10 11
3 Third 1) Shift Executive Min. B.
Sc.
DD - 1 374 1) Shift Executive DD - 1 374/262
2) Shift Executive AQ 274 2) Shift Executive AQ 251
3) Shift Executive Form - 1 259 3) Shift Executive Form - 1 235
4) Shift Executive NKS/MAA 319/266 4) Shift Executive NKS/MAA 319/266
5) Shift Executive EO 263 5) Shift Executive EO 263
6) Shift Executive DD - 2 358 6) Shift Executive DD - 2 358
7) Shift Executive Form - 2 349/348 7) Shift Executive Form - 2 349/348
8) Shift Executive Sol - 2 264 8) Shift Executive Sol - 2 264/334
9) Shift Executive Sol – 3 368 9) Shift Executive Sol – 3 368
10) Shift Executive ETP /PTP 218 10) Shift Executive ETP /PTP 218
11) Shift Executive Mono Azo 292 11) Shift Executive Mono Azo 292
12) Shift Executive AQ - 2 251/279 12) Shift Executive AQ - 2 251/279
13) Shift Executive AQ – 1 389/390 13) Shift Executive AQ - 1 390
14) Shift Executive AMINO 218 / 339 14) Shift Executive AMINO 365
Note:
1. The shift may change but the person will be available against each shift
2. Prepare 2 to 3 Dy. I.C. even if there is only one or two shifts.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-215
Report No. 1718A058
7.9.6.3 SITE MAIN CONTROLLERS:
Sr.
No.
Site Main Controller's Runner's
Name in priority
order Designation Qualification
Place of availability Phone No. Name &
Designation
Place of
availability Phone No. In the
Factory
Residence
Address
In the
Factory Residence
1 2 3 4 5 6 7 8 9 10 11
1
Mr. Hardattbhai
General
Manager
B. A.
Form - 2
101, ShreejiVihar Apt. VyashFalia,
Palsana
343
9924903599 Mr. Balbirbhai Factory
Manager cum
P.R.O.
ADM
Building
230
2
Mr. K B
Vishwakarma
DGM
M Sc. AQ Plant Peradise
Tower, Station
Road, Navsari
224
9879323596
Mr.Omprakash
Godara
Sr. Manager P &
A
ADM
Building
216
3 Mr. Balbir Singh
Pilania
AGM EHS B.A. ADM
Building
VyashFaliaPalsana 230 9824106565 Mr. Shasikant
Jha
Manager EHS
EHS
Department
231, 234
4 Mr. Milind.Joshi AGM
MMS
M.Sc. R.M. Store 72, Sant Shri
Asharam
Nagar,Jiyav,
Budiya road,
Bhestan.
257 9825127741 Mr. Utkarsh
Kapadia
Manager EHS
EHS
Department
231, 234
5 Mr .Mukesh.Patel AGM B.E. (Chemical) NKS Plant F.No. -702
Nandini Apt.
Vesu
324 9824724340 DalsukhbhaiKakani
Manager EHS
EHS
Department
231, 234
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-216
Report No. 1718A058
7.9.6.4 KEY PERSONS:
Sr.
No.
Key Person's Next Person's
Departme
nt
Name (He may
be called at any
time for this
plan)
Designation Qualificati
on
Place of availability Phone No.
Name &
Designation
Place of availability Phone No.
In the
Factory
Residence
Address
In the
Factor
y
Reside nce In the
Factory
Residence Address
In the
Factory
Residence
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1
Safety,
Fire
& Gas
Control
Mr.
DalsukhKakani
EHS
Manager
MSc.
EHS
Dept.
MotaVarachha
Surat
231
234 99250
67074
Mr.Utkarsh
Kapadia
EHS
Dept.
Juna
Thana,
Navsari
231
234 99241
02389
2 Security Mr.Ram
Naresh Siswar
Security.
Officer
B.A. Main
Gate
As per List
Attached
203 /
240
82642
82638
Mr. Bhola Singh Main
Gate
Bharmin
Falia,
Kiritbhainichali,
palsana
203
99048
52592
3 Pollution
Control
Mr.ShasikantJha
Mr. Hardik
Masuria
ManagerEHS
Env. Eng.
M.Sc.
B.Sc.Enviro
EHS
Dept.
Rudhrax
Apt.,
Surat.
231,
234,
218,
365
238
97149
99336
98790
07233
Mr.Vipul Patel ETP
Plant
Panghat,
Vishakap ark Society,
Dudhiya
Talav ,
Navsari
218/365
94283
80236
4 Medical Dr.
GanpatTandel
Doctor MBBS,
AFIH
IPHA
Medical
Center
25, Sanskar
Nager Society,
Bhatar Road,
Surat
239
98791
31394
MrOmprakash
Godara
Main
Building
Nava
Falia,
Palsana
216
98244
77072
5 Transport Mr. Ram Singh Kulharia
Manager B.Com. Finish
Godown
Desai Falia,
Palsana
318 98244
77071
Mr.Banwari Bhai Finish
Godown
VareliPalsana 222 98244
77092
6 Production Mr. KB
Vishwakarma
D.G.M. M.Sc. ADM
Office
204,
Paradise Tower,Statio n
224 98793
23596
Mr.
RajendraPrajapati
Solvent -
2
336 98792
28458
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-217
Report No. 1718A058
Road, Navsari
Mr. KB
Vishwakarma
D.G.M. M.Sc. ADM
Office
204,
Paradise Tower,Statio n
Road, Navsari
224 98793
23596
Mr. Sanjay
Patil
Solv-1,
Bromide
245 98796
43415
Mr. KB
Vishwakarma
D.G.M. M.Sc. ADM
Office
204,
Paradise
Tower,Statio n Road,
Navsari
224 98793
23596
Mr. Rajendra Patel AQ-2
251 96241
73705
Mr. KB
Vishwakarma
D.G.M. M.Sc. ADM
Office
204,
Paradise
Tower,Statio n Road,
Navsari
224 98793
23596
Mr. S Chandran Mono
Azo
297 70969
14701
Mr. KB
Vishwakarma
D.G.M. M.Sc. ADM
Office
204,
Paradise Tower,Statio n
Road, Navsari
224 98793
23596
Mr. Rajesh Patel AQ - 1
389 94277
84648
Mr. KB
Vishwakarma
D.G.M. M.Sc. ADM
Office
204,
Paradise Tower,Statio n
Road, Navsari
224 98793
23596
Mr. Rashik
Sutasriya
Solv - 3
366 98259
48810
Mr. Yogesh
Sonani.
Sr. Manager M.Sc. DD - 2 45,
Ankita Park
Surat
353 98252
42182
Mr.Rajesh
Patel
DD - 2 352 99255
56174
Mr. Yogesh
Sonani.
Sr. Manager M.Sc. DD - 2 45,
Ankita Park
Surat
353 98252
42182
Mr. Eknath
Sonawne
Form - 2
341 95101
92866
Mr. Hasmukh Sr. Manager B.Sc. EO LuharFalia, 362 98253 Mr.Snehal EO 363 99096
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-218
Report No. 1718A058
Patel Undach,
Gandevi,
Bilimora
76478
Patel
79864
Mr. Mukesh
Patel
AGM B.E.
(Chemical)
DD -1 702
Nandini Apt.
Vesu Surat
324 98247
24340
Mr.JanalMaisuriya DD - 1
258 98258
60271
Mr. Mukesh
Patel
AGM B.E.
(Chemical)
NKS 702
Nandini Apt.
Vesu Surat
324 98247
24340
Mr. Sanjay
Rathod
NKS
319 96389
11955
Mr. Mukesh
Patel
AGM B.E.
(Chemical)
MAA 702 Nandini Apt.
Vesu Surat
324 98247
24340
Mr. Naresh
Tandel
MAA
266 98792
55136
Mr. Yogesh
Sonani.
Sr. Manager M.Sc. DD - 2 45,
Ankita Park
Surat
353 98252
42182
Mr. Paresh
Mistry
Form - 1
259 97234
25602
Mr. S K Jha Sr. Manager M.Sc. ETP Rudhrax
Apt., Surat.
231 97149
99336
Mr. Vipul
Patel
ETP
366
218
94283
80236
Mr. S K Jha Sr. Manager M.Sc. AMINO Rudhrax
Apt., Surat.
231 97149
99336
Mr. Vipul
Patel
ETP
366
218
94283
80236
7 Technical
Services
Dr. Mininath
Desmukh
Dr. B.B.Chauby
Manager
R&D LAB
Sr. Manager
Phd.
Phd.
R&D
LAB
QA &
QC Lab.
601, Amrapli
Apt., Umra,
SURAT. 104, Paradise
Tower,Statio n
Road, Navsari
253
209
97302
05057
94268
69076
Dr. Anand
Jain
Mr. Umesh
Patel
R&D
Lab.
QA & QC
Lab.
277
320
99704
10410
96016
02975
8 Stores Mr.Milind Joshi A.G.M. M.Sc.
R.M.S.
72, Shree
Yashanker, Sant
Shree Asaram
Nagar, Bhestan,
Surat
257
98251
27741 Mr. Ram
Sudhirsingh R.M.S.
204
9 Personnel Mr.Omprakash Sr.Manager M.Com. Main
Building
NavaFaliaPalsana 216
98244
77072 Mr.PundlikBhavsar H.R.
219
98241
19577
10 D&L Mr. Ramesh
Mishra Sr. Manager M.A., LLB
Finish
Store
Raj Abhishak
Sachin 316 98241
02259 Mr.Banwari D&L 222
98244
77092
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-219
Report No. 1718A058
7.9.7 EMERGENCY SIREN:
EMERGENCY ‘ON’ SIREN: FIRE MODE / TOXIC MODE 0-0-0-0-0-0-0-0 WAILING SIREN
(10 SEC)(5 SEC) (10 SEC)(5 SEC)……UP-DOWN-UP-DOWN - FOR THREE MINUTES
ALL CLEAR SIREN:
CONTINUOUS SIREN FOR 5 MINUTES
7.9.8 EMERGENCY CONTROL CENTRE (ECC):
ECC will be occupied by INCIDENT CONTROLLER... It will have provisions to sit for five persons, a
conference room to house 15 persons, and a store to accommodate safety materials storage required during EMERGENCY. The following documents, (latest revisions) will be kept in the emergency Control Center, for immediate reference and use, in the event of an EMERGENCY. A key will be kept with IC.
REFERENCE DOCUMENTS
1. On-site Emergency Plan – 5 copies
2. Off-site Emergency Plan – 5 copies 3. Plant - site plan - 5 copies 4. Area plan (SPECTRUM Palsana plant)- 5 copies
5. MSDS of all HAZCHEMS – Each chemical.
6. Short note books -25 no’s 7. Ball pens, Pencils, erasers, sharpeners -25+10 + 10+ 2 no’s
8. Digital Cameras – 2 no’s
9. Laptops – 2 no’s network connected.
LIST OF SAFETY MATERIALS:
1. Self Contained Breathing Apparatus- 10kg - 10 no’s
2. Full Face masks - 25 no’s 3. Trolley mounted oxygen cylinders - 5 no’s 4. Full body chemical protection suits - 10 no’s
5. Chemical splash proof goggles - 50 no’s
6. Aluminized fire fighting suits - 10 no’s 7. 25mm hose clips with screw clips - 10 no’s
8. Gum boots full length - 25 pairs
9. Leather hand gloves - 50 pairs 10. Electrical hand gloves - 5 pairs 11. Non permeable hand gloves - 25pairs
12. Safety helmets - 50 no’s 13. Safety shoes sizes - 60 pairs
14. Pick axles - 2 no’s
15. Shovels - 5 no’s 16. Rain coats full size - 10 no’s 17. Stretchers - 2 no’s
7.9.9 FIRST- AID MEDICAL SERVICES: First –Aid service center is available in the Main gate of plant. There is a doctor and qualified medical nurses.
They will be assisted by trained first aiders where- ever there is an urgent need.
Medical examinations are out sourced, and reports are maintained by the HR department. EHS manager has a formal agreement, with “Full fledged hospitals” in the nearby area of the plant, for
immediate admission and treatment to the injured.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-220
Report No. 1718A058
7.9.10 ASSEMBLY POINT/s: Assembly point is the place, where the non-emergency employees are assembled for a head count. Later they
are kept at the same place OR shifted to a safer place on the advice of IC. Two assembly points are planned.
Assembly point is located inside the site of the plant. Normally assembly points are away from the bulk storage locations, near to the plant main security gate, and located in upward side of the predominant wind
direction. The wind sock is installed, for instantly knowing the current wind direction, is located on the top of the plant building, and is clearly seen from the assembly points.
Assembly point No. Location
Assembly point No-1 Near. Main Gate
Assembly point No-2 In front north side of Main Building
Assembly point No-3 Near Emergency gate ( Formulation – 2 plant)
7.9.11 FIRE FIGHTING BUILT IN FACILITIES:
Fire hydrant system – Fire water storage, Fire Pump, Jockey pump, PP Power / DG Power, Fire
Room, systems to control water supply and power.
Hydrant Pipes, Risers, Spray Nozzles, control gate valves, Hydrant boxes, Hydrant control valves.
DCP, CO₂, FOAM portable fire extinguishers of different capacity.
Water and Foam Fire Tender stationed at CP.
7.9.11.1 AVAILABILITY OF FIRE FIGHTING FACILITES:
S.NO. PERTICULARS PARTICULARS
1. Fire Water Total Qty. = 1000 KL 3 Nos. of Reserviors
5 Nos. of overhead tanks
2. Other source & Capacity
Water reservoir having
345 m3 Capacity.
Water reservoir having 550 m3 Capacity.
3. No. of Hydrant Points 97
4. No. of fire pumps, type & capacity Jockey pump -2
Electric pump -2 Diesel pump -2
(171m3 /hours)
5. No. of Hose Reel & total
length
Hose Reel : 212 Nos.
Length : 15 m & 30 m
6. No. of Sprinklers Lifting height : 30 m Pressure : 7 kg/cm2
7. No of CO2 Extinguishers
53 Nos. (4.5 kgs) 42 Nos. (2.0 kgs)
8. Dry Powder Type Extinguishers
Type : DCP/ABC (2/5/6/10/25 Kgs Capacity)
Total : 223 Nos.
9. Form Type Extinguishers
Type: Mech. Foam (9 Lts. & 50Lts. ), Total: 24 Nos.
Type: 3% AFFF Solution 3360 Ltrs., Total : 168 Nos.
10. PPE’s : Respiratory: Self Breathing Apparatus: 11 Nos. Air Line Respirator : 10 Nos.
Gas Masks = 30 Nos.
Dust mask = 500 Nos. Non – respiratory:
Hand Gloves = 300 Nos. Goggles = 100 Nos.
Gum Boots = 50 Nos. Helmet = 50 Nos.
Ear plug = 25 Nos.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-221
Report No. 1718A058
Ear muff = 05 Nos. PVC suit = 10 Nos.
PVC apron = 10 Nos.
Fire suit = 02 Nos.
7.9.11.2 Fire Pumping Capacity M/s Spectrum Dyes & Chemicals Pvt. Ltd., Palsana Manufacturing Division is a dyes manufacturing, so
it is categorized under High HAZARD OCCUPANCIES, Sub Category –A as per Fire Protection Manual of TAC.
Under High Hazard Occupancy,Sub Category –A, Hydrant post (point) shall be provided for every 30
meter on the fire hydrant ring mains. This is in addition to required number of Fire Hydrant points for each
floor on risers at plant and other buildings.
7.9.11.3 Pump House details:
Reservoir Capacity 895 m3 dedicated for fire hydrant system
Main Pump Capacity 171 m3/hr. (1 nos.)
273 m3/hr. (1 nos.)
Jockey Pump Capacity 30 m3/hr. (1 nos.)
11 m3/hr. (1 nos.)
Diesel Pump Capacity 171 m3/hr. (1 nos.)
273 m3/hr. (1 nos.)
7.9.11.4 Fire Water Storage
Reservoir Capacity for Fire hydrant system is 895 m3 is also available for process water which can be used for fire hydrant system during fire emergency.
So, Time Duration for Fire Fighting = 895 m3/hrs. ≈ 2hrs
7.9.11.5 Booster Pump
The capacity of the Jockey Pumps shall neither be more than 5 % of the installed pumping capacity nor less
than 3 % thereof (with a minimum of 10.8 m3/hrs) as per TAC guidelines. Company has one Jockey
pump with capacity of 25 m3/hrs each. Hence, capacity of Jockey Pump has been found adequate.
7.9.11.6 POLLUTION CONTROL:
The water used for firefighting will be diverted to ETP
The wastes collected at the site of accident will be sent to waste yard in designated packages. EHS environment department will do the necessary formalities for its disposal.
7.9.11.7 WIND SOCKS:
Wind socks are installed on buildings to instantly catch up the wind direction. The sock flying indicates the DOWNWIND direction.
FOUR wind socks are installed. One at the top of the EO building Second SOLVENT-2 SHOP. Third
on the R.M Stores Fourth on ADMIN building.
7.9.11.8 RESCUE TEAMS:
The positions of RESCUE TEAM MEMBERS are created in all plants, departments and service
centers. They are given a RED HELMET for east identification. They are being trained in different
aspects of activities involving emergencies. They are from workers, operators, supervisors and chemists. They are well distributed in the shifts so that their availability is felt, round the clock.
On hearing the emergency siren the RESCUE team members (Respective shift) are requested to rush to the emergency site location and assemble at the Ground floor. Information will be given about their
arrival to ACCIDENT SITE CONTROLLER. They will form the team members for performing necessary activities as per the directions of their
respective team leaders.
Both during accidents and BIG events like EMERGENCIES they will be fully utilized.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-222
Report No. 1718A058
7.9.11.9 IMPORTANT EXTERNAL TELEPHONES NUMBERS
Sr.
No.
Name & address of the Telephone
Sr.
No.
Name & address of the Telephone
Dept. /service/Person
(including external
emergency services)
Numbers
Dept. /service/Person
(including external
emergency services)
Numbers
(external)
(external)
1 2 3 1 2 3
1
Disaster Management 0261 2471121 41
Medical Surgeon DISH 9904593112
Cell, 2472471 Surat 7383812981
Collector Office
42 Regional Transport
Officer, Surat
02612472436,
2472185
2 Additional Collector Surat
0261 2471121 43 State Manager Transport
Office, Surat 0261 2543365
2463819 44 Dy. Controller Of
Explosive, Vadodara 0265 2420512
2651060
45
Pollution Control Board 0261 – 2442696 ,
9978405520 ( Regional Officer ) 2429733
3 Disaster Management
Cell,
0261 2465112,
2465118 7574827586
4 Emergency Control Room,
SMC
0261 242350-55 46 Fire & Accident 0261 101
2451765/55,
2422285-87 47 Ambulance (SMC) 0261 102
Ext. 318,
9724346021 48 Ambulance 0261 – 102,108
5 Policy Control Room
0261 100, 2462100, 49 New Civil Hospital 0261 2208448
2462318 50 Old Civil Hospital 0261 2479311,
2479175
Fax- 2462200, 2462600
51 Mahavir Hospital
SURAT 0261- 2332829-32
6 Emergency Ambulance 108 52
Surat General Hospital 0261- 2479791
7 Mamlatdar Palsana 02622 264 SURAT
8 Commissioner, Surat
Municipal
9825144800, 0261
2422244 53 ESIC General Hospital
0261- 2244110
9 PSI Palsana 02622 264227 Majura Gate SURAT
10 DY SP 02622 226861 54 BASPS SURAT 0261-2781000
11 CPI 02622 220670
55
Mody General Hospital 02622 271621
12 DSP Palsana 02622 2651832,
2651833 Kadodara 02622 272345
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-223
Report No. 1718A058
98784 05082 56 (CHC) Central Health
Center, Palsana 02622 264232
13 IG Surat 0261
2668666,2650332
57
Khusi Hospital
02622 272023
14
Jt. Director Industrial 0261 2473501,
2472422
Kadodara
Safety & Health, (Surat
Region) Palsana
15
Dy. Director Industrial
0261 2472422 58
Snjeevni Hospital 02622 281184
Safety & Health, (Surat Region)
Chalthan 02622 281253
16 Chief Fire Officer, SMC,
Surat
0216 2414195-96,
2414139
59
Punit Hospital 02622 271454
17
Executive Engineer,
Public Health & Mechanical Division,
Gujarat Water Supply &
Several Board, Surat
0261 2687376 Kadodara 98251 67137
18 Dy. Director of
Information, District 0261 2479172 Palsana
19 Chief Civil Defense, Surat 0261 2472043
60
Omshivam Hospital 0261 2390290
20 Medical Superintendent,
NewCivilHospital, Surat
0261 2244456,
2244459 Sachine 0261 2396551
21 District Health Officer,
Surat
94285 09526,
9374146464
0261 2430589 61 Omshivam Hospital
Palsana 92280 86670
22 Reliance Fire Station 3035068, 3035555 62 Unity Orthopedic
Hospital 92280 77567
23 KRIBHCO Fire Station 0261 2802122 63
Garg Eye Hospital 02622 271073
24 ONGC Fire Station 0261 2840026 Kadodara
25 PEPLFire Station
Kadodara
9909904111 64
RevivaL Hospital 95377 90081
02622 291108,109 Kadodara
02637 75554,75678 65
Dhruv Hospital 02622 274671
26 BardoliFire Station 02622 220101 Kadodara
27 NavsariFire Station 02637 259001,
66 Care Hospital
02622 273108 245101 Kadodara
28 Colourtax Industries Pvt.
Ltd.
0261 239 9666 67
OMShivam Hospital 91739 99158
0261 224 0568 Kadodara
98250 56865
68
ESIC Dispensary
02622 282385
29 Navin Florine International
0261 2890326 – 329 Kadodara
9924822099 69
SMC, Fire Control Room
101, 0261 2414195,
30 Reliance Industries Ltd.
0261 4135999 Surat 2414196, 2414139
9998011387 70 Chief Fire Officer,
Surat, SMC
0261 2436636,2414195-
96
31 Goyal Knit Fab Pvt Ltd. 02622 - 265266
32 Noble Tax 02622 - 264032,
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-224
Report No. 1718A058
02622 - 264632
33 Laxmi Narayan Dyeing 02622 - 264501,
02622 - 264502
34 Vishnu Priya 02622 - 264164
35 T M Patel Dyeing 02622 - 264444
36 VirDev Pharma 02622 - 264504
37 GPPL 9824102606
38 Kotex Industries 9824102615
9824166165
39 Anubha Industries
9924028887
9826028887
9824700400
40 Spectrum Auxi Chem. 98241 06781
7.9.12 OCCUPATIONAL HEALTH AND SAFETY PROGRAM - MITIGATIVE MEASURES: Health hazards associated with the occupation are called occupational hazards. In chemical industry due to handling of toxic and hazardous chemicals there are possibilities of developing occupational diseases. The
manufacturing process does not involve hazardous chemicals of high health effects.
These diseases are caused due to
1. Acute exposure of chemical fumes.
2. Chronic effects of exposure of chemical fumes
M/s. Spectrum Dyes & Chemicals Pvt. Ltd, has planned for the following checks to curb the problem:
Pre - employment medical checkup at the time of employment.
Annual medical check must be done for all employees in once every year.
i. Occupational Health center for rendering immediate first aid prior to sending to nearby hospitals.
First aid training must be given to “a section” of employees.
ii. Monitoring of occupational hazards like noise, ventilation, chemical exposure shall be carried out at
frequent intervals, the records of which shall be documented. iii. Suitable PPEs have to be provided and application enforced. All the PPEs procured are of BIS
approved products. Work place enforcement of wearing is done regularly. The same will be followed
in the extension unit also. iv. All the hazardous chemicals are to be identified by the hazchem visuals. All the workmen have to be
properly trained.
v. Evaluation of health of workers viz. chest x ray, Audiometry, Spirometry Vision testing (Far and Near vision, color vision and any other ocular defect) ECG, during pre-employment and periodical examinations must be carried out.
vi. The injuries record and the gas effect record shall be maintained for assessing the controls at the
workplace monitoring.
7.9.12.1 Occupational Health Centre (OHC):
The OHC shall be maintained and controlled by qualified medical team consisting of doctors, nurses
and other Para medical staff.
The OHC shall be maintained for 24x7 – 365 days operation.
All the available antidotes as available shall be maintained by the OHC personnel.
A fully loaded ambulance shall be maintained for carrying persons to nearby Hospitals.
The safety officer shall maintain the legal requirement records in the prescribed formats as called in different laws.
Symptomatic treatment is given to the persons affected by chemicals by the authorized Medical
Practitioner.
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-225
Report No. 1718A058
HSE monthly reports have to be maintained.
7.9.12.2 HSE ORGANIZATION.
The systems to be maintained by HSE department shall be taken from BIS 14489 1998. There shall be
appropriate staff qualified as per the requirement of law, has to be maintained in the HSE department.
Periodic reports shall be sent to DIRECTOR OF INDUSTRIAL SAFETY &HEALTH (DISH) authorities
as specified in the law books.
The Inspection book remarks made by the Factory Inspector shall be fully complied and records
maintained.
7.9.13 DO’S &DON’T’S TO BE FOLLOWED:
DO’S:
All the machines are to undergo Preventive Maintenance latest by once in a year. Productive
maintenance rounds (Daily visual rounds) have to be undertaken periodically to assess the healthiness of the machines. Records to be maintained.
For critical machines: All fasteners, gaskets, oil rings, lubricating oils, plastic parts , hose
pipes etc., have to be changed at the time of maintenance.
All load bearing members of the machine parts have to be thoroughly cleaned and visually inspected for any cracks and other defects.
All the PPEs procured shall conform to BIS or other equivalent standards.
Use of PPEs in the form of visuals has to be displayed at appropriate places.
All Hygiene practices are to be followed; restrictions for entry to specified places have to be
displayed.
Emergency escape routes and exit points have to be vividly displayed.
Near- miss inspections have to be carried out, discussed with area owners and hazards to be mitigated.
Ammonia used in the chilling plants have to be suitably disposed, when there is leakage.
REUSE, RECYCLE, RECOVERY of chemicals and liquids shall be devised and practiced.
All hazardous wastes in the form of solids and liquids shall be disposed off as per the
stipulated regulations.
EMERGENCY mitigation equipment locations and routing has to be displayed at prominent
locations.
Pressure and temperature parameters have to be monitored and records maintained wherever
called for.
All cooling arrangements for controlling temperatures shall have standby arrangements.
All continuous processing facilities shall have power backup facility.
Emergency lighting system shall be available during emergencies.
DONT’S:
Mix different chemicals or other treatment products prior to adding to pool water.
Dispose of chemical product container without washing & drying completely.
Use dry chemical fire extinguishers (use water only!).
Dispose of spilled material or unused product in the TRASH or SEWER (use or dispose per
label directions).
Store liquid materials above solid materials.
Allow product to contact oil, grease, acid or organic material.
Smoke where pool chemicals are stored or used.
Use floor sweeping compounds when cleaning up pool chemicals.
Put spilled materials back in the original container.
Use temporary wiring.
Overload motors, circuits, or outlets.
Leave circuit breakers blocked in a closed position.
Overheat transmission shafts or bearings, especially if they're in an area with dust or lint.
smoke, lit fire or spark in the identified hazardous area
Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat
(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)
EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-226
Report No. 1718A058
panic, evacuate calmly and quickly perpendicular to wind direction through the designated
escape route
pay attention to the rumors and don’t spread rumors.
Provide housing near the industries producing or processing the hazardous chemicals, if
possible.
Sensitize the community living near the industrial units and they should be more vigilant about the nature of industrial units and associated risks.