eia & emp for 100 mw thermal power plant at...

M/S. ARCHEAN CHEMICAL

INDUSTRIES PVT. LTD.

Form I for Amendment in Environmental Clearance of Chemical Fertilizer Manufacturing Unit and Co-generation Power Plant (10 MW) at Greater Rann of Kachchh, Near Hajipir, Taluka Bhuj, District Kachchh, Gujarat.

SEPTEMBER 2014

Kadam Environmental Consultants w w w . ka d a m en v i r o . c o m

Envi ronment for Deve lopment

http://www.kadamenviro.com/

ARCHEAN CHEMICAL


AMENDMENT IN EC FOR CHEMICAL FERTILIZER MANUFACTURING

UNIT AND CO-GENERATION POWER PLANT (10 MW) AT

GREATER RANN OF KACHCHH QUALITY CONTROL

SHEET

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 I

M/S. ARCHEAN CHEMICAL INDUSTRIES PVT. LTD.

Form I for Amendment in Environmental Clearance of Chemical Fertilizer Manufacturing Unit and Co-generation Power Plant (10 MW) at Greater Rann of Kachchh, Near Hajipir, Taluka Bhuj, District Kachchh, Gujarat. © Kadam Environmental Consultants (‘Kadam’), September, 2014

This report is released for the use of the M/s. Archean Chemical Industries Pvt. Ltd., Regulators and

relevant stakeholders solely as part of the subject project’s Amendment in Environmental Clearance

process. Information provided (unless attributed to referenced third parties) is otherwise copyrighted

and shall not be used for any other purpose without the written consent of Kadam.

QUALITY CONTROL

Name of

Publication

Form I for Amendment in Environmental Clearance of Chemical Fertilizer Manufacturing

Unit and Co-generation Power Plant (10 MW) at Greater Rann of Kachchh, Near Hajipir,

Taluka Bhuj, District Kachchh, Gujarat.

Project

Number 1419391606

Report

No. 1 Version 1

Releas

ed

September,

2014

Prepared By Bhavin Jambucha

Released By Jagdishchandra Rathi, EIA Coordinator

DISCLAIMER

Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan.

Kadam also believes that the facts presented in the report are accurate as on the date it was written.

However, it is impossible to dismiss absolutely, the possibility of errors or omissions. Kadam therefore

specifically disclaims any liability resulting from the use or application of the information contained in this

report. The information is not intended to serve as legal advice related to the individual situation.

ARCHEAN CHEMICAL




GREATER RANN OF KACHCHH, GUJARAT TABLE OF CONTENTS

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 I

CONTENTS

1 SCOPING ................................................................................................... 1

1.1 FORM – 1 ............................................................................................... 1

2 DECLARATION: ......................................................................................... 10

3 ANNEXURES ............................................................................................. 11

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GREATER RANN OF KACHCHH, GUJARAT TABLE OF CONTENTS

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 II

LIST OF ANNEXURES

Annexure 1: Details of Products, Raw Material, Manufacturing Process............................................ 12

Annexure 2: Site Plan and Layout Plan ......................................................................................... 17

Annexure 3: Water Consumption and Waste Water Generation Details ............................................ 19

Annexure 4: Effluent Treatment Scheme ....................................................................................... 21

Annexure 5: Details of Air Emissions ............................................................................................. 23

Annexure 6: Details of Hazardous Waste Generation and Disposal .................................................. 24

Annexure 7: Storage and Transportation Details of Products (Mainly Bromine) ................................ 25

Annexure 8: Risk Assessment Report ............................................................................................ 27

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GREATER RANN OF KACHCHH, GUJARAT FORM 1

KADAM ENVIRONMENTAL CONSULTANTS | SEPTEMBER, 2014 1

1 SCOPING

1.1 FORM – 1

The scoping for the project has been done based on FORM 1, as per EIA Notification, dated

September 14, 2006 amended as on date. The scoping details are as follows:

I. Basic Information

S.

No. Item Details

1 Name of the Project/s Archean Chemical Industries Pvt. Ltd.

2 S. No. in the Schedule Project / Activity: 5(a) – Chemical Fertilizers

3

Proposed capacity / area / length /

tonnage to be handled/ command area

/ lease area / no. of wells to be drilled

Proposed production capacity will be 1,96,000

MT/Annum. Proposed Land area will be used: 253

hectares.

4 New / Expansion / Modernization

Amendment in Existing EC approval. (EC condition

number 19 as per F. No. J-11011/149/2010-IA

II(I) dated 2nd September, 2011)

5 Existing Capacity / Area etc.

S.N. Product Quantity

1 Sulphate of Potash 1,00,000

2 Liquid Bromine 12,500

3 Green Bromine 2,500

4 Epsomite 81,000

6 Category of Project (A or B) “A”

7 Does it attract the general conditions?

If yes, please specify.

No, Does not fall under Protected area under

Wildlife Protection Act, 1972. Does not fall under

Critically Polluted Areas. No eco-sensitive area as

per EA, 1986. International boundary beyond 10

Km.

8 Does it attract specific condition? If yes,

please specify N.A.

9

Location Rann of Kachchh.

Plot Survey / Khasra No. Un-Survey Land

Village Nr. Hajipir

Tehsil / Taluka / Mandal Bhuj

District Kachchh

State Gujarat

10 Nearest railway station / airport / along

with distance in km.

Bhuj railway station – 110 Km

Bhuj Airport – 110 Km

11

Nearest town, city, district

headquarters along with distances in

kms

Nearest village : Hajipir –16 Km

Nearest city : Bhuj –110 Km

District Headquarters: Bhuj

12 Village Panchayat, Zilla Parishad,

Municipal Corporation, Local Body

Hajipir Gram Panchayat

C/o Luna Juth Panchayat

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S.

No. Item Details

(complete postal address with

telephone nos. to be given)

At & P.O. Hajipir

Taluka: Bhuj, Pin Code- 370605

Dist. Kutch, Gujarat

13 Name of the applicant Archean Chemical Industries Pvt. Ltd.

14 Registered address 5 th Floor, Tower II, TVH Beliciaa Towers, 94,

MRC Nagar, Chennai – 600028, TamilNadu –India

15

Address for correspondence

Name Mr.V.Manickam

Designation Executive Vice President

Address

”Anandam”, D/4, Nu-10-B, Opp. Lions Club,

Shaktinagar, P.O. Gandhidham,

Dist. Kutch, Gujarat.

Pin Code 370 201

E-mail [email protected]

Telephone no. 044-43033444 /

02836-234259/234158/233841

Fax no. 02836-233400

16

Details of alternative sites examined, if

any. Location of these sites should be

shown on the Toposheet.

Rann of Kutch is the best location for extraction of

marine chemicals.

17 Interlinked Projects None.

18 Whether separate application of

interlinked project has been submitted? No.

19 If yes, date of submission N.A.

20 If no, reason N.A.

21

Whether the proposal involves approval

/ clearance under: if yes, details of the

same and their status to be given:

The Forest (Conservation) Act, 1980

The Wildlife (Protection) Act, 1972

The C.R.Z Notification, 1991

N.A.

22 Whether there is any Government order

/ policy, relevant / relating to the site N.A.

23 Forest land involved (ha.) No. It is the Greater Rann Of Kachchh.

24

Whether there is any litigation pending

against the project and / or land in

which the project is proposed to be set

up? Name of the Court, Case No.

Order / directions of the Court, if any

and its relevance with the proposed

project

No. New Project.

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II. Activity

1. Construction, operation or decommissioning of the project involving actions,

which will cause physical changes in the locality (topography, land use, changes in

water bodies, etc.)

S. No. Information/Checklist

Confirmation

Yes

/No

Details thereof (with approximate

quantities / rates, wherever possible)

with source of information data

1.1

Permanent or temporary change in

land use, land cover or topography

including increase in intensity of land

use (with respect to local land use

plan)

No The land is in saline desert.

1.2 Clearance of existing land, vegetation

and buildings? No

The present land is not used for any agricultural

activity.

1.3 Creation of new land uses? No Already existing saline land under use.

1.4 Pre-construction investigations e.g.

bore houses, soil testing? No Preconstruction activities already completed.

1.5 Construction works? No New plant constructed along with all the

associated utilities.

1.6 Demolition works? No No demolition activities envisaged.

1.7

Temporary sites used for construction

works or housing of construction

workers?

Yes Containerized accommodation provided for

workers.

1.8

Above ground buildings, structures or

earthworks including linear structures,

cut and fill or excavations

Yes Process, utility buildings, stores, administration

buildings already constructed.

1.9 Underground works including mining

or tunneling? No N.A.

1.10 Reclamation works? No N.A.

1.11 Dredging? No N.A.

1.12 Offshore Structure? No N.A.

1.13 Production and manufacturing

processes? Yes

Manufacturing process are given in Annexure

1.

1.14 Facilities for storage of goods or

materials? Yes

Store house provided for the storage of

products. Details given in Annexure 7.

1.15 Facilities for treatment or disposal of

solid waste or liquid effluents? Yes

Sewage will be treated in sewage treatment

plant and reused for irrigation.

Process Waste water generated from the unit

will be treated in the Effluent treatment plant.

The treated effluent will be sent back to the

solar evaporation ponds.

The ETP solid waste will be used for

strengthening of bunds of the solar ponds.

Other solid waste will be sent to TSDF – Details

in Annexure 5.

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Confirmation

Yes

/No




1.16 Facilities for long term housing of

operational workers? Yes

Housing facilities provided in nearby towns and

villages.

1.17 New road, rail or sea traffic during

construction or operation? Yes New approach road constructed in the desert.

1.18

New road, rail, air waterborne or other

transport infrastructure including new

or altered routes and stations, ports,

airports etc?

No N.A.

1.19

Closure or diversion of existing

transport routes or infrastructure

leading to changes in traffic

movements?

No N.A.

1.20 New or diverted transmission lines or

pipelines? No N.A.

1.21

Impoundment, damming, culverting,

realignment or other changes to the

hydrology of watercourses or aquifers?

No N.A.

1.22 Stream crossings? No N.A.

1.23 Abstraction or transfers of water from

ground or surface waters? No

N.A. Desalination plant installed for domestic

and process requirement. Sea water will be

used for process requirement.

1.24 Changes in water bodies or the land

surface affecting drainage or run-off? No N.A.

1.25

Transport of personnel or materials for

construction, operation or

decommissioning?

Yes

Transport of Personnel from nearby town.

Construction material will also be transported

from nearby villages or town.

1.26 Long-term dismantling or

decommissioning or restoration works? No N.A.

1.27

Ongoing activity during

decommissioning which could have an

impact on the environment?

No N.A.

1.28 Influx of people to an area either

temporarily or permanently? Yes

We have provided employment to locals during

construction and operational phase.

1.29 Introduction of alien species? No N.A.

1.30 Loss of native species or genetic

diversity? No N.A.

1.31 Any other actions? No N.A.

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2. Use of Natural resources for construction or operation of the Project (such as land,

water, materials or energy, especially any resources which are non-renewable or

in short supply):


confirmation

Yes

/No




2.1 Land especially undeveloped or

agricultural land (ha) No N.A.

2.2 Water (expected source & competing

users) unit: KLD Yes

Sea water will be used for operating the plant

Details given in Annexure 3.

2.3 Minerals (MT) No N.A.

2.4

Construction material stone,

aggregates, sand / soil (expected

source, MT)

No No construction activity, all civil works

completed.

2.5 Forests and timber (source, MT) No N.A.

2.6

Energy including electricity and fuels

(source, competing users) unit: fuel

(MT), energy (MW)

Yes

We have our own Captive Power Plant of

capacity – 12 MWA CPP.

Coal and lignite is being used as fuel in the

boiler. Details given in Annexure 5.

2.7 Any other natural resources (use

appropriate standard units) Yes Brine from Rann.

3. Use, storage, transport, handling or production of substances or materials, which

could be harmful to human health or the environment or raise concerns about

actual or perceived risks to human health.

S. No. Information / Checklist

confirmation

Yes

/No




3.1

Use of substances or materials, which

are hazardous (as per MSIHC rules) to

human health or the environment

(flora, fauna, and water supplies)

Yes

Chlorine will be used as raw material. Bromine

will be one of the products. Details of Storage &

Transportation given in Annexure 7.

3.2

Changes in occurrence of disease or

affect disease vectors (e.g. insect or

water borne diseases)

No N.A.

3.3 Affect the welfare of people e.g. by

changing living conditions? No N.A.

3.4

Vulnerable groups of people who

could be affected by the project e.g.

hospital patients, children, the elderly

etc.,

No N.A.

3.5 Any other causes No N.A.

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4. Production of solid wastes during construction or operation or decommissioning

(MT/month)


confirmation

Yes

/No




4.1 Soil, overburden or mine wastes No N.A.

4.2 Municipal waste (domestic and or

commercial wastes) No N.A.

4.3 Hazardous wastes (as per Hazardous

Waste Management Rules) Yes Details given in Annexure 6.

4.4 Other industrial process wastes No N.A.

4.5 Surplus product No N.A.

4.6 Sewage sludge or other sludge from

effluent treatment Yes

Gypsum in the form of ETP sludge will be

produced and will be used in strengthening of

bund.

4.7 Construction or demolition wastes Yes

Construction waste will be utilized for building

internal RCC road. Steel waste will be sold as

scrap.

4.8 Redundant machinery or equipment No N.A.

4.9 Contaminated soils or other materials No N.A.

4.10 Agricultural wastes No N.A.

4.11 Other solid wastes No N.A.

5. Release of pollutants or any hazardous, toxic or noxious substances to air (kg/hr)


confirmation

Yes

/No




5.1

Emissions from combustion of fossil

fuels from stationary or mobile

sources

Yes Emissions from boiler, by using coal and lignite

as fuel.

5.2 Emissions from production processes Yes

Bromine from the bromine bottling plant. A

scrubber installed for the same. Details given in

Annexure 5.

5.3 Emissions from materials handling

including storage or transport No N.A.

5.4 Emissions from construction activities

including plant and equipment No

Water will be sprayed to suppress the dust

emissions due to transport of construction

materials to the site.

5.5

Dust or odours from handling of

materials including construction

materials, sewage and waste

Yes

Water will be sprayed to suppress the dust

emissions due to transport of construction

materials to the site.

5.6 Emissions from incineration of waste No N.A.

5.7

Emissions from burning of waste in

open air (e.g. slash materials,

construction debris)

No N.A. no burning activity will be carried out in

open space.

5.8 Emissions from any other sources No N.A.

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6. Generation of Noise and Vibration, and Emissions of Light and Heat:


confirmation

Yes

/No




6.1 From operation of equipment e.g.

engines, ventilation plant, crushers No Manufacturing activity is in closed reactors.

6.2 From industrial or similar processes No N.A.

6.3 From construction or demolition Yes During construction, noise will be generated.

This will be temporary in nature.

6.4 From blasting or piling No

Piling activities will generate noise which will be

very localized. Ear muffs will be provided to the

workers.

6.5 From construction or operational

traffic Yes

Due to transport of construction materials by

trucks, noise will be generated. This will be

temporary in nature. Moreover there is no

habitat in the 10 km radius zone.

6.6 From lighting or cooling systems No N.A.

6.7 From any other sources No N.A.

7. Risks of contamination of land or water from releases of pollutants into the

ground or into sewers, surface waters, groundwater, coastal waters or the sea


confirmation

Yes

/No




7.1 From handling, storage, use or

spillage of hazardous materials Yes

From Chlorine and bromine handling.

Risk Assessment Report is attached as

Annexure 8.

7.2

From discharge of sewage or other

effluents to water or the land

(expected mode and place of

discharge)

No

Sewage is being treated in sewage treatment

plant and is being utilized for development and

maintenance of greenbelt. Effluents after

neutralization is be sent to solar evaporation

ponds.

7.3 By deposition of pollutants emitted to

air into the land or into water Yes

Scrubbers is being installed for use chlorine and

bromine.

7.4 From any other sources No N.A.

7.5

Is there a risk of long term build up of

pollutants in the environment from

these sources?

No N.A.

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8. Risk of accidents during construction or operation of the Project, which could

affect human health or the environment


confirmation

Yes

/No




8.1

From explosions, spillages, fires etc

from storage, handling, use or

production of hazardous substances

Yes

All safety measures is been taken as per

statutory norms. A detailed risk assessment is

given in Annexure 8.

8.2 From any other causes No N.A.

8.3

Could the project be affected by

natural disasters causing environmental

damage e.g. floods, earthquakes,

landslides, cloudburst etc)?

No N.A.

9. Factors which should be considered (such as consequential development) which

could lead to environmental effects or the potential for cumulative impacts with

other existing or planned activities in the locality


confirmation

Yes

/No


quantities/ rates, wherever possible) with

source of information data

9.1

Lead to development of supporting

Facilities, ancillary development or

development stimulated by the project

which could have impact on the

environment e.g.: supporting

infrastructure (roads, power supply,

waste or waste water treatment, etc.)

housing development extractive

industries supply industries, (other)

Yes

By putting our industry in remote area there is

a rise of development of transport industry,

engineering units, housing development in the

area.

9.2

Lead to after-use of the site, which

could have an impact on the

environment.

No N.A.

9.3 Set a precedent for later developments No N.A.

9.4

Have cumulative effects due to

proximity to other existing or planned

projects with similar effects

No N.A.

III. Environmental Sensitivity

S.

No. Areas

Name /

Identity

Aerial Distance (within 15 km) of the

proposed project location boundary

1

Areas protected under international

conventions, national or local

legislation for their ecological,

No N.A.

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S.

No. Areas

Name /

Identity

Aerial Distance (within 15 km) of the

proposed project location boundary

landscape, cultural or other related

value

2

Areas which are important or sensitive

for ecological reasons - Wetlands,

watercourses or other water bodies,

coastal zone, biospheres, mountains,

forests

No N.A.

3

Areas used by protected, important or

sensitive species of flora or fauna for

breeding, nesting, foraging, resting,

over wintering, migration

No N.A.

4 Inland, coastal, marine or underground

waters No N.A.

5 State, National boundaries Yes Our Plant site is located about 40 kms from

the international border.

6

Routes or facilities used by the public

for access to recreation or other

tourist, pilgrim areas

No N.A.

7 Defense installations Yes The area is controlled by Border Security

Force.

8 Densely populated or built-up area No N.A.

9

Areas occupied by sensitive man-made

land uses (hospitals, schools, places of

worship, community facilities)

No N.A.

10

Areas containing important, high

quality or scarce resources (ground

water resources, surface resources,

forestry, agriculture, fisheries, tourism,

minerals)

No N.A.

11

Areas already subjected to pollution or

environmental damage. (Those where

existing legal environmental standards

are exceeded)

No N.A.

12

Areas susceptible to natural hazard

which could cause the project to

present environmental problems

(earthquakes, subsidence, landslides,

erosion, flooding or extreme or adverse

climatic conditions)

Yes

Earthquake Prone area. The construction

activity are strictly adhere to building norms

laid down for earthquake zone.

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GREATER RANN OF KACHCHH, GUJARAT ANNEXURES


3 ANNEXURES

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Annexure 1: Details of Products, Raw Material, Manufacturing Process

List of Products are given in table below:

S. No. Products MT/Annum




4 Epsomite 81,000

List of Raw Materials required:

S. No. Raw Material MT/Annum

1 Chlorine 8,395

2 98% Sulphuric Acid 5,853

3 Quick Lime 70 % CaO 4,875

4 Caustic Soda lye 50% 5,500

5 Caustic Soda flakes 504

6 Feed Bittern 42,40,800

7 Harvested Salt Mixture 7,65,000

8 Crude Magnesium Salts 2,95,000

9 Sea Water 36,36,506

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Details of each Product:

1. Sulphate of Potash & Epsomite:



2 Epsomite 81,000

Raw material consumption per annum:

S. No. Material Quantity, MT

1 Harvested salt mixture 7,65,000

2 Crude magnesium salt 2,95,000

3 Sea water 11,62,000

Brief Process:

Harvested crude Magnesium salt will be leached in NaCl saturated circulating brine at an elevated

temperature making MgSO4 and minor amounts KCl (if any) get dissolved. After adjustment of the

solution in terms of MgSO4 concentration and post separation of non dissolved NaCl, the clear liquor

will be cooled to 10 - 15°C to produce a pure and NaCl free Epsomite. Some of this Epsomite will be

used in the process of SOP production, while the rest is saleable. The same circulation liquor will be

re-used and a small part will be bleed-off and sent to the solar pond system. The non dissolved NaCl

will be re-dissolved in Sea water and sent back to the solar ponds.

Secondly the Harvested Salt Mixture will be mixed with seawater in order to decompose Carnallite and

dissolve MgCl2. The remaining un-dissolved KCl, MgSO4 and NaCl mixture will be used for the SOP

process and the mother liquor called ‘Carnallite deomposed liquor’ which will be recycled to Solar

Pond.

The above two beneficiated raw salts 1) harvested epsomite salt and 2) harvested salt mixture will be

mixed together, in a KCl: MgSO4 concentration that corresponds to the same ratio as existing in

Kainite. This mixture called ‘Synthectic Kainite’ will be mixed with seawater and cooled SOP mother

liquor for dissolution, so that Primary Schoenite will be generated. The ‘Schoenite mother liquor’

separated from Primary Schoenite will be re-cycled to Solar Pond.

Primary Schoenite generated from the earlier stage and the recovered / secondary Schoenite will be

leached with Seawater at 48°C, by which K2SO4 begins to crystallize out while MgSO4 will remain in

solution. When the MgSO4 concentration will reach approx 225 g/1000g H2O, the resulting slurry will

be centrifuged, washed with small amount of fresh water and dewatered to produce SOP and a Hot

SOP mother liquor. The Hot SOP mother liquor will be cooled to 10 – 15°C in order to generate

recovered / secondary Schoenite and cooled SOP mother liquor, depending on the NaCl concentration

in Schoenite, purification of Schoenite will be accomplished by using a wash with fresh water and / or

a flotation to remove NaCl.

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Chemical Reaction:

2KCl.MgSO4.3H20 + MgSO4 + 3H2O K2SO4.MgSO4.6H2O + MgCl2 + 3H20

(Solid) (Solid) (Liquid) (Solid) (Solution)

K2SO4.MgSO4.6H2O + 2H20 K2SO4 + MgSO4 + 8H20

(Solid) (Liquid) (Solid products) (Solution)

Flow Chart with Material Balance

2. Liquid Bromine & Green Bromine (New Product):




Raw material consumption per annum:

S. No. Material Quantity, MT

1 Feed bittern 42,40,800

2 Sulphuric acid 98% 5,853

3 Chlorine 8,395

4 Caustic Soda (C/S)Lye 50% 5,500

5 Caustic Soda (C/S)Flakes 504

Brief Process:

Steaming out process (STO) for Liquid Bromine:

Feed bitterns from reservoir will be acidified to 3.5 pH by addition of acid in a feed tank and pumped

to the top of stripping tower packed with pall rings. Steam and chlorine will be injected at the bottom

of the tower. Liberated bromine will be condensed and purified in a separate tower by heating with

indirect steam, Bromine will again get condensed and refluxed backed to top of tower and liquid

bromine will be drawn from the bottom of this purifying tower, cooled and bottled in glass bottles

and/or filled in ISO tanks for dispatch.

Air Blow out Process (ABO) for Liquid Bromine / Green Bromine:

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Bittern from the reservoir will be acidified to pH 3.5 by the addition of acid in a feed tank and pumped

to the top of stripping tower packed with pall rings; air and chlorine will be injected at the bottom of

the tower. Liberated Bromine laden by air will be made to react with soda ash or caustic soda solution

venting of unreacted air by circulating in a series of packed towers.

The reaction in the absorber reactor is as follows:

3Na2CO3 + 3Br2 = 5NaBr + NaBrO3 + 3CO2

or, 6NaOH + 3Br2 = 5NaBr + NaBrO3 + 3H2O

Part of this enriched alkaline solution (AB solution) will be the mixture of bromide, bromate

compounds from which again Bromine will be regenerated by the addition of acid. Regeneration of

Bromine will be done by a method similar to steaming out process but with smaller equipment as the

feed liquor will be highly concentrated.

5NaBr + NaBrO3 + 6HCl = 6NaCl + 3Br2 + 3H2O

Regenerated Bromine led out by steam given at the bottom of the tower will be condensed, separated

and processed further in distillation unit for the removal of impurities and packed in glass bottles

and / or in ISO tanks for dispatch.

Green Bromine:

Part of AB solution - the bromide bromate mixture from air blow out process will be taken for the

addition of chlorine to convert bromide to bromate and to maintain the ratio at 2:1. This converted

mixture will be again mixed with alkaline solution and proper concentration of bromate will be

maintained at a neutral pH by addition of caustic soda. This will be green Bromine in solution. It can

be evaporated to form solids by crystallizing in open pan or closed evaporator, cooled, packed in bags

and sold. It can also be sold as liquid in containers.

Flow Chart with Material Balance:

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Annexure 2: Site Plan and Layout Plan

Site Plan

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Site Layout Map

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Annexure 3: Water Consumption and Waste Water Generation Details

Breakup of RO Water:

Sr.

No. Breakup

Proposed Water

Consumption

(KL/Day)

Proposed Waste Water

Generation

(KL/Day)

a Process 387.5 74.1

b Boiler 390.3 390.3

c Washings 258.3 258.3

d Cooling 261.6 183.1

e Domestic 190 152

Total 1487.7 905.8

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Annexure 4: Effluent Treatment Scheme

Sewage Treatment Plant

The sewage generated from the project will be taken to a sewage treatment plant and the treated

waste water will be used for green belt development and gardening. The total domestic waste water

generated will be about 152 m3/day.

Effluent Treatment Plant for Process Waste Water

The boiler blowdown, cooling tower blowdown, and washings effluent will be utilized for preparation of

lime slurry. The acidic effluent will be neutralized by this lime slurry in a stirred vessel. The settled

sludge which is gypsum will be utilized for strengthening of the bunds. The treated waste water is

recycled to solar ponds for solar evaporation

The waste water generated is acidic in nature. The acidity is mainly due to use of Sulphuric acid in the

reaction. The tentative characteristics of the untreated waste water are given as follows:

Sr. No. Parameter Range

1 pH 4.5-5.0

2 Suspended solids, mg/L 280 ~ 400 mg/L

3 Oil & Grease, mg/L 4 ~ 6 mg/L

4 BOD, mg/L 30 ~ 60 mg/L

5 COD, mg/L 100 ~ 150 mg/L

ARCHEAN CHEMICAL






Flow Chart

ARCHEAN CHEMICAL






Annexure 5: Details of Air Emissions

Air Pollution Control

Emissions from Boiler

A boiler with 50 % coal and 50% lignite as fuel will be used for the proposed project. A 60m height

stack with diameter at stack height of 1 m. is proposed. The fly ash generated will be sold to brick

manufacturers. To control the particulate matter an ESP is proposed.

The boiler will be equipped with air pollution control unit for control of particulate matter.

Sources of gaseous emissions from utility Boiler

Fuel used 50% Coal & 50% Lignite

Quantity of fuel 20000 TPA Coal + 30000 TPA Lignite

Type of emissions SO2, NOX & PM.

Stack height 60 meter

Stack diameter at the top 1 meter

Air pollution control system ESP is proposed to control the particulate matter

Details of Scrubber for Process Emissions

A scrubber will be attached to the bromine bottling section to capture the bromine gas liberated in the

process. It will be scrubbed using a packed tower primary scrubber (1 no.’s) followed by secondary

packed tower scrubber with caustic soda as scrubbing medium. The scrubber bleed will be recycled as

the process feed.

Stack attached to Bromine bottling section

Gas scrubbed Bromine

Stack height 20 meter

Type of primary scrubber Packed tower

Capacity of the primary scrubber 0.5 m3

No. of Scrubbers 1

Type of secondary scrubber Packed tower

Capacity of the secondary scrubber 1.5 m3

No. of Scrubbers 1

Scrubbing medium Caustic Soda

Disposal of scrubber bleed Recycled to Process feed

ARCHEAN CHEMICAL






Annexure 6: Details of Hazardous Waste Generation and Disposal

From the proposed project, gypsum 10,725 TPA will be produced as a result of neutralization of ETP

sludge will be reused in making of bunds. Used oil (1 TPA) and discarded bags and containers (5 TPA)

will be sold to authorized recyclers. Fly ash (3600 TPA) will be sold to brick manufacturers.

Sr.

No.

Waste

Details

Waste

Category

Proposed

Generation Mode of Disposal

1 ETP Sludge –

gypsum 34.3 10725 TPA

Will be used for preparation and

maintenance of bunds

2 Used oil 5.1 1 TPA Will be sold to authorized

recyclers.

3 Fly ash - 3600 TPA Will be sold to brick

manufacturers.

4

Discarded

bottles and

bags

33.3 5 TPA Will be sold to authorized

recyclers.

ARCHEAN CHEMICAL






Annexure 7: Storage and Transportation Details of Products (Mainly Bromine)

List of Proposed Products

Sr.

No. Product

Quantity

MT/Annum

Max.

Storage

at a time

Physical

Form Stored in MOC

1 Sulphate

of Potash 1,00,000 30,000 Solid

Closed

Shed

HDPE

lined

bag

2 Bromine 12,500 300 Liquid

Containers

/ Glass

Bottles

MS

Lead –

lined

3 Green

Bromine 2,500 250 Solid

Closed

Shed

HDPE

lined

bag

4 Epsomite 81,000 12,000 Solid Heaps in

closed shed

HDPE

lined

bag

Bromine Packing Method and Transportation in Glass Bottles:

Liquid Bromine will be filled in specially designed glass bottles of 1 liter capacity.

Filled bottles will be duly sealed with bottle caps & inserts. These bottles will be packed in wooden

crates / plastic crates.

Each wooden crate / plastic crate will have six partitions to accommodate six filled bottles.

After keeping filled bottles in wooden crates cushion materials like vermiculate will be filled in

crate to avoid breakages if any enroute.

After filling cushion materials in the wooden crates, crate will be packed with wooden lids duly

nailed & strapped with plastic strip.

Each truck will carry approximately 4.032 MT bromine (224 wooden crates x 6 bottles each)

depending up on truck capacity.

Loaded truck before leaving factory premises will be covered with Tarpalin.

About INR. 18 per Kg will be spent as packing cost.

Safety Measures during Transportation:

Each loaded truck will be provided with Sodium Thyosulphate (5 - 25 kg) for using enroute in case

of any leakages / spillages.

Each truck driver carrying bromine will be imparted safety training on how to handle bromine in

case of spillages / leakages.

Transport emergency card will be provided to each truck at the time of dispatch.

Each truck driver will be having mobile set to establish contacts with factory on day to day till

truck reaches at destination point.

ARCHEAN CHEMICAL






Checklist for Bromine Transport

Good & sound condition of vehicles having road worthy certificate issued by RTO to be used for

bromine transport

Trained drivers who are conversant with handling of hazardous chemicals are to be engaged for

bromine transport

In house training to truck drivers every six months by safety officer to be imparted

Safety PPE like, gum boots, hand gloves, face mask to be given to truck driver before leaving

loaded truck from factory gate

Dispatch / safety department should ensure before leaving loaded truck from factory gate to

provide neutralization chemicals like Sodium Thyosulphate powder to truck driver and driver to be

guided how to use the chemicals in case of leakages /spillages

Trem card to be handed over to truck driver which contains list of activities to be taken in case of

accidents.

Truck driver should be instructed to carry loaded trucks only on good roads connected to state /

national highways & not to take any short routes.

Truck driver should be instructed to carry mobile set & he should establish contact on day to day

with factory till truck reaches at destination point.

Truck driver should be instructed to ply / drive the loaded truck only during day time & no driving

during night time.

Truck drivers to be instructed to contact either our factory / Gandhidham office / Chennai office in

case of any accident happens like spillages/ leakages / toppeling of loaded truck

On receipt of information from truck driver safety officer / production officer should depute rescue

team immediately with safety PPES to accident spot

Head –safety should co-ordinate with rescue team till the matter get resolved.

ARCHEAN CHEMICAL






Annexure 8: Risk Assessment Report

Prepared By Archean Chemical Industries Pvt. Ltd Page : 1

HSE Department Rev. : 00

Archean Chemical Industries

Pvt. Ltd.

”Anandam” D/4, Nu-10-B, Opp. Lions Club,

Shaktinagar, P.O. Gandhidham-370 201

Dist. Kutch, Gujarat

RISK ASSESSMENT STUDY ( For Proposed Plant )

Nr. Hajipir, Ta: Bhuj,

Dist: Kuchchh.

PREPARED BY

VAIBHU SAFETY CONSULTANTS FF-11, Akshat Complex,

Nr. Reliance Petrol Pump,

High Tension Road, Subhanpura,

Vadodara-390 023

Phone: 9825756467/9427838021 (M)



CERTIFICATE

We are pleased to certify that this Risk Assessment study of Company has been

conducted by us.

This is the first Risk Assessment report of this company for new project and it has

been carried out during the month of June- 2010.

Risk Assessment is a legal requirement u/r 12-c & 68-O of the Gujarat Factories

Rules.

The recommendations are based on information supplied to us by the company and

our plant visits.

The Executive Summary is given in the beginning to highlight the important

summary of our report and methodology of the risk assessment carried out.

We are thankful to the Mr. Sethuram (Occupier) and Mr. R.R. Sorathia( Project

Incharge). In particular we acknowledge the continuous support given to us by Mr.

R.R.Sorathia for completion of this report.

FOR VAIBHU SAFETY CONSULTANT

Authorized Signatory



CONTENTS

SECTION

NO.

CONTENTS

NO. OF

PAGES

1 Executive Summary 5

2 Objectives, Philosophy and methodology of

Risk assessment

7

3 Introduction of the unit 9

3.1 Company Introduction 9

3.2 Details of Unit 9

3.3 Project setting 12

3.4 Organisational setup 16

3.5 List Of Proposed product 16

3.6 List of Proposed Raw Material 16

3.7 Details of storage of Hazardous Materials in

Bulk and control measures provided

17

3.8 Brief Description of process plant 18

3.9 Hazardous Properties Of The Chemicals,

Compatibilities, Special Hazard & Antidotes

18

3.10 Facilities / System for process safety,

transportation, fire fighting system and

emergency capabilities to be adopted

21

4 Hazard identification 27

4.1 Introduction 27

4.2 DOW’s Fire and Explosion Index 28

4.3 Failure Frequencies 29

4.4 Identification of Hazardous area 31

5 Risk Assessment 33

5.1 Effects of Release of Hazardous Substances 33

5.2 Identification of High Risk Areas 34

5.3 Modes of Failure 34

5.4 Damage Criteria for heat radiation 36

6 Consequence Analysis 37

6.1 Consequence Analysis 37

6.2 Assessment of Consequences Modeling results 63

6.3 Comments 64

7 Risk Reduction Measures 65

7.1 Design 65

7.2 Process 65

7.3 Bromine Storage & Handling Safety 66



7.4 Operation and Maintenance 67

7.5 Recommendations 68

8 Disaster Management plan 70

8.1 On site emergency Plan (OSEP) 70

8.2 Scope of OSEP 71

8.3 Elements of OSEP 71

8.4 Methodology 71

8.5 Emergencies Identified 71

8.6 Others 72

8.7 Emergency Organisation 72

8.8 Emergency Facilities 72

8.9 Emergency Escapes 73

8.10 Assembly points 73

8.11 Wind sock 74

8.12 Emergency transportation 74

8.13 Emergency communication 74

8.14 Warning Alarm/ Communication of Emergency 74

8.15 Emergency responsibilities 74

8.16 Mutual Aids 74

8.17 Mock Drill 74



SECTION I

EXECUTIVE SUMMARY

1.0 Executive Summary

1.1 Archean Chemical Industries Pvt. Ltd. retained the services of Vaibhu Safety

Consultants for carrying out Risk Assessment Studies for their Hajipir, Bhuj proposed

plant.

1.2 Experts from Vaibhu Safety Consultants visited the site on 19-20/01/2010 for inspection

of facilities to be erected and commissioned at site as per site plan and the environs and for

collection of relevant information about the installation and the operations will be carried

out in the plant. They also held detailed discussions on various aspects will be incorporated

for Chlorine tonner handling facilities, Bromine manufacturing process, Bromine storage

and handling facilities, HSE management system, procedures(SOP) and it

implementation, Emergency management plan, Emergency handling facilities, Emergency

organization and action plan., with the officers of the company.

1.3 In this plant Chlorine, Caustic soda (NaOH), Sulfuric Acid will be majorly used as raw

materials and received through road tanker and stored in designated tank farm area.

1.4 Proposed unit is classified as Major Accident Hazards unit ( MAH Installation ) based on

the storage of Chlorine, Bromine and Sulfuric Acid listed hazardous chemicals more than

specified threshold quantities.(Schedule 3 under Rule 68-J of the Gujarat Factories Rules-

1963 (2004).

1.5 The proposed unit is located at very remote place in Greater Rann Of Kutch, 16 kms north

of Hajipir, which is the nearest village.

1.6 Separate utility plant is provided for chilling cooling, Steam and Air utilities are common

for all plants.

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

identified and their consequences are modeled mathematically using HAMSGAP software.

1.8 The study indicates that possible hazards associated with the plant are confined to (a) HSD

storage tank area, road truck unloading area (b) Chlorine tonner storage area. (c) Bromine

Day tank of both process plant (d) ISO container filling area. Various hazard scenarios

have been identified for Risk Assessment and the consequences modeled. The results of

the analysis have been summarized in the table appended.

1.9 It will be observed from the summary that the consequences of hazards associated with any

possible spills / leaks except for catastrophic failure of Chlorine tonner and bromine day

tank release scenarios would be of a relatively small in nature and would be taken care of

with the proposed emergency facilities and the manpower deployed at the plant.

1.10 The possibility of occurrence of such hazards and their effects could be further reduced by

implementing the suggestions made in this report.



1.11 Catastrophic failure of Chlorine tonner and Bromine day tank and ISO container resulting

in major toxic releases is very unlikely events barring gross neglect of time tested safety

standards and procedures set up by the industry.

1.12 The possibility of occurrence of major toxic release and mishaps is considered very remote

and the field management’s total commitment to implementation of safety systems and

procedures.

1.13 However considering the potential for major hazards, however remote they may be,

associated with storage area, some suggestions are made in the subsequent chapters for

further improvement in the areas of safety, environmental impact, Emergency facilities and

emergency preparedness plan.

1.14 Conclusion Based on the

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

2) Discussions with company officials,



CHAPTER II

OBJECTIVE, PHILOSOPHY AND METHODOLOGY OF RISK ASSESSMENT

2.1 Objective :

The main objectives of the Risk Assessment (RA) study is to determine damage due to

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

assess safety level of the facility.

The principle objective of this study was to identify major risks in the manufacture of

chemicals and storage of hazardous chemical at site and to evaluate on-site & off-site

consequences of identified hazard scenarios. Pointers are then given for effective

mitigation of hazards in terms of suggestions for effective disaster management,

suggesting minimum preventive and protective measures & change of practices to ensure

safety.

2.2 PHILOSOPHY :

This report is limited to the following:

� Identification of major risk areas.

� Hazard identification/Identification of failure cases

� Consequential analysis of probable risks / failure cases

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

cases

o Risk assessment on the basic of the above evaluation & risk acceptability

o Minimum preventive & protective measures to be taken to minimize risks to

maximum possible extent.

� Giving pointers for effective disaster management

� Suggesting other measures to further lower the probability of risk

2.3 Methodology

The procedure used for carrying out the Quantitative Risk Assessment Study is outlined

bellow:

Identify Credible Loss Scenarios for the facility under the study by discussion with

ACIPL. Simulate loss Scenarios to determine the vulnerable zones for toxic dispersion

using software packages HAMSGAP.

Suggest mitigating measures to reduce the damage, considering all aspects of the facilities.

The flowchart of the methodology for the present study is shown in following page.



RISK ASSESSMENT STUDY METHODOLOGY FLOWCHART

START

FACILITY, PROCESS AND METEOROLOGICAL DATA COLLECTION

LISTING OUT OF HAZARDOUS OPERATIONS & STORAGE DETAILS

DEFINING OF PARAMETERS FOR EACH OF CHEMICALS & EACH OF

HAZARDS

IDENTIFICATION OF FAILURE SCENARIOS & QUANTIFICATION OF

PROBABLE HAZARDS ASSOCIATED WITH THEM

DEFINING RELEASE TYPE (CONTINUOUS OR INSTANTANIOUS ) &

DETERMINE RELEASE RATES

SIMULATION OF SELECTED CASES FOR CONSEQUENCE MODELING

PREPARATION OF SUMMERY OF CONSEQUENCE RESULTS

EVALUATION OF POTENTIAL RISK TO THE SURROUNDING

POPULATION

DISCUSSION & RECOMMENDATION OF MITIGATIVE / REMEDIAL

MEASURES

END



SECTION III

INTRODUCTION OF THE UNIT

3.1 COMPANY INTRODUCTION

M/s. Archean Chemicals Industries Pvt. Ltd., is going to establish its manufacturing

unit of Fertilizer products and Bromine and Green Bromine at & post Village Hajipir,

Taluka Bhuj, Dist. Kutch.-370605

Archean Group is a privately held and professionally managed business conglomerate with

diversified business interests in high growth sectors including mining & minerals,

industrial salt, shipping & shipbuilding, building materials, energy, oil & gas services, and

industrial chemicals & fertilizers.

Established in 1984 by Chairman, Mr. P B Anandam, Archean Group has strategic

investments and transnational operations across India, Europe, South America, Middle

East, Africa, Southeast and North Asia. Today, Archean has employees throughout the

world with 1,050 employees in India and over 3,500 employees globally.

Business verticals in which the group operates today include:

• Mining and Minerals (Core Minerals, PT Core Mineral Indonesia)

• Industrial Salt (Jakhau Salt Co. Pvt. Ltd., Bharat Salt Refineries Ltd.)

• Building Materials (Archean Granites Pvt. Ltd.)

• Shipping (Good earth Maritime Limited and its subsidiaries)

• Industrial Chemicals and Fertilizer (Industries Chimiques du Sénégal – ICS)

Archean Group has a track record of successfully implementing various projects and

expansions in the above fields. One of the group company, Archean Chemical Industries

Pvt. Ltd. is putting up this marine chemical complex in Greater Rann of Kutch.

Proposed unit is classified as Major Accident Hazards unit ( MAH Installation ) based on

the storage of the listed hazardous chemicals more than specified threshold

quantities.(Schedule 3 under Rule 68-J of the Gujarat Factories Rules-1963 (2004).

3.2 DETAILS OF UNITS

Sr. No. Particulars

1. Full Name & Address of

Unit

: M/s. Archean Chemicals Industries Pvt. Ltd.


Shaktinagar, P.O. Gandhidham-370 201 Dist.

Kutch, Gujarat

2. Telephone No.

Fax No. Email

: 044-43033444

02836-234259/234158/233841

02836-233400 [email protected] /

[email protected]



3. Site Address : M/s. Archean Chemicals Industries Pvt. Ltd Nr. Hajipir, Taluka Bhuj,

Dist. Kutch.-370605

4. Month & Year of

Establishment

: Upcoming unit

5. Full name & Address of

the occupier

: Mr. Sethuram

5th Floor, Tower – 2,

TVH Beliciaa Tower No. 94, MRC Nagar,

Chennai – 600 028

6. Full name & Address of

the Factory manager

: Mr. R.R.Sorathia


Shaktinagar, P.O. Gandhidham-370 201 Dist.

Kutch, Gujarat

7. Man Power

: Upcoming unit

8. No. Of shift & Shift

timing

: I shift : 07.00 to 015.00 Hrs

II Shift : 15.00 to 23.00 Hrs

III shift :23.00 to 07.00 Hrs

General Shift : 09.00 to 18.00 Hrs

9. Environs

(Nearest Facilities)

1. Railway Station : Bhuj railway station – 110 Km

Bhuj Airport – 110 Km

2. Police Station : Police Station - Nakhatrana (65 km)

3. Fire Station : Bhuj Fire station – 110 Km

4. Hospitals : Hospital - Nakhatrana (65 km)

10. Meteorogical Data

Latitude 23º 49’ 53.16” N

Longitude 69º 14’ 12.19” E

Temperature

Maximum 45º C

Minimum 2 º C

Relative Humadity :

Maximum 56 %

Minimum 7 %

Annual Rain Fall :

Average 162.7 mm



Seasonal wind directions :

Jan- Feb N / NNW / ENE

March – Sept SW / WSW

Oct to Dec N / NNE

Wind Velocity :

Avg. Wind Speed 6 m/s

11. Total Land at Plant Proposed Land area used will be: 262 hectares.

12. Power connection Demand : 10MW

13. DG Set 750 KVAX 3 Nos

14. List of emergency facilities (proposed)

A. DCP type 5 kg fire extinguishers 25 nos

B. CO2 type fire extinguishers 4.5 kgs 10 nos

C. Sand Buckets 10 nos

D. Safety helmets 200 nos

E. Water curtain nozzles 2 nos

F. Stretchers 01 nos

G. First aid box with anti snake serum 10 nos

H. Rubber hand gloves 200 nos

I. Resuscitator 05 no

J. Electric siren with 3 km range 01 no

K. Hand operated siren 2 nos

L. Pressure type self contained breathing apparatus with

spare cylinder (30 minutes)

06 nos

M. Safety Shower

10 nos

15. Fire Water Reservoir :- 2000 M3

16. Other Source of Water : Sea

17. Fire Pump Details (Proposed)

Pump Detail Number of

Pump

Head Capacity

(Flow)

KW/HP

Jockey Pump

01 70 mtr 10.8 m3/h 10

Electrical Pump

01 70 mtr 173m3/h 70

Total

02 Nil Nil Nil



18. License & Approval:

A. Factory Inspectorate

Licence No : To be Applied

B. GPCB To be applied after EC

C. Solid waste Disposal

Member ship :

D. Explosive

licence No : Particulars Licence no Validity

Chlorine To be applied

3.3 PROJECT SETTING:

The plant is located at 730 13’ 10” East longitude & 21

0 18’30” North latitude Nr. Hajipir

village, Ta: Bhuj, Dist : Kuchchh in Gujarat State. The area is classified as Greater Rann

of Kuchchh.

The site location is shown as figure 1.1. and plant layout is provided as figure 1.2.

M/s. Archean Chemical Industries Pvt. Ltd., intends to setup a unit in Greater Rann Of

Kutch, Near Hajipir, Ta.: Bhuj, District: Kutch, Gujarat. The company intends to

manufacture Sulphate of Potash, Liquid Bromine, Green Bromine and Epsomite. The total

area required by the plant will be about 62 hectares. The proposed site is about 16 kms

north of Hajipir, which is the nearest village.



Figure 1.1



Figure 1.2



Figure 1.2 A



3.4 ORGANISATIONAL SET UP

Factory Manager

Plant manager

Shift Incharge / Plant Technicians / Chemists /

Maintenance Engineers / Electricians & mechanics

Helper/ Worker

3.5 LIST OF PROPOSED PRODUCTS

Table-3.1

Sr. No. Product Quantity

MT/Annum

Max. Storage

At A Time

MT

Physical

form

Stored In MOC

1 Sulphate of

Potash

1,00,000 30, 000 Solid Closed Shed HDPE

lined bag

2 Bromine 12,500 300 Liquid Containers/

Glass bottles

MS

Lead-

lined

3 Green Bromine 2,500 250 Solid Closed shed HDPE

lined bag

4 Epsomite 81,000 12000 Solid Heaps in closed

Shed

HDPE

lined bag

3.6 LIST OF PROPOSED RAW MATERIALS

Sr.

No.

Raw Material Quantity

MT/Annum

Max. Storage

At A Time

MT

Physical

form

Stored In MOC

1 Chlorine 8,395 280 Liquid Tonners MS/CH

2 Quick Lime 70 %

CaO

4,875 115 Solid Bags in closed

Shed

HDPE

3 Caustic Soda lye

50%

5,500 200 Liquid Tanks MS

4 Caustic Soda flakes 504 20 Solid Bags in closed

Shed

HDPE

5 98% Sulphuric

Acid

5,853 200 Liquid Tanks MS

6 Kainite 7,65,000 3,60,000 Solid Open Shed Loose

7 Sea Water 36,36,506 10,00,000 Liquid Pond Loose

8 Feed Bittern 42,40,800 25,00,000 Liquid Pond Loose

9 Epsomite 2,95,000 1,00,000 Solid Open shed Loose



3.7 Details of Storage of Hazardous Materials in Bulk

NAME OF

HAZARDOUS

SUBSTANCE

MAX. STORAGE

CAP.[Qty.]

PLACE

OF IT’S

STORAGE

OPERATING

PRESSURE

AND TEMP.

TYPE OF

HAZARD

CONTROL

MEASURE PROVIDED

Liquid

Bromine,

18MT X 10 Nos.

ISO MS lead

lined containers

=180 MT and 3

Kg x 40000 glass

bottles packed in

6667 wooden

boxes each

Containing 6

bottles =120 MT

4 m3 x 2 nos. MS

glass lined Day

tanks - maximum

storage at any

point of time will

be 18

MT

15 m3 x 2 nos.

MS glass lined

Day tanks -

maximum storage

at any point of

time will be 72

MT

ISO

container /

Plant store

Area

Air blow

out process

Area

Steaming

out process

Plant

ATP

Toxic &

corrosive

� Separate store will be made in cool

and dry place.

� Safe handling procedure for bromine

will be prepared, displayed and

trained to employees.

� Emergency handling procedure will

be prepared and train for the same.

� PPEs will be procured and made it

compulsory for bromine handling.

� Close process will be designed for

bromine handling.

� Nitrogen pressure or pump transfer

will be adopted for bromine handling.

� Hazard identification and emergency

action plan will be prepared and train

all plant people for the same.

� SOP will be prepared for safe

handling and storage of Bromine

� NFPA lable will be prepared and

displayed on containers & storage

tank.

Green

Bromine

250 MT in HDPE

lined bags

Storage

Area

ATP Corrosive

Caustic Soda

Flakes,

Caustic Soda

lye 50%

20 MT

200 MT Tank

Godown ATP

Corrosive

Corrosive

� Safety Showers provided

� Caution note provided

� Dyke wall provided

� Level gauge provided.

� Double drain valve provided to tank

� Required PPEs provided to all

employees

Sulphuric

Acid

200 MT

Tanks MS

Storage

tank

ATP

Corrosive � Double drain valve will be provided

to sulfuric Acid storage tank

� Full body protection will be provided

to operator.

� Caution note and emergency first aid

will be displayed and train for the

same to all employees.

� Safety shower and eye wash will be

provided in storage tank area and

plant area.

� Total close process will be adopted

for Sulfuric acid handling.

� Dyke wall will be provided to storage

tank

� Tanker unloading procedure will be

prepared.

� SOP will be prepared for sulfuric

Acid handling.

� Training programme will be

conducted for safe handling and

emergency handling of Sulfuric Acid.



Chlorine 900 Kg x 300

Nos. Tonners

Tonners ATP

Corrosive Following steps will be adopted.

• SOP will be prepared for safe handling

of Chlorine tonners.

• Chlorine Emergency Kit will be

procured and kept ready at chlorine

shed.

• Chlorine Hood with blower will be

provided with scrubbing arrangement.

• Safety Shower and eye wash will be

provided in Chlorine shed area.

• Tonner handling EOT crane will be

installed in Chlorine shed area for safe

tonner handling.

• Safety Valve will be provided on

chlorine header line and it will be

connected to caustic scrubber.

• SCBA sets will be kept ready at

chlorine handling area.

• Safety valve will be provided on

vaporizer header and outlet of safety

valve connected to scrubber.

• Flow and temperature controllers will

be provided on process line.

HSD for fuel 24KL X 1 No.

U/G tank

Licence

premises

Atmospheric

Ambient

temp.

Fire

Transport:

1. Raw Material :

� Chlorine will be transported in tonners.

� Sulphuric acid will be transported in closed tanks.

2. Finished Product:

� Bromine will be transported in closed ISO tanks or closed bottles.

3.8 BRIEF DESCRIPTION OF PROCESS

Process description, Flowchart and reactions are provided in EIA report.

3.9 MSIHC Report:

According to MSIHC Rules (Manufacture, Storage and Import of Hazardous Chemical

Rules, 1989), a report on the toxicity characteristics for the chemicals involved is as

presented below in the form of tables.



HAZARDOUS PROPERTIES OF THE CHEMICALS, COMPATIBILITIES, SPECIAL HAZARD AND ANTIDOTES

Table-3.3

HAZARDOUS PROPERTIES OF CHMICALS INVOLVED

Sr

No Chemicals

TLV

ppm

LD50

Oral

mg/Kgs

LD50

Dermal

mg/Kgs

LC 50

mg/l

Flammable

Gas @20

Deg. C (Y/N)

LEL

%

UEL

%

FP

Deg.

C

BP

Deg. C

Class (As per

petroleum

classification)

Chemical Class

(As per MSIHC

Rules)

1 Chlorine N.A N.A N.A 293

ppm/1hr.

N N.A N.A N.A -34 A Hazardous

2 Liquid Bromine 0.1 2600 N.A 2700

mg/m3

N N.A N.A N.A 58 -- Hazardous

3 98% Sulphuric Acid N.A 2140 N.A 510

mg/m3

N N.A N.A N.A 290 -- Hazardous

F = FIRE T = TOXIC E = Explosive R = REACTIVE BP = BOILING POINT LEL = LOWER EXPLOSIVE LIMIT UEL = UPPER EXPLOSIVE LIMIT SP.GR = SPECIFIC GRAVITY VD = VAPOUR DENSITY ER = EVAPORATION RATE H = HEALTH HAZARD CLASS F = FIRE HAZARD CLASS R = REACTIVE HAZARD BR = BURNING RATE TLV = THRESHOLD LIMIT VALUE PPM = PARTS PER MILLION STEL = SHORT TERM EXPOSURE LIMIT NFPA = NATIONAL FIRE PROTECTION ASSOCIATION-usa



TABLE 2.5 :Applicability Of MSIHC Rules, 1989:

APPLICABILITY OF MSIHC Rules, 1989 (As Ammended in 2000)

Storage of Chemical

Sr.No. Chemical Class Chemical Name Quantity at Storage

works (MT)

Total Qty

(MT)

Thresold Quantity as per Schedule 3 (MT)

Column 3 Column 4

1 Extremely Flammable Liquid Nil Nil Nil 1000 5000

2 Very Highly Flammable Liquids Nil Nil Nil 1500 10000

3 Highly Flammable liquids which

remains liquid under pressure Nil Nil Nil 25 200

4 Highly Flammable liquids Nil Nil Nil 2500 20000

5 Flammable liquids Nil Nil Nil 5000 50000

6 Flammable Gas Nil Nil Nil 15 200

7 Extremely Toxic Nil Nil Nil Not Specified Not Specified

8 Highly Toxic Nil Nil Nil Not Specified Not Specified

9 Toxic Nil Nil Nil Not Specified Not Specified

10 Hazardous

Sulfuric Acid 200 Not Specified Not Specified

Epsomite

Liquid Bromine 300 300 40 --

Chlorine 280 280 10 25



3.10 Facilities / System for process safety, transportation, fire fighting system and

emergency capabilities to be adopted

Following facilities and system will be installed / implemented.

3.10.1 Process safety

1. Process will be carried out in close loop and system.

2. DCS operation plant . Built in safety technology will be adopted for

bromine manufacturing plant.

3. Instrument & Plant Air System will be provided for control all

parameters.

4. High level, low level, High pressure, low pressure, high temp, high

flow, low flow indication and cut off interlocking will be provided on

storage as well as process reactors.

5. Safety valve provided on reactor and pressure storage tanks.

6. Electric earthing (Double) will be provided.

7. Emergency handling equipments like SCBA sets, Fire extinguishers,

Gas mask, PPEs, Chlorine emergency Kit, chlorine hood, caustic pit,

Air line respirator, will be provided.

8. Industrial waste water after neutralization in ETP will be sent to solar

evaporation ponds.

9. Scrubbers provided on all process vents and online air monitoring

system will be provided on process venting system and parameters will

be maintained as per GPCB norms.

10. Chilling & cooling alternative arrangement with standby pumps will

be provided.

11. Chlorine will be charged in reactor by close loop. Flow, Temperature

and pressure wil l be maintained as per process requirement by DCS

control system and interlocking and cutoff control will be provided on

reactor.

3.10.2 Bromine Storage & Handling Safety

12. The amount of bromine in storage will be kept to a minimum.

13. Minimize the dispersal of bromine vapors by locating the storage area

on low ground. Low curbs or walls (called dikes), 200 mm high, will

be provided to protect the area from external flooding and to minimize

the dispersal of bromine vapors. The minimum diked volume will be

be equivalent to the largest storage tank plus 10%.

14. Adequate size sump will be provided for collecting bromine spills and

pump away collected rainwater and fire-fighting water.

15. Floors will be of impervious construction, preferably concrete.

16. Bromine iso tanks should be stored no closer than 10 meters from

human or animal consumable articles. Explosives and flammable

materials should not be stored close to bromine.



17. There should be a strengthened approach way for emergency vehicles

on two sides of the installation.

18. Hoses will be PTFE with stainless steel braid covering and carbon

steel flanges. Screwed fittings will not used.

19. Provide lightning protection.

20. There would be suff icient bromine storage tank capacity or an empty

iso tank to accommodate the transfer of bromine from a leaking

container

21. Area where bromine will be used or stored will be enclosed so that

unauthorized persons and animals are prevented from entering the

area. Adequate lighting will be provided to allow sufficient night

surveillance. Surveil lance will be provided 24 hours a day.

22. Personnel escape routes will be clearly marked and it will be

maintained without any obstructions including adequately sized doors

and windows.

23. Facilities l ike offices, eating, showering and changing rooms, will be

located in up wind direction and remote from the area where bromine

is handled or stored. Provide an adequate supply of clean water for

washing and showers.

24. Emergency siren, te lephone will be provided in storage area for the

reporting of accidents or emergency situations. The emergency

telephone numbers will be displayed at prominent locations and it

include the fire department, ambulance service, emergency response

team, hospital and police.

25. A wind sock will be provided which will clearly visible from all

points on the site and replaced as required. This is required for

indicating wind strength and direction.

26. Emergency respirator equipment cabinets( Cupboard) will be installed

not more than 30 meters or ten seconds walking distance from any

location in the storage area.

27. Showers and eyewash fountains wil l be provided, clearly marked, well

lit and with unobstructed access.

28. Signs will be posted prominently at the site entrance and throughout

the installation with area maps showing access ways, hydrant

locations, emergency showers, location of emergency equipment and

emergency telephone numbers.

29. All management and operating personnel involved in the use or

handling of bromine will undergo safety training, in addition to

specific task training.

30. Only experienced well-trained operators will be allowed to receive and

unload bromine receptacles.

31. The management wil l ensure that emergency response plans have been

made and coordinated with the emergency response local authorities.

32. Bromine glass bottle capacity 3.0 / 3.5 Kg and six bott les are stored in

one packing box.

33. Bromine will be stored in dry and cool place and well ventilated area.

34. Safety permit for hazardous material loading unloading will be

prepared and implemented.



35. Fire hydrant system and water sprinkler system installed at tank farm

area.

3.10.3 Loading Procedure for ISO container.

36. Open pressure release line blind flange and connect ISO container

pressure release line to plant scrubber header line and open valve. Use

a new rubber gasket (use limit - 24 hours) to ensure tight connection.

37. Make sure the absorber unit is working and capable of handling vented

bromine fumes from ISO container.

38. Remove the blind flange above the valve.

39. Connect charging line to the valve inlet. Use a new rubber gasket (use

limit - 24 hours) to ensure tight connection.

40. Open the valve and all the valves in your liquid loading line.

41. Start pump for charging bromine in ISO container.

42. Personal protective equipment will be used as per requirements and

details given bellow.

43. Liquid bromine will be charge through bromine storage tank, which

will be on weighing shell so transfer quantities can be measured.

Generally ISO container of 18MT will be used for shipping.

44. When the container filled, Off charging pump. Drain flexible hose

properly in ISO container and close charging line valve and ISO

container charging line valve.

45. Disconnect hose connection safely and blind ISO container charging

line as well as storage tank charging line.

46. Disconnect vent line and blind ISO container vent line.

47. Close cover dome and pin it securely.

3.10.4 Safe Transportation procedure to be adopted for Bromine ISO container and

bromine glass bottle crate.

The driver and assistant driver of any vehicle transporting bromine should

comply with the following requirements: 48. GPS will be installed in all the trucks and ISO container vehicle.

49. Driver and assistant will be trained in using GPS.

50. Open space separated from public highway and public dwellings,

where public does not normally pass. No passengers are allowed.

51. The crew shall know how to use fire-fighting appliances.

52. The driver or driver's assistant may not open a package containing

bromine.

53. Bromine receptacles are not to be checked with open flames.

54. No smoking is permitted around the transport unit or in the vicinity of

the vehicle during handling operations.

55. The engine is to be shut off during all handling operations unless

required to drive pumps, hoist, etc.

56. Parking brakes are to be applied whenever parked.



57. If the vehicle is parked on a road at night or with poor visibility,

warning signs are to be placed 10 meters ahead of and behind the

vehicle.

58. TREM CARD provided to all t ransporters and trained for

transportation Emergency of Hazardous chemicals.

59. All trucks having 1 kg Sodium Thiosulfate bag.

3.10.5 Personal Safety Precautions

Following personal Protective equipments are to be made compulsory when handling

Bromine.

60. American National Standards Institute (ANSI) approved chemical

safety goggles at all times when handling Br2.

61. Use a full face shield over eyewear.

62. Full body protection PVC suite

63. Eyewash fountains should be located in areas where bromine is

handled, used or stored.

64. When in danger of contact with liquid bromine, wear an approved

chemical resistant suit.

65. PVC boots should be worn over shoes for extra protection.

66. Have NIOSH approved respirators and self-contained breathing

apparatus available.

67. Gloves : 100% Nitrile rubber gloves or Neoprene gloves

3.10.6 Safety Practices in the Work Area

68. We will inform our all employees of the potential hazards of contact

with bromine and train them in appropriate first-aid procedures.

69. Bromine handling areas will be clearly marked and restricted to

qualified, trained personnel only.

3.10.7 Ventilation

70. We will maintain bromine vapor concentration in the work area to less

than 0.1 ppm with adequate exhaust hoods, ventilation systems and

scrubbers. Analyze air for proper control.

71. Transfer or repackage bromine only in a controlled, closed

environment.

72. Exhaust ventilating systems will be used in enclosed areas where

bromine is handled.

3.10.8 Containers And Storage


one packing box.




3.10.9 Neutralization in case of spillage leakage

75. Neutralization with Lime Powder.

3.10.10Emergency Procedures

In case of bromine emergencies, follow recommended first aid and emergency response

procedures adopted

3.10.11Transportation Emergencies

In emergency situations resulting from vehicle accidents:

76. Notify the local police, fire departments, emergency responders and

the carrier.

77. Isolate the area.

78. Any person not dressed in proper protective clothing and not using a

NIOSH approved self-contained breathing apparatus should be kept a

safe distance away.

79. Call to the supplier

80. Seek immediate medical assistance for those injured and follow

recommended first aid procedures.

3.10.12Leaking Containers

81. When handling a leaking bottle personal protective clothing, goggles

and NIOSH approved self contained breathing equipment must be

worn.

82. Clear contaminated area of non-essential personnel and send them to

assembly point.

83. Pour hypo solution*, lime and water slurry or soda ash solution over

the spill . Hypo-bromine reactions produce hydrobromic acid.

84. Dry sodium thiosulfate and liquid bromine produce a violent reaction;

do not mix them.

85. Using cold water, wash neutralized bromine into a sump for transfer to

an approved waste disposal facility where the waste can be processed.

86. Ventilate the area to remove the ammonium bromide and any bromine

fumes. Scrub the floors and equipment with soap and water.

3.10.13First Aid Procedure

87. Immediate medical assistance is required if bromine is swallowed,

inhaled or has contacted the eyes or skin.

88. If bromine has been ingested, do not give anything by mouth. Seek

medical attention immediately. Do not induce vomiting.

89. If bromine has been inhaled, move the exposed person to a well

ventilated area. Seek medical attention immediately. The victim

should be placed in a comfortable sitting or partly reclining position.

The exposed individual should avoid exertion. If vomiting occurs, turn



the patient on his side to avoid choking. Keep the patient warm. If the

patient is coughing and showing signs of respiratory distress, properly

trained personnel should administer oxygen.

90. For skin contact, the affected area must be flooded immediately with

large amounts of clean water from a safety shower or other appropriate

source of flowing water. Wash with 10 % sodium Thiosulfate solution

& again wash with water. Seek medical attention immediately. All

contaminated clothing, including shoes, should be removed as quickly

as possible while the victim is under the shower. Washing should be

continued for a minimum of 30 minutes. If possible, continue to wash

the affected area during transport to medical facilities. (Extended

wash times of two hours or more have proven beneficial.)

91. If bromine liquid or vapor contacts the eyes, they must be irrigated

immediately with large amounts of running water. Eye wash stations

are preferable for irrigation. If one is not available, a hose, water

source with a liberal , gentle flow may be utilized. The eyelids must be

held apart during irrigation to ensure contact of water with all

accessible tissues of the eyes and lids. Eyes should be washed

continuously for a minimum of 30 minutes. If possible, continue

flushing the eyes while transporting the employee to a physician. In

all cases of bromine injury, obtain immediate medical attention.

Provide emergency personnel with information about all materials

used by the person and provide appropriate information about bromine

and first aid procedures.



SECTION IV

HAZARD IDENTIFICATION

4.1 INTRODUCTION

Risk assessment process rests on identification of specific hazards, hazardous areas and

areas vulnerable to effects of hazardous situations in facilities involved in processing and

storage of chemicals.

In fact the very starting point of any such assessment is a detailed study of materials

handled & their physical / chemical / thermodynamic properties within the complex at

various stages of manufacturing activity. Such a detailed account of hazardous materials

provides valuable database for identifying most hazardous materials, their behaviour

under process conditions, their inventory in process as well as storage and hence helps in

identifying vulnerable areas within the complex.

Hazardous posed by particular installation or a particular activity can be broadly

classified as fire and explosive hazards and toxicity hazards. Whether a particular

activity is fire and explosive hazardous or toxicity hazardous primarily depends on the

materials handled and their properties.

It will be from the above discussion that study of various materials handled is a

prerequisite from any hazard identification process to be accurate. Based on this study

the hazard indices are calculated for subsequent categorization of units depending upon

the degree of hazard they pose.

The main hazard in this plant only bromine manufacturing, handling and storage,

concern has always been toxic release prevention and control as these are the main hazard

posed by this unit. This concern has grown through the lose of life, property and

materials experienced after experienced after major disasters, which have occurred over

the years.

Identification of hazards is the most important step to improve the safety of any plant.

The hazard study is designed to identify the hazards in terms of chemicals, inventories

and vulnerable practices /operations.

The hazard evaluation procedures use as a first step by chemical process industries and

petroleum refineries are checklists and safety reviews. Dow and Mond fire and explosion

indices, which make use of past experience to develop relative ranking of hazards, is also

extensively used. For predictive hazard analysis, Hazard and Operability studies

(HAZOP), Fault tree analysis, Event tree analysis, Maximum credible accident and

consequence analysis etc are employed.



4.2 Dow’s fire and Explosion Index (F & EI)

4.2.1 Steps in fire and explosion index calculation are given below :

4.2.2 Results of fire explosion and toxicity indices.

TABLE- 4.1 Sr.

No

Material

Stored

Storage

Qty.

Nh Nf Nr M

F

GPH SPH FEI Degree of

hazard

Radius

of expo.

(ft.)

Th Ts TI Degree of

Hazard

1. Chlorine 900 Kg. X

280 Nos.

3 0 0 1 2.05 2.82 5.8 Light 4.9 250 125 22.0 Severe

2. Bromine 18 MT ISO

Cont. / 3 kg

Bottle

3 0 0 1 2.05 2.82 5.8 Light 4.9 325 125 26.4 Severe

3. Sulfuric acid 200MTX1

Tanks

1 3 0 1 2.05 1.5 5.3 Light 4.5 250 125 20.1 Severe

4. HSD 24 0 0 0 10 2.55 1.93 49.21 Light 41 0 50 2.4 Light

FEI= MF x GPH x SPH

TI = Th + Ts x ( 1+ GPH tot + SPH tot )

-------------

100 Nh = NFPA Health rating GPH = General Process Hazard

Nf = NFPA Fire rating SPH = Special Process Hazard

Nr = NFPA Reactive rating FEI = Fire Explosion Index

MF = Material Factor Th = Penalty Factor

Ts = Penalty for Toxicity TI = Toxicity Index

Select Pertinent Process

Determine Material Factor

Calculate GHP(F1),

General Process Hazards

Calculate SPH(F2), special

process Hazards

Determine Hazard Factor

F1 X F2 =F3

F3XMaterial Factor

=F & E Index

Determine Exposure area



4.3 Failure Frequencies

4.3.1 Hazardous material release scenarios can be broadly divided into 2 categories

I) catastrophic failures which are of low frequency and

II) ruptures and leaks which are of relatively high frequency.

Releases from failure of gaskets, seal, rupture in pipelines and vessels fall in the second

category whereas catastrophic failure of vessels and full bore rupture of pipelines etc fall

into the first category.

4.3.2 Typical failure frequencies are given below:-

TABLE-4.2

Item Mode of failure Failure frequencies

Atmospheric

storage

Catastrophic failure

Significant leak

10-9 /yr

10-5 /yr

Process Pipelines

< = 50 mm dia Full bore rupture

Significant leak

8.8 x 10-7 /m.yr

8.8 x 10-6 /m.yr

> 50 mm <=150mm dia Full bore rupture

Significant leak

2.6 x 10-7 /m.yr

5.3 x 10-6 /m.yr

< 150 mm dia Full bore rupture

Significant leak

8.8 x 10-8 /m.yr

2.6 x 10-6 /m.yr

Hoses Rupture 3.5 x 10-2 /m.yr



TABLE-4.3

TABLE-4.4



4.4 Identification of Hazardous Areas:

A study of process for manufacturing as given in chapter 2 of the report indicates the

following:

Various raw materials used in the manufacturing processes are listed in Table-3.2 in

Section-3 along with mode / type of storage & storage conditions. It can be readily seen

that raw materials even though hazardous in nature, are used in continuous process &

inventory is low at process plant. However some chemicals such as Chlorine, sulphuric

Acid are used / common in more than one process & therefore their inventory requirement

is higher. Bromine, Sulphuric Acid and Chlorine are stored separately . List of chemicals

stored in larger quantities is provided in Table-4.5

Following areas considered as a Hazardous area of the plant.

(a) CCOE approved Chlorine tonner Shed

(b) Bromine Day tank area.

(c) Bromine ISO container filling station.

(d) Sulfuric Acid storage area.

4.4.1 Evaluation Of Hazards :

4.4.1.1 Major inventory of Hazardous chemicals within the factory premises are-

The materials were studied with respect to their flammability, reactivity and toxicity based

on the criteria given by the NFPA (NFPA ratings). Material factor values were determined

using these ratings. General process hazards and Special process hazards for all the

materials stored were determined as per the guidelines given by DOW Chemicals

Company in DOW Index. FEI values for all these materials were calculated form the

above data.

Value of material factor, General Process Hazard & Special Process Hazard as also FEI /

TI values & degree of hazard are given in Table 4.1 It can be seen storage in tank farms is

mostly in the Severe category due to pressure storage and highly flammable and toxic

nature of chemicals. The radius of exposure for various tanks considering FEI Values is

also calculated and presented in the Table.

4.4.1.2 Evaluation of Process Areas :

� Proposed Bromine process plant would be a state of the art Technology process fully

automatic DCS operation and continuous process plant. Thus the inventory of

hazardous chemicals is in the plant is very small.

� Proposed plants will be controlled by Distributed Control System (DCS) to provide an

integrated plant control built in safety devices. Process parameters control and

interlocking will be provided and foolproof safety interlocking and logics applied at

design level and maintained.



� Thus Produce units will do not warrant any detailed calculations as consequences due

to any worst case scenario due to small quantity of material & damage is such a case is

expected to be limited to within the factory premises.

� Considering this, the risk analysis and consequences studies are concentrated on

storage in bulk.



SECTION V

RISK ASSESSMENT

5.1 Effects Of Releases Of Hazardous Substances

Hazardous substances may be released as a result of failures / catastrophes,

causing possible damage to the surrounding area. In the following

discussion, an account is taken of various effects of release of hazardous

substances and the parameters to be determined for quantification of such

damages.

In case of release of hazardous substances the damages will depend largely

on source strength. The strength of the source means the volume of the

substance released. The release may be instantaneous or semi-continuous.

In the case of instantaneous release, the strength of the source is given in

kg and in semi-continuous release the strength of the source depends on the

outflow time (kg/s.).

In order to fire the source strength, it is first necessary to determine the

state of a substance in a vessel. The physical properties, viz. Pressure and

temperature of the substance determine the phase of release. This may be

gas, gas condensed to liquid, liquid in equilibrium with its vapour or

solids.

Instantaneous release will occur, for example, if a storage tank fails.

Depending on the storage conditions the following situations may occur.

The source strength is equal to the contents of the capacity of the storage

system.

In the event of the instantaneous release of a liquid a pool of liquid will

form. The evaporation can be calculated on the basis of this pool.

Pool Fire

In the event of the instantaneous release of a liquid a pool of liquid will

form. The evaporation can be calculated on the basis of this pool.

The heat load on object outside a burning pool of liquid can be calculated

with the heat radiation model. This model uses average radiation intensity,

which is dependent on the liquid. Account is also taken of the diameter-to-

height ratio of the fire, which depends on the burning l iquid. In addition,

the heat load is also influenced by the following factors :



� Distance from the fire

� The relative humidity of the air (water vapour has a relatively high

heat-absorbing capacity)

� the orientation i.e. horizontal/vert ical of the objective irradiated with

respect to the fire.

DISPERSION CASES :

PLUMES :

Plumes are continuous release of hazardous gases and vapours. Smoke from

a chimney is an example. Plumes can cause FIRES AND EXPLOSIONS as

secondary scenarios.

PUFFS :

Puffs are instantaneous release of hazardous gases and vapours. Puffs can

give rise to FIRE BALLS and vapour cloud explosions(VCE). A special

case of vapour cloud explosion is the Boiling Liquid Evaporating Vapour

Explosion (BLEVE).

SPILLS POOL:

Spills are liquid pools created by leaking liquid chemicals. Spills cause

evaporation and dispersal of toxic gases and if the spilled liquid is

flammable, then it can catch fire creating a pool fire also the vapours can

cause explosion.

5.2 Identification of High Risk Areas :

Following areas considered as a High Risk area of the plant.

(a) CCOE approved Chlorine tonner Shed

(b) Bromine Day tank area.

(c) Bromine ISO container filling station.

(d) Sulfuric Acid storage area.

5.3 Modes of Failure:

5.3.1 Following failure are considered for detailed analysis and safe distances computed:

� Liquid release due to catastrophic failure of storage vessel or road tanker.

� Liquid release through a hole/crack developed at welded joints/flanges / nozzles /

valves etc.

� Vapour release due to exposure of liquid to atmosphere in the above scenarios.

Considering the quantity of storages & nature of Toxic nature storage, following scenarios

were taken up for detailed analysis & safe distances computed :



� Dispersion of vapour up to LC-50 ( Fatal ), Immediate Danger to Life and Health

(IDLH ) and TLV ( Threshold Limit Value ) concentration Dispersion of vapour to

toxic end points

Failure cases considered for consequence analysis are representative of worst-case

scenarios. Probability of occurrence of such cases is negligible (less than 1 x 10-6

per

year) because of strict adherence to preventive maintenance procedures within the

complex. General probabilities for various failure is provided in Table-4.2, 4.3 and

4.4, but consequences of such cases can be grave & far reaching in case such systems

fail during life history of the company. Hence such scenarios are considered for

detailed analysis. It is to be noted however that such situations are not foreseeable or

credible as long as sufficient measures are taken. Also, consequence analysis studies

help us evaluate emergency planning measures of the Company.

Table-5.2

Scenario

No.

Failure Type Failure Mode Consequence

1. Puff Isopleth Simulation

For Chlorine Tonner

Catastrophic Failure

Catastrophic

failure

Puff dispersion up to LC 50

Human, IDLH and TLV

level.

2. Point source plume release

for Chlorine liquid/ gas

phase valve failure.

Random failure Point source dispersion up

to LC 50 Human, IDLH and

TLV level.

3. Spill Pool Evaporation 200

MT Sulfuric Acid storage

Tank catastrophic failure

Catastrophic

failure

Spill pool Evaporation

dispersion up to LC 50,

IDLH and TLV level.

4. Puff release for Bromine

12 MT Day tank

catastrophic failure

Catastrophic

failure

Puff release up to LC 50,

IDLH and TLV level.

5. Spill pool Evaporation for

Bromine 12 MT Day tank


Catastrophic

failure



IDLH and TLV level.


45 MT Day tank


Catastrophic

failure


IDLH and TLV level.


Bromine 45 MT Day tank


Catastrophic

failure



IDLH and TLV level.


18 MT ISO container


Catastrophic

failure


IDLH and TLV level.


Bromine 18 MT ISO

container catastrophic

failure.

Catastrophic

failure



IDLH and TLV level.

10. HSD road tanker unloading

hose 100 release

Random failure Unconfined Pool file.



5.4 Damage Criteria For Heat Radiation:

Damage effects vary with different scenarios. Calculations for various

scenarios are made for the above failure cases to quantify the result ing

damages.

The results are translated in term of injuries and damages to exposed

personnel, equipment, building etc.

Tank on fire /Pool fire due to direct ignit ion source on tank or road tanker

or catastrophic failure or leakage or damage from pipeline of storage

facilities or road tanker unloading arm, can result in heat radiation causing

burns to people depending on thermal load and period of exposure.

All such damages have to be specified criteria for each such resultant

effect, to relate the quantifier damages in this manner, damage cri teria are

used for Heat Radiation.

TABLE 5.3

DAMAGE CRITERIA – HEAT RADIATION

Heat Radiation

Incident Flux KW/m2 Damage

38 100% lethality, heavy damage to tanks

37.5 100% lethality, heavy damage to equipment.

25 50% lethality, nonpiloted ignition

14 Damage to normal buildings

12.5 1% lethality, piloted ignition

12 Damage to vegetation

6 Burns (escape routes)

4.5 Not lethal, 1st degree burns

3 1st degree burns possible

(personnel only in emergency allowed)

2 Feeling of discomfort

1.5 No discomfort even after long exposure



CHAPTER VI

CONSEQUENCE ANALYSIS

6.1 Consequence analysis.

In the risk analysis study, probable damages due to worst case scenarios

were quantified and consequences were analyzed with object of emergency

planning. Various measures taken by the company and findings of the study

were considered for deciding acceptability of risks.

6.1.1 Weather Data :

Average wind speed : 5 m / sec.

Average Ambient Temperature : 35 deg. c.

Average Humidity : 30 %

Atmospheric Stability : CD

6.1.2 Assumption :

6.1.2.1 For Chlorine supply system as follows.

♦ Chlorine tonner catastrophic failure i .e. 900 kg gas puff dispersion

♦ For Chlorine liquid/ gas phase valve failure release scenario, we

have considered release rate 1000 grms/sec. Maximum contents of

the tonners wil l be release within 900 seconds or 15 minutes.

♦ We have calculated following hazardous distance for the above

mentioned scenarios.

♦ Fatality (LC-50 for Human)

♦ Immediate danger to life and health (IDLH) concentration area

♦ TWA/TLV concentration distance( Meters)

6.1.2.2 For Sulfuric Acid storage tanks/ road tanker as follows.

♦ Storage tank catastrophic failure i .e. So3 fumes puff dispersion

♦ For Sulfuric Acid outlet line valve failure release scenario, we have

considered fumes release rate 1000 grms/sec. 900 kgs release within

15 minutes.



♦ Fatality Human ( LC-50 )





6.1.2.3 For Bromine Day tank/ ISO container as Follows..

♦ Bromine Day tank catastrophic failure puff dispersion

♦ Bromine Spill pool Evaporation.



♦ Fatality ( LC-50 )



6.1.2.4 For HSD Road tanker catastrophic failure( Unloading arm 100 % failure)

Catastrophic failure is considered for 20 MT HSD road tanker while

unloading and due to unconfined spread of liquid on ground and ignition

source availability, unconfined pool fire will occur.



Scenario-1 Puff Isopleth Simulation For Chlorine Tonner Catastrophic Failure

TABLE –A FOR CHLORINE

Scenario : PUFF DISPERSION

Input Data Results of Computations

Stored quantity 1 MT Tonner Max. ground level conc. 456393 ppm

Instantaneous Puff

Release quantity

900 kgs Dist. of maxi. ground level

conc.

17 meter

Molecular weight 70.9

Wind speed 3.0 m/s

Density ( Air) 2.49kg/m3

Hazard Level Concentration

(PPM)

End point

(Meter)

LC50 Human 1017 210.30

IDLH 10 856.39

TWA/ TLV 1 1619.16

• LC50 HUMAN (1017 ppm) area up to 210 meter, IDLH (Immediate danger to life and health)

concentration area up to 856 meter and TWA (1 PPM ) area up to 1619 meter. Therefore 856

meter area in wind direction is considered as evacuation area.



Scenario-2 Point source plume release for Chlorine tonner liquid/ gas phase valve failure

TABLE –B FOR CHLORINE

Scenario : POINT SOURCE PLUME RELEASE


Stored quantity 1 MT Max. ground level conc. 501046ppm

Rate of release 1000 g/s Dist. of maxi. ground level

conc.

5 meter

Molecular weight 70.9

Wind speed 6.0 m/s

Density ( Air) 2.49kg/m3

Hazard Level Concentration

(PPM)

End point

(Meter)

LC50 HUMAN 1017 51.91

IDLH 10 445.25

TWA/ TLV 1 1035.91


concentration area up to 445 meter and TWA (1 PPM ) area up to 1038 meter. Therefore 445

meter area in wind direction is considered as evacuation area.



Scenario – 3 Spill Pool evaporation module for Sulphuric Acid Storage Tank catastrophic

failure

TABLE – C

Spill Pool evaporation module for Sulphuric Acid Storage Tank catastrophic failure

Scenario : SPILL POOL


Stored quantity 200 MT End point

(meter) Release Rate 1000 Gms/ Sec. ( As SO3)

LC50 Human 460 ppm (1460 mg/m3) 59.85

IDLH value 3.0ppm (15mg/m3) 587.63

TLV value 0.2 ppm (1mg/m3) 1349.6

Results


concentration( 3 ppm) area up to 587.63 meter and TWA (0.2 PPM ) area up to 1349.6 meter.

Therefore 587.63 meter area in wind direction is considered as evacuation area.



Scenario – 4 Puff Release for Bromine 12 MT day tank catastrophic failure

TABLE – D

Puff Release for Bromine 12 MT dat tank catastrophic failure

Scenario : Puff release



(meter) Release quantity 12 MT

LC50 Human 1075 ppm 902

IDLH value 3.0 ppm 8369

TLV value 0.1 ppm 30273

Results


concentration( 3.0 ppm) area up to 8369 meter and TWA (0.1 PPM ) area up to 30273 meter.

Therefore 8369 meter area in wind direction is considered as evacuation area.



Scenario – 5 Spill Pool Evaporation for Bromine 12 MT day tank catastrophic failure

TABLE – E

Spill Pool Evaporation for Bromine 12 MT day tank catastrophic failure




(meter) Evaporation rate 1500 g/s




Results






Scenario – 6 Puff Release for Bromine 45 MT day tank catastrophic failure

TABLE – F

Puff Release for Bromine 45 MT dat tank catastrophic failure








Results

• LC50 HUMAN (1075 ppm) area up to 1487 meter, IDLH (Immediate danger to life and

health) concentration( 3.0 ppm) area up to 13794 meter and TWA (0.1 PPM ) area up to 49808

meter. Therefore 13794 meter area in wind direction is considered as evacuation area.



Scenario – 7 Spill Pool Evaporation for Bromine 45 MT day tank catastrophic failure

TABLE – G

Spill Pool Evaporation for Bromine 45 MT day tank catastrophic failure





LC50 Human 1075 ppm 68.55



Results






Scenario – 8 Puff Release for Bromine 18 MT ISO container catastrophic failure

TABLE – H

Puff Release for Bromine 18 MT ISO container catastrophic failure








Results

• LC50 HUMAN (1075 ppm) area up to 1051 meter, IDLH (Immediate danger to life and

health) concentration( 3.0 ppm) area up to 9757 meter and TWA (0.1 PPM ) area up to 49808

meter. Therefore 35274 meter area in wind direction is considered as evacuation area.



Scenario – 9 Spill Pool Evaporation for Bromine 18 MT ISO container catastrophic failure

TABLE – I

Spill Pool Evaporation for Bromine 18 MT ISO container catastrophic failure





LC50 Human 1075 ppm 61.97



Results






Scenario –10 Unconfined Pool Fire for HSD road tanker catastrophic failure

TABLE –J

Unconfined Pool Fire for Solvent road tanker catastrophic failure

Scenario : UNCONFINED POOL FIRE


Stored quantity 20 KL Max. IHR at flame centre height 115 Kw/m2

Pool diameter 17(m) Flame centre height 20 meter

Pool liquid depth 0.1 (m) Maximum Flame width 19.09 meter

Wind speed 6 m/s Mass burning rate liquid 2.1 kg/ m2/min.

Liquid Density 820 kg/m3 Flame burnout time 71.11 Mims.

Incident Intensity of

Heat Radiation

(IHR) at ground

level KW /m 2

IHR-

Isopleth

Distance

( Meters )

Effect if IHR at Height of Simulation

37.5 18.5 Damage to process equipment. 100 % Fatal in 1 Min. 1 %

fatal in 10 sec.

25.0 22.7 Min. to ignite wood ( without flame contact ). 100 % fatal

in 1 Min. Significant injury in 10 sec.

12.5 32.1 Min. to ignite wood (with flame contact). 1 % fatal in 1

min. 1 st deg. burn in 10 sec.

4.0 56.7 Pain after 20 secs. Blistering unlikely.

1.6 89.6 No discomfort even on long exposure.

Results

♦ In the 18.5 meter radius area is considered as 100% fatality in 1 min.

♦ In the 22.7 meter radius first degree burn in 10 sec.

♦ In the 56 meter radius area will give pain after 20 seconds. Blistering unlikely.

♦ In the 89.6 meter radius area is considered as safe area and no discomfort even on long

exposure.



6.2 Assessment Of Consequence Modeling Results :

Results of consequence analysis for the release of toxic chemicals are depicted in Table

6.3.

TABLE - 6.3

Type of failure considered Spill quantity

consideration

Max.

Credible loss

scenario in

MT.

Evaporati

on Rate

Grm/ Sec.

LC50

Distance

in meter

IDLH

Distance

in meter

TLV

Distance

in meter

Scenario-1 Puff Isopleth

Simulation For Chlorine

Tonner Catastrophic

Failure

900 kgs - 210 856 1619

Scenario-2 Point source

plume release for

Chlorine tonner liquid/

gas phase valve failure

900 kgs 1000 51 445 1035

Scenario-3 Spill Pool

Evaporation 200 MT

Sulfuric Acid storage

Tank catastrophic failure

200 MT 1000 59 587 1349

Scenario-4 Puff release

for Bromine 12 MT Day

tank catastrophic failure

12 MT - 902 8369 30273

Scenario-5 Spill pool

Scenario-2 Evaporation



12 MT 1500 50 1418 10017




45 MT - 1487 13795 49808


Evaporation for Bromine

45 MT Day tank


45 MT 2620 68 1954 13787


for Bromine 18 MT ISO

container catastrophic

failure

18 MT - 1051 9757 35274


Evaporation for Bromine

18 MT ISO container

catastrophic failure.

18 MT 2148 61 1743 12310



6.3 Comments

The appended table 6.3 summarizes the consequences of the various hazards analyzed

under this study.

As can be seen from the results of the summary of the Risk Analysis study, the Fatality

zone due to bromine up to 1485 meters in worst case scenario. Immediate Danger to life

and health up to 13795 meter. In case of Bromine release, evacuation zone maximum up to

13795 meter and company has to plan for evacuation accordingly. It is observed on the

Google map there is no any village or residential or any industrial activity in 15 kms.

vicinity area. In such case only company employees may be affected.

On site Off site emergency preparedness plan

On site Off site emergency plan to be prepared.

Emergency handling facilities and training:

All employees should be well aware about possible emergencies and its consequences,

emergency control equipments and practices to control such hazardous condition within

premises.



SECTION VII

RISK REDUCTION MEASURES

Some of the safeties and risk reduction measures adopted and recommended for the safety of the

plant are as follows:-

7.1 Design

7.1.1 During the design stage itself adequate care has been taken for design, selection,

fabrication, erection and commissioning of Flammable and toxic liquid handling facilities

and other equipment, piping, pipe fittings, electrical equipment etc. relevant and prevalent

international and Indian standards has been followed for design, fabrication, inspection of

the storage tanks and other equipment.

7.1.2 Civil foundations will be suitably designed to take care of earthquakes, cyclones,

landslides, flooding, collapse of structures etc.

7.1.3 Plant operator and staffs will be selected well experience and qualified for chemical plant

operation.

7.1.4 All key personals will be trained for emergency handling procedures and regular Mock-

Drills has been conducted on various scenarios.

7.2 Process

1. Process will be carried out in close loop and system.

2. DCS operation plant . Built in safety technology will be adopted for

bromine manufacturing plant.

3. Instrument & Plant Air System will be provided for control all

parameters.

4. High level, low level, High pressure, low pressure, high temp, high

flow, low flow indication and cut off interlocking will be provided on

storage as well as process reactors.

5. Safety valve, provided on reactor and pressure storage tanks.

6. Electric earthing (Double) will be provided.

7. Emergency handling equipments like SCBA sets, Fire extinguishers,

Gas mask, PPEs, Chlorine emergency Kit, chlorine hood, caustic pit,

Air line respirator, will be provided.

8. Industrial waste water after neutralization in ETP will be sent to solar

evaporation ponds.

9. Scrubbers provided on all process vents and online air monitoring

system will be provided on process venting system and parameters will

be maintained as per GPCB norms.

10. Chilling & cooling alternative arrangement with standby pumps will

be provided.

11. Chlorine will be charged in reactor by close loop. Flow, Temperature

and pressure wil l be maintained as per process requirement by DCS



control system and interlocking and cutoff control will be provided on

reactor.

7.3 Bromine Storage & Handling Safety

1. The amount of bromine in storage will be kept to a minimum.

2. Minimize the dispersal of bromine vapors by locating the storage area

on low ground. Low curbs or walls (called dikes), 200 mm high, will

be provided to protect the area from external flooding and to minimize

the dispersal of bromine vapors. The minimum diked volume will be

be equivalent to the largest storage tank plus 10%.

3. Adequate size sump will be provided for collecting bromine spills and

pump away collected rainwater and fire-fighting water.

4. Floors will be of impervious construction, preferably concrete.

5. Bromine iso tanks should be stored no closer than 10 meters from

human or animal consumable articles. Explosives and flammable

materials should not be stored close to bromine.

6. There should be a strengthened approach way for emergency vehicles

on two sides of the installation.

7. Hoses will be PTFE with stainless steel braid covering and carbon

steel flanges. Screwed fittings will not used.

8. Provide lightning protection.

9. There would be suff icient bromine storage tank capacity or an empty

iso tank to accommodate the transfer of bromine from a leaking

container

10. Area where bromine will be used or stored will be enclosed so that

unauthorized persons and animals are prevented from entering the

area. Adequate lighting will be provided to allow sufficient night

surveillance. Surveil lance will be provided 24 hours a day.

11. Personnel escape routes will be clearly marked and it will be

maintained without any obstructions including adequately sized doors

and windows.

12. Facilities l ike offices, eating, showering and changing rooms, will be

located in down wind direction and remote from the area where

bromine is handled or stored. Provide an adequate supply of clean

water for washing and showers.

13. Emergency siren, te lephone will be provided in storage area for the

reporting of accidents or emergency situations. The emergency

telephone numbers will be displayed at prominent locations and it

include the fire department, ambulance service, emergency response

team, hospital and police.

14. A wind sock will be provided which will clearly visible from all

points on the site and replaced as required. This is required for

indicating wind strength and direction.

15. Emergency respirator equipment cabinets( Cupboard) will be installed

not more than 30 meters or ten seconds walking distance from any

location in the storage area.



16. Showers and eyewash fountains wil l be provided, clearly marked, well

lit and with unobstructed access.

17. Signs will be posted prominently at the site entrance and throughout

the installation with area maps showing access ways, hydrant

locations, emergency showers, location of emergency equipment and

emergency telephone numbers.

18. All management and operating personnel involved in the use or

handling of bromine will undergo safety training, in addition to

specific task training.

19. Only experienced well-trained operators will be allowed to receive and

unload bromine receptacles.

20. The management wil l ensure that emergency response plans have been

made and coordinated with the emergency response local authorities.


one carat.


23. Safety permit for hazardous material loading unloading will be

prepared and implemented.

24. Fire hydrant system and water sprinkler system installed at tank farm

area.

25. Sodium Thiosultate 10 % solution & lime powder to be kept available

near bottling area.

7.3.1 Pumps

a) Required out let valve and NRV provided on pump outlet.

b) Modular fire extinguishers provided near of most of the pumps.

c) FLP type and mechanical seal type pump installed for flammable chemicals.

7.3.2 Pipelines

a) Proper supports and clamping are provided

b) Double earthing provided to all electrical motors.

c) Colour code as Per IS maintained.

7.4 Operation and Maintenance

Operations and maintenance of the plant is being in accordance with the well-established

safe practices. Some of the guidelines are as follows:-

a) Periodic testing of hoses for leakages and continuity.

b) Earthing of all plant equipment and earthing of vehicles under unloading operations.

c) Annual testing of all safety relief valves.

d) Planned preventive maintenance of different equipment for their safety and reliable

operations.

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

measurement, joint and weld efficiency etc.

f) Comprehensive color code scheme to identify different medium pipes.



g) Strict compliance of safety work permit system.

h) Proper maintenance of earth pits.

i) Strict compliance of security procedures like issue of identify badges for outsides, gate

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

j) Strict enforcement of no smoking regime.

k) Periodic training and refresher courses to train the staff in safety, fire fighting and first

aid.

7.5 Recommendations

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

are confined within the factory boundary walls in case of fire & explosion, except in the

event of a catastrophic failure of storage tanks of Bromine it will create OFF site

emergency situations and required more attention and emergency preparedness for combat

such situations. To minimize the consequential effects of the risk scenarios, following

steps are recommended.

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

Chemicals Rules, 1986 & the factories Act, 1948.

� Air line respirator provision to be made in Chlorine and bromine handling & storage

tank farm area.

� Chlorine hood with blower and neutralizing pit arrangement needs to be made at

Chlorine tonners storage area.

� React with water and generate toxic fumes while contact with water caution note to be

displayed in Bromine and Sulfuric Acid tank farm area.

� Fire hydrant system to be installed as per TAC/NFPA Norms in each plant and

buildings.

� Dyke wall and collection pit with drain valve needs to be provided in storage area and

one underground dumping vessel to be provided for bromine emergency spillage.

� Tanker unloading and Bromine loading procedure needs to be displayed at tanker

loading/unloading area.

� Periodic On Site Emergency Mock Drills and occasional Off Site Emergency Mock

Drills to be conducted, so those staffs are trained and are in a state of preparedness to

tackle any emergency.

� Emergency handling facilities and fire protection system as per provided in report to

be procure and maintained in tip top condition at all time.

� Safe operating procedure to be prepared for hazardous process and material handling

process.

� Safety devices and control instruments to be calibrated once in a year.

� Proper colour work as per IS 2379 to plant pipeline and tank, equipments to be done

once in a six month to protect from corrosion.

� Permit to work system to be implemented 100 % for hazardous work in the plant.

� Safety manual as per Rule-68 K & P and Public awareness manual as per 41 B & C be

prepared and distributed to all employees and nearby public.

� The details of emergency equipments are given in this report along with its quantity to

be procured and maintained at site.

� Manual call points for emergency identification to be installed in plant premises.



� Fire & Safety organization to be setup and qualified safety officer with supporting

staff to be employed for implementation of HSE management system.

� On line gas detection system needs to be provided in Chlorine shed area and Bromine

storage tank farm area and work place exposure to be maintained in plant bellow TLV

concentration at all time..

� All vents to be connected with scrubber system.

� A HAZOP study to be carried out for Bromine manufacturing plant and storage

facilities.

� Induction safety course to be prepared and trained all new employees before starting

duties in plant.

� Bromine transportation to be facilitated with GPS system for better emergency

handling purpose.

� All employees who will be handle Bromine shall be well experience and well trained

for bromine handling before starting the job and records to be maintained as per

requirements of F.A. Sec.-41 B.

� All drivers and his assistant shall be well trained and to be certified for Safe bromine

transportation and emergency.

� Emergency preparedness plan to be designed as per activities hazard and hazardous

scenarios considered in risk assessment.



SECTION VIII

DESASTER MANAGEMENT PLAN

An onsite emergency in the industries involving hazardous processes or in hazardous installations

is one situation that has potential to cause serious injury or loss of life. It may cause extensive

damage to property and serious disruption in the work area and usually, the effects are confined to

factory or in several departments of factory, premise. An emergency begins when operator at the

plant or in charge of storage cannot cope up with a potentially hazardous incident, which may tum

into an emergency.

8.1 ONSITE EMERGENCY PLAN

8.1.1 OBJECTIVES OF ONSITE EMERGENCY PLAN

A quick and effective response at during an emergency can have tremendous significance

on whether the situation is controlled with little loss or it turns into a major emergency.

Therefore, purpose an emergency plan is to provide basic guidance to the personnel for

effectively combating such situations to minimize loss of life, damage to property and loss

of property.

An objective of Emergency Planning is to maximize the resource utilisation and combined

efforts towards emergency operations are as follows. :

8.1.2 DURING AN EMERGENCY.

� To increase thinking accuracy and to reduce thinking time.

� To localize the emergency and if possible eliminates it.

� To minimize the effects of accident on people and property.

� To take correct remedial measures in the quickest time possible to contain the incident

and control it with minimum damage.

� To prevent spreading of the damage in the other sections.

� To mobilize the internal resources and utilize them in the most effective way

� To arrange rescue and treatment of causalities.

8.1.3 DURING NORMAL TIME.

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

working condition.

• To keep the concerned personnel fully trained in the use of emergency equipment.

• To give immediate warning tooth surrounding localities in case of an emergency

situation arising.

• To mobilize transport and medical treatment of the injured.

• To get help from the local community and government officials to supplement

manpower and resources.



• To provide information to media & Government agencies, Preserving records,

evidence of situation for subsequent emergency etc.

8.2 SCOPE OF OSEP

This OSEP is prepared for industrial emergencies like fires, explosions, toxic releases, and

asphyxia and does not cover natural calamities and societal disturbances related

emergencies (like strikes, bomb threats, civil commission’s etc.)

8.3 ELEMENTS OF ONSITE EMERGENCY PLAN

The important elements to be considered in plan are

� Emergency organization

� Emergency Facilities.

� Roles and Responsibilities of Key Personnel and Essential Employee.

� Communications during Emergency

� Emergency Shutdown of Plant & Control of situation.

� Rescue Transport & Rehabilitation.

� Developing Important Information.

8.4 METHODOLOGY.

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

• Identification and assessment of hazards and risks.

• Identifying, appointment of personnel & Assignment of Responsibilities.

• Identification and equipping Emergency Control Centre.

• Identifying Assembly, Rescue points Medical Facilities.

• Formulation of plan and of emergency sources.

• Training, Rehearsal & Evaluation.

• Action on Site.

Earlier, a detailed Hazard Analysis and Risk Assessment was carried out on hazards and

their likely locations and consequences are estimated following the standard procedure.

However the causing factors for above discussed end results may be different and causing

factors are not discussed in this plan.

8.5 EMERGENCIES IDENTIFIED

Emergencies that may be likely at bulk fuel storage area, process plant, cylinder storage

area, and drum storage shed, and autoclave reactor area. There are chances of fire and

explosive only.



8.6 OTHERS

Other risks are earthquake, lightning, sabotage, bombing etc., which are usually, not in the

purview of management control.

8.7 EMERGENCY ORGANISATION.

Plant organization is enclosed. Based on the plant organization, which includes shift

organization, an Emergency Organization is constituted towards achieving objectives of

this emergency plan.

Plant Manager is designated as Overall in Charge and is the Site Controller.

The following are designated as Incident Controllers for respective areas under their

control. Shift in charge Engineer (Plant Operations) is designated at Incident Controller for

all areas of plant.

8.8 EMERGENCY FACILITIES

8.8.1 EMERGENCY CONTROL CENTRE (ECC)

It is a location, where all key personnel like Site Controller, Incident Controller etc. can

assemble in the event of onset of emergency and carry on various duties assigned to them.

Plant Manager’s Office is designated as Emergency Control Centre. It has P&T telephone

as well as internal telephones, ECC is accessible from plant located considerably away

from process plant, Storage’s and on evaluation of other locations, Plant Manager’s Room

find merit from the distance point of view, communication etc.

8.8.2 FACILITIES PROPOSED TO BE MAINTAINED AT EMERGENCY CONTROL

CENTRE (ECC)

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

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

District Emergency Authority).

• Intercom Telephone.

• P&T Telephone.

• Telephone directories (Internal, P&T)

• Factory Layout, Site Plan

• Plans indicating locations of hazardous inventories, sources of safety equipment,

hydrant layout, location of pump house, road plan, assembly points, vulnerable zones,

escape routes.

• Hazard chart.

• Emergency shut-down procedures.

• Nominal roll of employees.

• List and address of key personnel



• List and address of Emergency coordinators.

• List and address of first aides,

• List and address of first aid fire fighting employees,

• List and address of qualified Trained persons.

8.8.3 FIRE FIGHTING FACILITIES.

• Internal hydrant system

• Portable extinguishers

8.8.4 FIRE PROTECTION SYSTEMS

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

facilities and consist of

• Hydrant system for exterior as well as internal protection of various buildings/areas of

the plant.

• Portable extinguishers and hand appliances for extinguishing small fires in different

areas of the plant.

• Water cum foam monitor to be provided in bulk fuel storage area.

• Fire water pumps.

• Two (2) independent motor driven pumps each of sufficient capacity and head are

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

purpose.

8.8.5 HYDRANT SYSTEM.

Adequate number of fire hydrants and monitors will be provided at various locations in

and around the buildings and other plant areas. The hydrants will be provided on a

network of hydrant mains drawing water from the hydrant pump, which starts

automatically due to drop of pressure in the event of operating the hydrant valves. We are

suggesting you to go for TAC approved hydrant system for foolproof safety and benefit

from fire policy premium.

8.9 EMERGENCY ESCAPES

The objective of the emergency escape is to escape from the hazardous locations, to the

nearest assembly point or the other safe zone, for rescue and evacuation.

8.10 ASSEMBLY POINT.

Assembly point is location, where, persons unconnected with emergency operations would

proceed and await for rescue operation.



8.11 WIND SOCK.

Wind socks for knowing wind direction indication would be provided at a suitable location

to visible from many locations. It is proposed to install windsocks at E.O storage area and

Administration Building so as to be visible from different locations in the plant.

8.12 EMERGENCY TRANSPORT.

Emergency Ambulance would be stationed at the Administration Office and round the

clock-driver would be made available for emergency transportation of injured etc.

However, the other vehicles of the company also would be available for emergency

services.

8.13 EMERGENCY COMMUNICATION.

There are two kinds of communication system provided.

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

(b) Mobile phone

8.14 WARNING/ALARM/COMMUNICATION OF EMERGENCY

The emergency would be communicated by operating electrical siren for continuously for

five minutes with high and low pitch mode.

8.15 EMERGENCY RESPONSIBILITIES:

Priority of Emergency Protection.

• Life safety

• Preservation of property

Restoration of the normalcy

8.16 MUTUAL AID

While necessary facilities are available and are updated from time to time, sometimes, it

may be necessary to seek external assistance; it may be from the neighboring factories or

from the State Government as the case may be.

8.17 MOCK DRILL

Inspite of detailed training, it may be necessary to try out whether, the On site – Off site

Emergency Plan works out and will there be any difficulties in execution of such plan. In

order to evaluate the plan and see whether the plan meets the objectives of the On site –

Off site Emergency Plan, occasional mock drills are contemplated. Before undertaking the

drill, it would be very much necessary to give adequate training to all staff members and

also information about possible mock drill. After few pre-informed mock drills, few UN-



informed mock drills would be taken. All this is to familiarize the employees with the

concept and procedures and to see their response. These scheduled and unscheduled mock

drills would be conducted during shift change, public holidays, in night shift etc. To

improve preparedness once in 6 months and performance is evaluated and Site Controller

maintains the record. Incident Controller (IC) coordinates this activity.

CONTACT DETAILS

Vadodara (Head Office)

871/B/3, GIDC Makarpura, Vadodara, India – 390 010.

E: [email protected]; T:+91-265-3001000; F: +91-265-3001069

Delhi / NCR

Spaze IT Park, Unit No. 1124, IIth Floor, Tower B3, Sector 49, Near Omaxe City Centre Mall, Sohna Road,

Gurgaon, Haryana, INDIA - 122002.

E: [email protected]; T: +91-124-4242430 to 436; F: +91-124-4242433

Kadam Environmental Consultants w w w . ka d a m en v i r o . c o m

Envi ronment for Deve lopment

mailto:[email protected]

mailto:[email protected]

http://www.kadamenviro.com/

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