risk assessment 1.1 introduction · m/s. delta finochem pvt. ltd., wadivarhe, igatpuri, nashik,...

M/S. Delta Finochem Pvt. Ltd., Wadivarhe, Igatpuri, Nashik, Maharashtra. Risk Assessment

Sadekar Enviro Engineers Pvt. Ltd

Risk Assessment

1.1 Introduction

As indicated in the earlier chapters of EIA the expansion project facilitates to manufacture

API and Intermediate chemicals poses various types of hazards due to storage, handling &

transportation of various chemicals, which are indicated in Chapter no. 2 of EIA report.

In order to study the risks envisaged by the activities, the following methodology was

adopted.

1.1.1 The factory would be manufacturing different products under the category of API &

Intermediate chemicals accounting to a production of 13619.3 MT/A & By-product

generation with rate of 1860 MT/A. However, HAZOP studies have been carried out for

some hazardous operations and process.

1.1.2 A detailed scrutiny of all the raw materials and products was done which would be

stored on the site. The detailed list of raw materials is tabulated below in Table no – 1.

1.1.3 Plot layouts showing locations of tanks, fire hydrant tanks & other safety features are

depicted in the plot layout discussed in the onsite emergency plan.

1.2 MSDSs:

Brief MSDSs of all the above chemicals and other raw materials which would be used in the

manufacturing processes of products are used as reference for preparation of Quantitative risk

assessment & HAZOP study.

1.2.1 A Quantitative Risk Assessment based on the software ALOHA – Arial Locations of

Hazardous Atmospheres was carried out. The criteria failure scenarios considered for

ALOHA depend on the type of storage whether above ground/ underground, physical state of

the chemical stored, chemical properties of the chemical. The summary of the ALOHA

footprints are attached as Annexure 7.1 in EIA report.

Table 1: Details of Raw Materials/Bi products/ Products Stored in Tank

Sr.

no

Name of Raw

Material

Storage

Tank Dimensions of Tank

Maximum

Storage

Quantity at

any given

time as per

CS

Dyke Dimension

1 Methanol 1 ⌀ 1.8 m X 6.35 m

Length 16000 L 34 Sq.m. X 1.0 m

2 Toluene 1 ⌀ 1.8 m X 6.35 m

Length 16000 L 34 Sq.m. X 1.0 m



3

MDC

(Dimethyl

chloride)

1 ⌀ 1.8 m X 6.35 m

Length 16000 L 34 Sq.m. X 1.0 m

4 Iso Propyl

Alcohol 1

⌀ 2.46 m X 4.2 m

height 20000 L

23.5 Sq.m. X 1.0

m

5 Acetone 1 ⌀ 2.40 m X 3.82 m

height 15000 L

20 Sq.m. X 0.85

m

6 Ethyl Acetate 1 ⌀ 2.02 m X 4.0 m

height 12000 L

16.0 Sq.m. X 0.85

m

7 Liquefied

AMMONIA 1

⌀ 2.46 m X 4.2 m

height 20000 L 25 sqm. X 1 m

8 Aq. Ammonia

solution (25% ) 1

⌀ 2.46 m X 4.2 m

height 20000 L 25 sqm. X 1 m

Table No 2: Gases storage details

Sr.

No.

Name of

Raw Material

Number

of

cylinder

Dimensions of

cylinders

Cylinder

pressure

bar

Volume

of gas

in lit

Storage

qty. at

any

given

time

1 Ammonia gas 60 dia.370 mm

Length 1015 mm 7 kg/cm

2 50 lit 60

2 Hydrogen chloride

gas (HCl gas) 24

dia.232 mm

Length 1450 mm

156 Kgf/

cm2

50 lit 24

3 Hydrogen 2

Out side dia. 235

mm

Length 1450 mm

140

kg/cm2

5900 L 2

Table No 3: ALOHA Footprints

Substance Scenario. Effects

considered

LOC Distance,

m

Toluene Spill of entire

chemical

contained in

tank-

evaporating

puddle

Toxic area of

vapor cloud

AEGL-3 3700 ppm 10

AEGL-2 560 ppm 23

AEGL-1 67 ppm 86

Flammable area

of vapor cloud-

non burning

liquid pool

60% LEL 6600 ppm <10

10% LEL 1100 ppm 18

Blast area of

vapour cloud

Destruction

of building

8.0 psi LOC never

exceeded



explosion

Serious

injury likely

3.5 psi <10

Shatter

glass

1.0 psi <10

Burning Puddle

/ Pool Fire

Thermal

radiation from

pool fire-

burning puddle

Red 10 kW/sq.m. <10

Orange 5 kW/sq. m. 15

Yellow 2 kW/sq. m. 25

Leak from hole

in horizontal

cylindrical tank

Heavy Gas AEGL-3 3700 ppm 11

AEGL-2 560 ppm 35

AEGL-1 67 ppm 124

Flammable Area

of Vapor Cloud

60% LEL 6600 ppm <10

10% LEL 1100 ppm 23

Overpressure

(blast force)

from vapor

cloud explosion

Red 8.0 psi LOC was

never

exceeded

Orange 3.5 psi <10

Yellow 1.0 psi 10

Thermal

radiation from

pool fire

Red 10.0 kW/sq.

m.

<10

Orange 5.0 kW/sq.

m.

<10

Yellow 2.0 kW/sq.

m.

<10

BLEVE of

flammable

liquid in

Horizontal

cylindrical tank

Thermal

radiation from

fireball

Red 10.0 kW/sq.

m.

301

Orange 5.0 kW/sq.

m.

425

Yellow 2.0 kW/sq.

m.

664

Methanol

Evaporating

Puddle (Note:

chemical is

flammable)

Toxic area of

vapor cloud

AEGL-3 7200 17

AEGL-2 2100 47

AEGL-1 530 103

Flammable area

of vapour cloud

60% LEL 43080 <10

10% LEL 7180 19

Overpressure

(blast force)

from vapor

cloud explosion

Destruction

of building

8.0 psi No part of

cloud is

above LEL Serious

injury likely

3.5 psi



Shatter

glass

1.0 psi

Burning puddle-

pool fire

Thermal

radiation from

pool fire

Red 10.0 kW/sq.

m.

<10

Orange 5.0 kW/sq.

m.

<10

Yellow 2.0 kW/sq.

m.

<10

Leak from hole

in horizontal

cylindrical tank

Toxic area of

vapour cloud

Red 7200 ppm 19

Orange 2100 ppm 40

Yellow 530 ppm 91

Flammable Area

of Vapor Cloud

Red 43080 ppm

= 60% LEL

<10

Yellow 7180 ppm =

10% LEL

19

Overpressure

(blast force)

from vapor

cloud explosion

No

explosion:

no part of

the cloud is

above the

LEL at any

time

Leak from hole

in horizontal

cylindrical tank-

Flammable

chemical is

burning as it

escapes from

tank

Thermal

radiation from

pool fire

Red 10.0 kW/sq.

m.

<10

Orange 5.0 kW/sq.

m.

<10

Yellow 2.0 kW/sq.

m.

<10

BLEVE of

flammable

liquid in

horizontal

cylindrical tank

Thermal

radiation from

fireball

Red 10.0 kW/sq.

m.

194

Orange 5.0 kW/sq.

m.

280

Yellow 2.0 kW/sq.

m.

442

Acetone Evaporating

Puddle (Note:

chemical is

flammable)

Heavy Gas Red 5700 ppm 96

Orange 3200 ppm 127

Yellow 200 ppm 553



Flammable Area

of Vapor Cloud

Red 15600 ppm 61

Yellow 2600 ppm 141

Overpressure

(blast force)

from vapor

cloud explosion

Red 8.0 psi LOC was

never

exceeded

Orange 3.5 psi 40

Yellow 1.0 psi 67

Burning Puddle

/ Pool Fire

Thermal

radiation from

pool fire

Red 10.0 kW/sq.

m.

28

Orange 5.0 kW/sq.

m.

41

Yellow 2.0 kW/sq.

m.

65

Leak from hole

in vertical

cylindrical tank-

Flammable

chemical

escaping from

tank (not

burning)

Heavy Gas Red 5700 ppm 21

Orange 3200 ppm 29

Yellow 3200 ppm 129

Flammable Area

of Vapor Cloud

Red 15600 ppm 11

Yellow 2600 ppm 32

Overpressure

(blast force)

from vapor

cloud explosion

Destruction

of building

8.0 psi LOC was

never

exceeded

Serious

injury likely

3.5 psi <10

Shatter

glass

1.0 psi 19

Thermal

radiation from

pool fire

potentially

lethal within

60 sec

10.0 kW/sq.

m.

<10 m

2nd degree

burns within

60 sec

5.0 kW/sq.

m.

<10 m

pain within

60 sec

2.0 kW/sq.

m.

<10 m

BLEVE of

flammable

liquid in vertical

cylindrical tank

Thermal

radiation from

fireball

potentially

lethal within

60 sec

10.0 kW/sq.

m.

230

2nd degree

burns within

60 sec

5.0 kW/sq.

m.

329

pain within

60 sec

2.0 kW/sq.

m.

515



Dimethyl

Chloride

Evaporating

Puddle (Note:

chemical is

flammable)

Heavy Gas Red 6900 ppm =

AEGL-3 [60

min]

49

Orange 560 ppm =

AEGL-2 [60

min]

164

Yellow 200 ppm =

AEGL-1 [60

min]

288

Flammable Area

of Vapor Cloud

Red

84000 ppm

= 60% LEL

= Flame

Pockets

18

Yellow

14000 ppm

= 10% LEL

36

Overpressure

(blast force)

from vapor

cloud explosion

Red 8.0 psi LOC was

never

exceeded

Orange 3.5 psi 10

Yellow 1.0 psi 17

Thermal

radiation from

pool fire

potentially

lethal within

60 sec

10.0 kW/sq.

m.

<10

2nd degree

burns within

60 sec

5.0 kW/sq.

m.

<10

pain within

60 sec

2.0 kW/sq.

m.

<10

Leak from hole

in horizontal

cylindrical tank

Flammable

chemical

escaping from

tank (not

burning)


AEGL-3 [60

min]

34

Orange 560 ppm =

AEGL-2 [60

min]

112

Yellow 200 ppm =

AEGL-1 [60

min]

200

Flammable Area

of Vapor Cloud

Red 84000 ppm 11

Yellow 14000 ppm 23

Overpressure

(blast force)

from vapor

Red 8.0 psi LOC was

never

exceeded



cloud explosion Yellow 1.0 psi 16

Thermal

radiation from

pool fire

potentially

lethal within

60 sec

10.0 kW/sq.

m.

<10

2nd degree

burns within

60 sec

5.0 kW/sq.

m.

<10

pain within

60 sec

2.0 kW/sq.

m.

<10

Thermal

radiation from

fireball

potentially

lethal within

60 sec

10.0 kW/sq.

m.

99

2nd degree

burns within

60 sec

5.0 kW/sq.

m.

170

pain within

60 sec

2.0 kW/sq.

m.

285

Iso propyl

alcohol

Evaporating

Puddle (Note:

chemical is

flammable)

Heavy Gas Red 12000 ppm

= PAC-3

<10

Orange 2000 ppm =

PAC-2

19

Yellow 400 ppm =

PAC-1

47

Flammable Area

of Vapor Cloud

Red

12000 ppm

= 60% LEL

= Flame

Pockets

<10

Yellow 2000 ppm =

10% LEL

19

Overpressure

(blast force)

from vapor

cloud explosion

Red 8.0 psi LOC was

never

exceeded

Orange 3.5 psi <10

Yellow 1.0 psi <10

Burning Puddle

/ Pool Fire

Thermal

radiation from

pool fire

potentially

lethal within

60 sec

10.0 kW/sq.

m.

<10

2nd degree

burns within

60 sec

5.0 kW/sq.

m.

10



pain within

60 sec

2.0 kW/sq.

m.

17

Leak from hole

in vertical

cylindrical tank

Flammable

chemical

escaping from

tank (not

burning)


= PAC-1

<10

Orange 2000 ppm =

PAC-2

20

Yellow 400 ppm =

PAC-3

48

Flammable Area

of Vapor Cloud

Red 12000 ppm

= 60% LEL

= Flame

Pockets

<10

Yellow 2000 ppm =

10% LEL =

20

Overpressure

(blast force)

from vapor

cloud explosion

Red 8.0 psi =

destruction

of buildings

LOC was

never

exceeded

Orange 3.5 psi =

serious

injury likely

<10

Yellow 1.0 psi =

shatters

glass

<10

Leak from hole

in vertical

cylindrical tank

Flammable

chemical is

burning as it

escapes from

tank

Thermal

radiation from

pool fire

Red 10.0 kW/(sq

m) =

potentially

lethal within

60 sec

<10

Orange 5.0 kW/(sq

m) = 2nd

degree burns

within 60

sec

<10

Yellow 2.0 kW/(sq

m) = pain

within 60

sec

<10

BLEVE of

flammable

liquid in vertical

Thermal

radiation from

Red 10.0 kW/(sq

m) =

potentially

261



cylindrical tank fireball lethal within

60 sec

Orange 5.0 kW/(sq

m) = 2nd

degree burns

within 60

sec

372

Yellow 2.0 kW/(sq

m) = pain

within 60

sec

582

Ethyl

Acetate

Evaporating

Puddle (Note:

chemical is

flammable)


= PAC-3

11

Orange 1700 ppm =

PAC-2

23

Yellow 1200 ppm =

PAC-1

30

Flammable Area

of Vapor Cloud

Red

13080 ppm

= 60% LEL

= Flame

Pockets

10

Yellow

2180 ppm =

10% LEL

22

Overpressure

(blast force)

from vapor

cloud explosion

Red 8.0 psi =

destruction

of buildings

LOC was

never

exceeded

Orange 3.5 psi =

serious

injury likely

<10

Yellow 1.0 psi =

shatters

glass

14

Thermal

radiation from

pool fire

Red 10.0 kW/(sq

m) =

potentially

lethal within

60 sec

<10

Orange 5.0 kW/(sq

m) = 2nd

degree burns

within 60

sec

<10

Yellow 2.0 kW/(sq

m) = pain

14



within 60

sec

Leak from hole

in vertical

cylindrical tank

Flammable

chemical

escaping from

tank (not

burning)


= AEGL-3

[60 min]

11

Orange 1700 ppm =

AEGL-2 [60

min]

23

Yellow 1200 ppm =

AEGL-1 [60

min]

29

Flammable Area

of Vapor Cloud

Red 13080 ppm

= 60% LEL

= Flame

Pockets

10

Yellow 2180 ppm =

10% LEL

21

Overpressure

(blast force)

from vapor

cloud explosion

Red 8.0 psi =

destruction

of buildings

LOC was

never

exceeded

Orange 3.5 psi =

serious

injury likely

<10

Yellow 1.0 psi =

shatters

glass

14

Leak from hole

in vertical

cylindrical tank

Flammable

chemical is

burning as it

escapes from

tank

Thermal

radiation from

pool fire

Red 10.0 kW/(sq

m) =

potentially

lethal within

60 sec

<10

Orange 5.0 kW/(sq

m) = 2nd

degree burns

within 60

sec

<10

Yellow 2.0 kW/(sq

m) = pain

within 60

sec

<10

BLEVE of

flammable

liquid in vertical

cylindrical tank

Thermal

radiation from

fireball

Red 10.0 kW/(sq

m) =

potentially

lethal within

60 sec

201



Orange 5.0 kW/(sq

m) = 2nd

degree burns

within 60

sec

288

Yellow 2.0 kW/(sq

m) = pain

within 60

sec

454

Aqueous

ammonia

solution

(25%)

Evaporating

Puddle (Note:

chemical is

flammable)


AEGL-3 [60

min])

286

Orange (160 ppm =

AEGL-2 [60

min])

815

Yellow 30 ppm =

AEGL-1 [60

min])

2.1

Flammable Area

of Vapor Cloud

Red 90000 ppm

= 60% LEL

= Flame

Pockets

19

Yellow 15000 ppm

= 10% LEL

79

Overpressure

(blast force)

from vapor

cloud explosion

Red 8.0 psi =

destruction

of buildings

LOC was

never

exceeded

Orange 3.5 psi =

serious

injury likely

LOC was

never

exceeded

Yellow 1.0 psi =

shatters

glass

14

Ammonia

gas

Direct Source-

Entire gas is

leaked at once


AEGL-3 [60

min]

1.8 km

Orange 160 ppm =

AEGL-2 [60

min

4.0 km

Yellow 30 ppm =

AEGL-1 [60

min])

8.0 km

Flammable Area

of Vapor Cloud

Red 90000 ppm

= 60% LEL

= Flame

448



Pockets

Yellow 15000 ppm

= 10% LEL

860

Overpressure

(blast force)

from vapor

cloud explosion

Red 8.0 psi =

destruction

of buildings

LOC was

never

exceeded

Orange 3.5 psi =

serious

injury likely

LOC was

never

exceeded

Yellow 1.0 psi =

shatters

glass

383

Leak from hole

in vertical

cylindrical tank

Flammable

chemical

escaping from

tank (not

burning)

Overpressure

(blast force)

from vapor

cloud explosion

No

explosion:

no part of

the cloud is

above the

LEL at any

time

Leak from hole

in vertical

cylindrical tank

Flammable

chemical is

burning as it

escapes from

tank

Thermal

radiation from

jet fire

Red 10.0 kW/(sq

m) =

potentially

lethal within

60 sec

<10

Orange 5.0 kW/(sq

m) = 2nd

degree burns

within 60

sec

<10

Yellow 2.0 kW/(sq

m) = pain

within 60

sec

<10

Hydrogen

chloride gas

Leak from hole

in vertical

cylindrical tank

Non-flammable

chemical is

escaping from

tank

Heavy Gas

Red 100 ppm =

AEGL-3 [60

min]

22

Orange 22 ppm =

AEGL-2 [60

min]

48

Yellow 1.8 ppm =

AEGL-1 [60

min]

160



Release of

entire gas

instantaneously


AEGL-3 [60

min]

1.7 km

Orange 22 ppm =

AEGL-2 [60

min]

3.0 km

Yellow 1.8 ppm =

AEGL-1 [60

min]

8.1 km

Hydrogen

Gas

Direct Source Toxic area of

vapor cloud

Red 400000 ppm

= PAC-3

133

Orange 230000 ppm

= PAC-2

166

Flammable Area

of Vapor Cloud.

Chemical is not

burning

Red 24000 ppm

= 60% LEL

= Flame

Pockets

489

Yellow 4000 ppm =

10% LEL

941

Overpressure

(blast force)

from vapor

cloud explosion

Red 8.0 psi =

destruction

of buildings

414

Orange 3.5 psi =

serious

injury likely

419

Yellow 1.0 psi =

shatters

glass

465

Leak from hole

in vertical

cylindrical tank

Flammable

chemical

escaping from

tank (not

burning)

Overpressure

(blast force)

from vapor

cloud explosion

Red 8.0 psi =

destruction

of buildings

200

Orange 3.5 psi =

serious

injury likely

221

Yellow 1.0 psi =

shatters

glass

309

Leak from hole

in vertical

cylindrical tank

Flammable

Thermal

radiation from

jet fire

Red 10.0 kW/(sq

m) =

potentially

lethal within

60 sec

<10



chemical is

burning as it

escapes from

tank

Orange 5.0 kW/(sq

m) = 2nd

degree burns

within 60

sec

<10

Yellow 2.0 kW/(sq

m) = pain

within 60

sec

14

Interpretation:

Based on the unsafe distances identified by

the software output, the MCLS (maximum

credible loss scenario) for the factory works

out to about 8100 meter for entire release of

hydrogen chloride gas with 1.8 ppm

concentration in the atmosphere.

The scenario considered for assessing the

impact by quantitative risk assessment was

taken from CPR18 E.

The probability of occurrence of the scenario

is 5 × 10-6

y-1

, which is very less. The Disaster

management plan highlights the suggestive

measures to be taken during the occurrence of

such an accident.

Table No. 4: Interpretation Table

Threat

zone

Toxic Level of Concern Receptors Effects

Red -

1700

meters

AEGL-3 - 100 ppm

susceptible individuals,

could experience life-

threatening health effects or

death.

Workers working near

in the premises, people

residing and working

surrounding the plant

and agricultural area

and biotic

environment towards

west

Environmental Effects

:-

This can cause life

threatening effects on

aquatic plant and

animal life. The acidic

fumes are corrosive in

nature and can cause



Orange-

3000

meters

AEGL-2 - 22 ppm

Susceptible individuals

could experience

irreversible or other

serious, long-lasting

adverse health effects or an

impaired ability to escape.

Surrounding biotic

environment towards

west of the company.

Traffic on Murambi-

Avarli road

damage to metallic

structures and buildings

etc.

The soil may become

acidic in nature after

deposition of

hydrochloric acid and

can facilitate soil

erosion.

Human Effects:-

Hydrochloric acid is

corrosive to the eyes,

skin, and mucous

membranes. Acute

inhalation exposure

may cause coughing,

hoarseness,

inflammation and

ulceration of the

respiratory tract, chest

pain, and pulmonary

edema in humans.

Chronic occupational

exposure to

hydrochloric acid has

been reported to

cause gastritis,

chronic bronchitis,

dermatitis, and

photosensitization in

workers. Prolonged

exposure to low

concentrations may

also cause dental

discoloration and

erosion

Presently No

information is

available on the

carcinogenic effects

of hydrochloric acid

in humans.

Yellow -

8100 m

AEGL-1 – 1.8 ppm

Susceptible individuals

could experience notable

discomfort, irritation, or

certain asymptomatic

nonsensory effects.

However, the effects are

not disabling and are

transient and reversible

upon cessation of exposure.

Major receptors are

people in Murambi

and Modale village,

and surrounding flora

and fauna

However to further reduce the occurrence of such accidents, following precautions would be

taken by M/s Delta Finochem Pvt. Ltd.



Recommendations suggested for HCL and other Corrosive Liquid storage tanks and

cylinders:

i) HCl storage tank breather valve is connected to scrubber to control HCl vapors in

atmosphere.

ii) Dedicated storage area is provided.

iii) HCl storage tank is covered with acid proof tiles, the dyke is coated with acid/alkali

proof paint and the flooring is also covered with acid/alkali proof tiles.

iv) Store away from the combustible materials.

v) Appropriate PPEs to be used during handling of solutions / chemicals.

vi) Keep containers in tightly closed and in cool, dry and well ventilated area.

vii) Keep in proper storage cabinets and shelving. Use lowest shelve possibly.

viii) Assure all bottles are properly labeled.

ix) Proper precautions to be taken during chemical preparation.

x) Wearing PPEs, Laboratory work surface should be cleaned at the end of each working

day.

xi) Dispose off contaminated material in accordance with hazardous waste disposal

guidelines.

xii) Decontaminate all the equipment before removing from designated area.

Recommendations for Flammable Liquids Storage:

i) Dedicated storage area to be provided.

ii) Keep containers tightly closed/sealed until ready for use.

iii) Keep containers in cooled and ventilated area.

iv) Avoid all possible source of ignition.

v) Keep away from heat and their sources.

vi) Use suitable PPE during handling of chemicals.

vii) Storage area should be away from incompatibilities such as oxidizing agents,

metals & acid.

viii) Avoid direct contact with body.

ix) Chemical spill kit to be maintained to avoid possible effects from spillage.

x) Chemical transfer line should be periodically inspected and well maintained to

avoid possibility for leakage of chemical.

xi) Periodic inspection of dykes to be done.



1.3 DOW Fire and Explosion Index

The DOW index is performed for all flammable chemicals which is to be stored in raw

material storage building for proposed expansion activity. Details of DOW index is given in

table below, The DOW summary sheet is displayed below in table no. 5. The DOW index

worksheet is attached in Annexure 7.2 in EIA report.



Table No. 5: List of hazardous chemicals and its respective DOW F & E Index

Chemical Storage

Considered N h N f N r

Material

Factor,

MF

F1

(General

Process

Hazard)

F2

(Special

Process

Hazard)

F3

(Hazard

Factor)

Fire &

Explosion

Index

Degree

of

Hazard

Tributyl bromide Drums 2 3 0 16 2.55 1.66 4.233 67.72 Moderate

Acetonitril Drums 2 3 0 16 2.55 1.66 4.233 67.72 Moderate

N Butyl bromide Drums 2 3 0 16 2.55 1.72 2.38 63.64 Moderate

Butanol Drums 1 3 0 16 2.55 1.46 3.73 59.6 Light

Carbon Bags 1 3 0 16 2.3 1.71 3.93 62.9 Light

Ethyl

Chloroformate Drums 4 3 1 16 2.55 2.06 5.25 84.04 Moderate

Ethanol Drums 2 3 0 16 2.55 1.66 4.23 67.7 Moderate

Methyl isobutyl

ketone Drums 2 3 1 16 2.55 1.66 4.233 67.72 Moderate

Pentanol Carboy 1 3 0 16 2.55 1.46 3.72 59.56 Light

Tetrahydrofuran Drums 2 3 1 16 2.55 1.66 4.23 67.72 Moderate

Triethyl amine Drums 3 3 0 16 2.55 1.88 4.79 76.8 Moderate

FO Tank 1 2 0 10 1.95 1.9 3.705 37.05 Light



Storage recommendation for CCOE Area (PESO controlled area)

The Petroleum and Explosive Safety Organization standards are followed for storage of solvents/

flammable chemicals.

1. Earthing is provided to the storage area for dealing with the static charges that might generate

during the loading and unloading of the solvents.

2. Provision of sand buckets, foam monitor, fire extinguishers & hydrant line near PESO area

were made available.

3. Appropriate drainage with the slope of 2 % is provided to remove small and large spillage of

the chemicals.

4. Provision of spill kit is provided to deal with the minor spillage scenario.

5. Permission of Joint Chief Controller (explosives), West circle is obtained

6. Petroleum storage is constructed of non combustible materials. Non-bulk storage of ‘class A’

petroleum is done in the separated building which complies license conditions.

7. The secondary containment is provided and is kept clean and free from any accumulation of

inflammable liquids.

8. The storage shed is ventilated near the ground level and also near the roof. The ventilators

are covered with two layers of fine copper or non corrodible metal wire gauge of mesh not

less than 11 meshes per linear cm.

9. No alterations are carried out without written permission of licensed authority.

10. The safety distance of 7.5 m is kept from the shed.

11. All the empty receptacles are kept securely closed unless they have been thoroughly cleaned.

12. The suitable extinguishers (DCP) are kept immediately outside the storage shed.

13. Access of un-authorized person to petroleum receptacles is restricted.

14. Daily inventory of petroleum is maintained.

Recommendation/Suggestions for non-PESO area

1. The raw materials are stored according to their compatibility with other raw materials.

2. Company has adequate written operating instruction and fully documented operating

discipline for emergency shutdown, normal operating conditions, routine shutdown etc. which

are important for maintaining satisfactory control of a unit.

3. The raw materials are stored in a dedicated area with minimum interference.



4. The provision of fire water supply is provided through the hydrant line passing from the raw

material storage area.

5. Provision of hand Extinguishers are provided and found to be adequate with reference to the

storage quantity of raw materials.

1.4 Toxicity (Mond’s) Index

Introduction

The principle and general approach used in the DOW method of hazard evaluation have been

further developed by ICI Mond Division, the revised Mond Fire, Explosive and Toxicity index is

a series of papers by Lewis (1979). The main developments made to the DOW Index in the

Mond Index are:

1. It covers a wider range of process and storage installation

2. It covers the processing of chemicals with explosive properties

3. A calculation procedure is included to allow for the off-setting effects of good design and

control and safety instrumentation

4. The procedure has been extended to cover plant layout

5. Separate indices are calculated to access the hazards of fire, internal explosion and aerial

explosion.

Some of the raw materials stored in the site are toxic in nature. Hence appropriate standard

operating procedures are established by the company for ensuring the safety of the workers

handling the raw materials on daily basis. Some selected toxic raw materials are used for

calculating the toxicity index using Mond's index. The Mond's index worksheet is attached as

Annexure 7.3 in EIA report.



Table No. 6: Monds Toxicity index of toxic chemicals

Sr. No. Raw Materials Storage

Quantity

No. of

Drums/Tanks/bags

Nh Exposure limit,

ppm

1 Ammonia gas 20 Kl 1 above ground

tank

4 20

2 Liquor ammonia 20 Kl 2 above ground

tanks

4 30

3 Sulphuric Acid 4 MT 67 3 0.25 ppm

4 Nitric acid 4 MT 89 3 15

5 Phosphoric acid 3 MT 11 3 2

6 Acetic acid 2 MT 58 3 10 ppm

7 Phosphorous Oxychloride

3 MT 60 3 0.2

8 Phosphorous

trichloride

3 MT 176 3 0.5

9 Piperazine 3 MT 60 4 5 mg/m3

10 Hydrochloric acid 2 MT 50 3 2 ppm

11 Thioglycolic Acid 3 MT 75 3 2

12 Thionyl chloride 3 MT 11 4 4.9

13 Thiourea 4 MT 15 3 --

14 Tripropyl amine 3 MT 19 3 6.4

15 Triethyl amine 3 MT 20 3 1

16 Formaldehyde 2 MT 40 3 0.3

17 Chloroform 2 MT 7 4 0.5



Table no. 7: Calculated Mond’s Index and degree of Hazard for Hazardous chemicals.

Chemicals Storage

Nh (NFPA

Index

Number)

Th

(Toxicity

factor)

Ts

(Correction

factor)

F1

General

Process

Hazard

F2

Special

Process

Hazard

Toxicity

Index

Degree of

Hazard

Ammonia gas Tank

4 325 125 2.55 2.0 10.18 High

Liquor ammonia Tank

4 325 125 2.55 1.8 9.93 High

Sulphuric Acid Drum

3 250 125 2.55 1.7 9.06 Moderate

Nitric acid Drum 3 250 125 2.55 1.7 9.06 Moderate

Phosphoric acid Drum 3 250 125 2.55 1.7 9.06 Moderate

Acetic acid Drum 3 250 125 2.55 1.86 9.26

Moderate

Phosphorous Oxychloride Drum 3 250 125 2.55 1.6 8.93

Moderate

Phosphorous trichloride Drum 3 250 125 2.55 1.6 8.93 Moderate

Piperazine Bags 4 325 125 2.55 2 10.18 High

Hydrochloric acid Drum 3 250 125 2.55 1.7 9.06

Moderate

Thioglycolic Acid Drum 3 250 125 2.55 1.6 8.93

Moderate



Thionyl chloride Drum 4 325 125 2.55 1.8 9.93 High

Thiourea Bags 3 250 125 2.55 1.6 8.93

Moderate

Tripropyl amine Drum 3 250 75 2.55 1.6 6.36

Moderate

Triethyl amine Drum 3 250 125 2.55 1.76 9.13

Moderate

Formaldehyde Drum 3 250 125 2.55 1.6 8.93

Moderate

Chloroform Drum 4 325 125 2.55 1.8 9.93 High



Toxicity (Mond) Index recommendations:

1. The raw materials are stored according to their compatibility.

2. Toxic materials are stored in cool place and kept away from heat.

3. Toxic material can cause breathing difficulty therefore storage area is well ventilated.

4. Good housekeeping practice is implemented in storage area.

5. Appropriate drainage with the slope of 2 % is provided to remove small and large spillage of

the chemicals.

6. The provision of fire water supply is provided through the hydrant line passing from the raw

material storage area

7. PPE’s are used wherever necessary.

8. MSDS recommendations are strictly followed while chemical storage and handling.

Recommendations for ‘High’ Mond Index chemical storage:

1. The chemicals are isolated from another chemical in well-ventilated area and hazard

warning information is shown.

2. SOP is prepared for handling such chemicals and it should be strictly followed.

3. Spill kit is provided for storage to limit the spill of materials. Suitable Absorbent like

sodium bi carbonate is used to absorb the spill.

4. Proper training is provided to workers prior to handling and transporting chemicals.

5. PPE’s like face shield, goggles, apron, gloves, gumboots are used while handling the

chemicals to avoid exposure to chemicals.

risk assessment 1.1 introduction · m/s. delta finochem pvt. ltd., wadivarhe, igatpuri, nashik,...

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