suven life sciences ltd. environmental impact assessment...

Suven Life Sciences Ltd. Environmental Impact Assessment Report

6-1 Team Labs and Consultants

6.0 RISK ASSESSMENT AND DAMAGE CONTROL 6.0 Introduction

This chapter presents the risk assessment study results for the plant operations, transport

and storage of raw materials, and identifies maximum credible accident scenarios to draw

the emergency management plan addressing various credible scenarios identified.

6.1. Objectives and Scope

The production of Synthetic Organic chemicals (bulk drug and intermediates) involves

usage of many chemicals which are both hazardous and toxic in nature. The risks

associated with the chemical industry are commensurate with their rapid growth and

development. Apart from their utility, chemicals have their own inherent properties and

hazards. Some of them can be flammable, explosive, toxic or corrosive etc. The whole

lifecycle of a chemical should be considered when assessing its dangers and benefits. In

order to ensure the health and safety of persons at or near the facilities, Govt. has

approved some regulations. The regulation requires Employers to consult with employees

in relation to:

- Identification of major hazards and potential major accidents

- Risk assessment

- Adoption of control measures

- Establishment and implementation of a safety management system

- Development of the safety report

The involvement of the employees in identification of hazards and control measures

enhances their awareness of these issues and is critical to the achievement of safe

operation in practice. In order to comply with regulatory authorities, M/s Suven Life

Sciences Ltd., have entrusted Team Labs and Consultants, Hyderabad to review and

prepare Hazard analysis and Risk assessment for their facility along with an approach to

on-site emergency preparedness plan as required under the acts and rules. (Manual on

emergency preparedness for chemical hazards, MOEF, New Delhi). In this endeavor, the

methodology adopted is based on;



• visualizing various probable undesirable events which lead to major accidents

• detailed and systematic assessment of the risk associated with each of those

hazards, including the likelihood and consequences of each potential major accident

event; and

• identifying the technical and other control measures that are necessary to reduce

that risk to a level that is as low as reasonably practicable

The strategy to tackle such emergencies, in-depth planning and person(s) or positional

responsibilities of employees for implementation and coordination of timely and effective

response measures are described in onsite detail in Emergency Plan.

6.2 Project Details

The project site is located at Sy No. 99, 101-109, Dasaigudem Village, Suryapet Mandal,

Nalgonda district, Telangana. The site is situated at the intersection of 170 07’ 07” (N)

latitude and 790 38’ 50” (E) longitude. The site elevation above mean sea level (MSL) is 182

m. The plant is surrounded by National Highway No. 9 in north, Musi Canal in south,

Tanda road in east and open land in west direction. The nearest human settlement from

the site is Durajpalli located at distance of 1 km from the site in east direction. The main

approach road is NH-9 is at a distance of 0.35 km in north direction. The nearest railway

station is Miryalaguda at a distance of 31 km in SW direction and the nearest airport is

Shmshabad located at a distance of 128 km in West direction. Musi River is flowing from

NW to SW direction and passing the study area at a distance of 6.8 km in southwest

direction. There are no national parks, sanctuaries and ecologically sensitive areas within

the impact area of 10 km radius. There is one reserve forest in the study area. Indergonda

RF is at a distance of 5 km in southeast direction. The total site area of the project is 70

acres. The manufacturing capacities of the proposed bulk drug and intermediates after

expansion and by-products are presented in Table 6.1 and Table 6.2 Chemical inventory is

presented in Table 6.3



Table 6.1 Proposed Manufacturing Capacity – After Expansion S.No Name of the Product Capacity

Kg/Day TPM 1 Methyl-2-(Chloromethyl Phenyl)-3-Methoxy-2-Acrilate (MCPMA) 2168 65 2 5-Cyano pthalide 336 10 3 4-hydroxy-5-methyl pyrrolo[2,1-f][1,2,4]triazine-6-carboxylic acid ethyl

ester (PTZN) 81 2

4 Gabapentine 96 3 5 Divalproex Sodium 300 9 6 Azacytocine 112 3 7 4,6-dichloro pyrimidine (4,6- DCPY) 227 7 8 Adenine 132 4 9 1-{[5-methyl-3-(trifluoromethyl)-1H-pyrazol-1-yl]acetyl}piperiidne-4-

carbothiomide (MPC) 787 24

10 Losartan potassium (LP) 150 5 11 Theobromine (TBN) 243 7 12 Malonic acid 324 10 13 Cyanoacetamide 380 11 14 Barbituric Acid (BBA) 500 15 15 Imatanib 299 9 16 5-Fluoro-4,6-Dichloro pyrimidine (5-Fluro-4,6-DCPY) 303 9 17 1,2,3-Trizole 472 14 18 Chloro Ethoxy Ethyl Acetate (CEEA) 521 16 19 Entacapone 100 3 20 Calcium Acetate 180 5 21 Carprofen 71 2 22 Tetra hydro ribo furanose 83 2 23 2,4-Dichloro-5-methyl pyrimidine (2,4-DCMPY) 330 10 24 Piperinyl alcohol 208 6 25 2-Chloro-4-Methyl pyrimidine (CMP) 522 16 26 Chloro ethyliodo pyrimidine 248 7 27 Cyano Acetic Acid (CAA) 1144 34 28 Lamotrigen 188 6 29 Methyl Cyanoaceate (MCA) 1136 34 30 Ethyl Cyanoaceate (ECA) 2600 78 31 Tomsulosin 30 1 32 Homoveratryl Amine (HVA) 167 5 33 D-Mannose 410 12 34 Verapamil HCl 182 5 35 Nitazozoxanide 250 8 36 Zolmitripton 100 3 37 2-methyl pyrolidine carboxilic acid 133 4 38 Hydroxy tetrahydrofuran 213 6 39 2,5-diamino 4,6-dichloro pyrimidine (DADCP) 332 10 40 1-Tert-butoxy carbonyl amino cyclobutane carboxylic acid (BCAC) 280 8 41 Benzhydrol Thioacetamide (BTA) 285 9



42 Benzoin 356 11 43 2-n-Butyl-4-formyl-5-chloro imidazole (BCFI) 297 9 44 Fenoprofen Calcium dihydrate 110 3 45 Capacitabine 170 5 46 Chloro propyl amino pyrazole 99 3 47 Fluoro Phenyl Methanone 229 7 48 3,5-Diacetoxy acetophenone (DAAP) 521 16 49 1-Bromo -2-iodo benzene (BIB) 474 14 50 L-Xylose 274 8 51 5-Bromo-2-iodo pyrimidine 176 5 52 8-chloro theophylline 259 8 53 S- Indoline-2-carboxilic acid 210 6 54 2,4-Dichloro-5-Nitro pyrimidine (DCNPY) 116 3 55 Dimethyl thiophenol 311 9 56 2-Amino-5-Chloro Benzoic acid (ACB acid) 267 8 57 Methyl-Napthalene-1-Methyl-amine Hydro chloride (NAP) 382 11 58 3-Hydroxy- N-benzyl pyrrolidine (BHP) 200 6 59 Valsartan 86 3 60 Carbonyl amino cyclo butiric acid 228 7 61 Metane sulfonyl-L-lucyne 202 6 62 2,4-Diamino-6-hydroxy pyrimidine (DAHP) 247 7 63 5-Chlorothiophene-2-carboxylic acid (5-CTA) 396 12 64 3,5-Dibenzoyl tartaric acid (DBTA) 436 13 65 Pamabromo 332 10 66 2-chloro-5-iodo benzoic acid 492 15 67 Tetra hydro isoquinoline (THIQ) 153 5 68 2,4-Dichloropyrimidine (2,4-DCPY) 345 10 69 Doxofylline 365 11 70 Dimethyl dithiophosphoric 71 2 71 Aripiprazole 143 4 72 Phentramine hydrochloride 200 6 73 D-Penicillamine 80 2 74 dimethyl phenyl isothiocyanate 216 6 75 2-Chlorothioxanthene-9-one (2-CTX) 367 11 76 2,6-dichloro-4,8-dipiperdine-1-yl-pirimido5,4d)pyrimidine (DDH) 250 7 77 Homoveratryl Amine (HOVA) 428 13 78 Thiozole-5-carboxaldehyde 182 5 79 2,5-Dimethylamino-2-phenyl Butan-1-Ol (RC-105) 267 8 80 Amino Dimaleate (ADM) 418 13 81 2,4,5-Trichloro pyrimidine (TCPY) 198 6 82 4,4-Nitro phenyl-3-marpholine(NPMP) 116 3 Worst case- 6 Products on campaign basis 8356 251



Table 6.2 List of By-Products – After Expansion S.No Name of Product Stage Name of By-Product Capacity

Kg/day TPM 1 Methyl-2-(Chloromethyl Phenyl)-

3-Methoxy-2-Acrilate IV Sodium Sulfate 1467.9 44.0 V Sodium hydrogen Sulfate 810.2 24.3 VI Potassium chloride 671.5 20.1

2 5-Cyano Phthalide IV Sodium Sulfate 313.9 9.4 3 4-hydroxy-5-methyl pyrrolo[2,1-

f][1,2,4]triazine-6-carboxylic acid ethyl ester (PTZN)

I Methylamine hydrochloride 43.9 1.3

4 Gabapentine II Ammonium Sulfate 228.8 6.9 5 4,6-Dichloro pyrimidine crude I Formic acid 81.0 2.4

II Phosphoric acid 301.8 9.1 6 1-{[5-methyl-3-(trifluoromethyl)-

1H-pyrazol-1-yl]acetyl}piperiidne-4-carbothiomide (MPC)

I Sodium Sulfate 415.5 12.5

7 Losartan potassium III 5,5 Dimethyl hydantoin 26.5 0.8 8 Theobromine IV Sodium bromide 154.2 4.6 9 4,6-Dichloro-5-fluoro pyrimidine

crude I Formic acid 92.8 2.8 II Phosphoric acid 359.2 10.8

10 Entacapone Aluminium hydroxide 28.8 0.9 11 Carprofen I Acetic acid 30.7 0.9

III Boric acid 5.9 0.2 V Sodium acetate 25.3 0.8

12 2-Chloro-4-Methyl pyrimidine I Sodium Sulfate 337.3 10.1 13 Lamotrigine II Sodium phosphate 39.6 1.2 14 Tamsulosin Hydrochloride III Potassium chloride 4.5 0.1

IV Sodium Sulfate 18.5 0.6 V Potassium bromide 12.9 0.4

VII Sodium Bromide 8.2 0.2 15 Verapamil Hydrochloride (Pure) III Sodium bromide 38.7 1.2 16 Zolmitriptan I Sodium Sulfate 164.4 4.9 17 2-methyl pyrolidine carboxilic

acid I Lithium iodide 167.4 5.0

18 3-Hydroxy tetra hydrofuran II Boric acid 314.0 9.4 Sodium Sulfate 761.6 22.8

19 Benzhydral Thioacetamide II Sodium bromide 79.5 2.4 20 2-Butyl-4-formyl-5-chloro

imidazole II Ammonium phosphate 236.8 7.1

21 Fenoprofen Calcium Dihydrate IV Potassium Sulfate 80.3 2.4 Manganese dioxide 80.1 2.4

22 Capacitabine I Pyridine Hydrochloride 66.0 2.0 II Sodium acetate 85.2 2.6

23 Chloro propyl amino pyrazole II Lithium chloride 37.4 1.1 24 5-Bromo-2-Iodo benzene I Sodium Sulfate 279.6 8.4 25 2,4-Dichloro-5 nitro II Phosphoric acid 230.0 6.9



pyrimidine(DCNPY) 26 Dimethyl thiophene II Zinc chloride 306.4 9.2 27 N-Methyl napthalene

methylmamine II Monomethyl amine HCl 148.0 4.4

28 3-Hydroxy- N-benzyl pyrrolidine

II Boric acid 137.0 4.1

29 Valsartan II Triethyl amine HBr 55.1 1.7 III Triethyl amine HCl 33.8 1.0 IV Succinic acid 59.6 1.8

30 Methane Sulfonyl L-leucyne I Potassium Sulfate 47.8 1.4 III Boric acid 28.0 0.8

31 2,4-Diamino-6-hydroxy pyrimidine

I Sodium nitrate 166.3 5.0

32 Pamabrom I Sodium bromide 103.4 3.1 33 2-chloro-5-iodo benzoic acid II Potassium acetate 192.0 5.8 34 Tetra Hydro Isoquinoline III Hydrobromic acid 83.2 2.5 35 2,4-Dichloropyrimidine I Phophoric acid 453.8 13.6 36 Dimethyl phenyl isothiocyanate I Sodium Sulfate 123.2 3.7 37 2-Chlorothioxanthene-9-one III Sulfuric acid 145.6 4.4 38 2,6-dichloro-4,8-dipiperdine-1-yl-

pirimido5,4d)pyrimidine (DDH) I Spent Sulfuric acid 400.0 12.0

IV Phosphoric acid 145.3 4.4 39 Thiozole 5 Carboxyaldehyde I Acetic acid 72.8 2.2

III Phosphoric acid 192.4 5.8 IV Hydrobromic acid 71.6 2.1

40 2,5-Dimethylamino-2-phenyl Butan-1-Ol (RC105)

III Methyl sodium Sulfate 195.3 5.9 IV Aluminium chloride 184.6 5.5

41 2,4,5-Trichloro pyrimidine (TCPY)

II Phosphoric acid 213.7 6.41



Table 6.3 List of Raw Materials and Inventory (Terms of Reference No. 18) S.No Name of Raw Material Max Storage

Quantity (Kgs) Physical

State Mode of Storage

Type of Hazard

Mode of Transport

1 (2-Chloroethoxy) Acetic Acid 470 Liquid Drums Irritant By Road 2 (2R)-2-Trichloro methyl Oxazolidine -5-one 375 Liquid Drums Flammable By Road 3 1-(3-Dimethylaminopropyl)-3-ethylcarbodiimide

HCl 132 Solid Bags Irritant By Road

4 1,1,3,3-Tetra methoxy propane 150 Liquid Drums Flammable By Road 5 1-(2,3-Dichlorophenyl) Piperazine Hydrochloride 130 Solid Bags Irritant By Road 6 1,3-dibromo dimethyl hydantoin 210 Powder Bags Flammable By Road 7 1,3-dibromo propane 350 Liquid Drums Irritant By Road 8 1,4-Dichlorobutane 75 Liquid Drums Flammable By Road 9 1-Amino cyclobutane carboxylic acid HCl 170 Solid Bags Irritant By Road 10 1,4-Dioxane 200 Liquid Drums Flammable By Road 11 2,2-chloromethyl-phenyl(-3-methoxy-Acrylol-

Chloride) 2380 Solid Bags Corrosive By Road

12 2,2,6,6,-Tetramethyl piperidine -1 -Oxyl (TEMPO) 10 Liquid Drums Flammable By Road 13 2- Amino-5-chloro-2-fluorobenzophenone 285 Powder Bags Irritant By Road 14 2,2-Dipropyl Malonic Acid 420 Liquid Drums Irritant By Road 15 2,3 Dichloro benzoyl cyanide 200 Solid Bags Irritant By Road 16 2,3-Di-O-acetyl-5-deoxy-5-fluoro-N-4-(Pentyloxy

Carbonyl) Cytidine 225 Liquid Drums Corrosive By Road

17 2-Amino-5-nitro thiazole 145 Solid Bags Irritant By Road 18 2-Amino-2-methyl-1-propanol 90 Liquid Drums Irritant By Road 19 2,6-Dimethyl aniline 210 Liquid Drums Irritant By Road 20 2-anilino ethanol 100 Solid Bags Irritant By Road 21 2-Chloro Acetamide 120 Crystalline HDPE Bags Toxic By Road 22 2-Bromo aniline 380 Solid HDPE Bags Toxic By Road 23 2-Bromo malonaldehyde 149 Solid Bags Irritant By Road 24 2-Chloro-5-Iodo benzoic acid 200 Solid HDPE Bags Toxic By Road 25 2-chlorothiophene 315 Liquid Drums Flammable By Road 26 2-Chlorobenzonitrile 240 Crystalline Bags Irritant By Road



27 2n-Butyl-4-Chloro-5-formyl imidazole 190 Solid Bags Irritant By Road 28 2-Cyano-N,N-diethyl acetamide 65 Liquid Drums Non hazard By Road 29 2-keto gulonic acid 415 Liquid Drums Irritant By Road 30 4-(Dimethylamino) Pyridine 2 Solid Bags Irritant By Road 31 3-oxopentanoic acid methyl ester 125 Liquid Drums Flammable By Road 32 3,5-Dihydroxy acetophenone 400 Solid Bags Irritant By Road 33 3-methyl phenyl acetonitrile 205 Liquid Drums Irritant By Road 34 4-Amino-L-Phenyl Oxazolidinone 100 Liquid Drums Corrosive By Road 35 4-Chlorothiophenol 255 Liquid Drums Corrosive By Road 36 4-Hydroxy benzoic acid 200 Solid Bags Irritant By Road 37 4-Cyano pyridine 310 Crystalline Bags Irritant By Road 38 5-Carboxy Phthalide 420 Solid Bags Irritant By Road 39 5-Cyanopthalide 352 Solid Bags Irritant By Road 40 4-Nitrobenzoyl chloride 102 Crystalline Bags Corrosive By Road 41 5-Acetonyl-2-methoxy benzene sulfonamide 25 Solid Bags Toxic By Road 42 7-Sodiumoxy-3,4-Dihydro-1H-quinolin-2-one 110 Solid Bags Toxic By Road 43 Acetic acid 4300 Liquid Drums Flammable By Road 44 Acetic anhydride 1350 Liquid Drums Irritant By Road 45 Acetone 15000 Liquid Storage

tanks Flammable By Road

46 Acetonitrile 2220 Liquid Drums Flammable By Road 47 Acetyl chloride 260 Liquid Drums Flammable By Road 48 Activated Carbon 1850 Solid Bags Non Hazard By Road 49 Alluminium Chloride 500 Powder HDPE Bags Carcinogenic By Road 50 Aminoguanidine bicarbonate 135 Powder Bags Irritant By Road 51 Ammonia 400 Gas Cylinders Toxic By Road 52 Ammonium chloride 200 Powder Bags Irritant By Road 53 Ammonium Hydroxide 1030 Liquid Drums Toxic By Road 54 Ammonium thiocyanate 130 Powder Bags Irritant By Road 55 Aniline 150 Liquid Drums Toxic By Road 56 Aqueous ethanol 2700 Liquid Drums Flammable By Road 57 Azobis Butyronitrile 10 Crystalline Bags Flammable By Road



58 Benzahydrol 235 Solid HDPE Bags Toxic By Road 59 Benzaldehyde 450 Liquid Drums Irritant By Road 60 Benzoyl chloride 1145 liquid Drums Irritant By Road 61 BOC anhydride 570 Liquid Drums Flammable By Road 62 Benzylamine 160 Liquid Drums Corrosive By Road 63 Bromine 540 Liquid Drums Toxic By Road 64 Bromobenzene 120 Liquid Drums Flammable By Road 65 Bromochloropropane 70 Liquid Drums Flammable By Road 66 Chloro acetaldehyde di methyl acetol (CADMA) 150 Liquid Drums Irritant By Road 67 Calcium Acetate 200 Solid Bags Irritant By Road 68 Calcium hydroxide 120 Solid Bags Irritant By Road 69 Calciumoxide 125 Powder Bags Corrosive By Road 70 Carbazole 100 Powder HDPE Bags Carcinogenic By Road 71 Carbon tetra chloride 215 Liquid Drums Toxic By Road 72 Celite 10 powder Bags Irritant By Road 73 Chlorine 2270 Gas Cylinders Irritant By Road 74 Chloro acetaldehyde dimethyl acetal 350 Liquid Drums Flammable By Road 75 Chloroacetyl chloride 390 Liquid Drums Toxic By Road 76 Chloro ethoxy ehanol 430 Liquid Drums Corrosive By Road 77 Chloroform 3000 Liquid Drums Irritant By Road 78 chlorosulfonic acid 290 Liquid Drums Corrosive By Road 79 Copper powder 25 Solid Bags Flammable By Road 80 Cuprous chloride 200 Solid Bags Irritant By Road 81 Cyano Acetic Acid 4450 Crystalline Bags Corrosive By Road 82 Cyanoquanidine 110 Powder Bags Non Hazard By Road 83 Cyclohexane 2000 Liquid Drums Toxic By Road 84 Cyclohexanone 100 Liquid Drums Irritant By Road 85 Cyclopropane carboxylic acid 100 Liquid Drums Corrosive By Road 86 Darco 12 Powder Bags Non hazard By Road 87 Dibromo ethane 25 Liquid Drums Toxic By Road 88 Diethanol amine HCL 355 Liquid Drums Carcinogenic By Road 89 Diethoxy dimethyl butanamine 100 Liquid Drums Corrosive By Road



90 Diethyl ether 1500 Liquid Drums Flammable By Road 91 Diethyl Maleate 40 Liquid Drums Carcinogenic By Road 92 Diethyl Malonate 1060 Liquid Drums Irritant By Road 93 Diethyl sulfate 70 Liquid Drums Toxic By Road 94 Dimethyl formamide 3050 Liquid Drums Flammable By Road 95 Dimethyl acetamide 500 Liquid Drums Carcinogenic By Road 96 Dimethyl sulfate 1600 Liquid Drums Toxic By Road 97 Dimethyl sulfone 50 Crystalline Bags Non Hazard By Road 98 Dimethylsulfoxide 870 Liquid Drums Non Hazard By Road 99 D-ribose 50 Powder Bags Non Hazard By Road 100 D-tartaric acid 310 Crystalline Bags Irritant By Road 101 Ethylene Dichloride (EDC) 3870 Liquid Drums Flammable By Road 102 EDTA 10 Powder Bags Irritant By Road 103 Ethyl alcohol 10000 Liquid Storage


104 Ethyl Acetate 20000 Liquid Storage tanks

Flammable By Road

105 Ethyl cyano acetate 1260 Liquid Drums Irritant By Road 106 Ethyl aceto acetate 80 Liquid Drums Non Hazard By Road 107 Ethylene glycol 95 Liquid Drums Carcinogenic By Road 108 Flourodiethyl malonate 400 Liquid Drums Corrosive By Road 109 Flourobenzene 700 Liquid Drums Flammable By Road 110 Formaldehyde 100 Liquid Drums Toxic By Road 111 Formamide 2000 Liquid Drums Carcinogenic By Road 112 Formic acid 330 Liquid Drums Flammable By Road 113 Glycine 140 Solid Bags Non Hazard By Road 114 glycine ethylester hydrochloride 85 Crystalline Bags Corrosive By Road 115 Guanidine nitrate 620 Crystalline Bags Irritant By Road 116 Hexane 8100 Liquid Drums Flammable By Road 117 Homoveratronitrile 650 Solid Bags Irritant By Road 118 Hydrazine 85 Liquid Drums Flammable By Road 119 Hydrazine hydrate 210 Liquid Drums Irritant By Road



120 Hydrobromic acid 100 Liquid Drums Irritant By Road 121 Hydrochloric acid 3870 Liquid Drums Irritant By Road 122 Hydrogen 55 Gas Cylinders Flammable By Road 123 Hydrogen chloride 210 Gas Cylinders Flammable By Road 124 Hydrogen perroxide 140 Liquid Drums Corrosive By Road 125 Hydroxylamine Hydrochloride 40 Crystalline HDPE Bags Carcinogenic By Road 126 Hydroxylamine sulfate 100 Crystalline HDPE Bags Carcinogenic By Road 127 Hyflow 60 Solid Bags Non hazard By Road 128 Indole-2-carboxylic acid 250 Solid Bags Non hazard By Road 129 Isatoic Anhydride 700 Powder Bags Irritant By Road 130 Iso propyl Alcohol .HCL 740 Liquid Drums Irritant By Road 131 Isobutyraldehyde 130 Liquid Drums Flammable By Road 132 Isopropyl Acetate 260 Liquid Drums Flammable By Road 133 Isopropyl alcohol 20000 Liquid Storage

tanks Irritant By Road

134 Isopropyl Bromide 51 Liquid Drums Flammable By Road 135 Isovanillin 89 Powder Bags Irritant By Road 136 Lithium bis(trimethyl silyl) amide 160 Powder Bags Crystallline By Road 137 Lithium Diisopropylamide (LDA) 165 Liquid Drums Toxic By Road 138 L-Malic acid 770 Powder Bags Irritant By Road 139 L-Valine methyl ester HCl 70 Crystalline Bags Non hazard By Road 140 Malano nitrile 105 Solid HDPE Bags Toxic By Road 141 Manganese Dioxide 40 Solid Bags Irritant By Road 142 Mannose syrup 1000 Solid Bags Irritant By Road 143 Methanesulfonic acid 110 Liquid Drums Corrosive By Road 144 Methanol 2 x 30000 Liquid Storage


145 Methyl amine 150 Liquid Drums Flammable By Road 146 Methyl formate 950 Liquid Drums Flammable By Road 147 Methyl iodide 200 Liquid Drums Toxic By Road 148 Methyl tert butyl ether 2150 Liquid Drums Flammable By Road 149 Methylene Dichloride (MDC) 20000 Liquid Storage

tanks Carcinogenic By Road



150 m-Hydroxy Acetophenone 100 Crystalline Bags Irritant By Road 151 Methyl Iso Butyl Ketone 2000 Liquid Drums Flammable By Road 152 Monochloro benzene 1800 Liquid Drums Flammable By Road 153 Monomethyl Urea 140 Crystalline Bags Non hazard By Road 154 M-xylene 270 Liquid Drums Flammable By Road 155 N,N-dimethyl aniline 1400 Liquid Drums Toxic By Road 156 N,N diethyl aniline 180 Liquid Drums Toxic By Road 157 N-Acetyl-L-leucine 90 Crystalline Bags Non hazard By Road 158 Naphthalene 360 Solid Bags Flammable By Road 159 N-Bochydroxyl amine 75 Crystalline Bags Non Hazard By Road 160 n-Butyl Cyanide 160 Liquid Drums Flammable By Road 161 n-Butyllithium 35 Liquid Drums Flammable By Road 162 Nickel 60 Powder HDPE Bags Carcinogenic By Road 163 N-Iodo succinamide 220 Crystalline Bags Irritant By Road 164 Nitric acid 580 Liquid Drums Toxic By Road 165 Nitro vanillin 95 Powder Bags Irritant By Road 166 Nitromethane 60 Liquid Drums Flammable By Road 167 N-Methylpyrolidinone 400 Liquid Drums Flammable By Road 168 NN-Dimethylformamide dimethylacetal 75 Liquid Drums Flammable By Road 169 n-Pentylchloroformate 105 Liquid Drums Flammable By Road 170 n-Propanol 1760 Liquid Drums Flammable By Road 171 O- Xylene 10000 Liquid Storage


172 O-Acetyl salicyl chloride 200 Solid Bags Corrosive By Road 173 Orotic acid 150 Solid Bags Irritant By Road 174 Ortho dichloro benzene 400 Liquid Drums Irritant By Road 175 O-Tolyl Benzonitrile 100 Liquid Drums Flammable By Road 176 Oxalylchloride 85 Liquid Drums Toxic By Road 177 Palladium 10 Solid Bags Flammable By Road 178 Palladium on Carbon 70 Solid Bags Non Hazard By Road 179 Palladium hydroxide (20%) 6 powder Bags Irritant By Road 180 Paraformaldehyde 160 Solid Bags Flammable By Road



181 Phentermine 180 Liquid Drums Irritant By Road 182 Phenyl ethylamine 10 Liquid Drums Toxic By Road 183 Phenyl Hydrizine 15 Liquid Drums Toxic By Road 184 Phosphoric acid 375 Liquid Drums Toxic By Road 185 Phosphorus oxychloride 5340 Liquid Drums Toxic By Road 186 Phosphorus pentachloride 170 Powder HDPE Bags Toxic By Road 187 Phosphorus pentasulfide 250 Solid Bags Flammable By Road 188 Phosphoryl trichloride 130 Liquid Drums Toxic By Road 189 Piperonal 220 Solid Bags Irritant By Road 190 Potassium Carbonate 175 Crystalline Bags Irritant By Road 191 Potassium hydroxide 860 Flakes Bags Corrosive By Road 192 Potassium iodate 90 Solid Bags Oxidizer By Road 193 Potassium iodide 710 Crystalline HDPE Bags Toxic By Road 194 Potassium Permanganate 145 Solid Bags Irritant By Road 195 potassium tert-butoxide 60 Solid Bags Irritant By Road 196 Propiophenone 240 Liquid Drums Irritant By Road 197 P-Toluene sulfonic acid(PTSA) 50 Solid HDPE Bags Carcinogenic By Road 198 Pyridine 100 Liquid Drums Flammable By Road 199 R+ (a) methyl benzyl amine 175 Liquid Drums Toxic By Road 200 Raney Nickel 130 Solid Bags Flammable By Road 201 Silica gel 745 Solid Bags Irritant By Road 202 Sodium azide 400 Crystalline HDPE Bags Toxic By Road 203 Sodium bicarbonate 625 Crystalline Bags Irritant By Road 204 Sodium Borohydride 545 Powder Bags Flammable By Road 205 Sodium carbonate 140 Crystalline Bags Irritant By Road 206 Sodium chloride 50 Solid Bags Non Hazard By Road 207 Sodium cyanate 60 Solid Bags Irritant By Road 208 Sodium cyanide 860 Crystalline HDPE Bags Toxic By Road 209 Sodium hydro sulfide, NaSH 140 Liquid Drums Toxic By Road 210 Sodium hydroxide 20000 Liquid Storage

tanks Corrosive By Road

211 Sodium Hypochlorite 890 Liquid Drums Corrosive By Road



212 Sodium methoxide 1950 Solid Bags Corrosive By Road 213 Sodium nitrite 780 Solid Bags Irritant By Road 214 Sodium sulfate 30 Solid Bags Irritant By Road 215 Sodium Sulfite 290 Solid Bags Irritant By Road 216 sodium thiosulfate 40 Powder Bags Non hazard By Road 217 Sulfamide 228 Powder Bags Irritant By Road 218 Sulfolane 1900 Crystalline Bags Irritant By Road 219 Sulphuric Acid 4200 Liquid Drums Irritant By Road 220 Sulphur 28 Flakes Bags Irritant By Road 221 t-butanol 220 Liquid Drums Flammable By Road 222 Triethylamine Hydrochloride 80 Crystalline Bags Irritant By Road 223 Tetra-n-butyl ammonium bromide(TBAB) 20 Solid Bags Irritant By Road 224 Tri ethyl benzyl ammonium chloride(TEBAC) 35 Crystalline Bags Irritant By Road 225 Tetrahydrofuran 3600 Liquid Drums Irritant By Road 226 Theophylline 750 Powder HDPE Bags Toxic By Road 227 Thio Urea 100 Crystalline Bags Irritant By Road 228 Thionyl chloride 2500 Liquid Drums Toxic By Road 229 Thymine 300 Powder Bags Non Hazard By Road 230 Toluene 2 x 30000 Liquid Storage

tanks Toxic By Road

231 Tributyl tin chloride 80 Liquid Drums Toxic By Road 232 Trichloroisocyanuric Acid 120 Powder Bags Oxidizer By Road 233 Triethyl amine 2220 Liquid Drums Flammable By Road 234 Triethyl orthoformate 170 Liquid Drums Irritant By Road 235 Uracil 545 Powder Bags Non Hazard By Road 236 Urea 580 Solid Bags Irritant By Road 237 Valeryl Chloride 37 Liquid Drums Flammable By Road 238 Valproic Acid 300 Solid Bags Irritant By Road 239 Vitride 395 Liquid Drums Irritant By Road 240 Xylene 1460 Liquid Drums Toxic By Road 241 Zinc 155 Solid HDPE Bags Toxic By Road



6.3 Process Description

The manufacturing process for all the products is presented in Chapter 2. (Page No. 2-6 to

2-253) of the report.

6.4 Plant Facilities

The manufacturing facility shall be provided with

1) Production blocks 2) Utilities 3) Quality Control, R&D lab 4) Effluent treatment plant 5) Warehouses

6) Tank farm area 7) Cylinder Storage 8) Administrative Office 9) Solvent recovery area

The production facilities shall be designed for proper handling of materials and machines.

Safety of operators, batch repeatability and process parameter monitoring shall be the

major points of focus in the design of facility. The current Good Manufacturing Practices

(GMP) guidelines shall be incorporated as applicable to synthetic organic chemicals

manufacturing facilities.

6.4.1 Production Blocks:

The Production blocks will consist of SS and glass lined reactors, storage tanks, shell &

tube heat exchangers, evaporators, vacuum pumps, packed columns, Agitated Nutche

Filter and Dryers, crystallizers, layer separators etc. The area shall be provided with

proper concealed drainage facility and all process facilities shall be performed under

protective environment.

6.4.2 Utilities:

The proposed expansion requires additional steam. It is proposed to establish 2 x 10 TPH

coal fired boilers in addition to existing 3 TPH and 4 TPH coal fired boilers boilers to meet

the steam requirement both for process and ZLD system. It is proposed kept 1 x 10 TPH

boiler as standby. The DG sets required for emergency power during load shut down is

estimated at 2100 KVA and accordingly 1 x 1000 Kva DG sets are proposed for expansion



in addition to existing 500 KVA and 600 KVA DG sets. The list of utilities is presented in

the following Table 6.4.

Table 6.4 List of Utilities S. No Description Capacity

Existing Proposed Total after Expansion 1 Coal Fired Boilers 1 x 3 TPH

1 x 4 TPH 2 x 10 TPH* 2 x 10 TPH

1 x 3 TPH and 1 x 4 TPH 2 Thermic Fluid Heater --- 1 lac K.cal/hr 1 Lac K.Cal/hr 3 DG Set** 500 KVA

600 KVA 1000 KVA 1 x 1000 KVA

1 x 600 KVA 1 x 500 KVA

* 1 x 10 TPH boiler shall be kept as standby **DG sets will be used during load shut down periods only.

6.4.3 Quality Control, R&D Lab

The QC department shall comprise of an in-process lab with instruments like HPLC, GC

etc. It will be maintained by highly qualified and trained people. The activities include:

• In-process quality check during manufacturing • Validation of facilities • Complaint handling

Also a process development laboratory shall be provided for in-house process

development , initial evaluation of process technology in case of technology transfer, back-

up for production department to address any issues arising during commercial production

6.4.4 ETP and Solid waste storage

The total effluents segregated into two streams High COD/ TDS and Low COD/ TDS

streams based on source of generation. These effluents are treated in Zero Liquid

Discharge system and the treated effluents are reused for cooling towers make-up.

6.4.5 Ware Houses:

The plant shall have sufficient storage facility for safe handling of raw materials. All solid

raw materials shall be stored in marked areas with proper identification. Liquid raw

materials and solvents like which are available in drums will be stored according to



material compatibilities and flammability. Adequate fire fighting facilities shall be

provided as per NFPA norms.

6.4.6 Tank Farm Area:

A separate tank farm area shall be provided for storing liquid raw materials, especially

solvents with high inventory and also for toxic, corrosive chemicals. Dykes shall be

provided to ensure safety in case of tank failure. Acid proof lining for the dykes shall be

provided for acid storage tanks. Condensers for low volatile solvent storage tanks vents.

6.4.7 Cylinders storage Area:

Gas cylinders storage should conform to SMPV-Unfired rules-1981. Hydrogen cylinders

should be stored in approved Gas Storage pad. Chained and capped when not in use.

Operational cylinder should be firmly secured. Pressure regulator, metal piping, non-

return valve, and safe residue bleed off arrangement should be incorporated in installation

design. Strict hot work control and display of danger signs should be ensured.

6.4.8 Administrative Office:

An Administrative office shall be provided at the entrance of the factory to ensure the

entry of authorized personnel only into the premises.

6.4.9 Water Sump:

Water sump of 200 Kl capacity shall be provided for fire fighting in case of emergencies.

6.4.10 House Keeping:

A regular house keeping schedule with adequate preventive maintenance shall be ensured

so that the plant is consistently maintained as per GMP standards.

6.4.11 Facility layout and design:

The layout of all the various areas required for the facility, as mentioned above is

considered. In laying out the above areas, isolation of the various process areas from the

utilities and non-process areas is considered in view of both containment and cGMP. A

tentative plant layout is shown in Fig 6.1.



Fig 6.1 Plant Layout of Suven Life Sciences Ltd.

Green Belt

DESCRIPTION

MAINTENANCE ENGG.OFFICE

3 B , 3 C , 3 D

GATE

Gate

SOLVENT STORAGE TANKS

SVL

285A

3B

SOLVENT DRUMS STORE

Gate

01

4.5 M WI

DE RO

AD

Q.C.D

MAIN EN

TRANCE

STORE

Storm Water

18

12.0

GREEN BELT

SVL

26

22

DRY HCL.PLANT

GMP BLOCK

11SVL

WASH AREA

27

Storm

Water

Green Belt

Road

TIME OFFICE & PERSONAL DEPT.

SVL

Future

SOLVENT STORAGE YARD.

WATER SUMP

PLANT LAYOUT

CT-1001

10A

35

18

15

SVL

25.0

Storage Pond

27

24

SVL

10

Green Belt

FABRICATION SHED

30

4A

2.4

1B

29

DM WATER PLANT & OFFICE

6.0 M WID

E ROAD

11

DRUMS STORAGE SHED

3C

22

09

02

17A

4.5 M WID

E ROAD

13

ENGG.STORE & CONF.HALL

ROAD

24

NATION

AL HIG

H WAY

NO.9

VIJAYAW

ADA T

O HYD

ERABADSECURITY

SVL

DRYING & PACKING SVL

CANTEEN & MAINTANCE DEPT.

05

36

20 & 21

PRODUCTION BLOCK -2

Gate

17A

06

GATE

3A

EFFLUENT TREATMENT PLANT

Storage

Pond

MMA. Tan

ks

33

ELECTRICAL PANEL ROOM FOR

34

DS TANKS

03

Stora ge Tank

25

26

6.0 m Road

NALA

16

TANDA ROAD

SVL

GREEN BELT

6

UNIT - 1, DASAIGUDEM VILLAGE,SURYAPET(M) , NALGONDA ( D.T), A.P

SVL

12

BLOCK

N

19

PARKING SHED

ROAD

23

SVL

ROAD

2

14

104.0

Road

SVL

4.5 M WID

E ROAD

23

TOILLETS

Road

PRODUCTION BLOCK - 3 A

Green Belt

R.M.STORE & BONDED STORE

1033

Storm Water

ROA

D

17 GateABSORPTION SYSTEM

Checked by :

QCD

Prepared by:

35Gree

n Belt

TANKS

07

Approved by :

CYCLE S

HED

ROAD

4.5 M WI

DE RO

AD

Storage Tank

08

14

34

134.5 M

WIDE

ROAD

GATE

DISPENSARY & TIME OFFICE

ROAD

QA & ADMINISTRATIVE OFFICE

CYLINDER STORAGE SHED

17

Open Area

GATE

29

Effective Date :

3508

ENT

21

12

Title:

16

32

04

SVL

BLOCK -3 MCC PANEL ROOM

AMMONIA VAPOUR

DWG.No : SUVEN- 01-001

28

OFFICE

Store

LIQUID RAW MATERIAL TANKS

4.5 M WI

DE RO

AD

UTILITY BLOCK

SVL

ELECTRICAL TRANSFORMER

Rev.0

GENERATOR ROOM

ROAD

5.0 M W

IDE RO

AD

PRODUCTION BLOCK -4 , 4A, 4B

SVL

Storm Water

6.0 m Road

NO

Green Belt

25

SVL

15

PRODUCTION BLOCK -1, 1A,1B

SVL

3D

1A

0709

4B

Open Area

1

BOILER HOUSE 4T/ 5T

DRYING & PACKING AND

20

19



6.5 Hazard Analysis and Risk Assessment

6.5.1 Introduction.

Hazard analysis involves the identification and quantification of the various hazards

(unsafe conditions) that exist in the plant. On the other hand, risk analysis deals with the

identification and quantification of risks, the plant equipment and personnel are exposed

to, due to accidents resulting from the hazards present in the plant.

Hazard and risk analysis involves very extensive studies, and requires a very detailed

design and engineering information. The various hazard analysis techniques that may be

applied are hazard and operability studies, fault-tree analysis, event-tree analysis and

failure and effects mode analysis.

Risk analysis follows an extensive hazard analysis. It involves the identification and

assessment of risks; the neighboring populations are exposed to as a result of hazards

present. This requires a thorough knowledge of failure probability, credible accident

scenario, vulnerability of population's etc. Much of this information is difficult to get or

generate. Consequently, the risk analysis is often confined to maximum credible accident

studies.

In the sections below, the identification of various hazards, probable risks, maximum

credible accident analysis, consequence analysis are addressed which gives a broad

identification of risks involved in the plant.

6.5.2 Hazard Identification

The Hazard identification process must identify hazards that could cause a potential major

accident for the full range of operational modes, including normal operations, start-up,

and shutdown, and also potential upset, emergency or abnormal conditions. Employers

should also reassess their Hazard identification process whenever a significant change in

operations has occurred or a new substance has been introduced. They should also

consider incidents, which have occurred elsewhere at similar facilities including within the

same industry and in other industries.



Hazard identification and risk assessment involves a critical sequence of information

gathering and the application of a decision-making process. These assist in discovering

what could possibly cause a major accident (hazard identification), how likely it is that a

major accident would occur and the potential consequences (risk assessment) and what

options there are for preventing and mitigating a major accident (control measures). These

activities should also assist in improving operations and productivity and reduce the

occurrence of incidents and near misses.

The chemical and process industries have been using a variety of hazard identification

techniques for many years, ranging from simple screening checklists to highly structured

Hazard and Operability (HAZOP) analysis. Each technique has its own strengths and

weaknesses for identifying hazards. It is impossible to compare hazard identification

techniques and come to any conclusion as to which is the best. Each technique has been

developed for a specific range of circumstances taking many factors into account including

the resources required to undertake the analysis, expertise available and stage of the

process. While HAZOP is primarily a tool for hazard identification, the HAZOP process

can also include assessment of the causes of accidents, their likelihood and the

consequences that may arise, so as to decide if the risk is acceptable, unacceptable or

requires further study. Moreover, a formal guidance for applying this technique is

available. Collaboration between management and staff is fundamental to achieving

effective and efficient hazard identification and risk assessment processes.

After identifying hazards through a qualitative process, quantification of potential

consequences of identified hazards using simulation modeling is undertaken. Estimation

of probability of an unexpected event and its consequences form the basis of quantification

of risk in terms of damage to property, environment or personnel. Therefore, the type,

quantity, location and conditions of release of a toxic or flammable substance have to be

identified in order to estimate its damaging effects, the area involved, and the possible

precautionary measures required to be taken.



Considering operating modes of the facility, and based on available resources the following

hazard identification process chosen are:

a) Fire Explosion and Toxicity Index (FETI) Approach; b) HAZOP studies; c) Maximum Credible Accident and Consequence Analysis (MCACA); d) Classification of Major Hazard Substances; e) Manufacture Storage and Import of Hazardous Chemical Rules, 1989 (GOI Rules,

1989); f) Identification of Major Hazardous Units.

The physical properties of solvents used in the process are presented in Table 6.2 which

forms the basis for identification of hazards during storage and interpretation of the

Manufacture, Storage and Import of Hazardous Chemical Rules, 1989 (GOI Rules, 1989)

The interpretation of “The Manufacture Storage and Import of Hazardous chemicals”

issued by the Ministry of Environment and Forests, GOI, which guides the preparation of

various reports necessary for safe handling and storage of chemicals shows that the

present project requires preparation of safety reports before commencing operation and

risk assessment is not mandatory. The applicability of various rules is presented in Table

6.5.

Table 6.5 Applicability of GOI Rules to Storage/Pipeline S. No

Chemical Inventory KL

Threshold Quantity (T) For Application of Rules Applicable Rules 5,7-9, 13-15 10-12

1 Acetone 15 1500 10000 4 (1) (a), (2), 5,15 2 Dichloromethane 20 1500 10000 4 (1) (a), (2), 5,15 3 Isopropyl alcohol 15 1500 10000 4 (1) (a), (2), 5,15 4 Methanol 2 x 30 1500 10000 4 (1) (a), (2), 5,15 5 Toluene 2 x 30 1500 10000 4 (1) (a), (2), 5,15 6 Ethanol 10 1500 10000 4 (1) (a), (2), 5,15 7 Ethyl Acetate 20 1500 10000 4 (1) (a), (2), 5,15 8 O-Xylene 10 1500 10000 4 (1) (a), (2), 5,15



Table 6.6 Physical Properties of Raw Materials and Solvents S.No Name of Raw material TLV

(ppm) Toxicity Level Flammable Limit Chemical Class

(As per MSIHC Rules)

LD50 LD50 LC 50 (mg/1) Oral

(mg/kg) Dermal (mg/kg)

LEL (%)

UEL (%)

FP (OC)

BP (OC)

Class (As per Petroleum

Classification 1 Acetic Acid 10 3310 1060 88 4.0 19.9 39 118 C Flammable 2 Acetic anhydride 5 1780 4320 4200 2.0 10.2 49 138 C Flammable 3 Acetone 1000 5800 20000 5540 2.6 13.0 20 1.0 8.1 -22 69 B Flammable 15 Isopropyl alcohol 400 5045 12800 100000 2.0 12.7 12 82.4 B Flammable 16 Isopropyl ether 500 8470 14480 162000 1.0 21.0 -28 67 C Flammable 17 Methanol 200 5628 15800 64000 5.5 36.5 11 64.5 A Flammable 18 Methyl isobutyl ketone 100 2737 6480 23500 1.8 10.0 -4 79.64 C Flammable 19 Methyl t-butyl ether 50 4000 10000 23576 1.6 15.1 -33 55.2 C Flammable 20 n-Heptane 400 15000 9750 4900 1.0 7.0 -4 98.4 B Flammable 21 N-methyl-2-pyrrolidone 50 3914 5100 8000 1.3 9.5 91 82 B Carcinogenic 22 Tetrahydrofuran 200 1650 2000 2160 1.5 12.4 -21.5 66 B Flammable 23 Toluene 200 636 12124 313 1.2 8.0 4 110.6 B Flammable 24 Xylene 100 50 1 7 24 138.5 B Flammable



6.5.3 Fire & Explosion Index (F & EI):

6.5.3.1 Methodology

Dow Chemical Company issued a guideline for hazard determination and protection. By

this method a chemical process unit is rated numerically for hazards. The numerical

value used is the Fire and Explosion Index (F&EI) which is most widely used for hazard

evaluation in chemical process industries.

The guide applies to process unit only and not to auxiliary units such as power

generating stations, plant water systems, control rooms, fired heaters, structural

requirements, corrosive nature of material handled and personal safety equipment. These

are regarded as basic features that do not vary according to the magnitude of the fire and

explosion hazard involved. The guide also does not cover the processing and handling of

explosives such as dynamite, TNT etc.

Computation of F&EI

The F&EI is calculated as a product of Material factor, General process hazard factor, and

special process hazard factor The Material factor is a measure of the intrinsic rate of

potential energy release from fire or explosion of most hazardous material or mixture of

materials present in significant quantity, whether it is raw material, intermediate,

product, solvent etc, by combustion or chemical reaction. “In significant quantity” here

means such quantity that the hazard represented by the material actually exists. The

National Fire Protection Agency of USA (NFPA) have specified standard values for

material factor which should be used for F&EI calculations and are available in Dow’s

Hazard Classification Guide. In case it is not readily available, it can be calculated using

the heat of combustion, flammability indices etc.

General process hazards are factors that play a primary role in determining the

magnitude of loss of incident. It takes into account the nature of the reaction, ventilation

of the unit, accessibility of the unit, drainage facilities etc., Special process hazards are



factors that contribute primarily to the probability of a loss of incident. They consist of

specific process conditions that have shown themselves to be major causes of fire and

explosion incidents. It takes into account toxicity of the material, operating pressure,

operation near flammable range, quantity of material, joints and packing, use of hot oil

exchange system etc., The F&EI index is calculated as a product of Material factor,

General process hazard factor, and Special process hazard factor.

Hazard Ranking

The hazard ranking based on F&EI value is presented in Table 6.7. Table 6.7 Degree of Hazard for F&EI

F&EI Index Range Degree of Hazard 1 – 60 Light

61 – 96 Moderate 97 – 127 Intermediate 128 – 158 Heavy

159 & above Severe The estimated values of F&EI and hazard ranking are given in the Table 6.8. The radius

of exposure is determined by 0.26 meter x respective F&EI. The estimated values of F&EI

reflect light hazard in view of the low volume of chemicals.

The fire and explosion index evaluation can be very useful in developing plant layouts or

adding equipment and buildings to existing plants. Evaluation of the F&EI calculations

and layout considerations will result a safe, operable, maintainable and cost-effective

arrangement of equipment and buildings.

Table 6.8 Fire & Explosion Index for Tank farm S. No. Name of the Solvent Fire &

Explosion Index (F1*F2*MF)

Radius of Exposure (m)

F&EIx0.26

Degree of Hazard

1 Acetone 73.77 19.18 Moderate 2 Dichloromethane 93.62 24.34 Moderate 3 Ethanol 64.48 16.76 Moderate 4 Ethyl acetate 72.48 18.84 Moderate 5 Isopropyl alcohol 72.34 18.81 Moderate 6 Methanol 74.17 19.28 Moderate 7 Toulene 86.82 22.57 Moderate 8 O-Xylene 78.69 20.46 Moderate



F& E index value is found to be moderate reflecting the threshold limits as prescribed in

MSHC rules. Both MSHC rules and F & E index indicate that the present facility does not

require a detailed risk assessment.

6.5.4 Hazard and Operability Study (HAZOP)

Hazard and Operability Study (HAZOP) is a highly structured and detailed technique,

developed primarily for application to chemical process systems. A HAZOP can generate

a comprehensive understanding of the possible ‘deviations from design intent’ that may

occur. However, HAZOP is less suitable for identification of hazards not related to

process operations, such as mechanical integrity failures, procedural errors, or external

events. HAZOP also tends to identify hazards specific to the section being assessed, while

hazards related to the interactions between different sections may not be identified.

However, this technique helps to identify hazards in a process plant and the operability

problems. It is performed once the engineering line diagrams of the plant are made

available. It is carried out during or immediately after the design stage. The purpose of

the study is to identify all possible deviations from the way the design/operation is

expected to work and all the hazards associated with these deviations. A multi-

disciplinary team was constituted with chemical, mechanical and instrumentation

engineers, R&D chemist and production manager.

The preparative work for HAZOP studies consisted of four stages i.e., obtaining the data,

converting into usable form, planning the sequence of the study and arranging the

necessary meetings. The documents referred to for the study include process description,

process flow diagrams, P&I diagrams plant layout, operating manuals including startup

& shutdown, safety instructions etc., The parameters such as temperature, pressure, flow,

level were investigated for deviation and hazard situations are identified.

Some basic definitions of terms frequently used in HAZOP studies are deviation, causes,

consequences and guide words etc., Deviations are departures from the design intent

which are discovered by systematically applying the guide words. Causes are the reasons



why deviations might occur. Consequences are the reasons why deviations should they

occur. Guide words are simple words used to understand a particular plant section in

operating condition in order to guide and simulate the creative thinking process and so

discover deviations. NO, less, more, as well as, part of, reverse, other than are guide

words used.

6.5.5 Hazard Factors

A study of past accident information provides an understanding of failure modes and

mechanisms of process and control equipment and human systems and their likely effects

on the overall plant reliability and safety. Some of the major contributing factors for

accidents in chemical industries are:

S. No Contributing Factor Percent Loss 1 Equipment design faults 41 2 Process design faults 10 3 Operator errors 31 4 Maintenance deficiencies 12 5 Material hazards 6

A study by AIChE (1972) indicates that majority of equipment of component failures

involve compressors, furnaces and heat exchangers as there are lesser opportunities to

take them off for maintenance. The frequency of equipment or component failures is

observed as follows:

S. No Equipment Frequency (%) 1 Compressors 30 2 Furnaces 18 3 Heat Exchangers 17 4 Process Vessels 18 5 Others 17

However, failures of storage vessels and those during transportation have been reported

more frequently than cases of plant failures. The failure rate of various equipment in a

typical power plant is provided in the following table.



Equipment Failure Rates Failure rate Failures 10-6/h Electric motors (general) 10 Transformers (



Failure rate Failures 10-6/h Magnetic clutches 6 Fixed orifices 1 Variable orifices 5 Nozzle and flapper assemblies: Blockage 6 Breakage 0.2 Filters: blockage 1 Leakage 1 Rack-and-pinion assembles 2 Knife-edge fulcrum: wear 10 Springs (heavily stressed) 1 (Lightly stressed) 0.2 Hair springs 1 Calibration springs: creep 2 Breakage 0.2 Vibration mounts 9 Mechanical joints 0.2 Grub screws 0.5 Pins 15 Pivots 1 Nuts 0.02 Bolts 0.02 Boilers (all types) 1.1 Boilers feed pumps 2.5 Cranes 7.8

6.5.6 Common Causes of Accidents

Engineering and Instrumental

Based on the analysis of past accident information, common causes of major chemical

plant accidents are identified as:

• Poor house keeping • Improper use of tools, equipment, facilities • Unsafe or defective equipment facilities • Lack of proper procedures • Improving unsafe procedures • Failure to follow prescribed procedures • Jobs not understood • Lack of awareness of hazards involved



• Lack of proper tools, equipment, facilities • Lack of guides and safety devices • Lack of protective equipment and clothing

Failures of Human Systems

An assessment of past chemical accidents reveals human factor to be the cause for over

60% of the accidents while the rest are due to other plant component failures. This

percentage will increase if major accidents alone are considered for analysis. Major

causes of human failures reported are due to:

• Stress induced by poor equipment design, unfavorable environmental conditions, fatigue, etc.

• Lack of training in safety and loss prevention. • Indecision in critical situations. • Inexperienced staff being employed in hazardous situations.

Often, human errors are not analyzed while accident reporting and accident reports only

provide information about equipment or component failures. Hence, a great deal of

uncertainty surrounds analysis of failure of human systems and consequent damages.

The number of persons/materials are potentially exposed to a specific hazard zone is a

function of the population density and distribution near the accident location. The failure

rate data and ignition sources of major fires are presented in the following Tables 6.9 and

6.10.

Table 6.9 Failure Rate Data

S.No Item International Data 1. Process Controllers 2.4 x 10-5 hr-5 2. Process control valve 2.0 x 10-6 hr-1 3. Alarm 2.3 x 10-5 hr-1 4. Leakage at biggest storage tank 5.0 x 10-5 yr-1 5. Leakage of pipe line 1 x 10-7 m-1 yr-1 6. Human Failure 1 x 10-4 (demand)-1



Table 6.10 Ignition Sources of Major Fires S.No Ignition Source Percent 1. Electrical (wiring of motors) 23% 2. Smoking 18% 3. Friction 10% 4. Over heated material 8% 5. Burner flames 7% 6. Combustion sparks 5% 7. Spontaneous ignition 4% 8. Cutting & welding 4% 9. Exposure (fires jumping into new areas) 3% 10. Incendiarism (fires maliciously set) 2% 11. Mechanical sparks 2% 12. Molten substances 1% 13. Chemical actions 1% 14. Static sparks 1% 15. Lightening 1% 16. Miscellaneous 1%

6.6 Maximum Credible Accident and Consequence Analysis (MCACA)

The potential hazards due to toxic and inflammable nature of the raw materials, process

streams and products can be quantified. However, it is necessary to carry out a hazard

analysis study to visualize the consequences of an unexpected release from chemical

plant, which consists of a number of process units and tank farm facilities. The present

study provides quantified picture of the potential hazards and their consequences

6.6.1 Methodology

MCACA aims at identifying the unwanted hazardous events, which can cause maximum

damage to plant and personnel. At the first instance, all probable accident scenarios are

developed. Scenarios are generated based on properties of chemicals, physical conditions

under which reactions occur or raw materials stored, as well as material strength of

vessels and conduits, in-built valves and safety arrangements, etc. Creating a scenario

does not mean that it will occur, only that there is a reasonable probability that it could. A



scenario is neither a specific situation nor a specific event, but a description of a typical

situation that covers a set of possible events or situations.

This is the basis of the risk study; it tells us what may happen so that ways and means of

preventing or minimizing the possibility can be devised. The next step is estimation of

the probability of each accident scenario. A credible accident is one within the realm of

possibility and is likely to be severe enough to cause significant damage. This concept

comprises of two parameters- probable damage caused by an accident and probability of

occurrence of an accident .There may be types of accidents that may occur frequently, but

would cause very little damage. And there may be other types that may cause great

damage, but would have a very low probability of occurrence. Both are important and

need to be considered, even if they are later discarded. A host of probable accident

scenarios are visualized examined and credibility of probable events is established based

on engineering judgment, past accident data and expertise in the field of risk analysis.

The following steps are involved in identifying the maximum credible accident scenarios.

a. A detailed study of the process and plant information including process flow diagrams

and piping & instrumentation diagrams.

b. Hazard classification of chemicals, operations and equipment.

c. Identification of representative failure cases of vessels and pipelines and the resulting

release scenarios

d. Establishment of credibility of visualized scenarios based on past accident data.

6.6.2 Identification of Vulnerable Areas

The unit operations in the process and storage areas involve mass and energy transfer

operations to effect the necessary physical changes. Nature of chemicals and the

operating conditions create special hazardous situations. In the present case the chemicals

handled are flammable and toxic in nature. With these factors in mind a thorough

examination of the process information is carried out and a list of inventories of the

hazardous chemicals is prepared to identify the hazardous situations. Based on the raw



material consumptions determined from the pilot scale studies, experience in handling

commercial scale processes and logistics in procurement of raw materials, the inventories

to be maintained for each of the raw material and its mode of storage is determined. High

inventory liquid raw materials like solvents are usually stored in tank farms, while solids

and other low inventory liquids are stored in ware house based on compatibility,

reactivity, toxicity etc. with appropriate safety and fire fighting facilities to handle any

kind of emergencies. The solvent tank farm and the capacity of each tank is mentioned

in table 6.4.

6.6.3 Representative Accident Scenarios

A study of past accidents, which took place in similar process units and the present plant,

provides reasons and course of accidents and there by focusing on most critical areas. A

thorough examination of engineering details indicated many possible scenarios like

gasket leak, pinholes in pipes and vessels apart from rupture of pipelines and vessels

and catastrophic failure of vessels resulting in a pool. Heat radiation damage distances

for Pool fire was considered.

Failure Frequency:

The release scenarios considered above can be broadly divided in to two categories

(i) Catastrophic failures which are of low frequency and

(ii) Ruptures and leaks which are of relatively high frequency

Vapor or liquid release from failure of gasket, seal and rupture in pipe lines and vessels

fall in second category whereas catastrophic failure of vessels and full bore rupture of

pipe lines etc., fall in to first category. Typical failure frequencies are given in Table 6.11.

Table 6.11 General Failure Frequencies Item Mode of failure Failure frequencies Pressure Vessel

Serious leak 1.0*10-5/Year Catastrophic 3.0*10-6/Year

Pipe lines =50 mm dia

Full bore rupture 8.8*10-7/m.year Significant leak 8.8*10-6/m.year



>50 mm =150 mm dia


>150 mm dia


hose Rapture/Failure 4.0*10-5/hr Unloading arm Rapture/Failure 3.0*10-8/hr Check valve Failure on demand 1.0*10-4/on demand motor operated valve Failure on demand 1.0*10-3/ on demand Flange Leak 3.0*10-4/ Year Pump seal Leak 5.0*10-3/ Year Gasket failure Failure 5.0*10-5/ Year Process safety valve(PSV)

Lifts heavily 4.0*10-3/ Year Blocked 1.0*10-3/ Year Lifts lightly 6.0*10-2/ Year

6.7 Consequence Analysis

The accidental release of hazardous chemicals leads to subsequent events, which actually

cause the damage. The damages are of three types.

1) Damage due to heat radiation.

2) Damage due to Over pressure effects subsequent to explosion

3) Damage due to toxic effects

The type of damage and extent of damage depends on nature of chemical, the conditions

of release, atmospheric conditions and the subsequent events. The sequence of probable

events following the release of a hazardous chemical is schematically shown in Figure

6.2. The best way of understanding and quantifying the physical effects of any accidental

release of chemicals from their normal containment is by means of mathematical

modeling. This is achieved by describing the physical situations by mathematical

equations for idealized conditions and by making corrections for deviation of the

practical situations from ideal conditions. In the present study ALOHA software from

USEPA. These models for various steps are described in the following sub-sections.

6.7.1 Release Models and Source strength

This depends on the nature of failure of the unit and the content of the unit and operating

temperature and pressure of the unit. The release may be instantaneous due to total

failure of storage unit or continuous due to leakage or rupture of some component of the



storage facility. The material discharged may be gas or liquid or the discharge could be

manifested through two phase flow. The models that are used to calculate the quantity of

liquid/vapor released are:

Fig 6.2 Steps in Consequence Calculations

The following criteria tables present heat radiation intensities (Table 6.12), radiation

exposure and lethality (Table 6.13), and damage due to peak over pressure is presented

in Table 6.14.



Table 6.12 Damage Due to Incident Radiation Intensities S. No Incident

Radiation (KW/m2)

Type of Damage Intensity Damage to Equipment Damage to the People

1 37.5 Damage to process Equipment 100% lethality in 1 min.

1% lethality in 10 sec.

2 25.0 Minimum energy required to ignite wood at indefinitely long exposure without a flame

50 % lethality in 1min.

Significant injury in 10 sec.

3 19.0 Maximum thermal radiation intensity allowed n thermally unprotected adjoining equipment.

---

4 12.5 Minimum energy to ignite with a flame, melts plastic tubing

1% lethality in 1 min.

5 4.0 -- Causes pain if duration is longer than 20 sec, however blistering is unlikely ( First degree burns)

6 1.6 -- Causes no discomfort on Longer exposure

Source: Techniques for Assessing Industrial Hazards by World Bank

Table 6.13 Radiation exposure and lethality

Radiation Intensity (KW/m2)

Exposure Time (seconds)

1% Lethality Degree Burns

1.6 -- 0 No Discomfort even after longer exposure

4.5 20 0 1st 4.5 50 0 1 st 8.0 20 0 1 st 8.0 50



Table 6.14 Damage Due to Peak Over Pressure Human Injury Structural Damage

Peak Over Pressure (bar)

Type of Damage Peak over Pressure (bar)

Type of Damage

5 – 8 100% lethality 0.3 Heavy (90%Damage) 3.5 – 5 50% lethality 0.1 Repairable (10%Damage) 2 – 3 Threshold lethality 0.03 Damage of Glass

1.33 – 2 Severe Lung damage 0.01 Crack of Windows 1 – 11/3 50% Eardrum rupture - -

Source : Marshall, V.C.(1977)’ How lethal are explosives and toxic escapes. 6.7.2 Results of Consequence Analysis (Terms of Reference No.57)

The damages due to the accidental release of chemicals are of three types. a) Damage due to heat radiation b) Damage due to Over pressure effects subsequent to explosion c) Damage due to Toxic effects 6.7.2.1 Analysis of Hazardous Scenarios

The hazardous chemicals involved are stored within the threshold limits of storage and

hence few representative chemicals mainly solvents were studied.

6.7.2.1.1 Heat radiation effects

When a non-boiling liquid spills, it spreads into a pool. The size of the pool depends on

the availability of the bund and obstacles. The heat load on objects outside a burning pool

of liquid is calculated with the heat radiation model. The average heat radiation intensity,

the diameter-to-height ratio dependent on the burning liquid, geometric view, distance

from the fire, relative humidity of air, horizontal or vertical orientation of the object

radiated with respect to fire are factored. All storage tanks in tank-farm area are provided

with dykes. For each of the hazardous chemicals involved various scenarios such as pipe

line leaks of 5mm or pipeline ruptures or catastrophic vessel ruptures of the inventories

as outlined have been considered and damage distances for Lower Flammability Limits

(LFL) and heat radiation effects for the three levels of intensity are calculated and

presented in Table 6.15 . Heat radiation damage distances for most of the scenarios are

not occurring in the case of release from 25 mm holes at a height of 0.1 m from the bottom



of the tank for one hour, in the solvent stroage tanks. In case of pipeline leaks, 5 mm

leaks are considered for 15 mm and 50 mm pipe sizes. The release rates from 5 mm leaks

are observed to be low, and these leaks have low incident hazard. The concentration of

the flammable material in the vapor cloud was found to be below the lower flammability

limits.

Table 6.15 Heat Radiation Damage Distances – Tank Farm S.

No Name of Solvent Tank

Capacity (KL)

Dia (m)

Height (m)

Hole Dia

(mm)

Release Rate

(Kg/sec)

Heat radiation damage distances in m for KW/m2

37.5 12.5 4.0 1 Acetone 15 2.3 3.8 25 0.38



LDlo - Lethal dose low The lowest concentration of a chemical at which some test animals die following

inhalation exposure.

IDLH- Immediate Danger to Life and Health The maximum concentration limit to which a healthy worker can be exposed for 30

minutes and escape without suffering irreversible health effects or escape impairing

symptoms.

LD50 – Median lethal dose The dose at which 50 percent of test animals die following exposure. Dose is usually

expressed as milligrams for kilogram of body weight of test animal. The most popular

way of expressing lethality of toxic loads is to use probit functions.

P = A + B ln (Cn t) where P is probit value, A , B, n – constants specific to the chemical t -- time of exposure in seconds, c – concentration in mg /m 3 or ppm

Knowing the concentration level and time of exposure, the percentage lethality may be

estimated. However for most of the chemicals the characteristic constants are not available

and in such cases IDLH values are used.

The storage of toxic chemicals was evaluated with respect to failure of containment

resulting in toxic dispersion and the toxic damage distances were calculated using

ALOHA software. The results of the same are presented in Table 6.16.

Table 6.16 Toxic Dispersion Damage Distance S.No Name of Raw material Diameter

(m) Height

(m) Storage Pressure

Release Rate

(Kg/sec)

IDLH (ppm)

Distance (m)

1 Ammonia (50Kg) 0.87 0.27 7.86 Bar 0.004 300 17 2 Hydrogen Chloride (1000Kg) 0.30 0.65 42.26 Bar 0.066 50 117



Fig 6.3 Toxic Dispersion of Ammonia Cylinder

Fig 6.4 Toxic Dispersion of 1Ton HCl Cylinder.



6.7.2.1.2 Overpressure effects:

When an unignited gas cloud mixes with air and reaches the flammable range and if the

cloud ignites wither a flash fire or flash fire explosion can occur. Since the burning time is

shorter, instead of heat radiation from a flash fire, peak overpressure as a function of

distance from the centre of the cloud is derived. In case of pipeline leaks, damage

distances due to overpressure effects are not observed. The values are found to be similar

as there are no pressurized storage tanks in the tank farm, and the over pressure

distances are contingent on the tank capacity.

6.7.3 Observations:

From the previous incident records published in literature and hydrocarbon release data

bases, it has been observed that pinhole leaks contribute highest percentage where as the

second cause is small sized leaks of 25 mm diameter in tank farm. Accordingly the

consequence analysis was carried out for 25 mm sized leaks in the tank farm.

6.7.4 Recommendations:

The following are the recommendations to minimize the hazards and improve the safety

of the proposed plants. Plants of this nature, which handle a variety of chemicals, face

problems of fire and vapor cloud explosions. It has been observed that for the proposed

plants the damage distances are more or less confined to the plant area only. Taking

precautionary safety measures as outlined below can further minimize these effects.

• In view of hazardous nature of operations, it is recommended to adopt best practices

with respect to design, operation and maintenance.

• It is recommended that all flammable areas and process area be maintained free of

ignition sources. Ensure that sources of ignition, such as pilot lights, electrical

ignition devices etc., at strategic locations like solvent storage areas are avoided.

• All electrical fittings involved in and around the pipeline and operation system

should conform to flame/explosion proof regulations.

• Strict hot work control and display of danger signs should be ensured.



• It is recommended to provide one fire hydrant point in the tank-farm area to take

care of any emergency. Installation of fire water hydrant net work is suggested.

• It is suggested to provide fire extinguishers in process plant at solvent storage area

and the vents of solvent tanks to be provided with PESO approved flame arrestors.

• Fire protection equipment should be well maintained so that it is available when

required. They should be located for quick accessibility. Provide carbon dioxide fire

extinguishers and DCP extinguishers for Electrical fires.

• It is suggested to have a periodical review of safety awareness and safety training

requirements of plant employees with respect to hazards present in the plant.

• In general, all pipelines carrying flammable liquids/vapor are periodically checked

for their integrity. Spillages have to be avoided and disposal should be done

quickly.

6.7.5 Toxic Management Plan (Terms of Reference No.Add. TOR 5 & 6)

The list of chemicals identified to have toxic or carcinogenic nature is presented in Table

6.17.

Table 6.17 List of Toxic/Carcinogenic Chemicals and Mode of Storage/Transport S.No Name of Raw

Material Max

Storage Quantity

(Kgs)

Physical State

Mode of Storage

Type of Hazard

Mode of Transport

1 2-Chloro Acetamide 120 Crystalline HDPE Bags Toxic By Road 2 2-Bromo aniline 380 Solid HDPE Bags Toxic By Road 3 2-Chloro-5-Iodo

benzoic acid 200 Solid HDPE Bags Toxic By Road

4 5-Acetonyl-2-methoxy benzene sulfonamide

25 Solid Bags Toxic By Road

5 7-Sodiumoxy-3,4-Dihydro-1H-quinolin-2-one

110 Solid Bags Toxic By Road

6 Alluminium Chloride 500 Powder HDPE Bags Carcinogenic By Road 7 Ammonia 400 Gas Cylinders Toxic By Road 8 Aniline 150 Liquid Drums Toxic By Road 9 Benzahydrol 235 Solid HDPE Bags Toxic By Road 10 Bromine 540 Liquid Drums Toxic By Road 11 Carbazole 100 Powder HDPE Bags Carcinogenic By Road



12 Carbon tetra chloride 215 Liquid Drums Toxic By Road 13 Chloroacetyl chloride 390 Liquid Drums Toxic By Road 14 Cyclohexane 2000 Liquid Drums Toxic By Road 15 Dibromo ethane 25 Liquid Drums Toxic By Road 16 Diethyl Maleate 40 Liquid Drums Carcinogenic By Road 17 Formaldehyde 100 Liquid Drums Toxic By Road 18 Formamide 2000 Liquid Drums Carcinogenic By Road 19 Hydroxylamine HCl 40 Crystalline HDPE Bags Carcinogenic By Road 20 Hydroxylamine

sulfate 100 Crystalline HDPE Bags Carcinogenic By Road

21 Lithium Diisopropylamide

165 Liquid Drums Toxic By Road

22 Malano nitrile 105 Solid HDPE Bags Toxic By Road 23 Methyl iodide 200 Liquid Drums Toxic By Road 24 Methylene Dichloride 20000 Liquid Storage

tanks Carcinogenic By Road

Handling: Storage & handling in compliance with MSDS. The transfer of solvents shall be

mainly by closed pipeline systems, while solvents are transferred from drums by using

air operated diaphragm pumps in closed hoods. Solid phase raw materials are charged

by using closed hoppers to avoid dust emissions and hazard of static electricity. SOP’s

for better operational control.

Engineering Control Measures: All the operations filtration, centrifugation, drying is

conducted in closed conditions. Forced dry ventilation system to hoods. Vent condensers

in series to reactors, distillation columns, driers and centrifuge to mitigate atmospheric

emissions of toxics. Solvents with low boiling point will be stored in double limpet coil

storage tanks with coolant circulation.

Vents of secondary condensers connected to vacuum pumps followed by tertiary

condenser. Common headers connecting all the process vents and the same are connected

to scrubbers. Low boiling solvents tanks are connected with reflux condensers to

minimise the loss. The transfer pumps shall be provided with mechanical seals.

Personnel Protective Equipment: Personal protective equipment shall be provided to all

employees including contract employees. All the employees shall be provided with

gumshoe, helmet, masks, goggles. The other equipment like ear muffs, gloves, respirators,



aprons etc., will be provided to employees depending on the work area allocated to them.

The PPE selection shall strictly follow the prescribed guidelines of MSDS.

Health Monitoring of Employees: The pre employment screening and periodic medical

examination shall follow the guidelines of factories act. The pre employment screening

shall obtain medical history, occupational history followed by physical examination and

baseline monitoring for specific exposures.

Pre employment check up will be made mandatory and following test will be conducted:

• Plan of evaluation of health of workers

Chest x rays ECG Haemogram (examination of the blood) Urine (Routine and Microscopic) Complete physical examination

- Musculo-skeletal disorders (MSD) - Backache - Pain in minor and major joints - Fatigue, etc.

Frequency of Health Monitoring Occupation Type of evaluation Frequency Process area Complete blood count, platelet count, and

measurement of kidney and liver function, and medical examination with focus on liver, kidney, nervous system and skin,

Every 5 years to age



Transportation of raw materials may result in accidents due to high speed collision, low

speed collision, overturning and non-accident-initiated release. The initiating and

contributing causes are presented in Table 6.18

Table 6.18 Truck Incidents – Initiating and Contributing Causes Human Errors Equipment Failures System or Procedural

Failures External Events

Driver Impairment

Non-dedicated trailer Driver incentives Vandalism/ Sabotage

Speeding RR crossing guard Driver training Rain Driver Overtired Failure Carrier selection Fog Contamination Leaking Valve Container Specification Wing Overfilling Leaking Fitting Route selection Flood/washout Other Vehicle's Driver

Brake Failure Emergency response training

Fire at rest areas/parking reas

Taking Tight Insulation/Thermal Protection Failure

Speed Enforcement Earthquake

Unsecured Load Relief device failure Driver rest periods Existing accident Tire failure Maintenance Inspection Soft shoulder Overpressure Time of day Restrictions Material defect Steering failure Sloshing High center of gravity Corrosion Bad Weld Excessive Grade Poor Intersection design Suspension system

The scenarios presented for storages are calculated for transport related

incidents/accidents and presented in Table 6.19.

Table 6.19 Transportation Specific Concerns

Concern Road Spill on Water Over or near a body of water Unconfined Pools In an undisturbed flat area BELVE-Induced catastrophic vessel failure

Possible if sufficient quantity in car with small leak to feed fire or if double tank trailer or burning fuel leak

Toxic products of combustion or reaction

Dependent on material and whether ignition occurs



6.7.7 Control Measures for Accidental Spillage of Chemicals Name of the Chemical Stored

Storage Details Hazard Rating Systems Type of Hazards Involved Persons Effected

Control Measures Quantity

(KL) Pressure/

Temp TLV

(PPM) STEL (PPM)

FP (OC)

Acetone 30 NTP 1000 500 -20 Highly flammable liquid and vapor. Causes serious eye irritation. May cause drowsiness or dizziness.

Operators Maintenance Technicians

Keep away from heat/sparks/open flames/hot surfaces. - No smoking. Avoid breathing dust/ fume/ gas/ mist/ vapors/ spray. IF IN EYES: Rinse cautiously with water for several minutes. Remove contact lenses, if present and easy to do. Continue rinsing. Safety board’s displayed on the tank. Effective ventilation must be provided. For accidental contact if you feel unwell, seek medical advice immediately. Handling of Acetone with Safety gloves and protective clothing

Dimethyl Formamide

30 NTP 10 58 Flammable liquid and vapor Harmful in contact with skin Causes serious eye irritation Harmful if inhaled


Avoid exposure - obtain special instructions before use. Avoid contact with skin and eyes. Avoid inhalation of vapor or mist. Keep away from sources of ignition - No smoking. Take measures to prevent the buildup of electrostatic charge. Wear respiratory protection. Avoid breathing vapors’, mist or gas. Ensure adequate ventilation.

Methanol 20 NTP 1000 1000 14 Highly flammable liquid and vapor.


Keep away from heat/sparks/open flames/hot surfaces. Use personal protective equipment. Avoid breathing vapors, mist or gas. Ensure adequate ventilation. Remove all sources of ignition. Evacuate personnel to safe areas.

Methylene Dichloride

20 NTP 50 13 Limited evidence of a carcinogenic effect.


Do not breathe gas/fumes/vapour/spray. Avoid contact with skin and eyes Wear suitable protective clothing and



gloves. Store in cool place. Keep container tightly closed in a dry and well-ventilated place. Containers which are opened must be carefully resealed and kept upright to prevent leakage

Toluene 20 NTP 200 4 Highly flammable liquid and vapor. May be fatal if swallowed and enters airways. Causes skin irritation May cause drowsiness or dizziness. May cause damage to organs through prolonged or repeated exposure


Keep away from heat/sparks/open flames/hot surfaces. - No smoking. Avoid breathing dust/ fume/ gas/ mist/ vapours/ spray. Use personal protective equipment as required. IF SWALLOWED: Immediately call a POISON CENTER or doctor/ physician. Do NOT induce vomiting. Use personal protective equipment. Avoid breathing vapors, mist or gas. Ensure adequate ventilation



6.8 Disaster Management Plan (Terms of Reference No.57)

6.8.1 Introduction

A disaster is a catastrophic situation in which suddenly, people are plunged into

helplessness and suffering and, as a result, need protection, clothing, shelter, medical and

social care and other necessities of life.

Disasters can be divided into two main groups. In the first, are disasters resulting from

natural phenomena like earthquakes, volcanic eruptions, storm surges, cyclones, tropical

storms, floods, avalanches, landslides, and forest fires. The second group includes

disastrous events occasioned by man, or by man's impact upon the environment.

Examples are armed conflict, industrial accidents, radiation accidents, factory fires,

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

other structural collapses, air, sea, rail and road transport accidents and can reach

catastrophic dimensions in terms of human loss.

There can be no set criteria for assessing the gravity of a disaster in the abstract since this

depends to a large extent on the physical, economic and social environment in which it

occurs. However, all disasters bring in their wake similar consequences that call for

immediate action, whether at the local, national or international level, for the rescue and

relief of the victims. This includes the search for the dead and injured, medical and social

care, removal of the debris, the provision of temporary shelter for the homeless, food,

clothing and medical supplies, and the rapid re- establishment of essential services.

An emergency may be said to begin when operator at the plant or in charge of storage of

hazardous chemicals cannot cope up with a potentially hazardous incident, which may

turn into an emergency. The emergencies could be a major fire or explosion or release of

toxic gas or a combination of them.

The proposed plant will store fuels, which are flammable in nature, and the storage will be

as per the Controller of Explosives and OISD norms. The hierarchy of the employees is



yet to be determined and the project is still in the initial stages of designing. Hence a

tentative disaster management plan is prepared to be suitably modified before

commissioning of the plant.

6

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