0 0 19092014A2NEUAnnexure-Updated Form1 PDF
0 0 19092014A2NEUAnnexure-Updated Form1 PDF
0 0 19092014A2NEUAnnexure-Updated Form1 PDF
ARCHEAN CHEMICAL
INDUSTRIES PVT. LTD.
Kadam
Environmental Consultants
www.kadamenviro.com
This report is released for the use of the M/s. Archean Chemical Industries Pvt. Ltd., Regulators and
relevant stakeholders solely as part of the subject project’s Amendment in Environmental Clearance
process. Information provided (unless attributed to referenced third parties) is otherwise copyrighted
and shall not be used for any other purpose without the written consent of Kadam.
QUALITY CONTROL
Form I for Amendment in Environmental Clearance of Chemical Fertilizer Manufacturing
Name of
Unit and Co-generation Power Plant (10 MW) at Greater Rann of Kachchh, Near Hajipir,
Publication
Taluka Bhuj, District Kachchh, Gujarat.
Project Report Releas September,
1419391606 1 Version 1
Number No. ed 2014
DISCLAIMER
Kadam has taken all reasonable precautions in the preparation of this report as per its auditable quality plan.
Kadam also believes that the facts presented in the report are accurate as on the date it was written.
However, it is impossible to dismiss absolutely, the possibility of errors or omissions. Kadam therefore
specifically disclaims any liability resulting from the use or application of the information contained in this
report. The information is not intended to serve as legal advice related to the individual situation.
CONTENTS
1 SCOPING ................................................................................................... 1
2 DECLARATION: ......................................................................................... 10
3 ANNEXURES ............................................................................................. 11
LIST OF ANNEXURES
Annexure 1: Details of Products, Raw Material, Manufacturing Process............................................ 12
1 SCOPING
1.1 FORM – 1
The scoping for the project has been done based on FORM 1, as per EIA Notification, dated
September 14, 2006 amended as on date. The scoping details are as follows:
I. Basic Information
S.
Item Details
No.
1 Name of the Project/s Archean Chemical Industries Pvt. Ltd.
2 S. No. in the Schedule Project / Activity: 5(a) – Chemical Fertilizers
Proposed capacity / area / length / Proposed production capacity will be 1,96,000
3 tonnage to be handled/ command area MT/Annum. Proposed Land area will be used: 253
/ lease area / no. of wells to be drilled hectares.
Amendment in Existing EC approval. (EC condition
4 New / Expansion / Modernization number 19 as per F. No. J-11011/149/2010-IA
II(I) dated 2nd September, 2011)
S.N. Product Quantity
1 Sulphate of Potash 1,00,000
5 Existing Capacity / Area etc. 2 Liquid Bromine 12,500
3 Green Bromine 2,500
4 Epsomite 81,000
6 Category of Project (A or B) “A”
No, Does not fall under Protected area under
Wildlife Protection Act, 1972. Does not fall under
Does it attract the general conditions?
7 Critically Polluted Areas. No eco-sensitive area as
If yes, please specify.
per EA, 1986. International boundary beyond 10
Km.
Does it attract specific condition? If yes,
8 N.A.
please specify
Location Rann of Kachchh.
Plot Survey / Khasra No. Un-Survey Land
Village Nr. Hajipir
9
Tehsil / Taluka / Mandal Bhuj
District Kachchh
State Gujarat
Nearest railway station / airport / along Bhuj railway station – 110 Km
10
with distance in km. Bhuj Airport – 110 Km
Nearest town, city, district Nearest village : Hajipir –16 Km
11 headquarters along with distances in Nearest city : Bhuj –110 Km
kms District Headquarters: Bhuj
Village Panchayat, Zilla Parishad, Hajipir Gram Panchayat
12
Municipal Corporation, Local Body C/o Luna Juth Panchayat
S.
Item Details
No.
(complete postal address with At & P.O. Hajipir
telephone nos. to be given) Taluka: Bhuj, Pin Code- 370605
Dist. Kutch, Gujarat
13 Name of the applicant Archean Chemical Industries Pvt. Ltd.
5 th Floor, Tower II, TVH Beliciaa Towers, 94,
14 Registered address
MRC Nagar, Chennai – 600028, TamilNadu –India
Address for correspondence
Name Mr.V.Manickam
Designation Executive Vice President
”Anandam”, D/4, Nu-10-B, Opp. Lions Club,
Address Shaktinagar, P.O. Gandhidham,
15 Dist. Kutch, Gujarat.
Pin Code 370 201
E-mail manickam@acipl.co
044-43033444 /
Telephone no.
02836-234259/234158/233841
Fax no. 02836-233400
Details of alternative sites examined, if
Rann of Kutch is the best location for extraction of
16 any. Location of these sites should be
marine chemicals.
shown on the Toposheet.
17 Interlinked Projects None.
Whether separate application of
18 No.
interlinked project has been submitted?
19 If yes, date of submission N.A.
20 If no, reason N.A.
Whether the proposal involves approval
/ clearance under: if yes, details of the
same and their status to be given:
21 N.A.
The Forest (Conservation) Act, 1980
The Wildlife (Protection) Act, 1972
The C.R.Z Notification, 1991
Whether there is any Government order
22 N.A.
/ policy, relevant / relating to the site
23 Forest land involved (ha.) No. It is the Greater Rann Of Kachchh.
Whether there is any litigation pending
against the project and / or land in
which the project is proposed to be set
24 up? Name of the Court, Case No. No. New Project.
Order / directions of the Court, if any
and its relevance with the proposed
project
II. Activity
1. Construction, operation or decommissioning of the project involving actions,
which will cause physical changes in the locality (topography, land use, changes in
water bodies, etc.)
Facilities for long term housing of Housing facilities provided in nearby towns and
1.16 Yes
operational workers? villages.
2. Use of Natural resources for construction or operation of the Project (such as land,
water, materials or energy, especially any resources which are non-renewable or
in short supply):
3 ANNEXURES
Brief Process:
Harvested crude Magnesium salt will be leached in NaCl saturated circulating brine at an elevated
temperature making MgSO4 and minor amounts KCl (if any) get dissolved. After adjustment of the
solution in terms of MgSO4 concentration and post separation of non dissolved NaCl, the clear liquor
will be cooled to 10 - 15°C to produce a pure and NaCl free Epsomite. Some of this Epsomite will be
used in the process of SOP production, while the rest is saleable. The same circulation liquor will be
re-used and a small part will be bleed-off and sent to the solar pond system. The non dissolved NaCl
will be re-dissolved in Sea water and sent back to the solar ponds.
Secondly the Harvested Salt Mixture will be mixed with seawater in order to decompose Carnallite and
dissolve MgCl2. The remaining un-dissolved KCl, MgSO4 and NaCl mixture will be used for the SOP
process and the mother liquor called ‘Carnallite deomposed liquor’ which will be recycled to Solar
Pond.
The above two beneficiated raw salts 1) harvested epsomite salt and 2) harvested salt mixture will be
mixed together, in a KCl: MgSO4 concentration that corresponds to the same ratio as existing in
Kainite. This mixture called ‘Synthectic Kainite’ will be mixed with seawater and cooled SOP mother
liquor for dissolution, so that Primary Schoenite will be generated. The ‘Schoenite mother liquor’
separated from Primary Schoenite will be re-cycled to Solar Pond.
Primary Schoenite generated from the earlier stage and the recovered / secondary Schoenite will be
leached with Seawater at 48°C, by which K2SO4 begins to crystallize out while MgSO4 will remain in
solution. When the MgSO4 concentration will reach approx 225 g/1000g H2O, the resulting slurry will
be centrifuged, washed with small amount of fresh water and dewatered to produce SOP and a Hot
SOP mother liquor. The Hot SOP mother liquor will be cooled to 10 – 15°C in order to generate
recovered / secondary Schoenite and cooled SOP mother liquor, depending on the NaCl concentration
in Schoenite, purification of Schoenite will be accomplished by using a wash with fresh water and / or
a flotation to remove NaCl.
Chemical Reaction:
2KCl.MgSO4.3H20 + MgSO4 + 3H2O K2SO4.MgSO4.6H2O + MgCl2 + 3H20
Brief Process:
Steaming out process (STO) for Liquid Bromine:
Feed bitterns from reservoir will be acidified to 3.5 pH by addition of acid in a feed tank and pumped
to the top of stripping tower packed with pall rings. Steam and chlorine will be injected at the bottom
of the tower. Liberated bromine will be condensed and purified in a separate tower by heating with
indirect steam, Bromine will again get condensed and refluxed backed to top of tower and liquid
bromine will be drawn from the bottom of this purifying tower, cooled and bottled in glass bottles
and/or filled in ISO tanks for dispatch.
Air Blow out Process (ABO) for Liquid Bromine / Green Bromine:
Bittern from the reservoir will be acidified to pH 3.5 by the addition of acid in a feed tank and pumped
to the top of stripping tower packed with pall rings; air and chlorine will be injected at the bottom of
the tower. Liberated Bromine laden by air will be made to react with soda ash or caustic soda solution
venting of unreacted air by circulating in a series of packed towers.
Part of this enriched alkaline solution (AB solution) will be the mixture of bromide, bromate
compounds from which again Bromine will be regenerated by the addition of acid. Regeneration of
Bromine will be done by a method similar to steaming out process but with smaller equipment as the
feed liquor will be highly concentrated.
Regenerated Bromine led out by steam given at the bottom of the tower will be condensed, separated
and processed further in distillation unit for the removal of impurities and packed in glass bottles
and / or in ISO tanks for dispatch.
Green Bromine:
Part of AB solution - the bromide bromate mixture from air blow out process will be taken for the
addition of chlorine to convert bromide to bromate and to maintain the ratio at 2:1. This converted
mixture will be again mixed with alkaline solution and proper concentration of bromate will be
maintained at a neutral pH by addition of caustic soda. This will be green Bromine in solution. It can
be evaporated to form solids by crystallizing in open pan or closed evaporator, cooled, packed in bags
and sold. It can also be sold as liquid in containers.
Site Plan
The sewage generated from the project will be taken to a sewage treatment plant and the treated
waste water will be used for green belt development and gardening. The total domestic waste water
generated will be about 152 m3/day.
The boiler blowdown, cooling tower blowdown, and washings effluent will be utilized for preparation of
lime slurry. The acidic effluent will be neutralized by this lime slurry in a stirred vessel. The settled
sludge which is gypsum will be utilized for strengthening of the bunds. The treated waste water is
recycled to solar ponds for solar evaporation
The waste water generated is acidic in nature. The acidity is mainly due to use of Sulphuric acid in the
reaction. The tentative characteristics of the untreated waste water are given as follows:
Flow Chart
The boiler will be equipped with air pollution control unit for control of particulate matter.
Max.
Sr. Quantity Physical
Product Storage Stored in MOC
No. MT/Annum Form
at a time
HDPE
Sulphate Closed
1 1,00,000 30,000 Solid lined
of Potash Shed
bag
Containers MS
2 Bromine 12,500 300 Liquid / Glass Lead –
Bottles lined
HDPE
Green Closed
3 2,500 250 Solid lined
Bromine Shed
bag
HDPE
Heaps in
4 Epsomite 81,000 12,000 Solid lined
closed shed
bag
Liquid Bromine will be filled in specially designed glass bottles of 1 liter capacity.
Filled bottles will be duly sealed with bottle caps & inserts. These bottles will be packed in wooden
crates / plastic crates.
Each wooden crate / plastic crate will have six partitions to accommodate six filled bottles.
After keeping filled bottles in wooden crates cushion materials like vermiculate will be filled in
crate to avoid breakages if any enroute.
After filling cushion materials in the wooden crates, crate will be packed with wooden lids duly
nailed & strapped with plastic strip.
Each truck will carry approximately 4.032 MT bromine (224 wooden crates x 6 bottles each)
depending up on truck capacity.
Loaded truck before leaving factory premises will be covered with Tarpalin.
About INR. 18 per Kg will be spent as packing cost.
Each loaded truck will be provided with Sodium Thyosulphate (5 - 25 kg) for using enroute in case
of any leakages / spillages.
Each truck driver carrying bromine will be imparted safety training on how to handle bromine in
case of spillages / leakages.
Transport emergency card will be provided to each truck at the time of dispatch.
Each truck driver will be having mobile set to establish contacts with factory on day to day till
truck reaches at destination point.
Good & sound condition of vehicles having road worthy certificate issued by RTO to be used for
bromine transport
Trained drivers who are conversant with handling of hazardous chemicals are to be engaged for
bromine transport
In house training to truck drivers every six months by safety officer to be imparted
Safety PPE like, gum boots, hand gloves, face mask to be given to truck driver before leaving
loaded truck from factory gate
Dispatch / safety department should ensure before leaving loaded truck from factory gate to
provide neutralization chemicals like Sodium Thyosulphate powder to truck driver and driver to be
guided how to use the chemicals in case of leakages /spillages
Trem card to be handed over to truck driver which contains list of activities to be taken in case of
accidents.
Truck driver should be instructed to carry loaded trucks only on good roads connected to state /
national highways & not to take any short routes.
Truck driver should be instructed to carry mobile set & he should establish contact on day to day
with factory till truck reaches at destination point.
Truck driver should be instructed to ply / drive the loaded truck only during day time & no driving
during night time.
Truck drivers to be instructed to contact either our factory / Gandhidham office / Chennai office in
case of any accident happens like spillages/ leakages / toppeling of loaded truck
On receipt of information from truck driver safety officer / production officer should depute rescue
team immediately with safety PPES to accident spot
Head –safety should co-ordinate with rescue team till the matter get resolved.
PREPARED BY
This is the first Risk Assessment report of this company for new project and it has
been carried out during the month of June- 2010.
Risk Assessment is a legal requirement u/r 12-c & 68-O of the Gujarat Factories
Rules.
We are thankful to the Mr. Sethuram (Occupier) and Mr. R.R. Sorathia( Project
Incharge). In particular we acknowledge the continuous support given to us by Mr.
R.R.Sorathia for completion of this report.
Authorized Signatory
1 Executive Summary 5
2 Objectives, Philosophy and methodology of 7
Risk assessment
3 Introduction of the unit 9
3.1 Company Introduction 9
3.2 Details of Unit 9
3.3 Project setting 12
3.4 Organisational setup 16
3.5 List Of Proposed product 16
3.6 List of Proposed Raw Material 16
3.7 Details of storage of Hazardous Materials in 17
Bulk and control measures provided
3.8 Brief Description of process plant 18
3.9 Hazardous Properties Of The Chemicals, 18
Compatibilities, Special Hazard & Antidotes
3.10 Facilities / System for process safety, 21
transportation, fire fighting system and
emergency capabilities to be adopted
4 Hazard identification 27
4.1 Introduction 27
4.2 DOW’s Fire and Explosion Index 28
4.3 Failure Frequencies 29
4.4 Identification of Hazardous area 31
5 Risk Assessment 33
5.1 Effects of Release of Hazardous Substances 33
5.2 Identification of High Risk Areas 34
5.3 Modes of Failure 34
5.4 Damage Criteria for heat radiation 36
6 Consequence Analysis 37
6.1 Consequence Analysis 37
6.2 Assessment of Consequences Modeling results 63
6.3 Comments 64
7 Risk Reduction Measures 65
7.1 Design 65
7.2 Process 65
7.3 Bromine Storage & Handling Safety 66
EXECUTIVE SUMMARY
2.1 Objective :
The main objectives of the Risk Assessment (RA) study is to determine damage due to
major hazards having damage potential to life & property and provide a scientific basis to
assess safety level of the facility.
The principle objective of this study was to identify major risks in the manufacture of
chemicals and storage of hazardous chemical at site and to evaluate on-site & off-site
consequences of identified hazard scenarios. Pointers are then given for effective
mitigation of hazards in terms of suggestions for effective disaster management,
suggesting minimum preventive and protective measures & change of practices to ensure
safety.
2.2 PHILOSOPHY :
2.3 Methodology
The procedure used for carrying out the Quantitative Risk Assessment Study is outlined
bellow:
Identify Credible Loss Scenarios for the facility under the study by discussion with
ACIPL. Simulate loss Scenarios to determine the vulnerable zones for toxic dispersion
using software packages HAMSGAP.
Suggest mitigating measures to reduce the damage, considering all aspects of the facilities.
The flowchart of the methodology for the present study is shown in following page.
START
END
M/s. Archean Chemicals Industries Pvt. Ltd., is going to establish its manufacturing
unit of Fertilizer products and Bromine and Green Bromine at & post Village Hajipir,
Taluka Bhuj, Dist. Kutch.-370605
Archean Group is a privately held and professionally managed business conglomerate with
diversified business interests in high growth sectors including mining & minerals,
industrial salt, shipping & shipbuilding, building materials, energy, oil & gas services, and
industrial chemicals & fertilizers.
Proposed unit is classified as Major Accident Hazards unit ( MAH Installation ) based on
the storage of the listed hazardous chemicals more than specified threshold
quantities.(Schedule 3 under Rule 68-J of the Gujarat Factories Rules-1963 (2004).
Temperature
Maximum 45º C
Minimum 2ºC
Relative Humadity :
Maximum 56 %
Minimum 7%
Average 162.7 mm
Wind Velocity :
The plant is located at 730 13’ 10” East longitude & 210 18’30” North latitude Nr. Hajipir
village, Ta: Bhuj, Dist : Kuchchh in Gujarat State. The area is classified as Greater Rann
of Kuchchh.
The site location is shown as figure 1.1. and plant layout is provided as figure 1.2.
M/s. Archean Chemical Industries Pvt. Ltd., intends to setup a unit in Greater Rann Of
Kutch, Near Hajipir, Ta.: Bhuj, District: Kutch, Gujarat. The company intends to
manufacture Sulphate of Potash, Liquid Bromine, Green Bromine and Epsomite. The total
area required by the plant will be about 62 hectares. The proposed site is about 16 kms
north of Hajipir, which is the nearest village.
Factory Manager
Plant manager
Helper/ Worker
Table-3.1
Liquid 18MT X 10 Nos. ISO ATP Toxic & Separate store will be made in cool
Bromine, ISO MS lead container / corrosive and dry place.
lined containers Plant store Safe handling procedure for bromine
=180 MT and 3 Area will be prepared, displayed and
Kg x 40000 glass trained to employees.
bottles packed in Emergency handling procedure will
6667 wooden be prepared and train for the same.
boxes each PPEs will be procured and made it
Containing 6 compulsory for bromine handling.
bottles =120 MT Close process will be designed for
4 m3 x 2 nos. MS bromine handling.
glass lined Day Nitrogen pressure or pump transfer
tanks - maximum Air blow will be adopted for bromine handling.
storage at any out process Hazard identification and emergency
point of time will Area action plan will be prepared and train
be 18 all plant people for the same.
MT SOP will be prepared for safe
15 m3 x 2 nos. handling and storage of Bromine
MS glass lined NFPA lable will be prepared and
Day tanks - displayed on containers & storage
maximum storage Steaming tank.
at any point of out process
time will be 72 Plant
MT
Green 250 MT in HDPE Storage ATP Corrosive
Bromine lined bags Area
Caustic Soda 20 MT Godown ATP Corrosive Safety Showers provided
Flakes, Caution note provided
Dyke wall provided
Caustic Soda 200 MT Tank Corrosive Level gauge provided.
lye 50% Double drain valve provided to tank
Required PPEs provided to all
employees
Sulphuric 200 MT Storage ATP Corrosive Double drain valve will be provided
Acid Tanks MS tank to sulfuric Acid storage tank
Full body protection will be provided
to operator.
Caution note and emergency first aid
will be displayed and train for the
same to all employees.
Safety shower and eye wash will be
provided in storage tank area and
plant area.
Total close process will be adopted
for Sulfuric acid handling.
Dyke wall will be provided to storage
tank
Tanker unloading procedure will be
prepared.
SOP will be prepared for sulfuric
Acid handling.
Training programme will be
conducted for safe handling and
emergency handling of Sulfuric Acid.
Transport:
1. Raw Material :
Chlorine will be transported in tonners.
Sulphuric acid will be transported in closed tanks.
2. Finished Product:
Bromine will be transported in closed ISO tanks or closed bottles.
1 Chlorine N.A N.A N.A 293 N N.A N.A N.A -34 A Hazardous
ppm/1hr.
2 Liquid Bromine 0.1 2600 N.A 2700 N N.A N.A N.A 58 -- Hazardous
mg/m3
3 98% Sulphuric Acid N.A 2140 N.A 510 N N.A N.A N.A 290 -- Hazardous
mg/m3
F = FIRE T = TOXIC
E = Explosive R = REACTIVE
BP = BOILING POINT LEL = LOWER EXPLOSIVE LIMIT
UEL = UPPER EXPLOSIVE LIMIT SP.GR = SPECIFIC GRAVITY
VD = VAPOUR DENSITY ER = EVAPORATION RATE
H = HEALTH HAZARD CLASS F = FIRE HAZARD CLASS
R = REACTIVE HAZARD BR = BURNING RATE
TLV = THRESHOLD LIMIT VALUE PPM = PARTS PER MILLION
STEL = SHORT TERM EXPOSURE LIMIT NFPA = NATIONAL FIRE PROTECTION ASSOCIATION-usa
36. Open pressure release line blind flange and connect ISO container
pressure release line to plant scrubber header line and open valve. Use
a new rubber gasket (use limit - 24 hours) to ensure tight connection.
37. Make sure the absorber unit is working and capable of handling vented
bromine fumes from ISO container.
38. Remove the blind flange above the valve.
39. Connect charging line to the valve inlet. Use a new rubber gasket (use
limit - 24 hours) to ensure tight connection.
40. Open the valve and all the valves in your liquid loading line.
41. Start pump for charging bromine in ISO container.
42. Personal protective equipment will be used as per requirements and
details given bellow.
43. Liquid bromine will be charge through bromine storage tank, which
will be on weighing shell so transfer quantities can be measured.
Generally ISO container of 18MT will be used for shipping.
44. When the container filled, Off charging pump. Drain flexible hose
properly in ISO container and close charging line valve and ISO
container charging line valve.
45. Disconnect hose connection safely and blind ISO container charging
line as well as storage tank charging line.
46. Disconnect vent line and blind ISO container vent line.
47. Close cover dome and pin it securely.
3.10.4 Safe Transportation procedure to be adopted for Bromine ISO container and
bromine glass bottle crate.
The driver and assistant driver of any vehicle transporting bromine should
comply with the following requirements:
48. GPS will be installed in all the trucks and ISO container vehicle.
49. Driver and assistant will be trained in using GPS.
50. Open space separated from public highway and public dwellings,
where public does not normally pass. No passengers are allowed.
51. The crew shall know how to use fire-fighting appliances.
52. The driver or driver's assistant may not open a package containing
bromine.
53. Bromine receptacles are not to be checked with open flames.
54. No smoking is permitted around the transport unit or in the vicinity of
the vehicle during handling operations.
55. The engine is to be shut off during all handling operations unless
required to drive pumps, hoist, etc.
56. Parking brakes are to be applied whenever parked.
68. We will inform our all employees of the potential hazards of contact
with bromine and train them in appropriate first-aid procedures.
69. Bromine handling areas will be clearly marked and restricted to
qualified, trained personnel only.
3.10.7 Ventilation
70. We will maintain bromine vapor concentration in the work area to less
than 0.1 ppm with adequate exhaust hoods, ventilation systems and
scrubbers. Analyze air for proper control.
71. Transfer or repackage bromine only in a controlled, closed
environment.
72. Exhaust ventilating systems will be used in enclosed areas where
bromine is handled.
73. Bromine glass bottle capacity 3.0 / 3.5 Kg and six bottles are stored in
one packing box.
74. Bromine will be stored in dry and cool place and well ventilated area.
3.10.10Emergency Procedures
In case of bromine emergencies, follow recommended first aid and emergency response
procedures adopted
3.10.11Transportation Emergencies
3.10.12Leaking Containers
4.1 INTRODUCTION
Risk assessment process rests on identification of specific hazards, hazardous areas and
areas vulnerable to effects of hazardous situations in facilities involved in processing and
storage of chemicals.
In fact the very starting point of any such assessment is a detailed study of materials
handled & their physical / chemical / thermodynamic properties within the complex at
various stages of manufacturing activity. Such a detailed account of hazardous materials
provides valuable database for identifying most hazardous materials, their behaviour
under process conditions, their inventory in process as well as storage and hence helps in
identifying vulnerable areas within the complex.
It will be from the above discussion that study of various materials handled is a
prerequisite from any hazard identification process to be accurate. Based on this study
the hazard indices are calculated for subsequent categorization of units depending upon
the degree of hazard they pose.
The main hazard in this plant only bromine manufacturing, handling and storage,
concern has always been toxic release prevention and control as these are the main hazard
posed by this unit. This concern has grown through the lose of life, property and
materials experienced after experienced after major disasters, which have occurred over
the years.
Identification of hazards is the most important step to improve the safety of any plant.
The hazard study is designed to identify the hazards in terms of chemicals, inventories
and vulnerable practices /operations.
The hazard evaluation procedures use as a first step by chemical process industries and
petroleum refineries are checklists and safety reviews. Dow and Mond fire and explosion
indices, which make use of past experience to develop relative ranking of hazards, is also
extensively used. For predictive hazard analysis, Hazard and Operability studies
(HAZOP), Fault tree analysis, Event tree analysis, Maximum credible accident and
consequence analysis etc are employed.
4.2.1 Steps in fire and explosion index calculation are given below :
F3XMaterial Factor
=F & E Index
4.3.1 Hazardous material release scenarios can be broadly divided into 2 categories
Releases from failure of gaskets, seal, rupture in pipelines and vessels fall in the second
category whereas catastrophic failure of vessels and full bore rupture of pipelines etc fall
into the first category.
TABLE-4.2
TABLE-4.4
A study of process for manufacturing as given in chapter 2 of the report indicates the
following:
Various raw materials used in the manufacturing processes are listed in Table-3.2 in
Section-3 along with mode / type of storage & storage conditions. It can be readily seen
that raw materials even though hazardous in nature, are used in continuous process &
inventory is low at process plant. However some chemicals such as Chlorine, sulphuric
Acid are used / common in more than one process & therefore their inventory requirement
is higher. Bromine, Sulphuric Acid and Chlorine are stored separately . List of chemicals
stored in larger quantities is provided in Table-4.5
4.4.1.1 Major inventory of Hazardous chemicals within the factory premises are-
The materials were studied with respect to their flammability, reactivity and toxicity based
on the criteria given by the NFPA (NFPA ratings). Material factor values were determined
using these ratings. General process hazards and Special process hazards for all the
materials stored were determined as per the guidelines given by DOW Chemicals
Company in DOW Index. FEI values for all these materials were calculated form the
above data.
Value of material factor, General Process Hazard & Special Process Hazard as also FEI /
TI values & degree of hazard are given in Table 4.1 It can be seen storage in tank farms is
mostly in the Severe category due to pressure storage and highly flammable and toxic
nature of chemicals. The radius of exposure for various tanks considering FEI Values is
also calculated and presented in the Table.
Proposed Bromine process plant would be a state of the art Technology process fully
automatic DCS operation and continuous process plant. Thus the inventory of
hazardous chemicals is in the plant is very small.
Proposed plants will be controlled by Distributed Control System (DCS) to provide an
integrated plant control built in safety devices. Process parameters control and
interlocking will be provided and foolproof safety interlocking and logics applied at
design level and maintained.
RISK ASSESSMENT
The source strength is equal to the contents of the capacity of the storage
system.
Pool Fire
In the event of the instantaneous release of a liquid a pool of liquid will
form. The evaporation can be calculated on the basis of this pool.
The heat load on object outside a burning pool of liquid can be calculated
with the heat radiation model. This model uses average radiation intensity,
which is dependent on the liquid. Account is also taken of the diameter-to-
height ratio of the fire, which depends on the burning liquid. In addition,
the heat load is also influenced by the following factors :
DISPERSION CASES :
PLUMES :
Plumes are continuous release of hazardous gases and vapours. Smoke from
a chimney is an example. Plumes can cause FIRES AND EXPLOSIONS as
secondary scenarios.
PUFFS :
Puffs are instantaneous release of hazardous gases and vapours. Puffs can
give rise to FIRE BALLS and vapour cloud explosions(VCE). A special
case of vapour cloud explosion is the Boiling Liquid Evaporating Vapour
Explosion (BLEVE).
SPILLS POOL:
Spills are liquid pools created by leaking liquid chemicals. Spills cause
evaporation and dispersal of toxic gases and if the spilled liquid is
flammable, then it can catch fire creating a pool fire also the vapours can
cause explosion.
5.3.1 Following failure are considered for detailed analysis and safe distances computed:
Considering the quantity of storages & nature of Toxic nature storage, following scenarios
were taken up for detailed analysis & safe distances computed :
Table-5.2
Scenario Failure Type Failure Mode Consequence
No.
1. Puff Isopleth Simulation Catastrophic Puff dispersion up to LC 50
For Chlorine Tonner failure Human, IDLH and TLV
Catastrophic Failure level.
2. Point source plume release Random failure Point source dispersion up
for Chlorine liquid/ gas to LC 50 Human, IDLH and
phase valve failure. TLV level.
3. Spill Pool Evaporation 200 Catastrophic Spill pool Evaporation
MT Sulfuric Acid storage failure dispersion up to LC 50,
Tank catastrophic failure IDLH and TLV level.
4. Puff release for Bromine Catastrophic Puff release up to LC 50,
12 MT Day tank failure IDLH and TLV level.
catastrophic failure
5. Spill pool Evaporation for Catastrophic Spill pool Evaporation
Bromine 12 MT Day tank failure dispersion up to LC 50,
catastrophic failure IDLH and TLV level.
6. Puff release for Bromine Catastrophic Puff release up to LC 50,
45 MT Day tank failure IDLH and TLV level.
catastrophic failure
7. Spill pool Evaporation for Catastrophic Spill pool Evaporation
Bromine 45 MT Day tank failure dispersion up to LC 50,
catastrophic failure IDLH and TLV level.
8. Puff release for Bromine Catastrophic Puff release up to LC 50,
18 MT ISO container failure IDLH and TLV level.
catastrophic failure
9. Spill pool Evaporation for Catastrophic Spill pool Evaporation
Bromine 18 MT ISO failure dispersion up to LC 50,
container catastrophic IDLH and TLV level.
failure.
10. HSD road tanker unloading Random failure Unconfined Pool file.
hose 100 release
Tank on fire /Pool fire due to direct ignition source on tank or road tanker
or catastrophic failure or leakage or damage from pipeline of storage
facilities or road tanker unloading arm, can result in heat radiation causing
burns to people depending on thermal load and period of exposure.
All such damages have to be specified criteria for each such resultant
effect, to relate the quantifier damages in this manner, damage criteria are
used for Heat Radiation.
TABLE 5.3
Heat Radiation
Incident Flux KW/m2 Damage
38 100% lethality, heavy damage to tanks
37.5 100% lethality, heavy damage to equipment.
25 50% lethality, nonpiloted ignition
14 Damage to normal buildings
12.5 1% lethality, piloted ignition
12 Damage to vegetation
6 Burns (escape routes)
4.5 Not lethal, 1st degree burns
3 1st degree burns possible
(personnel only in emergency allowed)
2 Feeling of discomfort
1.5 No discomfort even after long exposure
CONSEQUENCE ANALYSIS
In the risk analysis study, probable damages due to worst case scenarios
were quantified and consequences were analyzed with object of emergency
planning. Various measures taken by the company and findings of the study
were considered for deciding acceptability of risks.
6.1.2 Assumption :
6.1.2.4 For HSD Road tanker catastrophic failure( Unloading arm 100 % failure)
• LC50 HUMAN (1017 ppm) area up to 210 meter, IDLH (Immediate danger to life and health)
concentration area up to 856 meter and TWA (1 PPM ) area up to 1619 meter. Therefore 856
meter area in wind direction is considered as evacuation area.
• LC50 HUMAN (1017 ppm) area up to 51 meter, IDLH (Immediate danger to life and health)
concentration area up to 445 meter and TWA (1 PPM ) area up to 1038 meter. Therefore 445
meter area in wind direction is considered as evacuation area.
TABLE – C
Spill Pool evaporation module for Sulphuric Acid Storage Tank catastrophic failure
Results
• LC50 HUMAN (460 ppm) area up to 59 meter, IDLH (Immediate danger to life and health)
concentration( 3 ppm) area up to 587.63 meter and TWA (0.2 PPM ) area up to 1349.6 meter.
Therefore 587.63 meter area in wind direction is considered as evacuation area.
TABLE – D
Puff Release for Bromine 12 MT dat tank catastrophic failure
Results
• LC50 HUMAN (1075 ppm) area up to 902 meter, IDLH (Immediate danger to life and health)
concentration( 3.0 ppm) area up to 8369 meter and TWA (0.1 PPM ) area up to 30273 meter.
Therefore 8369 meter area in wind direction is considered as evacuation area.
TABLE – E
Results
• LC50 HUMAN (1075 ppm) area up to 50 meter, IDLH (Immediate danger to life and health)
concentration( 3.0 ppm) area up to 1418 meter and TWA (0.1 PPM ) area up to 10017 meter.
Therefore 8369 meter area in wind direction is considered as evacuation area.
TABLE – F
Puff Release for Bromine 45 MT dat tank catastrophic failure
Results
• LC50 HUMAN (1075 ppm) area up to 1487 meter, IDLH (Immediate danger to life and
health) concentration( 3.0 ppm) area up to 13794 meter and TWA (0.1 PPM ) area up to 49808
meter. Therefore 13794 meter area in wind direction is considered as evacuation area.
TABLE – G
Results
• LC50 HUMAN (1075 ppm) area up to 68 meter, IDLH (Immediate danger to life and health)
concentration( 3.0 ppm) area up to 1954 meter and TWA (0.1 PPM ) area up to 13787 meter.
Therefore 1954 meter area in wind direction is considered as evacuation area.
TABLE – H
Puff Release for Bromine 18 MT ISO container catastrophic failure
Results
• LC50 HUMAN (1075 ppm) area up to 1051 meter, IDLH (Immediate danger to life and
health) concentration( 3.0 ppm) area up to 9757 meter and TWA (0.1 PPM ) area up to 49808
meter. Therefore 35274 meter area in wind direction is considered as evacuation area.
TABLE – I
Results
• LC50 HUMAN (1075 ppm) area up to 61 meter, IDLH (Immediate danger to life and health)
concentration( 3.0 ppm) area up to 1743 meter and TWA (0.1 PPM ) area up to 12310 meter.
Therefore 1743 meter area in wind direction is considered as evacuation area.
TABLE –J
Unconfined Pool Fire for Solvent road tanker catastrophic failure
Results
Results of consequence analysis for the release of toxic chemicals are depicted in Table
6.3.
TABLE - 6.3
The appended table 6.3 summarizes the consequences of the various hazards analyzed
under this study.
As can be seen from the results of the summary of the Risk Analysis study, the Fatality
zone due to bromine up to 1485 meters in worst case scenario. Immediate Danger to life
and health up to 13795 meter. In case of Bromine release, evacuation zone maximum up to
13795 meter and company has to plan for evacuation accordingly. It is observed on the
Google map there is no any village or residential or any industrial activity in 15 kms.
vicinity area. In such case only company employees may be affected.
All employees should be well aware about possible emergencies and its consequences,
emergency control equipments and practices to control such hazardous condition within
premises.
Some of the safeties and risk reduction measures adopted and recommended for the safety of the
plant are as follows:-
7.1 Design
7.1.1 During the design stage itself adequate care has been taken for design, selection,
fabrication, erection and commissioning of Flammable and toxic liquid handling facilities
and other equipment, piping, pipe fittings, electrical equipment etc. relevant and prevalent
international and Indian standards has been followed for design, fabrication, inspection of
the storage tanks and other equipment.
7.1.2 Civil foundations will be suitably designed to take care of earthquakes, cyclones,
landslides, flooding, collapse of structures etc.
7.1.3 Plant operator and staffs will be selected well experience and qualified for chemical plant
operation.
7.1.4 All key personals will be trained for emergency handling procedures and regular Mock-
Drills has been conducted on various scenarios.
7.2 Process
7.3.1 Pumps
7.3.2 Pipelines
Operations and maintenance of the plant is being in accordance with the well-established
safe practices. Some of the guidelines are as follows:-
7.5 Recommendations
7.5.1 From the Risk Analysis studies conducted, it would be observed that by and large, the risks
are confined within the factory boundary walls in case of fire & explosion, except in the
event of a catastrophic failure of storage tanks of Bromine it will create OFF site
emergency situations and required more attention and emergency preparedness for combat
such situations. To minimize the consequential effects of the risk scenarios, following
steps are recommended.
Plant should meet provisions of the Manufacture, storage & Import of Hazardous
Chemicals Rules, 1986 & the factories Act, 1948.
Air line respirator provision to be made in Chlorine and bromine handling & storage
tank farm area.
Chlorine hood with blower and neutralizing pit arrangement needs to be made at
Chlorine tonners storage area.
React with water and generate toxic fumes while contact with water caution note to be
displayed in Bromine and Sulfuric Acid tank farm area.
Fire hydrant system to be installed as per TAC/NFPA Norms in each plant and
buildings.
Dyke wall and collection pit with drain valve needs to be provided in storage area and
one underground dumping vessel to be provided for bromine emergency spillage.
Tanker unloading and Bromine loading procedure needs to be displayed at tanker
loading/unloading area.
Periodic On Site Emergency Mock Drills and occasional Off Site Emergency Mock
Drills to be conducted, so those staffs are trained and are in a state of preparedness to
tackle any emergency.
Emergency handling facilities and fire protection system as per provided in report to
be procure and maintained in tip top condition at all time.
Safe operating procedure to be prepared for hazardous process and material handling
process.
Safety devices and control instruments to be calibrated once in a year.
Proper colour work as per IS 2379 to plant pipeline and tank, equipments to be done
once in a six month to protect from corrosion.
Permit to work system to be implemented 100 % for hazardous work in the plant.
Safety manual as per Rule-68 K & P and Public awareness manual as per 41 B & C be
prepared and distributed to all employees and nearby public.
The details of emergency equipments are given in this report along with its quantity to
be procured and maintained at site.
Manual call points for emergency identification to be installed in plant premises.
A quick and effective response at during an emergency can have tremendous significance
on whether the situation is controlled with little loss or it turns into a major emergency.
Therefore, purpose an emergency plan is to provide basic guidance to the personnel for
effectively combating such situations to minimize loss of life, damage to property and loss
of property.
• To keep the required emergency equipment in stock at right places and ensure the
working condition.
• To keep the concerned personnel fully trained in the use of emergency equipment.
• To give immediate warning tooth surrounding localities in case of an emergency
situation arising.
• To mobilize transport and medical treatment of the injured.
• To get help from the local community and government officials to supplement
manpower and resources.
This OSEP is prepared for industrial emergencies like fires, explosions, toxic releases, and
asphyxia and does not cover natural calamities and societal disturbances related
emergencies (like strikes, bomb threats, civil commission’s etc.)
Emergency organization
Emergency Facilities.
Roles and Responsibilities of Key Personnel and Essential Employee.
Communications during Emergency
Emergency Shutdown of Plant & Control of situation.
Rescue Transport & Rehabilitation.
Developing Important Information.
8.4 METHODOLOGY.
The consideration in preparing Emergency Plan will be included the following steps:
Earlier, a detailed Hazard Analysis and Risk Assessment was carried out on hazards and
their likely locations and consequences are estimated following the standard procedure.
However the causing factors for above discussed end results may be different and causing
factors are not discussed in this plan.
Emergencies that may be likely at bulk fuel storage area, process plant, cylinder storage
area, and drum storage shed, and autoclave reactor area. There are chances of fire and
explosive only.
Other risks are earthquake, lightning, sabotage, bombing etc., which are usually, not in the
purview of management control.
Plant organization is enclosed. Based on the plant organization, which includes shift
organization, an Emergency Organization is constituted towards achieving objectives of
this emergency plan.
The following are designated as Incident Controllers for respective areas under their
control. Shift in charge Engineer (Plant Operations) is designated at Incident Controller for
all areas of plant.
It is a location, where all key personnel like Site Controller, Incident Controller etc. can
assemble in the event of onset of emergency and carry on various duties assigned to them.
Plant Manager’s Office is designated as Emergency Control Centre. It has P&T telephone
as well as internal telephones, ECC is accessible from plant located considerably away
from process plant, Storage’s and on evaluation of other locations, Plant Manager’s Room
find merit from the distance point of view, communication etc.
The following facilities and information would be made available at the ECC
• Latest copy of Onsite Emergency Plan and off sites Emergency Plan (as provided by
District Emergency Authority).
• Intercom Telephone.
• P&T Telephone.
• Telephone directories (Internal, P&T)
• Factory Layout, Site Plan
• Plans indicating locations of hazardous inventories, sources of safety equipment,
hydrant layout, location of pump house, road plan, assembly points, vulnerable zones,
escape routes.
• Hazard chart.
• Emergency shut-down procedures.
• Nominal roll of employees.
• List and address of key personnel
These systems are proposed to protect the plant by means of different fire protection
facilities and consist of
Adequate number of fire hydrants and monitors will be provided at various locations in
and around the buildings and other plant areas. The hydrants will be provided on a
network of hydrant mains drawing water from the hydrant pump, which starts
automatically due to drop of pressure in the event of operating the hydrant valves. We are
suggesting you to go for TAC approved hydrant system for foolproof safety and benefit
from fire policy premium.
The objective of the emergency escape is to escape from the hazardous locations, to the
nearest assembly point or the other safe zone, for rescue and evacuation.
Assembly point is location, where, persons unconnected with emergency operations would
proceed and await for rescue operation.
Wind socks for knowing wind direction indication would be provided at a suitable location
to visible from many locations. It is proposed to install windsocks at E.O storage area and
Administration Building so as to be visible from different locations in the plant.
Emergency Ambulance would be stationed at the Administration Office and round the
clock-driver would be made available for emergency transportation of injured etc.
However, the other vehicles of the company also would be available for emergency
services.
The emergency would be communicated by operating electrical siren for continuously for
five minutes with high and low pitch mode.
• Life safety
• Preservation of property
Restoration of the normalcy
While necessary facilities are available and are updated from time to time, sometimes, it
may be necessary to seek external assistance; it may be from the neighboring factories or
from the State Government as the case may be.
Inspite of detailed training, it may be necessary to try out whether, the On site – Off site
Emergency Plan works out and will there be any difficulties in execution of such plan. In
order to evaluate the plan and see whether the plan meets the objectives of the On site –
Off site Emergency Plan, occasional mock drills are contemplated. Before undertaking the
drill, it would be very much necessary to give adequate training to all staff members and
also information about possible mock drill. After few pre-informed mock drills, few UN-
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