Annexure: 2 - Welcome to Environment · 2017-06-08 · Annexure Pest Control India Pvt. Ltd. Table 2: Project plot specific floral inventory (naturally grown vegetation in open spaces

Annexure Pest Control India Pvt. Ltd.

Annexure: 2.1





Annexure: 3.1 - Detailed Floral & Faunal Inventory

Table 1: Project plot specific floral inventory (vegetation by virtue of existing green belt)

Botanical Name Habit Family Local Name Origin No. of plants Area (sq. m.)

Existing green belt GB-5

Ixora coccinea Sh Rubiaceae Rugmini Na 21 220

Hibiscus rasa-sinensis Sh Malvaceae Jaswand Na 17

Bougainvillea spectabilis (Dwarf

variety)

Cl Nyctaginaceae Booganvel In 6

Catharanthus roseus Hb Apocynaceae Sadaphuli In 13

Duranta erecta Sh Verbenaceae -- In 5

Existing green belt GB-6

Polyalthia longifolia Tr Annonaceae Devdar/Ashok Na 2 130

Syzygium cumini Tr Myrtaceae Jambul Na 1

Ficus religiosa Tr Moraceae Peepal Na 1

Mangifera indica Tr Anacardiaceae Amba Na 1

Hibiscus rasa-sinensis Sh Malvaceae Jaswand Na 13

Ixora coccinea Sh Rubiaceae Rugmini Na 16

Total existing green belt area & no. of plants 95 350

Hb - Herb, Cl - Climber, Sh - Shrub, Tr - Tree, Na - Native, In - Introduced


Table 2: Project plot specific floral inventory (naturally grown vegetation in open spaces

within the project plot)

Sr. No. Botanical Name Habit Family Local Name Origin

Naturally grown vegetation in the project plot

1 Blumea oxyodonta Hb Asteraceae -- Na

2 Tridax procumbens Hb Asteraceae -- Nt

3 Scoparia dulcis Hb Scrophulariaceae -- Na

4 Alternanthera sessilis Hb Amaranthaceae Kanchari Na

5 Ageratum conyzoides Hb Asteraceae Ghaneri osaadi Na

6 Vernonia sp. Hb Asetrace -- Na

7 Euphorbia hirta Hb Euphorbiaceae Dudhi Na

8 Amaranthus viridis Hb Amaranthaceae Math Na

9 Parthenium

hysterophorus

Sh Asteraceae -- Nt

10 Calotropis gigantea Tr Asclepiadaceae Rui Na

11 Hyptis suaveolens Hb Lamiaceae Jungali tulas Nt

12 Lantana camara Sh Verbenaceae Ghaneri Nt

Hb - Herb, Sh - Shrub, Tr - Tree, Na - Native, Nt - Naturalized

Table 3: Floral diversity observed in the study area

Sr.

No. Botanical Name Habit Family Local Name

IUCN

Status

Origin

Inner 5 km (Core Study Area)

1 Avicennia marina Tr Acanthaceae Tivar Least

Concern ver 3.1

Na

2 Avicennia

officinalis Tr Acanthaceae Tivar

Least Concern ver

3.1

Na

3 Acanthus

ilicifolius Sh Acanthaceae Marandi

Least Concern ver

3.1

Na

4 Ceriops tagal Tr Rhizhophoraceae -- Least

Concern ver 3.1

Na

5 Caesalpinia

bonduc Cl Caesalpiniaceae Sagarlata

Not

Assessed

Na

6 Derris scandens Cl Fabaceae Garudvel Least

Concern ver 3.1

Na

7 Derris trifoliata Cl Fabaceae Karanj vel Not

Assessed

Na

8 Clerodendrum

inerme Sh Verbenaceae Vanjai

Not

Assessed

Na

9 Salvadora persica Tr Salvadoraceae Pilu Not Na


Assessed

10 Lantana camara Sh Verbenaceae Ghaneri Not

Assessed

Na

11 Ipomoea pes-

caprae Cl Convolvulaceae Maryada-vel

Not

Assessed

Na

12 Calotropis

gigantea Tr Asclepiadaceae Rui

Not

Assessed

Na

13 Fimbristylis

ferruginea Hb Cyperaceae --

Least Concern ver

3.1

--

14 Sesuvium

portulacastrum Hb Aizoaceae Dhapa

Not

Assessed

Na

15 Ipomoea obscura Cl Convolvulaceae Pilobonvaei Not

Assessed

Na

16 Typha

domingensis Hb Typhaceae Pan-kanis

Least Concern ver

3.1

Na

17 Cyperus rotundus Hb Cyperaceae Barik motha Least

Concern ver 3.1

Na


Assessed

Nt

19 Hyptis suaveolens Hb Lamiaceae Jungali tulas Not

Assessed

Nt

20 Chromolaena

odorata

Hb Asteraceae Tivra gandha Not

Assessed

Nt

21 Persicaria glabra Hb Polygonaceae Sheral Least

Concern ver 3.1

Na

22 Ricinus communis Tr Euphorbiaceae Aerandal Not

Assessed

Na

23 Ipomoea carnea Sh Convolvulaceae Besharam Not

Assessed

Nt

24 Thespesia

populnea Tr Malvaceae Paras pipal

Not

Assessed

Na

25 Lysiloma

latisiliquum Tr Fabaceae --

Not

Assessed

--

26 Blumea oxyodonta Hb Asterace -- Not

Assessed

Na

27 Sphaeranthus

indicus Hb Asteraceae Gorakhmundi

Least Concern ver

3.1

Na

28 Millingtonia

hortensis

Tr Bignoniaceae Kaval nimb Not

Assessed

Na

29 Quisqualis indica Cl Combretaceae Vilayati chambeli Not

Assessed

Na

30 Bougainvillea

spectabilis Cl Nyctaginaceae Booganvel

Not

Assessed

In


31 Tecoma stans Tr Bignoniaceae Ghantiful Not

Assessed

In

32 Nerium oleander Sh Apocynaceae Kaner Least

Concern ver 3.1

Na

33 Thevetia

peruviana Tr Apocynaceae Pivli kaner

Not

Assessed

Nt

34 Tabernaemontana

divaricata Tr Apocynaceae Ananta

Not

Assessed

Na

35 Plumeria rubra Tr Apocynaceae Chafa Not

Assessed

In

36 Psidium guajava Tr Myrtaceae Peru Not

Assessed

Na

37 Annona squamosa Tr Annonaceae Sitaphal Not

Assessed

In

38

Carica papaya Tr Caricaceae Papaya Data Deficient ver

3.1

Na

39 Peltophorum

pterocarpum Tr Caesalpiniaceae Tambadsheng

Not

Assessed

In

40 Spathodea

campanulata Tr Bignoniaceae Pichkari

Not

Assessed

In

41 Ipomoea obscura Cl Convolvulaceae Pungali Not

Assessed

Na

42 Merremia vitifolia Cl Convolvulaceae Navli Not

Assessed

Na

43 Mucuna pruriens Cl Fabaceae Khaj kuiri Not

Assessed

Nt

Outer 5 km (Buffer Study Area)

1 Butea

monosperma Tr Fabaceae Palash

Not

Assessed

Na

2 Cassia fistula Tr Caesalpiniaceae Bahava Not

Assessed

Na

3 Calotropis

gigantea Sh Asclepidaceae Rui

Not

Assessed

Na

4 Mucuna pruriens Cl Fabaceae Khaj kuiri Not

Assessed

Nt

5 Gliricidia sepium Tr Fabaceae -- Not

Assessed

In

6 Amaranthus viridis Hb Amaranthaceae Math Not

Assessed

Na

7 Tectona grandis Tr Verbenacea Saag Not

Assessed

Na

8 Peltophorum

pterocarpum Tr Caesalpiniaceae Tambadsheng

Not

Assessed

In


9 Macaranga peltata Tr Euphorbiaceae Chandwar Not

Assessed

Na

10 Moullava spicata Tr Caesalpiniaceae Wagati Not

Assessed

Na

11 Acacia

auriculiformis Tr Mimosaceae --

Least Concern ver

3.1

In

13 Bombax ceiba Tr Bombacaceae Sawar Not

Assessed

Na

14 Microcos

paniculata Tr Tiliaceae Shirali

Not

Assessed

Na

15 Alstonia scholaris Tr Apocynaceae Saptaparni

Lower Risk/least

concern ver 2.3

Na

16 Caryota urens Tr Arecaceae Bherli maad Least

Concern ver 3.1

Na

17 Oroxylum indicum Tr Bignoniaceae Tetu Not

Assessed

Na

18 Dregea volubilis Cl Asclepiadaceae Harandodi Not

Assessed

Na

19 Helicteres isora Tr Sterculiaceae Murudsheng Not

Assessed

Na

20 Cocos nucifera Tr Arecaceae Naral Not

Assessed

Na

21 Calycopteris

floribunda Cl Combretaceae Ukshi

Not

Assessed

Na

22 Mangifera indica Tr Anacardiaceae Amba Data

Deficient ver 2.3

Na

23 Artocarpus

heterophyllus Tr Moraceae Phanas

Not

Assessed

Na

24 Terminalia

bellirica Tr Combretaceae Baheda

Not

Assessed

Na

25 Wrightia tinctoria Tr Apocynaceae Kala kuda

Lower Risk/least

concern ver 2.3

Na

26 Carissa carandas Sh Apocynaceae Karwanda Not

Assessed

Na

27 Terminalia

paniculata Tr Combretaceae Kinjal

Not

Assessed

Na

28 Xylia xylocarpa Tr Mimosaceae Jambha Not

Assessed

Na

29 Callicarpa

tomentosa Tr Verbenaceae Ayamsar

Not

Assessed

Na

30 Syzygium cumini Tr Myrtaceae Jambul Not

Assessed

Na


31 Tabernaemontana

alternifolia Tr Apocynaceae Naag kuda

Not

Assessed

Na

32 Terminalia

elliptica Tr Combretaceae Ain

Not

Assessed

Na

33 Ficus racemosa Tr Moraceae Umber Not

Assessed

Na

34 Madhuca

longifolia Tr Sapotaceae Mahua --

Na

35 Schleichera

oleosa Tr Sapindaceae Kusum

Not

Assessed

Na

36 Ficus benghalensis Tr Moraceae Vad Not

Assessed

Na

37 Erythrina

suberosa Tr Fabaceae Pangara

Not

Assessed

Na

38 Bridelia retusa Tr Phyllanthaceae Asana Not

Assessed

Na

39 Sterculia guttata Tr Sterculiaceae Kukar Not

Assessed

Na

40 Holoptelea

integrifolia Tr Ulmaceae Ainsadada

Not

Assessed

Na

41 Catunaregam

spinosa Tr Rubiaceae Ghela

Not

Assessed

Na

42 Cordia dichotoma Tr Boraginaceae Shelu Not

Assessed

Na

43 Ficus religiosa Tr Moraceae Pimpal Not

Assessed

Na

44 Terminalia

catappa Tr Combretaceae Jangali badam

Not

Assessed

Na

45 Azadirachta indica Tr Meliaceae Kadu limb Not

Assessed

Na

46 Pongamia pinnata Tr Fabaceae Karanj Least

Concern ver 3.1

Na

47 Albizia lebbeck Tr Mimosaceae Siris Not

Assessed

Na

48 Neolamarckia

cadamba Tr Rubiaceae Kadamba

Not

Assessed

Na

49 Dalbergia sissoo Tr Fabaceae Shisham Not

Assessed

Na

50 Leea indica Sh Vitaceae Karkani Not

Assessed

Na

51 Heterophragma

quadriloculare

Tr Bignoniaceae Waras Not

Assessed

Na

52 Bambusa bambos Hb Poaceae Bamboo Not

Assessed

Na


53 Argemone

mexicana Hb Papaveraceae Dhtora

Not

Assessed

Nt

54 Pithecellobium

dulce Tr Mimosaceae Vilayati chinch

Not

Assessed

Nt

55 Moringa oleifera Tr Moringaceae Shevaga Not

Assessed

Na

56 Typha

domingensis Hb Typhaceae Pan-kanis

Least Concern ver

3.1

Na

57 Cyperus rotundus Hb Cyperaceae Barik motha Least

Concern ver 3.1

Na


Assessed

Nt

59 Hyptis suaveolens Hb Lamiaceae Jungali tulas Not

Assessed

Nt

60 Chromolaena

odorata

Hb Asteraceae Tivra gandha Not

Assessed

Nt

Hb - Herb, Cl- Climber, Sh -Shrub, Tr - Tree, Na - Native, Nt- Naturalized, In - Introduced


Table 4: Avifaunal diversity observed in the Study Area

Sr.

No.

Family Scientific

Name

Common

Name

IUCN

Status

WPA

Assessment

Habitat Feeding Habit Dwelling

Status

1 Leiothrichidae Turdoides

striatus

Jungle

Babbler

Least Concern ver

3.1

Schedule -

IV

Outlying jungle,

gardens, groves

of trees about

towns &

villages

Omnivorous R

2 Pycnonotidae Pycnonotus

cafer

Red

Vented

Bulbul

Least Concern ver

3.1

Schedule -

IV

Gardens, light

scrub jungle,

near and away

human

habitations

Omnivorous R

3 Pycnonotus

jocosus

Red

Whiskered

Bulbul

Least Concern ver

3.1

Schedule -

IV

Though enters

gardens prefers

wooded

localities

Omnivorous R

4 Meropidae Merops

orientalis

Small Bee

Eater

Least Concern ver

3.1

-- Gardens, light

scrub jungle,

near and away

human

habitations

Insectivorous R

5 Halcyonidae Halcyon

smyrnensis

White-

throated

Kingfisher

Least Concern ver

3.1

Schedule -

IV

Near ponds,

puddles, rain-

filled ditches,

inundated paddy

fields, near

shore, also in

wooded country

away from

water

Piscivorous &

Insectivorous

R

6 Columbidae Streptopelia

chinensis

Spotted

Dove

Not Assessed Schedule -

IV

Open well

wooded &

Granivorous R


cultivated

country freely

enters gardens

7 Columba livia Blue Rock

Pigeon

Least Concern ver

3.1

-- Lives in close

association with

man in human

inhabited areas

Granivorous R

8 Alcedinidae Alcedo atthis Small Blue

Kingfisher

Least Concern ver

3.1

Schedule -

IV

Near streams,

tanks, puddles

Piscivorous &

Insectivorous

R

9 Charadriidae Vanellus

indicus

Red-

wattled

Lapwing

Least Concern ver

3.1

-- Open country,

ploughed fields,

grazing land,

margins & dry

beds of tanks,

puddles

Insectivorous R

10 Ardeidae Bubulcus ibis Cattle

Egret

Least Concern ver

3.1

Schedule -

IV

Reed swamps in

& around

surface water

bodies

Insectivorous

& Piscivorous

R

11 Egretta

garzetta

Little Egret Least Concern ver

3.1

Schedule -

IV

Jheels, Swamps,

Wetlands etc.

R

12 Ardeola grayii Indian

Pond

Heron

Least Concern ver

3.1

Schedule -

IV

Found wherever

there is water

Insectivorous

& Piscivorous

R

13 Nycticorax

nycticorax

Black-

crowned

Night-

Heron

Least Concern ver

3.1

Jheels, inland

waters, tidal

creeks &

mangrove

swamps

Carnivorous R

14 Dicruridae Dicrurus

macrocercus

Black

Drongo

Least Concern ver

3.1

Schedule -

IV

A familiar bird

of open country

Omnivorous R

15 Corvidae Corvus House Least Schedule - Lives in close Omnivorous R


splendens Crow Concern ver 3.1

V association with

man in human

inhabited areas

16 Corvus

macrorhynchos

Jungle

Crow

Least Concern ver

3.1

- Chiefly a bird of

country side but

also seen in

town & villages

Omnivorous R

17 Sturnidae Acridotheres

tristis

Common

Myna

Least Concern ver

3.1

Schedule -

IV

An associate of

human

inhabited areas

Omnivorous R

18 Sturnus

pagodarum

Brahminy

starling

Least Concern ver

3.1

Schedule -

IV

Freely enters

gardens, towns,

villages, partial

to moist

grassland, near

grazing cattle’s

Omnivorous RM

19 Muscicapidae Saxicola

caprata

Pied

Bushchat

Least Concern ver

3.1

-- Sparsely

scrubbed

country &

hillsides,

common in

neighborhood of

cultivation &

villages

Insectivorous R

20 Alaudidae Ammomanes

phoenicura

Rufous-

tailed lark

Least Concern ver

3.1

-- Scrub covered

plains

Insectivorous R

21 Phalacrocoracidae Phalacrocorax

niger

Little

Cormorant

Least Concern ver 3.1

-- Inland waters,

brackish

lagoons, tidal

creeks

Piscivorous R

22 Muscicapidae Saxicoloides

fulicata

Indian

Robin

Least Concern ver

3.1

-- Stony scrub

country

Insectivorous R


23 Copsychus

saularis

Oriental

Magpie-

Robin

Least Concern ver

3.1

-- In & around

villages along

shrubberies

Insectivorous

& Herbivorous

R

24 Psittacidae Psittacula

krameri

Rose-

ringed

Parakeet

Least Concern ver

3.1

Schedule –

IV

Wooded

country,

Cultivations,

Orchards

Frugivorous R

25 Accipitridae Milvus migrans Black Kite Least Concern ver

3.1

-- Carnivorous R

26 Cuculidae Centropus

sinensis

Greater

Coucal

Least Concern ver

3.1

Schedule-

IV

Open forest,

Scrubs,

Shrubbery

Carnivorous R

27 Passeridae Passer

domesticus

House

sparrow

Least Concern ver

3.1

-- A confirmed

hanger-on of

man

Omnivorous R

28 Rallidae Amaurornis

phoenicurus

White-

breasted

Waterhen

Least Concern ver

3.1

-- Moist ground

overgrown with

tangles of

bushes, margins

of jheels &

ponds

Omnivorous R

29 Porphyrio

poliocephalus

Grey-

headed

Swamphen

Not Assessed -- Reedy swaps,

Margins of

jheels

overgrown with

bushes

Omnivorous R

30 Phoenicopteridae Phoenicopterus

roseus

Greater

Flamingo

Least Concern ver

3.1

Schedule-

IV

Jheels, Lagoons,

Salt pans,

Estuaries

Insectivorous-

seeds of marsh

plants-organic

ooze

M

31 Phoeniconaias

minor

Lesser

Flamingo

Near Threatened ver

3.1

Schedule-

IV

Salt pans,

Estuaries

Phytoplankton

(algae, diatoms

etc.)

M


32 Ciconiidae Mycteria

leucophala

Painted

Stork

Near Threatened ver

3.1

Schedule-

IV

Marshy areas,

Lagoons, Salt

pans, Estuaries

Carnivorous LM

33 Anastomus

oscitans

Asian

Openbill-

Stork

Least Concern ver

3.1

Schedule-

IV

Marshy areas,

Lagoons, Salt

pans, Estuaries

Carnivorous LM

34 Threskiornithidae Pseudibis

papillosa

Red-naped

ibis

Least Concern ver

3.1

Schedule-

IV

Neighborhood

of rivers, jheels,

fallow land

Omnivorous R

35 Plegadis

falcinellus

Glossy ibis Least Concern ver

3.1

Schedule-

IV

Jeels, River

banks, Marshes

Carnivorous R


Table 5: Faunal diversity observed in the Study Area

Sr.

No.

Common

Name

Scientific Name Family IUCN Status WPA

Assessment

Mammals

1 Indian Palm

Squirrel

Funambulus

palmarum

Sciuridae Least

Concern ver 3.1

--

2 Stray dog Canus sp. Canidae -- --

3 Pig Sus sp. Suidae -- --

4 Buffalo Bubalus sp. Bovidae -- --

Reptiles

1 Brahminy skink Eutropis carinata Scinidae

Least

Concern ver 3.1

--

2 Forest calotes Calotes rouxii Agamidae Least Concern ver

3.1 --

3 Oriental garden

lizard Calotes versicolor Agamidae

Not yet assessed --

Secondary Data

Reference I - Baseline Survey of birds at proposed Navi Mumbai International Airport

(NMIA) area TRI-MONTHLY REPORT APRIL-JUNE, 2013 - Bombay Natural History

Society

The authors of the above this reference have documented the avifauna diversity in the 10 km

radial area of the proposed Navi Mumbai International Airport (NMIA) site which is in close

proximity to the current project in consideration.

The study area in common/overlapping for the secondary data study & current project in

consideration is shown in the following figure.


Figure: Annexure EB 3.1 - Study area of the secondary data & current project in

consideration

Study Period: Authors had conducted the study during the period of April-June 2013 whereas

the report had been compiled considering the literature review from the year 2011.


The findings of the study are as described below.











Reference II - A CONTRIBUTION TO AVIFAUNA OF URAN (RAIGAD),

MAHARASHTRA, INDIA - Malwadkar A. M. Dept. of Zoology, S. M. Joshi College,

Hadapsar, Pune - 411028

The authors of the research paper have documented the avifaunal diversity of some of the

wetlands & terrestrial habitats in Uran Village. These sites are near to the study area of the

project in consideration as depicted in the following figure.


Figure: Annexure EB 3.2 - Study area of the secondary data & current project in

consideration


Study Period: Authors had conducted the study during the period of June 2007 to May 2009.

The findings of the study are as described below.



Annexure : 4.1

Incremental Concentration for PM10


Incremental Concentration for PM2.5


Incremental Concentration for SO2


Incremental Concentration for NOx


Incremental Concentration for CO


Annexure 4.2

Raw Effluent Sample (Process + Scrubber) :

Sr.No. Parameters Result Units Method

1. pH 4.5 - APHA( 22ndEdition ) 4500 H+-B : 2012

2. COD 9850.0 mg/l APHA( 22ndEdition ) 5220-B : 2012

3.

4

BOD (270C 3 day) 3423.0 mg/l APHA( 22ndEdition ) 5210-B : 2012

4. TDS 34820.0 mg/l APHA( 22ndEdition ) 2540-C : 2012

5. TSS 7942.0 mg/l APHA( 22ndEdition ) 2540-D : 2012

Chemical consumption for Primary Treatment – I (Lime + Alum + Poly):

Sample

Qty. I

Chemical Consumption

10% Lime 10% Alum 0.1 % Poly Sludge Volume

1000ml Qty 4 ml 1.2 ml 2.0 ml

5 % pH 8.1 7.06 6.80

The Results of analysis after Primary Treatment:

Sr.No. Parameters Results Units Method

1. pH 7.1 - APHA( 22ndEdition ) 4500 H+-B 2012


3.

4.



5. TSS 79.0 mg/l APHA( 22ndEdition ) 2540-D : 2012

ANALYSIS REPORT FOR WATER SAMPLE

Report No. SEETL/05/17/215

Name of Client M/s. Pest Control (India) Pvt. Ltd.

0 Pvt. Ltd. Address of Client Taloja MIDC

Treatment of HCOD/HTDS effluent ( Composite Process )


The Results of analysis after Distillation:




3.

4.



5. TSS BDL mg/l APHA( 22ndEdition ) 2540-D : 2012

The Results of analysis after mixing of Distillate + Sewage:

Sr.No. Parameters Distillate

Sewage After

mixing of

effluent

Units Method

1. pH 6.7 7.9 7.4 - APHA( 22ndEdition ) 4500 H+-B

2012 2. COD 1320.00 879 1030.0 mg/l APHA( 22ndEdition ) 5220-B : 2012

3.

4.

BOD (270C 3 day) 481.00 263 348.19 mg/l APHA( 22ndEdition ) 5210-B : 2012

4. TDS 510.0 981 808.11 mg/l APHA( 22ndEdition ) 2540-C : 2012

5. TSS BDL 325 208.19 mg/l APHA( 22ndEdition ) 2540-D : 2012

Biological Treatment:

Sr.No. Parameters Results Unit Method

12 hrs. 24hrs. 36hrs.

1. pH 7.7 7.9 8.0 - APHA( 22ndEdition ) 4500 H+-B

2012 2. COD 760.0 472.0 210.0 mg/l APHA( 22ndEdition ) 5220-B : 2012

3.

BOD (270C 3 day) 281.0 170.0 68.0 mg/l APHA( 22ndEdition ) 5210-B : 2012

4. TDS 804.6 800.0 798 mg/l APHA( 22ndEdition ) 2540-C : 2012

The Results after PSF/ACF:




3.

4.




RO Treatment:

Sr.

No. Parameters

Results

Unit Method

RO Permeate RO Reject

1. pH 7.1 7.6 - APHA( 22ndEdition ) 4500 H+-B 2012

2. COD 22.0 928.0 mg/l APHA( 22ndEdition ) 5220-B : 2012

3.

BOD (270C 3 day) 8.0 293.0 mg/l APHA( 22ndEdition ) 5210-B : 2012

4. TDS 39.0 3697.0 mg/l APHA( 22ndEdition ) 2540-C : 2012


Annexure : 4.3

Custic Image showing dispersion of Noise during construction phase


Annexure : 4.4

Custic Image showing dispersion of Noise during operation phase


Annexure : 7.1

PEST CONTROL INDIA PVT. LIMITED

PLOT 38 -39, TALOJA MIDC, NAVADE VILLAGE, PANVEL, RAIGAD, MAHARASHTRA

HAZOP STUDY FOR THE PROPOSED UNIT

JANUARY 2017


01. INTRODUCTION

M/s PCI limited propose to establish a facility to manufacture bromadiolone technical (a pesticide) at their existing site at Taloja.

02. METHODOLOGY

The site visit was conducted at the factory in the month of September 2016. The laboratory scale R&D set up was seen at the

site. The documents pertaining to the processes such as rough process flow diagram and process description of stage wise

manufacturing process made available by the client, MSDS of the substances involved, etc. were made available. Detailed discussions

were held with the concerned officials of the factory regarding the process.

Based on the above HAZOP worksheets were prepared by applying standard procedures of using guide words to generate

deviations in the process parameters. Corrective actions wherever necessary were indicated.

03. THE NAMES OF THE PRODUCTS STUDIED

a. Bromadiolone Technical.

04. PERSONS INVOLVED IN THE HAZOP STUDY

Sr.

No. No.

Name Designation

Organisation

01. Shri. Gopal Krishna Rao Head, R & D Pest Control (India) Pvt. Ltd.

02. Shri. Vilas Andhere Site Manager Pest Control (India) Pvt. Ltd.

03. Shri. Amogh Joshi Environmental Engineer Sadekar Enviro Engineers Pvt. Ltd.

04. Shri. D. K. Joshi Proprietor / HAZOP Team Facilitator Parag Enterprises


05. THE DOCUMENTS REFERRED TO

No regular P & I D was made available. A rough process flow diagram, which was referred to is enclosed at Annexure “A” to this

report.

Details of the process made available are enclosed in Annexure “B” to this report.

List of raw materials involved in given in Annexure “C” to this report

Copies of MSDS of raw materials involved are given in Annexure “D” to this report

06. ACKNOWLEDGEMENT

Parag Enterprises wish to thank the management of the Pest Control (India) Pvt. Ltd. for giving them the opportunity to carry out

the job. The observations could be done without any inhabitations and the free access was provided to all the documents / records /

files necessary for compilation of the report.


07. THE HAZOP RECOMMENDATIONS

Sr. No. Recommendation

01 Spill control kit to be provided and spill control procedure to be developed

02 Regular calibration of the temperature indicator to be ensued

03 Temperature controller to be provided on the bromine addition line so that if the temperature goes beyond 20 deg. c., the

addition should stop

04 Orifice plate (calibrated) to be provided in the bromine addition line.

05 Provide two valves in the bromine addition line.

06 Procedure to be developed for periodic checking of the integrity of the glass lining.

07 To provide protective paint on the glass flask so as to ensure that splinters of glass flask do not take place in case of

breakage of the same.

08 Glass flask to be provided with wire mesh protection

09 To obtain a certificate from the suppler of the glass flask to confirm that it can withstand full vacuum.

10 Scrubber working to be ensured before starting the batch.

11 The reactor is adequately inertised by nitrogen purging to prevent fire and explosion.

12 The inertisation procedure to be defined and validated

13 Ensure slow addition of dry powder with the help of an earthed SS scoop.

14 The addition of borohydride should be done through glove box


08. THE HAZOP WORKSHEETS HAZOP COVERSHEET

STAGE 1 – PREPARATION OF 4 BROMO BIPHENYL

Node No. 01

Design Intention Preparation of liquid bromine solution in EDC

Steps involved

Receiving 57 lit EDC

Cooling to 20 deg. c

receive 8.3 l bromine in glass flask by applying vacuum to glass flask

add bromine slowly over one hour to EDC

drain the bromine solution in HDPE barrels.

P & I D Nil

Equipment MS/GLR – 600 lit, glass addition flask for bromine

SOP No. -

Available controls -

Services Operating Parameters

Temperature Pressure Flow rate/ Quantity

EDC Room temp. Atmosphere 57 lit

Bromine Room temp. Atmosphere 8.3 lit


Node No.: 01

Guide Word Deviation Causes Consequences Controls

Existing Additional(Proposed)

No / not Not pertinent

Less Less EDC received

Leakage during addition

Health hazard associated with EDC

- Spill control kit to be provided and spill control procedure to be developed.

(1)

Less bromine received


Health hazard associated with bromine

- Spill control kit to be provided and spill control procedure to be developed

More More than 20 deg. c. during addition of bromine

Inaccurate temperature indicator

Generation of more vapors of bromine, which may not get absorbed in the scrubber system

- Regular calibration of the temperature indicator to be ensued.

(2)

Faster addition of bromine

Generation of more vapors of bromine, which may not get absorbed in the scrubber system

- Temperature controller to be provided on the bromine addition line so that if the temperature goes beyond 20 deg. c., the addition should stop.

(3)

Orifice plate (calibrated) to be provided in the bromine addition line.

(4)

Failure of the addition valve

Provide two valves in the bromine addition line.

(5)


Other than Unsafe operation

Damaged glass lining


- Procedure to be developed for periodic checking of the integrity of the glass lining.

(6)

Breakage of glass flask

Health and environmental hazards associated with bromine

- To provide protective paint on the glass flask so as to ensure that splinters of glass flask do not take place in case of breakage of the same.

(7)

Glass flask to be provided with wire mesh protection

(8)

Implosion of the glass flask due to vacuum.

Health and environmental hazards associated with bromine

To obtain a certificate from the suppler of the glass flask to confirm that it can withstand full vacuum.

(9)

Ineffective working of the scrubber

Environmental emission of bromine vapours

- Scrubber working to be ensured before starting the batch.

(10)

Part of Not pertinent

Reverse Not pertinent

As well as Not pertinent

Node No. 02

Design Intention To carry out bromination reaction

Steps involved

Receive 57 lit of EDC in GLR

Receive 40 kg of biphenyl

Receive 0.26 kg of FeCl3

Receive 0.6 kg of iodine

Receive the solution of bromine in EDC slowly at the rate of not more than 15 lit/hr, maintaining temperature below 25 deg. c.


Quench the reaction mass in ice in HDPE barrel.

Receive the quenched mass back to GLR 600 lit.

Settle for 1 hour (organic layer at the bottom, aqueous layer at top, which is sent to ETP)

Distil organic layer to recover EDC. Residue from distillation is the crude product

Reside is fractionated to get 4 dibromophenol

P & I D

Equipment HDPE container containing Bromine solution in EDC, MS/GLR – 600 lit, glass flask

SOP No. -

Available controls Spill control kit provided




Bromine solution in EDC Room temp. Atmosphere 65 lit (app.)

FeCl3 0.26 kg

Iodine crystal 0.6 kg.

Node No.: 02








Less bromine received





More More than 25 deg. c. during addition of bromine solution


Generation of more vapours of bromine, which may not get absorbed in the scrubber system

- Regular calibration of the temperature indicator to be ensued

Faster addition of bromine solution

Generation of more vapours of bromine, which may not get absorbed in the scrubber system

- Temperature controller to be provided on the bromine solution addition line so that if the temperature goes beyond 25 deg. c., the addition should stop.

Orifice plate (calibrated) to be provided in the bromine solution addition line.


Provide two valves in the bromine solution addition line


Damaged glass lining


- Procedure to be developed for periodic checking of the integrity of the glass lining

Breakage of glass flask

Health and environmental hazards associated with bromine in EDC

- To provide protective paint on the glass flask so as to ensure that splinters of glass flask do not take place in case of breakage of the same.

Glass flask to be provided with wire mesh protection

Ineffective working of the scrubber

Environmental emission of bromine vapors

- Scrubber working to be ensured before starting the batch.





HAZOP COVERSHEET

STAGE 2 – PREPARATION OF 4 BROMO BIPHENYL ACETOPHENONE

Node No. 03

Design Intention Preparation of 4 bromo biphenyl acetophenone

Steps involved

Receiving 57 lit EDC in reactor

Addition of AlCl3 at 5 C

Add acetyl chloride at 25 C

Prepare solution of HCl by mixing 10 L conc. HCl and ice

Pour the above reaction mass in cold dilute HCl solution prepared

Settle the mass.

After layer separation add petroleum ether gradually to organic layer to form slurry.

Filter the slurry through neutsche filter.

Dry the wet cake in vacuum tray dryer to get dry powder of 4-bromo bi phenyl acetophenone.

P & I D Nil

Equipment MS/GLR – 600 lit, HDPE barrels

SOP No. -

Available controls -




Acetyl chloride Room temp. Atmosphere 42 lit

Petroleum ether Room temp. Atmosphere 40 lit


Node No.: 03








Less acetyl chloride received


Health hazard associated with acetyl chloride


More More than 25 deg. c. during addition of acetyl chloride


Generation of more vapours of acetyl chloride

- Regular calibration of the temperature indicator to be ensued

Faster addition of acetyl chloride solution

Generation of more vapours of acetyl chloride, which may not get react and escape to scrubber

- Temperature controller to be provided on the acetyl chloride addition line so that if the temperature goes beyond 25 deg. c., the addition should stop.

Orifice plate (calibrated) to be provided in the acetyl chloride addition line.


Provide two valves in the acetyl chloride addition line



addition of Pet. ether in a reactor which contains oxygen

possibility of fire -- The reactor is adequately inertised by nitrogen purging to prevent fire and explosion.

(11) – this is not additional control?




HAZOP COVERSHEET

STAGE 3 – PREPARATION OF CHALCONE

Node No. 04

Design Intention Synthesis of Chalcone

Steps involved

Inertize the reactor with nitrogen.

addition of 399 L methanol by vacuum in SS reactor

At 25 C add 26 kg 4 bromobiphenyl acetophenone

Addition of sodium methoxide at 30 C with stirring

Addition of 14 kg benzaldehyde at 28-32 C

Agitate the reaction mass for 12 hours at 32 C

Filter product (chalcone) on neutsche filter

Wash chalcone with methanol at 10 C and send wet chalcone cake to next stage

Methanol will be sent to recovery

P & I D

Equipment MS/GLR – 600 lit, glass flask,


SOP No.

Available controls None



methanol Room temp. Atmosphere 379 lit

Sodium methoxide 30 Atmosphere 25 kg

benzaldehyde 25 Atmosphere 14 kg

Node No.: 04



No/ Not Not pertinent

Less Not pertinent

More Not pertinent

Other than

unsafe operation

inadequate inertization before addition of methanol

possibility of fire -- The inertization procedure to be defined and validated.

(12)

Generation of static charges during addition of dry 4 bromo biphenyl acetophenone

possibility of fire -- Ensure slow addition of dry powder with the help of an earthed SS scoop.

(13)





HAZOP COVERSHEET

STAGE 4 – PREPARATION OF BDL KETONE (BROMODIALONE KETONE)

Node No. 05

Design Intention Synthesis of bromodialone ketone

Steps involved

Addition of 260 L 1,4- dioxane in SS reactor at RT

Add 24 kg chalcone cake at RT

Addition of 15 kg 4- hydroxy cumarine

Addition of 1 kg piperidine

Stir the reaction mass at 100 C

Reflux for 12 hours then cool.

At 65 C recover 1,4- dioxane for reuse

add water at 80-85 C for 2 hours

Filter the mass in neutsche to receive solid wet product

ML will be sent to ETP

P & I D

Equipment SS – 600 lit

SOP No. -




Dioxane Room temp. Atmosphere 260 Lt

Chalcone Room temp. Atmosphere 24 kg

4 hydroxy cumarine Room temp. Atmosphere 15 kg

Piperidine Room temp. Atmosphere 1 kg


Node No.: 05








More Not pertinent

Other than

unsafe operation

addition of pet. ether in a reactor which contains oxygen

possibility of fire -- the reactor is adequately inertized

Generation of static charges during addition of dry 4 hydroxy cumarine

possibility of fire -- Ensure slow addition of dry powder with the help of an earthed SS scoop





HAZOP COVERSHEET

STAGE 5 – PREPARATION OF BROMODIOLONE

Node No. 06

Design Intention Synthesis of bromadialone

Steps involved

Addition of 368 L IPA in SS reactor

Addition of 26 L 1,4- dioxane

Addition of 0.6 kg PEG-400

Stir the reaction mass

Addition of 28 kg bromadiolone ketone wet cake with stirring at 30 C

Cool the reaction mass to 16 C and add 1.76 kg sodium borohydride.

Stir the reaction mass for 6 hrs at 25-30 C

Add 150 L HCl at 15 C

Add 190 L water with stirring

At constant 25 C stir the reaction mass for 2 hours then filter by neutsche filter

Wash the cake with 500 L water

Add toluene to wet cake to form slurry

Distil water from slurry

Wash dry cake with Petroleum ether and vacuum dry the final product

P & I D

Equipment SS – 600 lit

SOP No. -




IPA Room temp. Atmosphere 368 Lt

1,4- dioxane Room temp. Atmosphere 26 kg

bromadiolone ketone 30 Atmosphere 28 kg

boro hydride Room temp. Atmosphere 1.76 kg

HCl 15 Atmosphere 150 L


Node No.: 06




Less Less IPA received

Leakage and spillage during addition

Health hazard associated with IPA


More Not pertinent

Other than

unsafe operation

addition of IPA in a reactor which contains oxygen

possibility of fire -- the reactor is adequately inertized

Generation of static charges during addition of dry sodium boro hydride

possibility of fire -- The addition of borohydride should be done through glove box.

(14)





Annexure A: FLOW-DIAGRAM OF MANUFACTURING PROCESS OF BROMADIOLONE TECHNICAL

Biphenyl

Bromine

Sodium Thiosulphate

FeCl3

Iodine

4-Bromo biphenyl

AlCl3

EDC

4-Bromo-

biphenyl

Acetyl Chloride

Petroleum

Ether

4-Bromo biphenyl

Aceto phenone

4-Bromo biphenyl

Aceto phenone

Benzaldehyde

Methanol

Sodium

Methoxide

Chalcone BDL Ketone

Chalcone

4-hydroxy

coumarine

Acetone

Piperidine

1,4-Dioxan

BDL Ketone Sodium

Borohydride

Bromadiolone

Technical

Filtration & Drying of

Bromadiolone Technical

PEG 400 1,4-Dioxan


ANNEXURE B: STAGE WISE PROCESS DETAILS

Inputs Process steps Critical

Parameters

Output

1)Liquid bromine solution preparation

Reator-RV-04: 600 Litres MS/GL reactor having

mechanical stirring, TP and chilled water condenser.

The vent of condenser is attached to chilled caustic

(10%) scrubber.

57 LITRES

Charge EDC

Cool to below 20 deg. C (If required check

using glass thermometer) – the reactor would have

a thermowell why to use glass thermometer

8.3 LITRES Step for receipt of bromine from bottle to glass pot to be

added

Add

Liquid Bromine through glass pot, under stirring preferably with dip pipe. Time for addition any data on heat of dilution ?

(Approx 127 ltr= 183kgs)

Stir for 1 hrs for good mixing, Unload the material

in close

HDPE barrel

(II) Bromination Reaction

Reactor RV 04 600 Ltrs MS/GL reactor having

mechanical stirring, TP and chilled water condenser.

The vent of condenser is attached to chiled caustic

(10%) scrubber)

57ltrs.

Charge

EDC in the reactor

40 kgs Charge Biphenyl under stirring to get solution.

0.26 Kgs

Charge

FeC13

0.6 Kgs

Charge

Iodine

Cool reaction mass to 20-25 deg. C.

After reaction is over, quench reaction mass to ice

taking in open mouth HDPE drums stir manually with

wooden sticks.

Transfer the reaction mass to Reactor RV-04 through siphon/vaccum.

Allow reaction mass to settle for 1 hr.

100 ltr. Transfer organic mass in reactor RV-04 and stir with

Water

27 ltr.

Add:

10 %sodium thiosulfate solution

Allow reaction mass to settle for 1 hrs


Separate the organic mass from bottom layer.

Remove aqueous layer in HDPE drum (closed mouth).

EDC Recovery:

Reator-RV-04: 600 Litres MS/GL reactor having Mechanical stirring, TP and chilled water condenser. The Vent of condenser is attached to chilled caustic (10%) scrubber.

OUT PUT 20 KGS APPROX

Stage (2) Process Details

Inputs Process steps Critical

Parameters

Output

Assembly :50 Litres. Glass assembly (GR-3) having

stirring and chilling arrangement.

260

Litres.

Charge

EDC in 50 lit glass assembly how can we receive 250

lits?

2 0 kgs Charge

4-Bromobiphenyl to reactor under stirring at room temperature

(25-35 deg C) and stir further for half an hour

Cool reaction mass to 0-5 deg.C.

42 kgs

Charge

AlCl3 (solid?)at 0-5 deg C under stirring

Observe the exotherm for 10 min and the ice from bath.

Maintain reaction temperature at 25-35 deg. C for 1 hour

24 0 kg

10 Ltr

After reaction completion, Pour reaction mass to crushed

Ice and Conc. HCl kept in HDPE open mouth drum

under agitation with wooden paddle.

Baring total mass to RT and Stir for 1 hr.

Transfer this mass to MSGL(r-04, 600 LTRS).

Heat mass to 40 deg C. With hot water?

Keep reaction mass for layer separation for 1 hr.

Separate the EDC layer.

300

Ltrs

Give

water washing EDC layer

Charge EDC layer to reactor and distil out

EDC under atmospheric pressure.

40 ltrs

Charge by pump

Petroleum ether and stir to make a good slurry.


Filter the slurry product in neutsche filter to get off-white

powder.

40 ltrs

Charge

Petroleum ether to reactor and charge material back to reactor to make a good re-slurry and stir for 1 hr.

FILTER =DRY CAKE =20 KGS APPROX

Stage (3) Process details Inputs Process Steps Critical

Parameters

output

Assembly:100 Litres SS reactor having stirring

and cooling water arrangement with Nitrogen

atmosphere.

399 Ltrs Charge

Methanol

20 kg Charge

Bromobiphneyl acetophenone.

25 kgs Charge

Sodium methoxide solution.

Start agitation at 30 deg C.

14 kgs Add

Benzaldehyde from addition funnel over the period of 2 hrs at 28-32 deg C.

Maintain reaction under agitation at 28-32 deg C

12 hrs.

If reaction is OK,

Cool reaction mass to 10-12 deg C.

Filter the mass in filtration

neutsche. Collect ML.

110 Ltrs

Wash the cake with

Chilled methanol of 10-2 deg C. Collect washing.

Take the Methanol wash for Methanol

recovery. Recovered methanol may be

recycled.

Filter through centrifuge =24 kg

Stage (4) Process details

Inputs Process Steps Critical

Parameter

s

Output


Assembly: 100 Litres SS reactor having stirring

and cooling water arrangement.

260Ltrs

Charge

Dioxane

Start agitation.

24 kgs

Charge

Chalcone at RT.

15 kg Charge

4-Hydroxy Coumarine at RT

1. kg Charge Piperidine

Heat reaction mass to get reflux(99-100 deg C).

Reflux reaction mass for 12 hrs.

If reaction has completed, Distil out Dioxane (about

85% of input qty) under vacuum below 65 deg C.

300 Ltrs Charge

Water at 80-85 deg C over a period of 2hrs.

Maintain reaction at 80-85 deg C for 2 hrs.

Cool reaction mass to 70 deg C.

Filter the product while hot to get light yellow

colour powder. ML to be discarded.

Wash the product with

Hot water of 70 deg C., water washing to be

discarded.

Suck dry the cake.=28 kgs

Stage (5) Process details

Inputs Process Steps Critical

Parameter

rs

Output

Assembly water: 600 Litres MSGL reactor having

stirring cooling water arrangement.

368 ltrs Charge

IPA

26 ltrs Charge

1,4-Dioxane

0.6 ltrs Charge

PEG-400

Start Stirring.

28 kgs Charge

BDL-Ketone unde agitation.

Stir for 30 min at RT

Cool reaction mass to15 deg C.

1.76 kgsx2 Add

Sodium borohydrid in two lots at 15 degC in 30 minutes


After addition of Sodium borohydride second lot,

allow temperature to go to 25-30 deg C.

Stir at 25-30 deg C 6hrs.

Monitor the reaction completion by IIPLC.

Unreacted BDL-Ketone should be less than

0.1%.

.

If reaction has gone for completion, cool to 15-20

degC.

150 Ltrs

190 Ltrs

add mixture of

Conc. HCI and

Water, through addition pot at 15-20 deg C.

Stir at 25 deg C for 2 hrs.

Filter the product through

neutsche filter. (Preserve

washing fo IPA recovery)

500 ltrs Give washing with

Water6 lots at RT till cake is free from Chloride. (Check with silver nitrate solution. Procedure: Take 1 gms cake in DW=5ML and mix thoroughly and filter. Take filtrate for testing)

Suck dry the cake

Wet weight=6.95kgs.

20ltrs Re slurry the cake by charging

Toluene in reactor.

Distil out water azeotropically by distillation under

vacuum by keeping reaction mass temperature max of

60-65 deg C

Cool reaction mass to 15 deg C.

Filter the product.

Suck dry the cake.

100 ltrs Give washing with chilled

Petroleum ether of 15 deg C.

Suck dry the cake. Wet

weight=7.8kgs.

Dry the cake =20 kgs


ANNEXURE C: LIST OF RAW MATERIALS WITH QUANTITY

Raw Material Total quantity,

kg/month

1 Acetone 1157

2 Acetyl Chloride 285

3 Acetic Acid 97

4 Aluminuim Chloride 399

5 Benzaldehyde 86.8

6 Toulene 1147.26

7 Bromine 112

8 Biphenyl 380

9 1,4- Dioxane 3395

10 Ethylene di Chloride 4587.6

11 Ferric Chloride 2.5

12 4-Hydroxy Coumarine 191.4

13 Hydrochloric Acid 30% 2640.7

14 Iodine 8.89

15 Iso propyl Alchohol 5547.2

16 Methanol 5339

17 Petroleum Ether 1428

18 Peperidine 13.3

19 Peg 400 7.6

20 Sodium Thiosulphate 25.28

21 Sodium Methoxide 30% 302

22 Sodium Borohydride 81.9

TOTAL 27234.43


ANNEXURE D: MSDS OF RAW MATERIALS

Soft copies of MSDS are attached with the document


ANNEXURE E: ADDITIONAL INFORMATION ON HAZOP STUDY

1. WHAT IS „HAZOP‟ ?

“HAZOP” ( Hazard and Operability ) study of an operation is defined as follows

“The application of a formal, systematic, critical examination to the process of

engineering intentions of a facility to assess the hazard potential of mal-operation or

malfunctioning of individual items of equipment and the consequential effects on the

facility as a whole.”

Incidentally, a “HAZARD” is defined as :-

It is a physical situation with a potential for -

Human injury

Property damage

Damage to environment

Lessening the ability to perform a prescribed function.

2 THE METHODOLOGY

HAZOP study is a procedure used to review the design and operations of a

hazardous process facility. It is used to identify all possible cases of deviation from

normal safe operation that could lead to any hazard/ environmental risk / operability

problems etc. Some of the causes may be unrealistic and so the desired

consequences will be rejected as not meaningful. Some of the consequences may

be trivial and would be considered no further. However, There may be some

deviations with both causes that are conceivable and consequences that are

potentially hazardous. These potential hazards are then noted for

recommendations/actions.

Having examined a part of the design materials of construction, safety arrangements

and recorded potential hazards associated with it the team attempts to find out the

suitable modifications , improvements, measures, etc. which may be adopted to

prevent deviations from the processes and engineering intentions and consequent

hazard and operability problems. After finalising the recommendations, the study

progresses to focus on the next part of the design. The examination is repeated until

the whole plant has been studied. HAZOP is a systematic and highly structured


study with a critical approach to examine the process and engineering intentions of

the process design. The most important of these terms are:

TERM MEANING

Intention The intention defines how the selected section/unit is expected to operate.

Deviation These are departures from the intention which are discovered by

systematically applying the guide words.

Causes These are the reasons why deviations might occur. Once a deviation has

been shown top have a conceivable or realistic cause, it can be treated as

meaningful.

Consequences They are the results of deviations should they occur

Hazards The consequences, which can cause damage, injury or loss.

Guide words These are simple words, which are used to qualify the intentions in order

to guide and stimulate the thinking process and so discover deviations. A

list of guide words along with the likely causes is given in Table 1.

3 THE AIMS

The primary aims of HAZOP are:

To identify the cause of all deviations of changes from the design intent.

To determine all major hazard and operability problems associated with these

deviations.

To decide whether action is required to control the hazard or operability problem.

To ensure that the actions decided upon are implemented and documented.

4 THE PROCEDURE ADOPTED

The complete process studied is divided into discrete nodes. For each node, every

parameter or guideword deviation is considered; for each deviation, causes are

identified; and for each cause, consequences are identified. After considering

proposed protection for each consequence, recommendations for actions are made,

if the remaining level of risk is considered

unacceptable.

5 THE STEPS USED

The sequence of steps used to conduct the HAZOP are as follows:


Select and confirm the scope of node.

Explain the general design intentions and operating conditions of the node.

Specify the node’s process parameters.

Select a process parameter ( Flow, Pressure etc.) and specify the design intention

relating to this parameter.

Apply a deviation ( more, less etc. ) to the parameter and develop meaningful

causes, hazards of the deviation from the intention.

Identify all scenarios, causes/hazards of the deviation from the intention.

Identify all major consequences associated with each cause without regards to

safeguards.

Specify predominant safeguard against each consequence.

Make recommendations to mitigate the consequences if the severity is

unacceptable.

Reiterate the above steps for other guidewords.

Reiterate the above steps for all other nodes in review.

The team should document all recommendations submitted during the study.

When a study team decided that major redesign of a plant/section is necessary, it records

the parameters for the redesigning and a HAZOP review is required, when the redesign is

complete.

When the information data base contains a questionable fact, it is best to assume that it is

correct and not that appropriate action with a rider to the effect that the data should be

verified first.

If the leader or any team member believes that a particular system of P & I diagram should

not be studied by the team either because it is identical to the system already studied or

because it involves no additional hazards, this must be agreed upon by the team and the

reasons recorded in the report.


TABLE:1

GUIDE WORD

CAUSE

No flow Wrong routing - blockage - incorrectly fitted check valve - burst

pipe - large leak - equipment failure ( isolation valve, pump vessel, etc. ) - incorrect pressure differential - isolation in error etc.

Reverse Flow Defective check valve - siphon effect - incorrect pressure

differential - two way flow - emergency venting - incorrect operation - in line spare equipment etc.

More flow Increased pumping capacity - increased suction pressure -

reduced delivery head - greater fluid density - exchanger tube leaks - restriction orifice plates deleted - cress connection of systems - control faults - control valve trim changed - running two pumps - etc.

Less flow Line restrictions - filter blockage - defective pumps - fouling of

vessels, valves, orifice plates - density or viscosity changes - etc

More level Outlet isolated or blocked - inflow greater than outflow - control failure - faulty level measurement - gravity liquid balancing etc.

Less level Inlet flow stops - leak - outflow greater than inflow - control

failure - faulty level measurement - draining of vessel etc

More Pressure

Surge problems - connection to high pressure system - gas breakthrough (inadequate venting ) - defective isolation procedures for relief valves - thermal overpressure - positive displacement pumps - failed open PCV’s design pressures, specifications of pipes, vessels, fittings, instruments etc.

GUIDE WORD

CAUSE

Less pressure Generation of vacuum condition - condensation - gas dissolving in

liquid - restricted pump compressor suction line -undetected leakage - vessel drainage - blockage of blanket gas reducing valve etc.

More temperature Ambient conditions - fouled or failed exchanger tubes - fire situation -

cooling water failure - defective control - heater control failure - internal fire - reaction control failures - heating medium leak into process etc.

Less temperature Ambient conditions - reducing pressure - fouled or failed exchanger

tubes - loss of heating - depressurization of liquefied gas - Joule/Thompson effect - etc.

More viscosity Incorrect material or composition - incorrect temperature - high solids’

concentration - settling of slurries - etc.


Composition change

Leaking isolation valves - leaking exchanger tubes - phase change - incorrect feed stock/specification - inadequate quality control - process control upset - reaction intermediates/by-products - settling of slurries etc.

Contamination Leaking exchanger tubes - Leaking isolation valves - incorrect

operation of system – interconnected systems (especially services, blanket systems) - effect of corrosion - wrong additives - ingress of air - shutdown and start up conditions - grade change - etc.

Relief Relief philosophy (process fire etc.) - type of relief device and reliability

- relief valve discharge location - pollution implications - two phase flow - effect of de-bottlenecking on relief capacity - inlet and outlet piping etc.

GUIDE WORD

CAUSE

Instrumentation Control philosophy - location of instruments - response time - setpoint

of alarms and trips and ability to change - time available for operator intervention - alarm and trip testing - fire protection - top control amplifiers - panel arrangement and location - auto/manual facility and human error - fail safe philosophy etc.

Sampling Sampling procedure and operator safety - time for analysis result -

calibration of automatic samplers - reliability/accuracy of representative sample - diagnosis of result - loss of sample flow etc.

Corrosion/erosion Cathodic protection arrangements - internal/external corrosion

protection - engineering specifications - Zinc embrittlement - stress corrosion cracking - fluid velocities - etc.

Service Failure of instrument air /steam /nitrogen /cooling water /hydraulic

power water or other - contamination of instrument air, nitrogen etc. - telecommunications - heating and ventilation system - computers etc.

Abnormal operation

Purging – flushing - start-up - normal shutdown – emergency shutdown - emergency operations - inspection of operating machines - of machinery etc

Maintenance Isolation philosophy - drainage - purging - cleaning – drying - slip

plates - access - rescue plan – training - pressure testing - work permit system - condition monitoring - lifting & manual landing - etc.

GUIDE WORD

CAUSE

Ignitions Grounding arrangements - insulated vessels/equipment - low

conductance fluids - splash filling of vessels - insulated strainers and valve components - dust generation – powder handling equipment - electrical classification - flame arrestors - hot work - hot surface - auto


ignition - pyrophoric material etc.

Safety Toxic properties of process materials - fire and gas detection system/alarms - emergency shutdown arrangement - fire fighting response time - emergency shutdown arrangement - emergency and major emergency training - contingency plans - TLV’s of process material and methods of detection - noise - knowledge of hazards of process materials - first aid/ medical resources - effluent disposal hazards created by others (adjacent storage areas/ process plant etc. ) - testing of emergency equipments - compliance with local /national regulations etc.


Annexure : 7.1

The basic data used for running ALOHA

SITE DATA:

Location: PEST CONTROL INDIA PVT. LTD., INDIA

Building Air Exchanges Per Hour: 0.40 (unsheltered double storied)

Time: March 30, 2017 1506 hours ST (using computer's clock)

ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)

Wind: 3.02 meters/second from NW at 10 meters

Ground Roughness: urban or forest Cloud Cover: 3 tenths

Air Temperature: 27° C

Stability Class: F (user override)

No Inversion Height Relative Humidity: 60%

1) CHEMICAL DATA FOR METHANOL:

Chemical Name: METHANOL Molecular Weight: 32.04 g/mol

AEGL-1 (60 min): 530 ppm AEGL-2 (60 min): 2100 ppm AEGL-3 (60 min): 7200 ppm

IDLH: 6000 ppm LEL: 71800 ppm UEL: 365000 ppm

Ambient Boiling Point: 64.7° C

Vapor Pressure at Ambient Temperature: 0.18 atm

Ambient Saturation Concentration: 184,410 ppm or 18.4%


The ALOHA Footprints (Methanol)

I) Methanol

Source :-Puddle

Scenario :- Evaporating Puddle of Flammable Chemical

1. Toxic area of vapour cloud

SOURCE STRENGTH:

Evaporating Puddle (Note: chemical is flammable)

Puddle Area: 2.25 square meters Puddle Volume: 2.25 cubic meters

Ground Type: Concrete Ground Temperature: 27° C

Initial Puddle Temperature: 27° C

Release Duration: ALOHA limited the duration to 1 hour

Max Average Sustained Release Rate: 247 grams/min

(averaged over a minute or more)

Total Amount Released: 14.2 kilograms

THREAT ZONE:

Model Run: Gaussian

Red : less than 10 meters(10.9 yards) --- (7200 ppm = AEGL-3 [60 min])

Note: Threat zone was not drawn because effects of near-field patchiness

make dispersion predictions less reliable for short distances.

Orange: less than 10 meters(10.9 yards) --- (2100 ppm = AEGL-2 [60 min])



Yellow: 18 meters --- (530 ppm = AEGL-1 [60 min])



Model Run: Gaussian

Red : less than 10 meters(10.9 yards) --- (7200 ppm = AEGL-3 [60 min])



Orange: less than 10 meters(10.9 yards) --- (2100 ppm = AEGL-2 [60 min])







I) Methanol

Source :-Puddle


2. Flammable area of vapour cloud

SOURCE STRENGTH:









THREAT ZONE:

Threat Modeled: Flammable Area of Vapor Cloud

Model Run: Gaussian

Red : less than 10 meters(10.9 yards) --- (43080 ppm = 60% LEL = Flame Pockets)



Yellow: less than 10 meters(10.9 yards) --- (7180 ppm = 10% LEL)




Model Run: Gaussian








I) Methanol

Source :-Puddle


3. Blast area of vapour cloud

SOURCE STRENGTH:









THREAT ZONE:

Threat Modeled: Overpressure (blast force) from vapor cloud explosion

Type of Ignition: ignited by spark or flame

Level of Congestion: uncongested

Model Run: Gaussian

No explosion: no part of the cloud is above the LEL at any time




Model Run: Gaussian



I) Methanol

Source :-Puddle

Scenario :- Burning puddle of flammable chemical

Thermal radiation from pool fire

SOURCE STRENGTH:

Burning Puddle / Pool Fire



Flame Length: 2 meters

Burn Duration: ALOHA limited the duration to 1 hour

Burn Rate: 2.25 kilograms/min

Total Amount Burned: 135 kilograms

THREAT ZONE:

Threat Modeled: Thermal radiation from pool fire

Red : less than 10 meters(10.9 yards) --- (10.0 kW/(sq m) = potentially lethal within 60 sec)

Orange: less than 10 meters(10.9 yards) --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)

Yellow: less than 10 meters(10.9 yards) --- (2.0 kW/(sq m) = pain within 60 sec)






2) CHEMICAL DATA FOR ISOPROPANOL:

CHEMICAL DATA:

Chemical Name: ISOPROPANOL Molecular Weight: 60.10 g/mol

PAC-1: 400 ppm PAC-2: 400 ppm PAC-3: 12000 ppm





The ALOHA Footprints (Iso Propyl Alcohol)

The ALOHA Footprints

II) Iso Propyl Alcohol

Source :-Puddle


Toxic Area of Vapor Cloud

SOURCE STRENGTH:









THREAT ZONE:

Model Run: Gaussian

Red : less than 10 meters(10.9 yards) --- (12000 ppm = PAC-3)



Orange: less than 10 meters(10.9 yards) --- (400 ppm = PAC-2)



Yellow: less than 10 meters(10.9 yards) --- (400 ppm = PAC-1)




Model Run: Gaussian

Red : less than 10 meters(10.9 yards) --- (12000 ppm = PAC-3)



Orange: less than 10 meters(10.9 yards) --- (400 ppm = PAC-2)



Yellow: less than 10 meters(10.9 yards) --- (400 ppm = PAC-1)





Source :-Puddle


Flammable Area of Vapor Cloud

SOURCE STRENGTH:









THREAT ZONE:


Model Run: Gaussian








Model Run: Gaussian









Source :-Puddle


Blast Area of Vapor Cloud Explosion

SOURCE STRENGTH:









THREAT ZONE:




Model Run: Gaussian





Model Run: Gaussian




Source :-Puddle

Scenario :- Burning Puddle of Flammable Chemical


SOURCE STRENGTH:








THREAT ZONE:










3) CHEMICAL DATA FOR ACETONE:

CHEMICAL DATA:

Chemical Name: ACETONE Molecular Weight: 58.08 g/mol


LEL: 26000 ppm UEL: 130000 ppm




The ALOHA Footprints (Acetone)

III) Acetone

Source :-Direct

Scenario :- Spill of entire chemical present in single drum

1. Heavy Gas

SOURCE STRENGTH:

Direct Source: 200 kilograms Source Height: 0

Release Duration: 1 minute

Release Rate: 3.33 kilograms/sec

Total Amount Released: 200 kilograms

THREAT ZONE:

Model Run: Heavy Gas

Red : 94 meters --- (5700 ppm = AEGL-3 [60 min])

Orange: 132 meters --- (3200 ppm = AEGL-2 [60 min])



200 0 200 400 600 800 400

200

0

200

400

meters

meters

greater than 5700 ppm (AEGL-3 [60 min])



wind direction confidence lines

wind


III) Acetone

Source :-Direct


2. Flammable Area of Vapor Cloud

SOURCE STRENGTH:





THREAT ZONE:



Red : 52 meters --- (15600 ppm = 60% LEL = Flame Pockets)

Yellow: 148 meters --- (2600 ppm = 10% LEL)

100 0 100 200 300 150

50

0

50

150

meters

meters

greater than 15600 ppm (60% LEL = Flame Pockets)

greater than 2600 ppm (10% LEL)


wind


III) Acetone

Source :-Direct


3. Overpressure (blast force) from vapor cloud explosion

SOURCE STRENGTH:





THREAT ZONE:





Red : LOC was never exceeded --- (8.0 psi = destruction of buildings)

Orange: LOC was never exceeded --- (3.5 psi = serious injury likely)

Yellow: LOC was never exceeded --- (1.0 psi = shatters glass)









4) CHEMICAL DATA FOR ACETYL CHLORIDE:

CHEMICAL DATA:

Chemical Name: ACETYL CHLORIDE Molecular Weight: 78.50 g/mol

PAC-1: 0.85 ppm PAC-2: 9.4 ppm PAC-3: 56 ppm





IV) Acetyl Chlorinde

Source :-Direct

Scenario :- Spill of entire chemical present in single carboy

1. Heavy Gas

SOURCE STRENGTH:

Direct Source: 30 liters Source Height: 0

Source State: Liquid

Source Temperature: 27° C


Release Rate: 549 grams/sec


THREAT ZONE:


Red : 434 meters --- (56 ppm = PAC-3)

Orange: 1.0 kilometers --- (9.4 ppm = PAC-2)

Yellow: 2.9 kilometers --- (0.85 ppm = PAC-1)


0 1 2 3 4 5 2

1

0

1

2

kilometers

kilometers

greater than 56 ppm (PAC-3)

greater than 9.4 ppm (PAC-2)

greater than 0.85 ppm (PAC-1)


wind



Source :-Direct



SOURCE STRENGTH:







THREAT ZONE:



















Source :-Direct


3. Overpressure from vapor cloud explosion

SOURCE STRENGTH:







THREAT ZONE:
















5) CHEMICAL DATA FOR ACETIC ACID:

CHEMICAL DATA:

Chemical Name: ACETIC ACID, GLACIAL Molecular Weight: 60.05 g/mol

ERPG-1: 5 ppm ERPG-2: 35 ppm ERPG-3: 250 ppm





V) Acetic Acid

Source :- Direct


1. Heavy Gas

SOURCE STRENGTH:







THREAT ZONE:


Red : 230 meters --- (250 ppm = ERPG-3)

Orange: 640 meters --- (35 ppm = ERPG-2)

Yellow: 1.6 kilometers --- (5 ppm = ERPG-1)


0.5 0 0.5 1 1.5 2 1

0.5

0

0.5

1

kilometers

kilometers

greater than 250 ppm (ERPG-3)




wind


V) Acetic Acid

Source :- Direct



SOURCE STRENGTH:







THREAT ZONE:


















V) Acetic Acid

Source :- Direct



SOURCE STRENGTH:







THREAT ZONE:
















6) CHEMICAL DATA FOR TOULENE:

CHEMICAL DATA:

Chemical Name: TOLUENE Molecular Weight: 92.14 g/mol






VI) Toluene

Source: - Direct

Scenario: - Spill of entire chemical present in single Drum

1. Heavy Gas

SOURCE STRENGTH:





THREAT ZONE:






200 0 200 400 600 800 1000 500

300

100

0

100

300

500

meters

meters





wind


VI) Toluene

Source: - Direct



SOURCE STRENGTH:





THREAT ZONE:





100 0 100 200 300 150

50

0

50

150

meters

meters

greater than 6600 ppm (60% LEL = Flame Pockets)



wind


VI) Toluene

Source: - Direct



SOURCE STRENGTH:





THREAT ZONE:
















7) CHEMICAL DATA FOR BROMINE:

CHEMICAL DATA:

Chemical Name: BROMINE Molecular Weight: 159.81 g/mol

AEGL-1 (60 min): 0.033 ppm AEGL-2 (60 min): 0.24 ppm AEGL-3 (60 min): 8.5 ppm

IDLH: 3 ppm




VII) Bromine

Source: - Direct

Scenario: - Spill of entire chemical present in single bottle

1. Heavy Gas

SOURCE STRENGTH:





THREAT ZONE:


Red : 312 meters --- (8.5 ppm = AEGL-3 [60 min])

Orange: 1.5 kilometers --- (0.24 ppm = AEGL-2 [60 min])

Yellow: 3.2 kilometers --- (0.033 ppm = AEGL-1 [60 min])


0 1 2 3 4 5 2

1

0

1

2

kilometers

kilometers

greater than 8.5 ppm (AEGL-3 [60 min])




wind


8) CHEMICAL DATA FOR 1,4-DIOXANE:

CHEMICAL DATA:

Chemical Name: 1,4-DIOXANE Molecular Weight: 88.11 g/mol





VIII) 1,4-Dioxane

Source: - Puddle

Scenario: - Evaporating Puddle

1. Heavy Gas

SOURCE STRENGTH:









THREAT ZONE:

Model Run: Gaussian

Red : less than 10 meters(10.9 yards) --- (215000 ppm)



Orange: less than 10 meters(10.9 yards) --- (21000 ppm)



Model Run: Gaussian

Red : less than 10 meters(10.9 yards) --- (215000 ppm)



Orange: less than 10 meters(10.9 yards) --- (21000 ppm)




VIII) 1,4-Dioxane

Source: - Puddle

Scenario: - Evaporating Puddle of Flammable Chemical


SOURCE STRENGTH:









THREAT ZONE:


Model Run: Gaussian








Model Run: Gaussian








VIII) 1,4-Dioxane

Source: - Puddle

Scenario: - Evaporating Puddle of Flammable Chemical


SOURCE STRENGTH:







(Averaged over a minute or more)


THREAT ZONE:




Model Run: Gaussian





Model Run: Gaussian



VIII) 1,4-Dioxane

Source: - Puddle

Scenario: - Burining Puddle of Flammable Chemical


SOURCE STRENGTH:








THREAT ZONE:










9) CHEMICAL DATA FOR ETHYLENE DICHLORIDE:

CHEMICAL DATA:

Chemical Name: ETHYLENE DICHLORIDE Molecular Weight: 98.96 g/mol

ERPG-1: 50 ppm ERPG-2: 200 ppm ERPG-3: 300 ppm


Carcinogenic risk - see CAMEO Chemicals




IX) Ethylene Dichloride

Source: - Puddle

Scenario: - Evaporating Puddle of flammable chemical

1. Gaussian

SOURCE STRENGTH:









THREAT ZONE:

Model Run: Gaussian

Red : 20 meters --- (300 ppm = ERPG-3)



Orange: 27 meters --- (200 ppm = ERPG-2)



Yellow: 58 meters --- (50 ppm = ERPG-1)


20 0 20 40 60 80 40

20

0

20

40

meters

meters

greater than 300 ppm (ERPG-3) (not drawn)

greater than 200 ppm (ERPG-2) (not drawn)



wind



Source: - Puddle


2. Flammable area of vapor cloud

SOURCE STRENGTH:









THREAT ZONE:


Model Run: Gaussian








Model Run: Gaussian









Source: - Puddle



SOURCE STRENGTH:









THREAT ZONE:




Model Run: Gaussian

No explosion: no part of the cloud is above the LEL at any time.




Model Run: Gaussian




Source: - Puddle

Scenario: - Burning Puddle of flammable chemical

4. Thermal radiation from pool fire

SOURCE STRENGTH:








THREAT ZONE:










10) CHEMICAL DATA FOR ETHYLENE OXIDE:

CHEMICAL DATA:

Chemical Name: ETHYLENE OXIDE Molecular Weight: 44.05 g/mol

AEGL-1 (60 min): N/A AEGL-2 (60 min): 45 ppm AEGL-3 (60 min): 200 ppm


Carcinogenic risk - see CAMEO Chemicals


Vapor Pressure at Ambient Temperature: greater than 1 atm

Ambient Saturation Concentration: 1,000,000 ppm or 100.0%

IX) Ethylene Oxide

Source: - Direct

Scenario: - Leakage in storage cylinder

1. Heavy Gas

SOURCE STRENGTH:





Note: This chemical may flash boil and/or result in two phase flow.

THREAT ZONE:




Yellow: no recommended LOC value --- (N/A = AEGL-1 [60 min])


200 0 200 400 600 800 1000 500

300

100

0

100

300

500

meters

meters



no recommended LOC value for AEGL-1 (60 min) (not drawn)


wind


IX) Ethylene Oxide

Source: - Direct


2. Flammable area of vapor cloud

SOURCE STRENGTH:






THREAT ZONE:







20 0 20 40 60 80 100 50

30

10

0

10

30

50

meters

meters

greater than 18000 ppm (60% LEL = Flame Pockets) (not drawn) greater than 3000 ppm (10% LEL) wind direction confidence lines

wind


IX) Ethylene Oxide

Source: - Direct



SOURCE STRENGTH:






THREAT ZONE:







Yellow: 20 meters --- (1.0 psi = shatters glass)

10 0 10 20 30 40 20

10

0

10

20

meters

meters

greater than 8.0 psi (destruction of buildings) greater than 3.5 psi (serious injury likely) greater than 1.0 psi (shatters glass) wind direction confidence lines

wind


IX) Ethylene Oxide

Source: - Cylinder containing pressurized flammable liquid

Scenario: - Leaking Tank, Chemical is not Burning as it escape into atmosphere

1. Heavy gas

SOURCE STRENGTH:

Leak from hole in vertical cylindrical tank

Flammable chemical escaping from tank (not burning)

Tank Diameter: 0.35 meters Tank Length: 0.85 meters

Tank Volume: 0.082 cubic meters

Tank contains liquid Internal Temperature: 27° C

Chemical Mass in Tank: 35 kilograms Tank is 49% full

Circular Opening Diameter: 0.06 meters

Opening is 0 inches from tank bottom


Max Average Sustained Release Rate: 583 grams/sec



Note: The chemical escaped as a mixture of gas and aerosol (two phase flow).

THREAT ZONE:




Yellow: no recommended LOC value --- (N/A = AEGL-1 [60 min])


200 0 200 400 600 800 400

200

0

200

400

meters

meters



no recommended LOC value for AEGL-1 (60 min) (not drawn)


wind


IX) Ethylene Oxide




SOURCE STRENGTH:














THREAT ZONE:








20 0 20 40 60 80 100 50

30

10

0

10

30

50

meters

meters

greater than 18000 ppm (60% LEL = Flame Pockets) (not drawn)



wind


IX) Ethylene Oxide




SOURCE STRENGTH:














THREAT ZONE:







Yellow: 29 meters --- (1.0 psi = shatters glass)


20 0 20 40 60 30

10

0

10

30

meters

meters

greater than 8.0 psi (destruction of buildings)

greater than 3.5 psi (serious injury likely)

greater than 1.0 psi (shatters glass)


wind


IX) Ethylene Oxide


Scenario: - Leaking Tank, Chemical is Burning as jet fire

1. Thermal radiation from jet fire

SOURCE STRENGTH:


Flammable chemical is burning as it escapes from tank







Flame Length: 17 meters Burn Duration: 20 seconds

Burn Rate: 21.5 kilograms/sec

Total Amount Burned: 35.0 kilograms

Note: The chemical escaped from the tank and burned as a jet fire.

THREAT ZONE:

Threat Modeled: Thermal radiation from jet fire

Red : 10 meters --- (10.0 kW/(sq m) = potentially lethal within 60 sec)

Orange: 10 meters --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)

Yellow: 20 meters --- (2.0 kW/(sq m) = pain within 60 sec)


20 10 0 10 20 30 20

10

0

10

20

meters

meters

greater than 10.0 kW/(sq m) (potentially lethal within 60 sec)

greater than 5.0 kW/(sq m) (2nd degree burns within 60 sec)

greater than 2.0 kW/(sq m) (pain within 60 sec)

wind


IX) Ethylene Oxide


Scenario: - BLEVE of flammable liquid in vertical cylinder tank

1. Thermal radiation from Fireball

SOURCE STRENGTH:

BLEVE of flammable liquid in vertical cylindrical tank



Tank contains liquid

Internal Storage Temperature: 27° C


Percentage of Tank Mass in Fireball: 100%

Fireball Diameter: 19 meters Burn Duration: 2 seconds

THREAT ZONE:

Threat Modeled: Thermal radiation from fireball

Red : 36 meters --- (10.0 kW/(sq m) = potentially lethal within 60 sec)

Orange: 51 meters --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)

Yellow: 80 meters --- (2.0 kW/(sq m) = pain within 60 sec)


100 50 0 50 100 150 100

50

0

50

100

meters

meters

greater than 10.0 kW/(sq m) (potentially lethal within 60 sec)

greater than 5.0 kW/(sq m) (2nd degree burns within 60 sec)

greater than 2.0 kW/(sq m) (pain within 60 sec)

wind


Annexure: 7.3

DOW INDEX

1. Acetone

Tank No. -- Equipment Name Acetone Storage in Drums ( 0.4 MT)

Basic Material for Material factor Acetone Density, kg/l 0.791

Properties of material

N h 1 N f 3 N r 0 M.F. 16

Boil. pt. 133.1 0F 56.2 0C Flash pt. - 4 0F -20 0C

HC = Heat of Comb. 12300 BTU / lb

Quantity of the material 505.6 l 400 kg 882 Lb

Storage conditions Temp 25 0C Pressure 1.0 Bar

Penalty factor

range

Penalty factor used

1.General Process

Hazard

Base Factor 1.00 1.00

Exothermic Chemical Reaction 0.30 to 1.25 0.00

Endothermic Processes 0.20 to 0.40 0.00

Material handling and transfer 0.25 to 1.05 0.85

Enclosed or Indoor Process Units 0.25 to 0.90 0.00

Access 0.20 to 0.35 0.00

Drainage and Spill Control 0.25 to 0.50 0.50

General Process Hazard Factor ( F1 ) 2.35

2.Special Process

Hazard


Toxic material(s) 0.20 to 0.80 0.20

Sub atmospheric pressure (< 500 mm

Hg)

0.50 0.00

Operation in or near flammable range

_____inerted ______noninerted

0.00 to 0.80

1. Tank farm storage flammable

liquids

0.50 0.00

2. Process upset or purge failure 0.30 0.00

3. Always in contact of Flame

process

0.80 0.00

Dust Explosion 0.25 to 2.00 0.00

Pressure Operating pressure psig

Relief setting ________

psig

0.00

Low temperature 0.20 to 0.30 0.00

Quantity of flammable / unstable

material

1. Liquids or gases in process 0.00

2. Liquids or gases in storage 0.16

3. Combustible Solids in Storage, Dust

in Process

0.00

Corrosion & Erosion 0.10 to 0.75 0.10


Leakage - Joints & Packing 0.10 to 1.50 0.00

Use of Fired Equipment 0.00

Hot oil heat exchange system 0.15 to 1.15 0.00

Rotating Equipment 0.50 0.00

Special Process Hazard Factor ( F2 ) 1.46

Process Unit Hazard Factor ( F3 = F1 x F2) 3.431

Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 54.89

Degree of Hazard Light

Radius of Exposure 46.1 ft

Area of Exposure 6673.1 ft2

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-up Severe

RECOMMENDED MINIMUM FEATURES ACCORDING TO

DOW FIRE AND EXPLOSION INDEX

Preventive & Protective Features Fire & Explosion Index Number Index for the present case

0-20 20-40 40-60 60-75 75-90 >90 54.89

Feature

optional

Suggested Recomme

nded

Feature

required

1) Fireproofing 1 2 2 3 4 4 √

2) Water spray

a) directional 1 2 3 3 4 4 √

b) area 1 2 3 3 4 4 √

c) curtain 1 1 2 2 2 4 √

3) Special instrumentation

a) temperature 1 2 3 3 4 4 √

b) pressure 1 2 3 3 3 4 √

c) flow control 1 2 3 4 4 4 √

4) Dust, blowdown, spill control 1 1 2 3 3 4 √

5) Internal examination 1 2 3 3 4 4 √


6) Combustible gas

monitors

a) signal alarm 1 1 2 3 3 4 √

b) actuate equipment 1 1 2 2 3 4 √

7) Remote operation 1 1 2 3 3 4 √

8) Diking, (Not Applicable as

barrel storage)

1 4 4 4 4 4

9) Blast & barrier walls

separation

1 1 2 3 4 4 √

1) Feature optional 2) Feature suggested 3) Feature recommended 4) Feature required

2. Acetyl Chloride

Tank No. -- Equipment Name Acetyl Chloride 30 Liter Carboy

(30 lit X 1)

Basic Material for Material factor 24 Density, kg/l 1.1


N h 3 N f 3 N r 2 M.F. 14

Boil. pt. 125.6 0F 52 0C Flash pt. 40 0F 4.4 0C


Quantity of the material 30 l 33 kg 72.7 Lb


Penalty factor

range

Penalty factor used

1.General Process

Hazard






Access 0.20 to 0.35 0.00



2.Special Process

Hazard




Hg)

0.50 0.00



0.00 to 0.80


liquids

0.50 0.00




process

0.80 0.00




psig

0.00



material




in Process

0.00









Degree of Hazard Moderate






1-60 Light

61-96 Moderate

97-127 Intermediate

128-158 Heavy

159-up Severe

RECOMMENDED MINIMUM FEATURES ACCORDING TO DOW FIRE AND EXPLOSION INDEX

Preventive & Protective

Features

Fire & Explosion Index Number Index for the present case

0-20 20-40 40-60 60-75 75-90 >90 90.24

Feature

optional

Suggested Recomme

nded

Featu

re

requi

red



2) Water spray


b) area 1 2 3 3 4 4 √

c) curtain 1 1 2 2 2 4 √



b) pressure 1 2 3 3 3 4 √


4) Dust, blowdown, spill

control

1 1 2 3 3 4 √


6) Combustible gas

monitors





barrel storage)

1 4 4 4 4 4


separation

1 1 2 3 4 4 √


3. Acetic Acid

Tank No. -- Equipment Name Acetic Acid (30 lit Carboy)



N h 3 N f 2 N r 1 M.F. 14

Boil. pt. 244.6 0F 118.1 0C Flash pt. 102 0F 39 0C


Quantity of the material 30 l 31.5 kg 69.44 Lb


Penalty factor

range

Penalty factor used

1.General Process

Hazard







Access 0.20 to 0.35 0.00



2.Special Process

Hazard



Sub atmospheric pressure (< 500 mm Hg) 0.50 0.00



0.00 to 0.80

1. Tank farm storage flammable liquids 0.50 0.00



process

0.80 0.00



Relief setting ________ psig

0.00


Quantity of flammable / unstable material


2. Liquids or gases in storage 0.00 3. Combustible Solids in Storage, Dust in

Process

0.00















1-60 Light

61-96 Moderate

97-127 Intermediate

128-158 Heavy

159-up Severe




Features


0-20 20-40 40-60 60-75 75-90 >90 41.6

Feature

optional

Suggested Recomme

nded

Feature

require

d


2) Water spray


b) area 1 2 3 3 4 4 √

c) curtain 1 1 2 2 2 4 √



b) pressure 1 2 3 3 3 4 √



control

1 1 2 3 3 4 √


6) Combustible gas

monitors





barrel storage)

1 4 4 4 4 4


separation

1 1 2 3 4 4 √

1)Feature optional 2) Feature suggested 3) Feature recommended 4) Feature required


4. Benzaldehyde

Tank No. -- Equipment Name Benzaldehyde (60 lit in Carboy)



N h 2 N f 2 N r 0 M.F. 10

Boil. pt. 354 0F 179 0C Flash pt. 148 0F 64.4 0C


Quantity of the material 60 l 62.4 kg 137.5 Lb


Penalty factor

range

Penalty factor used

1.General Process

Hazard






Access 0.20 to 0.35 0.00



2.Special Process

Hazard






0.00 to 0.80




process

0.80 0.00




0.00




2. Liquids or gases in storage 0.00 3. Combustible Solids in Storage, Dust in

Process

0.00











Radius of Exposure 22 ft





1-60 Light

61-96 Moderate

97-127 Intermediate

128-158 Heavy

159-up Severe



Features


0-20 20-40 40-60 60-75 75-90 >90 26.25

Feature

optional

Suggested Recomme

nded

Feature

required


2) Water spray


b) area 1 2 3 3 4 4 √

c) curtain 1 1 2 2 2 4 √



b) pressure 1 2 3 3 3 4 √



control

1 1 2 3 3 4 √

√

5) Internal examination 1 2 3 3 4 4

6) Combustible gas

monitors




8) Diking, (Not Applicable 1 4 4 4 4 4


as barrel storage)


separation

1 1 2 3 4 4 √


5. Toluene

Tank No. -- Equipment Name Toluene (200 kg Drums X 4 nos)



N h 2 N f 3 N r 0 M.F. 16

Boil. pt. 231 0F 110.6 0C Flash pt. 40 0F 4.4 0C




Penalty factor

range

Penalty factor used

1.General Process

Hazard






Access 0.20 to 0.35 0.00



2.Special Process

Hazard






0.00 to 0.80




process

0.80 0.00




0.00





3. Combustible Solids in Storage, Dust in

Process

0.00
















1-60 Light

61-96 Moderate

97-127 Intermediate

128-158 Heavy

159-up Severe



Features


0-20 20-40 40-60 60-75 75-90 >90 56.4

Feature

optional

Suggested Recomme

nded

Feature

required


2) Water spray


b) area 1 2 3 3 4 4 √

c) curtain 1 1 2 2 2 4 √



b) pressure 1 2 3 3 3 4 √



control

1 1 2 3 3 4 √


6) Combustible gas


monitors




8) Diking, (Not Applicable

as barrel storage)

1 4 4 4 4 4


separation

1 1 2 3 4 4 √


6. 1,4- Dioxane

Tank No. -- Equipment Name 1,4 - Dioxane (200 kg Drums X 8 nos)



N h 2 N f 3 N r 1 M.F. 16

Boil. pt. 214 0F 101.1 0C Flash pt. 53.6 0F 12 0C


Quantity of the material 1553.3 l 1600 kg 3527.4 Lb


Penalty factor

range

Penalty factor used

1.General Process

Hazard






Access 0.20 to 0.35 0.00



2.Special Process

Hazard






0.00 to 0.80




process

0.80 0.00




0.00







Process

0.00















1-60 Light

61-96 Moderate

97-127 Intermediate

128-158 Heavy

159-up Severe



Features


0-20 20-40 40-60 60-75 75-90 >90 56.4

Feature

optional

Suggested Recomme

nded

Feature

required


2) Water spray


b) area 1 2 3 3 4 4 √

c) curtain 1 1 2 2 2 4 √



b) pressure 1 2 3 3 3 4 √




control

1 1 2 3 3 4 √


6) Combustible gas

monitors





as barrel storage)

1 4 4 4 4 4


separation

1 1 2 3 4 4 √


7. Ethylene Di Chloride

Tank No. -- Equipment Name Ethylene Di Chloride (200 kg Drums X 15

nos)



N h 2 N f 3 N r 0 M.F. 16

Boil. pt. 182.3 0F 83.5 0C Flash pt. 55.4 0F 13 0C




Penalty factor

range

Penalty factor used

1.General Process

Hazard






Access 0.20 to 0.35 0.00



2.Special Process

Hazard






0.00 to 0.80





process

0.80 0.00




0.00






Process

0.00















1-60 Light

61-96 Moderate

97-127 Intermediate

128-158 Heavy

159-up Severe



Features


0-20 20-40 40-60 60-75 75-90 >90 56.4

Feature

optional

Suggested Recomme

nded

Feature

required


2) Water spray



b) area 1 2 3 3 4 4 √

c) curtain 1 1 2 2 2 4 √



b) pressure 1 2 3 3 3 4 √



control

1 1 2 3 3 4 √


6) Combustible gas

monitors





as barrel storage)

1 4 4 4 4 4


separation

1 1 2 3 4 4 √


8. Iso Propyl Alcohol

Tank No. -- Equipment Name Iso Propyl Alcohol ( 200 kg Drum X 9

Nos)



N h 1 N f 3 N r 0 M.F. 16

Boil. pt. 180.5 0F 82.5 0C Flash pt. 53 0F 11.6 0C




Penalty factor

range

Penalty factor used

1.General Process

Hazard






Access 0.20 to 0.35 0.00




2.Special Process

Hazard






0.00 to 0.80




process

0.80 0.00




0.00






Process

0.00















1-60 Light

61-96 Moderate

97-127 Intermediate

128-158 Heavy

159-up Severe




Features


0-20 20-40 40-60 60-75 75-90 >90 48.8

Feature

optional

Suggested Recomme

nded

Feature

required


2) Water spray


b) area 1 2 3 3 4 4 √

c) curtain 1 1 2 2 2 4 √



b) pressure 1 2 3 3 3 4 √



control

1 1 2 3 3 4 √


6) Combustible gas

monitors





as barrel storage)

1 4 4 4 4 4 √


separation

1 1 2 3 4 4 √



9. Methanol

Tank No. -- Equipment Name Methanol ( 200 kg Drum X 10 Nos)



N h 1 N f 3 N r 0 M.F. 16

Boil. pt. 148.1 0F 64.5 0C Flash pt. 53.6 0F 12 0C




Penalty factor

range

Penalty factor used

1.General Process

Hazard






Access 0.20 to 0.35 0.00



2.Special Process

Hazard






0.00 to 0.80




process

0.80 0.00




0.00






Process

0.00
















1-60 Light

61-96 Moderate

97-127 Intermediate

128-158 Heavy

159-up Severe



Features


0-20 20-40 40-60 60-75 75-90 >90 48.8

Feature

optional

Suggested Recomme

nded

Feature

required


2) Water spray


b) area 1 2 3 3 4 4 √

c) curtain 1 1 2 2 2 4 √



b) pressure 1 2 3 3 3 4 √



control

1 1 2 3 3 4 √


6) Combustible gas

monitors






as barrel storage)

1 4 4 4 4 4 √


separation

1 1 2 3 4 4 √


10. Petroleum Ether

Tank No. -- Equipment Name Petroleum ether ( 200 kg Drum X 4 Nos)



N h 1 N f 4 N r 0 M.F. 21

Boil. pt. 140 0F 60 0C Flash pt. 0 0F -18 0C




Penalty factor

range

Penalty factor used

1.General Process

Hazard






Access 0.20 to 0.35 0.00



2.Special Process

Hazard






0.00 to 0.80




process

0.80 0.00




0.00







Process

0.00









Degree of Hazard Moderate






1-60 Light

61-96 Moderate

97-127 Intermediate

128-158 Heavy

159-up Severe



Features


0-20 20-40 40-60 60-75 75-90 >90 64.15

Feature

optional

Suggested Recomme

nded

Feature

required


2) Water spray


b) area 1 2 3 3 4 4 √

c) curtain 1 1 2 2 2 4 √



b) pressure 1 2 3 3 3 4 √



control

1 1 2 3 3 4 √



6) Combustible gas

monitors





as barrel storage)

1 4 4 4 4 4


separation

1 1 2 3 4 4 √



Annexure: 7.4

TOXICITY INDEX (MONDS INDEX)

Methodology:

Toxicity Index : Th + Ts (1+GPH+SPH)

100

Where, SPH = Special Process Hazard

GPH = General Process Hazard

Th = Toxicity factor based on the NFPA hazard index (0 – 4)

Ts = Correction factor (additional penalty) for toxicity based on Maximum

Allowable Concentration (MAC) value in ppm

Th (Toxicity Factor): For Acetic acid will be 250 from the table no. 6.6 as the Nh factor for

Acetic acid is 3

Ts (Correction Factor): For Acetic acid will be 75 from the table no. 6.7 as the MAC is 10 ppm

Table No. Toxicity factor Index

NFPA Index Number Toxicity Factor (Th)

0 0

1 50

2 125

3 250

4 325


Table : Correction factor for Toxicity

MAC (in ppm) Ts

5 and below 125

Between 5 and 50 75

50 and more 50

Table Toxicity Index

The resulting TI values are ranked into three categories:

1-5 Light

6-9 Moderate

10-up High


1) Monds Index of Acetic Acid

General & Special Process Hazard

1.General Process

Hazard






Access 0.20 to 0.35 0.00



2.Special Process

Hazard




Hg)

0.50 0.00



0.00 to 0.80


liquids

0.50 0.00


3. Always in Flammable range

process

0.80 0.00




psig

0.00



material




in Process

0.00








Therefore from the above table the GPH and SPH is coming to be around 1.75 and 1.7

respectively.

Calculation of Toxicity Index:


100

Toxicity Index : [250 + 75 (1 + 1.75 + 1.7)]/100

Toxicity Index : 5.83

The Toxicity Index for acetic acid is calculated to be around 5.83 which indicate that the degree

of hazard is moderate from table no. 7.23

2) Monds Index of Bromine


1.General Process

Hazard






Access 0.20 to 0.35 0.00



2.Special Process

Hazard




Hg)

0.50 0.00



0.00 to 0.80


liquids

0.50 0.00



process

0.80 0.00




psig

0.00



material





in Process

0.00








respectively.



100

Toxicity Index : [250 + 125 (1 + 1.50 + 1.70)]/100


The Toxicity Index for Benzene is calculated to be around 7.75 which indicate that the degree of

hazard is moderate from table no. 7.23

3) Monds Index of Biphenyl


1.General Process

Hazard






Access 0.20 to 0.35 0.00



2.Special Process

Hazard




Hg)

0.50 0.00




0.00 to 0.80


liquids

0.50 0.0



process

0.80 0.00




psig

0.00



material




in Process

0.00








respectively.



100

Toxicity Index : [125 + 125 (1 + 1.75 + 1.5)]/100


The Toxicity Index for Biphenyl is calculated to be around 6.56 which indicate that the degree of

hazard is moderate from table no. 7.23


4) Monds Index of Hydrochloric Acid


1.General Process

Hazard






Access 0.20 to 0.35 0.00



2.Special Process

Hazard




Hg)

0.50 0.00



0.00 to 0.80


liquids

0.50 0.0



process

0.80 0.00




psig

0.00



material




in Process

0.00







Therefore from the above table the GPH and SPH is coming to be around 1.5 and 1.7 respectively.



100


Toxicity Index : [250 + 125 (1 + 1.5 + 1.7)]/100


The Toxicity Index for Hydrochloric Acid is calculated to be around 7.75 which indicate that the

degree of hazard is moderate from table no. 7.23

5) Monds Index of Peperidine


1.General Process

Hazard






Access 0.20 to 0.35 0.00



2.Special Process

Hazard




Hg)

0.50 0.00



0.00 to 0.80


liquids

0.50 0.0



process

0.80 0.00




psig

0.00



material




in Process

0.00









respectively.



100

Toxicity Index : [250 + 125 (1 + 2.35 + 1.7)]/100


The Toxicity Index for Peperidine is calculated to be around 8.81 which indicate that the degree

of hazard is moderate from table no. 7.23

6) Monds Index of Sodium Methoxide


1.General Process

Hazard






Access 0.20 to 0.35 0.00



2.Special Process

Hazard




Hg)

0.50 0.00



0.00 to 0.80


liquids

0.50 0.0



process

0.80 0.00




psig

0.00




material




in Process

0.00








respectively.



100

Toxicity Index : [250 + 75 (1 + 1.75 + 1.7)]/100


The Toxicity Index for Sodium Methoxide is calculated to be around 5.83 which indicate that the

degree of hazard is moderate from table no. 7.23


Annexure: 10.1




Annexure: 10.2

PEST CONTROL (INDIA) PVT LTD TALOJA

HEALTH, SAFETY AND ENVIRONMENT POLICY

Health, Safety and Environmental Protection ( HSE ) are part of our commitment

to conduct our activities in harmony with society and nature and without

compromising the health and safety of our stakeholders. We expect all our

employees to implement the HSE Policy.

We Integrate Health, Safety and Environmental Protection into our business strategies to add

value to the-enterprise, to manage risk and to enhance the reputation.

The health and safety of our employees, neighbors, customers and consumers, and the

Protection of the environmental are company.

Priorities consistently pursued throughout the Priorities consistently pursued throughout the

group.

We take HSE into account in all business decisions and activities. Business sectors establish

proper structures and allocate sufficient resources in order to line up to this policy.

We shall comply with all relevant statutory requirements in the area of Health, Safety

and Environment.


For doing so, if any expertise or advice needed, then the same will be made available

from site HSE officer, Sector HSE officer or Corporate Safety and Environment

Department.

Each employee shall comply with the HSE guidelines and the laws applicable to her or

his area of operational responsibility.

We want to be a leader in Health, Safety and Environmental Protection by managing

these disciplines actively, consistently and efficiently.

We strive for continual improvement in our HSE performance through relevant

technologies and methods. We measure progress and verity compliance with our own

HSE guidelines and regulatory requirements through audits and management reviews.

We foster awareness & a sense of responsibility for HSE among our employees; to

this end we provide appropriate information and training and develop their HSE skills.

While considering the career advancement of an employee. Commitment to HSE will be

considered as an important factor.

We optimize the use of natural resources and minimize the environmental impact of our

activities and of our products over their life cycle. We assess HSE implications to ensure

that the benefits of new products, processes and technologies outweigh remaining risk.

We care about the expectations and concerns of our stakeholders.


We provide our employees with safe workplaces. We promote programmed to maintain

or improve the health of our employees. Safety Committees consisting of workmen

actively participate in improving and effectively implementing safety measures.

We inform our customers and the consumers about the characteristics of our products

and give advice on their proper use and safe disposal.

We inform our customers and the consumers, sub contractors, transporters and other

agencies and offer assistance for achieving an HSE performance matching our own.

We recognize the interests of our shareholders, neighbors the authorities and the public

at large in our HSE performance. We openly communicate and provide all information

necessary to understand the risks and effects of our operations on health, safety and

the Environment.

A resume of HSE performance of the Company shall be provided in every annual

report.

ANIL S RAO (CEO & CMD)

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

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Annexure: 2 - Welcome to Environment · 2017-06-08 · Annexure Pest Control India Pvt. Ltd. Table 2: Project plot specific floral inventory (naturally grown vegetation in open spaces