CHAPTER - 7 RISKASSESSMENT&DISASTERMANAGEMENTPLANenvironmentclearance.nic.in/writereaddata/online/... · analyzed. The tools used for identification are experience, detailed process

M/s. Gemasko Pharmachem Industries

EIA Report: Proposed Expansion of Synthetic Organic Manufacturing UnitGIDC Estate, Vapi, Dist- Valsad, Gujarat. (Category: 5(f))

EIA Consultant: Unistar Environment& Research Labs. Pvt. Ltd.(QCI-NABET Accredited)

)

Chapter 7: Risk Assessment & Disaster Management Page:226

CHAPTER - 7

RRIISSKK AASSSSEESSSSMMEENNTT && DDIISSAASSTTEERR MMAANNAAGGEEMMEENNTT PPLLAANN7.1 BACKGROUND

Risk Assessment is a management tool for determining the hazards and risk associated with the various

activities of a project and computes the damage potential of these hazards to life and property. Risk

Assessment provides basis for determining the safety measures required to eliminate, minimize and

control the risks as detailed in Disaster Management Plan (DMP) to handle onsite and offsite emergencies.

In Chemical Industry, Risk Assessment is carried out for the various hazards involved in storage and

handling of hazardous raw materials, intermediates and finished products as well as for the manufacturing

processes used by the unit.

7.2 OBJECTIVES

The given study was focused to fulfill the following objectives:

Identification of safety areas

Ientification of process and storage hazards

Visualization of maximum credible accident (MCA) scenarios

Consequence analysis of scenarios

Determination of quantities released, impact zones

Estimation of damage distances for the accidental release scenarios with recourse to Maximum

Credible Accident (MCA) analysis

Preventive and control measures required for reducing the risk factors

Delineation of Disaster Management Plan

7.3 SCOPE OF WORK

Based on the objectives as defined above, the scope of work for the given study has been framed as under:

1. Hazard Identification

General description of project

Study of manufacturing activities

Study of plant facilities and layout

Hazardous inventory

Associated process and storage hazards




)


Safety measures as proposed by the proponent

2. Hazard Assessment

Identification of MCA and worst case scenarios using standard techniques

Consequence analysis of selected scenarios using EFFECT model on ALOHA software

3. Determination of risk reduction measures

4. Preparation of DMP

5. Recommendations

7.4 METHODOLOGY

Following methodology has been followed for given Risk Assessment Study as described in “Guidelines for

Chemical Process Quantitative Risk Assessment” by CCPS with the help of frequency data from “Purple

Book” ,2008.

The guidelines given by SEAC as well as Technical Guidance Manual of MoEF have also been followed.

Collecting Input data about Process,Inventories and Site conditions

Hazard Identification

Defining the Potential Accident Scenarios

Evaluation of Consequences and Estimation of Accident Frequencies

Estimate the Impacts

Estimate the Risk

Identify and Prioritize the Risk Reduction measures.

7.5 HAZARD IDENTIFICATION

This is important and critical step in risk assessment. It is critical because Hazard omitted is hazard not

analyzed. The tools used for identification are experience, detailed process knowledge, engineering codes,

checklist, HAZOPs etc.

This risk assessment is being done for the proposed new production facilities in the existing unit. The

hazards involved in the process are due to-,

Material handled: Flammable, Toxic

The materials involved are of toxic and flammable nature. The major hazardous materials and their

hazardous properties are tabulated in previous section. The major hazard of material handling is handling

of solvents.

Other hazardous materials handled are strong acids HCL, THF and liquor ammonia. However the inventory

of these chemicals is less and there is no storage in tanks.




)


The manufacturing process does not involve high pressure and high temperature reactios or processes.Normal lookout for materials, initiating events and incidents are tabulated in table in following pages.

Process Hazards Initiating Events Incident OutcomeSignificant Inventories of : Equipment Failure Discharge of gas or liquid to

atmosphereFlammable Material Pumps Dispersion of Material(Toxic)Combustible Material Valves FiresUnstable Material Sensors Pool fireCorrosive Material Interlock Jet FireAsyphyxiants Loss Of containment Flash FireShock Sensitive Materials Tanks ExplosionHigly Reactive Materials Vessels Confined ExplosionToxic Materials Pumps Unconfined ExplosionExtreme PhysicalConditions

Heat Exchangers Dust Explosion

High Temperatures System Failure Physical ExplosionHigh Pressures Human ErrorCryogenic Temperatures Design FailureVacuumPressure CyclingTemperature Cycling

Vibration/LiquidHammering

7.5.1 Fire and Explosion HazardsThe unit will handle no. of solvents, few are to be stored in carboys and drums and few in storage tanks.

However, not more than two storage tanks of 10 KL capacity are proposed for any solvent.

7.5.2 Toxic Release HazardsLeakage or rupture in pipelines, valves, and reaction vessels can cause release of toxic gas into the

immediate environment posing serious risk to health and environment.

The unit shall take following measures to prevent such mishap.

The condition of connected piping shall be checked regularly for leakages.

Safety valves are installed at all pressure vessels and shall be periodically calibrated and

maintained.

Interlock devices and cut-off system for critical operations.




)


7.5.3 Chemical SpillThe unit shall use chemicals stored in drums and carboys which have to be transferred from storage area

to shop floor manually.

For this,

Appropriate PPE are identified for each chemical and shall be provided to workers.

Adequate trolleys and lifting tackles shall also be provided for transferring purpose.

The safety manual of the unit to be given to workers shall have details about which PPE is to be

used for which chemical so that the safety of the workers is ensured provided they use the suitable

PPE.

Good quality materials shall be used for transferring corrosives.

Regular thickness testing of equipment, pipelines etc. shall be carried out to check and control corrosion.

7.6 FREQUENCIES ESTIMATION:

The risk is computed as product of consequence of event and frequency of occurring of the event. As part

risk assessment frequency estimation is one of the activity. In literature and published guidelines the

frequencies of catastrophic failure of various equipments are published. For this assessment the used set

of frequencies is taken from Dutch Purple book, 2008.

Table 7.1 Failure Frequencies

No Item Mode Of Failure Failure Frequency1 Atmospheric Storage Tanks Catastrophic Failure 10E-9 /yr

Significant Leak 10E-5 /yr2 Process Pipelines

<=50mm Dia Full Bore rupture 8.8 x 10E-7 /yrSignificant Leak 8.8 x 10E-6 /yr

>50mm<=150mm Dia Full Bore rupture 2.6 x 10E-7 /yrSignificant Leak 5.3 x 10E-6 /yr

<150mm Dia Full Bore rupture 8.8 x 10E-7 /yrSignificant Leak 2.6 x 10E-6 /yr

3 Hoses Rupture 3.5 x 10E-2 /yr4 Pressure Vessel Catastrophic Failure 3 x 10E-6 /yr

Significant Leak(6" nozzle) 7 x 10E-6 /yr5 Liquid Line Pipeline Leak 3 x 10E-7 /yr

Fittings Leak 5 x 10E-6 /yr6 vapor line Leak 3 x 10E-6 /yr7 6" Pipe Leak (1 kg/s) 6x 10E-6 /yr




)


8 3" Pipe Leak (1 kg/s) 6 x 10E-5 /yr9 Flange Leak (1 kg/s) 3 x 10E-4 /yr10 Pump Seal Leak (1 kg/s) 5 x 10E-3 /yr

(Source: Dutch Purple book, 2008.)

7.6.1 Failure History DataTable 7.2 Failure History data

Sr.No.

Item International Data Indian Data

1 Process Controller 2.4 x 10-5 hr-1 3.0 x 10-5 hr-12 Process Controller Valve 2 x 10-6 hr-1 2.4 x 10-5 hr-13 Alarm 2.3 x 10-5 hr-1 4.6 x 10-5 hr-14 Leakage at biggest storage tank 5 x 10-5 yr-1 3.0 x 10-5 yr-15 Leakage pipe line 1 x 10-7 m-1yr-1 3.0 x 10-8 m-1yr-16 Human failure 1 x 10-4 (demand)-1 1.8 x 10-3 (demand)-1

7.6.2 Assumed Failure Rate for the StudyTable 7.3 Assumed failure rate for the study

SrNo.

Item Rupture (yr-1) Leakage (yr-1)

1 Pipe lines<3”3”-15”>15

10-610-7--

10-510-610-8

2 Vessel- pressurized- Atmospheric

5 x 10-61 x 10-5

5 x 10-51 x 10-4

7.7 SAFE OPERATING PROCEDURES (SOP)

Preparing safe operating procedures for handling of hazardous chemicals is the first step towards

implementing safety in the production area. The unit shall prepare safe operating procedures for handling

of hazardous chemicals. The information from MSDS is used in preparing SOPs. The material is prepared in

English as well as local language for easy understanding by workers.

The following points shall be included in the SOP:

properties of the chemical

handling and storage instructions

emergency control measures

personal protective equipment

Various possibilities of accident and methods for prevention.




)


During safety trainings, importance of use of SOPs shall be explained. Regular supervision will be also

carried out by seniors to verify whether SOPs are followed satisfactorily.

7.8 STORAGE AND HANDLING OF HAZARDOUS CHEMICALS

Table 7.4 Storage Capacities of Products & Raw materials

Sr.No.

Name ofhazardoussubstances

Max. Qtyto bestoredMT

Mode of storage(in drums /carboys/storage tanks, bagsetc.)

Storageconditions(T & P)

Type of HazardPossible(Fire,explosion, etc.)

1 Acetic Acid 10 KL 1 KL HDPE Drums AmbientLiquid

IrritativeCorrosive

2 Acetone 5 KL 0.2 KL MS Drums AmbientLiquid

FireIrritative

3 Caustic Flakes 50 MT 25 Kg HDPE wovenbags

AmbientSolid

IrritativeCorrosive

4 Phthallic Anhydride 3.0 MT 25 Kg HDPE wovenbags

AmbientSolid

FlammableIrritative

5 Methanol 20 KL 10 KL-Storage tank AmbientLiquid Fire

6 Toluene 20 KL 10 Kl-Storage tank AmbientLiquid Fire

7 Hydrochloric acid 5 KL 0.5 KL HDPE Carboys AmbientLiquid

CorrosiveIrritative

8 N Hexane 10 KL 10 KL-Storage tank AmbientLiquid Fire

9 IPA 20 KL 10 KL-Storage tank AmbientLiquid Fire

10 Liq. Ammonia 5 KL 0.5 KL HDPE Carboys AmbientLiquid

Toxic,Irritative

11 Meta Bromoanisole 5 KL 1 KL HDPE Drums Ambient

LiquidToxic,Irritative

12 Cyclohexanone 5 KL 0.2 KL MS Drums AmbientLiquid Fire

13 Tetra hydro furan 2 KL 0.2 KL MS Drums AmbientLiquid

ToxicIrritative

14 Xylene 5 KL 0.2 KL MS Drums AmbientLiquid Fire

15 Dimethyl amineHCl 5 KL 0.5 KL HDPE Carboys Ambient

Liquid Fire

16Monomethylaminesolution

5 KL 0.2 KL MS Drums AmbientLiquid

Toxic,Irritative




)


7.9 STORAGE HAZARDS AND CONTROL MEASURES

Table 7.5 Storage Hazards and their Control Measures

Sr.No

Name of theHazardousSubstance

Max.storedin MT

ModeofStorage

State &OperatingPr. &Temp.

Type ofHazardsPossible

PreventiveMeasuresprovided

ControlMeasuresProvided

1 Acetic Acid 10KL

1 KLHDPEDrums

AmbientLiquid

IrritativeCorrosive

Suitable PPEprovided,Separatestorage area forflammable andnon-flammablechemicalsStorage andhandlingprocedures asper MSDS,ProperhousekeepingpracticesProper loadingand unloadingpracticesFixed piping forliquid pumpingSuitable trolleysfor solidmaterialtransferring,flameprooffittings,Earthing,lightningarrestors, nosmoking zones.

Fire – Fireextinguishers,fire fightingteamToxic control –first-aid andmedical facilitiesOnsite and Off-site Emergencyplan PPE(respiratory aswell as non-respiratory)Spill control kits,and neutralizingmedia

2 Acetone 5 KL0.2 KL

MSDrums

AmbientLiquid

FireIrritative

3 Caustic Flakes 50MT

25 KgHDPE

wovenbags

AmbientSolid

IrritativeCorrosive

4Phthallic

Anhydride3.0MT

25 KgHDPE

wovenbags

AmbientSolid

FlammableIrritative

5Methanol 20 KL

10 KL-Storage

tank

AmbientLiquid Fire

6Toluene 20 KL

10 Kl-Storage

tank

AmbientLiquid Fire

7 Hydrochloricacid 5 KL

0.5 KLHDPE

Carboys

AmbientLiquid

CorrosiveIrritative

8N Hexane 10 KL

10 KL-Storage

tank

AmbientLiquid Fire

9IPA 20 KL

10 KL-Storage

tank

AmbientLiquid Fire

10Liq. Ammonia 5 KL

0.5 KLHDPE

Carboys

AmbientLiquid

Toxic,Irritative

11 Meta Bromoanisole 5 KL

1 KLHDPEDrums

AmbientLiquid

Toxic,Irritative

Suitable PPEprovided,Separatestorage area forflammable andnon-flammablechemicalsStorage andhandlingprocedures asper MSDS,ProperhousekeepingpracticesProper loadingand unloadingpractices

Fire – Fireextinguishers,fire fightingteamToxic control –first-aid andmedical facilitiesOnsite and Off-site Emergencyplan PPE(respiratory aswell as non-respiratory)Spill control kits,and neutralizingmedia

12Cyclohexanone 5 KL

0.2 KLMS

Drums

AmbientLiquid Fire

13 Tetra hydrofuran 2 KL

0.2 KLMS

Drums

AmbientLiquid

ToxicIrritative

14Xylene 5 KL

0.2 KLMS

Drums

AmbientLiquid Fire

15 Dimethylamine HCl 5 KL

0.5 KLHDPE

Carboys

AmbientLiquid Fire

16 Mono 5 KL 0.2 KL Ambient Toxic,




)


Sr.No

Name of theHazardousSubstance

Max.storedin MT

ModeofStorage

State &OperatingPr. &Temp.

Type ofHazardsPossible

PreventiveMeasuresprovided

ControlMeasuresProvided

methylaminesolution

MSDrums

Liquid Irritative Fixed piping forliquid pumpingSuitable trolleysfor solidmaterialtransferring,flameprooffittings,Earthing,lightningarrestors, nosmoking zones.

7.10 PROCESS HAZARDS AND THEIR CONTROL MEASURES

Table 7.6 Process Hazards and their Control Measures

Sr.No.

Cause Reason Hazard Probability /Severity

PreventiveMeasures shall beprovided

ControlMeasuresshall beprovided

1. Leakagefrom line /valve

Failure ofvalve orjoints

ChemicalSpillToxicRelease,Fire

Low/Medium All lines / valvesperiodicallychecked,

CW and CHW injacket

PSVs / rupture discsprovided onreactors & jacketOperators trainedfor the process andSOPsPPE provided toworkers

FireExtinguisher,Sand buckets,First-aid andMedicalfacilities

2. Failure ofpart ofvessel orjacket

Overpressure andfailure ofsafetydevice

3. Spillagefrom drums

Manualerror,rupture




)


7.11 OTHER HAZARDS AND CONTROL

Table 7.7 Other Hazards and their Control Measures

Sr.No.

Name ofpossibleHazards oremergency

Its sources & reasons Its effects onpersons,property andenvironment

Place ofEffect

Control measuresprovided

1 Fire due toNatural gas

Rupture of pipelinecarrying Natural gas fromthe gas station to theboilers

Damage toproperty andperson

Wholefactory

Pressure Relief valveprovided and inspectedregularly. Pipe fittingsand valves checked forleakages, corrosion etc.Fire extinguishersprovided at suitablelocations in the plant andboiler section

2 MechanicalHazards

Rotating Equipments viz.Agitator drives, pumps,centrifuges – accidentalentanglement of clothesor body touch, electricalshockHand Tools and portablepower tools – hit or fallon body part due to mis-operation or suddenstartup or manual error,electrical shock

Damage toperson

Productionarea

Guards are provided onall rotating equipment.The hand tools are keptat specified location sothat they are easilyavailable when required.Proper earthing isprovided to all electricalequipment and checkedregularly

3 Steam &Electricity

Sparks, Electrical shocks Damage toproperty andperson

Productionarea aswell asMCCRoom,storageareas

Flameproof fittings,proper earthing, flamearrestors on storagetanks, covered cabletrays, lightning arrestorprovided

4 Road /Transportation Hazard

Hit of the vehicle ortrolley

Loss ofproperty andperson

Wholefactory

Restricted vehicularmovement, Operatortraining on safetransportation

5 LighteningHazard

Natural Loss ofproperty andperson

Wholefactory

Lightening Arrestorinstalled

6 Cyclone Natural Loss ofproperty andperson

Wholefactory

Disaster Management

7 Spillage Pipe leakage, Flange jointleakage

Loss ofproperty andperson

Wholefactory

Adequate PPE for escape




)


7.12 PROPOSED SAFEGUARDS FOR THE EXPANSION PROJECT

7.12.1 Proposed Health & Safety Measures Most of the hazardous chemicals shall be unloaded and transferred through closed pipeline using

dedicated pumps or neutral gas pressure.

The bulk chemicals storage area shall be kept away from the main production areas.

The storage of flammable and corrosive chemicals will be segregated from each other.

The entire plant operations shall be monitored and controlled by various indicators and controllers

which provide substantial safety.

Pressure and temperature indicators shall be kept on each equipment and necessary locations on

pipelines

Emergency siren will be provided at security gate and admin block

Safe operating procedures will be developed for handling of hazardous chemicals and for critical

process operations.

Work Permit system will be implemented for hot work in Plant / Off-Site / Storage area, Vessel

Entry Permit, Working at Height, Opening of the Process lines.

Adequate instrumentation for monitoring and control of process parameters such as temp and

pressure gauges, Non-return valves, Pressure Safety valves and Rupture discs shall be provided on

reactors, boiler in order to check and prevent run-away conditions or accidents

Proper earthing will be done to all vessels, reactors, columns, pumps, and other process and

mechanical accessories.

Training programs will be planned to be conducted for workmen in following areas :

Operational safety procedures start up and shut down procedure.

Handling and storage of hazardous chemicals precautions against exothermic and pressure

reactions.

Importance of using personal protective equipment

Handling and operation of Self-breathing apparatus

Understanding of MSDS Information

Causes of Accident and preventive measures

Good housekeeping

Fire Fighting




)


All employees shall be covered under Group Insurance Policy along with personal accident cover

Accident records shall be maintained

Periodical medical checkup of employees shall be done & health records will be kept and health

card to be issued to each and every employee.

All the equipment and pipelines are marked for identification

All the safety devices instruments like safety valves, Rupture disc shall be tested, inspected and

recalibrated as per safety norms.

Hydraulic testing of pressure vessels and jackets, and tanks shall be done through Government

approved Competent Person. (As per rule).

Match boxes, Cigarettes, Mobile, any petroleum product shall be prohibited. Visitors shall be

required to deposit such items at security gate.

7.12.2 Proposed Safety Equipment / Facilities Extinguishers will be placed at all the appropriate places. Sand buckets will be also made available.

Eye washers / showers shall be provided.

Self Contained Breathing apparatus (SCBA) shall be procured for emergency handling.

Personal protective equipments shall be provided to all the employees.

Safety valves, compound pressure gauges and manometers provided.

Lightning arrester is to be installed at the admin. Block.

Electrical grounding of the vessels / equipment/machinery.

Wherever require flameproof electrical fittings shall be used.

Wherever feasible, interlock and auto cutoff systems for automation shall be provided to minimize

manual error.

Mutual aid from neighboring industries will be made available whenever need arises.

7.13 PROPOSED FIRE FIGHTING SYSTEM

7.13.1 Fire ExtinguishersFor the proposed project the unit has planned to install following fire extinguishers at the plant.

Table 7.8 Details of fire extinguishers

Details of fire extinguishers5 kg DCP fire extinguishers 10 Nos. (Min.)9 kg Foam type extinguisher 10 Nos. (Min.)




)


7.14 PERSONAL PROTECTIVE EQUIPMENT

Table 7.9 Details of Personal Protective Equipment

Type of Non-Respiratory PersonalProtective Equipment

To Protect Against -

PVC apron, Cotton Apron Heat and splashing of oil, grease, dust and corrosive chemicalsduring transfer or handling of corrosive Chemicals.

Dust mask Chemical dust while transferring powdered chemicals packedin bags.

Hand gloves (canvas, rubber) Heat and corrosive liquids like acids & alkalis.Safety goggles Liquid chemical splash and dustSafety shoes, Gum boots Contact with corrosive, hot chemicalsFace Shield Damage to face due to splashing of chemicals, hot liquids,

Spark and intense glare during welding, metal dust duringgrinding / cutting

Ear muffs/plugs - damage to hearing due to high noise in boiler, D.G rooms,mechanical work

Safety ShowersChemical splash over full body, clean-up of chemical tracesfrom clothes and body

7.15 VISUALIZATION OF ACCIDENT SCENARIOS

Based on the inventory, physical and chemical properties as well as the activities associated with storage

and handling of hazardous chemicals, the largest potential hazard inventories are considered. Different

release scenarios are visualized for these inventories and short-listed for carrying out the consequence

analysis.

One scenario considered for all is ‘Catastrophic Failure’, which is the worst case (WC) and frequency of

which is very rare in the lifetime of the plant.

Hence most credible accident scenarios (MCA) are also considered primarily leaks from tanks or vessels.

Normally all vessels or tanks have following connections

Inlet Pipe, Outlet Pipe, Level indication connections, Vent pipe, Minimum Flow line(If pump is at

outlet), Pressure indication connection

Leak in the vessel or leak from the flange joints of these connections is possible. The leak through flange

failure is considered from 50% of flange perimeter and accordingly equivalent area is calculated. This area

is approximated to hole of 50mm or 2” diameter. The small bore pipes less than 2” is considered full bore

leak.




)


MCA (Maximum Credible Accident) analysis is considered the most appropriate consequence analysis

method for risk assessment since it does not involve quantification of the probability of occurrence of an

accident and estimates the consequent effects of an accident scenario in terms of damage distances of

heat radiation, toxic releases, vapor cloud explosion, pool fire etc. Major hazards posed by hazardous

chemical storages can be assessed using MCA analysis.

7.15.1 Selection of Initiating Events and ScenariosFollowing event tree is followed for deciding toxic and/or flammable effects:

Based on the inventory of hazardous chemicals and their hazardous properties, following accident

scenarios have been visualized for the given project.




)


Table 7.10 Accident scenarios selected for the project

No HazardousChemical

Storage Type TotalStorageCapacity , KL

ConsequenceType

Scenario

1 n-Hexane Tank 10 Flammable WCS MCS2 IPA Tank 20 Flammable WCS MCS3 Acetone 200L MS Drums 5 Flammable MCS4 THF 200L MS Drums 2 Flammable,

toxicMCS

5 Acetic acid 200L MS Drums 5 Toxic MCS6 Liquid Ammonia 500L Carboys 5 Toxic MCS

The hazard information of the chemicals to be handled in the unit is tabulated in Table below. MSDS of

chemicals is attached as Annexure – 8.




)


Table 7.1 Hazard Information of Materials Handled




)






)






)


7.16 CONSEQUENCE ANALYSIS

Hazardous substance on release can cause damage on a large scale in the environment. The extent of

damage is dependent upon the nature of the release and the physical state of the material. It is necessary

to visualize the consequences and the damages caused by such releases. The quantification of the damage

can be done by means of various models, which can further be related in terms of injuries and damage to

exposed population and buildings.

Software used for consequence analysis for proposed project of M/s. Gemasko Pharmachem Industries:

ALOHA (AREAL LOCATIONS OF HAZARDOUS ATMOSPHERES)

Aloha is a computer program designed especially for use by people responding to chemical accidents, as

well as for emergency planning and training. ALOHA can predict the rates at which chemical vapors may

escape into the atmosphere from broken gas pipes, leaking tanks, and evaporating puddles. It can then

predict how a hazardous gas cloud might disperse in the atmosphere after an accidental chemical release.

ALOHA is an air dispersion model, which you can use as a tool for predicting the movement and dispersion

of gases. It predicts pollutant concentrations downwind from the source of a spill, taking into consideration

the physical characteristics of the spilled material. ALOHA also accounts for some of the physical

characteristics of the release site, weather conditions, and the circumstances of the release. Like many

computer programs, it can solve problems rapidly and provide results in a graphic, easy-to-use format. This

can be helpful during an emergency response or planning for such a response.

ALOHA provides output as amount of chemical discharged from the source as well as its concentration in

air it takes in to account different levels of concentrations for a specified chemical. Different concentration

levels are given below:

ERPG 1: is the maximum airborne concentration below which it is believed that nearly all individuals could

be exposed for up to 1 hour without experiencing other than mild transient adverse health effects or

perceiving a clearly defined, objectionable odor.


be exposed for up to 1 hour without experiencing or developing irreversible or other serious health effects

or symptoms which could impair an individual's ability to take protective action.


be exposed for up to 1 hour without experiencing or developing life-threatening health effects.




)


IDLH: The Immediately Dangerous to Life or Health (IDLH) level. A chemical's IDLH is an estimate of the

maximum concentration in the air to which a healthy worker could be exposed without suffering

permanent or escape-impairing health effects.

In order to assess the damage, the damage criteria have to be first defined.

There are three principle types of exposures to hazardous effects

Heat radiation from a jet, pool fire, a flash fire or a BLEVE

Explosion,

Toxic effects, from toxic materials or toxic combustion products

A basis for the weather conditions (Temperature, wind speed etc.) is chosen for input in these models.

7.16.1 Assumptions Common for all Scenarios1 The atmospheric stability class is taken as D and wind speed is taken as 3 m/s. For particular cases

if this is changed it is explained in that particular case.

2 The prevailing wind direction is from SW to NE.

3 The release time in case of credible scenario is taken as 15 mins. This time includes detection,

response and isolation during event.

4 The consequences of toxic material are calculated upto the LC50 concentration for catastrophic

failure and Maximum credible scenario. (If LC50 value is not available, then which ever value is

available from IDLH, ERPG, and AGCL).

5 For thermal radiation the distances for radiation level 8 kw/m2, 4kw/m2 and 1.6kw/m2 are

calculated.

6 For vapor cloud explosion the distance for overpressure of 0.2psi is calculated.

Specific assumptions are mentioned in the detailed description of each scenario.

7.16.2 Summarized Table for effects of Consequences7.16.2.1 Toxic End Points

Table 7.12 Toxic end points

Plant HazardousMaterial

EquipmentConsrd

ScenarioSelected

Qty.Released

EndPoint

EndpointConcentrati

on

Max Dist.

Storagearea

n-Hexane Storage tank Catastrophicfailure

576 kg IDLH 1100 ppm 40 m

Storage n-Hexane Storage tank Leakage 42.3 kg IDLH 1100 ppm < 10 m




)


area from valveor pipeline

Storagearea

IPA Storage tank Catastrophicfailure

155 kg IDLH 2000 ppm <10 m

Storagearea

IPA Storage tank Leakagefrom valveor pipeline

11 kg IDLH 2000 ppm < 10 m

Storagearea

Acetone 200 litre drum spillage 157 kg IDLH 2500 ppm 32 m

Storagearea

THF 200 litre drum spillage 161 kg IDLH 2000 ppm 22 m

Storagearea

Acetic Acid 200 litre drum spillage 47.7 kg IDLH 50 ppm 55 m

Storagearea

LiquorAmmonia

500 L carboys spillage 37.5 kg IDLH 300 ppm 94 m

7.16.2.2 Flammable Endpoints

Table 7.13 Flammable Endpoints

Plant Hazard-ous

Material

Equipment Consrd

ScenarioSelected

Amt.Released

FlashFire

EnvelopeDia.

ExplosionOverpres

sureDistancefor 0.5psi

pool/ JetFire

Heat IradiationMaximumdistances,

m

kg m m 10Kw/m2

4Kw/m2

2Kw/m2

Storagearea

n-Hexane

Storagetank

Catastrophic failure

576 41 38 Poolfire

<10

26 38

Storagearea

n-Hexane

Storagetank

Leakagefrom valveor pipeline

42.3 < 10 No threat Poolfire

<10

<10

10

Storagearea

IPA Storagetank

Catastrophic failure

155 <10 No threat <10 13 18

Storagearea

IPA Storagetank

Leakagefrom valveor pipeline

11.1 <10 No threat <10 <10

<10

Storagearea

Acetone 200 litredrum

spillage 157 31 30 <10 15 21

Storagearea

THF 200 litredrum

spillage 161 22 27 <10 13 19

Storagearea

AceticAcid

200 litredrum

spillage 47.7 <10 -- -- -- -- --

Detailed output of aloha is attached as annexure – 12.




)


7.16.3 Inference of Consequence analysisFrom the results of consequence analysis, it can be concluded that the effect of toxic release may go offsite

for n-hexane, acetone, acetic acid and liquor ammonia. A strong off-site emergency plan is therefore

required for these scenarios.

From the results of consequence analysis of flammable endpoints, it is indicated that the threat zone shall

be within the factory premises.

7.17 DISASTER MANAGEMENT PLAN

Disaster Management Plan is a management tool used by the industry to get prepared for preventing and

controlling disasters resulting from the various hazards as identified earlier. The plan accounts for all the

different facilities related to firefighting, medical treatment, pollution control which is required during an

emergency. In a nut-shell it is an action plan of pre-emergency, during emergency and post-emergency

activities and lists the infrastructure, information, personnel responsibilities, procedures, and instruction

manual.

The proponent M/s. GPI is an SSI unit and the risks associated with the project are having low probability

and severity.

However, to avoid haphazard situation on occurrence of an emergency, Disaster Management Plan for the

proposed project of M/s. GPI has been laid and reproduced below.

Disaster Management Plan of M/s. Gemasko Pharmachem Industries

It is a must for any industry or manufacturing facility to plan in advance for handling emergencies since

such situations arise all of a sudden and contain high potential to cause havoc. This is done by preparing

ON site emergency plan, which provides all details of safety measures available within the factory premises

as well as role of each category of employees on event of an emergency.

M/s. GEMASKO PHARMACHEM INDUSTRIES has prepared detailed emergency on-site plan.

Further an OFF site emergency plan is also prepared by the concerned government authority which

contains details about steps to be taken to inform related Government agencies, Medical Centers, Rescue

teams and other local agencies, in an event where the emergency poses danger to surrounding area

requiring evacuation.

7.17.1 Levels of Emergency & ResponseLevel Response

Fire On-site Emergency

Slow gas release On-site Emergency

High gas release Off-site Emergency




)


Pressure Vessel Failure Major Emergency

Chemical Spill or leakage Minor Emergency

7.17.2 Training on Emergency PlanDuring the training on emergency plan following points were covered:

Emergency organization chart

Responsibility of each employee

Hazards in the process and storage and their control measures

First aid and antidotes

Understanding ON SITE / OFF SITE emergency

Using of wind flag for finding wind direction

7.17.3 Site Map Showing Important LocationsSite map of the factory is to be displayed at the gate showing following important locations.

This type of information is very useful particularly during emergency.

Facility/Arrangement LocationEmergency control center (S) – ECC Admn. BlockEscape routes and assembly points Admn. Block

Security GateCommunication centers / Telephone facility Internal & External emergency communications

EPABXSecurity office (direct dialing)

Fire alarm Boiler HousePlant areaAt admn. Bldg.

Siren / hooter At security gates

Emergency equipment Stores (all respiratory/non respiratory PPE/Safetyequipments are stored here)

Medical aid First Aid facilities shall be available at admin blockFire and Toxicity control arrangement :Fire fighting system

Fire extinguishers

Pollution Control arrangement Incident and environment control arrangementinclude efficient control over water, soil/land and airpollution. Appropriate scrubber, exhaust, areinstalled as per requirement and kept ready forimmediate use.

Shutdown process Manual shut down instructions are being prepared

Plant surrounding Necessary information for approaching Authorities in




)


Villages/city, road approach, medical facility near by,fire service, police station and other aid etc isavailable.

7.17.4 Emergency Alarms & Equipment for Emergency ControlThe type of siren to be sounded major and minor emergencies are given in table below. This will take all

the personal that are present in the plant to become aware about the occurrence. The plant operation

personnel are required to vacate their work spots as early as possible and move to pre-designated safe

places called the assembly points.

CODED SIREN FOR EMERGENCY DECLARATION

NATURE OFEMERGENCY

SIREN CODE SYMBOL

Minor emergency(Fire)

Continuous for 30 seconds ∫∫∫∫∫

Major emergency(Fire or Pressure release)

Long siren followed by short sirenFor 60 seconds with break every 15seconds

All clear signal(When emergency iscontrolled)

Continues siren for 5 [Five] minutes

The control of emergency mainly involves combating the fire/explosion, toxic releases and arresting any

hazardous materials spillages/leakages using the various methods available for risk control as per the

emergency plan. The proper & safer method of handling these hazardous materials is given in MSDS. Also

the personal working in the affected zone should be evacuated and affected persons are to be given

immediate first aid/medical attention. The procedure developed by the unit for performing the above tasks

is dealt in the subsequent sections of this chapter.

7.17.5 Safe Assembly PointsSr. No. ofAssembly

Point

Location AccommodationCapacity

At the time ofEmergency – personincharge

PPE that may berequired

1.

2.

Admn. Bldg.

SecurityGate

Approx. 20-25

Approx. 40

ConcernedAccounts personnel

Security In-charge

SCBA, nose masks,PVC gloves, suit, etc.




)


7.17.6 Declaration of EmergencyAn emergency is an abnormal event, which could result in danger to personnel, property and environment

such as fire explosion, gas leak, serious injuries to personnel etc.

Emergency is declared by raising wailing siren.

Two types of siren are used for declaring an emergency

1. Wailing Siren

The wailing siren is having typical rising and lowering sound.

2. Evacuation siren

The evacuation siren is signaled by one single siren of 1 to 1.5 minutes duration.

All employees are given proper training regarding identifying the sirens and as to what to do on hearing the

emergency siren.

7.17.7 Emergency Management TeamThe management of the emergency is to be made operative by a well-structured organization (team)

comprising of responsible group leaders. The following emergency management executive/personnel are

required to play stellar role in combating the emergency.

1. Site Main Controller

2. Incident Controller (Manager (Oprns.) /manager (Maintenance))

3. Deputy Incident Controllers (Deputy Manager / Asst. Manager)

4. Essential Workers

5. Key Personnel

6. Plant Supervisor/Operator

7. Communication Controller/Telephone Operator

8. Personnel Officer

9. Security Officer

10. Safety Officer

The unit has a well-organized Emergency Management Team comprising of responsible employees as

mentioned below:

Sr. No. Position / Area Identified Personnel / Department

1 Site Main Controller Managing Director

2 Coordinator for out side help Managing Director / Production manager




)


3 Incident Controller Managers (Prod./Maint.) / Shift In-charges

4 Deputy Incident Controller Deputy Prod. Managers / Shift In-charges5 Emergency Services Officer Manager (Maintenance)8 Safety Officer Manager (Maintenance)

9 Traffic Controller Security Head /On duty Security Officer

10 Communication Officer Head - Admn. & Commerce

11 Runner Admn. PersonnelsHelpers on duty

ORGANIZATION STRUCTURE OF EMERGENCY MANAGEMENT

OPRN./MAIN.IN-CHARGE

SITE MAIN CONTROLLER

PERSONNELASSISTANT

SAFETYOFFICER

INCIDENTCONTROLLER

DY. INCIDENTCONTROLLER

WORKMANOPERATOR

DISASTERAUTHORITIES

EXTERNALHOSPITALS

EXT.FIRESERVICE




)


7.17.8 Responsibilities Of Emergency Management PersonnelAs said earlier, without a well defined procedure often confusing arises leading to precious loss of

‘’Response Time’’ and loss to human lives, plant & property. Hence the responsibilities/duties of the

emergency management personnel are defined given in table below.

EMERGENCY MANAGEMENTEXECUTIVE/PERSONNEL

RESPONSIBILITY

01. Site main Controller Inform higher management.Inform adjacent industries if necessary.Get in touch with district authorities.Declare the nature of emergency if already has not beendone.Ensure proper coordination amongst variousfunctionaries.Take care of all activities regarding handling ofemergency situation.Give all clear signals when the emergency has beencontrolled.

02. Incident Controller(Shift-in-charge)

On hearing emergency, he will rush To the incident siteand take charge of the overall situation.Instruct for stoppage of the plant if necessaryDecide scale of emergency, direct all operations withinthe affected areas with the priority for safety ofpersonnel, and minimize damage to the plant, propertyand environment.Pending arrival of the site controller, direct shuttingdown plant and evacuation of personnel.Coordinate with fire and security officer and first aidpersonnel as and when they arrive at the incident site.Also designate and coordinate with communicationcontroller.

03. Essential workers(Plant supervisor/operator)

Initiate action to control emergencyEmergency situation to be reported to shift in-charge.It is a task force of trained workers for :Fire fighting, Gas leakage and spill controlHelp fire people and mutual aid teamsShutting down plant and making it safeEmergency engineering work viz. mechanical, electrical,instrumentation, cranes etc.Providing emergency power, water, lighting etc.




)


04 Telephone operator Maintain communication with incident controller/sitecontrollerInform personnel officerOn instruction from site/incident controller direct staff toact as runners if phone/communication fail.Maintain log of incident report.On instructions from site/incident controller inform allthe local fire brigade and other agencies as instructed.

05. Personnel officer Mobilize transport to meet the requirements ofemergency.Coordinate with police, press and media if required.Receive reports from assembly points and pass on theabsence information to the site controllerOrganize medical camp with adequate medical facultyEnsure adequate supply of medicines and first aidmaterialProvide hourly situation reports to the GM (works)office, indicating men, equipment and materials involvesat each area under the influence of emergency.

05. Personnel officer Arrange for hospitalization and treatment at outsidehospitals as required.Mobilize extra medical help from outside if necessaryInform the incident controller regarding the ambulanceleaving the site, name (s) of patients and destinations,(i.e.) hospitals or first aid centers.

06. Security officer Review emergency situation regarding fire andperiodically report to the site controllerOrganize the group to fight the emergency andcoordinate with them.Ensure equipment and material to extinguish the fireAdvice site controller to call up outside agencies, police,medical and fire bridges when needed and coordinatethem.Assess damages due to fire during and after emergency.Assist in evacuating personnel from the affected area.Cordon the affected zone and not to allow anybody inthe cordoned off area.

07. Safety officer Direct rescue operations in the affected areaEnsure preventive safety measures are initiated inneighboring areas, which are likely to be affected.Replace the used safety equipment like masks, breathingapparatus etc.Invalidate all safety permits in the affected andsurrounding areas.Ensure documentation of the accident information asper statutory requirement.




)


7.17.9 Standard Operating Procedure (Emergency)As soon as emergency alarm is heard, all essential workers shall report to IC or SMC.

The runner among the workers shall inform SMC / IC and key personnel if they are not at site.

IC shall reach the affected area and evaluate the type of emergency and inform DPMC accordingly.

IC or SMC.

According to the type of emergency / accident, IC or SMC shall instruct the essential workers to get

equipped with PPE / Fire fighting equipment and devices available at the unit to assist the emergency

control team of DPMC.

The messenger amongst the workers shall deliver messages to nearby units as per the instructions of SMC /

IC.

The in-charge of Medical arrangements shall prepare first-aid and other required facilities for the injured.

When DPMC team reaches the site, the other essential workers shall assist them in controlling the

emergency as per their instructions.

IC would keep SMC informed about the status of control measures being taken at the site and ask for other

requirements eg. Mutual aid, equipment etc. if he finds necessary.

SMC would co-ordinate with outside agencies regarding control measures being taken, need for external

help, evacuation, medical treatment, etc.

CHAIN OF COMMAND

08. Key perssonel(Managerial staff)

Ensure that all systems affected or likely to be affectedby the hazardous are safety isolated or shutdown.Coordinate the efforts of operating and maintenancepersonal to contain or arrest or the hazardous.Ensure that adequate safety equipments are availableand are property used.Coordinate with safety officer to ensure that all thepersonnel trapped in the effected area are brought outsafety.

Other outside agencies SMC Mutual aid teamsFire Brigade

IC

Key Personnel Essential Workers




)


Priority sequence

1. First Aid rescue

2. Message to key personnel and nearby units.

3. Evacuation

4. Emergency control and property protection

5. Message to outside agencies and Mutual aid teams

7.17.10 Controlling emergencyThe probable emergency situations that can arise in the unit and the corresponding control actions are

described below.

Flammable releases

Source / Incident - Fire involving spilled combustible material near or in flammable storage areas

Control action –

1. Any one who notices fire shall sound emergency alarm.

2. SMC/IC who is at site, shall immediately rush to the scene and assess the situation. For fire due to

spillage of combustible material, he activates the on-site plan as –

3. He cuts off electric supply to that area and evacuates all the persons to safe assembly points.

4. He calls in DIC (if DIC is not present there) and asks essential workers to fight fire with dry chemical /

CO2 fire extinguisher or sand.

5. He informs DPMC telling them in briefly about kind of fire and type of extinguishers required

6. He informs mutual aid teams and asks for necessary help.

7. He arranges first-aid / hospitalization for the affected persons.

8. Fire officer on reaching the site, takes charge of the fire-fighting operations

9. Mutual aid teams are asked for help in the form of first-aid, transport etc.

10. If fire is growing, fire officer informs IC who alerts neighbouring units and through SMC gets more fire-

fighting help.

11. Fire fighting is continued till fire is fully overcome

12. After extinguishing fire, fire officer cools the entire area with water spray and checks that no re-ignition

is likely. After that, he declares the area safe.

13. IC tells essential workers to sound all clear

14. The incident is recorded

15. SMC arranges to inform families / relatives of injured / dead.




)


16. SMC issues authorized statement to press/media.

17. SMC informs Factories Inspector about the incident and related information

Toxic releases

Source / Incident – Pressure release due to failure of - stuffing box gland packing / pressure release valve /

vessel / pipeline failure

There is no danger of major release of toxic materials. However a control action plan has been drafted for

any sudden event of toxic release.

Control action –

1. Any one who notices the release shall sound emergency alarm.

2. SMC/IC who is at site, shall immediately rush to the scene and assess the situation.

3. He shall inform DPMC about the emergency. For toxic release from a reactor, he activates the on-site

plan as –

4. He evacuates all the persons to safe assembly points.

5. He calls in DIC (if DIC is not present there) and asks essential workers to wear self-breathing apparatus

and if the reaction is exothermic, start cooling water flow in the reactor jacket and cool the reactor as

soon as possible

6. The essential workers stop all the charging pumps of that reactor and the nearby reactors.

7. The DPMC team on reaching the site, take charge of the controlling action.

8. The essential workers and key personnel assist the DPMC team and act as per their instructions.

9. The IC or SMC informs mutual aid teams and asks for necessary help.

10. He arranges first-aid / hospitalization for the affected persons.

11. Mutual aid teams are asked for help in the form of first-aid, transport etc.

12. When the leak stops and the air is clear of toxic release, DPMC official tells IC to sound all clear

13. The vessel / rupture disc / gland packing is attended by maintenance department.

14. The incident is recorded

15. SMC arranges to inform families / relatives of injured / dead.

16. SMC issues authorized statement to press/media.

17. SMC informs Factories Inspector about the incident and related information

Chemical Spill

Spill Control Procedure




)


1. Transfer of spilled material into suitable containers (if the spilled material is acidic fluid) using

appropriate PPE

2. Transfer of material from leaky storage tank to containers using appropriate PPE

3. Neutralization of spilled material

4. Cleaning of spill site

5. Directing all the effluent through effluent treatment plant

6. Incineration of flammable waste

7. Disposal of disposable solid waste at approved site

Dyke walls of sufficient size shall be provided to tank yards. Neutralizing material shall be kept nearby. For

dilution, water connection shall be provided on all sides of tank farms. Sand buckets shall also provide for

covering spillage of flammable / corrosive materials.

7.17.11 Evacuation & TransportationAll non-essential workers shall be evacuated from incident area and adjacent areas to safe assembly points.

Assembly points are clearly marked and assembly point in-charge are also designated. The assembly point

in-charge is a well-trained supervisor who shall keep record of persons arriving at the assembly point and

direct them for proper gathering. He shall also inform the ECC about the persons gathered at the assembly

point. Those in need of medical treatment shall be transported to first-aid center / hospital as the case

may be. In case of major emergency all non-essential workers shall be transported to temporary shelter.

7.17.12 Safe Close-DownAs per the instructions from IC or SMC, some parts or full of the plant shall be closed down by the essential

workers. The procedure for safe shut-down and start-up is given in safety manual given to all workers.

7.17.13 Use of Mutual AidMutual aid from neighbouring units shall be called up as and when required. The aid shall be taken under

the supervision of SMC.

7.17.14 Use of External AuthoritiesOutside authorities such as Police, District Emergency Authority (DEA), Factory Inspector, GIDC officer,

Sarigam Industries Association, Regional Pollution Control Board, nearby hospitals etc. shall be informed of

the on-site and off-site emergency plans and called in as per need.




)


7.17.15 Medical TreatmentInjured workers shall be located and given prompt first-aid by essential workers and key personnel. Those

requiring medical treatment shall be taken to the hospital / outside medical center.

7.17.16 Accounting for personnelThrough daily muster rolls and with the help of shift-incharge the head count shall be undertaken to find

out whether persons are missing and if so immediate search shall be carried out to locate them. The list

shall include company employees, contract workers as well as visitors. Help from local authority or fire-

brigade shall be taken if required. This list shall be kept with time keeper / security officer at any time and

shall be used to account for personnel. Injured shall be taken to hospitals and their families/relatives shall

be informed. Casualties would be identified, their families and local authority shall be informed.

7.17.17 Access to RecordsIn order to inform families / relatives of injured / dead, a up-to-date list of names and addresses of all the

workers is maintained in addition to the muster roll where shift-wise attendance is marked. Such list

includes health records. This list is available at the ECC and one such copy is available at our head office.

7.17.18 RehabilitationIn case of Toxic release or chemical spillage, after the DPMC official ensures that the incident area is safe,

the IC would arrange for clean-up of all mess. Then only, he would allow people to re-enter the location.

In case of fire, the DPMC official shall ensure that the area is cooled down and there are no chances of re-

ignition. IC shall arrange for clean-up of the area and then only people shall be allowed to re-enter the

area for work.

Even when all clear has been given, great care shall be taken when re-entering affected areas and no work

in connection with the salvage, collection of evidence or start up shall be taken up until a thorough

examination of the area has been carried out. The statutory powers of the Factory Inspector shall be kept

in mind before any evidence is disturbed. Particular care shall be taken to avoid the introduction of

possible sources of ignition, such as diesel engines, hand or power operated tools, flame cutting

equipment, etc. until it has been established that no flammable materials are present where they could be

ignited.




)


7.17.19 Mitigation of Environmental Impact during emergencyIn order to minimize loss or damage to the environment as well as personnel, following instructions shall

be followed during an emergency and after an emergency has been controlled.

Fire

1. Immediately cutoff contact of fire with flammable material or prevent spread of fire by other means

2. Use water or suitable fire extinguisher to extinguish fire

3. Contain the contaminated water or any other liquid to prevent it going to soil or drain and divert it to

ETP storage tank. If required treat it before sending to ETP tank

4. Any solid waste generated should be collected, stored and send to BEIL.

Chemical Spillage

1. In case of Material coming out of the bottom valve due to valve leakage or failure, it shall be contained

in side the dyke wall and will be transferred to HDPE plastic drum by help of pump / piping.

2. The tank shall be emptied by pumping the material into spare tank using extra nozzle. In case of

flammable material, after the tank is emptied, it shall be vented at highest point to vapors. In case of

acids and alkalis, the tank shall be flushed completely with water. Repair or replacement work shall be

started only after confirming that the tank is not contaminated with the chemical.

3. Preventions of failure: Preventive maintenance of bottom value shall be carried out as per schedule. To

prevent any leakage from tank body, thickness checking shall be same as per schedule.

Documents

CHAPTER - 7 RISKASSESSMENT&DISASTERMANAGEMENTPLANenvironmentclearance.nic.in/writereaddata/online/... · analyzed. The tools used for identification are experience, detailed process