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List of Annexure

Number Annexure

Annexure 1 Risk Assessment Plan & Disaster Management Plan

Annexure 2 HAZOP Study Report

Annexure 3 Environment Management Plan

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Annexure 1: Risk Assessment Plan & Disaster Management Plan

Document No. Integrated Management System Clause No.

CCPL / IMS / OSEP 01

Chemspec Chemicals Pvt Ltd.,

Plot No. 3 C, MIDC Taloja,Tal. Panvel, Dist- Raigad, Pin 410 208,

Maharashtra, India.

Revision No.:00 Page 2 of 103

Revision date:------

Issue No.:01

Copy No.: Issue Date: 01.06.2014

Title- ON SITE IMERGENCY PREPAREDNESS PLAN

ON-SITE EMERGENCY PREPAREDNESS

& CONTROL PLAN

Prepared By-

CHEMSPEC CHEMICALS PVT.LTD. PLOT NO.3-C, MIDC TALOJA, TAL. PANVEL, DIST.-

RAIGAD, MAHARASHTRA-410208 JULY-2015

3

Prepared By Safety Officer Approved By GM-QA/QC

INDEX

SR. NO. PARTICULARS PAGE NO.

1 Introduction 1-3

2 On-site Plan 4

3 Organizational set-up 5-6

4 Organizational set-up at a glance 7

5 Responsibility of works main controller (WMC). 8

6 Responsibility of works incident controller (WIC) 9

7 Response functions in case of emergency action plan 10-14

8 Duties assigned to key persons to attend an emergency other than

general shift.

15

9 Outside Organization if involved in assisting during emergency 16

10 Details of liaison arrangement between the organizations. 17

11 Information on the preliminary hazard analysis 17-24

12 System elements, safety relevant and details of site 25-40

13 List of key persons/key agencies 41-47

14 Emergency control centre (ECC) 48

15 Chemicals (Quantities and toxicological data):-

Transformation if any which could occur:-

Purity of hazardous chemicals:-

49

16 Likely dangers to the working area

Enumerate effects of

49

17 Details regarding alarm: 50-52

18 Reliable measuring instruments, control units and servicing of such

equipments

Precautions in designing of the foundation and load bearing parts of the

52

4

building

Continuous surveillance of operations

Maintenance and repair work according to the generally recognized

rules of good engineering practices

19 Details of communication facilities available during emergency and

those requires for an off-site emergency

52

20 Details of fire fighting and other facilities available during emergency

and those requires for an off-site emergency

53-59

Prepared By Safety Officer Approved By GM-QA/QC

5

6

INTRODUCTION

This On-site Emergency Preparedness Plan is prepared with the objectives that this

plan will develop to make best possible use of resources at the command of M/s.

Chemspec Chemicals Pvt. Ltd.

The guidelines given in Schedule 6 (Rule 12-1) of “The Maharashtra Factories (Control

of Industrial Major Accidents Hazards) Rules, 2003” are referred while preparing the

plan.

Mr. ATUL MORE, AM (EHS), was assigned the responsibility as coordinator and other

concerned section in-charges associated with the team in providing necessary information

and documents for perusal.

Total numbers of employees working inside the factory on any one day are 195 employees.

Working Hours

Working Hours in Shift Time

7

General shift 09:30 Hrs TO 17:30 hrs. First shift 07:00 Hrs TO 15:00 Hrs Second Shift 15:00 Hrs TO 22:00 Hrs Third Shift 22:00 Hrs TO 07:00 Hrs Name of Occupier –Mr. RUSHABH VORA. Name of Director - Mr. K. S.KATIYAL. Name of G.M.Works - Mr. V.H. SHETTY.

ABOUT COMPANY

The driving philosophy of Chemspec from its inception in 1978 is total Excellence. This has made chemspec the acknowledge leader in manufacturing of various bulk intermediates and personal care ingredients, Today chemspec has established a strong domestic and international presence as one of the preferred suppliers of Pharmaceutical intermediates and speciallity chemicals and personal care industries having an impressive list of customers in domestic market and globally as well.

We have achieved this with quality products good business practices and an impeccable reputation as reliable supplier with strict adherence to deliver schedule and quality.

The company has ISO 9001-2008 certification & follows the all legal legislation in respect of quality standards.

The company has individual Quality Policy.

The company has individual Environment, Health, safety Policy.

The company manufactures cosmetic chemicals and Pharma intermediates.

ON-SITE EMERGENCY PREPAREDNESS PLAN

The On-site Emergency Preparedness Plan will help the factory to;

Control the incident and contain it with minimum damage.

Restore normalcy as quickly as possible with minimum adverse effect on the people,

property and environment.

Rescue victims and treat them suitably.

Safe -guard others by evacuating them where necessary.

Identify the persons affected and give necessary first-Aid, Medical treatment.

Inform relatives of the casualties.

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Provide authoritative information to news -media and others.

Preserve relevant records and equipment needed as evidence in any subsequent

inquiry.

Rehabilitate the people in the affected areas.

Effective communication system.

Proper training to all concerned personnel.

Identify adequate technical facilities.

Identify potential risk and hazards.

DETAILS ON ON-SITE EMERGENCY PLAN

NAME & ADDRESS OF PERSONS FURNISHING THE INFORMATION

Mr. V. H. Shetty. GM – Works

ORGANISATIONAL SET-UP

Works Main Controller (WMC)

Alternate

GM –Works

DGM – Maintenance / Chief Production

Works Incident Controller (WIC)

Alternate

D G M –Works /Production

AM-Production/Sr. Executive /Executive

Advisory Team Managing Director/V.P./Directors

QC/R&D Manager

AM (EHS)

Emergency Control Centre (ECC)

Alternate

HR/Administration office

Security Control Cabin

Assembly Point

Alternate place

Main Gate

Outside Main Gate

Communication System Phones/ Mobiles

Alarm /Siren

Security Control Cabin

(To be given by security I/c in consultation with

WMC/WIC)

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Process Control/Shutdown

Respective in-charge (operation) available at site.

(as per directives of WIC).

Leak Control

Respective in-charges (operation & maintenance)

available at site.

Fire fighting

Alternate

Security Personnel with the help of trained

employees.

Outside Fire Fighting Services (If called).

Rescue/ Evacuation

Security Personnel with the help of office staff/Fire

Fighting Personnel.

Traffic control Security Personnel

Engineering Activities

(Repairs of plant, Equipment, Services,

Power)

In charge/Supervisors (Engineering)

First-Aid/ Hospital Employee /Security I/c,

Casualty clearance Employee /Security I/c,

Communication (External) M.D./ Directors communicates to Govt.

Authorities through his office.

Welfare Administration & Personnel officials

All Clear WMC in consultation with WIC

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ORGANISATIONAL SET-UP AT A GLANCE

Works Main Controller (WMC) GM – Works

DGM – Engg. & Proj

Works Incident Controller (WIC) DGM - Production

Sr. Executive/ Production Executive

Leak Control

Respective supervisors (operation

& maintenance) available at site.

Process Control/Shutdown

Respective supervisors (operation) as

per directives of WIC.

Rescue/ Evacuation

Security Personnel with the help of

employee /Fire Fighting Personnel.

Fire fighting

Security Personnel with the help of trained employees.

Outside Fire Fighting Services (If called).

Engineering Activities

(Repairs of plant, Equipment, Services, Power) Supervisors (Engineering)

First-Aid/ Hospital

Employee /Security I/c,

Casualty clearance

Employee /Security I/c,

Traffic control

Security Personnel

All Clear

WMC in consultation with

Communication (External)

WMC informs Director. M.D./Directors communicates to Govt.

Authorities through his office.

Welfare

Administration &

Personnel officials

Advisory Team

M.D./Directors V.P./Q.C./R&D

Managers

AM (EHS)

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RESPONSIBILITIES ASSIGNED TO KEY PERSONNEL

I- RESPONSIBILITY OF WORKS MAIN CONTROLLER (WMC).

Immediately on knowing about the emergency, proceed to the Emergency Control

Centre. Relieve Incident Controller of responsibility for overall main control.

Depending on seriousness of the emergency, ensure outside help, and arrange to

inform nearby factories.

Ensure key personnel are in their places.

Exercise control of the unaffected areas.

Continuously review possible developments.

Arrange shutdown of plant and evacuation in consultation with WIC and other key

personnel.

Ensure that casualties are receiving adequate attention and relatives are advised to

extend necessary co-operation by Hospital.

Ensure that statutory authorities are informed.

Ensure accounting of personnel by WIC.

Regulate vehicular movements in the Unit.

Arrange for recording of chronological sequence of activities of an emergency.

In consultation with Director, preparation of incident statement to be submitted to

news media.

In case of likely aggravation of the incident, arrange to warn the nearby population

through Police.

II- RESPONSIBILITY OF WORKS INCIDENT CONTROLLER (WIC) Immediately on knowing about the emergency, he will proceed to the location. Assess

the scale of emergency.

Activate the emergency procedure as required.

Direct all operations within the affected area as per priority.

Direct Operating Staff to reduce effect of emergency by -

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Immediately eliminating ignition sources (in case of fire).

Isolating areas of emergency by closing valves.

Emergency safe shutdown of the operation as per procedure.

Stop transfer of chemicals, loading/unloading.

Evacuate persons from process area and carry out immediate head count, and

direct them to assembly point.

Secure safety of personnel.

Minimize damage to Equipment.

Direct rescue and fire fighting/emergency control operations.

Ensure that affected area is cordoned off and is searched for casualties.

Ensure that all non-essential workers in the affected area are evacuated to the

appropriate assembly point.

Establish contact with Emergency Control Centre.

Pending arrival of WMC, assume the charge of WMC.

Directing the shutdown of operations and evacuation.

Suggest to WMC for help from any outside agency.

Report all significant development to WMC.

Provide information in any subsequent enquiry into the cause and circumstances of

the emergency.

RESPONSE FUNCTIONS IN CASE OF EMERGENCY

ACTION PLAN - (ROLE IN BRIEF)

Any person noticing a Fire or Release of Toxic Gas

Attracts attention of nearby persons by shouting

Informs Security Personnel on duty, Informs Operational in charge/Supervisor

Takes First-Aid measures (If trained in first-aid measures)

Operational in charge/Supervisor -

Informs to WIC

13

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Security Personnel

Informs key persons as per list.

Keep the telephone lines clear and free for communication.

Controls the main gate, allows only persons connected with emergency operations,

ambulance or other emergency vehicle inside the gate.

Works Incident Controller ( WIC )

Goes to the incident site when gets information.

Assess the situation.

Informs WMC accordingly.

Works Main Controller ( WMC )

Goes to the ECC when gets information.

In consultation with WIC, if situation warrants, instructs Security In-charge to blow

alarm as per prescribed Alarm Code.

Takes charge of ECC and starts acting as per the procedure given in the plan when

emergency is declared.

All employees

On hearing alarm / siren

All emergency key persons will report to ECC.

Supervisor / operator at affected area will stop the operation, keep in readiness for

evacuation if necessary and wait for further instructions from WMC/WIC.

Security will guide contract workmen and visitors to assemble at the assembly point.

Action by Various Designated Team / Agencies

On hearing alarm or getting message the respective team reports to ECC and starts acting

as per the procedure given in the plan.

Electrical Maintenance person isolate power to the affected area,

All outside agencies like Fire brigade, Police, Mutual Aid group, etc. (If called) will

follow instructions and work under the guidance of WIC.

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External Communication –

M.D./Directors/ V.P. communicates to Fire Brigade and relatives of injured person (if

any) through his office.

.D./Directors/ V.P. also communicates to Govt. Authorities / Press and News Media.

All Clear –

WMC is the only authority to decide an all-clear siren to be sounded & accordingly,

security In-charge sounds alarm, if gets instruction from WMC.

RESPONSE FUNCTIONS IN CASE OF EMERGENCY ACTION PLAN

AT A GLANCE

Any person noticing a fire/explosion Attracts attention of nearby persons by shouting. Informs Security Personnel on duty. Informs operation in-charge. Takes First Aid measures (If trained in First Aid measures)

Shift in-charge Informs to WIC, security

Security In-charge

Control Room I/c - Informs to WMC, WIC, and other key personnel (as listed in plan). Controls the main gate. Security person will allow only persons connected with emergency operations, ambulance or other emergency vehicle inside the gate.

KEY PERSONS

(AS LISTED IN PLAN)

Works Incident Controller (WIC)

Goes to the incident site when gets information. Assess the situation. Informs WMC accordingly.

Works Main Controller (WMC) Goes to the ECC when gets information. In consultation with WIC, if situation warrants, instructs Security In-charge to blow alarm as per prescribed Alarm Code. Takes charge of ECC and starts acting as per the procedure given in the plan when emergency is declared.

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WMC (Communication between WMC and WIC) WIC

Key persons and other Employees-

All emergency key persons will report /contact at ECC & wait for

instruction from WMC.

Plant personnel at affected area will stop the operation, keep in

readiness for evacuation if necessary and wait for further instructions

from WMC/WIC.

Action by Various Designated team / Agencies On hearing alarm or getting message, the respective team reports to ECC.

With the instructions of WMC, maintenance executive (mechanical, electrical) &

technicians rush to incident side and works as per direction of WIC.

All outside agencies like Fire brigade, Mutual Aid group, etc, (If called) will follow

instruction of WIC.

Administration Official and Security I/c make arrangement to send injured

person(s)/casualties to Hospitals.

External Communication

WMC informs Managing Director

Managing Director through his office informs to Govt. Authorities/media (if so required). .

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DUTIES ASSIGNED TO KEY PERSONS TO ATTEND AN EMERGENCY

OTHER THAN GENERAL SHIFT

Major accident/incident if occurred in salient hours

Supervisor (operation) and security in-charge have to rush to incident site. After their

assessment and considering the gravity of situation consult WMC / WIC and as per

instructions declare an emergency. Once it is decided that an emergency exists,

Supervisor (operation) instructs security in-charge to blow the siren as per code.

Supervisor (operation) assumes the responsibilities of WIC till his arrival. Security

personnel inform all key persons as listed in the plan. Other guidelines are followed as

provided in the plan for normal working hours.

OUTSIDE ORGANISATIONS IF INVOLVED IN ASSISTING DURING ON–SITE

EMERGENCY.

(a) TYPE OF ACCIDENTS Emergency planning begins with the identification and assessment of the principal

hazards.

The plan for the Unit considers the hazards, viz.

Toxic gas release

Fire/Explosion

(b) RESPONSIBILITY ASSIGNED In case of requirement of help from outside organization, WMC will inform the following

organizations to rush up their assistance;

MIDC Fire Brigade

Hospitals

MIDC water Supply

MSEB

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Nearby Factories (under mutual aid scheme)

Police Station

DETAILS OF LIAISON ARRANGEMENT BETWEEN THE ORGANISATIONS.

Periodical meetings are held between the members of Industrial Association. Following

Information is maintained and updated under the Mutual Aid they exchange assistance in

case of emergency;

Name of the key persons in each factory to be contacted during emergency along-

with their contact telephone numbers

Machinery/equipment available

Number of professionals/first-aid trained employees available during emergency

Name of chemicals stored/used with their capacities

INFORMATION ON THE PRELIMINARY HAZARD ANALYSIS

List of Finished Goods & Raw Material

LIST OF FINISH GOODS:

Product No. Name of Product Capacity

1 Trichlorocarbanilde ( TCC) 50 MT/M

2 Octyl methoxy cinnamate ( OMCX) 20 MT/M

3 Buty Methoxy cinnamate Methane ( CHEM-1789) 30 MT/M

4 2-Butyl 4-Chloro 5- Formylimidazole (BCFL) 6 MT/M

5 Triphenyl Tetrazoyl bromo byphenyl (TTBB) 6 MT/M

6 4 Bromomethyl-2- Cyanbifihennyl 5 MT/M

7 2- Phenyl Benzimidazole s. sulfonic acid 6 MT/M

LIST OF RAW MATERIALS:

Sr. No. LIST OF RAW MATERIAL

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1. PCA

2. Di Chloro Phenyl

3. MCB

4. Hy flow

5. SMO Powder

6. Ethyl Acetate

7. Phosphoric Acid

8. Formic Acid

9. Liquid Paraffin

10. Para Anise Aldehyde

11. SMO Powder

12. Ethyl Acetate

13. Phosphoric Acid

14. Formic Acid

15. Liquid Paraffin

16. 2- Ethyl Hexanol

17. 4-methoxy Acetophenone

18. Toluene

19. Soda Amine

20. PPBBA Ester

21. Charcoal

22. Methanol

23. Soda Ash

24. HCL

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25. Crude BCFI

26. OTBN

27. DMF

28. Zncl2

29. Sodium Bicarbonate

30. Tri Ethyl Chloride

31. EDC

32. Methanol

33. NBS

34. Acetone

35. Benzoic acid

36. Charcoal

RM & FINISHED GOODS STORAGE DETAILS

Name of Material Mode of Storage

MS/SS/HDPE/Paper Bags

Capacity

(kg)

Storage condition

Ambient/under pressure

Safety measures provided

Para Tetra Butyl benzoic Acid

Paper Bags 25 Ambient pressure Stored Separately

4-Methoxy Acetophenone HDPE Drums 200 Ambient pressure Stored Separately

Sodium Amide MS Drum 150 Under Pressure without moisture

Stored Separately

Sodium Bicarbonate Gunny Bags 50 Dry Area Stored Separately

Hydrochloric acid C. P. Carboy 40 Room Temp. Stored Separately

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3,4 Di chloro aniline Gunny Bags 50 Room Temp. Stored

Separately

Para Chloro Aniline Gunny Bags 50 Room Temp. Stored separately

Ethyl Acetate Overhead tank 19 KL Room Temp. Stored separately

Para Anisic Aldehyde MS Drum 225 Room Temp. Stored separately

2 Ethyl Hexanol Acid Overhead Tank 16 KL Room Temp. Stored separately

Sodium Methoxide Powder MS Drum 100 Under Pressure without moisture

Stored separately

Liquid Paraffin HDPE Drums 210 Room Temp. Stored separately

Formic Acid Carboy 35 Room Temp. Stored separately

Phosphoric Acid Carboy 35 Room Temp. Stored separately

Acetic Acid Carboy 35 Room Temp. Stored separately

Orthotoly Benzo Nitrile Fibre Drum 50 Room Temp. Stored separately

Sodium Azide Fibre Drum 25 Dry Area without moisture

Stored separately

MDC Overhead tank 12 KL Room Temp. Stored separately

Sodium Nitrite Gunny Bags 25 Dry Area without moisture

Stored separately

Tri Ethyl Amine (TEA) MS Drum 150 Room Temp. Stored separately

Trityl Chloride ( TLC) Fibre Drum 50 Dry Area without moisture

Stored separately

DDH HDPE Drum 50 Room Temp. Stored separately

AIBN Corrugated Box

25 Room Temp. Stored separately

TEA HCL Gunny Bags 50 Dry area without moisture

Stored separately

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ISO Butyl Alcohol Carboy 50 Dry area without moisture

Stored separately

Methanol Underground storage Tank

20 KL Room Temp. Stored separately

Toluene Underground storage Tank

16 KL Room Temp. Stored separately

98 % Sulphuric Acid Carboys 50 Dry area without moisture

Stored separately

Caustic Soda Flakes Gunny Bags 50 Dry area without moisture

Stored separately

Hyflow Paper Bags 22.7 Dry area without moisture

Stored separately

Activated Carbon Gunny Bags 50 Dry area without moisture

Stored separately

TTBB Fiber Drums 25 Kgs In dry Place away from Sunlight

Stored Separately

TCC Paper Bags 25 Kgs In dry place away from Sunlight

Stored Separately

OMCX HDPE Drums 235 Kgs. In dry Place away from Sunlight

Stored Separately

Spiro Fiber Drum 25 Kgs. In dry place away from Sunlight

Stored Separately

Chemsol -45 Paper Cartoon Box

20 Kgs In dry Place away from Sunlight

Stored Separately

BMDM Paper Cartoon Box

25 Kgs. In dry place away from Sunlight

Stored Separately

Chem-05 HDPE Drums 200 Kgs. In dry Place away from Sunlight

Stored Separately

Chem-PO Paper Cartoon Box

20 kgs. In dry place away from Sunlight

Stored Separately

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(a) TYPES OF ACCIDENT

I - Fire / Explosion

If the flammable chemicals leak out from pipelines (due to cracks, holes rupture),

pipeline flanges (due to damaged gaskets, overhead flanges without flange gourd), no

proper bondings to pipeline flanges carrying flammable chemicals, no proper earthing to

equipment, leakage from vessel/tanks/container (due to cracks, holes rupture), spillage

(due to overflow, improper handling of containers) and the flammable chemical when

comes out in working atmosphere and gets ignition source Fire is possible and in

confined space leads to an Explosion.

Hazard Identification Risk Analysis Risk Control

Work

Activity

Hazard Which

can cause

Likelihood Severity Risk Recommended

Control Measures

1 Unloading

of

flammable

chemicals

Minor

Leakage

from

unloading

lines

Fire if

gets

ignition

source

Possible - has

a good chance

of occurring

Serious Medium

Risk

Leak material should

be collected in metal

container (properly

earthed) and it should

be transfer in the tank.

No Ignition source

should be available

where flammable

chemicals are handled.

2 Transfer

through

pump

Leakage

from pump

Fire if

gets

ignition

source

Possible - has

a good chance

of occurring

Serious Medium

Risk

Schedule is to be

prepared for

Preventive

maintenance of pump.

Avoid dispersal of

spilled material and

runoff and contact

with soil, waterways,

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drains and sewers.

26


Work

Activity

Hazard Which

can cause


Control Measures

Stop leak if without

risk. Move

Contain and collect

spillage with non-

combustible,

absorbent material

e.g. sand, earth,

vermiculite or

diatomaceous earth

Use spark-proof

tools and

explosion-proof

equipment.

Dispose of via a

licensed waste

disposal contractor.

Contaminated

absorbent material

may pose the same

hazard as the

spilled product.

3 Material

Handling

Spillage Fire if

gets

ignition

source

Possible - has

a good chance

of occurring

Serious Medium

Risk

Contain and collect

spillage with non-

combustible,

absorbent material

e.g. sand, earth,

vermiculite or

diatomaceous earth

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Over pressurization of reaction vessel, uncontrolled exothermic reaction, run-away

reaction, decomposition may lead to an explosion or any abnormality in the process can

cause Fire & Explosion.

II - Release of Toxic Material

If the Toxic chemicals leak out from pipelines (due to cracks, holes rupture), pipeline

flanges (due to damaged gaskets, overhead flanges without flange gourd), leakage from

vessel/tanks/container (due to cracks, holes rupture), spillage (due to overflow, improper

handling of containers)

IDENTIFICATION AND CONTROL OF HAZARDS

Sr.

No.

Activities Associated Hazard Effect of Hazard Preventive measures

1 Electrical Short circuiting Electrocution or Use hand gloves & other

and place in

container for

disposal according

MPCB norms.


Work

Activity

Hazard Which

can cause


Control Measures

4 Handling of

hazardous

chemicals or

attending the

leakage.

Contact with

hazardous

chemicals

Exposed

person (s)

may have

toxic

effect.

Possible - has

a good chance

of occurring

Serious Medium

Risk

Enforce the use of

suitable Personal

Protective

equipment (PPE).

Chemical handling

procedure is to be

displayed.

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installations &

usage

fire PPE

Don’t lay wire under mats,

door ways

Employ licensed electricians

to carry out electrical

instillation

Use one socket for one

appliance

Ensure usage of only fully

insulated, undamaged wires

or cables

Don’t place bare wire ends

in a socket

Ensure earthing of

equipments

Sr.

No.


Do not use damaged cords

and avoid temporary

connections

Do not allow open/bare

connections

Provide all connections

through ELCB

Protect electrical

cables/equipment’s from

water and naked flames

Check all connections before

energizing

Overloading of Bursting of system Display voltage & current

29

electrical system leading to fire ratings prominently with

‘Danger signs’

Ensure approved cable size,

voltage grade and type

Sr.

No.


Switch off the electrical

utilities when not in use

Do not allow unauthorized

connections

Ensure proper grid wise

distribution of power

Improper laying of

overhead and

underground

transmission

lines/cables

Can cause

electrocution and

prove fatal

Do not lay unarmored cable

directly on ground, wall, top

of trees.

Maintain atleast 3m distance

from HT cables

All temporary cables should

be laid at least 750mm

below ground on 100mm

fine sand overlying by brick

soling

Sr.

No.


Proper sleeves should be

provided at road crossings

Provide cable route markers

indicating the type and depth

of cables at intervals not

exceeding 30m and at the

diversions/termination

30

Use sparking tools in

the flameproof areas

Spark may cause

fire if flammable

mixture comes in

contact with such

sparks.

Non-sparking tools to be

used in such areas.

Cables exposed from

glands, damaged

cables of Flameproof

fittings.

Spark may cause

fire if flammable

mixture comes in

contact with such

sparks.

Electrical inspection is to be

done on regular basis.

Sr.

No.


2 Working at

heights

Person can fall down May sustain severe

injuries or prove

fatal

Provide guard rails/barricade

at the work place

Use PPE like safety belts,

full body harness with two

life-lines, helmets, safety

shoes etc.

Obtain work permit before

starting the work at height

above 2m

Fall arrest systems like

safety nets, must be installed

Provide proper working

space (min. 0.6m x 0.6m)

Tie/weld working platform

with fixed support

Avoid movement on beams

Sr.

No.


May hit the Keep the work place neat

31

scrap/material

stacked at the

ground or in

between

and clean

Remove the scrap

immediately

Material can fall

down

May hit the

workers working

at lower levels and

prove fatal

Keep the work place neat

and clean

Remove the scrap

immediately

Barricade the area at ground

level

Do not through or drop

materials or equipment from

height

All tools to be carried in

atoll-kit bag

Remove scrap from the

planks

Ensure wearing of helmet by

the workers at lower level.

Sr.

No.


3 Hand/ power

tools

Unguarded moving

parts like grinding

wheel, drill bit

It may injure the

operator.

Use proper guard

Wheel may get

detached and hit

passer by as flying

missile causing

serious injury

Use proper guard

Ensure tightening

mechanism of the tool

Supply of power

without earthing

Electrocution Always use 3-pin plug

Ensure good earthing

32

4 Lifting

equipments

Failure of load lifting

and moving

equipments

Can cause

accident and prove

fatal

Regular inspection of all

moving machinery

Check quality, size, and

condition of all chain pulley

blocks, slings, U-clamps, D-

shackles, wire ropes etc.

Sr.

No.


Overloading of

lifting equipments

Can cause

accident and prove

fatal

Safe lifting capacity of

derricks, and winches should

be ascertained

The max. safe working load

shall be marked on all lifting

equipments

Check the weight of columns

and other heavy items

painted on them and

accordindecide about an

angle of erection

Allow only trained operators

and riggers during crane

operations

Statutory inspection/testing

of lifting tools/tackles,

cranes should be carried out.

Sr.

No.


Statutory inspection/testing

of lifting tools/tackles should

be carried out.

5 Vehicular Reversing the Accident may Vehicle should always be

33

movement vehicle occur and prove

fatal

manned by a driver and a

cleaner

Provide reverse horn on the

vehicle

6 Use of

flammable

material

Vapour/gas/dust may

come in contact with

air and ignition

source

Fire/explosion Combustible materials are to

be kept at isolated place and

away from ignition source.

Safe handling procedure of

chemicals is to be prepared

and to be displayed.

(b) SYSTEM ELEMENTS OR EVENTS THAT CAN LEAD TO A MAJOR

ACCIDENT.

Operational Units

Vessels/Reactors/containers

Connected pipelines

Storage Units

Leakages of hazardous chemicals due to rupture/cracks/holes of pipe lines, failure of

welded joints, failure of valves, rupture/leakage of equipment or and storage container.

Failure of pumps

Fire, Explosion or/and Toxic effects may cause due to hazardous properties of hazardous

chemicals that handled in plants.

c) SAFETY RELEVANT COMPONENTS

Plant Buildings/ Structures:

Structure stability

Emergency exits

Fire protection System

34

Operational unit

Parameter Monitoring

Proper earthing/bondings

Safe Operating Procedures

Emergency electrical supply

Emergency exits

Fire Protection System

Statutory Inspection/testing

Availability of appropriate fire extinguishers

Good house keeping

Safe Handling Procedures

Spill Control procedure

DETAILS ABOUT THE SITE

(a) LOCATION OF DANGEROUS SUBSTANCES

(Exhibited in Annexure)

LIST OF KEY PERSONS

Name Designation Phones

Cell Office ( Ext.)

Rushabh Vora Managing Director 9323003960 27401932 / 35 – ( 102)

K.S.Katiyal Director- Operations 9930965985 27401932 / 35 – ( 103)

Subhash Sen Executive- Director 9822000256 27401932 / 35 – ( 118)

Vasudev Shetty General Manager-Works 9004758793 27401932 / 35 – (117)

Atul Aphale Asst. Works - Manager 9619910082 27401932 / 35 – (148)

Chetan Galagali Dy. Manager – Production 9967663887 27401932 / 35 – (147)

Balasaheb Chavan Asst Manager- Production 9004170660 27401932 / 35 – (159)

35

Ashok Mahale Asst Manager- Production 9767973303 27401932 / 35 – (147)

K.Radhakrishnan Asst Manager- Production 9987013973 27401932 / 35 – (174)

Prabhakar Babar Shift in Charge- Production 8454945203 27401932 / 35 – (159)

Vasant Shelar Shift in Charge- Production 9373820888 27401932 / 35 – (147)

Shriram Gosavi Shift in Charge- Production 9270083542 27401932 / 35 – (147)

Vishnu Narkhede Supervisor – Production 9820424408 27401932 / 35 – (147)

Sameer Pathan Supervisor – Production 9594318296 27401932 / 35 – (159)

Dhruwadev Bhatkar Supervisor – Production 9819726168 27401932 / 35 – (159)

Rajendra Shette Shift in Charge- Production 9930373597 27401932 / 35 – (147)

Tulshiram Patil Shift in Charge- Production 9892447134 27401932 / 35 – (174)

Narapareddy Vippala Plant Manager - Production 8625025291 27401932 / 35 – (116)

Anand Deshpande Dy.Manager – Production 9422091367 27401932 / 35 – (151)

Milind Name Production – Executive 9220410773 27401932 / 35 – (160)

Hanumant Shinde Shift in Charge- Production 9004458322 27401932 / 35 – (160)

Nandu Gondhali Supervisor – Production 9833144115 27401932 / 35 – (160)

Shashank Jangam Supervisor – Production 9970062638 27401932 / 35 – (160)

L.B. Yadawa General Manager –QC/MR 9819832159 27401932 / 35 – (169)

Surya Prakash Dubey Asst.Manager-QC 9920530397 27401932 / 35 – (169)

Vinayak Mahajan General Manager – R & D 7303676092 27401932 / 35 – (176)

Sudhir Patil Sr.Manager – R & D 9223301834 27401932 / 35 – (157)

Vinayak Kulkarni Manager – R & D 9619830168 27401932 / 35 – (171)

Sunil Budhale Asst. Manager- BSR 9920530638 27401932 / 35 – (162)

Chandrakant Narkhede DGM - Maintenance 9930270084 27401932 / 35 – (153)

Shamrao Ahire Manager -Maintenance 9594365107 27401932 / 35 – (116)

36

Prakash Nangare Asst. Manager – Maint. 9823694951 27401932 / 35 – (153)

Madhukar Darade D G M- Administration 7710022349 27401932 / 35 – (120)

Kamlesh Sharma G.M.- Finance & Accounts 9819832159 27401932 / 35 – (130)

Amit Bhatra Manager -Commercial 9925719079 27401932 / 35 – (125)

Harrish Ashar DGM -Purchase 9821716390 27401932 / 35 – (119)

Hanmant Mohite Officer -Stores 9421002718 27401932 / 35 – (163)

Ranjan Powar Officer - Stores 7715013818 27401932 / 35 – (105)

Atul More Asst. Manager – EHS 8097908838 27401932 / 35 – (113)

Yashwant wagh Executive - EHS 9987275969 27401932 / 35 – (149)

CCPL Main gate Security 27401932 / 35 – (164)

37

38

39

40

41

EMERGENCY CONTROL CENTRE (ECC)

The Emergency Control Centre is situated at Administrative Office and alternate place is

at Security Control Room. WMC and WIC are available during general shift hours.

Supervisor and Security personnel are also available general shift. (Factory works in day

shift only)

The ECC is equipped with following information for ready reference:

Layout Plan showing hazardous areas and escape routes

Material Safety Data Sheets

List of telephone numbers of key personnel & response agencies

Copy of On-site Emergency Preparedness Plan

List of Personal Protective Equipments for fire fighting with its location & Number

Communication System

List of Fire Fighting Equipments with Nos. and location Map.

List First aid boxes / trained first aid Employees.

AIRPORT

( 1 ) INTERNATIONAL AIRPORT TERMINAL – SAHAR (

ANDHERI )

28366700

( 2 ) DOMESTIC AIRPORT TERMINAL – SANTACRUZ 26112850, 26113300

ROADWAYS

( 1 ) PANVEL 27452320

( 2 ) VASHI 27662833

( 3 ) ACCIDENT INFORMATION 24451366

( 4 ) LOST PROPERTY

RAILWAY

( 1 ) CENTRAL RAILWAY ENQUIRY 134

( 2 ) WESTERN RAILWAY ENQUIRY 131

POST OFFICE

( 1 ) POST OFFICE – TALOJA 27412354

42

ENUMERATE EFFECTS OF

(i) Stress and Strain caused during normal operation:-

No Stress and Strain are caused during normal operation.

(ii) Fire and Explosion inside the plant and effect, if any, of Fire and Explosion

outside:-

The heat radiation due to Major Fire/ Explosion inside the factory can have effect on

employees as well as general public up to the damage distance.

DETAILS REGARDING:

(i) Warning, alarm, safety and security systems

Appropriate warning boards at prominent locations cautioning the employees against

smoking, unsafe acts/practices etc.

Boards giving specific instructions in hazardous area, alarm / siren system as per the code

(ii) Alarm and hazard control plans in line with disaster control and hazard control

planning, ensuring the necessary technical and organizational precaution.

ALARM

To alert the employees of an emergency, an alarm / siren system is installed. WMC will

consult WIC or his alternative for declaring emergency and sounding alarm / siren as per

code.

ALARM CODE

Following is the alarm code to indicate an emergency.

FIRE/EXPLOSION

Two interrupted wailing sounds of 30 seconds duration each with a gap of 30

seconds.

TOXIC RELEASE

One interrupted wailing sounds of 30 seconds duration.

ALL CLEAR

Long whistle of one -minute duration.

43

TESTING OF ALARM

Every Saturday at 02.30 P.M. one of the above alarms will be sounded for testing.

FIRE ALARM SYSTEM IN CCPL

Sr. No. Location No. Of MCP No. of Hooter

Zone on Fire Alarm

Panel 1 Admin Building Ground Floor 1 1 Zone -1 2 Admin Building First Floor 1 Zone-1 3 Admin Building Second Floor 1 Zone-1 4 FMCG Plant ground Floor 1 1 Zone-1 5 FMCG Plant First Floor 1 Zone-1 6 FMCG Plant Second Floor 1 Zone-1 7 FMCG Plant Third Floor 1 Zone-2 8 TCC Plant Ground Floor 1 1 Zone-2 9 Utility Area 1 Zone-2 10 Boiler 1 1 Zone-2 11 Engg. Store 1 Zone-2 12 R.M. Store 1 Zone-2 13 B.S.R. Plant 1 Zone-2

Total 4

** Fire Alarm Panel Located in Security Room.

** Manual Siren system is avail near FMCG Plant Ground Floor entrance. Siren Location = 1. Near FMCG Plant & 2. Above TCC Plant

Fire Alarm Panel details

Make Ravel Electronic Pvt. Ltd.

Fire Extinguisher Zone Description Page No. 1 of 2 Format No. SF005/F/01-00

Sr. No. FEZ NO. FEZ Location Type Capacity

(Kg)

44

1 1 Security gate M/F 9 KGS 2 2 Admin Building -1 ABC 6 KGS 3 3 Admin Building -2 ABC 6 KGS 4 4 Admin Building Entrance ABC 6 KGS 5 4A QC Laboratory ABC 9 KGS 6 5 QC Laboratory ABC 9 KGS 7 6 QC Laboratory ABC 6 KGS 8 7 R & D Laboratory ABC 9 KGS 9 8 R & D Laboratory ABC 6 KGS 10 9 R & D Laboratory M/F 6 KGS 11 10 BSR ABC 9 KGS 12 11 BSR ABC 9 KGS 13 12 BSR ABC 9 KGS 14 13 BSR Co2 9 KGS 15 14 RM Stores ABC 6 KGS 16 15 RM Stores ABC 6 KGS 17 16 RM Stores Co2 9 KGS 18 17 RM Stores ABC 9 KGS 19 18 RM Stores ABC 9 KGS 20 19 RM Stores M/F 9 KGS 21 20 OMCX Plant Ground Floor Co2 4.2 KGS 22 21 OMCX Plant Ground Floor ABC 9 KGS 23 22 OMCX Plant Ground Floor ABC 6 KGS 24 23 OMCX Plant First Floor ABC 6 KGS 25 24 OMCX Plant First Floor Co2 9 KGS 26 25 OMCX Plant First Floor ABC 6 KGS 27 26 Pilot Plant ABC 9 KGS 28 27 Pilot Plant ABC 9 KGS 29 28 Pilot Plant ABC 9 KGS 30 29 Engineering Store ABC 9 KGS 31 30 Engineering Store ABC 6 KGS 32 31 Engineering Store M/F 6 KGS 33 32 Utility M/F 9 KGS 34 33 Utility ABC 9 KGS 35 34 Utility ABC 6 KGS 36 35 Utility ( Work Shop ) Co2 4 KGS

45

37 36 Utility ( Work Shop ) ABC 6 KGS 38 37 Pharma Plant First Floor ABC 4 KGS 39 38 Pharma Plant First Floor Co2 3 KGS 40 39 Pharma Plant First Floor ABC 4 KGS 41 40 Pharma Plant First Floor ABC 6 KGS 42 41 Pharma Plant Second Floor Co2 4.5 KGS 43 42 Pharma Plant Second Floor ABC 9 KGS 44 43 Pharma Plant Second Floor Co2 9 KGS 45 44 Pharma Plant Second Floor Co2 4.5 KGS 46 45 Pharma Plant Third Floor ABC 9 KGS 47 46 Pharma Plant Third Floor ABC 6 KGS 48 47 Pharma Plant Third Floor ABC 6 KGS 49 48 Pharma Plant Third Floor ABC 6 KGs 50 49 Pharma RFD M/F 9 KGS 51 50 Pharma RFD M/F 9 KGS 52 51 Pharma RFD Panel Board Co2 4.5 KGS 53 52 FMCG Ground Floor M/F 50 KGS 54 53 FMCG Ground Floor ABC 9 KGS 55 54 FMCG Ground Floor Co2 4.5 KGS 56 55 FMCG Ground Floor Co2 9 KGS 57 56 FMCG Ground Floor M/F 50 KGS 58 57 FMCG First Floor M/F 9 KGS 59 58 FMCG First Floor M/F 6 KGS 60 59 FMCG First Floor M/F 6 KGS 61 60 FMCG First Floor ABC 9 KGS 62 61 FMCG First Floor ABC 9 KGS 63 62 FMCG Second Floor ABC 9 KGS 64 63 FMCG Second Floor Co2 4.5 KGS 65 64 FMCG Second Floor ABC 9 KGS 66 65 MCC Electrical Room ABC 5 KGS 67 66 MCC Electrical Room ABC 9 KGS 68 67 MCC Electrical Room ABC 9 KGS 69 68 Staircase Ground floor ABC 6 KGS 70 69 Staircase First Floor M/F 4.5 KGS 71 70 Staircase Second Floor M/F 6 KGS 72 71 Staircase Third Floor ABC 6 KGS 73 72 Staircase Third Floor ABC 9 KGS 74 73 TCC Plant Ground Floor Co2 21.5 KGS 75 74 TCC Plant Ground Floor Co2 9 KGS 76 75 TCC Plant Ground Floor ABC 9 KGS 77 76 TCC Plant First Floor Co2 4.5 KGS

46

78 77 TCC Plant First Floor Co2 9 KGS 79 78 Fire Pump House ABC 4 KGS 80 79 Fire Pump House ABC 4 KGS 81 80 Fire Pump House ABC 4 KGS

82 81 Occupational Health center BC (DCP)

9 KGS

83 82 Occupational Health center BC ( DCP)

9 KGS

84 83 Occupational Health center BC ( DCP)

6 KGS

85 84 Occupational Health center M/F 9 KGS 86 85 Occupational Health center M/F 9 KGS 87 86 Occupational Health center C02 3 KGS

DETAILS OF HYDRANT PUMP (MAIN HYDRENT PUMP) 1 NAME OF PARTY Kirloskar brother limited pump 2 PUMP NO CE-80/26 3 SERIAL NO 1.89E+10 4 MOC CI 5 O/A NO 2189A9010/0280 6 TOTAL HEAD 70 M 6 DISCHARGE 110 m3/Hr.

47

7 SPEED 2839 RPM 8 BHP/KW 74 A 9 MOTER HP 3 PHASE -30 HP

11 LOCATION Hydrant Pump House

DETAILS OF FIRE HYDRANT PUMP ( Jockey pump) 1 PUMP TYPES PHM-25/26A 2 SERIAL NO 1789311415 3 TOTAL HEAD 70 MM 4 DISCHARGE 10.8 M3 5 SPEED 2900 RPM 6 MOTER 7.5 HP

7 LOCATION Hydrant Pump House

DETAILS OF FIRE HYDRANT PUMP (HYDRANT) D. G. PUMP 1 ENGG. TYPE 4R1040NR 2 ENGG NO 4H2280.20/122004 3 SPEED 2000RPM 4 RATING KW/HP 47.8 /65 5 LOCATION Hydrant Pump House

PRESENT STATUS OF FIRE HOSE BOX / PIPES / HYDRANT POST

SR. NO.

LOCATION HYDRANT POST( point)

HYDRANT BOX / HOSE

PIPES BRANCH NOZZEL

HOSE REELS

1 Main gate Point -1 1,Hose box and 2

house pipes 1

2 Front admin

building Point -1 1,Hose box and 2

house pipes 1

3 BSR Front Point -1 1,Hose box and 2

house pipes 1

4 RMS back side Point -1 1,Hose box and 2

house pipes 1

5

OMCX ( Distillateion plant

) back side

Point -1

1,Hose box and 2 house pipes

1

48

6 New store room

back side Point -1 1,Hose box and 2

house pipes 1

7 pilot plant (

GEAT) Point -1 1,Hose box and 2

house pipes 1

8 Nitrogen plant Point -1 1,Hose box and 2

house pipes 1

9 Near boiler side (

ETP) Point -1 1,Hose box and 2

house pipes 1

10 ETP ( open area) Point -1 1,Hose box and 2

house pipes 1

11 ETP sludge bed

side Point -1 1,Hose box and 2

house pipes 1

12 Utility building Point -1 1,Hose box and 2

house pipes 1

13 Water tank by d.

water side Point -1 1,Hose box and 2

house pipes 1

14 pharma out side

interence Point -1 1,Hose box and 2

house pipes 1 1 Reel

15

pharma/FMCG building

Enterance Point -1 1,Hose box and 2


16 TCC Plant ( frient

) Point -1 1,Hose box and 2

house pipes 1

17 TCC plant (

corner) Point -1 1,Hose box and 2

house pipes 1

18 FMCG out side

interence Point -1 1,Hose box and 2


19 RM Store Point -1 1,Hose box and 2

house pipes 1

20 Distilltion plant (

front ) Point -1 1,Hose box and 2

house pipes 1

21 new store room (

front) Point -1 1,Hose box and 2

house pipes 1

22 Near by rest room Point -1 1,Hose box and 2

house pipes 1

23 Pilot plant ( near

by DG) Point -1 1,Hose box and 2


24 Pharma/FMCG

building 1 st Point -1 1,Hose box and 2


25 Pharma/FMCG

building 2nd Point -1 1,Hose box and 2


26 Distillation Plant

2 nd foor Point -1 1,Hose box and 2


27 Distillation plant

3 rd foor Point -1 1,Hose box and 2


49

28 Distillation plant

4 th foor Point -1 1,Hose box and 2


29 Distalisation Plant

5 th foor Point -1 1,Hose box and 2


30 FMCG 1 st foor Point -1 1,Hose box and 2


31 pharma 2 foor Point -1 1,Hose box and 2

house pipes 1

Water Hydrant Tank details:

CHEMSPEC CHEMCIALS PVT LTD. TANK-1

Water tank ( storage ) Hydrant tank details

Tank Details RCC ( 1) Tank details

12.900m*3.58 m *2.700m

Total size 124.69*1000 Capacity 125m3 Location near by FMCG

CHEMSPEC CHEMCIALS PVT LTD. TANK-2

Water tank ( storage ) Hydrant tank details Tank Details

RCC ( 2)

Tank details

20.500M*3.600M*2.700M

Total size 199.29*1000

Capacity 200m3

Location nearby FMCG

Reliable measuring instruments, control units and servicing of such equipments

Concerned Engineers carry out maintenance of instruments.

Precautions in designing of the foundation and load bearing parts of the building

50

Periodic inspections by competent person for stability of structure / building are carried

out.

Continuous surveillance of operations

All operations are carried out under the supervision of operation in charge.

Documents/Registers are maintained for receipt and dispatch of chemical. All critical

operating parameters are monitored maintained and recorded

Maintenance and repair work according to the generally recognized rules of good

engineering practices

Maintenance and repair work in accordance with safety acts / rules and good engineering

practices.

Periodic preventive maintenance as per periodical maintenance schedule.

Statutory inspections as per schedule.

DETAILS OF COMMUNICATION FACILITIES AVAILABLE DURING

EMERGENCY AND THOSE REQUIRES FOR AN OFF-SITE EMERGENCY.

Company has effective Telephone Communication System and if required messengers

are also arranged.

DETAILS OF FIRE FIGHTING AND OTHER FACILITIES AVAILABLE

DURING EMERGENCY AND THOSE REQUIRES FOR AN OFF-SITE

EMERGENCY.

FIRE PROTECTION SYSTEM

Water storage capacity : 200 cubic meter

Hydrant Electric pump’s detail : 2280lpm (137mph) x 70m Head

Standby Diesel Pump : 2280lpm (137mph) x 70m Head

Electric Jockey Pump : 180lpm (10.8mph) x 70m Head

Number Hydrant points

(Yard/External) + (Stair Case/Fire Escape) = Total nos.

51

21 11 32

Fire Hose Boxes : 32 Total nos.

Fire Hoses RRL type with Male/Female Cplgs : 64 nos. (15m)

First Aid Hose Reels: 11 nos. (30m long 20dia rubber hose)

Fire Brigade Inlets for direct pumping into hydrant piping: 2 no. at Main Gate with built in 2 NRV

Fire Brigade inlets for filling underground fire water tank: 1 no. at Main Gate

Water sprinkler system provided in: Tank farm area and OMCX Plant.

LIST OF FIRE EXTINGUISHERS-

Sr. No. Type of Fire Extinguishers Capacity Location 1) DCP Type Fire Extinguishers 9.0 kg Near Occupational Health 2) DCP Type Fire Extinguishers 6.0 kg Near Occupational Health 3) CO2 Type Fire Extinguishers 9.0 kg OMCX Plant Ist Floor, BSR, 4) CO2 Type Fire Extinguishers 21.5 kg FMCG Plant 5) CO2 Type Fire Extinguishers 4.5 kg OMCX Plant, Pharma IInd 6) CO2 Type kg Fire 3.0 kg Pharma Ist Floor, Near OHC 7) ABC Type Fire Extinguishers 6.0 kg Admin Building, QC lab., 8) ABC Type Fire Extinguishers 9.0 kg QC lab. R & D lab. ,BSR,RM 9) ABC Type Fire Extinguishers 5.0 kg MCC Electrical Room, Fire 10) Mechanical Foam Type Fire 6.0 Ltr. R & D Lab, Engg. Store 11) Mechanical Foam Type Fire 4.5 Ltr. Pharma RFD, FMCG Plant 12) Mechanical Foam Type Fire 9.0 Ltr. RM Store, Security Gate, 13) Mechanical Foam Type Fire 50.0 Ltr. FMCG Plant, Pilot Plant, RM

LIST OF CERTIFIED FIRST AIDERS

SR.NO. NAME OF FIRST AIDRES DEPT. CONTACT NUMBER

1 Atul Mhatre R & D 8097702259

2 Prashant Patil Q.C. 9870944148

3 Suryaprakash Dubey Q.C. 9175817489

4 Milind Name Pharma-Production 9220410773

5 Prabhakar Babar FMCG- Production 9768315297

6 Sagar Bhoir Maintenance 9769262117

52

7 Yashwant Wagh EHS 9987275969

8 Balkrishna Dere BSR 9222001255

9 K. Radhakrishnan FMCG-Production 9987013973

10 Ravindra Metkari R & D 9890377852

11 Ramesh Patil Pharma-Production 8898100236

12 Santosh Dare Pharma-Production 9029111890

13 Mahendra Gaikwad Pharma-Production 9768342282

14 Abhay Patil FMCG-Production 9222117598

15 Naresh Agalave FMCG-Production 9619494839

Annexure 2: HAZOP Study Report

M/s Chemspec Chemicals Pvt. Ltd.

Plot No. 3 C, MIDC Industrial Area, Taloja Raigad-Maharashtra – 410208

HAZOP STUDY REPORT

NOVEMBER 2014

53

Prepared by

M/s MAHARASHTRA INDUSTRIAL ENGINEERING SERVICES KHANDA COLONY, PANVEL , NAVI MUMBAI

PREFACE

M/s Maharashtra Industrial Engineering Services have been appointed by M/s Chemspec Chemicals Pvt. Ltd., to carry out HAZOP study of their above-mentioned manufacturing Facility located at Plot No 3 C, MIDC Industrial Area, Taloja Raigad-Maharashtra - 410208 This report summarizes the outcome of the HAZOP study carried out at their manufacturing unit on November ’ 2014 The study and recommendations are based on information made available to M/s Maharashtra Industrial Engineering Services at the time of this study. M/s Maharashtra Industrial Engineering Services has exercised all responsible skill, care and diligence in carrying out this study. This report is not deemed to be any undertaking, warranty or a certificate.

54

ACKNOWLEDGMENT The HAZOP team is grateful to the management of M/s. Chemspec Chemicals Pvt. Ltd. (Taloja) thus to Shri. V. H. Shetty (General Manager-Works). We are very thankful to Shri. NarapareddyVippala (Sr. Manager –Production) &Mr. Atul More – Asst. Manager (EHS) for their co-operation while on site visit as well as positive interactions in regards to HAZOP studies. The HAZOP team wishes the management a safe and efficient working.

55

INDEX

SR.NO. CONTENTS PAGE COVER PAGE

1

PREFACE

2

ACKNOLEDGEMENT 3

INDEX 4

1 INTRODUCTION

5 - 6

2 PROCESS DESCRIPTION

7 - 8

3 HAZOP STUDY METHODOLOGY

9

3.1 INTRODUCTION

9 - 13

3.2 PROCEDURE

13

3.3 REFERENCE DOCUMENTS FOR STUDY

14

3.4 HAZOP TEAM 14

56

3.5 HAZOP SESSION

14

HAZOP WORKSHEET

15 - 46

GENERAL RECOMMANADTION

47

INTRODUCTION M/s Chemspec Chemicals Pvt. Ltd., have commissioned M/s Maharashtra Industrial Engineering Services to carry out Hazard and Operability (HAZOP) study of their above mentioned manufacturing facility at Plot No 3 C, MIDC Industrial Area, Taloja Raigad-Maharashtra - 410208 The HAZARD IDENTIFICATION & RISK ASSESSMENT has been carried out with the following objectives:

1 Detailed study of the process design and operations of the facility with the aid of Piping & Instrumentation Drawings (P & IDs) for identification of hazards and problems related to operability.

2 Systematic and critical examination of the operations and engineering

intentions of process design by application of probability, duration & severity. Subsequently, determine the likely risks arising from operating parameters and procedures and other failures, which could result in various levels of risks viz. Low risk, Medium risk or High risk i.e. significant risks.

3 Submission of recommendations made by the Risk Assessment team

towards minimization of potential hazards, possible failures and their consequential impact.

57

The company M/s Chemspec Chemicals Pvt. Ltd., is registered under the Factories Act-1948 with the Directorate of Industrial Safety & Health, Maharashtra state. Their factory building plans have been approved by the Directorate of Industrial Safety & Health, Maharashtra State. The company is classified as Hazardous Activities Area, due to its nature and processing of natural gas , hence it was necessary from the statutory point of view to carry out ‘HAZOP ‘Study by the experts and prepare a report to that effect to identify the hazards existing in the process with hazardous situations occurring during the generation process. With the intention to carry out ‘HAZOP’ study, management of M/s. Chemspec Chemicals Pvt. Ltd., approached the processor and offered the responsibility to conduct the ‘HAZOP’ study submission of the report to factory. The expert visited the factory to survey and studies the manufacturing activities and the chemicals handled therein. They also studied the equipment details along with the constructions. The expert has discussion with the relevant personnel from the factory, engaged in the manufacturing activities. The report was made after going through the details collected during the visit.

58

PROCESS DESCRIPTION

PHENYL BENZIMADAZOLE SULPHONIC ACID: CHEMSOL-HS : STEP-I : SULPHONATION : Ortho Phenyl Di Amine [ OPDA ] react with Sulphuric acid will gives Ortho Phenyl Di Amine Sulphonic Acid. STEP-II : CONDENSATION: Ortho Phenyl Di Amine Sulphonic Acid condensation with Benzaldehyde gives PHENYL BENZIMADAZOLE SULPHONIC ACID [HS-Technical ].In this process Sodium Meta bi Sulphate used as Adduct. STEP-III : CRYSTALISATION: PHENYL BENZIMADAZOLE SULPHONIC ACID [HS- Technical ]re crystallized in water through charcoal treatment to get Pure PHENYL BENZIMADAZOLE SULPHONIC ACID. In this process Liq.Ammonia used for dissolve the material and Acetic Acid used for crystalline the material. LIST OR RAW MATERIAL FOR CHEMSOL- HS :

59

ORTHO PHENYL DI AMINE SULPHURIC ACID 98% METHANOL BENZALDEHYDE Liq. AMMONIA SODIUM META BI SULPHATE ACETIC ACID ACTIVATED CARBON HYFLOW

2- ETHYL HEXYL SALICYLATE : [ OS ] : STEP-I : ESTERIFICATION : Salicylic acid react with 2- Ethyl Hexanol in presence of Sodium Meta Bi Sulphate gives 2-ETHYL HEXYL SALICYLATE [OS ].In this reaction Excess 2-EH used as solvent.Further treated with Sodium Bi carbonate water to remove the unreacted Salicylic Acid and get 2-ETHYL HEXYL SALICYLATE technical as Crude. STEP-II : FRACTIONAL DISTILATION : 2-ETHYL HEXYL SALICYLATE technical subjected to fractional distillation and get the PURE 2-ETHYL HEXYL SALICYLATE [HS]. LIST OR RAW MATERIAL FOR OCTYL SALICYLATE : SALICYLIC ACID 2-ETHYL HEXANOL SODIUM BI SULPHATE SODIUM BI CARBONATE

60

ACTIVATED CARBON HYFLOW

HAZOP STUDY – MATHODOLOGY

HAZOP study is the technique used to review the design and operations of a hazardous process facility.

3.1 INTRODUCTION HAZOP is a systematic and highly structured study with a critical approach to examine the process and engineering intentions of the process design. HAZOP is used to identify all possible causes of deviation from normal safe operation that could lead to any safety and fire hazard, environmental risk or operatability problems. Some of the causes may be unrealistic and so they 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 /action. 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 process and engineering intentions and consequent hazard and operatability problems. After finalizing the recommendations, the study progresses to focus on the next part of the design. The examination is repeated until the whole system has been studied Intention: The intention defines how the selected section/unit is expected to operate.

61

Guide words: These are simple words, which are used to qualify the intention in order to guide and stimulate the thinking process and so discover deviations. A list of guidewords along with the likely causes is given in. Deviation: These are departures from the intention, which are discovered by systematically applying the guidewords. Causes These are the reasons why deviations might occure.Once a deviation has been shown to have a conceivable or realistic cause, it can be treated as meaningful. Consequences: They are results of deviations, should be occur. Hazards: The consequences, which can cause damage, injury or loss. The primary aims of HAZOP are:

To identify the cause of all deviations or changes from the design intent. To determine all major hazards and operatability problems associated with

these deviations. To decide whether action is required to control the hazard or operatabilty

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

Table 1 HAZOP GUIDE WORDS and EXAMPLE CAUSES

GUIDE WORD

DEVIATION CAUSES

NONE FLOW Wrong routing- blockage-incorrect slip plate- incorrectly filled 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 THAN FLOW Increased pumping capacity – increased suction pressure – reduced delivery head – greater fluid density – exchanger tube leaks – restriction orifice plates deleted – cross connection of systems – control faults – control valve trim changed – running two pumps –etc.

LESS THAN FLOW Line restriction – filter blockage – defective pumps – fouling of vessels, valves, orifice

62

plates – density or viscosity changes – etc. MORE THAN LEVEL Outlet isolated or blocked – inflow greater

than outflow – control failure – faulty level measurement – gravity liquid balancing – etc.

LESS THAN LEVEL Inlet flow stops –leak – outflow greater than inflow – control failure – faulty level measurement – draining of vessel – etc.

MORE THAN PRESSURE Surge problems – connection to high pressure system – gas break through( 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.

MORE THAN TEMPERATURE Ambient condition – fouled or failed exchanger tubes – fire situations – cooling water failure – defective control – heater control failure- internal fires – reaction control failures – heating medium leak into process etc.

LESS THAN TEMPERATURE Ambient condition – reducing pressure – fouled or failed exchanger tubes – loss of heating – depressurization of liquefied gas – Joule/Thompson effect – etc.

MORE THAN VISCOSITY Incorrect material or composition – incorrect temperature – high solids concentration – settling of slurries – etc.

OTHER THAN

COMPOSITION CHANGE

Leaking isolation vales 0 leaking exchanger tubes – phase change – incorrect feed stock/specification – inadequate quality control – process control upset– reaction intermediates/ by- products – settling of slurries - etc.

AS WELL AS 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

63

and start up conditions – grade change – etc.

RELIEF Relief philosophy ( process/fire etc. ) – type of relief device and reliability – relief valve discharge location – pollution implication – two phase flow – effect of debottlenecking on relief capacity – inlet and outlet piping – etc.

INSTRUMENTATION Control Philosophy – location of instruments – response time – set points of alarms and trip and ability to change – time available for operator invention – alarm and trip testing – fire protection – trip/control amplifiers – panel arrangement and location – auto/manual facility and human error – fail safe philosophy – etc.

SAMPLING Sampling procedure and operators safety – time for analysis results – 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 embitterment –stress corrosion cracking – fluid velocities –etc.

SERVICE Failure of instrument air/steam/nitrogen/ cooling water/ hydraulic power/ electric power/ water or other – contamination of instrument air, nitrogen etc. – telecommunications – heating and ventilation system – computers –etc.

ABNORMAL OPERATIONS

Purging – flushing – startup – normal shutdown – emergency shutdown – emergency operations – inspection of operating machines – guarding of machinery – etc.

MAINTENANCE Isolation philosophy – drainage – purging – cleaning – drying – slip plates – access – rescue plan – training – pressure testing – work permit system – condition monitoring –

64

lifting and manual handling – etc. IGNITION 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 materials – etc.

SAFETY Toxic properties of process material – fire and gas detection system/ alarms – emergency shutdown arrangement – fire fighting response time – emergency and major emergency training – contingency plans – TLVs of process materials 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 plants etc.) – testing of emergency equipments – compliance with local /national regulations – etc.

3.2 PROCEDURE

The process and instrumentation diagrams are divided into discrete nodes. For each node, every parameter/guideword deviation is considered. For each deviation, causes are identified and for each cause, consequences are determined. After considering existing protection for each consequence, recommendations for actions are made if the remaining level of risk is considered unacceptable. The sequence steps used to conduct the HAZOP are as follows: HAZOP steps:

1. Select and confirm the scope of a node. 2. Explain the general design intentions and operating conditions of the node. 3. Specify process parameters for node. 4. Select a process parameter (Flow, Pressure, etc.) and specify the design

intention relating to this parameter. 5. Apply the deviation (More, less, etc.) to the parameter and develop

meaningful causes/ hazards of the deviation from the intention. 6. Identify all scenarios causes/hazards of the deviation from the intention.

65

7. Identify all major consequences associated with each causes without regards to safeguards.

8. Specify predominate safeguards against each consequence. 9. Make recommendations to mitigate the consequences if the severity is

unacceptable. 10. Repeat above steps for other guidewords. 11. Repeat above steps for other process parameters. 12. Repeat above steps for all other nodes in review. 13. Document all recommendations agreed by the HAZOP team.

3.3 REFERENCE DOCUMENTS FOR THE STUDY

The lists of the documents referred for HAZOP study are as below:

Sr.No. Drawing Name Drawing Number 1 P & ID for the plant NIL

3.4 HAZOP TEAM

Chemspec Chemicals Pvt. Limited,

Maharashtra Industrial Engineering Services

Mr. Atul More. Mr. NarapareddyVippala

Mr. Prakash Logavi Mr. Deshmukh Mr. Sunil

3.5 HAZOP SESSION

Location

M/s Chemspec Chemicals Pvt. Ltd. Plot No 3 C, MIDC Industrial Area, Taloja Raigad-Maharashtra - 410208

Period

November ’14

The recommendations agreed in the meeting are listed in the report for further action.

66

67

HAZOP WORKSHEETS

68

CHEMSOL - HS

69

Date : November 2014 Plant :CHEMSOL HS P & I D/ EQUIPMENT NO.:- Unit/Section : R 801 Node/Pipeline No. :-Charging of Sulphuric Acid from Measuring tank.

SR. NO.

GUIDE WORD

DEVIATION POSSIBLE CAUSES

CONSEQUENCES HAZARDS ACTION TAKEN ACTION REQUIRED

1 NONE No flow

No level in tank Delay in operation ---- Ensure required level of Sulphuric Acid is available in measuring tank

Operational Vigilance.

Valves on the line closed in error.

Delay in operation ---- ----- Operational Vigilance. Preventive maintenance of valves shall be carried out.

Line rupture Major spillage Personal injury Line healthiness is

ensured. Line healthiness shall be ensured all the time. Painting shall be carried out on regular frequency. Prepare a “Spill Control Procedure”. In case of leak/spill, evacuate area if necessary. Attend the repair with personal protection equipment’s

70

2 MORE More Flow More flow/ level in

reactor Quality issues Quality will affect SOP & Batch sheet are in

place. SOP & Batch sheet shall be followed strictly.

3 LESS

OF Less flow Valves on the line

partially closed. Less feed to reactor Delay in

operation

Personal monitoring. Operational Vigilance.

Leaks in the line (from pipeline or flanges)

Less feed to reactor.

Personal Injury. Line healthiness is ensured. Flange guards are provided on flange joints.

Line healthiness shall be ensured all the time. Painting shall be carried out on regular frequency. Prepare a “Spill Control Procedure”. In case of leak/spill, evacuate area if necessary. Attend the repair with personal protection equipment’s

4 AS

WELL AS

Additional material

Not applicable

71

5 PART OF

Diversion of flow

Not Applicable

6 OTHER

THAN A total different material.

Not Applicable

7 REVER

SE Reverse Flow

Nor Applicable

72

Date : November 2014 Plant : CHEMSOL HS P & I D/ EQUIPMENT NO.:- Unit/Section : R 801 Node/Pipeline No. :- Addition of OPDA through hopper

SR. NO.

GUIDE WORD

DEVIATION

POSSIBLE CAUSES


1 NONE No flow

Hopper valve is closed in error.

Delay in operation ---- Manual Addition as per Batch sheet. Ensure valve is in open condition.


2 MORE More Flow More flow/addition Quality issues Quality will affect SOP & Batch sheet are in


3 LESS



operation


Less Addition Quality issues Quality will affect SOP & Batch sheet are in


73

4 AS WELL AS

Additional material

Addition of other material alongwith desired

Quality issues, cross contamination, unintended reaction


SOP & Batch sheet are in place.

SOP & Batch sheet shall be followed strictly. Operational Vigilance.

5 PART

OF Diversion of flow

Not Applicable

6 OTHER


Addition of totally other material other than desired


Quality issues, cross contamination, unintended reaction.



7 REVER

SE Reverse Flow

Nor Applicable

74

Date : November 2014 Plant : CHEMSOL HS P & I D/ EQUIPMENT NO.:- Unit/Section : R 801 Node/Pipeline No. :-Charging DM water to reactor.

SR. NO.

GUIDE WORD



1 NONE No flow

No level in tank Delay in operation ---- Flow meter provided Operational Vigilance.



Line rupture DM water spillage ---- Line healthiness is

ensured. Line healthiness shall be ensured all the time. Painting shall be carried out on regular frequency.

2 MORE More Flow More flow/ level

in reactor Quality issues Quality will affect SOP & Batch sheet are in


75

3 LESS OF Less flow Valves on the line partially closed.

Less feed to reactor Delay in operation




Line healthiness is ensured.

Line healthiness shall be ensured all the time. Painting shall be carried out on regular frequency.

4 AS WELL

AS Additional material

Not applicable

5 PART OF Diversion of

flow Valve on other reactor is open



6 OTHER


Not Applicable

7 REVERSE Reverse

Flow Nor Applicable

76

Date : November 2014 Plant : CHEMSOL HS P & I D/ EQUIPMENT NO.:- Unit/Section : R 802 Node/Pipeline No. :-Quenching R 801 reaction mass in R 802 at below 65 to 70 Deg C.

SR. NO.

GUIDE WORD



1 NONE No flow

Quenching by gravity

Valve blocked

Delay in operation ---- ---- Operational Vigilance. Ensure cleanliness free movement of valve while carrying out inspection.



Line rupture, Material spillage ---- Line healthiness is


77

2 MORE More Flow Human error Temperature will raise

Quality of product will affected

Temperature gauge is provided.

Operational vigilance

3 LESS OF Less flow Valves on the

line partially closed.



4 AS WELL


Not applicable ---- ---- ---- ----


flow Carry over to vaccum system

Vaccum system problem

Less yield Gauge provided Operational Vigilance.

6 OTHER


Not Applicable ---- ---- ---- ----

7 REVERSE Reverse

Flow Nor Applicable

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

78

Date : November 2014 Plant : CHEMSOL HS P & I D/ EQUIPMENT NO.:- Unit/Section : R 803/4 Node/Pipeline No. :- Addition of Liquid Ammonia for pH adjustment

SR. NO.

GUIDE WORD



1 NONE No flow

Human error Operational delay ----- Manual Addition as per Batch sheet. Ensure valve is in open condition.


2 MORE More Flow More

flow/addition Quality issues Quality will affect SOP & Batch sheet are in


3 LESS OF Less flow Less Addition Quality issues Quality will affect SOP & Batch sheet are in


4 AS WELL







79

5 PART OF Diversion of flow.

Not Applicable

6 OTHER







7 REVERSE Reverse

Flow.

Nor Applicable

80

Date : November 2014 Plant : CHEMSOL HS P & I D/ EQUIPMENT NO.:- Unit/Section : R 803/4 Node/Pipeline No. :- Addition of Acetic Acid for pH adjustment

SR. NO.

GUIDE WORD



1 NONE No flow








4 AS WELL







81

5 PART OF Diversion

of flow.

Not Applicable

6 OTHER







7 REVERSE Reverse

Flow.

Nor Applicable

82

Date : November 2014 Plant : CHEMSOL HS P & I D/ EQUIPMENT NO.:- Unit/Section : R 803/4 Node/Pipeline No. :- Charging Sodium Meta Bi-Sulphate in reactor

SR. NO.

GUIDE WORD



1 NONE No flow

Hopper valve is closed in error.

Delay in operation ---- Manual Addition as per Batch sheet. Ensure valve is in open condition.





3 LESS OF Less flow Valves on the

line partially closed.



Less Addition Quality issues Quality will affect SOP & Batch sheet are in


Leaks in the line (from pipeline or



Line healthiness shall be ensured all the time.

83

flanges) Painting shall be carried out on regular frequency.

4 AS WELL







5 PART OF Diversion

of flow

Not Applicable

6 OTHER







7 REVERSE Reverse

Flow

Nor Applicable

84

Date : November 2014 Plant : CHEMSOL HS P & I D/ EQUIPMENT NO.:- Unit/Section : R 803/4 Node/Pipeline No. :- Charging of Benzaldehyde to additional vessel

SR. NO.

GUIDE WORD



1 NONE No flow

No level in tank Delay in operation ---- Ensure required level of Benzaldehyde is available in measuring tank




Line rupture Major spillage Personal injury


Line healthiness shall be ensured all the time. Painting shall be carried out on regular frequency. Prepare a “Spill Control Procedure”. In case of leak/spill, evacuate area if necessary.

85

Attend the repair with personal protection equipment’s

Fire Ensure fire prevention by

required precautions As it comes under very low LEL there are chances of fire in case spillage comes in contact with ignition source. Spill control media shall be disposed immediately otherwise it can also lead to spontaneous ignition.




3 LESS



operation



Less feed to reactor. Personal Injury. Fire

Line healthiness is ensured. Flange guards are provided on flange joints.

Line healthiness shall be ensured all the time. Painting shall be carried out on regular frequency.

86

Prepare a “Spill Control Procedure”. In case of leak/spill, evacuate area if necessary. Attend the repair with personal protection equipment’s

4 AS

WELL AS

Additional material

Not applicable

5 PART

OF

Diversion of flow

Not Applicable

6 OTHER


Not Applicable

7 REVER

SE Reverse Flow

Nor Applicable

87

OCTYL SALICYLATE

88

Date : November 2014 Plant : OCTYL SALICYLATE P & I D/ EQUIPMENT NO.:- Unit/Section : R 901 Node/Pipeline No. :- Charging of 2Ethyl Hexanol

SR. NO.

GUIDE WORD



1 NONE No flow

No level in tank Delay in operation ---- Ensure required level of 2- Ethyl Hexanol is available in tank




Line rupture Major spillage Personal injury Line healthiness is

ensured. Line healthiness shall be ensured all the time. Painting shall be carried out on regular frequency. Prepare a “Spill Control Procedure”. In case of leak/spill, evacuate area if necessary.

89

Attend the repair with personal protection equipment’s




3 LESS



operation



Less feed to reactor. Personal Injury.

Line healthiness is ensured. Flange guards are provided on flange joints.

Line healthiness shall be ensured all the time. Painting shall be carried out on regular frequency. Prepare a “Spill Control Procedure”. In case of leak/spill, evacuate area if necessary. Attend the repair with personal protection equipment’s

90

4 AS WELL AS

Additional material

Not applicable

5 PART

OF

Diversion of flow

Not Applicable

6 OTHER


Not Applicable

7 REVER

SE Reverse Flow

Nor Applicable

91

Date : November 2014 Plant : OCTYL SALICYLATE P & I D/ EQUIPMENT NO.:- Unit/Section : R 901 Node/Pipeline No. :- Charging Salicylic Acid

SR. NO.

GUIDE WORD



1 NONE No flow








4 AS WELL







92

5 PART OF Diversion of flow

Not Applicable

6 OTHER







7 REVERSE Reverse

Flow

Nor Applicable

93

Date : November 2014 Plant : OCTYL SALICYLATE P & I D/ EQUIPMENT NO.:- Unit/Section : R 803/4 Node/Pipeline No. :- Addition of Sodium Bi Sulphate

SR. NO.

GUIDE WORD



1 NONE No flow

Not Applicable ---- ----- Manual Addition as per Batch sheet. Ensure valve is in open condition.







4 AS WELL







94

5 PART OF Diversion of flow

Not Applicable

6 OTHER







7 REVERSE Reverse

Flow

Nor Applicable

95

Date : November 2014 Plant : OCTYL SALICYLATE P & I D/ EQUIPMENT NO.:- Unit/Section : R 803/4 Node/Pipeline No. :- Addition of Sodium Bicarbonate for pH adjustment

SR. NO.

GUIDE WORD



1 NONE No flow

Not Applicable ---- ----- Manual Addition as per Batch sheet. Ensure valve is in open condition.







4 AS WELL


Addition of other material alongwithdesired

Quality issues, cross contamination,

Quality issues, cross contamination,


SOP & Batch sheet shall be followed strictly.

96

unintended reaction unintended reaction


5 PART OF Diversion

of flow

Not Applicable

6 OTHER







7 REVERSE Reverse

Flow

Nor Applicable

97

Date : November 2014 Plant : OCTYL SALICYLATE P & I D/ EQUIPMENT NO.:- Unit/Section : R 902 Node/Pipeline No. :- Recovery of 2 Ethyl Hexanol by applying vaccum

SR. NO.

GUIDE WORD



1 NONE No flow

Vaccum issue Valves on the line closed in error. Line rupture, vaccum drop.

Delay in operation ---- Gauge provided Operational Vigilance.

Delay in operation ---- ----- Operational Vigilance.

Preventive maintenance of valves shall be carried out.

Material spillage ---- Line healthiness is


2 MORE More Flow More flow No issues

---- --- ---

98

3 LESS OF Less flow Valves on the line partially closed.



Vaccum drop / Leaks in the line (from pipeline or flanges)


---- Vaccum system & Line healthiness is ensured.

Line healthiness shall be ensured all the time. Required vaccum shall be ensured.

4 AS WELL


Not applicable ---- ---- ---- ----


flow Carry over to vaccum system

Vaccum system problem

Less yield Gauge provided Operational Vigilance.

6 OTHER


Not Applicable ---- ---- ---- ----

7 REVERSE Reverse

Flow

Nor Applicable ---- ---- ---- ----

99

GENERAL RECOMMEDATIONS

Considering the possibilities of human error and / or equipment failure. The possibilities of occurring unsafe condition cannot be ruled out and hence utmost concentration should be put on the operators and supervisors to see that the conditions elaborated in the HAZOP report do not acquire and in case it happens so, the remedial measures mentioned in the above report are immediately taken to avoid the emergency/dangerous occurrence. In order to avoid the causes mentioned in HAZOP REPORT, periodic checking and testing of safety measures and the equipment involved in manufacturing process must be adhered to for effecting total reliability of safety measures and the equipment. SOP should be prepared for critical operations and it should be known all. Essential PPE,s shall be provided to employees and supervisor should ensure that they are using the same. Regular training programs and refresher courses for the operators/supervisors and contract employees should be arranged periodically. Colour coding boards of pipe lines shall be displayed at various locations & identification boards /plates shall be displayed on equipments. All flange joints shall be properly bonded, all tanks, equipments, electrical motors shall be properly earthed. All sources of ignitions shall be identified for their control. Storage /stacking of various packing material should be as per recommended condition. All leaking containers shall be isolated & stored separately. Proper type of fire fighting media shall be made available nearby.Company is having DCP & Mechanical Foam fire extinguishers, these fire fightingequipments should be always maintained in good condition. Operation of these fire equipments should be known to everybody. Node wise important and critical recommendations are recorded in an executive summary.

100

Annexure 3: Environment Management Plan

EMP for Construction Phase

Sr. No.

Impact Potential Impact Mitigation Measures Proposed

1. Air Generation of dust, CO2, SOX, NOX

(Short term for a period of 6 months and Local)

Covering of construction material with sheets while transportation and storage.

Use of water sprinklers. Personal protective equipment

for labors. Project site is inside the

existing industrial complex. No impact on general public.

2. Noise and vibration Increase in the noise levels due to movement of vehicles and construction activities.

Vibration due to movement of vehicles and construction activities. (Short term for a period of 6 months and Local)

Proper service and maintenance of machines and vehicles to control noise.

Personal protective equipments for labors.

The impact due to vibration will be insignificant.

Project site is inside the existing industrial complex. No impact on general public.

3. Water Water pollution due to disposal of sewage will be curtailed with the existing effluent treatment plant. (Short term, Minor, Local)

Proper sanitation facilities in the construction site.

Treatment of sewage in existing ETP having a capacity of 115 KLD within premises. This is a design capacity for 231 persons. Presently only 181 people are using the facility.

4. Land Removal of top soil and change in soil quality.

Soil pollution due to discharge of sewage and solid waste onto land will be curtailed with the existing effluent treatment plant.

Use of removed soil for landscaping purposes, improving aesthetics.

Sanitation facilities in the construction site as well as labor camps.

Treatment and disposal of sewage and solid waste as per MPCB guidelines.

101

No change in land use pattern as project site is inside the existing industrial complex. (Minor and Local)

5. Biological Flora Fauna

Disturbance due to increase in noise. (Short term, Minor and Local)

Green belt development

6. Socio- economic Employment of construction workers (Direct, Positive)

People from nearby villages will be employed.

7. Occupational health

and safety Auditory ailment due

to noise will be prevented.

Dust emission (Short term, Minor and Local)

The use of personal protective equipments will be made stringent.

Water sprinkling system for dust generating area.

Anti honking policy in site premises conveyed to all contractors.

Non Conforming contractors will be penalized

Ear plugs to all workers working on noisy machineries.

Acoustic Enclosure for DG set Separation of Noisy Machinery

activity from nearby residential area/ barricading the same

EMP for Operation Phase

Environment Activity

proposed Potential Impact Mitigation Measures

Proposed AIR Increase in the air

pollutant concentration will be addressed using cyclonic separators and venture scrubbers.

Dust generation possibility is minimum as raw materials handled are liquids and product will be bugged in the

Use of Separators and scrubbers to control dust and fugitive emissions within the limits of MPCB regulations.

Personal Protective Equipments for Labours.

Strict Implementation of Hazardous waste Rules Act 1989, While storage/Handling/transportation of hazardous substances.

Regular monitoring of

102

existing bugging plant. (direct, Local, Sustainable)

emissions, provide high efficiency scrubbers.

NOISE AND VIBRATION

Increase in the noise levels will be minimized by using Equipments with noise level below 80db.

Vibration during operation of manufacturing unit.

Equipments with noise level below 80db only will be used.

Personal protective equipment for Employees like anti vibration gloves and ear plugs.

Project site is inside the existing industrial complex. No impact on general public.

Proper service and maintenance of machines to control noise.

By selecting low prone equipment.

By isolating the noise prone unit from the working personnel’s continuous exposure.

Noise level should be reduced by using absorbing materials at roofs tops and floors.

WATER Insignificant on groundwater.

Degradation of quality due to discharge of sewage and untreated water will be prevented.

Discharge of effluent from the manufacturing unit.

(Indirect, Negative, Minor, Local, sustainable)

Proper sanitation activities at construction site.

Treatment of sewage in existing ETP within premises.

ETP treated effluent will be in RO & MEE.

STP is proposed to treat sewage & treated water will be used for gardening.

LAND Pollution due discharge of sewage will be prevented.

Dust generation possibilities are minimum as the raw material handled are liquid and products will be bagged in existing bagging plant.

Proper sanitation activities at construction site.

Proper treatment and disposal of sewage and solid waste to CETP as per the guidelines of MPCB in existing ETP having a capacity of 115 KLD. This includes capacity for industrial and domestic effluents upto 181 persons. Presently 231 persons are

103

working in the complex. BIOLOGICAL FLORA FAUNA

Disturbance due to increase in noise. (Minor, Direct, Local, Sustainable)

Operational activities of heavy machines and transportation only in daytime.

Green Belt Development. Plantation of 102 trees on site to reduce pollution.

SOCIO-ECONOMIC

Employment to local people, (Positive, local)

People from the local area to be employed as far as possible.

OCCUPATIONAL HEALTH AND SAFETY.

Auditory ailment due to noise generated from the production unit will be minimized by using Equipments with noise level below 80db.

Wearing of personal protective equipments like gas masks, ear muffs etc will be strictly enforced.

Training/awareness programme about the handling/storage/transportation of hazardous materials.

Sign boards showing the hazardous nature and the method of handling near storage or handling area of all the hazardous materials.

First aid training for chemical or fire hazard related accidents.

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