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EIA/EMP Report for Expansion of M/s UPL Ltd. (Unit#10) MIDC,
Notified Industrial Estate, Tarapur, Boisar, Dist. Palghar, Maharashtra
Shivalik Solid Waste Management Ltd. 7 - 1
RISK ASSESSMENT
7.1 Introduction
UPL Limited, Unit#10 is engaged in manufacturing of various Technical
Grade Pesticides, intermediates chemicals and pesticide formulation
products. The existing unit was established and operated by M/s Punjab
Chemicals & Crop Protection Limited and obtained environmental clearance
for expansion from Ministry of Environment, Forest and Climate Change
vide letter no F. No. J-11011/712/2007-IA II (I) dated 15 April 2008. The
existing unit was taken over by UPL Limited on 14 March 2014
7.2 Storage of Hazardous Chemicals at the Plant
UPL will store and handle numbers of hazardous chemicals at the existing
plant and after expansion. Details of hazardous chemical name, physical
state, storage made, requirement and maximum storage are given in Table
7.1. The UPL has taken necessary safety measures at the plant as per
Manufacture, Storage and Import of Hazardous Chemical (Amendment)
Rules, 2000.
Table 7.1: Details of Storage of Hazardous Chemicals
Sr No
Hazardous
Chemical Name
Physical State
Storage mode Requirement
Maximum
Storage
Capacity
Tank /Drum /Bag MTM MT or KL
1 1,4 Dioxane Liquid 250 kg HDPE/MS Drum
73 8
2 2-Coumaranone Solid 250 kg HDPE/MS
Drum
90 10
3 2-Cyno Phenol Solid 250 kg HDPE/MS
Drum
53 7
4 2-ethyl Hexanol Liquid 120 kg Drum 7 0.84
5 3 Chloro 2,2 Dimethyl
propanoyl Chloride
Liquid 250 kg HDPE/
MS Drum
182.20 10
6. 4,6 Dimethoxy
pyrimidine 2 Amine
Liquid 25 kg Drum 24.7 2.65
7. 4,6 DCP Liquid 250 kg HDPE/MS
Drum
97.47 12
EIA/EMP Report for Expansion of M/s UPL Ltd. (Unit#10) MIDC,
Notified Industrial Estate, Tarapur, Boisar, Dist. Palghar, Maharashtra
Shivalik Solid Waste Management Ltd. 7 - 2
Sr No
Hazardous
Chemical Name
Physical
State Storage mode Requir
ement Maximum
Storage
Capacity
Tank /Drum /Bag MTM MT or KL
8. 4 methoxy 6 Methyl 2
Amino 1,3,5 triazine
Liquid 25 kg Fiber drum 21 2.25
9 Acetic Anhydrous Solid 500 kg HDPE jumbo
bag
420 45
10 Acetic Anhydride Solid 250 kg HDPE/MS
Drum
195 22
11 Acetonitrile Liquid 250 kg HDPE/MS
Drum
89 10
12 Ammonia Gas 900 kg Tonner 118 13.5
13 Asulam Technical Solid 500 kg HDPE jumbo
bag
919.12 100
14 ASAM Solid 50 Kg bag 9.03 3
15 Bromine Liquid Glassline Tank 89.1 6.3
16 Carbon di sulphide Liquid ISO Tank 322.2 35
17 Caustic flakes Solid 25 kg Poly liner Bag 451.6 48.4
18 Caustic Soda lye Liquid 35 KL Tank 300 35
19 Chloral Liquid 250 kg HDPE/MS
Drum
69 7.5
20 Chlorine Gas 900 kg Tonner 1020.4 109.8
21 Di Ethyl Amine Liquid 250 kg HDPE/MS
Drum
75 8.25
22 Di Methyl carbonate
(DMC)
Liquid 250 kg HDPE/MS
Drum
147.2 16
23 Dimethyl Formamide Liquid 250 kg HDPE/MS
Drum
22 3
24 Di Methyl
Phosphorous Amido
thioate (DMPAT)
Liquid 80 KL Tank 674 80
25 Di Methyl Sulphate Liquid 250 kg HDPE/MS
Drum
82 9
26 Ethyl Mercaptan Liquid 250 kg HDPE/MS
Drum
6.83 3
27 Ethyl Acetate Liquid 250 kg HDPE/MS
Drum
109 11.75
28 Ethyl 1 methyl 5
sulfamoyl 1, 1 H-
Liquid 250 kg HDPE/MS
Drum
30 5
EIA/EMP Report for Expansion of M/s UPL Ltd. (Unit#10) MIDC,
Notified Industrial Estate, Tarapur, Boisar, Dist. Palghar, Maharashtra
Shivalik Solid Waste Management Ltd. 7 - 3
Sr No
Hazardous
Chemical Name
Physical
State Storage mode Requir
ement Maximum
Storage
Capacity
Tank /Drum /Bag MTM MT or KL
pyrozole -4
carboxylate
29 Formaldehyde Liquid 250 kg HDPE/MS
Drum
78 8.5
30 Glyphosate technical Solid 25 kg HDPE Bag 57.6 6.17
31 Hydrochloric Acid Liquid Tank 129 14
32 Hydrochloric Acid
36%
Liquid 250 kg HDPE/MS
Drum
60 6.5
33 Hexane Liquid 250 kg HDPE/MS
Drum
5 0.75
34 Hydrazide hydrate Solid 25 kg HDPE Bag 450 48.22
35 Hydroxylamine
Hydrochloride
Solid 25 kg HDPE Bag 10 1.07
36 Hyflow powder Solid 25 kg HDPE Bag 1.5 0.17
37 Iso Propyl Alcohol Liquid 250 kg HDPE/MS
Drum
34 4
38 Liquor Ammonia Liquid 60 KLTank 489 60
39 Methanol Liquid 40 KLTank 227 30 (5 KL
above
ground &
25 KL
undergroun
d)
40 Methyl-2-{Isocyanate
sulfamoyl} Methyl }
Benzoate
Liquid 250 kg HDPE/MS
Drum
31 3.35
41 Methylene Di chloride Liquid 250 kg HDPE/MS
Drum
95.45 12
42 Methane Sulfuric Acid Solid 25 kg HDPE Bag 5 1
43 Metribuzine Technical Solid 500 kg HDPE jumbo
bag
464.5 50
44 Mono Iso Propyl
Amine
Liquid 250 kg HDPE/MS
Drum
29 3.25
45 N,N Dimethyl Aniline Liquid 250 kg HDPE/MS
Drum
30 3.25
46 O- chloro
Benzylchloride
Liquid 250 kg HDPE/MS
Drum
35 3.75
EIA/EMP Report for Expansion of M/s UPL Ltd. (Unit#10) MIDC,
Notified Industrial Estate, Tarapur, Boisar, Dist. Palghar, Maharashtra
Shivalik Solid Waste Management Ltd. 7 - 4
Sr No
Hazardous
Chemical Name
Physical
State Storage mode Requir
ement Maximum
Storage
Capacity
Tank /Drum /Bag MTM MT or KL
47 Oxygen Gas 50 kg Tonner 12.5 0.5
48 Phenol Liquid 250 kg HDPE/MS
Drum
194 21
49 Phosphorous Solid 250 kg MS Drum 97 13
50 Phosphorous Acid Liquid 250 kg HDPE/MS
Drum
21.15 2.5
51 Potassium Hydroxide Solid 50 kg HDPE jumbo bag 34.85 9
52 Phosphorous
Trichloride
Liquid 50 KL Tank 452 50
53 Pinacolone Liquid 40 KL Tank 366 40
54 Sodium Bisulphate Solid 25 kg HDPE Bag 9 1
55 Sodium Bromide solid Solid 500 kg HDPE jumbo
bag
89.1 10
56 Sodium Carbonate Solid 25 kg HDPE Bag 10 1.07
57 Sodium Hydride Solid 25 kg HDPE Bag 4.42 0.475
58 Sodium Hypochloride Liquid 300 KL Tank 2700 300
59 Sodium Methoxide Solid 25 kg HDPE Bag 88.4 10
60 Spent HCL Liquid 30 KL Tank 262 30
61 spent Sulphuric Acid Liquid 90 KL Tank 752 90
62 Sulfamoyl Isocyanate Solid 25 kg HDPE Bag 31 5
63 Sulfanilamid Liquid 250 kg HDPE/MS
Drum
282 30.25
64 Sulphur Solid 50 kg bag 19.8 15
65 Sulphuric Acid Liquid 65 KL Tank 560.13 65
66 Tri Methyl Phosphite Liquid 250 kg MS Drum 57 6.25
67 Triazinone Solid 500 kg HDPE jumbo
bag
588 63
68 White Phosphorous Solid 250 kg MS Drum 97 10.5
69 Bromine Liquid Tank 89 18
70 Sulphur Solid Bag-25 kg 20 5
71 Ethyl Hexanol Liquid 250 kg MS Drum 4 2
72 3Chloro-2,2-
Dimethylpropanoyl
Chloride
Liquid 250 kg HDPE Drum 182 20
73 Hydroxylamine
Sulphate
Solid Bag-25 kg 125.2 6
EIA/EMP Report for Expansion of M/s UPL Ltd. (Unit#10) MIDC,
Notified Industrial Estate, Tarapur, Boisar, Dist. Palghar, Maharashtra
Shivalik Solid Waste Management Ltd. 7 - 5
Sr No
Hazardous
Chemical Name
Physical
State Storage mode Requir
ement Maximum
Storage
Capacity
Tank /Drum /Bag MTM MT or KL
74 Thionyl Chloride
(SOCL2)/HCL
Liquid Tanker 9.8 6.3
75 2-Chloro
Benzylchloride
(OCBC)
Liquid 250 kg HDPE Drum 140 10
76 Alpha CPC Solid Bag-50 kg 59.6 30
77 DEA Liquid Tank 39.1 20
78 Toluene Liquid Tank 277.3 140
79 EDTA (50%) Solid Bag 0.2 0.2
80 Naphthol Solid Bag 60.2 30
81 Sodium Bicarbonate Solid Bag 90.9 45
82 PCl3 Liquid Tank 68.25 35
83 Hyflow Powder Solid Bag 1.5 0.75
84 4, 6- Dimethoxy
pyrimidine -2- Amine
Liquid Tank 20.9 10
85 Xylene Liquid Tank 1.75 1
86 Methyl-2-
{[Isocyanate
sulfamoyl] Methyl}
Benzoate
Liquid Tank 31 15
EIA/EMP Report for Expansion of M/s UPL Ltd. (Unit#10) MIDC,
Notified Industrial Estate, Tarapur, Boisar, Dist. Palghar, Maharashtra
Shivalik Solid Waste Management Ltd. 7 - 6
7.3 Hazard Identification
Hazard is defined as a chemical or physical condition that has the potential
for causing damage to people, property and/or the environment. Hazard
identification is the first step in the quantitative risk analysis and entails the
process of collecting information on:
• The types and quantities of hazardous substances stored, handled and
disposed in the location;
• The location of storage tanks & other facilities.
• Potential hazards associated with the spillage and release of hazardous
chemicals.
The starting point of the quantitative risk analysis study is the identification
of hazards and selection of scenarios that are then addressed for further
analysis.
7.3.1 Hazardous Materials Stored at the Plant
The plant is engaged in handling and storage of various flammable and
toxic hazardous materials. Details of hazardous materials, physical state,
physical and fire and toxicity properties of hazardous materials are given in
Table 7.2. Hazardous characteristic, storage mode and type of hazards
(as per NFPA) of the hazardous materials at the plant are given in Table
7.3.
7.3.2 Bulk Storage of Hazardous Materials
At the existing plant, some hazardous materials are stored in bulk quantity
in tanks and tonners while other hazardous materials are stored in HDPE/MS
tank, fibber drum and bags. Storage tank nos., type of storage (above or
underground storage), diameter and height of tanks, storage conditions,
dyke around tank farm and safety measures are described in Table 7.4.
EIA/EMP Report for Expansion of M/s UPL Ltd. (Unit#10) MIDC,
Notified Industrial Estate, Tarapur, Boisar, Dist. Palghar, Maharashtra
Shivalik Solid Waste Management Ltd. 7 - 7
7.3.3 Hazardous Conditions An accidental release of hazardous materials from barrels, cylinders,
tonners or tanks or piping would result in formation of fixed or spreading
pool. In case of immediate ignition of flammable hazardous materials, a
pool fire will result, while delayed ignition may result in explosion or flash
fire, if quantity of explosive mass is sufficient and some confinement is
present.
7.4 Accidental Release Scenarios for Consequence Analysis
The existing pesticides plant is dealing with many hazardous chemicals as
described above. Most of hazardous chemicals are flammable in nature and
may create threat to life and property in the event of spillage. Dykes have
been provided around the tanks for full containment. Subsequently, their
consequence will be confined within short distances in the form of thermal
radiation. In the event of release of toxic gases consequence may be off
site as toxic cloud will be moved towards wind direction. Accidental release
scenarios have been selected for consequence analysis. For selection of
maximum credible accident scenarios following methodology have been
adopted:
EIA/EMP Report for Expansion of M/s UPL Ltd. (Unit#10) MIDC, Notified Industrial Estate, Tarapur, Boisar,
Dist. Palghar, Maharashtra
Shivalik Solid Waste Management Ltd. 7 - 8
Table 7.2: Physical State, Physical and Fire and Toxicity Properties of Hazardous Materials
Sn. Hazardous
Materials
CAS
Numbers
Physical
State
Physical and Fire Hazard
Properties
Toxicity Sp
gr.
V.D.
B.P.
(˚C)
F.P.
(oC)
LEL
%
UEL
%
Auto.
Temp.
˚C
LC-50
(Inhl)
mg/l
LD-50
(O)
mg/kg
LD-50
(D)
mg/kg
1 1,4 Dioxane 123-91-1 Liquid 101.1 18.3 2 22 180 37000 NA 2000 1.0337 3.3
2 2-Coumaranone 553-86-6 Solid 249 112 NA NA NA NA NA NA NA NA
3 2-Cyno Phenol 611-20-1 Solid 149 NA NA NA NA NA NA NA NA NA
4 2-ethyl Hexanol 104-76-7 Liquid 186 75 0.88 9.7 288 234 1180 NA 1.83 4.49
5 3 Chloro 2,2 Dimethyl
Propanoyl Chloride
4300-97-4 Liquid 86 63 NA NA NA NA NA NA 1.19 5.35
6 4,6 Dimethoxy
Pyrimidine 2 Amine
36315-01-2 Solid 276 NA NA NA NA NA NA NA 1.43 NA
7 4,6 DCP 120-83-2 Solid 210 114 NA NA NA NA NA NA 1.40 5.62
8 4 methoxy 6 Methyl 2
Amino 1,3,5 triazine
1668-54-8 Liquid 329 153 NA NA NA NA NA NA 1.322 NA
9 Acetic Anhydride 64-19-7 Liquid 140 49 2.7 10.3 332 1000 1780 4 1.08 3.52
10 Acetonitrile 75-05-8 Liquid 81.6 2 4.4 16 524 5.1 2460 1250 0.79 1.4
11 Ammonia 7664-41-7 Gas -2.2 NA 16 25 651 NA 350 NA 0.9 0.59
12 Asulam Technical 2302-17-2 Solid 104 NA NA NA NA NA NA NA 1.18 NA
13 ASAM 112566-17-3 Solid NA NA NA NA NA NA NA NA NA NA
14 Bromine 7726-95-6 Liquid 58.8 NA NA NA NA NA 3100 NA 3.11 7.1
15 Carbon Di Sulphide 75-15-0 Liquid 46.3 -32 1.3 50 90 NA 3188 NA 1.263 2.63
16 Caustic flakes 1310-73-2 Solid 1388 NA NA NA NA NA NA NA 2.13 NA
17 Caustic Soda lye 1310-73-2 Liquid 145 NA NA NA NA NA NA NA 1.53 NA
EIA/EMP Report for Expansion of M/s UPL Ltd. (Unit#10) MIDC, Notified Industrial Estate, Tarapur, Boisar,
Dist. Palghar, Maharashtra
Shivalik Solid Waste Management Ltd. 7 - 9
Sn. Hazardous
Materials
CAS
Numbers
Physical
State
Physical and Fire Hazard
Properties
Toxicity Sp
gr.
V.D.
B.P.
(˚C)
F.P.
(oC)
LEL
%
UEL
%
Auto.
Temp.
˚C
LC-50
(Inhl)
mg/l
LD-50
(O)
mg/kg
LD-50
(D)
mg/kg
18 Chloral 7681-52-9 Liquid 96 57 NA NA NA NA 479 3030 1.9081 NA
19 Chlorine 7782-50-5 Gas NA NA NA NA NA 293 NA NA 1.47 2.49
20 Di Ethyl Amine 111-42-2 Liquid 55.5 -18 1.8 10.1 312 NA 540 820 0.71 2.5
21 Di Methyl Carbonate
(DMC) 616-38-6
Liquid 90 22 4.22 12.87 NA NA 6000 5000 1.0636 3.1
22 Dimethyl Formamide 68-12-2 Liquid 153 58 2.2 15.2 445 NA 2800 4720 0.949 2.7
23 Di Methyl Phosphorous
Amido thioate 10265-92-6
Liquid 162 52 NA NA NA NA 410 4360 1.283 NA
24 Di Methyl Sulphate 77-78-1 Liquid 188 83.3 NA NA 495 NA 140 NA 1.33 4.35
25 Ethyl Mercaptan 75-08-1 Liquid 35 4.83 2.8 18.2 299 NA 1034 NA 0.84 2.14
26 Ethyl Acetate 141-78-6 Liquid 77 7.2 2.2 7 427 NA 5620 NA 0.902 3.04
27 Ethyl Hexanol 104-76-7 Liquid 184 73.3 NA NA NA NA 3,290
mg/kg
LC50
(Rat):
1.2mg/l
0.08 NA
28 Ethyl 1 methyl 5
Sulfamoyl 1, 1 H-
pyrazole -4
carboxylate
88398-81-6 Solid NA NA NA NA NA NA NA NA NA NA
29 Formaldehyde 50-00-0 Liquid 96 60 7 73 300 0.203 100 NA 1.08 1.04
30 Glyphosate technical 1071-83-6 Solid NA NA NA NA NA 1500 5000 2000 1.705 NA
31 Hydrochloric Acid 7647-01-0 Liquid 108 NA NA NA NA 3124 900 NA 1.19 1.267
EIA/EMP Report for Expansion of M/s UPL Ltd. (Unit#10) MIDC, Notified Industrial Estate, Tarapur, Boisar,
Dist. Palghar, Maharashtra
Shivalik Solid Waste Management Ltd. 7 - 10
Sn. Hazardous
Materials
CAS
Numbers
Physical
State
Physical and Fire Hazard
Properties
Toxicity Sp
gr.
V.D.
B.P.
(˚C)
F.P.
(oC)
LEL
%
UEL
%
Auto.
Temp.
˚C
LC-50
(Inhl)
mg/l
LD-50
(O)
mg/kg
LD-50
(D)
mg/kg
32 Hydrochloric Acid 36% 7647-01-0 Liquid 108 NA NA NA NA NA NA NA 1.1 NA
33 Hexane 110-54-3 Liquid 68 -23 1.2 7.7 224 NA 28710 NA 0.66 3.0
34 Hydrazide Hydrate 7803-57-8 Solid 113.5 72 NA NA NA NA NA NA 1.1 NA
35 Hydroxylamine
Hydrochloride 5470-11-1
Solid NA 152 NA NA NA NA 141 NA 1.67 NA
36 Hyflow Powder 61790-53-2 Solid 2230 NA NA NA NA NA 500 NA 2.35 NA
37 Iso Propyl Alcohol 67-63-0 Liquid 82 12 1.2 12.7 399 16000 5045 12800 0.79 2.1
38 Liquor Ammonia 1336-21-6 Liquid -2.2 NA 16 25 651 NA 350 NA 0.9 0.59
39 Methanol 67-56-1 Liquid 64.5 12 6 36 464 64000 5628 NA 0.8 1.1
40 Methyl-2-{Isocyanate
Sulfamoyl} methyl}
Benzoate
93-58-3 Liquid 199 82 NA NA NA NA 1177 NA 1.04 4.7
41 Methylene Di chloride 75-09-2 Liquid 39.8 NA 12 19 556 NA 1600 NA 1.33 2.39
42 Methane Sulfonic Acid 75-75-2 Liquid 100 NA NA NA NA NA 1429 NA 1.2 3.31
43 Metribuzin Technical 21087-64-9 Solid NA NA NA NA NA 0.65 700 20000 1.29 NA
44 Mono Iso Propyl Amine 75-31-0 Liquid 33.5 -15 2 10.4 402 NA 111 380 0.694 2.04
45 N,N Dimethyl Aniline 121-69-7 Liquid 55.5 -18 1.8 10.1 312 NA 540 820 0.71 2.03
46 O- chloro
Benzylchloride 611-19-8
Liquid 416 180 NA NA NA NA 1140
NA 1.274 5.5
47 Oxygen 7782-44-7 Gas 100 NA NA NA NA NA NA 2500 1.13 0.62
48 Phenol 108-95-2 Liquid 182 79 1.7 8.6 715 630 317 669 1.057 3.25
EIA/EMP Report for Expansion of M/s UPL Ltd. (Unit#10) MIDC, Notified Industrial Estate, Tarapur, Boisar,
Dist. Palghar, Maharashtra
Shivalik Solid Waste Management Ltd. 7 - 11
Sn. Hazardous
Materials
CAS
Numbers
Physical
State
Physical and Fire Hazard
Properties
Toxicity Sp
gr.
V.D.
B.P.
(˚C)
F.P.
(oC)
LEL
%
UEL
%
Auto.
Temp.
˚C
LC-50
(Inhl)
mg/l
LD-50
(O)
mg/kg
LD-50
(D)
mg/kg
49 Phosphorous 7323-14-0 Solid NA NA NA NA 260 NA NA NA 2.36 NA
50 Phosphorous Acid 13598-36-2 Liquid 158 NA NA NA NA NA 1530 2740 1.685 3.4
51 Potassium Hydroxide 1310-58-3 Solid 1320 NA NA NA NA NA 273 NA 2.04 NA
52 Phosphorous
Trichloride 7719-12-2
Liquid 76 NA NA NA NA NA 18 NA 1.574 4.75
53 Pinacolone 75-97-8 Liquid 106.2 23 NA NA NA NA 610 NA 0.725 NA
54 Sodium Bisulphate 7681-38-1 Solid NA NA NA NA NA NA 2800 NA 2.435 NA
55 Sodium Bromide Solid 7647-15-6 Solid 1390 NA NA NA NA NA 3500 NA 3.21 NA
56 Sodium Carbonate 497-19-8 Solid NA NA NA NA NA NA 4090 NA 2.53 NA
57 Sodium Hydride 7646-69-7 Solid 360 NA NA NA 229 NA NA NA 0.89 NA
58 Sodium Hypochlorite 7681-52-9 Liquid 40 NA NA NA 230 NA 5800 NA 1.07 0.62
59 Sodium Methoxide 124-41-4 Solid 126 33 7.3 36 88 NA 2037 NA 1.1 1.1
60 Spent HCL 7647-01-0 Liquid 108 NA NA NA NA NA NA NA 1.1 NA
61 Spent Sulphuric Acid 7664-93-9 Liquid 270 NA NA NA NA NA 2140 NA 1.84 3.4
62 Sulfamoyl Isocyanate 15804-29-2 Solid NA NA NA NA NA NA NA NA NA NA
63 Sulfanilamide 15804-29-2 Liquid NA NA NA NA NA NA 3900 NA 1.08 NA
64 Sulphur 63-74-1 Solid 445 188 NA NA 248 NA 5050 2020 2.07 8.8
65 Sulphuric Acid 7704-34-9 Liquid 290 NA NA NA NA NA 2140 NA 1.84 3.4
66 Tri Methyl Phosphite 7664-93-9 Liquid 112 27 5.2 61.2 250 32700 4280 2600 1.052 NA
67 Triazinone 121-45-9 Solid NA NA NA NA NA NA 1724 5000 NA NA
EIA/EMP Report for Expansion of M/s UPL Ltd. (Unit#10) MIDC, Notified Industrial Estate, Tarapur, Boisar,
Dist. Palghar, Maharashtra
Shivalik Solid Waste Management Ltd. 7 - 12
Sn. Hazardous
Materials
CAS
Numbers
Physical
State
Physical and Fire Hazard
Properties
Toxicity Sp
gr.
V.D.
B.P.
(˚C)
F.P.
(oC)
LEL
%
UEL
%
Auto.
Temp.
˚C
LC-50
(Inhl)
mg/l
LD-50
(O)
mg/kg
LD-50
(D)
mg/kg
68 White Phosphorous 21087-64-9 Solid NA NA NA NA 30 3.03 4.3 100 1.83 4.66
69 Hydroxylamine
Sulphate 10039-54-0
Solid NA NA NA NA NA NA NA NA 1.67 NA
70 Thionyl Chloride
(SOCl2)/HCL 7719-09-7
Liquid 76 NA NA NA NA NA NA NA 1.64 4.1
71 2-Chloro
Benzylchloride (OCBC) 611-19-8
Liquid 214 82 NA NA NA NA NA NA 1.274 5.5
72 Alpha CPC 147-14-8 Solid NA NA NA NA NA NA NA NA 1.5 NA
73 Toluene 108-88-3 Liquid 111 7 3.3 19 422 49 636 16.3 0.86 3.14
74 EDTA (50%) 60-00-4 Solid NA NA NA NA NA NA 30 NA 0.72 NA
75 Naphthol 90-15-3
Solid 288 161 NA NA NA NA 1870 880
1.095
4 NA
76 Sodium Bicarbonate 144-55-8 Solid NA NA NA NA NA NA 3360 NA 2.159 NA
77 Xylene 1330-20-7 Liquid 138 24 1 7 464 NA 4300 1700 0.864 3.7
Note: B.P. : Boiling Point, F.P. Flash Point, LEL: Lower Explosive Limit, UEL: Upper Explosive Limit, Auto Temp: Auto Ignition Temperature, Sp.Gr:
Specific Gravity, V.D.: Vapour Density
EIA/EMP Report for Expansion of M/s UPL Ltd. (Unit#10) MIDC, Notified Industrial Estate, Tarapur, Boisar,
Dist. Palghar, Maharashtra
Shivalik Solid Waste Management Ltd. 7 - 13
Table 7.3: Hazardous Characteristic, Storage Mode and Type of Hazards (as per NFPA)
Sn. Hazardous Materials Storage Mode Hazardous Characteristic Type of Hazards [National Fire
Protection Association (U.S.A.)]
1 1,4 Dioxane HDPE/MS Drum Flammable Health: 2 Flammability: 3 Reactivity: 1
2 2-Coumaranone HDPE/MS Drum May be combustible at High
Temperature
Health: 2; Flammability: 1; Instability: 0
3 2-Cyno Phenol HDPE/MS Drum Non-flammable Health: 2; Flammability: 0; Reactivity: 0
4 2-ethyl Hexanol Drum Flammable Health: 2 Flammability: 2 Reactivity: 0
5 3 Chloro 2,2 Dimethyl Propanoyl
Chloride
HDPE/MS Drum Non-flammable Health: 2; Flammability: 0; Reactivity: 0
6 4,6 Dimethoxy Pyrimidine 2 Amine Drum Non-flammable Health: 1 Flammability: 0 Reactivity: 0
7 4 methoxy 6 Methyl 2 Amino 1,3,5
triazine
Fibber drum Non-flammable Health: 1 Flammability: 0 Reactivity: 0
8 Acetic Anhydride HDPE/MS Drum Flammable Health: 3 Flammability: 2 Reactivity: 1
9 Acetonitrile HDPE/MS Drum Flammable Health: 2 Flammability: 3 Reactivity: 0
10 Ammonia Tonner Toxic Health: 3 Flammability: 1 Reactivity: 0
11 Asulam Technical HDPE jumbo bag Non-flammable Health: 2; Flammability: 0; Reactivity: 0
12 Bromine Glassline Tank Non-flammable Health: 3 Flammability: 0 Reactivity: 0
13 Carbon Di Sulphide ISO Tank Flammable Health: 3 Flammability: 4 Reactivity: 0
14 Caustic flakes Polyliner Bag Non-flammable Health: 3; Flammability: 0, Reactivity 1
15 Caustic Soda lye Tank Non-flammable Health: 3; Flammability: 0, Reactivity 1
16 Chloral HDPE/MS Drum May be combustible at High
Temperature
Health: 2 Flammability: 1 Reactivity: 0
17 Chlorine Tonner Toxic Health: 0 Flammability: 0 Reactivity: 0
18 Di Ethyl Amine HDPE/MS Drum Flammable Health: 3 Flammability: 3 Reactivity: 0
19 Di Methyl Carbonate (DMC) HDPE/MS Drum Flammable Health: 1 Flammability: 3 Reactivity: 0
EIA/EMP Report for Expansion of M/s UPL Ltd. (Unit#10) MIDC, Notified Industrial Estate, Tarapur, Boisar,
Dist. Palghar, Maharashtra
Shivalik Solid Waste Management Ltd. 7 - 14
Sn. Hazardous Materials Storage Mode Hazardous Characteristic Type of Hazards [National Fire
Protection Association (U.S.A.)]
20 Dimethyl Formamide HDPE/MS Drum Flammable Health: 1 Flammability: 2 Reactivity: 0
21 Di Methyl Phosphorous Amido thioate
(DMPAT)
Tank Corrosive Health: 1 Flammability: 0 Reactivity: 0
22 Di Methyl Sulphate HDPE/MS Drum Combustible Health: 4 Flammability: 2 Reactivity: 0
23 Ethyl Mercaptan HDPE/MS Drum Flammable Health: 2 Flammability: 4 Reactivity: 0
24 Ethyl Acetate HDPE/MS Drum Flammable Health: 1 Flammability: 3 Reactivity: 0
25 Formaldehyde HDPE/MS Drum Flammable Health: 3 Flammability: 2 Reactivity: 0
26 Glyphosate technical HDPE Bag Non-flammable Health: 1 Flammability: 0 Reactivity: 0
27 Hydrochloric Acid Tanker Corrosive Health: 3 Flammability: 0 Reactivity: 1
28 Hydrochloric Acid 36% HDPE/MS Drum Corrosive Health: 2 Flammability: 0 Reactivity: 2
29 Hexane HDPE/MS Drum Flammable Health: 1 Flammability: 3 Reactivity: 0
30 Hydrazide Hydrate HDPE Bag Combustible Health: 1 Flammability: 1 Reactivity: 0
31 Hydroxylamine Hydrochloride HDPE Bag May be combustible at High
Temperature
Health: 3 Flammability: 1 Reactivity: 1
32 Hyflow Powder HDPE Bag Non-flammable Health: 2 Flammability: 0 Reactivity: 0
33 Iso Propyl Alcohol HDPE/MS Drum Flammable Health: 1 Flammability: 3 Reactivity: 0
34 Liquor Ammonia Tank Toxic Health: 3 Flammability: 0 Reactivity: 0
35 Methanol Tank Flammable Health: 1 Flammability: 3 Reactivity: 0
36 Methylene Di chloride HDPE/MS Drum May be combustible at High
Temperature
Health: 2 Flammability: 1 Reactivity: 0
37 Methane Sulfonic Acid HDPE/MS Drum Non-flammable Health: 3 Flammability: 0 Reactivity: 0
38 Metribuzin Technical HDPE jumbo bag Non-flammable Health: 1 Flammability: 0 Reactivity: 0
39 Mono Iso Propyl Amine HDPE/MS Drum Flammable Health: 3 Flammability: 4 Reactivity: 3
40 N,N Dimethyl Aniline HDPE/MS Drum Flammable Health: 3 Flammability: 4 Reactivity: 3
41 O- chloro Benzylchloride HDPE/MS Drum Toxic/Corrosive Health: 3 Flammability: 2 Reactivity: 0
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Sn. Hazardous Materials Storage Mode Hazardous Characteristic Type of Hazards [National Fire
Protection Association (U.S.A.)]
42 Oxygen Tonner Non-flammable Health: 2 Flammability: 0 Reactivity: 0
43 Phenol HDPE/MS Drum Flammable Health: 4 Flammability: 2 Reactivity: 0
44 Phosphorous MS Drum Flammable Health: 1 Flammability: 1 Reactivity: 1
45 Phosphorous Acid HDPE/MS Drum Highly corrosive Health: 3 Flammability: 0 Reactivity: 0
46 Potassium Hydroxide HDPE jumbo bag Non-flammable Health: 3 Flammability: 0 Reactivity: 1
47 Phosphorous Trichloride (PCl3) Tank Non-flammable Health: 4 Flammability: 0 Reactivity: 2
48 Pinacolone Tank Flammable Health: 2 Flammability: 3 Reactivity: 0
49 Sodium Bisulphate HDPE Bag Non-flammable Health: 3 Flammability: 0 Reactivity: 0
50 Sodium Bromide Solid HDPE jumbo bag Non-flammable Health: 2 Flammability: 0 Reactivity: 0
51 Sodium Carbonate HDPE Bag Non-flammable Health: 2 Flammability: 0 Reactivity: 1
52 Sodium Hydride HDPE Bag Flammable Health: 0 Flammability: 1 Reactivity: 0
53 Sodium Hypochlorite Tank Non-flammable Health: 1 Flammability: 0 Reactivity: 0
54 Sodium Methoxide HDPE Bag Flammable Health: 3 Flammability: 2 Reactivity: 2
55 Spent HCL Tank Corrosive Health: 2 Flammability: 0 Reactivity: 2
56 Spent Sulphuric Acid Tank Corrosive Health: 3 Flammability: 0 Reactivity: 2
57 Sulfanilamide HDPE/MS Drum May be combustible at High
Temperature
Health: 3 Flammability: 1 Reactivity: 0
58 Sulphur Bag Flammable Health: 1 Flammability: 1 Reactivity: 0
59 Sulphuric Acid Tank Corrosive Health: 3 Flammability: 0 Reactivity: 2
60 Tri Methyl Phosphite MS Drum Flammable Health: 2 Flammability: 3 Reactivity: 1
61 Triazinone HDPE jumbo bag Non-flammable Health: 0 Flammability: 3 Reactivity: 0
62 White Phosphorous MS Drum Spontaneously Flammable Health: 4 Flammability: 4 Reactivity: 2
63 Hydroxylamine Sulphate Bag May be combustible at High
Temperature
Health: 3 Flammability:1 Reactivity: 0
64 Thionyl Chloride (SOCl2)/HCL Tanker Non-flammable Health: 4 Flammability: 0 Reactivity: 2
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Sn. Hazardous Materials Storage Mode Hazardous Characteristic Type of Hazards [National Fire
Protection Association (U.S.A.)]
65 2-Chloro Benzylchloride (OCBC) HDPE Drum Toxic/Corrosive Health: 2 Flammability: 0 Reactivity: 0
66 Alpha CPC Bag May be combustible at High
Temperature
Health: 2 Flammability: 1 Reactivity: 0
67 Toluene Tanker Flammable Health: 2 Flammability: 3 Reactivity: 0
68 EDTA (50%) Bag May be combustible at High
Temperature
Health: 1 Flammability: 1 Reactivity: 0
69 Naphthol Bag May be combustible at High
Temperature
Health: 2 Flammability: 1 Reactivity: 0
70 Sodium Bicarbonate Bag Non-flammable Health: 1 Flammability: 0 Reactivity: 0
71 Xylene Tank Flammable Health: 2 Flammability: 3 Reactivity: 0
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Table 7.4: Details of Bulk Storage of Hazardous Materials
S
No.
Name of
Hazardous
Chemicals
Tank/Bulle
ts with Nos
Tank/Bullet
s/ Tonner
Types
(UG/AG)
Dia &
Height of
Tank
Storage
Conditions
(Pressure &
Temperature)
Dyke around
Tanks Farm
Safety Measure
already providing
1. Bromine
(Liquid)
ST-202(6.3
kl)
DT-202 A
(1 kl)
DT-202 B
(1 kl)
DT-202 C
(1 kl)
Tank (AG) S.T-202, D-
1763 mm
Horizontal
Height -
3205 mm
D.T-202,
A/B/C
D-1173 mm
Horizontal
Height -
1560 mm
Atmospheric
Pressure and
temperature
ST-202(6.3)-
9250Lx3920Wx250
H (mm)
1. PRS valve provided. 2. Safety signage. 3. SOP available. 4. Gas detector 5. SCBA set 6. Sodium thiosulphate
sprinkler system provided.
7. Scrubber system provided
2. Chlorine N.A Tonner
(Net weight:
900 kg)
N.A 8 to 10 kgs /
cm2,
atmospheric
temperature
1. Safety signage. 2. On site emergency
plan. 3. SOP available. 4. Gas detector. 5. Scrubber system
provided
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S
No.
Name of
Hazardous
Chemicals
Tank/Bulle
ts with Nos
Tank/Bullet
s/ Tonner
Types
(UG/AG)
Dia &
Height of
Tank
Storage
Conditions
(Pressure &
Temperature)
Dyke around
Tanks Farm
Safety Measure
already providing
3. 2-Ethyl
Hexanol
N.A Drum (Net
weight =170
kg)
N.A Atmospheric
Pressure and
temperature
Isolated storage area.
4. Methanol UGST-1(25
kl)
D.T-201(5
kl)
Tank(UG)
Tank(AG)
UGST – D-
2250 mm
Horizontal
Height
/Length-
6890 mm
DT-201 – D
–2005 mm
Height-
1950 mm
Atmospheric
Pressure and
temperature
UGST-
8700Lx4170W
(mm)
1. Isolated solvent yard. 2. Safety signage. 3. On site emergency
plan. 4. SOP available. 5. Fire hydrant system 6. Fire extinguisher
provided at nearest position.
7. Fire Bucket provided at nearest position
8. Cathodic protection & earthing to UGST-1
9. Double bonding provided for Earthing.
10. Earthing bonding provided to transferring line.
11. FLP system
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S
No.
Name of
Hazardous
Chemicals
Tank/Bulle
ts with Nos
Tank/Bullet
s/ Tonner
Types
(UG/AG)
Dia &
Height of
Tank
Storage
Conditions
(Pressure &
Temperature)
Dyke around
Tanks Farm
Safety Measure
already providing
5.
Spent Acid
(Sulphuric
Acid 50%)
Black Spiral
tank (90 kl) Tank (AG)
D- 2400 mm
Height-
4500 mm
Atmospheric
Pressure and
temperature
4880Lx3920Wx103
0H (mm)
Isolated storage area
with acid resistance dyke.
6. Caustic Soda
Lye (32%)
ST-203
(18.5 kl)
ST-204 (15
kl)
DT-203(3
kl)
Tank (AG)
ST-203-D-
2214 mm
HT.-4120
mm
ST-204.D-
2230 mm
Height-
5000 mm
DT.203 – D-
1513 mm
HT.-1870
mm
Atmospheric
Pressure and
temperature
11220Lx4970Wx98
0H (mm)
Isolated storage area
dyke.
7. Sulphur
(Powder) N.A 50 kg Bags N.A
Atmospheric
Pressure and
temperature
-`
Isolated Storage area
with fire hydrant & water
sprinkler.
8. Sodium
Bisulphite N.A 50 kg Bags N.A
Atmospheric
Pressure and
temperature
- Isolated Storage Area.
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S
No.
Name of
Hazardous
Chemicals
Tank/Bulle
ts with Nos
Tank/Bullet
s/ Tonner
Types
(UG/AG)
Dia &
Height of
Tank
Storage
Conditions
(Pressure &
Temperature)
Dyke around
Tanks Farm
Safety Measure
already providing
9. Sodium
Thiosulfate N.A 50 kg Bags N.A
Atmospheric
Pressure and
temperature
- Isolated Storage area.
10. Triazinone N.A 25 kg bags N.A
Atmospheric
Pressure and
temperature
- Isolated storage area.
11 Toluene Two Tanks
D- 5700 mm
HT.-6100
mm
Atmospheric
Pressure and
temperature
10.1Lx9.5Wx1.5H
Isolated Storage area
with fire hydrant with
dyke
12
Di Methyl
Phosphorous
Amido
thioate
DMPAT
One Tank
D- 2800 mm
HT.-4400
mm
Atmospheric
Pressure and
temperature
8.1Lx7.2wx1.5H Isolated Storage area
with dyke
13 Sodium
Hypochlorite One Tank
D- 6900 mm
HT.-9100
mm
Atmospheric
Pressure and
temperature
15.3Lx13.8wx1.5H Isolated storage area.
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7.4.1 Methodology for Selection of Accident Scenarios
The following steps have been followed for scenario selection for consequence
analysis:
• The hazardous materials handled at the plant and the associated hazards
were identified and assessed though materials safety data sheet.
• Operating and storage quantity, conditions of handling and storage of
hazardous materials were studied.
• An assessment was made of what inventories can get released accidentally.
7.4.2 Maximum Credible Scenarios for Consequence Analysis
At the plant, hazardous materials may be released due to loss of containment.
A leak can range in size from a pinhole leak to a catastrophic failure. In general,
smaller leaks have higher accident likelihood but lower consequence distances.
On the other hand, larger releases have lower accident likelihood but longer
consequence distance.
Criteria for Selection of Scenarios for Consequence Analysis: For
selection of maximum credible scenarios for consequence analysis for
quantitative risk assessment, the following criterion were considered:
• Hazardous chemicals which are highly flammable and flammable have been
selected for consequence calculations.
• Hazardous chemicals which are toxic gas and have potential to disperse as
toxic cloud have been used for consequence calculations.
Remaining hazardous chemicals, which are only combustible, non-flammable,
corrosive and do not have potential to create serious emergency situation, have
been studied qualitatively and risk mitigation measures have been provided
accordingly.
The selected scenarios for consequence calculations are given in Table 7.5.
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Table 7.5: List of Selected Scenarios for Consequence Analysis
Sl. Type of Release Outcome Cases Considered
1. Catastrophic rupture of 5 Kl AG
Methanol tank
Fixed Pool Fire in Dyke Area
Flash Fire/Explosion
2. Catastrophic rupture of 140 kl
Toluene Tank
Fixed Pool Fire in Dyke Area
Flash Fire/Explosion
3. Catastrophic Rupture of 1 kl Xylene
tank
Fixed Pool Fire
Flash Fire/Explosion
4. Release of Ammonia from Cylinder Dispersion of Toxic Vapour Cloud
5. Release of Chlorine from Tonner Dispersion of Toxic Vapour Cloud
6. Release of Bromine from 6.3 kl
Bromine tank
Dispersion of Toxic Vapour Cloud
7. Release of Sulphuric Acid from 65
kl Tank
Dispersion of Toxic/Corrosive
Vapour Cloud
8. Release Carbon Di Sulphide (35 kl
tank)
Fire, Flash Fire/Explosion
9. Diethylamine (DEA) (20 kl tank) Fire, Flash Fire/Explosion in Dyke
10 1,4 Dioxane (8 kl) Fire and Explosion
11. 2-ethyl Hexanol (0.84 Kl) Fire and Explosion
12. Acetonitrile (10 Kl) Fire and Explosion
13. Di Methyl Carbonate (DMC) (16 Kl) Fire and Explosion
14. Dimethyl Formamide (3 kl) Fire and Explosion
15. Ethyl Mercaptan (3 kl) Fire and Explosion
16. Ethyl Acetate (11.75 kl) Fire and Explosion
17. Formaldehyde (8.5 kl) Fire and Explosion
18. Hexane (0.75 kl) Fire and Explosion
19. Iso Propyl Alcohol (4 kl) Fire and Explosion
20. Mono Iso Propyl Amine (3.25 kl) Fire and Explosion
21. N,N Dimethyl Aniline (3.25 kl) Fire and Explosion
22. Phenol (21 kl) Fire and Explosion
23. Tri Methyl Phosphite (6.25 kl) Fire and Explosion
24. Ethyl Hexanol (2 Kl) Fire and Explosion
Note: Vapour Cloud Explosion (Confined) and Flash Fire (Non-confined)
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7.5 Consequence Analysis
Subsequent to the accidental release of hazardous materials, the consequence
of an accidental release depends on various factors e.g. type and quantity of
release, presence and location of an ignition source, meteorological conditions,
etc. Any loss of containment at the plant will lead to a release of hazardous
materials. The released quantity will depend on failure size and the duration of
release. All the tanks at the plant have been provided with bund (dyke). On
release of containment from tanks, a fixed pool may be formed, which may or
may not ignite. If immediate or delayed ignition takes place a pool fire will result.
Delayed ignition may also lead to vapour cloud explosion / flash fire, if release
quantities/surface areas are significant. In the event of release from transfer
piping and/or pipeline, spreading pool will be formed followed by spreading pool
fire on getting source of ignition.
The following effects are distinguished for consequence analyses for flammable
materials, immediate ignition followed by pool fire, or evaporation and delayed
ignition of a vapour cloud resulting in a fire and/or explosion. Representative
consequences distance up to where 1% fatality-occurs among those exposed,
has been calculated.
The following damage distances for thermal radiation have been used:
37.5 kW/m2 Damage to process equipment. 100%
lethality in 1min. 1% lethality in 10sec.
12.5 kW/m2 First degree burn for 10 sec exposure
4 kW/m2 First degree burn for 30 sec exposure
The 0.1 bar overpressure due to explosion at 1 % fatality has been considered
for computations.
Release of toxic hazardous materials like chlorine, ammonia, bromine and
sulphuric acid will result in dispersion of toxic vapour cloud toward wind
direction. Immediately Dangerous to Life or Health (IDLH) limit values for toxic
hazardous materials have been considered for computation of vulnerable
distances. IDLH Values for considered for toxic hazardous materials are given
below:
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Sn Toxic Hazardous Materials IDLH Values
1. Chlorine 10 ppm
2. Ammonia 300 ppm
3. Bromine 3 ppm
4. Sulphuric acid 20 ppm
7.5.1 Model Used for Consequence Analysis
The consequence analysis studies involve a large number of calculations for
which established computing aids are essential. PHAST/SAFETI software of
DNV has been used to perform the consequence calculations. PHAST/SAFETI is
a consequence and risk assessment software for calculation of physical effects
(fire, explosion, atmospheric dispersion) of the escape of hazardous materials.
PHAST/SAFETI (v6.7) software allows detailed modelling and quantitative
assessment of release of pure and mixtures of liquid and gaseous chemicals.
For computation of consequence distances for Hazardous chemicals which are
not available in PHAST data base, ALOHA software developed by EPA and the
NOAA (USA) was also used. ALOHA® is the hazard modelling program for the
CAMEO® software suite, which is used widely to plan for and respond to
chemical emergencies.
7.5.2 Summary of Consequence Analysis
The summary of maximum consequence distance for flammable hazardous
materials at UPL Plant is given in Table 7.6. The consequence distance are
marked on google image layout plan and presented in Figure 7.1 to Figure
7.12.
Table 7.6: Summary of Consequence Analysis for Flammable Hazardous
Materials
Sr.
No.
Release Scenarios Thermal
Radiation
Distance (m)
4 kW/m2
Flash Fire
Envelope
(m)
Explosion
Effects (Delayed
Ignition) (m)
0.1 Bar
1. Rupture of Methanol
Tank followed by
Immediate/ Delayed
Ignition
Pool Fire: 5.1 m 1.9 m No Explosion
effect
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Sr.
No.
Release Scenarios Thermal
Radiation
Distance (m)
4 kW/m2
Flash Fire
Envelope
(m)
Explosion
Effects (Delayed
Ignition) (m)
0.1 Bar
2. Rupture of Toluene
Tank followed by
Immediate/ Delayed
Ignition
Pool Fire:35.3m 39.4 m 16.4 m
3. Rupture of Xylene
Tank followed by
Immediate/ Delayed
Ignition
Pool Fire:11.3 m 1.2 m No Explosion
effect
4. Rupture of Hexane
Tank
Pool Fire: 13.1 m 2.5 m No Explosion
effect
5. Rupture of Carbon Di
Sulphide Tank
Pool Fire: 22.5 m 72.4 m 44.4 m
6. Rupture of Phenol
Tank
Pool Fire: 20.8 m 4.5 m No Explosion
effect
7. Diethylamine (DEA) 16.7 5.7 No Explosion
effect
8. 1,4 Dioxane 18.5 m 6.8 m No Explosion
effect
9. 2-ethyl Hexanol 7.8 m 3.1 m No Explosion
effect
10 Acetonitrile 19.5 m 4.6 m No Explosion
effect
11. Di Methyl Carbonate
(DMC)
22.7 m 5.7 m No Explosion
effects
12. Dimethyl Formamide 13.1 m 3.1 m No Explosion
effect
13. Ethyl Mercaptan 14.7 m 2.9 m No Explosion
effect
14. Ethyl Acetate 18.9 m 4.7 m No Explosion
effect
15. Formaldehyde 14.1 m 3.2 m No Explosion
effect
16. Iso Propyl Alcohol 15.2 m 4.1 m No Explosion
effect
17. Mono Iso Propyl
Amine
9.6 m 2.7 m No Explosion
effect
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Sr.
No.
Release Scenarios Thermal
Radiation
Distance (m)
4 kW/m2
Flash Fire
Envelope
(m)
Explosion
Effects (Delayed
Ignition) (m)
0.1 Bar
18. N,N Dimethyl Aniline 8.7 m 1.8 m No Explosion
effect
19. Tri Methyl Phosphite 10.3 m 1.4 m No Explosion
effect
20. Ethyl Hexanol 6.6 m 2.2 m No Explosion
effect
The summary of consequence distances for toxic hazardous materials like
Ammonia, Chlorine, Bromine and Sulphuric acid toxic vapors at UPL Plant is
given in Table 7.7.
Table 7.7: Summary of Consequence Analysis for Toxic Hazardous
Materials
Sr.
No.
Release Scenarios IDLH
Concentrations
Distances (max.)
1. Release of Ammonia from Cylinder followed
by Toxic Vapour Cloud Dispersion
377.62 m
2. Release of Chlorine from Tonner followed by
Toxic Vapour Cloud Dispersion
513.8 m
3. Release of Bromine followed by Toxic Vapour
Cloud Dispersion
255.74 m
4. Release of Sulphuric Acid from Tank followed
Toxic Vapour Cloud Dispersion
241.77 m
The consequence of accidental release of toxic hazardous materials will be off
site beyond the boundary of the plant. The consequence distances of IDLH
concentration for toxic hazardous chemicals are marked on google image layout
plan and presented in Figure 7.9 to Figure 7.12.
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Figure 7.1: Thermal Radiation Distance for Methanol 5 kl AG Tank
Figure 7.2: Thermal Radiation Distance for Toluene 140 kl Tank
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Figure 7.3: Overpressure Distance for Toluene 140 kl Tank
Figure 7.4: Thermal Radiation Distance for Xylene Tank
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Figure 7.5: Thermal Radiation Distance for Hexane Tank
Figure 7.6: Thermal Radiation Distance for Carbon Di Sulfide Tank
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Figure 7.7: Overpressure Distance for Carbon Di Sulfide Tank
Figure 7.8: Thermal Radiation Distance for Phenol Tank
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Figure 7.9: IDLH Concentration for Release from Ammonia Cylinder
Figure 7.10: IDLH Concentration for Release from Chlorine Tonner
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7.6 Frequency Analysis
Figure 7.11: IDLH Concentration for Release from Bromine Tank
Figure 7.12: IDLH Concentration for Release From Sulphuric Acid Tank
Tank
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The estimation of probability of an accident scenario is an essential step in
Chemical Process Quantitative Risk Analysis (CPQRA). The objective of Failure
Frequencies & Data Sources is to compile a database of existing leak frequency
data and ignition probabilities for use in quantitative risk analysis. Experience
data from operating companies in the petroleum and petrochemicals have been
used in this database. Apart from developing leak frequencies per equipment
item, generation of a hole size distribution i.e. information about the size of
releases, has been given priority. The holes size distributions are often based
on engineering judgment, as very little detailed information is available in this
area. The data taken from this database and used for this QRA are listed below:
Sn Equipment/Event Probability
1. Gas Sensor Failure 3.00×10-4
2. Controller Failure 3.00×10-2
3. Suction Pump Failure 1.08×10-2
4. Storage Tank Physical Defect 8.83×10-5
5. Storage Tank Bad Welding 1.88×10-4
6. Erosion of Storage Tank 1.00×10-3
7. Connecting Flange Damage 1.88×10-4
8. Leak Detector Failure 3.00×10-4
9. Pipe Erosion 1.00×10-3
10. Chlorine Alarm System Failure 3.30×10-4
11. Personnel did not detect the leak in five
minutes
9.50×10-2
12. Failure to reopen the valve after Replacement 5.01×10-5
13. Malfunction of Safety Valve 1.18×10-3
14. Chlorinator pressure-regulating valve fail 1.12×10-3
7.6.1 Equipment Failure Frequency
The data sources referred for failure frequencies are E & P Forum Frequency
database from TNO and Failure frequency data from the Rijnmond Report
(COVO Study). The failure frequencies have been distributed for three different
failure sizes, rupture, hole (50 mm equivalent hole size) and leak (13 mm
equivalent hole size).
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Equipment Rupture Hole Leak
Process
piping
4.0 x 10 -6 /m
yr
6.0 x 10 -6 /m yr 1.6 x 10 -5 /m yr
Storage Tank 1 x 10 –6 /yr 1 x 10 -5 /yr. 1 x 10 -4 /yr.
Pumps 1 x 10 –4 /yr 1 x 10 -3 /yr. 1 x 10 -2 /yr.
Valves 9.2 x 10 -6 /yr 1.8 x 10 -5 /yr. 5.3 x 10 -5/yr.
Flanges - 3.52 x 10 -6 / flange
yr
8.5x 10 -5/flange
yr
Tapping - - 1 x 10 -4 /yr.
7.6.2 Frequency Analysis for the Plant
The following methodology/ assumptions have been adopted:
• The release frequency is obtained by adding the failure frequencies of all the
valves, flanges, pumps, pipeline etc.
• The immediate ignition probability for pool fire has been taken as 0.065 and
delayed ignition probability has been taken as 0.035.
For the plant, accident frequencies for scenarios for various storage tanks
facilities are given below:
The release frequency for storage tanks at the plant is given below:
Storage Tank Catastrophic Failure Frequency 1E-6 tank -1 yr. -1
Accident likelihood for hose failure is given below:
Base flexible hose failure frequency 4.0E-6/hr
7.7 Risk Analysis and Summation
7.7.1 Qualitative Risk Matrix
Qualitative Risk Assessments are often shown in the form of a simple risk matrix
where one axis of the matrix represents the probability and the other axis
represents consequences. The risk then is identified by the intersection of the
chosen assessment level. Severity, Likelihood/ Probability ranking and Risk
Acceptability Criteria used for preparation of risk matrix for the plant are given
below:
I. Severity Ranking
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Severity Ranking
Catastrophic (Death/System Loss) 1
Major/ Critical (Serious injury) 2
Moderate (Less Serious Injury) 3
Minor/ Marginal (Minor Injury) 4
Insignificant/ Negligible (No injury) 5
II. Likelihood/ Probability Ranking
Likelihood/ Probability Ranking
Almost Certain E
Likely D
Possible C
Unlikely B
Impossible A
III. Risk Acceptability Criteria Ranking
Risk Ranking
Risk Acceptability Criteria Remark
H Unacceptable/High Management’s Decision/Action Plan Required. Potential off-site Impact.
M Medium Generally Minor Impact. Acceptable with Management’s Review. Specific monitoring or SOP to be followed.
L Low Acceptable without Review. Manage through Routine Procedure.
Risk matrix for the UPL plant. with implemented and proposed risk mitigation
measures is shown in Table 7.8.
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Table 7.8: Qualitative Risk Matrix for the project site
Likelihood/ Probability
Catastrophic (Death/Syste
m Loss)
Major/ Critical
(Serious injury)
Moderate (Less
Serious Injury)
Minor/ Marginal (Minor Injury)
Insignificant/
Negligible (No
injury)
1 2 3 4 5
Almost Certain E Low Low Moderate Moderate High
Likely D Moderate Moderate Moderate High High
Possible C Moderate Moderate Moderate High High
Unlikely B Moderate Moderate High High High
Impossible A High High High High High
7.7.2 Quantitative Risk Analysis & Summation
Risk is defined as the unwanted consequence of a particular activity in relation
to the likelihood that this may occur. Risk thus comprises of two variables-
magnitude of consequences & the probability of occurrence. The risk analysis
and summation are most often presented in terms of individual and group or
societal risk. Individual Risk is the probability of death occurring as a result of
accidents at a plant, expressed as a function of the distance from such an
activity. Such a risk actually exists only when a person is permanently at that
spot (out of doors). The individual risk is well illustrated with the aid of risk -
curves or Iso-risk contours. Societal risk is the probability of a certain number
of victims per year. In calculating the group risk demographic data relating to
the presence of humans is necessary. The societal risk is represented as an F-
N curve, which depicts the frequency of occurrence per year F of a certain
number of fatalities, N. The individual and societal risks from a existing and
after expansion of existing pesticide plant are the result of the cumulating of
risks connected with all possible scenarios. From the standpoint of what
constitutes acceptable risk levels from a complex, both the Individual as well as
Societal risk should be within the acceptance criteria.
The DNV Software model SAFETI (PHAST RISK) has been used for plotting
the iso-risk contour of individual risk and F-N curves of Societal Risk. The ‘PHAST
RISK’ (v6.7) program package is a very powerful tool to combine the
probabilities and consequences of all release scenarios considered into risk and
then sum them. Data input to SAFETI (PHAST RISK) comprises of results of
effects-consequence and frequency analyses for the scenarios included for risk
summation, along with population and meteorological data for the locality in
question.
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7.7.3 Risk Summation
Risk Acceptance Criteria
The risk analysis provides a measure of the risk resulting from plant. The
methodology for calculating risk levels has been well defined and consistent
results can therefore be expected. However, the assessment of the acceptability
or otherwise of that risk is left to the judgement and experience of the people
undertaking and/or using the risk assessment study. The normal approach
adopted is to relate the risk measures obtained to risk acceptance criteria.
Criteria Adopted for Individual Risk
As per Health and Safety Executive (HSE) UK, Individual Risk of death to the
members of the public outside the plant boundaries has been adopted as:
• 10-5 per year for intolerable risk
• Lower than 10-6 per year for negligible risk.
ALARP - Tolerability and Acceptability of Risk
Risk from a hazardous activity is judged against the benefits from the activity,
since no activity can claim to be totally risk-free. Risk criteria are recognised
below:
• There is a level of risk that is so high that it is considered unacceptable or
intolerable regardless of the benefits derived from an activity.
• There is also a level of risk that is low enough as to be considered negligible.
• Levels of risk in between are to be considered tolerable subject to their being
reduced As Low As is Reasonably Practicable (ALARP). In other words risks
are only tolerable provided that it can be demonstrated that all reasonably
practicable measures have been implemented to reduce risks. A reasonably
practicable risk reduction measure is one where the costs of implementation
are not grossly disproportionate to the risk reduction benefits achieved.
The above is the formulation of the, well-established, three tier structure of risk
criteria and risk control shown in Figure 7.13. The two horizontal straight lines
in divide risk space in to three regions. That above the upper line is the region
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of unacceptable risk, while that below the lower line is the region of acceptable
risk. The region in between is the so-called ALARP region where risk is
acceptable subject to its being As Low as Reasonably Practicable (the ALARP
principle). All the various levels proposed within each tier are judgmental. Actual
decisions on what should then be done in the ALARP region to reduce risk
depend on choice of specific remedial measures.
Risk in intolerable region implies that reduction is called for irrespective of any
other considerations. Such limits have been set out by various countries both
for Individual as well as Societal risk. In between the upper and lower bands
the risks should be reduced ‘As Low As Reasonably Practicable’ using a cost
benefit approach. In cost benefit analysis the reduction in risks associated with
a particular remedial measure are compared against the costs of implementing
the measure. Where the benefits exceed the costs, the measures can be said
to be cost justified.
The risk criteria simply attempt to establish whether is risk is “tolerable”. Below
is a list of words generally in use and their meaning.
ACCEPTABLE RISKS: Since risks in general are unwelcome no risk should be
called “acceptable”. It might be better to say that the activity may be acceptable
generally, but the risks can only ever be tolerable.
Figure 7.13: ALARP Principle
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TOLERABLE RISKS are risks the exposed people are expected to bear without
undue concern. A subtle difference is made out here between Acceptable Risks
and Tolerable Risks though these terms are sometimes used interchangeably.
NEGLIGIBLE RISKS are risks so small that there is no cause for concern and
there is no reason to reduce them.
Criteria Adopted for Societal Risk Criteria
In the assessment of the societal risk, demographic data on the offsite of the
plant have been used. Only the employees working in the plant are not included
in the 'society'. With regard to the risk of people employed in nearby industries
with similar risk, it is debatable to consider them as population.
FN Curve Slope
Intolerable Intercept With N=1
Negligible Intercept With N=1
Limit on N
Existing and New Plants
-1 10-3 10-6 -
Individual Risk Due to Existing Facilities
Iso risk contour for hazardous materials storage and handling at Unit # 10 of
UPL Ltd. are presented in Figure 7.14. From the figure, it is observed that risk
level contour 1.0E-5 is within the boundary of Plant. The risk level 1.0E-6 per
year individual risk contour also crosses the plant boundary, which is negligible.
It is thus clear that individual risk as computed 3.62898E-5/avg. yr higher than
1.0E-5/yr is within the UPL Ltd boundary and does not cover any populated
areas and is hence acceptable. The individual risk contours up-to risk level 1.0E-
6/avg. yr crosses boundary of the plant as toxic gas like chlorine from tonners
and ammonia gas may move outside the boundary. Day time individual risk as
2.33430E-5/avg yr, while night time individual risk as 5.57101E-5/ avg yr
remains within the boundary and considered as acceptable.
Societal Risk
The individual risk values for each location when combined with population at
that location gives the societal risk at same location i.e. the probability of a
certain number of victims per year. The total Societal Risk can be obtained by
adding the values for all the locations. The Societal risk is represented as F-N
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curve, frequency of number of fatalities (F) from all the accidents versus No. of
fatalities (N).
For Unit #10 of UPL Ltd., F-N curves have been drawn for combined (Day and
night) time and separately for day and Night time. These F-N curves are shown
in Figures 7.15 and 7.16, respectively. F-N curves show two straight lines
(with negative slope) which indicate the Societal Risk Acceptance criteria
adopted for this study. That above the upper line is the region of unacceptable
risk, while that below the lower line is the region of acceptable risk. The region
in between is the so-called ALARP Zone where risk is acceptable subject to its
being As Low As Reasonably Practicable (the ALARP principle). Major risk
contributors have been identified using the Analysis Tools feature of PHAST
RISK.
From Figures 7.15 and 7.16, it is observed that the F-N curve of societal risk
lies in the ALARP Zone in acceptable zone for risk 3.62038E-005 /avg yr.
Findings of Risk Analysis
Based on risk analysis and summation, following conclusions can be made:
1. Individual risk from existing and after proposed expansion of Unit #10 of
UPL Ltd., is tolerable, as it is below the tolerance criterion of individual risk
not to exceed 1.0E-5 per year outside the boundary,
2. Individual risk contour for 1.0E-5 per year is also within the boundary limit
of the plant,
Figure 7.14: Iso Risk Contours for UPL
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3. Individual risk contours for 1.0E-5 and 1.0E-6 per year are observed for
failure of Chlorine Tonner and ammonia cylinder, However, contour (1.0E-5
per avg. year) is within the boundary limit of plant.
4. Day time individual risk as 2.33430E-5/avg yr, while night time individual
risk as 5.57101E-5/ avg. yr remains within the boundary and considered as
acceptable.
F-N curve of societal risk as 3.62038E-005 /avg yr lies in the ALARP Zone and
in acceptable zone.
Figure 7.15: FN Curve for UPL
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7.8 Risk Mitigation Measures
7.8.1 Safety at the Existing Plant
Based on hazard identification, consequence analysis, risk analysis and
observations recorded during the plant visit, the following risk mitigation
measures to enhance safety at the UPL plant are emerged:
7.8.2 System Specific Measures
The plant has already adopted various safety measures for handling and storage
of hazardous materials. Safety initiatives adopted at the existing plant are
described below:
i. Occupational Health, Environment and Safety Policy The plant has prepared Occupational Health, Environment and Safety Policy.
The Occupational Health, Environment and Safety Policy has been displayed at
locations prominently within the plant and is circulated to all employees.
Figure 7.16: F-N Curve Combined for Day and Night Time
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ii. Environment, Health & Safety Organization a) Environment, Health & Safety Department The HSE department is managed by qualified, experienced and competent
personnel and strict safety controls are enforced for each hazardous activity.
iii. Accident Reporting, Investigation and Analysis Records for near-miss, incidents and accidents are maintained and analyzed to
take precautionary measures. All near-miss incidents and accidents are reported
and investigated to take corrective measures. The accident statistics and data
are maintained by Environment, Health & Safety Department. Accident statistics
and data are reviewed regularly by the senior management to take corrective
measures.
iv. Safety Inspections and Internal Audit Safety inspections are carried out regularly at the plant. Internal safety audits
are also conducted frequently.
v. Safety Education and Training (a) Safety Training There are provisions at the plant for induction training for new workers. The
assessment of the trainee is done to ensure the effectiveness of training.
(b) Periodic Training / Reporting The workers are trained as per need of training. (c) Safety Communication / Motivation / Promotion
• The system for safety suggestion schemes are implemented at the plant.
• There is provision at the plant for the safety contests for motivation of safety
at the plant.
vi. First Aid
• First aid boxes are available within various departments in existing plant.
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• First aid facilities will be provided through well-equipped first aid box &
Occupational Health Centre. Trained first aid persons will be available in each
shift. Pre- employment & periodic medical examination will be carried and
records will be maintained.
vii. Occupational Health
• The pre- employment and periodical medical check-up are carried out at
regular interval for all employees.
• Emergency vehicle/ambulance for the event of an emergency are available
round the clock at the plant in each shift.
7.8.3 Safety Measures at the Plant
i. Hazard Control Measures
• Procedures and actions are well defined and known to all operating
personnel for safe shut down of plant in case of failure of any power,
instrumentation, etc.
• All the tanks have been provided with temperature indicator, pressure gauge
and safety valves depending upon the process and operating parameters.
• HAZOP studies will be carried out using P&IDs for identification of hazards
during operation considering deviation of operational parameters, their
possible cause and consequence and safe guards.
• All the motors and other rotating equipment machines have been provided
with suitable safety guards.
• Fire extinguishers have also been installed in the plant area.
• Flame arrestors will be provided at all vent lines at solvent tanks.
• Suitable fire extinguishers, such as, DCP, CO2 & foam type have been kept
in every plant area at easily approachable spots and in sufficient numbers.
• Fire hydrant points with sufficient length of hose reel have been provided at
major emergency spots.
• Bound walls, bonded wire fencing, detached storage areas are kept away
from probable ignition sources;
• Safety showers and eye washers are installed at crucial places.
• Sufficient space has been provided for free movement in the plant area.
• Certificate of structure stability are taken from competent person.
• All elevated structures will be provided with lightening arrestors.
• All exposed parts of moving machineries will be provided with suitable
guards for personnel safety.
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• All piping and equipment will be provided with earthing connection and it
will be tested regularly.
• Safety valves & rupture disc will be provided to prevent over pressurization
of vessels and reactors.
• SOP will be available of safe shut-down of plant during any emergency
situation.
ii. Operational Safety
• All operators & maintenance personnel concerned with the plant will be
given material safety data sheets for hazardous chemicals and to be trained
to combat any leakage spillage, etc.
• Detections and sensors for smoke, heat, ammonia, chlorine, etc. will be
provided with alarm at strategic locations at the plant.
• Non-destructive thickness measurements will be carried out regularly
corrosion through competent person to prevent sudden bursting by thinning
out of metal by erosion or.
• Safety appliances like PVC suit, hand gloves, safety goggles, helmets etc.
will be used during material handling. Also, SCBA/emergency air masks will
be kept available all the time.
• Internal and external inspection of tanks, piping, thickness measurement of
piping, inspection and testing of lifting tackles, etc, will be carried out as per
schedule.
iii. Toxic Releases: Controls Small quantities - say leakage from piping, valves, pin holes etc. will be easily
controlled by isolating the equipment/piping etc. & using personal protective
equipment’s like helmet, shoes, hand gloves, airline respirator, breathing
apparatus (SCBA), apron, etc.
iv. Spillages, Leakages: Controls Depending on the leaking rate/source the following actions will be taken.
• Isolation/cutting of supply at leaking point, transfer to some other
vessel/equipment, and using protective appliances like hand gloves,
helmets, PVC suits etc.
• Efforts will be made, to prevent spread of spillage by neutralization/ earth
barriers.
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v. Hazards in Transportation: Controls Highly inflammable chemicals are transported by road. Therefore, adequate
safety precautions for transportation are followed.
The following safety precautions are suggested during transportation of toxic,
inflammable and corrosive chemicals in tankers, while loading and unloading,
transportation and response to emergencies arising out of leakages and
spillages of hazardous materials:
• Ensure TREM card with Tanker and tonner/cylinder transporting trucks.
• Park the vehicle at designated place.
• Stop the engine while unloading and loading of hazardous materials.
• Check-up spark arrester.
• Provide earthing to tanker securely.
• Ensure that fireman is available near the place with proper equipment’s.
• Connect the piping properly
• Before start unloading, check that, there will not be any leakage.
• In case of leakage, immediately attend the leakages & rectify it.
• After unloading is over, close the lid properly.
• Vehicle to be started only after removal of all pipelines connected with
tanker.
vi. Safety Instructions for Transportation of Hazardous Materials
• The name of the chemical along with pictorial sign denoting the dangerous
goods will be marked on the vehicle and the packing material.
• The name of the transporter, his address and telephone number will be
clearly written on the road tanker and on the vehicle.
• The important safety precautions will be mentioned on the tanker as a
warning label.
• The tanker or vehicle will not be used to transport any material other than
what is written on it.
• Only trained drivers and cleaners will transport hazardous chemicals.
• The transporter and the manufacturer must ensure the safe transportation
of the material.
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vii. Tankers
• The tanker will be checked for its fitness and safe condition before loading.
• During loading and unloading, the tanker will be breached and isolated
against any movement, while loading/unloading, use safety appliances.
• The tanker will not be overloaded by hazardous materials beyond the weight
permitted by the concerned authority.
• Check for leakages from the line connections before starting and stopping
the filling operations.
• Drive the vehicles carefully, especially in crowded localities and on bumpy
roads.
• Do not apply sudden break.
• The tanker will not be parked for long time on the way and especially in
crowded places. Park the vehicle away from residential areas.
viii. Maintenance Hazards
• Safety permit system like hot work, cold work, confined space entry will be
followed,
• Adequate inventory of spare parts will be maintained.
• Scaffoldings/Ladders will be used for maintenance.
• Personal Protective Equipment (PPEs) will be utilized for protection against fall,
hand injury, head injury etc.
• Maintenance procedures will be developed and followed.
• All physical hazards will be eliminated.
• Lifting tackles will be maintained and examined periodically as per rules &
regulation.
• Hand tools/power tools will be used with approved types and of good quality.
7.8.4 Overall Risk Reduction Measures
For risk mitigation/reduction, attempts will be made to either reduce inventories
that could get released in the event of loss of containment or failure likelihood’s
or both as feasible. Risk analysis identifies the major risk contributors, which
enables prioritization of the plant that deserve special attention in terms of
inspection and maintenance in particular and over all safety management as a
whole. Based on hazard identification, consequence analysis the following
suggestions to enhance safety at the plant are emerged.
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Risk Mitigation/Reduction Measures for Process Operations For the risk reduction at the process operations after expansion, the following
mitigation measures are given:
• A written process safety information document may be compiled for general
use.
• Personnel especially contractor workers at the plant will be made aware
about the hazardous substance stored at the plant and risk associated with
them.
• The process design information in the process safety information compilation
must include P&IDs/PFDs; process chemistry; maximum intended inventory;
acceptable upper and lower limits, pressures, flows and compositions and
process design and energy balances.
• The document compilation will include an assessment of the hazards
presented including (i) toxicity information (ii) permissible exposure limits.
(iii) physical data (iv) thermal and chemical stability data (v) reactivity data
(vi) corrosivity data (vii) information on process and mechanical design.
• Heat, smoke, ammonia, chlorine detectors may be provided at strategic
locations in the plant and indication of detectors/sensors will be provided in
main control room.
• Thickness survey for tanks and piping will be carried out periodically as per
standard practices.
• Safety measures in the form of do's and don'ts will be displayed at strategic
locations especially in Marathi and English language.
• Personnel engaged in handling of hazardous chemicals will be trained to
respond in an unlikely event of emergencies.
• The plant will check and ensure that all instruments provided in the plant
are in good condition and documented.
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Personal Protective Equipment If a worker enters a hazardous area, he must wear suitable personal protective
equipment (PPE). Workers will be taught when and how to use mask or
respiratory apparatus (SCBA) provided. Without SCBA entry into the confined
space or toxic gas area will not be attempted.
• Keep personal protective equipment where it can be accessed quickly,
outside the hazardous material storage area and away from areas of likely
affected.
• Each employee will maintain his personal protective equipment in clean,
working condition at all times.
• All equipment will be used and maintained in accordance with the
manufacturer’s instructions.
• Equipment installed for body and eye wash will be checked properly for
uninterrupted operation.
Risk Mitigation Measures for Proposed Expansion
• Hazardous chemicals will be stored in separate storage along with necessary
safety measures.
• Hazardous process operations will be carried out by trained operators &
under supervision Process Safety Engineer.
• Hazardous chemicals will be handled in close circuit.
• Enclosures will be provided with vent connected to scrubber for Bromine etc.
• Safety fittings like safety valve, pressure reducing valve, vent, flame
arrestor, pressure / temperature indicators, level indicators, rupture discs
etc. will be provided to the concern equipment.
• Calibration of all instruments in the plant will be carried out periodically.
• Loading/unloading will be ensured with earthing & bonding for flammable
chemicals.
• Flameproof fitting, earthing & bonding of equipment’s & pipelines will be
provided for flammable chemicals.
• Work permit system will be followed strictly.
• Periodic onsite emergency mock drills will be arranged.
• Work area monitoring will be done periodically.
• Safety training’s will be given to the workers for handling of hazardous
chemicals.
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• Monthly Cholinesterase enzyme (Blood) test will be carried for those who
will work in manufacturing process.
• Protective clothing will be provided to all workers & casual workers and these
will be regularly washed properly.
• Necessary PPE’s will be readily available. Jobs will be accomplished using
relevant PPEs
• Necessary cautionary and safety awareness placards will be displayed at
conspicuous places in company.
• Eating & chewing will be prohibited in manufacturing area.
Bulk Storage of Finished Product
• Stacking of manufactured products in warehouse will be restricted to certain
fixed height. Drums/plastic carboys/jars & other finished goods packing shall
not be stacked at very high levels. This may cause accidents.
• Some space must be left while storing the product to easily identify lot
numbers.
• It will be marked with Lot No. for easy stacking and removal.
• It will be insured that plant personnel are wearing safety protective
equipment while entering in the warehouse or handling products.
Handling of Hazardous Materials
• Personal protective equipment used by the workers during handling of
hazardous chemicals, will be replaced after certain time.
• If any spillage of hazardous chemicals, it will be cleaned and disposed as per
standard practiced.
• Empty drums of hazardous chemicals will neutralize immediately.
• Workers engaged in handling of hazardous chemicals will be made aware of
properties of hazardous chemicals.
• Material Safety Data Sheets (MSDS) will be displayed in storage area.
• Do's and don'ts will be displayed at strategic locations especially in Marathi
and English languages.
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General Working Conditions at the Plant after Expansion (a) House Keeping
• All the passages, floors and stairways will be maintained in good condition.
• The system will be available to deal with any spillage of dry or liquid chemical
at the plant.
• Walkways will be always kept free from obstructions.
• In the plant, precaution, instructions and Do's and don'ts will be displayed
at strategic locations in Marathi and English Languages.
• All pits, sumps will be properly covered or securely fenced.
(b) Ventilation
• Adequate ventilation will be provided in the work floor environment,
hazardous material storage and warehouse for products.
• The work environment will be assessed and monitored regularly as local
ventilation is most effective method for controlling dust and gaseous
emissions at work floor.
Safe Operating Procedures
• Safe operating procedures will be available for hazardous materials handling,
operations and equipment.
• The workers will be informed of consequences of failure to observe the safe
operating procedures.
• Safe operating procedures will be formulated and updated, specific to
process & equipment and distributed to concerned plant personnel.
• Safety procedure near anhydrous Ammonia and Chlorine tonners will be
prepared and displayed meticulously in Marathi and English languages.
Work Permit System Work permit system will be followed at the plant during maintenance. Fire Protection
• Well-designed pressured hydrant system comprising with jockey pump,
electrical & diesel pumps, hydrant, monitor, etc maintained at the plant.
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• The firefighting system and equipment will be tested and maintained as per
relevant standards.
• Heat and smoke detectors will be provided at the plant and shall be
calibrated and maintained properly.
Static Electricity
• All equipment and storage tanks/containers of flammable hazardous
materials will be bounded and earthed properly.
• Electrical pits shall be maintained clean and covered.
• Electrical continuity for earthing circuits of earth pits will be maintained.
• Periodic inspections will be carried for earth pits and record will be
maintained.
Communication System Communication facilities will be checked periodically for its proper functioning. Safety Inspections The system will be initiated for checklist based routine safety inspection and
internal safety audit of the plant after expansion. Safety inspection team shall
be formed from various disciplines and departments.
Predictive and Preventive Maintenance
Predictive and preventive maintenance schedule will be prepared for equipment,
piping, pumps, etc., after expansion of the plant.
Electrical Safety
• Insulation pad at HT panels shall be replaced at regular interval.
• Housekeeping in MCC room shall be kept proper for safe working conditions.
• All the three-phase motor and equipment will be double earthed.
• Danger signage showing bone and skull will be displayed at all three phase
motors.
• Insulation mat will be provided to the three phase electrical control panels.
Colour Coding System Colour coding for piping and utility lines shall be followed in accordance with IS:
2379:1990.
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Control of Odour The efforts will be made to control odour from the plant. Odour Threshold
Concentrations for Hazardous Chemicals is as give below:
Sn. Hazardous Chemicals Odor Threshold Concentration
1. Methanol 200 ppm (MSDS)
2. Isopropyl Alcohol 400 ppm (MSDS)
3. Toluene 200 ppm (MSDS)
4. Ammonia Gas 5 ppm (MSDS)
5. Bromine 0.1 ppm (MSDS)
6. Chlorine 0.5 ppm (USEPA)
7 Tri Methyl Phosphite 0.0001 ppm (ACGIH)
8 Di Methyl Sulphate Not Established as per USEPA (faint, onion-like odor)
Mock Drill Exercises Mock drills are conducted once in year. Exercises or drills have two basic
functions, namely training and testing of systems. While exercises do provide
an effective means of training in response procedures, their primary purpose is
to test the adequacy of the emergency management system and to ensure that
all response elements are fully capable of managing an emergency situation.
Mock drills are best means of accomplishing the following goals and objectives: 1. To reveal weaknesses in the plans and procedures before emergencies
occur.
2. To identify deficiencies in resources (both in manpower and equipment).
3. To improve the level of co-ordination among various response personnel,
departments and agencies.
4. To clarify each individual’s role and areas of responsibility.
Based on outcomes of emergency response plan will be updated accordingly.
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7.9 DISASTER MANAGEMENT PLAN (DMP)
7.9.1 Objective of DMP
In order to be in a state of readiness to face any accident or disaster caused by
the project operation, a Disaster management plan is required to be prepared.
The plan should cover possible disaster, On and Off-site emergency
preparedness plans, establishment of emergency Control Centre (ECC).
Location of emergency services and duties of officers / staff during emergency.
Basic Contents of DMP
Basically, DMP contains following aspects
1. Description of site
2. Brief description of the plant
3. On – site Emergency plan
4. Off- site Emergency plan
Mode of Emergency
Process Emergency Natural Calamities Man-made &/or Extraneous
Heavy Toxic Leakage/ Spillage
Flood Riots/Civil Disorder/Mob Attack
Fire Earthquake Terrorism
Explosion Cyclone Sabotage
Failure of Critical Control system
Outbreak of Disease Bomb Threat
In-adequate maintenance Tsunami War/Hit by missiles
Abduction
Food Poisoning/Water Poisoning
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On-Site Emergency
The On-site emergency plan: deals with, measures to prevent and control emergencies
within the factory and not affecting outside public or Environment.
Off-Site Emergency
The Off-site emergency plan: deals with, measures to prevent and control
emergencies affecting public and the environment outside the premises
7.9.2 On- Site Emergency Plan
Company has on-site emergency plan for existing site/activities. After proposed
expansion company will be update on-site emergency plan for proposed activity.
1. Scope of Site Emergency Plan
The existing site contain following nature of emergencies in the factory:
• Emission of chemical vapors into the shop floor ambience and any injurious effects of
physical contact with corrosive chemicals, inhalation of fumes, vapors and solvents.
The consequences is being off minor type and major emergency in this case is not
perceived.
• Fire preceded or followed by explosion. Explosion is in tanks, barrels, drums and
cylinders due to pressure build up. A safety arrangement is being made in pressure
vessels.
2. Preventive measures and plant safety
During construction
Safety precaution and preventive measures adopted in built in design, maintenance,
instrumentations, handling housekeeping, storage, loading, unloading, transportation
etc.
During operation
Colour code system: is/Will be adopted
Work permit system: is/Will be adopted
Safety Audit: Internally and externally planned
Breakdown/Periodic maintenance and preventive maintenance schedule: Schedule
is/will be prepared and regular breakdown maintenance is carried out after getting
written job order from department where the equipment is used.
Other precautions: All other precautions is/will be taken (need based) from time to
time.
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1. Development of details inspection procedures for various equipment and system
2. Record keeping
All identified vital records of the factory is/will be kept in safeguard them in the event
of an emergency. Back up storage facility is/will be provided.
3. Safety Awareness among the workers
Details of training and periodic retraining programs for the personnel of safety and
fire department
Security guards who act as firemen during fire emergency are trained, retrained and
refreshed on regular basis. Safety professional is sent for external training and some
training program also conducted at works site by external experts of the field.
Details of Training and retraining programs for the workers
Training programs on safety aspects with special attention to firefighting are regular
feature of company. Plant organizes 3-4 sessions every month on safety aspects and
cover good number of workmen in these programs.
All these training programs would at least include the following:
• Lectures
• Seminars and workshop
• Practical Exercises
• Distribution and practice safety instructions
• Safety quiz contests/competitions for individual as also for groups
• Display of safety posters and safety slogans at convenient and conspicuous places.
• Explanation of instructions (in the language easily understood by workers) about the
possible hazards involved in handling of chemicals ad methods to deal with such
hazards failing which possible emergency situation are likely to arise.
• Developing safety instructions for every job and ensuring practice to these instructions/
booklets or manuals by workers.
• Educating workers about the
o Measures taken to ensure safety and control physical and health hazards.
o Physical and health hazards arising out from the exposure of handling substance
o Measures to be taken by workers to ensure safe handling, loading and unloading.
o Storage and transportation of hazardous substances
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o Meaning of various labels and marking used on containers of hazardous substances and to whom to report
o Measures to be taken in case of any spillage or leakage.
4. Public Awareness
The provision of a liaison officer of factory to serve information with public, personnel
manager can play this role. Company can develop a formal public information
procedure during an incident. This may include pamphlets, newspaper stories, periodic
radio, TV announcements and instructive programs for school, inmates of hospitals,
as well as for the dependent aged persons. They provide accurate information to the
general public in order to prevent panic and protect themselves as well as others. As
certain information will need to be communicated quickly, one person would be
identified to serve as spokesperson. It is strongly recommended that the individual
identified has training and experience in public information spokesman can identify for
media, the appropriate individual who have specialized knowledge about the event
and its consequences. The claim of command would therefore include this
spokesperson other members of the response team would be instructed to direct all
communication, and public relation issues to this one person.
5. Medical facilities
Medical aid and services is/will be available and to be pressed into service at short
notice including action plan for medical management to deal with medical
emergencies.
Occupational Health Centre
• OHC is/will be provided with emergency care equipment, emergency medicines,
Documentation Facilities etc at the site.
• Strength and Status of medical staff at occupational Health Centre
• Qualified Doctor & other assistant shall be appointed.
• Medical Facilities is/will be provided inside the factory will be sufficient in case of First
Aid only. Company takes services from outside medical facilities.
6. Personal Protective Equipment
Company has arranged sufficient of PPEs in plant and provided to dust mask for
protection against dust, PVC Gloves for chemical handling, Splash Protection goggles
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for splash protection, ear plug and ear muff from noise protection, leather palm for
general handling, helmet for head protection to their workers.
7. Details of firefighting arrangement
Fire is classified in following three classes. The appropriate fire extinguishers are used
to extinguish the different class of fire.
• Class A – General Fire – Cotton Waste, Paper, Rubbish and Scrap: water, ABC powder
type
• Class B – liquid Fire – All solvents, Resin, Paints, LDO, HSD: Mechanical foam, ABC
type
• Class C – Gaseous /Electrical fire – Gaseous fire & panels etc.: CO2, DCP/ABC
8. Disaster Control Measures
Disaster control measures including mutual aid scheme plan for coordination and
interaction with various external agencies including administrative agencies in the
event of a major risk occurrence and rescue and relief operation plan reflecting
possible projected target population that may be affected. Addresses and telephonic
directory of nearby hospital, Doctors and Nursing Homes will be made available in
disaster control centre.
Rescue and Relief operation plan
Rescue and relief operation plan would be formulated keeping in view all possible
incidents such as fire/explosion/release of toxic materials, spillage of hazardous
materials, release of radioactive materials etc. and to make following arrangement for
communication and appoint key persons to execute the plan.
Communication
Raising the alarm – Manager (Production)
Declaring the major emergency – Manager Manufacturing & plant Manager Works
Making the emergency known to:
• Those inside the works – HR Manager
• The outside emergency services – HR Manager
• Key personnel outside normal working hours – HR Manager
• To authorities of contact persons of neighboring factories.
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Appointment of key personnel and essential workers
The following persons are appointed and their responsibilities and duties would be
specified and clearly spelt out
1. Site Main Controller (SMC)
2. Incident Controller (IC)
3. Other Key Personnel
4. Production heads
5. Manager Quality Control
6. Manager engineering
7. Safety Officer.
Action on site
1. Making emergency known to key personnel. Concerned person and agencies: Works
Incident controller
2. Evacuation: Shift Officer, Particular Area in charge
3. Controlling the situation: Production heads, Shift Officer, Works Incident Controller
4. Accounting for personnel: Works Incident Controller/Works Main Controller
5. Access the records: HR Manager/Works Main Controller
6. Termination of emergency: Works Main controller
7. Public Reaction: Works Main Controller/Personnel Manager
8. Rehabilitation: Works Main Controller/Personnel Manager
9. Re-Entry Procedure: Works Main Controller, works incident controller
Emergency Shutdown procedure
Shift Officer/Production head in consultation with Engineering. Manager has to shut
down, following the prescribed procedure.
Action off-Site
Informing the police, voluntary organization, local administration for rescue operation
and for controlling and regulation the traffic in order to save the mobile population
from effects of smoke due to fire etc. by works main controller/HR manager through
telephone. Making emergency known to community. By blowing three hooters of 30
seconds intermittent with interval of 10 seconds in between road traffic/rail
traffic/radio press/T.V. works main controller. HR Manager.
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Emergency Organization chart
Emergency Control Centre (ECC):
The emergency control center (or room) is the place from which the operations to
handle the emergency are directed and coordinated. The site main controller, key
personnel and senior officers of the fire, police, factory inspectorate, district authorities
and emergency services will attend it. The center should be equipped to receive and
transmit information and directions from and to the incident controller and areas of
the works as well as outside. It should also have equipment for logging the
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development of the incident to assist the controllers to determine any necessary
action.
In addition to the means of communication, the center should be equipped with
relevant data and equipment which will assist those manning the center to be
conversant with the developing situation and enable them to plan accordingly.
It should be sited in an area of minimum risk and close to a road to allow for ready
access by a radio-equipped vehicle for use if other systems fail or extra communication
facilities are needed.
For large sites or where Fire may occur might be anticipated, consideration should be
given to setting up two control centers to ensure, so far as is possible, that one will
be available for use, should the other be disabled. If necessary the police will assist to
set up an emergency control center remote from the works.
7.9.3 Off- Site Emergency Plan
Objective
In the effects of the accident or disaster inside the plant is felt outside its premises, it
calls for an off-site emergency plan (figure 7.17), which would be prepared and
documented in advance in consultation with the district authorities
The off-site emergency plan prepared herein is/will deal with those incidents identified
under Level – 3 in the on-site plan, which have the potential to harm persons or the
environment outside the boundary of the factory premises
Off-site emergency plan has been drawn up with a view to mobilize resources and
integrate with district contingency plan for an effective system of command and
control in combating the emergency.
Thus in brief the two main purpose of the off-site emergency plan are:
To provide the local / district authorities, police, fire brigade, doctors, surrounding
industries and the public, the basic information of risk and environment impact
assessment and to appraise them of the consequences and the protection prevention
measures and control plans and to seek their help to communicate with the public in
case of major emergency
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To assist the district authorities for preparing the off-site emergency plan for the
district or particulate area and to organize rehearsal from time to time and initial
corrective action based on the lesson learnt
Figure 7.17: OFF-SITE EMEGENCY PLAN