Chlorine Emission Presentation-New

7/30/2019 Chlorine Emission Presentation-New

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IPCLGandhar Petrochemicals Complex



Location of Chlorine Vent

Wind Directi

NE to SW

Wind Spee

9 Km/Hr



GANDHAR COMPLEX - PRODUCT FLOW DIAGRAM

Salt

Semi-RichGas

(from GAIL)

C2 C3

SeparationPlant

C2 C3

Mixture

GasCracker

Plant Ethylene

EDC / VCMPlant

Chlorine

Chlor-Alkali

Plant

VCM

PVC

Plant

HDPE

Plant

HCL

CausticSoda Flakes

Caustic

Soda Lye

Caustic Soda

Prill

Lean Gas EO/EG

Plant

PVC

EthyleneOxide

Ethylene

Glycol

HDPE

Raw Material ProductsIntermediate



IPCL - CHLOR ALKALI PLANT

Capacity

Caustic : 460.00 TPD Chlorine : 400..00 TPD

Major Sections :

Primary Brine : Preparation of Brine

Secondary Brine : Purification of Brine

Cell House : Electrolysis of Brine

Chlorine : Compression and Liquifaction of Chlorine

CEU / CCU : Concentration of Caustic Soda

M/s UHDE Membrane Cell TechnologyDate of Commissioning : 01 Apr 1997

On line Use.

Licensed Storage Capacity - 460.00 MT

At no Time stored More than 40.00 T



Salt

DM Water

BrinePreparation

BrinePurification

Electrolsysis

Power

Chlorine Treatment :

Drying, Compression,

Liquifaction

Chlorine Gas to

VCM

Chlorine

Evaporation

HydrogenChlorine

Caustic Soda

Schematic Diagram Of Process



Function Of Hypo Section :

To Neutralize The Waste Chlorine Gases From The Plant

Areas With Caustic Soda And Make Sodium Hypo

Chlorite

Hypo Section : Part of Chlorine Section

Normal Capacity :750 Kg/Hr of Chlorine

Emergency Handling Capacity:3.00 Tons of Chlorine in

10 min - Neutralizing Capacity for Plant full Load

Design Capacity – Hypo Section



Schematic of Hypo System

Waste

Chlorine

18 mHeight

Vent

Caustic

Over Head

Tank

Suction

Tank I

Suction

Tank II

Pump Pump

Chlorine Emission

Faulty RedoxMeter

Final Scrubber

Estimated Chlorine

Release : 26.00 Kg



Date of Occurrence

of Incident : 20 – 12 - 2002

Time : 21:05 Hr

First Information of Leak :

Report of Chlorine Smell By Other Plants And

By People From Jageshwar Village - Due to

Wind Direction

Immediate Action TakenThe plant was Stopped Immediately within 8

minutes. All The Chlorine System Was Isolated

And Thorough Check Of All Pressurized

Chlorine System was done by Ammonia

Plant Was Under Shut Down Since Morning For Routine

Maintenance. Restarted at 19:00 Hr. Under Stabilization at

The Time Of Incidence



Chronology Of Events

Plant Re-Start Up : 17:00 Hr

HCl Furnace Start up : 19:40 Hr

First Report Of Smell : 21:05 Hr

Plant Load Reduction : 21:05 Hr

Complete Check Up Of All Areas Of The Plant. No identifiable leak could be

found

Plant Shut Down Was Taken At 21:29 Hr

Senior People Of IPCL Visited The Site Along With Fire And Safety Personnel

No Chlorine Smell Could Be Found

Thorough Checking Of Pressurized Chlorine Equipment With Ammonia For

Any Leaks

Follow Up Actoins



Ambulance / Fire Services / Security people visited Plant at 21:30 HrVillagers Arrived and Treatment Given At OHC. Doctors From Nearby

Industries Called For Help

Transport Section Was Alerted To Keep Vehicles Ready If Evacuation

Is Required

RGSS Personnel Were Posted At OHC To Help The Villagers Coming

For Treatment

Since Dahej Telephone Exchange Was Down, Angareshwar Pump

Station Was Contacted To Give Messages to ED -GC and GM -O At

22:00 Hr

WTD At Baroda Was Informed Using M/s Dodsal Communication

System At 22:00 Hr

At 23:00 Hr Senior Executives Of IPCL Visited The Complex And

Jageshwar And No Chlorine Smell Could Be Found

On-Site Emergency Actions



Message Was Conveyed To Senior Factory Inspector, Bharuch And

Officer Of GPCB At Bharuch By 23:00 Hr. They Arrive At 01:30 Hr

Police Authorities From Dahej Police Station Also Arrive To AssessThe Situation

Between 01:30 Hr and 03:30 Hr GPCB Officials Vistied The Complex

And Jageshwar Village. No Chlorine Smell Found. Nil Reading on

Detection Tube

Total Of 335 Villagers Were Given Treatment For Cough And Throat

Irritation And Released The Same Night

Eight People Were Sent To Bharuch For Close Observation

Doctors Visited Jageshwar Village Daily For 7 Days For PreventiveHealth Check UP

No Fatal Injury In The Incident



Limitations Which Influenced the Occurrence

of the incident :

Low Concentration Of Caustic in The

Suction Tank -Scrubbing Tank

Effective Low Volume of the Over Head Tank

Off-Line of Suction Tank I due to Maintenance

Faulty Indication Of Redox Meter

Gas Detector In the Opposite Direction Of Wind



Actions Taken Before Re-start of the Plant

All the instruments of Hypo System Were Checked

And Calibrated

Concentration Of Caustic in The Over Head Tank

Increased to Increase the Caustic Concentration

Dosed to Suction Tanks

Taking in line Of Hypo Suction Tank I Also

Installation of One Gas Detector Near to The HypoVent Stack



Actions Taken to Prevent Recurrence of the

Incident :

SOP of Hypo System Was Revised To Meet TheIncreased Safety in Operation

To Keep Both The Suction Tanks Always in Line

Additional Two Chlorine Sensors -Total 3

With Hooter in DCS And Recording Provided Near The

Chlorine Vent

Replacement of Caustic Head Tank

Regular Sampling of Gas Coming Out of The Vent

Installation of additional Redox Meters in The Suction

Tank

Provision of Chlorine Gas Sensors in Other Locations inthe Vicinity - Complex Boundary Near Village



Actions Taken to Increase Awareness and Integrity

Additional Siren Installed On Complex Boundary Near

Village Jageshwar

Regular Ambient Air Monitoring is Carried Out In theVillage

Windsocks Provided in The Surrounding Village

Review / Rehearsal Of Onsite Emergency Plan

Interaction With Nearby Industries At Working Level

Improving External Communication System



Actions Taken to Increase Awareness and Integrity

Safety Audits by Internal And External Agencies At

Regular Intervals

Discussions with Chlor – Alkali Industries to reach the root

cause for this Incidence

Discussions with UIL – Mumbai our Technology Licencors

to Review our SOPs for the Plant Operations

Plant Audit done by RIL- Safety Team to review our

Infrastructure Requirements for safe Plant Operations so as

to avoid Reoccurrence of such incidence

Safety Audit done by Euro – Chlor Belgium to review our

Infrastructure Requirements for safe Plant Operations so as

to avoid Reoccurrence of such incidence

Meeting with Neighboring industries as a confidenceBuilding Measure in Our Safety Management System.



We are confident from the Lessons learnt from

the accident and the follow up action we have

undertaken.We are sure that the chances of reoccurrence of such Incidence are non - Existent

Chlorine Emission Presentation-New

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