Nakoda Chemicals Limited Environmental Impact Assessment...

Nakoda Chemicals Limited Environmental Impact Assessment Report

7-1 Pridhvi Envirotech Pvt. Ltd

CHAPTER 7.0: RISK ASSESSMENT AND DISASTER

MANAGEMENT

7.1 Introduction

M/s.Nakoda Chemicals Limited proposed to expand the production

capacity of existing Bulk Drugs and Bulk Drug Intermediates

manufacturing plant at Plot No. 64/A and 65/B, Phase-I, IDA

Jeedimetla, Medchal District, Telangana State. The site is situated

between 17030’59.8” North and 17031’03.3 North Latitude and

78027’04.7” East and 78027’07.8” East Longitude. The existing land

area of the plant is 1.25 acres. The unit acquired additional land of

2.74 acres adjacent to the site in Plot no. 65/B for expansion

activity. Thus the total area of the unit is 4.0 Acres.

7.2 Site Location and Surrounding

7.2.1 Site Location and facilities

M/s. Nakoda Chemicals Limited, IDA Jeedimetla is Surrounded by

Road on all sides and Neo spark chemicals on the Eastern side.

Following facilities are there in the unit

• Production Area

• Ware House

• QC/QA laboratory

• Utilities Block

• Services area

• Generator Room

• Effluent Treatment Plant

• Cooling towers

• Purified Water system

• Scrap yard



7.2.2 Description of the area around the installation:

East : Neo Spark Chemicals

South , North & West : Road

Table 7.1

Surrounding features of the site with distances

Area Distance Remarks

Resident/Village area 0.7 km Shapur nagar

Market 0.7 km Shapur nagar

Govt. Hospital 0.8 km Gajula Ramaram road

School 0.7 km Primary & Secondary

Others:

Railway Station

Police Station

7.0 km

0.8 km

7.3 Objectives and Scope

The production of synthetic organic chemicals involves usage of

many chemicals which are both hazardous and non-hazardous in

nature. Risk analysis has been carried out to identify the hazardous

materials and quantify the hazards to arrive at safe disaster

management plan and emergency preparedness plan for storage

and handling of the potentiality hazardous materials. Also the

purpose of carrying out risk assessment study for M/s. Nakoda

Chemicals limited is to obtain clearance from the Ministry of

Environment and forests (MOEF) which calls for a study on nature

of hazards due to proposed location of process and storage units

and also to study whether any accident, if occurs leads to any off-

site disaster. In this endeavour, the study objectives are outlined

here under.



i) Hazard identification and Visualization of Maximum

Credible Accident Scenarios.

• To identify major hazards relating to fire, explosion and

toxicity due to chemicals, processes and storages of the

proposed units.

ii) Hazard Analysis and Risk Assessment

• Hazard analysis is the process of determining the release

probabilities and quantities, emission or release rates, the

routes/pathways by which the released substances could reach

the receptors, the fate of the substances in environmental media

through which they are transported or moved and the

characteristics of the receptors at risk.

• Disaster Management To provide guidelines for Disaster

Management Plan(DMP) for on-site emergencies and Emergency

Preparedness Plan(EPP) for off-site emergency, based on above

i) & ii) studies of proposed plant.

7.4 Production Details

The manufacturing capacities of are presented in Table 7.2

Table 7.2

Manufacturing Capacity of Proposed Products

S.No Product Name

Production Capacity

TPM

Product Description Drug/Intermediate/

Multipurpose

chemicals

1 Norfloxacin 2.08 Drug

2 PefloxacinMesilate di

hydrate 0.83

Drug

3 Acetazolamide 6.67 Drug

4 Lomefloxacin HCl 0.33 Drug

5 Famotidine 2.50 Drug

6 Ecabet Sodium 5.00 Drug

7 Menatetrenone 0.08 Drug

8 Prolonium Iodide 0.02 Drug



9 Stearic Hydrazide 0.02 Drug

10 Azelastin-1 0.02 Drug Intermediate

11 2 (2-Methoxy Phenoxy)

ethylamine (Anisole) 0.83 Drug Intermediate

12 n-Benzyl-n-ethyl-3-acetanilide 0.08 Multipurpose Chemicals

13 n-(3-ethyl(phenyl

methyl)) butyranilide 0.50 Multipurpose Chemicals

14 1,2,3,9-tetrahydro-4 H-

carbazol-4-one 0.19 Drug Intermediate

Total 19.17

Bi-Products

1 Weak Piperazine 42.15

2 n- methyl piperazine ML 10.7

3 Gum Residue 10.1

4 Weak acid (Acetic) 40.6

5 Dil Formic acid 0.2

6 Mixed Ammonium Salts* 54.2

* Mixed Ammonium salts are generated whenever Stage I and III

Effluents of Acetozolamide are treated in house

7.4.1 Process Description

The details of process are given in Enclosure I of Chapter 3

7.5 Hazard Analysis and Risk Assessment

7.5.1 Introduction

Hazard analysis is the process of determining the release

probabilities and quantities, emission or release rates, the

routes/pathways by which the released substances could reach the

receptors, the fate of the substances in environmental media

through which they are transported or moved and characteristics of

the receptors at risk. The basis of risk estimation is to determine

the dose-effect relationship between an indicator chemical and

receptor. Estimation of risk follows only when the hazard analysis

shows a frequency or occurrence, which is significant.



Risk evaluation is the process of identifying, whether the estimated

level of risk is tolerable. Tolerable risk is not equated with

acceptability; it refers to a willingness to live with a risk so as to

secure certain risk benefits, and in the confidence that the risk is

being properly controlled.

Hazard analysis involves the identification and quantification of the

various hazards (unsafe conditions) that exist in the plant. On the

other hand, risk analysis deals with the identification and

quantification of risks, the plant equipment and personnel are

exposed to, due to accidents resulting from the hazards present in

the plant.

Hazard and risk analysis involves very extensive studies, and

requires a very detailed design and engineering information. The

various hazard analysis techniques that may be applied are hazard

and operability studies, fault-tree analysis, event-tree analysis and

failure and effects mode analysis.

Risk analysis follows as extensive hazard analysis. It involves the

identification and assessment of risks; the neighbouring

populations are exposed to as a result of hazards present. This

requires a thorough knowledge of failure probability, credible

accident scenario, vulnerability of population’s etc. Much of this

information is difficult to get or generate. Consequently, the risk

analysis is often confined to maximum credible accident studies.

7.5.2 Common definitions

The common terms used in risk Assessment and Disaster

Management are elaborated below:

“Risk” is defined as a likelihood of an undesired event (accident,

injury or death) occurring within a specified period or under



specified circumstances. This may be either a probability depending

on the circumstances.

“Hazard” is defined as a physical situation, which may cause

human injury, damage to property or the environment or some

combination of these criteria

“Hazardous substance” means any substance or preparation,

which by reason of its chemical or physic chemical properties or

handling is liable to cause harm to human beings, other living

creatures, plants, micro-organisms, property or the environment

“Hazardous process” is defined as any process or activity in

relation to an industry which may cause impairment to the health

of the persons engaged or connected therewith or which may result

in pollution of their general environment.

“Disaster” is defined as a catastrophic situation that causes

damage, economic disruptions, loss of human life and deterioration

of health and health services on a scale sufficient to warrant an

extraordinary response from outside the affected area are

community. Disasters occasioned by man are factory fire

explosions and release of toxic gases or chemical substances etc.

“Accident” is an unplanned event, which has a probability of

causing personal injury or property damage or both.

“Emergency” is defined as a situation where the resources out pass

the demand. This highlights the typical nature of emergency; it will

be after experiences that enough is not enough in emergency

situations. Situations of these kinds are avoidable but it is not

possible to avoid them always.



In the sections below, the identification of various hazards,

probable risks in a process industry manufacturing optical

brighteners, maximum credible accident analysis, consequence

analysis are addressed which gives a broad identification of risks

involved in the plant.

7.5.3 Hazard Identification

Identification of hazards in the synthetic chemicals organic plant is

of primary significance in the analysis, quantification and cost

effective control of accidents involving flammable compounds. A

classical definition of hazard states that hazard is not in fact the

characteristic of system/plant/storage that presents potential for

an accident. Hence, all the components of a system/ plant/ process

need to be thoroughly examined to assess their potential for

initiating or propagating an unplanned event/sequence of events

which can be termed as an accident.

Typical schemes of predictive hazard evaluation and quantitative

risk analysis suggest that hazard identification step plays a key role

in estimation of probability of an unexpected event and its

consequences from the basis of quantification of risk in terms of

damage to property, environment or personal. Therefore the type,

quantity location and conditions of release of a toxic or flammable

substance have to be identified in order to estimate its damaging

effects, the area involved, and the possible precautionary measures

required to be taken.

Some of the hazard identification procedures are as follows:

a) Fire Explosion and Toxicity Index (FETI) Approach;

b) HAZOP studies



c) Maximum Credible Accident and Consequence Analysis

(MCACA);

7.5.3.1 Identification of Major Hazards from the unit

The Hazard identification process adopted is to identify hazardous

chemicals as per the statutory requirements of Manufacture

storage and import of Hazardous Chemical Rules, 1989

The identified chemicals for the risk assessment are presented in

the following Table 7.3

Table 7.3

List of Raw materials and Inventory

S.No Raw material Nature

of storage

Physical Form

Maximu

m storage quantity

Kgs

CAS NO

1 1,3 cyano hexane dione

Bags Solid 117.0 504-02-9

2 1,3

Dichloroacetone carboys Solid 771.8 534-07-6

3 2-Methyl

piperazine Bags Solid 74.4 109-07-9

4 3 Nitro Aniline Bags Solid 217.8

99-09-02

5 3-Chloro,4-Fluoro

aniline carboys Solid 1314.3 367-21-5

6 Acetic acid Tank Liquid 8093.5

64-19-7

7 Acetone Drums Liquid 5217.6

67-64-1

8 Acetonitrile Drums Liquid 1509.6

75-05-8

9 Acetyl chloride Drums Liquid 16.1

75-36-5

10 Ammonia Cylinder Gas 467.2

7664-41-7

11 Ammonium

Thiocynate Bags Solid 4228.9 1762-95-4

12 Benzyl Chloride Drums Liquid 228.7

100-44-7



13 Caustic soda

Flakes bags Solid 1552.3 1310-73-2

14 Carbon Bags Solid 789.9

7440-44-0

15 Caustic lye Tank Liquid 3193.2

1310-73-2

16 Chlorine gas Cylinder Gas 4075.8

7782-50-5

17 Chloroform Drums Liquid 635.0

67-66-3

18 Dicyclopentadione Drums Liquid 233.5

77-73-6

19 Diethyl Sulphate Drums Liquid 1892.3

64-67-5

20 Diethylether Drums Liquid 792.3 60-29-7

21 Di methyl Amine Drums Liquid 3.0

124-40-3

22 Dimethyl

Formamide Drums Liquid 4296.1 68-12-2

23 Di Methyl

Sulphoxide Drums Liquid 126.0 67-68-5

24 EDTA Bags Solid 4.6

139-33-3

25 Eichlorohydrin Drums Liquid 3.1

106-89-8

26 EMME Drums Liquid 2022.0

87-13-8

27 Ethanol Tank Liquid 17941.4

64-17-5

28 Ethyl acetate Drums Liquid 28.1

141-78-6

29 Formic Acid

(85%) Drums Liquid 144.5 64-18-6

30 Geranyllinaliol Drums Liquid 208.5

24034-73-9

31 Guaianyl Thiourea Bags Solid 725.4

2114-02-5

32 Guaicol Drums Liquid 567.0

90-05-1

33 Gumrosin Drums Solid 6854.4

8050-09-7

34 HCl Tank Liquid 5767.8

7647-01-0

35 Hydrazine Hydrate Drums Liquid 1628.0

10217-52-4

36 Hydrose Drums Solid 73.0

7775-14-6

37 Hyflow Bags Solid 77.9

68855-54-9



38

Hypo phosphoric

acid carboys Solid 120.8 7803-60-3

39 Isopropyl alcohol Tank Liquid 5877.0

67-63-0

40 Iron Bags Solid 211.9

7439-89-6

41 Iso Butyl chloride Drums Liquid 118.4

513-36-0

42

Light Liquid

Paraffin Tank Liquid 6157.0 8012-95-1

43 Liquid ammonia Tank Liquid 7717.1

1336-21-6

44 Lomefloxcin Acid Carboy Solid 160.8

100501-62-0

45 Menadione Bags Solid 93.8

58-27-5

46

Methane Sulphonic

acid Drums Liquid 126.0 75-75-2

47 Methanol Tank Liquid 19338.1

67-56-1

48 Methyl Iodide

Containe

rs Liquid 8.3 74-88-4

49 Mono Ethylamine Drums Liquid 1641.2

75-04-7

50 N-Butanol Drums Liquid 707.4

71-36-3

51 n-Hexane Tank Liquid 1510.5

110-54-3

52

n-Methyl

Piperazine Drums Liquid 4418.3 109-01-3

53

n-Sulphyl-3-chloro

hydrochloride Carboy Solid 401.1 1206492-70-0

54 Palladium Carbon

Plastic

tins Solid 1898.5 7440-05-3

55

Para Chloro Benzyl

Cyanate Drums Liquid 13.7 140-53-4

56 PEG Carboy Liquid 21.0

25322-68-3

57 phenyl hydrazine hydrochloride

Bags Solid 32.7 59-88-1

58

Phosphorus

oxychloride carboys Liquid 195.0 10025-87-3

59

Phosphous tri

Bromide Drums Liquid 52.9 7789-60-8

60 Piperzine Bags Solid 196.0

110-85-0



61 Potassium Iodide Drums Solid 1922.4

7681-11-0

62

Potassium tert-

butoxide Bags Solid 30.9 865-47-4

63 Pthalic Anhydrate Bags Solid 137.6

85-44-9

64 Pyridine Drums Liquid 24.0

110-86-1

65

Sodium

bicarbonate Bags Solid 39.5 144-55-8

66 Sodium carbonate Bags Solid 174.4

497-19-8

67 Sodium Chloride Bags Solid 1933.7

7647-14-5

68 Sodium Hydride Bags Solid 83.4

7646-69-7

69 Sodium hydroxide Bags Solid 5.5

1310-73-2

70 Sodium Sulphate Bags Solid 68.7

7757-82-6

71 Stearic acid Bags Solid 11.3

57-11-4

72 Sulfuric acid Tank Liquid 5526.9

7664-93-9

73

Tertiary Butyl

Ammonium

Bromide

Bags Solid 54.3 1643-19-2

74 Tetra hydro furan Drums Liquid 846.5

109-99-9

75 Thiourea Bags Solid 463.1

62-56-6

76 Toluene Tank Liquid 6857.9

108-88-3

77 Xylene Drums Liquid 1404.8

1330-20-7

78 Zinc acetate Bags Solid 44.6

557-34-6

Table 7.4

List of hazardous chemicals (listed in part II of schedule I of

MIHS Rules)

S.

No Raw material

Physical

form

Type of

hazard

Maximum Storage

quantity Kgs

Threshold

Quantity

(Rule 5,7,9 and

13 &15

Threshold

Quantity

(Rule 10 to 12

Level

of Hazard

1 Acetonitrile Liquid Flammable 1509.6 Not

specified Not

specified Level 1 Hazard



2 Acetic acid Liquid Flammable 8093.5 Not

specified Not


3 Acetone Liquid Flammable 5217.6 Not

specified Not


4 Ammonia Liquid Toxic,

corrosive 467.2 50T 500T

Level 1

Hazard

5 Benzyl chloride Solid Flammable 228.7 Not

specified Not


6 Chlorine Gas Toxic 4075.8 Not

specified

Not

specified

Level 1

Hazard

7 Chloroform Liquid Toxic 635.0 Not

specified Not


8 Dimethylamine Liquid Flammable 3.0 Not

specified Not


9 DMSO Liquid Flammable 126.0 Not

specified

Not

specified

Level 1

Hazard

10 Epichlorohydrin Liquid Flammable 3.1 Not

specified Not


11 Ethanol Liquid Flammable 17941.4 Not

specified Not


12 Ethylacetate Liquid Flammable 5.6 Not

specified

Not

specified

Level 1

Hazard

13 Formic acid Liquid corrosive 144.5 Not

specified Not


14 HCl Liquid corrosive 5767.8 25 T 250T Level 1

Hazard

15 Isopropyl alcohol

Liquid Flammable 5877.0 1500T 10000T Level 1 Hazard

16 Methanol Liquid Flammable 19338.1 Not

specified Not


17 n-Butanol Liquid Flammable 1510.5 Not

specified

Not

specified

Level 1

Hazard

18 n- Hexane Liquid Flammable 4418.3 Not

specified Not


19 Phenyl

hydrazine

hydrochloride

Solid Toxic 195.0 Not

specified

Not

specified

Level 1

Hazard

20 Phosphorous oxy chloride

Liquid corrosive 52.9 Not

specified Not


21 pyridine Liquid Flammable 39.5 Not

specified

Not

specified

Level 1

Hazard

22 Sodium

Hydroxide Solid Corrosive 707.4

Not specified

Not specified

Level 1 Hazard

23 Tetra

hydrofuran Liquid

Flammable /toxic

846.5 Not

specified Not


24 Toluene Liquid Flammable 6857.9 Not

specified

Not

specified

Level 1

Hazard

25 Thiourea Solid Toxic 463.1 Not

specified Not




Note :

Level I Hazard: Chemical is listed in schedule of chemicals but

threshold limit did not crossed 1st threshold or 2nd threshold limit as per

the schedule I of MSIHC Rules 2000

The Physical properties of the key chemicals stored are presented in the

following Table 7.5

Table 7.5

Physical properties & Hazard characteristics of Key Raw

materials

S.No Name of the

Material

Boiling

point oC

Flash

Point in oC

Explosive

Limits

volume %

in air

NFPA Rating

Health Fire

recativi

Reactivi

ty 1 Acetic acid 118.1 39 4-19.9 2 2 0

2 Acetone 55.6 -17.8 2.5-12.8 2 3 0

3 Acetonitrile 81.6 2 3-16 3 3 0

4 Ammonia -28 - 15-28 3 1 0

5 Caustic Lye 1390 - - 3 0 1

6 Diethyl ether 34.6 -40 1.8-4.8 1 4 1

7 Dimethyl amine 6.9 -50 2.8-14.4 3 4 0

8 Dimethyl

sulfoxide 189 89

3.0-3.5 2 2 0

9 Ethanol 78.2 12 3.3-19.0 2 3 0

10 Ethyl aceate 77 7.2 2.2-9.0 1 3 0

11 Hydrochloric acid 108.5 - - 3 0 1

12 Hexane 69 -26 1.2-7.7 2 3 0

13 Isopropyl alcohol 82.5 12.77 2-12.7 1 3 0

14 Methanol 65.5 16 6-3-6.5 1 3 0

15 n- Butanol 117.4 28.9 1.4-11.2 1 3 0

16 Pyridine 115.4 17 1.8-12.4 2 3 0

17 Tetrahyro furan 65 -14.5 1.8-11.8 2 3 1



18 Toluene 110.6 4.4 1.2-6.7 2 3 0

The interpretation of “The Manufacture storage and import of

hazardous chemicals Rules” issued by the ministry of Environment

and Forests, GOI which guides the preparation of various reports

necessary for safe handling and storage of chemicals shows that

the present object requires to prepare safety reports before

commencing operations and risk assessment is not mandatory .

The applicability of various rules is presented in Table 7.5

The chemical reactions involved in the process do not involve the

pressure temperature conditions in combination and does not lead

to any run any reactions hence a cursory HAZOP was conducted

and systematic emergency plan is presented

Safety measures for Transportation, Storage & Handling of

chemicals

� Solvent is proposed to be received by road tankers and stored in

barrels.

� Solvent unloading standard procedure will in place and will be

implemented for safe unloading of road tanker.

� Static earthing provision will be made for tanker unloading.

� Drum handling trolleys will be used for transportation of drums up

to plant.

� Muffler on the silencer of the tanker during entering in factory

premises.

� Display Boards will be provided on all storage tanks which

includes the name of the chemicals, stored Material of

construction and date of painting.

� Hazardous display board and national fire prevention association

code will be displayed on storage area.



� On-site detectors for fire based on heat &/or smoke detection with

alarm system will be provided as required.

� Fire extinguishers will be provided as required.

� First aids boxes will also be provided at different places wherever

required.

� Water showering system will be provided to the flammable

chemicals storage area, wherever required to avoid the

vaporization due to increase in atmosphere temperature.

� Area will be declared as “NO SMOKE ZONE”.

7.6 Fire& Explosion Index (F&EI):

7.6.1 Methodology

Dow Chemical Company issued a guideline for hazard

determination and protection. By this method a chemical process

unit is rated numerically for hazards. The numerical value used is

the Fire and Explosion Index (F&EI) which is most widely used for

hazard evaluation in chemical process industries.

The guide applies to process unit only and not to auxiliary units

such as power generating stations, plant water systems, control

rooms, fired heaters, structural requirements, corrosive nature of

material handled and personal safety equipment. These are

regarded as basic features that do not vary according to the

magnitude of the fire and explosion hazard involved. The guide also

does not cover the processing and handling of explosives such as

dynamite, TNT etc.

7.6.2 Computation of F&EI

The computation of fire and explosion index of each unit is based

on the material factor. This is a measure of the intrinsic rate of

potential energy release from fire explosion of most hazardous



material or mixture of materials present in significant quantity,

whether it is raw material, intermediate, product, solvent etc., by

combustion or chemical reaction. “In significant quantity” here

means such quantity that the hazard represented by the material

actually exists. The Nationality Fire Protection Agency of USA

(NFPA) have specified standard values for material factor which

should be used for F&EI calculations and are available in DOW’s

hazard classification guidein case it is not readily available, it can

be calculated using the heat of combustion, flammability indices

etc.

General process hazard are factors that play a primary role in

determining the magnitude of loss of incident. It takes into account

the nature of the reaction, ventilation of the unit, accessibility of

the unit, drainage facilities etc., special process hazards are factors

that contribute primarily to the probability of a loss incident. They

consist of specific process conditions that have shown themselves

to be major causes of fire and explosion incidents. It takes into

account toxicity of the material, operating pressure, operation near

flammable range, quantity of material, joints and packing, use of

hot oil exchange system etc., The F&EI calculated as a product of

material factor, general process hazard factor, and special process

hazard factor.

7.6.3 Hazard Ranking

The hazard ranking based on F&EI value is as follows

Table 7.6 Degree of Hazard for F&EI

F&EI Index Range Degrees of Hazard

1-60 Light

61-96 Moderate

97-127 Intermediate



128-158 Heavy

159 & above Severe

The estimated values of F&EI reflect light hazard in view of the low

volume of chemicals.

The fire and explosion index evaluation can be very useful in

developing plant layouts or adding equipment and buildings to

existing plants. Evaluation of the F&EI calculations and layout

considerations will result a safe operable, maintainable and cost

effective arrangement of equipment and buildings.

7.6.3.1 Maximum Credible Accident Analysis and Its Mitigation

Measures

A Maximum Credible Accident (MCA) can be characterized as the worst

credible accident. In other words: an accident in an activity, resulting in

the maximum consequence distance that is still believed to be possible.

A MCA-analysis does not include a quantification of the probability of

occurrence of the accident. Another aspect, in which the pessimistic

approach of MCA studies appears, is the atmospheric condition that is

used for dispersion calculations.

The Consequence Analysis has been done for selected scenarios by

ALOHA (version 5.4.4) of EPA. The details of software used for MCA

analysis are described below.

� A computer based version ALOHA 5.4.4 is used to calculate toxic

and explosive effect of the accidental release of liquid chemicals

within the plant area.

� ALOHA (Areal Locations of Hazardous Atmosphere) is a computer

program designed especially for use by people responding to

chemical release as well as for emergency planning and training.



� ALOHA was jointly developed by the National Oceanic and

Atmospheric Administration (NOAA) and the Environment

Protection Agency (EPA).

� The mathematical model is based on the Emergency Response

Planning Guidelines (ERPGs) which gives Toxic Levels of Concern

(LOCs) to predict the area where a toxic liquid concentration

might be high enough to harm people.

� ALOHA models key hazards-toxicity, flammability, thermal

radiation (Heat), and over pressure (expansion blast force)-

related to chemical releases that result in toxic gas dispersion, fire

and/or explosion.

7.6.3.2 Heat Radiation & Vapour cloud Fire distances of

Hazardous Storages

Following table gives the bulk storages of chemicals after expansion

activity.

Table 7.7

Bulk Storages after expansion

Existing tanks

S.NO Name of the chemicals

Capacity (KL)

MOC

No. Of Tanks

Tank Dia

(m)

Tank Height

(m)

Remarks

1 Methanol

60

MS

1 X 10 KL

5 x 10 KL

3.8

3.8

1.9

1.9 Below ground

2 Toluene 10 MS 1 X 10 KL

3.8 1.9

Below ground

3 Rectified

Spirit 17.5

MS 1 X 10 KL

1 x 7.5 KL 3.8

3.8

1.9

1.9

Below ground

4 IPA 22 MS 1 X 11 KL

1 x 11 KL

3.9

3.9

1.9

1.9

Below ground

5 Furnace Oil 22 MS 1 X 5 KL

1 x 17 KL

1.25

3.0

2.25

2.7 Above ground

6 Ammonia 10 MS 1X 10 KL

3.5 1.9 Above ground



6 HCl 18 FRP 1 X 18 KL 3.5

2.6

Above ground

7 Sulphuric

Acid 35

MS,

HDPE,

FRP

1 X 10 KL

1 x 10 KL

1 X 15 KL

3.3

3.5

4.0

2.0

2.0

2.22

Above ground

9 Acetic Acid 77 FRP,

HDPE

4 X 19.25

KL 3.5 2.6

Above ground

10 CS Lye 10 MS 1 X 10 KL


11 Weak

Piperzine 15

MS 1 X 15 KL 4 2.65

Above ground

Proposed tanks

12 Acetic acid 60 MS 2x30 KL


13 Sulphuric

acid 20

MS 1x20 KL 3.5 3.5

Above ground

14 Rectified

Spirit 10

SS 1 X 10 KL 3.5 2.0

Above ground

Out of the above, Toluene, Methanol, Ethanol, IPA are proposed to

be stored underground. C.S Lye, Weak Piperazine, Acetic acid,

Sulphuric acid, Rectified spirit, HCl, Ammonia and Furnace oil are

proposed to be stored in above ground tanks.

Consequences Analysis

From the proposed raw materials the following chemicals have

been taken considering their hazardous nature. The heat radiation

distances in case of pool fire for flammable storage tanks are

presented in the below Table 7.8 below



Table 7.8

Heat Radiation Damage Distances for storage tanks – Tank farm

S.No

Name of

Raw

material

Storage Tank Details

Scenario Details( Pool fire –

Leaking tank)

FEI

Index Tank

Capacity

(KL)

No.s Diameter

(m)

Height

(m)

Release

Rate

(Kg/min)

Heat radiation

damage distances

in m for KW/m2

10 5 2

1 Methanol 68 60 6 3.8 1.9 23.5 <10 <10 10

2 Toluene 100 10 1 3.8 1.9 24.5 <10 11 15

3 Ethanol 75 18 2 3.8 1.9 23.4 <10 <10 12

4 Isopropyl

alcohol

90 12 1 3.9 1.9 23.3 <10 <10 13

5 Acetic

acid

65 77 4 3.5 2.6 26.9 <10 <10 <10

Note:

2 kW/(sq m) -- people will feel pain after 45 seconds and receive

second degree burns after 3 minutes;

• 5 kW/(sq m) -- people will feel pain after 13 seconds and receive

second degree burns after 40 seconds; and

• 10 kW/ (sq m) -- people will feel pain after 5 seconds and receive

second degree burns after 14 seconds.

The storage is a small capacity facility and accordingly the F & E

index value is found to be moderate reflecting the threshold limits

as prescribed in MSHC rules. As can be seen, the heat radiation

distances are confined to plant area only.

Other hazardous chemicals stored in drums and vapour cloud fire

distances are estimated using ALOHA model and same are

presented in the Table 7.9 Below

Table 7.9



Liquid storages in Drums – Vapour cloud Fire distances

S.No

Name of

Raw

material

Storage Tank Details Scenario Details

FEI

Index

Storage

Invento

ry kgs

Each

Drum

capacity

NO. Of

Drums

Relea

se

Rate

(Kg/

sec)

Vapour cloud

fire distance

Red Oran

ge

Yell

ow

1 Acetone 95 2500 100 Kgs 25 1.67 11 - 13

2 Tetra

hydrofuran

108 300 50 Kgs 6 0.83 22 - 62

3 Chloroform 90 250 50 Kgs 5 4.17Kg

/min

33 359 -

7.6.3.3 Toxic chemicals storage and toxic impact distances:

Following chemicals are classified as toxic chemicals used by the

company. Toxic influence distances are estimated using ALOHA

model in case of Drum Leakages and presented below

Nak

od

a C

hem

icals

Lim

ited

E

nv

iro

nm

en

tal

Imp

act

Ass

ess

men

t R

ep

ort

7-2

2

Pri

dh

vi

En

vir

ote

ch P

vt.

Ltd

Tab

le 7

.10

Toxic

th

reat

zo

nes o

n r

ele

ase o

f ch

em

icals

S.N

o

Nam

e o

f

the s

olv

en

t

Sto

rag

e

cap

acit

y

Scen

ario

Deta

ils

Rele

ase

rate

(kg

/m

in)

AEG

L-3

Red

(m

)

AEG

L-3

Red

(p

pm

)

AEG

L-2

Oran

ge

(m

)

AEG

L-2

Oran

ge

(p

pm

)

AE

GL-1

Yello

w(m

)

AEG

L-1

Yello

w

(p

pm

)

1

Acetic a

cid

77

3.7

8

49

250

224

35

666

5

2

Meth

anol

60

10.8

16

7200

34

2100

117

530

3

Eth

yl aceta

te

50

50

23

10000

65

1700

79

1200

4

Tolu

ene

10

8.9

3

13

3700

35

560

197

67

5

Chlo

rform

100

100

53

3200

574

64

- -



Note :

AEGL-1 (Yellow zone): The airborne concentration of a substance above

which it is predicted that the general population, including susceptible

individuals, could experience notable discomfort, irritation, or certain

asymptomatic non sensory effects. However, the effects are not disabling

and are transient and reversible upon cessation of exposure.

AEGL-2 (Orange zone): The airborne concentration of a substance above


individuals, could experience irreversible or other serious, long-lasting

adverse health effects or an impaired ability to escape.

AEGL-3 (Red zone): The airborne concentration of a substance above


individuals, could experience life threatening health effects or death.

7.6.3.4 Analysis of quantitative risk assessment data:

Based on the above quantitative risk assessment, following

conclusions can be made.

� Flammability threat zones and heat radiation zones for

flammable chemicals are within the plant premises

� FEI index for flammable chemicals is moderate for all chemicals

� Storage quantities of flammable chemicals are well below the

threshold quantities

� Toxic threat zones (red category ) is within factory premises for

all toxic chemicals

� Toxic threat zone (Orange category) is going beyond factory

premises for 1 chemical

� However Yellow zone concentrations are well within TLV values

of the chemicals



7.6.3.5 Health Hazards from exposure to hazardous substances and

control measures.

Existing hazards considered from operational/equipment manuals.

Detailed Hazard identification and health based risk assessment of

various operations and processes are carried out.

Based on analysis 5 chemicals are identified as toxic chemicals in

liquid form. Toxic concentrations distances are determined based on

the modelling data and presented.

RISK MITIGATIVE MEASURES

� Material data sheets shall be available at user places.

� Engineering controls for leak detection and control of storage

tanks

� Availability of neutralization agents to control impact of any

leakages of chemicals

� Closed material handling system through pipes

� Spill control kits and procedures are established.

� Good Manufacturing practices and housekeeping practices are

established.

� Provide personal protective equipment (PPE) such as gloves,

goggles and respirators.

� Operators training on control measures by on job

training/induction training.

� Carry out practice drills for cleaning up spills safely – do this

before any spillages happen.

� Annual health checks are being carried out for all employees.

� Information to District authorities to tackle off-site emergency

situations

� Ensuring availability of antidotes in the plant and nearby public

hospital to tackle any off-site emergency situation



7.6.4 Hazard and Operability Study (HAZOP)

Safety and reliability of modern processing plant can be improved by

using procedures that recognize and eliminate potential problems in

the design stage. This is especially important because of the

increasing need to operate the different units, for economic reasons,

more closely to known risk situations. Hence, it requires refined

methods like HAZOP study technique for identifying hazardous

situations and problems and eliminating them at the design stage.

Based on process reactions, a list of process reactions were identified

for taking additional care precautions and presented in Table 7.11

Table 7.11 Hazardous processes and precautions suggested

Unit

process

Chemicals

involved

Equipment

&utilities

Temp/

Pressure

Emissio

ns Safety measures

Product : ACETAZOLAMIDE

Acetazolam

ide

DTA

GLR 50c - 1060c

Ammoni

um

Sulphate

In this stage Hydrazine

Hydrate is used by

converting into sulphate

salt by treating it with

Conc.H2So4. Once it forms

sulphate there will be no

free hydrogen. (Free

Hydrogen is present due

to decomposition of

Hydrogen Hydrate) We

keep excess H2So4 to avoid accident due to free

Hydrogen during heating.

NH2 . NH2 . H2O + H2So4

H2N . NH2 . H2So4.

Stage-I

1) Hydrazine

Hydrate

Stage-III

1) Chlorine Gas GLR 00c - 100c Cl2 gas

In this stage chlorine gas

(Cl2) is passed into

reaction mass through

sparger at 5-80c. The

excess of gas is absorbed

in closed scrubber

containing C.S. Lye

solution. During the gas

purging the scrubber is

kept always in alkaline

condition, so that no Cl2

gas will escape in

atmosphere.



Unit

process

Chemicals

involved

Equipment

&utilities

Temp/

Pressure

Emission

s Safety measures

Product : Norfloxacin Q-Acid

NFX /

Q.Acid

SSR 1200c -

2600c

Ethyl

alcohol

The High

temperature is

controlled carefully

by temperature

sensor. Stage-I

1) 3-Chloro 4-

Flouro Aniline

2) Ethoxy Methylene

Melonic Ester

Unit

process

Chemicals

involved

Equipment

&utilities

Temp/

Pressure

Emission

s Safety measures

Product : MENATETRENONE

Stage-I 1) Dicyclo

pentadiene SSR

1550c -

1600c

It is a dimer. To get

Monomer (Cyclo

Pentadiene) it was

cracked about 160-

1700c U/N2 gas.

During this operation

same unpleasant

smell of Cyclo

pentadiene will come,

which is absorbed in

KMnO4 solution. In

KMnO4 solution it is

oxidized to Co2 and

Water with no smell.

Stage-II 1) Phosphorus tri

bromide GLR

00c – (-)

200c

Bromine

Fumes

It is fuming material

at room temperature

and above. Before

unloading the

container is cooled to

about 150c. Then is

carefully charged in

to the reaction Mass

at about -180c to -

220c. The reaction is

carried out at -180c

to -220c.



Unit

process

Chemicals

involved

Equipment

&utilities

Temp/

Pressure

Emission

s Safety measures

Product : 2-(2-Methoxy Phenoxy) – Ethylamine

005 Anisole

Stage-I

1)Acetonitrile

SSR

500c -

1050c

1050c -

1350c

Ammonia

Gas

In this stage, the

acetonitrile and Mono

amino ethanol

treated at reflux and during reflux

ammonia gas is

liberated which is

absorbed in dilute

HCl solution.

CH3CN+H2N-CH2-

CH2-OH N

CH3-C + NH3

O

Oxazoline

Ammonia

Absorbed In

dilute HCl

2) Mono amino

ethanol

3) Zinc acetate

Unit

process

Chemicals

involved

Equipment

&utilities

Temp/

Pressure

Emission

s Safety measures

Product : Az elastin -1

Stage-III Sodium hydride SSR

Sodium Hydride is

moisture sensitive.

The reaction mass

M/C must be below

0.1% while charging

sodium hydride in to

the reaction mass,

and surrounding

should be kept dry.



Unit

process

Chemicals

involved

Equipment

&utilities

Temp/

Pressure

Emission

s Safety measures

Product : Ecabet Sodium

Stage-I

1.Gum Rosin

2.Palladium

Carbon

SSR 250-2600C Hydrogen

Gas

The Gum Rosin is

dehydrogenated in

presence of catalytic

amount of pd/c under

nitrogen gas passing

at 250-2600C. The

liberated hydrogen gas is absorbed in

water. The high

temperature is

controlled by Temp.

Sensor.

Unit

process

Chemicals

involved

Equipment

&utilities

Temp/

Pressure

Emission

s Safety measures

Product : Stearic Hydrazide

Stage-II

1. Stearic Acid

2. Methanol

3. Hydrazine

Hydrade

4. Ethyl Acetate

GLR/SSR 65-700C

In this reaction

hydrazine is used to

convert methyl

stearate to stearic

hydrazide in ethyl

acetate medium by

warming. The excess of hydrazine is

reacted with ethyl

acetate in the same

reaction and get

neutralized.



7.6.5 HAZOP WORK SHEETS & SAFETY MEASURES RECOMMENDED

Following work sheets shall be used for development of safety

measures

Process Parameter: Raw material flow

Table 7.12 HAZOP Work Sheet – Raw Material Flow

S.

No

Deviati

on Causes

Consequ

ences

Safety

Features/Measures Remarks

1 No Flow No supply

Malfunctioning of

pump

Power failure

No

Reaction

Operation control

devices and

emergency plant shut

down procedure,

alarm system etc.

Alternative Automatic

power source

Inspect

Operations

Frequently

2 Less

Flow

Malfunctioning of

pump

Malfunctioning of

Shut off valve

Valve on

charging line not

opened

Operation

al trouble

in

reactors

Operation control

devices and

emergency plant

shutdown procedure,

alarm systems etc.

Check the

shut off valve.

Ensure the

feed valve is

opened

3 More

Flow

Malfunction of

control valve

Operation

al trouble

in reactor

Flow regulators,

Excess flow diversion

devices to Alternative

storage or Flare etc.

Flow control

devices

inspection and

examination

and

maintenance

will be

continuous



II) Process Parameter: Pressure

Table 7.13 HAZOP Work Sheet - Pressure

S.No Deviatio

n Causes

Consequenc

es

Safety

Features/Measur

es

Remarks

1 No

Pressure

-- -- -- Not

Envisaged

during

operation

2 Low

Pressure

Malfunctioning

of pump

Malfunctioning

of Shut off

valve

Valve on

charging line

not opened

Leakages in

pipe line

Operational

trouble in

reactors

Periodic inspection

&Examination,

Maintenance

Leak detect system

Shut off valve

Low pressure

alarm/indicators

shall be provided

Pipe line and

flow control

devices

examined

frequently

3 High

Pressure

High

Temperature

Excess supply

Malfunction of

control valve

Operational

trouble in

reactor

Rupture of

pipe line

Fire or

Explosion

Periodic inspection

&Examination,

Maintenance

Pressure relief

system

Automatic flow

diverter

Alternative storage

system

Pipe line and

flow control

devices

examined

frequently



(III) Process Parameter: Temperature

Table 7.14 HAZOP Work Sheet: Temperature

S.No Deviation Causes Consequen

ces

Safety

Features/Measur

es

Remarks

1 No

Temperatu

re

-- -- -- Not

envisaged

during

operation

2 Low

Temperatu

re

Malfunctio

ning of

Temp.

Indicator

External

cooling

-- Calibration of

Temperature

indicators, periodic

Inspection

Examination

Examine the

pipe line and

control

devices

working

conditions

frequently

3 High

Temperatu

re

Malfunctio

ning of

Temp.Indi

cator

External

fire/Heatin

g

Rupture/

failure in

pipe line

Calibration of

Temp.Indicator,

periodic Inspection

Examination

Thermal Insulation

Around the pipe

Radiation

Detectors/Sensors

will be provided

Examine the

pipe line and

control

devices

working

conditions

frequently

7.6.6 Hazard Factors

A study of past accident information provides an understanding of

failure modes and mechanisms of process and control equipment and

human systems and their likely effects on the overall plant reliability

and safety.



Some of the major contributing factors for accidents in chemical

industries are:

Table 7.15

Contributing factors for accidents

S.No Contributing Factor Per cent Loss

1 Equipment design faults 41

2 Process design faults 10

3 Operator errors 31

4 Maintenance deficiencies 12

5 Material Hazards 6

A study AICHE (1972) indicates that majority of equipment of

component failures involve compressors, furnaces and heat

exchangers as there are lesser opportunities to take them off for

maintenance. The frequency of equipment or component failures is

observed as follows:

Table 7.16 Failure frequency statistics of key equipment

S.No Equipment Frequency (%)

1 Compressors 30

2 Furnaces 18

3 Heat Exchangers 17

4 Process Vessels 18

5 Others 17

However, failures of storage vessels and those during transportation

have been reported more frequently than cases of plant failures. The

failure rate of various equipment in a typical power plant is provided

in the following table.



7.6.7 Equipment Failure Rates

(Data from reliability Technology by A.E.Green and J.R Bourne,

Copyright C,1972,reproduced with permission of John Wiley and

Sons,Inc)

Table 7.17

Equipment failure rates

Equipment Failure

Rate(Failures/106h)

Electric Motors 10

Transformers(<15 kv) 0.6

Transformers(132-400k V) 0.7

General, (33k V) 2

Circuit breakers 10

Pressure vessels(general) 3

Pressure vessels

(High standard)

0.3

Pipes 0.2

Pipe joints 0.5

Ducts 1

Gaskets 0.5

Bellows 5

Diagrams(metal) 5

Diagrams(Rubber) 8

Unions and junctions 0.4

Hoses(heavily stressed) 40

Hoses(Lightly stressed) 4

Ball bearings(heavy duty) 20

Ball bearings(Light duty) 10

Roll bearings 5

Sleeve bearings 5



Shafts(heavily stressed) 0.2

Shafts(Lightly stressed) 0.02

Relief valves leakage 2

Relief valves blockage 0.5

Hand-operated valves 15

Control valves 30

Ball valves 0.5

Solenoid valves 30

Rotating seals 7

Sliding seals 3

‘O’ring seals 0.2

Couplings 5

Belt drives 40

Spur gears 10

Helical gears 1

Friction clutches 3

Magnetic clutches 6

Fixed orifices 1

Variable orifices 5

Nozzle and flapper assembles: blockage 6

Nozzle and flapper assembles:breakage 0.2

Filters: blockage 1

Filters: Leakage 1

Rock and pinion assembles 2

Knife edge fulcrum: wear 10

Springs(heavily stressed) 1

Springs(Lightly stressed) 0.2

Hair springs 1

Calibration springs: creep 2

Calibration springs: Breakage 0.2

Vibration mounts 9



Mechanical joints 0.2

Grub Screws 0.5

Pins 15

Pivots 1

Nuts 0.02

Bolts 0.02

Boilers(all types) 1.1

Boilers feed pumps 1012.5

Cranes 7.8

7.6.8 Common Causes of Accidents

Engineering and Instrumental

Based on the analysis of past accident information, common causes of

major chemical plant accidents are identified as:

• Poor house keeping

• Improper use of Tools, equipment, facilities

• Unsafe or defective equipment facilities

• Lack of proper procedures

• Improving Unsafe procedures

• Failure to follow prescribed procedures

• Jobs not understood

• Lack of awareness of hazards involved

• Lack of proper tools, equipment, facilities

• Lack of guides and safety devices

• Lack of protective equipment and clothing

7.6.9 Failures of Human Systems

Na assessment of past chemical accidents reveals human factor to the

cause for over 60% of the accidents while the rest are due to other

plant component failures. This percentage will increase if major



accidents alone are considered for analysis. Major causes of human

failures reported are due to:

� Stress induced by poor equipment design, unfavourable

environmental conditions, fatigue, etc.

� Lack of training in safety and loss prevention

� Indecision in critical situations.

� Inexperienced staff being employed in hazardous situations

Often, human errors are not analysed while accident reporting and

accident reports only provide information about equipment or

component failures. Hence, a great deal of uncertainty surrounds

analysis of failure of human systems and consequent damages.

The number of persons/materials are potentially exposed to a specific

hazard zone is a function of the population density and distribution near

the accident location. The failure rate data and ignition sources of

major fires are presented in the following Tables 7.17 and 7.18

Table 7.18 Ignition Sources of Major Fires

S. No Ignition source Percent

1 Electrical (wiring of motors) 23%

2 Smoking 18%

3 Friction 10%

4 Overheated material 8%

5 Burner flames 7%

6 Combustion sparks 5%

7 Spontaneous ignition 4%

8 Cutting & Welding 4%

9 Exposure (fires jumping into new areas) 3%

10 Incendiarism (fires maliciously set) 2%

11 Mechanical sparks 2%

12 Molten substances 1%

13 Chemical actions 1%

14 Static sparks 1%



15 Lightening 1%

16 Miscellaneous 1%

7.7 Disaster Management Plan

7.7.1 Introduction

A disaster is a catastrophic situation in which suddenly, people are

plunged into helplessness and suffering and, as a result, need

protection, clothing, shelter, medical and social care and other

necessities of life.

Disasters can be divided into two main groups In the first, are disasters

resulting from natural phenomena like earthquakes, volcanic eruptions,

storm surges cyclones, tropical storms. Floods, avalanches, landslides,

and forest fires. The second group includes disastrous events

occasioned by man, or by man’s impact upon the environment.

Examples are armed conflict. Industrial accidents, radiation accidents,

factory fires, explosions and escape of toxic gases or chemical

substances, river pollution, mining or other structural collapses, air, sea

rail and road transport accidents and can reach catastrophic

dimensions in terms of human loss.

There can be no set criteria for assessing the gravity of a disaster in

the abstract since this depends to a large extent on the physical,

economic and social environment in which it occurs. However, all

disasters bring in their wake similar consequences that call for

immediate action, whether at the local, national or international lever,

for the rescue and relief of the victims. This includes the search for the

dead and injured, medical and social care, removal of the debris, the

provision of temporary shelter for the homeless, food, clothing and

medical supplies, and the rapid re-establishment of essential services

An emergency may be said to begin when operator at the plant or in

charge of storage of hazardous chemicals cannot cope up with a

potentially hazardous incident, which may turn into an emergency. The



emergencies could be a major fire or explosion or release of toxic gas

or a combination of them

The proposed plant will store fuels, which are flammable in nature, and

the storage will be as per the Controller and the project is still in the

initial stages of designing. Hence a tentative disaster management

plan is prepared to be suitably modified before commissioning of the

plant.

7.7.2 Objectives of Emergency Management Plan (On-Site)

A quick and effective response during emergency can have tremendous

significance on whether the situation is controlled with little loss or it

turns into a major emergency therefore, the objectives of this onsite

emergency plan (ONSEP)

During Emergency: is to provide basic guidance to the personnel for

effectively combating such situations to minimize loss of life, damage

to property and loss of property.

• To Locate emergency and if possible to eliminate

• To minimize loss to personnel and property, in quickest time

possible

• Fire fighting equipments and safety Appliances should be made

available, in readily usable condition, in the event of emergency

• To decide for shutdown of the plant in case of emergency

• To localize the hazard/ accident

• To fix responsibilities to the persons in the plant in case of

emergencies

• To arrange rescue operations and treatment to the persons

affected

• To provide safety to other persons present in the plant at the time

of hazard

• To contain the hazard within the plant

• To get assistance from neighbouring industries under Mutual Aid,

fire Station, Hospitals etc.



• To alert the statutory authorities concerned for further action in

case the hazard is likely to extend to the outside area of the plant

During Normal Time:

• To keep the required emergency equipment in stock at right

places and ensure their working condition;

• To provide proper guidelines to all personnel for emergency

operations and escape

• Preserve relevant records and evidence for the emergency case

and subsequent enquiry

• Investigation and remedial measures to avoid reoccurrence of the

hazard

7.7.3 Scope of ONSEP

This ONSEP is prepared for industrial emergencies like fire, explosions,

toxic releases, asphyxia and does not cover natural calamities and

societal disturbances related emergencies (like strikes, bomb threats,

civil Commissions etc.). Also, the scope this ONSEP is limited to onsite

emergencies and does not include measures for offsite Emergency

Management.

Necessary information with regards to Off Site Emergency Management

will be furnished to district authorities.

7.7.4 Methodology of Development ONSEP

The consideration in preparing this Emergency Plan includes the

following steps:

• Identification , location and assessment of hazardous incident

• Alarm and communication sequences

• Identification and deployment of personnel assigning

responsibilities]identifying assembly point, Emergency Control

Centre, Fire Fighting and Personal Protective Equipment

utilization, First aid and Medical facilities

• Emergency Plant shut down



• Training and Rehearsal on Mock Drill

• Preparedness for Action on site

Earlier, a detailed Hazards Analysis and Risk Assessment were carried

out for the plant facilities and the hazards are quantified. The likely

location of hazards and consequences are evaluated, duly following the

standard procedure.

7.7.5 Elements of onsite Emergency Plan

Important elements considered in this plan are:

• Identification of emergencies

• Emergency organization

• Emergency facilities

• Emergency procedure

• Communications during emergency

• Rescue, Transport and Rehabilitation

• Roles and responsibilities of key personnel and essential

employees

• Mutual aid

7.7.6 Emergencies Identified

Following are the typical emergencies anticipated from this type of

industries

- Fire accidents at Bulk solvent storage & HSD areas

- Fire accidents at Boiler area, DG area

- Fire in reactors area

- Food /Water Contamination..

- Fire accidents in QC Laboratory.

- Major Spillage of solvents & HSD.

- Fire accident in scrap yard.

- Electric shocks.

- Reaction hazards in Hydrogenation area

- Hydrogen Cylinder explosion



- Catalyst fire

The other emergencies are asphyxiation of persons, apart from risks

due to cyclonic conditions, earth quake, lightning, floods (natural

calamities), sabotage, bombing (social and other reasons) etc. which

are not under the management control.

Priority of protection in the event of an emergency is; Life and Safety

of personnel, preservation of property, restoration of normalcy.

7.7.7 Emergency Organization

The responsibilities of key personnel for emergencies are clearly

defined as follows

An emergency control room as the focal point has been earmarked.

The control room flashes information to various agencies as shown in

the chart. This is located in an area of minimum risk and close to

road. Security and Time office room is the emergency control point.

7.7.8 Emergency Facilities

a) Emergency Control Centre (ECC)

It is a location where all key personnel like Site Controller, Emergency

Coordinators can take stock of situation or can assemble and monitor

aspects related to emergency and take decisions related to emergency.

The office room is designated as ECC. In case if this area is affected,

zone security room is designated as alternative ECC.

The following information and facilities would be maintained at the ECC

Plant control room: Latest copy of Onsite Emergency Plan and Off Site

Emergency Plan (as provided by District Emergency Authority)

• Intercom Telephone

• P&T Telephone

• Telephone Directories (internal and P&T)

• Factory Layout, Site Plan

• P&I diagrams, electrical connections plans indicating locations

of hazardous inventories, sources of safety equipment, hydrant



layout, location of pump house, road plan, assembly by points,

vulnerable zones, escape routes;

• Hazard Chart;

• Emergency shutdown procedures for generators and fuel

supply system;

• Nominal roll of employees;

• List and addresses of key personnel;

• List and addresses of first aid providers;

• List and addresses of employees trained in fire fighting;

• List and addresses of qualified trained persons;

• Material safety data sheets of raw materials;

• Duties of key personnel;

• Important addresses and telephone numbers including those of

fuel supplying company, government agencies, neighbouring

industries and other sources of help, outside experts;

The following emergency equipment is made available at alternate ECC

(Security point):

• Fire proximity suit/Gloves/Helmets;

• Hand tools suitable for pipelines (non sparking type);

• Teflon tape;

• Gas Explosion meter;

• Flame proof torches/batteries;

• Manila rope;

• Spark arrestor;

• First aid box;

• Special fire fighting information related to hydrocarbon fuels;

• Public address megaphone, hand bell, emergency torch.

b) Assembly Points

Assembly points are those locations where the persons who are not

connected with emergency operations can await either for further

instructions or for rescue transport and rehabilitation. Assembly



point is located opposite to Security and Time Office room which is

located far away from production area.

C) Emergency control systems present

The following emergency control systems are in place in M/s. Nakoda

Chemicals Limited

1. Lightening protection for all buildings and high raised chimneys.

2. Earthing & Bonding for electrostatic hazards.

3. Closed arrangement for solvent transferring.

4. Pressure Relief system & Rupture Discs etc.

5. Earth Rite system for road tanker loading and unloading.

6. Dust collection system with proper measures from electrostatic

hazards.

7. FLP fittings at Flammable materials handling areas.

8. Product containment booth at raw material sifting.

� Addressable fire detection system.

� Fire detectors

� Smoke detectors

9. Fire protection systems :

� Portable Fire Extinguishers

10. Occupational Health Centre.

11. Safe handling procedures.

12. Spill Control kits.

d) Location of First Aid Boxes

The first aid boxes are located at the following places production

blocks, Utilities block, Service areas, administrative office, time office,

and will be under the charge of EHS in-charge.

e) Fire protection system

An elaborate fire protection system is in place in M/s. Nakoda

Chemicals Limited about 37 Nos of fire extinguishers of various types



and 12 sand buckets placed at different locations. Fire Hydrant system

is in place to cover the entire plant including manufacturing blocks,

Bulk storage tanks and utility areas.

h) Emergency Escapes

Emergency escapes in the plant area and floor wise emergency are

conspicuously marked.

i) Wind Sock

Wind socks are located at the following locations

S.No. Location

1. Top of the new Production Block

7.8 ORGANISATION

Plant Manager is the over all in-charge of the plant operations and is

assisted by all department heads. Production activities are looked

after by both the Production Head/Managers, EHS activities by head

Safety, Health & Environment, Engineering aspects by head

(Maintenance) Plant Electrical maintenance by Electrical Engineer,

material inventory by stores head, Personnel & Administration wings,

other department heads are directly reporting to Unit Head.

7.9 MAN POWER

All Chemists/Executives/Assistants/Managers are well qualified and

experienced in finished dosage manufacturing Industry. Experience is

varying from 2 to 15 years in the similar field.

SHIFT TIMINGS

A Shift 06 Hrs - 14 Hrs

B Shift 14 Hrs – 22.00 Hrs



C Shift 22.00 Hrs – 06.00 Hrs

General Shift 8.30 Hrs – 17.30 Hrs

7.9.1 EMERGENCY ORGANISATION

1. An Emergency Organization is constituted including Plant Manager

Production Manager, Personnel Manager, Logistics Managers,

Assistant Managers, Safety Officer, Maintenance Personnel, Process

Engineer / Project Engineer, Production Officers, Shift In –charge,

Supervisors, Chemists, and Security In-charge,. Boiler Operators,

Electricians, Vehicle Drivers, Office Staff, Security Staff, Security

Staff are included as Essential Employees.

2. Plant Manager is designated as Site Controller

3. Production Manager is designated as Incident Controller as

alternate.

All Managers are usually present during day shift are designated as Key

Personnel and Coordinate different functions during non-emergency

and emergency situation

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7.9.2 EMERGENCY ORGANISATION ROLES AND RESPONSIBILITIES

7.9.2.1 SITE CONTROLLER - Plant Manager

On knowing about Emergency at plant, he would take charge of

Emergency Management immediately. If he is away from plant, he

would reach the plant as available at Site during an emergency,

Incident Controller would ascertain the same from Security and assume

charge as Site Controller till the Site Controller arrives at the Scene and

assumes charge.

HE WILL

1. Assess the magnitude of the situation on the advice of incident

controller and decides if staff need to be evacuated from their

assembly points. He will also coordinate between various

concerned agencies.

2. Exercise direct operation control over the emergency

3. Maintain a continuous review of possible development and assess

the situation in consultation with Incident controller and other Key

personnel as to whether shutting down the plant or any section of

the plant or bring the batches to safe position

4. Liaison with senior officials of Police, Fire Brigade, Medical and

Factories Inspectorate. Provide advice on possible effects on areas

outside the factory premises through Emergency Controller (

production Officer)

5. In consultation with the Incident Controller, call for external

help/mutual aid, if required

6. Arrange through Emergency Controller flashing information to the

Inspector of Factories, APPCB and other statutory Authorities.

7. Declares conclusion of emergency in consultation with Incident

Controller

8. Prepare the investigation report giving the sequence of events and

preserve the evidence for further enquiry.



Decides upon

9. Conclusion of emergency.

10. Keeps record of chronological events and prepare as an

investigation report and preserve evidence.

11. During non emergency time, Reviews Onsite Emergency plan

from time to time, taking into considerations of changing needs,

like product, chemicals, installations etc changes among persons

handling important assignments, issue of correction slips to plan,

Development and Issue of revised plans.

7.9.2.2 INCIDENT CONTROLLER – Production manager

1. In the absence of Site Controller, during an emergency

assumes charge as Site Controller also and hands over charge

sooner the Site Controller arrives in the site

2. Direct all operations and coordinate with the concerned to

ensure safety of personnel, minimise damage to the plant,

property and environment

3. Direct shutting down of plant and evacuate the people in the

plant and other areas which are likely to the affected by the

emergency, if required

4. Ensure all key personnel’s help is called in

5. Keep in constant touch with site controller for advice on further

appropriate action

6. Provide advice and information to the Fire, Security Officer and

outside fire brigade through the Fire & security Officer

7. Ensure that all non-essential workers are evacuated to the

appropriate assembly points

8. Report all the significant developments of the Liaison Officer

12. During non-emergency time, he would ensure that safety

related procedures. Personal protective equipment are

maintained up to date and in usable condition.



7.9.2.3 EMERGENCY CONTROLLER – Manager Logistics

1. On hearing about an Emergency, reach ECC or the location as

suggested by Site Controller, duly protecting themselves.

2. Report to Site Controller. Handles police and Press, if needed

3. Ensure that all non- essential workers in the affected area are

evacuated to assembly points in consultation with the Incident

Controller

4. Any important information as required to the senior officers will

be provided

5. Keep liaison with other co-ordinators to meet the requirements of

services such as materials, security management, transportation,

medical facilities etc. as required during emergency

6. He is in constant touch with the site controller and feed him

correct information of the situation.

7. Ensure that casualities receive adequate attention at medical

centre and arrange required additional help and inform relatives

of the injured

8. Engage suitable staff to act as runners or messengers who are

listed in the essential workers list between him and the Incident

Controller, if the telephone and other system of communication

fail due to any reason

9. Keep in constant touch with happenings at the emergency site

and offer suggestions to the incident Controller

7.9.2.4 Fire and security Officer

On hearing the Emergency alarm, he will reach Spot.

1. Take control over the fireman, trained plant personnel and

security staff and arrange required fire fighting facilities to the

emergency site. He will call fire brigade from Hyderabad, if

required.



2. Maintain communication with the Site Controller, Incident

Controller and Communication Officer.

3. Arrange to control the traffic at the gate and the incident area

4. Direct the security staff to the incident site to take part in the

emergency operations under his guidance and supervision

5. Evacuate the people in the plant or in the nearby areas as

advised by the Site Controller after arranging the transport

through Liaison Officer

6. Allow only those people who are associated with handling

emergency

7. Maintain law and order in the area; if necessary seek the help of

Police.

7.9.2.5 Safety Officer (Additional responsibility given to Personnel

Reports to Site Controller

On hearing the emergency alarm, he will proceed to this site

He will..

1. Make sure that all safety appliances are made available to the

emergency team.

2. Participate in rescue operations

3. Co-ordinate to transfer the injured persons to medical centre

and arrange for first aid

4. Keep in contact with the Incident Controller and inform the

condition of injured

5. He would train Employees regarding their role during

emergency, emergency facilities.

7.9.2.6 Engineer-In-charge and Electrician: (Maintenance

manager)

They will report to the Incident Controller at the incident site and close

down the services as directed by the Incident Controller



1. For isolating power supply wherever required including

ventilation system

2. Ensure water supply and functioning of telephones

7.9.2.7 Shit –in- Charge

1. He will act as Site controller. The moment he receives the

information about the emergency and co-ordinate all other

agencies through telephone

2. He will arrange for shutdown of the Process/Plant, if needed

3. He will rtake all preventive measures to stop spread of fire by

closing all the valves carrying inflammable materials and

arrange for evacuation

4. He will effectively utilize the Fire fighting devices to output the

fire till the arrival of the fire brigade, if needed

5. After the arrival of Plant Emergency Team, he will hand over the

charge to the Site Controller and help the team

7.9.2.8 Chemist

He alerts Shift-In-Charge in case of emergency.Takes remedial action

within his purview. Reports to Shift- In- Charge and assist him

i) Plant Operator

1. He alerts the Shift-In-Charge in case of emergency and he

alerts his Co-operators

2. He will assess the situation, takes remedial action within his

purview

ii) Informer

1. he alerts everybody by shouting about emergency

7.9.3 Other Essentials of Emergency Plan

1. Personnel For-

Water pump operation, DG Sets operation, Boiler operation, Fire

personnel, Electrician, Vehicle Drivers



2. Emergency Control Centre

It is located where Site Controller and others concerned assemble and

conduct operations in emergency. The facilities like P & T Telephones

and safety Appliances, Tools are available readily.

The Emergency Control Centre has been located at a place free from

the effects of hazards in the plant

3. Emergency Warning/ Alarm/ Emergency Communication

4. Familiarization of OSEP to all essential personnel in the Plant is

made

Mock drills are to be conducted periodically to assess the awareness

and familiarity of sequences of OSEP of the essential persons. The

suggestions of the personnel to improve the effectiveness of OSEP are

to be considered and OSEP is being reviewed for further

improvements and effectiveness.

The provision for alerting the personnel in the plant in case of

emergency has been made by ringing bell manually. In addition

messengers are available to communicate the warning to all the

persons in the plant.

7.10 RISK CONTROL PROCEDURES:

7.10.1 HAZARD COMMUNICATION PROGRAM

The department head or his/her designee is responsible for

compliance with the provisions of the hazard communication

program, systematic risk identification and control measures with

the help from EHS department. Training program for all

operators/executives on operational/equipment risk control

measures includes preventing flammable atmospheres by

engineering controls. Specific responsibilities include the periodic

review of department operations that use or store and handle

hazardous chemicals to ensure that

� Containers are properly labelled



� Appropriate signs have been posted

� Material safety Data sheets are available

� Chemical safety training has been provided and an inventory of

hazardous chemicals is maintained.

� Proper preventive measures on electrostatic hazards

� Follow good CGMP and dispensing practices.

� Regular inspection and checking to assure risk control (proper

earthling, functioning of safety interlocks, bonding,

transferring in closed system and no spillages) The EHS

Department will coordinate the implementation of the hazard

communication program.

Chemical manufacturers, importers, or distributors are required to

ensure that each container for hazardous chemicals is labeled with

hazardous warning signs, and the name and address of the

chemical manufacturer, importer or other responsible party. The

individual Departments will ensure that chemicals they receive are

labeled with the identity of the hazardous chemical(s) and

appropriate hazardous warning signs, and the name and address of

the chemical manufacturer, importer or other responsible party.

The user shall ensure that the indented chemicals are received

along with the MSDS from the supplier with the help of Supply

Chain Management (SCM) /Purchase.

• All employees who work in areas where there are hazardous

chemicals will receive chemical safety training at the time of

initial employment and documented

• chemical safety training includes the following essential

information:

• Location of hazardous materials in the work place

• Location and availability of material safety data sheets

• Acute and Chronic effects of chemicals

• Safe handling procedures

• Personal protective equipment’s (PPE)



• Emergency procedures and how to obtain First Aid.

• Spill clean – up and Waste disposal

7.10.2 Detailed Action Plan to mitigate in case of Emergency:

• When the emergency observed the operator/supervisor to

operate manual call point in case of emergency.

• Operator will move to safe distance and also ask nearby

personnel to move to safe place (Assembly point).

• Security will inform to site controller, incident controller & EHS

head.

• Incident controller (concern area head) will rush to the site and

ask ERT members to approach the site with SCBA and inform to

site controller to declare emergency.

• Site controller will inform to security to declare emergency by

hooting emergency siren based on the report received from

incident controller.

• Security will declare emergency based on site controller

instruction and request to evacuate by using a megaphone.

Wind direction also to be informed.

• Meanwhile incident controller will initiate the control procedure

with the help of ERT members (Spill control procedure/operating

fire hydrant system etc.).

• Help from maintenance dept. will be sought if necessary to cut

off power supply/ close the valves to receivers and any

temporary power connections to emergency appliances.

• Site controller will assess the situation from Emergency control

centre and will send ambulance, spill content/fire fighting

equipments and required PPE.

• Care shall be taken that no vehicle shall be allowed in the close

vicinity of the spill/fire (about 50 meters) and movements shall

be from upwind directions only.



• Incident controller will ask explosive meter to monitor the area

with the help of ERT member/Safety in-charge.

• Incident controller will inform site controller of requirement of

outside help, if any.

• When the situation is under control incident controller will

inform to site controller.

• Incident controller will ensure that,

o The spilled material, spill control materials and other

wastes are disposed off properly.

o Area washed with water thoroughly

o PPE are washed and kept at their respective locations.

o Spill control materials, fire extinguishers are replenished.

o Evidence recorded and maintained for further

investigations.

• Site controller will ask security to give “all clear” siren and

employees will be allowed to go to their respective work places, if

head count is complete.

• A meeting will be called in conference room with all block in-

charges, maintenance engineers, ERT members, security officer,

incident controller and site controller.

• The incident will be discussed in detailed and minutes will be

maintained for future improvements.

• A detail report will be prepared by site controller and incident

controller and submitted for management review.

7.10.3 Control Measures:

• A current inventory of all chemicals and hazardous chemicals

present in the workplace is maintained, the inventory of

flammable materials are maintained in less quantities.

• Lightening protection provided at diesel storage tanks area.

• Flammable solvents are handling at FLP areas.



• Flammable solvents are transferring by using metallic hand

operated pumps into metal containers. Proper earthing and

bonding provided for solvent handling equipments.

• Equipments only wiping with lint free cloth instead of cleaning with

flammable solvents.

• Dispensing carried out at FLP zone.

• Spill control kits are provided at flammable solvents handling

areas. Spill control procedures are also displayed to control risk.

• Explosion flaps provided for Air tray dryers to prevent explosion.

• Addressable fire detection system provided.

• Fire hydrant system provided with diesel driven backup.

7.10.4 HANDLING SPILLS

The risk assessment includes the following factors:

• The nature of the spilled chemical (high/low hazard material)

• The quantity spilled (large/small amounts)

• The location of the spill (difficult access, public site / bonded area)

When evaluating risks associated with chemical spills, the

following points need to be considered:

Is special training required to handle the situation?

Is special equipment required to clean up the spill? (i.e. Self-

Contained Breathing Apparatus (SCBA), Personal Protective

Equipment (PPE etc.)

Are special procedures required to clean up the spill? e.g. pumps,

hoses etc.

Where the response is HIGH to any of the above factors then the

spill must be considered as HIGH RISK.

7.10.4.1 SPILL CONTROLS (RISK CONTROLS):

Engineering – Handling in closed system. Bund provided for storage

area. Includes redesigning the work area, fixing rollover bund

guard(s) or maintenance.



Administrative – standard operating procedure, supervision, training

and signage.

Personal protective equipment – Includes PAPR/3M half face masks,

safety shoes, goggles, safety glasses and gloves.

• Spill kits available for use where assessed as required. The

contents of the spill kit should be relevant to the area and the

potential spill, this may include such things as;

• Soda Ash available for spills of corrosive liquids.

• Sand to absorb spilt liquids

• Absorbent pillows or booms to contain larger liquid spills and

prevent spills entering drains

• Heavy duty HDPE containers (with a lid) to contain hazardous

material prior to disposal.

• Appropriate personal protective clothing (such as chemical

resistant gloves, safety glasses)

• Spill kits are clearly labelled and located in an easily accessible

position for all staff.

7.10.4.2 SPILLS HANDLING PROCEDURE:

• If spill involves personal injury, remove clothing, flush with water

for 15 minutes.

• Alert people in the immediate area of spill.

• Wear protective equipment, including safety goggles, gloves

while going near the spillage.

• Avoid breathing vapors from spills.

• If spilled material is flammable, turn off ignitions and heat

sources.

• Confine spill to small area by creating a bund with soda ash and

sand.

• Absorb with soda ash, dry sand or adsorbent. Collect the residue,

place it in the empty container for disposal. Dispose as chemical

waste.



• Mop the spill area with water.

7.11 EVACUATION OF PERSONNEL:

On hearing the emergency siren all employees of the factory shall

proceed to assembly point as directed by their department heads.

Head count supervisor will take the head count at assembly point

and report the same to Site controller. During emergencies the

knowledge of exact direction of wind helps the plant personnel to

decide on the escape route to be taken for safe evacuation of

personnel and also the safe assembly points and emergency

operations center. It is therefore necessary that the personnel get

an idea of the direction of the wind by seeing the windsocks

provided at the following.

S. No. Location

1. Top of the new Production Block

7.12 INFORMATION TO RELATIVES OF INJURED

The relatives of injured will be informed by emergency coordinator

(security/transport). The employees residential address file is

available at emergency control centre and also in the residence of

emergency coordinator (security/transport). The communication to

the relatives of injured will be passed on through telecom or by a

messenger with car. The clear address of the injured person (Local

residential address/address of hospital if hospitalized) will be

communicated to the relatives.

7.13 INFORMATION TO LOCAL AUTHORITIES

In case of onsite emergency, the Dy. Chief inspector of factories

and inspector of factories will be informed immediately. The

information will be passed on over telecom, telegram or through a

messenger deputed by Emergency Controller.



After consulting Dy. Chief Inspector of factories and inspector of

factories, the information will be sent to Chief inspector of factories

also. The company will implement the advice of local authorities in

improving the safety in dealing with the event.

State Pollution Control Board authorities will be informed in case of

accidents like toxic gas release, spillage of hazardous chemicals.

7.14 INFORMATION TO DISTRICT AUTHORITIES

The Emergency controller/site controller/Head HR on advice of

Emergency controller is authorized to inform the police. The

inspector of Police Jeedimetla will be informed for the control of law

and order situation at the Plant or in vicinity or at hospital where

injured are under treatment.

Police department will be requested for protecting the lives of

employees and property of the company, evacuation of personnel

outside the Plant. District Collector, Dist. Medical Officer and

Superintendent of Police, Medchal district will be informed by Site

controller if required.

7.15 MOCKDRILL

Mock Drills would be organized once in six months to evaluate the

preparedness and functioning of OSEP. It is also planned to

undertake few informed and non formed mock drills (or rehearsals)

for meeting emergencies. Such rehearsals would be carefully

analyzed and shortcomings would be identified and necessary

corrections would be taken up. Site controller is responsible for

planning and execution and evaluation of mock drills. Also

information would be given to statutory authorities. It is proposed to

at-least conduct two mock drills in a year and over a period of time

all the sections in all the shifts would be covered. When truck drivers

carrying product are in the plant, they also would be trained



regarding transportation emergencies and how to react to minimize

the damage or effect on people.

7.16 REVIEW OF ONSITE EMERGENCY PLAN

1. Onsite Emergency Plan would be reviewed whenever there is a

change in product, or product route of manufacture, or addition

of new equipment or change in Site Controller.

2. Site Controller is responsible for such update and making

available latest copy or Onsite Emergency Plan to all concerned

in the organization as will as to the Statutory Authorities.

Nakoda Chemicals Limited Environmental Impact Assessment...

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