RISK ASSESSMENT 7.1 Introductionenvironmentclearance.nic.in/writereaddata/online/... · The...

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




Sr No

Hazardous

Chemical Name

Physical

State Storage mode Requir

ement Maximum

Storage

Capacity


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-


Drum

30 5




Sr No

Hazardous

Chemical Name

Physical


ement Maximum

Storage

Capacity


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%


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


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


Drum

29 3.25

45 N,N Dimethyl Aniline Liquid 250 kg HDPE/MS

Drum

30 3.25

46 O- chloro

Benzylchloride


Drum

35 3.75




Sr No

Hazardous

Chemical Name

Physical


ement Maximum

Storage

Capacity


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




Sr No

Hazardous

Chemical Name

Physical


ement Maximum

Storage

Capacity


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




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.




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


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

https://www.chemicalbook.com/CASEN_36315-01-2.htm

https://www.chemicalbook.com/CASEN_120-83-2.htm

https://www.sigmaaldrich.com/catalog/search?term=1668-54-8&interface=CAS%20No.&N=0&mode=partialmax&lang=en&region=IN&focus=product




Sn. Hazardous

Materials

CAS

Numbers

Physical

State


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

https://www.sigmaaldrich.com/catalog/search?term=1071-83-6&interface=CAS%20No.&lang=en&region=US&focus=product




Sn. Hazardous

Materials

CAS

Numbers

Physical

State


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

http://www.molbase.com/en/cas-611-19-8.html




Sn. Hazardous

Materials

CAS

Numbers

Physical

State


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

https://www.sigmaaldrich.com/catalog/search?term=7646-69-7&interface=CAS%20No.&N=0&mode=partialmax&lang=en&region=IN&focus=product




Sn. Hazardous

Materials

CAS

Numbers

Physical

State


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






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






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


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


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






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


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






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


67 Toluene Tanker Flammable Health: 2 Flammability: 3 Reactivity: 0

68 EDTA (50%) Bag May be combustible at High

Temperature


69 Naphthol Bag May be combustible at High

Temperature


70 Sodium Bicarbonate Bag Non-flammable Health: 1 Flammability: 0 Reactivity: 0

71 Xylene Tank Flammable Health: 2 Flammability: 3 Reactivity: 0




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




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




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.




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.

EIA/EMP Report for Expansion of M/s UPL Ltd. (Unit#10) MIDC, Notified

Industrial Estate, Tarapur, Boisar, Dist. Palghar, Maharashtra


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.




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


3. Catastrophic Rupture of 1 kl Xylene

tank

Fixed Pool Fire


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)




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:




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




Sr.

No.


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


effect

5. Rupture of Carbon Di

Sulphide Tank

Pool Fire: 22.5 m 72.4 m 44.4 m

6. Rupture of Phenol

Tank


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




Sr.

No.


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.




Figure 7.1: Thermal Radiation Distance for Methanol 5 kl AG Tank

Figure 7.2: Thermal Radiation Distance for Toluene 140 kl Tank




Figure 7.3: Overpressure Distance for Toluene 140 kl Tank

Figure 7.4: Thermal Radiation Distance for Xylene Tank




Figure 7.5: Thermal Radiation Distance for Hexane Tank

Figure 7.6: Thermal Radiation Distance for Carbon Di Sulfide Tank




Figure 7.7: Overpressure Distance for Carbon Di Sulfide Tank

Figure 7.8: Thermal Radiation Distance for Phenol Tank




Figure 7.9: IDLH Concentration for Release from Ammonia Cylinder

Figure 7.10: IDLH Concentration for Release from Chlorine Tonner




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




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).




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




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.




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.




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




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




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




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




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




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




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.




• 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.




• 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.




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.




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.




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.




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.




• 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.




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.




• 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.




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.




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




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.




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




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




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.




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.




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




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




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

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