ENVIRONMENT IMPACT ASSESSMENT REPORT M/S. AARTI INDUSTRIES LTD.(CUSTOM SYNTHESIS DIVISION),GIDC,VAPI

Transcription

1 Chapter 6 RISK ASSESSMENT & DISASTER MANAGEMENT PLAN In order to support the Environment Impact Assessment and Environment Management Plan, following additional studies have been included in the report. Risk Assessment Disaster Management Plan Occupational Health and Safety Management System 6.1 RISK ASSESSMENT M/s. Aarti Industries Ltd. (Custom Synthesis Division) deals with various chemicals, some of which are hazardous in nature by virtue of their intrinsic chemical properties or their operating temperatures or pressures or a combination of them. Fire, explosion, toxic release or combinations of them are the hazards associated with industrial plants using hazardous chemicals. More comprehensive, systematic and sophisticated methods of Safety Engineering, such as, Hazard Analysis and Quantitative Risk Assessment have been developed to improve upon the integrity, reliability and safety of industrial plants OBJECTIVES AND METHODOLOGY OF RISK ASSESSMENT Risk analysis follows an extensive hazard analysis. It involves the identification and assessment of risks the neighboring populations are exposed to as a result of hazards present. This requires a thorough knowledge of failure probability, credible accident scenario, vulnerability of population etc. Much of this information is difficult to get or generate. Consequently, the risk analysis is often confined to maximum credible accident studies. It provides basis for what should be type and capacity of its on-site and off-site emergency plan also what types of safety measures shall be required. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.1

2 OBJECTIVE OF RISK ASSESSMENT Risk assessment is carried out for the following objectives: 1. To identify hazard and risk resulting from the hazards 2. To study and foresee the effects of such risks on the workers, public, property and environment and to find out necessary control measures to prevent or minimize risk. 3. To comply the legal requirement by various safety and environment laws of the country. 4. To get the necessary information for Emergency planning and evacuation SCOPE OF THIS STUDY It has been proposed to establish a facility for manufacturing of bulk drugs and its Intermediates. The process deals with various hazardous chemicals. Hence, a quantitative risk assessment (QRA) was under taken to assess the risk impacts associated with the installation, and to establish whether these risks comply with the applicable criteria. The QRA study in this report has specifically been conducted considering the Terms of References (TOR) given by Industrial Projects Committee of MoEF for Environment Clearance (EC). The study covers following contents: Objectives, methodology of risk assessment Details on storage facilities Process safety, transportation, fire fighting systems, safety features and emergency capabilities to be adopted. Identification of hazards Consequence analysis Recommendations on the basis of risk assessment Disaster Management Plan. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.2

3 METHODOLOGY TO CONDUCT RISK ASSESSMENT Consequences of loss of containment can lead to hazardous situation in any industry handling potentially hazardous materials. Following factors govern the severity of consequence of the loss of containment. Intrinsic properties; flammability, instability and toxicity. Dispersive energy; pressure, temperature and state of matter. Quantity present Environmental factors; topography and weather. Consequence analysis and calculations are effectively performed by computer software using models validated over a number of applications. Consequence modeling is carried out by PHAST of DNV Software. PHAST contains data for a large number of chemicals and allows definition of mixtures of any of these chemicals in the required proportion. The calculations by PHAST involve following steps for each modeled failure case: - Run discharge calculations based on physical conditions and leak size. - Model first stage of release (for each weather category). - Dispersion modeling taking into account weather conditions. - In case of flammable gas release, calculate size of effect zone for fire and explosion DETAILS OF STORAGE FACILITIES The locations of storage of various chemicals have been marked on layout map (Figure no. 6.2). Details of the raw materials have been given in the Table no. 6.1 no.a & 6.1-B. Details of the chemicals stored at Storage Tank, Raw Material Stores, Cylinder Storage Yard are stated in Table No 6.1 no. A JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.3

4 Figure : 6.1 Layout plan (locations of storage of various chemicals) JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.4

5 Table : 6.1-A Storage Details of Raw Materials Sr.No 1. Raw Material 2-Amino-3-hydroxy Propionic acid Max. Storage Qty. Hazards Mode of Storage Capacity of single Unit Mode of transportation Storage Location 5000 Kg Dust Explosin HDPE drum 50 Kg Truck Raw material stores 2. Methanol ltrs Fire Under Ground Tank 20000lts Tanker Storage Tank 3. Acetone ltrs Fire Under Ground Tank 20000lts Tanker Storage Tank 4. Thionyl chloride 5100 kg Toxic Release HDPE drum 300 Kg By Road Raw material stores 5. PCl kg Toxic Release HDPE drum 40 Kg By Road Raw material stores 6. CHCl lts Toxic Release Above Ground Tank 15000lts By Road Storage Tank 7. CH3COCl 7000 kg Toxic Release HDPE drum 200 Liter By Road Raw material stores 8. Toluene 3000 kg Fire Under Ground Tank 2000 Liters Tanker 9. C4H9NO 4000 Kg Fire HDPE drum 200 Liter By Road Storage Tank Raw material stores 10. C5H8O 3000 Kg Fire HDPE drum 50 Kg By Road Raw material stores 11. C6H15NO 6000 Kg Fire HDPE drum 200 Liter By Road Raw material stores 12. Conc HCl ltrs Toxic Release Above Ground Tank 20000lts Tanker Storage Tank 13. Activated charcoal 1000 kg - 30 kg Bags 30 Kg By Road Raw material stores JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.5

6 Sr.No Raw Material Max. Storage Qty. Hazards 14. MDC ltrs Fire Mode of Storage Above Ground Tank Capacity of single Unit Mode of transportation Storage Location 15000ltrs Tanker Storage Tank 15. PTSA 5000 kg Health Hazard Bags 50 Kg By Road Raw material stores 16. Pd catalyst 300 kg Fire, Explosion HDPE drum 12 Kg By Road Raw material stores 17. Hydrogen 3.0 ton Fire, Explosion Cylinder 6 Kg By Road Cylinder storage yard 18. C7H8O 2.0 ton Fire Storage tank 5000 Ltrs Tanker Storage Tank 19. Na2CO kg Dust hazard Bags 25 Kg By Road Raw material stores 20. Na2SO kg Dust hazard Bags 50 kg By Road Raw material stores 21. Dry HCl 47 Cylinder 22. Thiophenol Kg Health Hazard HDPE drum Toxic Release Cylinder 32 kg By Road Cylinder storage yard 200 Ltr HDPE drum By Road Raw material stores 23. ONCB Kg Fire HDPE drum 200 Liter By Road Raw material stores 24. NaOH 3000 kg Health Hazard Bags 50 Kg By Road Raw material stores 25. DMF Kg Fire HDPE drum 200 Liter By Road Raw material stores 26. Reney nickel 300 kg Fire, explosion HDPE drum 25 Kg By Road Raw material stores 27. Phenyl chloroformate Kg Toxic Release HDPE drum 200 Liter By Road Raw material stores 28. N- Hexane Kg Fire HDPE drum 190 Kg By Road Raw material stores JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.6

7 Sr.No Raw Material Max. Storage Qty. Hazards Mode of Storage Capacity of single Unit Mode of transportation Storage Location 29. Phosphoric acid 1000 kg Toxic Release HDPE drum 25 Kg By Road Raw material stores 30. POCl kg Toxic Release HDPE drum 25 Kg By Road Raw material stores 31. C10H10BrNO Kg Health Hazard Bags 50 Kg By Road Raw material stores 32. C8H8KNO Kg Health Hazard Bags 50 Kg By Road Raw material stores 33. BrCH2COOC(CH3 ) Kg Health Hazard HDPE drum 25 Kg By Road Raw material stores 34. (CH3)3COK 5000 Kg Dust Explosion Bags 50 Kg By Road Raw material stores 35. NH2CH2CH2OH 5000 Kg Toxic HDPE drum 25 Liters By Road Raw material stores 36. IPA kg Fire MS drums 200 Lit By Road Raw material stores 37. C4H6O6 (Tartaric Acid) 5000 Kg Health Hazard Bags 50 Kg By Road Raw material stores 38. Catalyst (ni) 3000 Kg Health Hazard HDPE drum 25 Kg By Road Raw material stores 39. NH3 500 Kg Toxic release Cylinder 50 Kg By Road Cylinder storage yard 40. C6H4CINO4S 5000 Kg Health Hazard HDPE drum 25 Kg By Road Raw material stores 41. C12H16O Kg Health Hazard HDPE drum 25 Liters By Road Raw material stores 42. Cyclohexane 5000 kg Fire MS Drums 190 Kg By Road Raw material stores 43. C21H28O Kg Health Hazard HDPE drum 200 Liter By Road Raw material stores 44. Acetic acid 4500 kg Health Hazard HDPE drum 30 Kg By Road Raw material stores 45. Acetic anhydride 4000 Kg Health Hazard HDPE drum 200 Liter By Road Raw material stores JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.7

8 Sr.No Raw Material Max. Storage Qty. Hazards Mode of Storage Capacity of single Unit Mode of transportation Storage Location 46. Formic Acid 2000 kg Health Hazard HDPE drum 180 Kg By Road Raw material stores 47. KMnO Kg Health Hazard HDPE drum 25 Liters By Road Raw material stores 48. Pottasium hydroxide 1000 Kg Health Hazard Bags 50 Kg By Road Raw material stores 49. Ethylene dibromide 3000 kg Health Hazard HDPE drum 230 Kg By Road Raw material stores 50. Sodium sulphite 2000 kg Health Hazard HDPE drum 25 Kg By Road Raw material stores 51. Citric acid 5000 Kg Health Hazard HDPE drum 30 Kg By Road Raw material stores 52. C6H12O3 (DMTHF) 5000 Kg Fire HDPE drum 200 Liters By Road Raw material stores 53. Succindialdehyde 5000 Kg Fire Drum 25 Kg By Road Raw material stores 54. Methyl phenyl acetate 5000 Kg Health Hazard HDPE drum 200 Kg By Road Raw material stores 55. Ethyl formate 3000 Kg Fire HDPE drum 200 Kg By Road Raw material stores 56. Lnorvoline,ethylest er Hydrochloride 57. Pyruvic acid 2000 Kg 58. C23H29NO5S.C7H 8O3S.PTSA 5000 Kg Health Hazard HDPE drum 50 Kg By Road Raw material stores Health Hazard, Explosion Drum 25 Kg By Road Raw material stores Kg Health Hazard HDPE drum 50 Kg By Road Raw material stores JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.8

9 Sr.No Raw Material Max. Storage Qty. Hazards Mode of Storage Capacity of single Unit Mode of transportation Storage Location 59. Ethanol 5000 Kg Health Hazard HDPE drum 200 Liters By Road Raw material stores 60. Acetonitrile 2000 Kg Fire Drum 25 Kg By Road Raw material stores 61. L- phenyl alanine 2000 kg Dust Explosin Bags 25 Kg By Road Raw material stores 62. Formaldehyde 5000 Kg Health Hazard HDPE drum 200 Kg By Road Raw material stores 63. HBr 5000 kg Health Hazard HDPE drum 300 Kg By Road Raw material stores 64. Benzyl alcohol ltr Fire Under Ground Tank liters Tanker Storage Tank 65. PMPA 5000 kg Health Hazard MS drum 200 Kg By Road Raw material stores 66. n-butanol 2500 kg Fire Storage tank 5000 liters Tanker Storage Tank 67. Sodium methoxide 1000 kg Health Hazard, Fire MS drum 100 Kg By Road Raw material stores 68. MAA 5000 Kg Health Hazard Drum 50 Kg By Road Raw material stores 69. ATM 5000 Kg Health Hazard Drum 50 Kg By Road Raw material stores 70. DMA 2000 kg 71. MCPBA 5000 Kg Health Hazard, Explosion Health Hazard, Fire HDPE drum 200 Kg By Road Raw material stores MS drum 100 Kg By Road Raw material stores 72. Chloroform kl Health Hazard Above ground tank liters Tanker Storage Tank 73. Caffine 5000 Kg Dust explosion Drum 50 Kg By Road Raw material stores JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.9

10 Sr.No Raw Material 4-methoxy phenyl acetic acid Cyclohexanyle ethyl amine phosprous oxychloride Max. Storage Qty. Hazards Mode of Storage Capacity of single Unit Mode of transportation Storage Location 5000 Kg Health Hazard Bags 50 Kg By Road Raw material stores 5000 Kg Health Hazard HDPE drum 200 Kg By Road Raw material stores 5000 Kg Health Hazard Drum 25 Kg By Road Raw material stores 77. Orthoxylene 2500 kg Fire MS drum 170 Kg By Road Raw material stores 78. SBH 5000 Kg Health Hazard, Fire HDPE Drum 50 Kg By Road Raw material stores 79. Salt kg NA Bags 55 Kg By Road Raw material stores 80. Mandalic acid 2000 kg Dust explosion HDPE Drum 50 Kg By Road Raw material stores 81. Methyl formate 5000 Kg Health Hazard HDPE drum 300 Kg By Road Raw material stores 82. P2O Kg Health Hazard Drum 25 Kg By Road Raw material stores 83. Cyano Acetic acid Kg Health Hazard HDPE Drum 50 Kg By Road Raw material stores 84. Ammonium Acetate 1000 kg Health Hazard Bags 50 Kg By Road Raw material stores 85. Bromine 1000 Kg Toxic Release Bottle 1.5 Kg By Road Raw material stores 86. BI kg Dust Explosion Fiber Drum 25 Kg By Road Raw material stores 87. Sod. BI Sulphate 1000 kg Dust Explosion Bags 50 Kg By Road Raw material stores JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.10

11 Sr.No Raw Material Max. Storage Qty. Hazards Mode of Storage Capacity of single Unit Mode of transportation Storage Location 88. Sod. Bi Carbonate 1500 kg Dust Explosion Bags 50 Kg By Road Raw material stores 89. NMBA Kg Fire HDPE Drums 200 Kg By Road Raw material stores 90. Dry HCl 3000 Kg Toxic Release Cylinders 32 kg By Road Cylinder storage yard 91. Chlorin gas 5000 Kg Toxic Release Cylinders 1000 Kg By Road Cylinder storage yard 92. Liq Ammonia 5000 Kg Toxic Release HDPE Drums 40 Kg By Road Raw material stores 93. MDC ltr Fire Above GroundTank liters Tanker Storage Tank 94. AluminiumChloride 5000 kg Toxic Release Bags 25 Kg By Road Raw material stores 95. Acetyl chloride 7000 kg Toxic Release HDPE Drums 200 Kg By Road Raw material stores 96. 2,4 DFB 2500 kg Dust Explosion Fiber Drum 25 Kg By Road Raw material stores 97. Malic anhydride 3000 kg Dust Explosion Fiber Drum 25 Kg By Road Raw material stores 98. Activated carbon 1000 kg - Bags 30 Kg By Road Raw material stores JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.11

12 Table : 6.1-B Hazardous properties of Chemicals Sr. No. Chemicals FP o C BP o C SP.GR. VD vs air Vapour Pressure mm 20 o C LEL % UEL % IDLH LD 50 ORAL LC Methanol KPa mg/kg ppm 4 hours [Rat]. [Rat]. 2. Acetone KPa mg/kg mg/m 8 hours [Rat]. [Rat]. 3. Thionyl chloride KPa ppm 1 hours [Rat]. 4. Toluene KPa mg/kg mg/m 4 hours [Rat]. [Rat]. 5. Conc HCl kpa ppm Hydrogen C Dry HCl Kg/cm²g ppm 8. N- Hexane mmhg Phosphoric acid kpa IPA kpa mg/kg (Oral Rabbit) >5 gm/kg oralrat 1530 mg/kg [Rat] mg/kg [Rat]. 11 NH psig ppm Cyclohexane kpa mg/kg [Rat] ppm/1 hr (Inhalation Rat) >3367 ppm inhalation-rat 850 mg/m 1 hours [Rat] mg/kg [Rabbit] ppm (rat, 4 hours) - JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.12

13 Sr. No. Chemicals FP o C BP o C SP.GR. VD vs air Vapour Pressure mm 20 o C LEL % UEL % IDLH LD 50 ORAL LC Acetic acid kpa mg/kg 5620 ppm 1 hours [Rat]. [Mouse]. 12. Ethylene 108 mg/kg 7150 ppm 4 hour(s) mm of Hg dibromide [Rat]. [Rat]. 13. Ethanol kpa mg/kg ppm 8 hours [Rat]. [Rat]. 14. Acetonitrile kPa mg/kg [Rat.] HBr mg/kg 2858 ppm for kpa at kg/m3 93 O ppm (Intraperitoneal minutes. (inhalationrat) C -rat) 16. n-butanol kpa mg/kg 8000 mg/kg Oral, rat Inhalation, rat 17. Sodium methoxide mg/kg [Rat] Phosprous 380 mg/kg 32 ppm 4 hour(s) mm of Hg oxychloride [Rat]. [Rat]. 19. Bromine kpa mg/kg [Rat] Chlorin gas psig ppm ppm, rat 1 hour JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.13

14 6.1.3 DETAILS OF SAFETY MEASURES It is practically impossible to reduce the risk to zero. However, effective measures can certainly reduce the risk considerably. The safety measures intend to reduce the risk related to various hazards present at the work place. The details of various safety measures adopted by M/s. Aarti Industries Ltd.(Custom Synthesis Divisions) at various stages of project are as detailed below PROCESS SAFETY MEASURES IN EXISTING UNIT Safety measures have been adopted from the design stage itself. Safety Valve and pressure gauge are provided on reactor and its jacket (if jacket is provided). To control reaction parameters and avoid run-away reactions, utility like Chilling water, cooling water, vacuum lines, steam supply and their alternatives are made available. Static earthing provision is made at design stage to all solvent handling equipments, reactors, vessels & powder handling equipments. All the vessels and equipments are earthed appropriately and protected against Static Electricity. Also for draining in drums proper earthing facilities shall be provided. All emergency valves and switches and emergency handling facilities are easily assessable. Free Fall of any flammable material in the vessel is avoided. All solvents and flammable material storage tanks is stored away from the process plant and required quantity of material shall be charge in reactor by pump. PPEs to protect against any adverse health effect during operations, leakage, spillages or splash. PPE like Helmets, Safety Shoes, Safety Glasses, Acid-Alkali Proof Gloves etc. is provided to the employees and workers. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.14

15 Material Safety Data Sheets of Raw Materials & Products are made readily available on the shop floor SAFETY MEASURES DURING TRANSPORTATION AND UNLOADING OF TANKERS Transportation of raw materials is carried out in Drums on pallets (through tank lorries) for liquid raw materials and solvents Static earthing provision is made for tanker unloading. Earthed Flexible Steel hose is used for solvent unloading from the road tanker. Fixed pipelines with pumps are provided for solvent transfer up to Day tanks/reactors. Double mechanical seal type pumps are installed. NRV provision has been made on all pump discharge line SYSTEM FOR FIRE FIGHTING At M/s. Aarti Industries Ltd (Custom Synthesis Divisions), management has developed a well-resourced and adequate fire fighting network. Some of the details regarding the same areas under: Table: 6.2 Details of fire fighting network Type of Fire Extinguishes Number of Fire extinguishers Fire Water Reservoir Capacity Fire Pump Capacity Hydrant Pressure Foam Type and quantity Other relevant details ABC, DCP, CO2,Mechani cal foam, m3 Mainpump- 171m 3 /hr., Jokeypump- 10.8m 3 / hr, DG Engine- 171m 3 / hr 7.5kg/cm 2 AFFF Quantity liter. Sand bucket (9 lit.capac ity) -40 nos. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.15

16 OTHER FIRE FIGHTING MEASURES PROPOSED FOR EXPANSION PROJECT: Management shall consider the measures for fire prevention for the expansion project at the project planning as well as commissioning stage to avoid any outbreak of fire. Fire load calculation shall be carried out and Fire Extinguishers at different locations shall be provided at appropriate locations as per the TAC guidelines. Working staff will be given training to operate DCP and CO 2 extinguishers EMERGENCY CAPABILITIES The details of Emergency Capabilities have been discussed in Disaster Management Plan HAZARD IDENTIFICATION Identification of hazards in the proposed project activity is of primary significance of the analysis and quantification. Hazard states the characteristics of system/plant/process that presents potential for an accident. 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 IDENTIFICATION OF HAZARDOUS AREAS The procedure for QRA starts with identification of major risk areas at site. At M/s. Aarti Industries Ltd.(Custom Synthesis Divisions), major risk areas are as follows: Storage Tank Raw Material Stores Cylinder Storage Tank The hazardous chemical storage area has been shown in Figure no The major Hazardous chemicals to be stored, transported, handled and utilized within the plot area are summarized in the Table no. 6.1-A and Table no. 6.1-B, in section no JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.16

17 IDENTIFICATION OF FAILURE CASES FOR HAZARDOUS AREAS Raw materials are being transported through roads by trucks and tankers. Mode of storage is, Storage tanks Drums In this regard, the failure cases which may lead to release of hazardous chemicals are as under: Rupture of Drum Rupture of tank bottom valve Small gasket leaks in a flange joints CONSEQUENCE ANALYSIS In a plant handling hazardous chemicals, the main hazard arises due to storage, handling & use of these chemicals. If these chemicals are released into the atmosphere, they may cause damage due to resulting fires or vapour clouds. Blast Overpressures depend upon the reactivity class of material between two explosive limits. OPERATING PARAMETERS Potential vapour release for the same material depends significantly on the operating conditions. Especially for any liquefied gas, the operating conditions are very critical to assess the damage potential. If we take up an example of ammonia, if it is stored at ambient temperature, say 30 o C, and then the vapour release potential of the inventory is much higher as compared to the case if it is stored at 0 o C. INVENTORY Inventory Analysis is commonly used in understanding the relative hazards and short listing of release scenarios. Inventory plays an important role in regard to the potential hazard. Larger the inventory of a vessel or a system, larger the quantity of potential JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.17

18 release. The potential vapour release (source strength) depends upon the quantity of liquid release, the properties of the materials and the operating conditions (pressure, temperature). If all these influencing parameters are combined into a matrix and vapour source strength estimated for each release case, a ranking should become a credible exercise. LOSS OF CONTAINMENT Plant inventory can get discharged to Environment due to Loss of Containment. Certain features of materials to be handled at the plant need to the clearly understood to firstly list out all significant release cases and then to short list release scenarios for a detailed examination. Liquid release can be either instantaneous or continuous. Failure of a vessel leading to an instantaneous outflow assumes the sudden appearance of such a major crack that practically all of the contents above the crack shall be released in a very short time. The more likely event is the case of liquid release from a hole in a pipe connected to the vessel. The flow rate is depending on the size of the hole as well as on the pressure, which was present, in front of the hole, prior to the accident. Such pressure is basically dependent on the pressure in the vessel. The vaporization of released liquid depends on the vapour pressure and weather conditions. Such consideration and others have been kept in mind both during the initial listing as well as during the short listing procedure. In the study, Maximum Credible Loss accident methodology is to be used, therefore, the largest potential hazard inventories have been considered for consequence estimation DAMAGE CRITERIA In consequence analysis, use is made of a number of calculation models to estimate the physical effects of an accident (spill of hazardous material) and to predict the damage (lethality, injury, material destruction) of the effects. The calculations can roughly be divided in three major groups: a) Determination of the source strength parameters; b) Determination of the consequential effects; c) Determination of the damage or damage distances. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.18

19 The basic physical effect models consist of the following. SOURCE STRENGTH PARAMETERS * Calculation of the outflow of liquid, vapour or gas out of a vessel or a pipe, in case of rupture. Also two-phase outflow can be calculated. * Calculation, in case of liquid outflow, of the instantaneous flash evaporation and of the dimensions of the remaining liquid pool. * Calculation of the evaporation rate, as a function of volatility of the material, pool dimensions and wind velocity. * Source strength equals pump capacities, etc. in some cases. CONSEQUENTIAL EFFECTS In a process plant, the main hazard arises due to storage, handling & use of these chemicals. If these chemicals are released into the atmosphere, they may cause damage due to resulting fires or dispersion of toxic vapour. Following paragraphs gives details about various parameters affecting the consequences of a hazardous event. SELECTION OF DAMAGE CRITERIA In Consequence Analysis studies, in principle three types of exposure to hazardous effects are distinguished: 1. Heat radiation, from a jet, pool fire, a flash fire or a BLEVE. 2. Explosion 3. Toxic effects, from toxic materials or toxic combustion products. In the next three paragraphs, the chosen damage criteria for Sr. No. 1 and 3 are given and explained. Explosion is not included in this description as it is not relevant in present study. HEAT RADIATION The consequence caused by exposure to heat radiation is a function of: The radiation energy onto the human body [kw/m 2 ]; JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.19

20 The exposure duration [sec]; The protection of the skin tissue (clothed or naked body). The limits for 1% of the exposed people to be killed due to heat radiation, and for second-degree burns are given in the table herein: Table: 6.3 Damages to Human Life Due to Heat Radiation Exposure Duration Radiation for 1% lethality (kw/m 2 ) Radiation for 2 nd degree burns (kw/m 2 ) Radiation for first degree burns (kw/m 2 ) 10 Sec Sec Since in practical situations, only the own employees will be exposed to heat radiation in case of a fire, it is reasonable to assume the protection by clothing. It can be assumed that people would be able to find a cover or a shield against thermal radiation in 10 sec. time. Furthermore, 100% lethality may be assumed for all people suffering from direct contact with flames, such as the pool fire, a flash fire or a jet flame. The effects due to relatively lesser incident radiation intensity are given below. Table: 6.4 Effects Due to Incident Radiation Intensity Incident radiation kw/m Effect Minimum Energy required for igniting wood (without flame contact). 100 % fatal in 1 min. Significant injury in 10 sec. Minimum heat required to ignite wood (with flame contact). 1 % fatal in 1 min. First degree burn in 10 sec. 4 Pain after 20 sec. Blistering unlikely. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.20

21 INTOXICATION The consequences from inhalation of a toxic vapour/gas are determined by the toxic dose. This dose D is basically determined by: - Concentration of the vapour in air; - Exposure duration. Furthermore, of course, the breathing rates of the victim, as well as the specific toxic mechanism unto the metabolism play an important role. The dose is defined as D = C n.t, with: C = concentration of the toxic vapour, in [ppm] or [mg/m 3 ]; t n = exposure duration, in [sec] or [min]; = exponent, mostly > 1.0; this exponent takes into account the fact that a high concentration over a short period results in more serious injury than a low concentration over a relatively longer period of exposure. The value of n should be greater than zero but less than 5. The given definition for D only holds if the concentration is more or less constant over the exposure time; this may be the case for a (semi) continuous source. In case of an instantaneous source, the concentration varies with time; the dose D must be calculated with an integral equation: D = C n.dt For a number of toxic materials, so-called Vulnerability Models (V.M.) have been developed. The general equation for a V.M. (probit function) is: Pr = a + b.ln (C n.t), with Pr = probit number, being a representation of the percentage of people suffering a certain kind of damage, for instance lethality Pr = 2.67 means 1% of the population; Pr = 5.00 means 50% of the population; a and b material dependent numbers; C n.t = dose D, as explained above. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.21

22 The values for a and b are mostly derived from experiments with animals; occasionally, however, also human toxicity factors have been derived from accidents in past. In case only animal experiments are available, the inhalation experiments with rats seem to be best applicable for predicting the damage to people from acute intoxication. Although much research in this field have been done over the past decades, only for a limited number of toxic materials consequence models have been developed. Often only quite scarce information is available to predict the damage from an acute toxic exposition. Data transformation from oral intoxication data to inhalation toxicity criteria is sometimes necessary. Generally, in safety evaluations pessimistic assumptions are applied in these transformation calculations. The calculated damage (distance) may be regarded as a maximum. For the purposes of a response to a major incident, the IDLH value level has been chosen for the wounded criteria. This type of injury will require medical attention ASSUMPTIONS FOR CONSEQUENCE ANALYSIS For Consequence Analysis, assumptions regarding Meteorological, Pasquil Stability Classes, Wind velocity, Ambient Temperature, Relative Humidity, Inventory, Ground Roughness, Model used etc. are very important. In this report, the following assumptions have been considered. Table: 6.5 Weather data used for the study Wind speed (m/s) Pasquill stability 1.5 F 1.5 D 5 D SOFTWARE USED FOR CALCULATIONS 1. PHAST MICRO v CAMEO JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.22

23 SCENARIOS CONSIDERED FOR CONSEQUENCE ANALYSIS 1. In this study, the scenarios for consequence analysis have been selected considering: The physical and chemical properties of hazardous materials Hazards ranking by NFPA Operating and storage conditions of chemicals 2. Only catastrophic failure cases have been considered and not partial or small failures. The objective of the study is emergency planning, hence only holistic & conservative assumptions are used for obvious reasons. Hence though the outcomes may look pessimistic, the planning for emergency concept should be borne in mind whilst interpreting the results. 3. In this study, results of consequence analysis shall be used for; a. Emergency Planning b. Deciding Evacuation Routes c. Deciding Location of Assembly Points and ECC d. Resource Allocation for mitigation 4. Scenarios Identified for consequence analysis (Table no. 6.6). Table : 6.6 Scenario identified for consequence analysis Scenario Flammable Scenarios Description of Scenario Pressure & Temp. Stored Quantity 1 Release of Methanol NTP 20 KL 2 Release of Acetone NTP 20 KL 3 Release of Toluene NTP 20 KL 4 Release of n-hexane NTP 190 Kg Release of Toxic Chemicals 5 Release of HCl NTP 32 Kg (1 Cylinder) 6 Release of Ammonia NTP 50 Kg (1 Cylinder) JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.23

24 Table : 6.7 Scenario#1 Release of Methanol Release of Methanol due to failure of unloading hose from tanker Input Data Material Discharge Temperature Mass inventory of Material Scenario Data Type of Event Hole Diameter Radiatio n Level (KW/m 2 ) Distance (meter) 1.5/F 1.5/D 5/D Methanol 40 o C 20 KL Failure of Unloading hose from tanker 100 mm Late Pool Fire Results Effect if IHR at Height of simulation Minimum Energy required for igniting wood (without flame contact). 100 % fatal in 1 min. Significant injury in 10 sec Minimum heat required to ignite wood (with flame contact). 1 % fatal in 1 min. First degree burn in 10 sec Pain after 20 sec. Blistering unlikely. Flash Fire Results Conce ntratio n (ppm) UFL ( ) LFL (73000 ) LFL Frac (36500 ) Averaging Time Distance (m) Category 1.5/F Category 1.5/D Category 5/D S S S JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.24

25 Figure : 6.2 Risk contours for scenario#1: Risk Contous for Late Pool fire for 1.5/D weather condition JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.25

26 Figure : 6.3 Risk contours for scenario#1: Risk Contous for Flash fire for LEL and 50% LEL JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.26

27 Figure : 6.4 Flash fire Envelope of Methanol JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.27

28 Table: 6.8 Scenario#2 Release of Acetone Release of Acetone due to Leakage of unloading arm of tanker Input Data Material Discharge Temperature Mass inventory of Material Scenario Data Type of Event Hole Diameter Acetone 40 o C 20 KL Leakage from unloading arm 100 mm Radiation Distance (meter) Level (KW/m 2 ) 1.5/F 1.5/D 5/D Pool Fire Results Effect if IHR at Height of simulation Minimum Energy required for igniting wood (without flame contact). 100 % fatal in 1 min. Significant injury in 10 sec Minimum heat required to ignite wood (with flame contact). 1 % fatal in 1 min. First degree burn in 10 sec Pain after 20 sec. Blistering unlikely. Concentration (ppm) Averaging Time Flash Fire Results Distance (m) Category 1.5/F Category 1.5/D Category 5/D UFL (128000) S LFL (26000) S LFL Frac (13000) S JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.28

29 Figure : 6.5 Risk contours for scenario#2: Risk Contous for Late Pool fire for 1.5/D weather condition JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.29

30 Figure : 6.6 Risk Contous for Flash fire for LEL and 50% LEL JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.30

31 Figure : 6.7 Flash Fire Envelope for Acetone JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.31

32 Table : 6.9 Scenario#3 Release of Toluene Release of Toluene due to failure of unloading arm of tanker Input Data Material Discharge Temperature Mass inventory of Material Scenario Data Type of Event Hole Diameter Radiation Level (KW/m 2 ) 1.5/ F Toluene 40 o C 20 KL Tanker unloading arm failure 100 mm Pool Fire Results Distance (meter) Effect if IHR at Height of simulation 1.5/D 5/D Minimum Energy required for igniting wood (without flame contact). 100 % fatal in 1 min. Significant injury in 10 sec Minimum heat required to ignite wood (with flame contact). 1 % fatal in 1 min. First degree burn in 10 sec Pain after 20 sec. Blistering unlikely. Concentrati on (ppm) UFL (71000) LFL (12000) LFL Frac (6000) Averaging Time Flash Fire Results Distance (m) Category 1.5/F Category 1.5/D Category 5/D S S S JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.32

33 Figure : 6.8 Risk contours for scenario#3: Risk Contous for Late Pool fire for 1.5/D weather condition Concentration JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.33

34 Figure : 6.9 Risk Contous for Flash fire for LEL & 50% LEL JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.34

35 Figure : 6.10 Flash Fire Envelope for Toluene JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.35

36 Table : 6.10 Scenario#4 Release of n-hexane Release of n-hexane due to Catastrophic rupture of drum Input Data Material Discharge Temperature Mass inventory of Material Scenario Data n-hexane 40 o C Drum Capacity:190 Kg Type of Event Pool Fire Results Distance (meter) Radiation Level (KW/m 2 ) 1.5/F 1.5/D Mode of Failure: Catastrophic Effect if IHR at Height of simulation Concentration (ppm) Averaging Time Flash Fire Results Minimum Energy required for igniting wood (without flame contact). 100 % fatal in 1 min. Significant injury in 10 sec. Minimum heat required to ignite wood (with flame contact). 1 % fatal in 1 min. First degree burn in 10 sec. Pain after 20 sec. Blistering unlikely. Distance (m) Category 1.5/F Category 1.5/D UFL (76800) S LFL (10500) S LFL Frac (5250) S JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.36

37 Figure : 6.11 Risk contours for scenario#4: Risk Contous for Late Pool fire for 1.5/D weather condition JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.37

38 Figure : 6.12 Risk contour for flash fire for LEL & 50% LEL JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.38

39 Table : 6.11 Scenario#5 Release of HCl Release Of HCl Due to 2 mm Leakage from Cylinder Input Data Material Discharge Temperature Mass inventory of Material to discharge Scenario Data Type of Event Leakage size HCl 40 o C Cylinder Capacity 32 Kg Leakage In Cylinder 2 mm Result IDLH Concentration Release Duration Downwind Distance (meter) Category 1.5/F Category 1.5/D Category 5/D 50 ppm 10 min No Hazard Results:- 33 meter in downwind direction is considered as evacuation area. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.39

40 Figure : 6.13 Risk contours for scenario#5: HCL JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.40

41 Table : 6.12 Scenario#6 Release of Ammonia Release Of Ammonia Due to 3 mm Leakage from Cylinder Input Data Material Discharge Temperature Mass inventory of Material to discharge Scenario Data Type of Event Leakage size Release rate Result IDLH Concentration Ammonia 40 o C Cylinder Capacity: 50 Kg Leakage In Cylinder 3 mm 2 Kg/s Downwind Distance (meter) Release Duration Category Category 1.5/F Category 1.5/D 5/D 300 ppm 10 min Results:- 52 meter in downwind direction is considered as evacuation area. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.41

42 Figure : 6.14 Risk contours for scenario#6: JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.42

43 Figure : 6.15 Maximum concentration of footprint of Ammonia JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.43

44 Consequence Analysis Summary Table : 6.13 Late Pool-Fire Scenarios Sr. No. Scenario Radiation level Ihr (kw/m 2 ) distance in different weather condition 1.5F 1.5D 5 D 1 Release of Methanol 25 KW/M KW/M KW/M KW/M Release of Acetone 12.5 KW/M KW/M KW/M Release of Toluene 12.5 KW/M Release of n- Hexane 4 KW/M KW/M KW/M KW/M Table : 6.14 Flash Fire Scenarios Sr. No. 1 2 Scenario Release of Methanol Release of Acetone Concentration (ppm) Distance (meter) Category 1.5/F Category 1.5/D Category 5/D UFL (360000) LFL (73000) LFL Frac (36500) UFL (128000) LFL (26000) LFL Frac (13000) Release of UFL (71000) JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.44

45 4 Toluene Release of n- Hexane LFL (12000) LFL Frac (6000) UFL (76800) LFL (10500) LFL Frac (5250) Table : 6.15 Toxic Release Scenarios Sr. No. Scenario Idlh concentration Downwind distance (meter) Category Category Category 1.5/F 1.5/D 5/D 1 Release of HCl 50 ppm No Hazard 2 Release of Ammonia 300 ppm RECOMMENDATIONS BASED ON CONSEQUENCE ANALYSIS 1. Pool Fire Scenarios: Effect of heat radiation reaches to the farthest distance in weather condition 5D. Third degree burn radius (12.5 Kw/M 2 ) is maximum in case of Acetone (32.9m/5D) for same size of releases. It can be seen from the summarized table above that the maximum radius (26m) of IHR 25 KW/m2 is reached in case of pool fire of Acetone in weather condition of 5/D. The maximum radius of IHR 25 KW/M 2 in case of Methanol, Toluene, and n-hexane is 20.3m (5D), 11.3m (5D), 7.98m (1.5D), respectively. Toluene pool fire poses the least danger compared to the pool fires of all the chemicals listed above for same sized leak and inventory. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.45

46 2. Flash Fire Scenarios: Of all the chemicals listed above, Acetone vapor travels to the farthest distance for the same sized leakage or releases in any weather condition. Vapor of Acetone (50 % LEL concentration) reaches as far as 28 meter. If it gets an ignition sources in this radius, it may create a flash fire. Vapor of methanol (50 % LEL concentration) reaches up to 4 m only in 1.5/F weather condition. 3. Dispersion Scenarios: The IDLH concentration (50 ppm) of HCl may reach up to 32.4 meter of 1.5/F weather condition. The IDLH concentration (300 ppm) of Ammonia may reach up to 52 meter of 1.5/D weather condition. Evacuation plan to be designed considering the dispersion distances summarized above OTHER RECOMMANDATIONS TO REDUCE THE RISK OF FIRE, EXPLOSION AND TOXIC RELEASE (FOR EXPANSION PROJECT) 1. Evacuation plan shall be made considering the dispersion distances summarized above. 2. Structures, equipments and supports shall be designed considering the effects of flash fire modeled above. 3. Fire detection and suppression facilities shall be used. 4. Procedures shall be developed for start-up and schedules shall be made for regular inspection of plant machinery. 5. Fire load calculation will be carried out and fire fighting system shall be installed accordingly. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.46

47 6. Loading and unloading of wastes in storage tank shall only be done under the supervision of the well trained and experienced staff. 1. SAFETY PRECAUTIONS TO BE CONSIDERED DURING TRANSPORTATION AND HANDLING OF SOLVENTS LIKE TOLUENE, METHANOL, HEXANE, ACETONE: Table : 6.16 Safety precautions to be considered during Transportation and handling of solvents like Toluene, Methanol, Hexane, Acetone: Sr. No. Activity Safety precautions 1 Transportation of Solvents (Toluene, Methanol, Hexane, Acetone) by road tanker Training will be provided to driver and cleaner regarding the safe driving, hazard of Flammable chemicals, emergency handling and use of SCBA sets. TREM card will be kept with TL. SCBA set will be kept with TL. Fire extinguishers will be kept with TL. Flame arrestor will be provided to TL exhaust. Instructions will be given not to stop road tanker in populated area. Hazard Identification symbol and emergency telephone number will be displayed as per HAZCHEM CODE. Appropriate PPEs will be kept with TL. In case of leak or spill: Do not touch damaged containers or spilled material unless wearing appropriate protective clothing. Stop leak if you can do it without risk. Use water spray to reduce vapors; do not put water directly on leak, spill area or inside container. Keep combustibles (wood, paper, oil, etc.) away from spilled material. If a tank, rail car, or tank truck is involved in a fire, isolate it for 0.5 mi (800 m) in all directions; also consider initial evacuation for 0.5 mi (800 m) in all directions. Isolate the area Isolate the container JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.47

48 Sr. No. Activity Safety precautions 2 Solvents transfer from storage tank to Day tank 3 Solvent transfer from Day tank to reactor. Double mechanical seal type FLP type pump shall be provided. Double on / off switch shall be provided at tank farm and process area near day tank. Pump auto cut off with day tank high level shall be provided. Flame arrestor shall be provided on day tank vent. Over flow shall be provided for additional safety and it shall be connected to main storage tank. NRV shall be provided on pump discharge line. Double Jumper clip shall be provided to all solvent handling pipelines. Double static earthing shall be provided to day tank. Total quantity of day tank material shall be charged in to reactor at a time. NRV shall be provided on day tank outlet line. Static earthing shall be provided to storage tank. Double Jumpers shall be provided to pipeline flanges. 2. FOR HAZARDOUS CHEMICAL STORAGE TANK FARM Class A petroleum products will be received through road tanker and stored in storage tank as per petroleum rules. Tank farm will be constructed as per explosive department requirement and separation distance will be maintained. Tanks shall be located and marked in designated area of hazardous chemical storage. Color coding for the chemicals shall be observed in piping as distribution network. Static earthing provision will be made for road tanker as well as storage tank. Flame arrestor with breather valve will be provided on vent line. Road tanker unloading procedure will be prepared and implemented. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.48

49 Fire load calculation will be done and as per fire load Hydrant System will be provided as per NFPA std. and Fire extinguishers will be provided as per fire load calculation. Spark arrestor will be provided to all vehicles in side premises. Flame proof type equipments and lighting will be provided. Lightening arrestor will be provided on the top of chimney. Trained and experience operator will be employed for tank farm area. NFPA label (hazard identification) capacity and content will be displayed on storage tank. Solvents will be transferred by pump only in plant area and day tank will be provided. Overflow line will be return to the storage tank or Pump On-Off switch will be provided near day tank in plant. Jumpers will be provided on solvent handling pipe line flanges. Flexible SS hose will be used for road tanker unloading purpose and other temperature connection. All tanks shall be uniformly tagged. Level indicator shall be provided in tanks. Industrial type electric fittings shall be provided. Adequate fire fighting equipments will be provided. Anti corrosive paint shall be done. Safety instruction board will be displayed. 3. FOR DRUM/CARBOY STORAGE AREA Proper ventilation will be provided in godown. Proper label and identification board /stickers will be provided in the storage area. Conductive drum pallets will be provided. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.49

50 Drum handling trolley / stackers/fork lift will be used for drum handling. Separate dispensing room with local exhaust and static earthing provision will be made. Materials will be stored as per its compatibility study and separate area will be made for flammable, corrosive and toxic chemical drums storage. Smoking and other spark, flame generating item will be banned from the Gate. 4. SAFETY PRECAUTIONS FOR CYLINDER STORAGE AREA: Handling of Cylinder Store cylinders upright and secure them with a chain, strap, or cable to a stationary building support or to a proper cylinder cart to prevent them from tipping or falling. Completely close the valves, and keep the valve protection devices, such as caps or guards, securely in place. Store cylinders in a dry, well-ventilated area at least 20 feet from combustible materials. Do not keep cylinders in lockers. If they leak, a buildup of flammable or other types of gases can occur inside the locker. Mark the storage area with proper precautionary signs, such as flammable, oxidizer, or toxic. Place them in a location where they will not be subject to mechanical or physical damage, heat, or electrical circuits to prevent possible explosion or fire. Keep cylinders away from vehicle traffic. Store empty cylinders separate from full ones. Keep oxygen cylinders 20 feet away from fuel-gas cylinders, such as acetylene, or separate them with a non-combustible barrier (such as a wall) at least 5 feet high with a fire-resistance rating of at least one-half hour. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.50

51 Transportation of Cylinders Most accidents or injuries involving cylinders happen when moving or handling the gas cylinders. Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders to avoid personal injury and cylinder damage. Wear protective footwear, safety glasses, and heavy gloves. Securely install the valve protection devices, such as caps or guards. Secure cylinders upright to a proper hand truck or cylinder cart designed for the purpose. Don't drag or roll them use a properly designed cart or hand truck. When using a crane, be sure to use proper cradles, nets, boats, or special platforms designed for this purpose to prevent cylinders from falling. Prevent damage handle carefully avoid dropping or banging them. Do not lift by the protective cap/guard or use magnets or slings to lift or move them since valves may be damaged or sheared off. 5. SAFETY PRECAUTIONS FOR CHLORINE GAS: Chlorine Cylinder shall be stored in well ventilated, isolated detached building. Suitable hand truck shall be used to move cylinders. Pressure regulator appropriate for cylinder pressure and contents shall be used. Chlorine Detector and Alarm shall be installed. Suitable Plastic pipe work shall be used. Chlorine Cylinders shall be stored at 10-27oC. High temp. & pressure relief device shall be installed in Valve. Following table showing the effect of chlorine on human body. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.51