RISK ASSESSMENT. The salient features of this package: It gives the consequence results in terms of Flammable, Toxic and Explosion effects.

Transcription

1 RISK ASSESSMENT 1.1 GENERAL UPL Ltd. is a larg scal pstics & intrmdiats manufacturing unit locatd in GIDC Notif Industrial ara, Vapi and falls in Schdul 5 (b) Catgory A of EIA Notification Th xpansion projct involvs th production of pstics, pstics intrmdiats and pstics formulation from 1921 TPM to 5177 TPM. For th xpansion projct, th company intnds to procur th availabl latst tchnology for manufacturing th products. Th principl objctiv of this study is to ntify major risks in th manufacturing procss and to valuat on-sit & off-sit consquncs of ntif hazard scnarios. To giv ffctiv mitigation of hazards in trms of suggstions for ffctiv disastr managmnt, suggsting minimum prvntiv and protctiv masurs & chang of practics to nsur Occupational Halth and Safty Objctiv of th study Th principl objctiv of this study is to ntify major risks in th manufacturing procss and to valuat on-sit & off-sit consquncs of ntif hazard scnarios. To giv ffctiv mitigation of hazards in trms of suggstions for ffctiv disastr managmnt, suggsting minimum prvntiv and protctiv masurs & chang of practics to nsur Occupational Halth and Safty Tools and Softwar Th consqunc analysis for th modld scnarios has bn don using DNV s softwar PHAST Vrsion 6.7(Procss Hazard Analysis Softwar Tool) which allows assssmnt of situations which prsnt potntial hazards to lif, proprty and th nvironmnt, and to quantify thir svrity. PHAST xamins th progrss of a potntial incnt from th initial rlas to far-fild disprsion including modling of pool sprading and vaporation, and flammabl and toxic ffcts. It is rcommndd for us by th Ministry of Environmnt & Forsts pr its EIA Gulins, datd January PHAST Profssionals sophisticatd modling calculats distancs ffct producd by hazardous vnts. With this information, you can valuat th nd for mitigating masurs such as changs in dsign, opration or rspons. PHAST softwar can b usd to modl a proposd facility or oprational chang to as th slction of th most ffctiv solutions. With PHAST Profssional, you can dfin spcial vnts, modl th chang in a lak ovr tim, and invstigat th dtails of bhavior with spcial stand-alon modls and much, much mor. PHAST is intgratd into safty and mts rgulatory rquirmnts. It uss unif disprsion modling to calculat th rsults of th rlas of matrial into atmosphr Th salint faturs of this packag: It givs th consqunc rsults in trms of Flammabl, Toxic and Explosion ffcts. 1. Flammabl paramtrs covrd undr this packag is- Dfins th LEL and UEL zon Jt fir and pool fir scnario along with thir rspctiv ffct zons (risk contour). Flash fir and fir ball nvlop 2. Toxic paramtrs- Cloud concntration at usr dfind tim as wll as location Catgoriz th toxic rsults in trms of ERPG, IDLH and STEL valus. Summariz rsults in trms of quivalnt toxic dos along with ffct zons. 3. Explosion paramtrs- Catgoriz th xplosion ffcts in trms of ovrprssurs lvls along with distanc covrd. BLEVE (Boiling Expanding Vapor Explosion) Elaboratd Qualitativ and Quantitativ Risk assssmnt Th mthodology 1

2 Th mthodology includs, Hazard ntification, Slction of potntial loss scnarios, Simulation of rlas sourc modl on DNV s PHAST, Vrsion 6.7 Plotting th damag contour on sit map Ths stps undrtakn to carry out risk assssmnt for this projct ar dscribd blow in Chaptr. 2

3 1.1.3 Chmical proprtis S. No 1 Raw Matrials/ Products Actic anhydr Formula (CH 3 CO) 2 2 Acrylonitril C 3 -H 3 -N 3 Ammonia NH 3 4 Bnzaldh yd 5 Bromin Br Carbon Ttra Chlor Chlorin Gas Di-chloro mthan (MDC) Dimthylfor mam Ethyl Actat Ethyl Mrcaptan Ethyln dichlor C 7 H 6 O CCl 4 Cl 2 C-H 2 -Cl 2 HCON(CH 3 ) 2 C 4 H 8 O 2 C 2 H 6 S C 2 H 4 CL 2 13 Hxan C 6 -H 14 CAS Numb r Stat Gas Color Light Clar Colorls s Colorls s Not availabl Rd- Brown Not availabl Grnis h gas Colorls s Colorls s to light yllow Colorls s colorlss Colorls s Clar Colorls Odor Strong mild Pach krnls Ammonia -lik (Strong.) Not availabl Pungnt. Suffocati ng Not availabl Mol. Wt (g/mo l) Flas h Poin t ( C) NA Boili ng Poin t ( C) Mlti ng Poin t ( C) IDL H (pp m) NA NA Pungnt 71 NA Swt odor Amin lik. (Slight.) 84.9 NA NA Fruity garlic odor Swt odor Gasolinlik or Stabi lity Hazard Flammabl and Toxic Flammabl & Highly corrosiv in prsnc of aluminum, of coppr Combustibl & Toxic Toxic irritant Toxic irritant Toxic iritant and and and Toxic and Corrosiv Hazardous Flammabl & Toxic Flammabl Flammabl & Toxic Spc ific Grav ity (g/cc ) LE L % UE L % NA NA Odour thrsh old (ppm) Vap our Dn sity (air= 1) Not availa bl NA NA NA NA NA NA NA NA Flammabl Flammabl

4 S. No Raw Matrials/ Products Hydroquino n Isopropyl alcohol Formula C 6 H 4 (OH) 2 (CH 3 )2CHOH 16 Mthanol CH 3 OH Mthyl Chloro Format Phnyl isocyanat Phosphoro us Trichlor Thionyl Chlor C 2 -H 3 -CL-O 2 C 7 H 5 NO PCl 3 Cl 2 OS 21 Tolun C 7 H 8 22 Trithylami n (CH 3 CH 2 )3N 23 Trimthyl Orthoforma t C 4 -H 10 -O 3 NA- Not Applicabl CAS Numb r Stat Soli d Color s Whit Colorls s Colorls s Colorls s Colorls s to light yllow. Clar Colorls s to light yllow. Clar Colorls s to light yllow Colorls s Colorls s Colorls s. Clar Odor ptrolu m-lik (Slight.) NA rubbing alcohol Alcohol lik. Pungnt whn crud Mol. Wt (g/mo l) Strong 94.5 Acr Pungnt. Irritant. Lik Hydrochl oric ac Suffocati ng. Flas h Poin t ( C) Boili ng Poin t ( C) Mlti ng Poin t ( C) IDL H (pp m) NA NA Swt Ammonia cal Pungnt. Aromatic, str-lik Stabi lity Hazard Toxic and Corrosiv Spc ific Grav ity (g/cc ) LE L % Flammabl Flammabl UE L % Odour thrsh old (ppm) Vap our Dn sity (air= 1) 1.33 NA NA NA NA Flammabl NA NA >1 Flammabl and irritant Toxic and Corrosiv Toxic irritant and Flammabl and Toxic NA NA NA NA NA NA NA NA NA NA Flammabl Flammabl Not availa bl 3.48 NA

5 1.1.4 Scnarios for Simulation S. No. Nam of th Matrial Hazard involvd Capacity of storag tank/ containr/ tonnr/ drum at Sit Storag Paramtrs Prssur (bar) Tmp. ( C) Scnario Consrd Consqunc 1 Acrylonitril Flammabl, Toxic 2 Chlorin Toxic 3 Dimthylformam Flammabl, Toxic 30 m 3 atmosphric ambint 900 kg Chlorin tonnr 9 ambint 15 m 3 atmosphric ambint 4 IPA-Isopropyl alcohol Flammabl 15 m 3 atmosphric ambint 5 Thionyl Chlor Toxic 5 m 3 atmosphric ambint 10mm lak Catastrophic ruptur 2mm lak Catastrophic ruptur 10mm lak Catastrophic ruptur 10mm lak Catastrophic ruptur 2mm lak Catastrophic ruptur Jt fir, Pool fir, Explosion Pool fir, Explosion Toxic Disprsion Toxic Disprsion Jt fir, Pool fir, Explosion Pool fir, Explosion Jt fir, Pool fir, Explosion Pool fir, Explosion Toxic Disprsion Toxic Disprsion 5

6 1.2 QUALITATIVE RISK ASSESSMENT Many a tims risk involvd in various procsss / procss quipmnts cannot b addrssd compltly by consqunc analysis. As a consrvativ approach, ths risks hav bn consrd sparatly undr this topic. Th approach is to ntify hazards associatd in opration of quipmnts as wll as in procsss, assssing its impacts, ranking th risk posd by it and finally to propos rmdial actions/mitigation masurs such that th risk is minimizd to tolrabl lvl. Th Risk Matrix prsntd blow should b rfrrd in valuating this assssmnt. In Qualitativ Risk Assssmnt, risk has bn analyzd using mthodology calld HIRA-Hazards Idntification & Risk Assssmnt. In HIRA, major manual activitis carr out by plant prsonnl as wll as contract labors hav bn consrd. Qualitativ Risk Assssmnt has bn carr out for th following aras: Storag and Handling of Sol Chmicals lik Hydroquinon Storag and Handling of Corrosiv Chmicals lik Acrylonitril, Hydroquinon, Phosphorous Trichlor, Chlorin Gas Storag and Handling of Toxic Chmicals lik Actic anhydr, Ammonia, Bnzaldhyd, Bromin, Dimthylformam, Ethyl Mrcaptan, Thionyl Chlor, Tolun, Carbon Ttra Chlor, Phosphorous Trichlor, Chlorin Gas Risk involvd in various procsss / procss quipmnt cannot b addrssd compltly by consqunc analysis. As a consrvativ approach, ths risks hav bn consrd sparatly undr this topic. Th approach is to ntify hazards associatd in opration of quipmnt as wll as in procsss, assssing its impacts, ranking th risk posd by it and finally to propos rmdial actions/mitigation masurs such that th risk is minimizd to tolrabl lvl. Th Risk Matrix prsntd in Tabl 7.1, is rfrrd in valuating th assssmnt. Risk accptability critria givn in Tabl 7.2. LIKEHOOD/ PROBABILITY Tabl 1 Risk Matrix for Qualitativ Risk Assssmnt Catastrophic (Dath/ Systm Loss) Major/ Critical (Srious injury/ Illnss) Modrat (Lss Srious Injury/ Illnss) SEVERITY Minor/ Marginal (Minor Injury/ Illnss) Insignificant/Ngligibl (No injury /illnss) Almost Crtain E H H H M M Likly D H H M M L Possibl C H M M M L Unlikly B M M M L L Impossibl A M M L L L Tabl 2 Risk Accptability Critria Risk Risk Accptability Rang Critria Rmarks H Unaccptabl/ High Managmnt s Dcision/Action Plan Rquird. Potntial off-sit Impact. M Mdium Gnrally Minor Impact. Accptabl with Managmnt s Rviw. Spcific monitoring or SOP to b followd. L Low Accptabl without Rviw. Manag through Routin Procdur. 6

7 Svrity Liklihoo d Risk Svrity Liklihoo d Risk Storag and Handling of Sol Chmicals Initial Risk Rsual Risk S. No. Procss Or Activity Associatd Hazards Halth & Safty Impact (Risk) Mitigation Masurs 1 2 Handling Chmical bags Claning of Chmical Spillag. Chmical Exposur Dust Exposur. Skin and y irritation 2 C M Inhalation. 2 C M Oprators/Workrs to b traind for Saf Work Practics. Chmical handling bags to b labld proprly Availability of Ey wash and Safty showr station narby Kp away from sourcs of ignition. Ground all quipmnt containing matrial. Us an approvd/crtif rspirator or quivalnt Us of suitabl protctiv clothing lik Splash goggls, Lab coat, Dust rspirator, Wash with a disinfctant soap and covr th contaminatd skin with an anti-bactrial cram Kp away from incompatibls such as oxizing agnts, alkalis Kp containr in cool & dry plac Us appropriat tools to put th spilld sol in a convnint wast disposal containr Vapor and dust rspirator, Dust mask shall b usd. Suitabl protctiv clothing, glovs, boots shall b usd. 1 B L 1 B L 7

8 Svrity Liklihood Risk Svrity Liklihood Risk Storag and Handling of Corrosiv Chmicals Initial Risk Rsual Risk S. No. Procss Or Activity Associatd Hazards Halth & Safty Impact (Risk) Mitigation Masurs 1 Acs Loading & Unloading. Exposur to ac fums (du to lakag in pip/ containr/ valvs tc.). Splash ovr body Spillag. Skin/ Ey irritation. Toxic Vapor inhalation tc. Ac burns 2 C M Loading & Unloading activity shall b carr out in wll-vntilatd ara undr propr suprvision. Training for lifting and chmical transporting tchniqu from on location to anothr location will b provd Priodic Inspction of flangs/frrul joints shall b carr out. Availability of Ey wash and Safty showr station narby. Nutralization mdia shall b kpt availabl in aras whr acs ar stord/ handld/ usd. PPEs lik chmical safty goggls or full fac shild, Rubbr or noprn glovs and additional protction including imprvious boots, apron shall b usd. 1 B L Rspirators shall b usd. Ac proof floorings shall b constructd. Kp containr in a cool, wll-vntilatd ara. Kp away from incompatibls such as combustibl matrials, organic matrials, mtals, acs, moistur 2 Working in Storag Ara. Exposur to ac fums. Svr irritation to ys, skin. Body burns. 3 C M In cas of spillag, Absorb with DRY arth, sand or othr non-combustibl matrial. Us watr spray to rduc vapors PPEs lik chmical safty goggls or full fac shild, Rubbr or noprn glovs and additional protction including imprvious boots, apron shall b usd. 2 B L Rspirators shall b usd. Ey wash stations & Safty Showr shall b 8

9 Svrity Liklihood Risk Svrity Liklihood Risk Initial Risk Rsual Risk S. No. Procss Or Activity Associatd Hazards Halth & Safty Impact (Risk) Mitigation Masurs installd in nar vicinity. Only traind prsonnl shall b allowd to work in this ara. Dyk wall shall b provd. Lvl indicator shall b provd. Provision of adquat Dyk wall. Absorb with DRY arth, sand or othr non-combustibl matrial. 3 Tank ovrflow /lakag from joints tc. Exposur to ac fums. Svr irritation to ys, skin. 3 B M PPEs lik chmical safty goggls or full fac shild, Rubbr or noprn glovs and additional protction including imprvious boots, apron shall b usd. 2 B L Rspirators shall b usd. Ey wash stations & Safty Showr shall b installd in nar vicinity. 9

10 Svrity Liklihoo d Risk Svrity Liklihoo d Risk Storag and Handling of Toxic Chmicals Initial Risk Rsual Risk S. No. Procss Or Activity Associatd Hazards Halth & Safty Impact (Risk) Mitigation Masurs Dyk will b prov. Shall b stord in wll-vntilatd ara. Ey wash station and Safty Showr shall b installd in narby location. Maintnanc shall b carr as pr schdul. 1 Chmical handling / Loading & Unloading Exposur to fums (du to lakag from joints, corrodd lins failur tc.). Skin burn. Ey irritation and rspiratory disordr. 3 C M Employ will b provd with imprvious cloths, glovs, fac shild (ight-inch minimum), dust and splash proof safty goggls, chmically rsistant safty shos, tc. Propr trainings to b provd to th oprators/ workrs. SOPs to b prpard and followd th sam. 2 B L Kp containr in a cool, wll-vntilatd ara. Kp away from incompatibls such as rducing agnts, combustibl matrials, organic matrials, mtals, acs, moistur. Do not allow th ara whr cylindrs ar stord to xcd 52 C for chlorin. 2 Working in Storag Ara Exposur to fums du to spillag. Svr irritation to ys, skin tc. Intrnal body burns. 3 C M Splash goggls. Full suit. Vapor rspirator. Boots. Glovs. A slf-containd brathing apparatus should b usd to avo inhalation of th product. B sur to us an approvd/crtif rspirator or quivalnt Exhaust vntilation or othr nginring controls to kp th airborn concntrations of vapors blow thir rspctiv thrshold limit valu. Maintain th Oxygn lvl abov 19.5% in th workplac for chlorin handling 2 B L Bromin will b absorb with an inrt matrial and put th spilld matrial in an appropriat wast disposal 10

11 Svrity Liklihoo d Risk Svrity Liklihoo d Risk Initial Risk Rsual Risk S. No. Procss Or Activity Associatd Hazards Halth & Safty Impact (Risk) Mitigation Masurs Ey wash station or Safty Showr shall b installd in storag ara. Provision of an automatic lak dtction systm Display of Safty warning posturs/signs ins th ara. Lvl indicator shall b installd and th sam shall b chckd for its propr opration. 3 Tank ovrflow Chmical Exposur Eys and Skin irritation. 4 B M Dyk wall shall b availabl to contain th spill. 2 B L Priodic inspction to b carr for all th rlatd accssoris of lvl indicator. 11

12 1.3 QUANTITATIVE RISK ASSESSMENT Quantitativ Risk Assssmnt (QRA) is a structurd approach to ntifying and undrstanding th hazards and risks associatd with Storag and Handling of flammabl/ toxic chmicals. Th assssmnt starts by taking into account an invntory of hazardous chmicals stord, liklihood of lakag/ spillag associatd with it and slcting th worst cas scnario for consqunc stimation. Finally, suggsting th masurs to minimiz or mitigat risks to mt appropriat accptability critria. Th planning for mrgncy vacuation shall b born in mind whilst intrprting th rsults. Consqunc analysis In a plant handling hazardous chmicals, th main hazard ariss du to storag and handling of hazardous chmicals as mntiond abov. If ths chmicals ar rlasd into th atmosphr, it may caus damag du to rsulting firs or vapor clouds. Blast ovrprssurs dpnd upon th ractivity class of matrial btwn two xplosiv limits. Damag critria In consqunc analysis studis, in principal thr typs of xposur to hazardous ffcts ar distinguishd: 1. Hat radiation, from jt, pool fir, a flash fir or a BLEVE Explosion Toxic ffcts, from toxic matrials or toxic combustion products. Th chosn damag critria ar givn and xplaind as pr th Gulins for QRA PHAST Softwar, vrsion 6.7 (DNV) & Purpl Book for QRA rlasd by Cntr for Chmical Procss Safty (CCPS). Planning Hazards that can lad to accnts in oprations ar discussd in this sction. Important hazardous vnts ar classif in Tabl 7.3. Tabl 3: Evnt Classification BLEVE Typ of Evnt Dflagration Dtonation Explosion Fir Firball Flash Fir Jt Fir Pool Fir Spill Rlas Structural Damag Vapor Cloud Explosion Explanation Boiling Evaporating Vapor Explosion; may happn du to catastrophic failur of rfrigratd or prssurizd gass or liqus stord abov thir boiling points, followd by arly ignition of th sam, typically lading to a fir ball Is th sam as dtonation but with raction occurring at lss than sonic vlocity and initiation of th raction at lowr nrgy lvls A propagating chmical raction of a substanc in which th raction front advancs in th unractd substanc at or gratr than sonic vlocity in th unractd matrial A rlas of larg amount of nrgy that form a blast wav Fir Th burning of a flammabl gas cloud on bing immdiatly ignitd at th dg bfor forming a flammabl/xplosiv mixtur. A flammabl gas rlas gts ignitd at th farthst dg rsulting in flash-back fir A jt fir occurs whn flammabl gas rlass from th piplin (or hol) and th rlasd gas ignits immdiatly. Damag distanc dpnds on th oprating prssur and th diamtr of th hol or opning flow rat. Pool fir is a turbulnt diffusion fir burning abov a horizontal pool of vaporizing hydrocarbon ful whr th ful has zro or low initial momntum Loss of containmnt. Rlas of flu or gas to th surroundings from unit s own quipmnt / tanks causing (potntial) pollution and / or risk of xplosion and / or fir Brakag or fatigu failurs (mostly failurs causd by wathr but not ncssarily) of structural support and dirct structural failurs Explosion rsulting from vapor clouds formd from flashing liqus or non-flashing liqus and gass Hazard and Damag Assssmnt 12

13 Toxic, flammabl and xplosiv substancs rlasd from sourcs of storag as a rsult of failurs or catastrophs, can caus losss in th surrounding ara in th form of: Toxic gas disprsion, rsulting in toxic lvls in ambint air, Firs, firballs, and flash back firs, rsulting in a hat wav (radiation), or Explosions (Vapor Cloud Explosions) rsulting in blast wavs (ovrprssur). Consquncs of Fir/Hat Wav Th ffct of thrmal radiation on popl is mainly a function of intnsity of radiation and xposur tim. Th ffct is xprssd in trm of th probability of dath and diffrnt dgr of burn. Th consqunc ffcts stud to assss th impact of th vnts on th rcptors ar: Radiation (kw/m2) Tabl 4: Damag du to Radiation Intnsity Damag to Equipmnt Damag to Popl 1.2 Solar hat at noon Minimum lvl of pain thrshold 2.0 PVC insulatd cabl damag Causs pain if duration is longr than 20 sc. But blistring is unlikly Pain thrshold rachd aftr 8 sc. Scond dgr burns aftr 20 sc Minimum nrgy to ignit wood with a flam; 1% lthality in on minut. First dgr burns mlts plastic tubing. in 10 sc Svr burns aftr 5 sc Minimum nrgy to ignit wood at ntifying long 100% lthality in 1 min. Significant injury in xposur without a flam. 10 sc Svr damag to plant 100% lthality in 1 min. 50% lthality in 20 sc. 1% lthality in 10 sc. Consquncs of Ovrprssur Th ffcts of th shock wav vary dpnding on th charactristics of th matrial, th quantity involvd and th dgr of confinmnt of th vapor cloud. Th pak prssurs in an xplosion thrfor vary btwn a slight ovr-prssur and a fw hundrd kilopascals (kpa). Whras dwlling ar dmolishd and windows and doors brokn at ovrprssurs as low as bar. Dirct injury to popl occurs at gratr prssurs. Th prssur of th shock wav dcrass raply with th incras in distanc from th sourc of th xplosion. Ovrprssur (bar) Tabl 5: Ovrprssur Damag Damag Annoying nois (137 db if of low frquncy Hz) Loud nois (143 db, sonic boom glass failur Occasional braking of larg glass windows alrady undr strain Brakag of small windows undr strain Typical prssur for glass brakag projctil limit; som damag to hous cilings; 10% window glass brokn Limitd minor structural damag Larg and small windows usually shattrd; occasional damag to window frams to to Minor damag to hous structurs Partial dmolition of houss, mad uninhabitabl Corrugatd asbstos shattrd; corrugatd stl or aluminum panls, fastnings fail, followd by buckling, wood panls (standard housing) fastnings fail, panls blown in Stl fram of clad building slightly distortd 13

14 Ovrprssur (bar) Damag Partial collaps of walls and roofs of houss to Concrt of cindr brick walls, not rinforcd, shattrd Lowr limit of srious structural damag to to to % dstruction of brickwork of houss Havy machins (3,000 lb) in industrial building suffrd littl damag; stl fram building distortd and pulld away from foundations. Framlss, slf -framing stl panl building dmolishd; ruptur of oil storag tanks Cladding of light industrial buildings rupturd Woodn utility pols snappd; tall hydraulic prss (40,000 lb) in building slightly damagd Narly complt dstruction of houss Loadd train wagons ovrturnd Brick panls, 8-12 inchs thick, not rinforcd; havy machin tools (7,000 lb) movd and badly Loadd trains boxcars compltly dmolishd Probabl total dstruction of buildings; havy machins tools (7,000 lb) movd and badly damagd, vry havy machins tools (12,000 lb) survivd. Limit of cratr lip Sourc: CCPS Consqunc analysis of chmical rlas Consquncs of Toxic Rlas Th ffct of xposur to toxic substanc dpnds upon th duration of xposur and th concntration of th toxic substanc. Short-trm xposurs to high concntration giv Acut Effcts whil long trm xposurs to low concntrations rsult in Chronic Effcts. Only acut ffcts ar consrd undr hazard analysis. Sinc thy ar likly crdibl scnarios. Ths ffcts ar: Irritation (rspiratory systm skin, ys) Narcosis (nrvous systm) Asphyxiation (oxygn dficincy) Systm damag (blood organs) Following ar som of th common trms usd to xprss toxicity of matrials. Thrshold Limit Valu (TLV): it is th prmittd lvl of xposur for a givn priod on a wightd avrag basis (usually 8 hrs. for 5 days in a wk) Short Tim Exposur Limit (STEL): It is th prmittd short trm xposur limit usually for a 15 minuts xposur. Immdiatly Dangrous to lif and halth (IDLH): It rprsnts th maximum concntration of a chmical from which, in th vnt of rspiratory failur, on could scap within 30 minuts without a rspirator and without xprincing any scap/impairing (g. Svr irritation) or irrvrsibl halth ffcts. Lthal Concntration Low (LCLo): It is th lowst concntration of a matrial in air, othr than LC50, which has bn rportd to caus a dath in human or animals. Toxic Concntration Low (TCLo): It is th lowst concntration of a matrial in air, to which humans or animals hav bn xposd for any givn priod of tim that has producd a toxic ffcts in humans or producd carcinognic, noplastignic or tratognic ffct in humans or animals. Emrgncy Rspons Planning Gulins 1 (ERPG1): Th maximum airborn concntration blow which it is blivd that narly all indivuals could b xposd for up to 1 hour (without a rspirator) without xprincing othr than mild transint advrs halth ffcts or without prciving a clarly dfind objctionabl odor. Emrgncy Rspons Planning Gulins 2 (ERPG2): Th maximum airborn concntration blow which it is blivd that narly all indivuals could b xposd for up to 1 hour without xprincing 14

15 or dvloping irrvrsibl or othr srious halth ffcts or symptoms that could impair thir abilitis to tak protctiv action. Emrgncy Rspons Planning Gulins 3 (ERPG3): Th maximum airborn concntration blow which it is blivd narly all indivuals could b xposd for up to 1 hour without xprincing or dvloping lif-thratning halth ffcts. Mtorology Atmosphric stability plays an important rol in th disprsion of th chmicals. Stability mans, its ability to supprss xisting turbulnc or to rsist vrtical motion. Atmosphric stability plays an important rol in th disprsion of chmicals. Stability mans, its ability to supprss xisting turbulnc or to rsist vrtical motion. Variations in thrmal and mchanical turbulnc and in wind spd ar gratst in th atmosphric layr in contact with th surfac. Th air tmpratur has influncd ths turbulncs gratly and air tmpratur dcrass with th hight. Th rat at which th tmpratur of air dcrass with hight is calld Environmnt Laps Rat (ELR). It will vary from tim to tim and from plac to plac. Th atmosphr is sa to b stabl, nutral or unstabl according to ELR lss than, qual to or gratr than Dry Adiabatic Laps Rat (DALR), which is a constant valu of 0.98 ºC pr 100 mtrs. Pasquill Stability Classs Pasquill has dfind Six (6) stability classs. A- Extrmly unstabl. B- Modratly unstabl C- Slightly unstabl. D- Nutral E- Slightly stabl. F- Modratly stabl. Thr prim factors that dfins Stability Solar radiation Night-tim sky ovr Surfac wind Whn th atmosphr is unstabl and wind spds ar modrat or high or gusty, rap disprsion of vapors will occur. Undr ths conditions, air concntrations will b modrat or low and th matrial will b disprsd raply. Whn th atmosphr is stabl and wind spd is low, disprsion of matrial will b limitd and air concntration will b high. Wathr Conditions Following Wathr conditions ar slctd for consqunc analysis Tabl 6: Wathr Condition Slctd Wathr Condition Tim Rmarks Tmpratur in C Wind spd m/s Stability Class Day Tim Prvalnt during th day, most tims of th yar D Night Tim Prvalnt during th night, most tims of th yar E Monsoon Priod Prvalnt during th monsoon months D Consquncs Analysis Th consquncs of th rlas of Hazardous substancs by failurs or catastrophs and th damag to th surrounding ara can b dtrmind by mans of modls. Modls hlp to calculat th physical ffcts rsulting from th rlas of hazardous substancs and to translat th physical ffcts in trms of injuris and damag to xposd population and nvironmnt. To assss th damag lvl causd by th various accntal vnts, it is ssntial to firm up th damag critria with rspct to diffrnt typs of accnts.g. thrmal radiation, toxicity, xplosion ovrprssur tc. 15

16 Consqunc analysis involvs th application of mathmatical, analytical and computr modls for calculation of ffcts and damags subsqunt to a hydrocarbon rlas accnt. Consqunc modls ar usd to prdict th physical bhavior of th hazardous incnts. Th tchniqus usd to modl th consquncs of hydrocarbon and othr hazardous matrial rlass covr th following: Modling of discharg rats whn hols dvlop in procss quipmnt/pip work/piplin. Modling of th siz and shap of flammabl and toxic gas clouds from rlass in th atmosphr. Modling of th flam and radiation fild of th rlass that ar ignitd and burn as jt fir, pool fir, flash fir and BLEVE/ Fir ball. Modling of th xplosion filds of rlass, which ar ignitd away from th point of rlas. Th information normally rquird for consqunc analysis includs mtorological conditions, failur data of quipmnt and componnts, ignition sourcs, population charactristics within and outs th plant, accptabl lvls of risk tc. MCAS Dvlopmnt Tchniqus As a first stp towards risk assssmnt is to ntify th possibl rlas scnarios basd on availabl information about scnario dvlopmnt for Maximum Crdibl Accnt Scnarios (MCAS). Slction of Maximum Crdibl Loss Scnarios (MCLS ) Following points ar consrd whil slcting th rlas scnarios: Flash point for flammabl chmicals IDLH of Toxic chmicals Oprating/ Storag Tmpratur and Prssur of th matrial Total invntory of th matrial Failur Rats A lak or ruptur of th tank / pip, rlasing som or all of its contnts, can b causd by brittl failur of th tank walls, wlds or connctd pipwork du to us of inadquat matrials, combind with loading such as wind, arthquak or impact. Th failur rats ar th dcing factor for slcting th MCAS. Th failur rats for slctd MCAS ar givn in Tabl 7.7 Tabl 7: Failur Frquncis for Storag Tanks Catgoris Catastrophic Ruptur Frquncy (pr tank pr yar) Lak Frquncy (pr yar) Atmosphric Storag Tank Prssur Vssls (for Hol Siz 10 to 50 mm) (for Hol Siz 1 to 10 mm) Rfrnc: Intrnational Association of Oil & Gas Producrs (OGP); Rport No , March

17 Simulation of Rlas and Dvlopmnt of Contours As th MCLS wr dvlopd for th slctd st of chmicals, th nxt stp is to carry out th consqunc analysis. Th consqunc analysis rsults along with thir contours ar prsntd in th following sctions Acrylonitril Radiation lvl ffct distanc, ovrprssur ffct distanc and Toxic dos ffct distanc du to th rlas of actic anhydr ar prsntd in tabl blow, Chmical (Storag Tank) Acrylonitril Failur Scnario Consqunc 10 mm Lak Lat pool fir Catastrophic Ruptur Lat pool fir / Lat Ignition Tabl 8 Effct Distanc du to Rlas of acrylonitril Mt Data Effctiv Distanc in mtr to Radiation Lvl 4 kw/m kw/m kw/m2 Ovrprssur Distancs in Mtrs 0.02 bar 0.13 bar 0.2 bar Effctiv Distanc in mtr to Toxic Lvl EPRG 1 EPRG 2 EPRG 3 IDLH (10 (35 (75 (85 ppm) ppm) ppm) ppm) 5.0/D /E /D /D /E /D Th contours for ffct distanc gnratd for th rlas of acrylonitril ar prsntd blow; 17

18 Figur 1: Lat Pool Fir ffct distanc Contour du to 10 mm lak in storag tank at wathr condition 5/D Figur 2: Maximum Concntration ffct distanc Contour du to 10 mm lak in storag tank at wathr condition 5/D. 18

19 Figur 3: Lat Explosion ffct distanc Contour du to Catastrophic ruptur of storag tank at wathr condition 5/D Chlorin Toxic dos ffct distanc du to th rlas of Chlorin is prsntd blow: Chmical (Storag Tank) Tabl 9: Effct Distanc du to Rlas of Chlorin Failur Scnario 2 mm lak Mt Data Effctiv Distanc in mtr to Toxic Lvl EPRG 2 (3 ppm) EPRG 3 (20 ppm) IDLH (10 ppm) 5.0/D /E /D Chlorin tonnr 5.0/D Catastrophic 3.0/E Ruptur 4.0/D Th contours for ffct distanc gnratd for th rlas of Chlorin ar prsntd blow; 19

20 Figur 4: Maximum Concntration ffct distanc Contour du to 2mm lak in chlorin tonnr at wathr condition 3/E Figur 5: Maximum Concntration ffct distanc Contour du to catastrophic ruptur of chlorin tonnr at wathr condition 3/E 20

21 1.3.3 Dimthylformam (DMF) Radiation lvl ffct distanc and Toxic dos ffct distanc du to th rlas of DMF ar prsntd blow: Tabl 10: Effct Distanc du to Rlas of DMF Chmical (Storag Tank) Di mthyl formam Failur Scnario Consqunc 10 mm Lak Lat pool fir Catastrophic Ruptur Lat pool fir Mt Data Effctiv Distanc in mtr to Radiation Lvl 4 kw/m kw/m kw/m 2 Effctiv Distanc in mtr to Toxic Lvl (Avraging tim is 600 sc) IDLH (500 ppm) 5.0/D /E /D /D /E /D Th contours for ffct distanc gnratd for th rlas of Di mthyl formam ar prsntd blow; Figur 6: Lat Pool Fir ffct distanc Contour du to 10 mm lak in storag tank at wathr condition 4/D 21

22 Figur 7: Maximum Concntration ffct distanc Contour du to Catastrophic ruptur of storag tank at wathr condition 3/E Iso Propyl Alcohol (IPA) Radiation lvl ffct distanc and ovrprssur ffct distanc du to th rlas of IPA ar prsntd blow: Tabl 11: Effct Distanc du to Rlas of IPA Chmical (Storag Tank) IPA Failur Scnario Consqunc 10 mm Lak Lat pool fir Catastrophic Ruptur Lat pool fir/ Lat ignition Mt Effctiv Distanc in mtr to Radiation Lvl Ovrprssur Distancs in Mtrs Data kw/m 2 kw/m 2 kw/m 2 bar bar bar 5.0/D /E /D /D /E /D Th contours for ffct distanc gnratd for th rlas of IPA ar prsntd blow; 22

23 Figur 8: Lat Pool Fir ffct distanc Contour du to Catastrophic ruptur of storag tank at wathr condition 5/D Figur 9: Lat Explosion ffct distanc Contour du to Catastrophic ruptur of storag tank at wathr condition 5/D 23

24 1.3.5 Isobutyln Radiation lvl ffct distanc and ovrprssur ffct distanc du to th rlas of Isobutyln ar prsntd blow: Chmical (Storag Tank) Isobutyln Failur Scnario Tabl 12: Effct Distanc du to Rlas of Thionyl chlor Consqunc 2 mm Lak Jt fir Catastrophic Ruptur Fir ball / Lat Ignition Mt Effctiv Distanc in mtr to Radiation Lvl Ovrprssur Distancs in Mtrs Data kw/m bar kw/m2 kw/m2 bar 0.2 bar 5.0/D /E /D /D NR /E NR /D NR NR: Not Rachd Th contours for ffct distanc gnratd for th rlas of isobutyln ar prsntd blow; Figur 10: Firball ffct distanc Contour du to Catastrophic ruptur of storag tank at wathr condition 3/E 24

25 Figur 11: Lat Explosion ffct distanc Contour du to Catastrophic ruptur of storag tank at wathr condition 5/D Thionyl chlor Toxic disprsion distanc du to th rlas of Thionyl chlor is prsntd blow: Tabl 13: Effct Distanc du to Rlas of Thionyl chlor Chmical (Storag Tank) Thionyl chlor Failur Scnario 2 mm lak Catastrophic Ruptur Effctiv Distanc in mtr to Toxic Lvl Mt Data (Avraging tim is 600 sc) EPRG 3 (10 ppm) 5.0/D /E /D /D /E /D 286 Th contours for ffct distanc gnratd for th rlas of Thionyl chlor ar prsntd blow; 25

26 Figur 12: Maximum Concntration ffct distanc Contour du to 2 mm lak in storag tank at wathr condition 3/D Figur 13: Maximum Concntration ffct distanc Contour du to catastrophic ruptur of storag tank at wathr condition 3/D 26

27 1.3.7 Rsults of Consqunc Analysis Th ffct of lat pool fir du to 10 mm lak scnario is confind to th sit boundary Th ffct of pool (dyk) fir and toxic disprsion du to failur of tanks for Chlorin, Isopropyl alcohol, Isobutyln and Thionyl chlor ar xtndd byond th plant boundary. Summary of ffct distanc (in mtr) for worst cas scnario of hazardous chmical consrd for consqunc analysis is givn blow: Effct Distanc in Mtrs at Wathr condition 4.0/D At IDLH Chmical/ Scnario Concntration (in At Radiation At Ovrprssur ppm) for Lvl 4 kw/m bar rspctiv chmicals Acrylonitril Tank 218 (5/D) 281 (5/D) 683 (5/D) Chlorin (3/E) Dimthylformam Tank 24 (5/D) - 60 (3/E) IPA-Isopropyl alcohol Tank 141 (5/D) 64 (3/E) - Thionyl Chlor Tank (3/E) Rcommndations 1. Construction phas Th following will b implmntd by th contractor whil carrying out civil construction Rquird PPE will b provd to covr occupational foot, had, haring, and y protction Fall Protction: Th Contractor is rquird to prov fall protction to mploys who ar working at hights qual to or gratr than 1.8 m. fall protction can b in th form of primtr protction such as guardrails and to rails, prsonal protctiv quipmnt (PPE), a safty monitoring systm, or a fall protction plan. Activitis that rquir prsonal fall protction systms includ stl rction bolting, rivting, fitting-up and plumbing-up, work ovr watr and som dp xcavation work Foot Protction: If machins or oprations prsnt th potntial for foot injury, th contractor will prov foot protction with saf dsign and construction for th work to b prformd. Workrs and visitors shall not b allowd on a construction sit without safty boots. Th foot protction will b provd for workrs working with concrt or cmnt. Gum boot shall b provd to avo contact with cmnt/rcc mixturs and mortar. Had Protction: If had hazards rmain aftr all stps hav bn takn to control thm (safty nts for work at hights, propr houskping), th Contractor will prov workrs with appropriat had protction. Safty hlmt will b rcommndd. Whn th workr is carrying load on th had a suitabl had protction will b provd. Nois Protction: Workrs shall war haring protction dvics (ar plugs, ar muffs, canal caps), whnvr th disl opratd ngins, DG st or othr noisy machins ar oprating in th ara. Ey Protction: Whn oprations prsnt potntial y injury from physical or chmical lmnts, th Contractor will slct, prov, maintain and rquird affctd workrs to us appropriat y protction. Ey protction is rquird whil working on RCC dismantling, stl fabrication, wlding, rough plastring and painting work. Any work which involvs looking ups also rquirs th protction.g. lctrical cabling on walls and ciling. Th various y protcting dvics lik safty glasss and goggls, fac shilds and wlding hlmts will b provd to workrs. Hand protction: Suitabl hand glovs shall b provd for working with cmnt or mortar. A suitabl anti-allrgic cram or protcting gl shall b appl on th hands for prsons who dvlop allrgy with cmnt or lim. Elctrical Safty 27

28 o o o o o o o o o A licnsd lctrician shall b dployd to complt all tmporary wiring and lctrical installations rquird for construction activitis. Fuss and circuit brakrs (ELCB s) shall b usd to protct mothrboards, conductors and quipmnt to avo short circuiting and lctric shock. MCB s and fuss will also to b usd to protct th lctrical quipmnt from ovr currnt and ovr voltag. Extnsion cords for quipmnt or as part of a tmporary wiring systm shall not b damagd or compromisd in any way and insulation must b of th highst grad. Th joints of lctrical wirs shall b avod or an xtnsion cord can b usd if ndd Anytim lctrical quipmnt will b dactivatd for rpair, or circuits will b shut off, th quipmnt will b lockd out and taggd at th point whr it can b nrgizd. Propr arthling will b nsurd for all quipmnt and lctrical panls Tmporary lights shall not b suspndd by thir cords. Th mployr shall prov th ncssary safty quipmnt, supplis and monitoring quipmnt to thir prsonnl. During th opration stag maintnanc of transformr and manning of lctrical substation shall b by th comptnt prsons only. 2. Oprational phas Enginring and Maintnanc: To nsur all drains and vnts on chmical pip lin to pump suction ar closd. To chck prvious shift log about not working of chmical transfrring pump and rady for startup. Not: In cas th pump is undr maintnanc. It can lad to damag of pump. To chck air Instrumnt systm for th good functioning and to maintain it priodically. To nsur no contamination and unintrruptd supply of instrumnt air by claning dry air lin filtrs rgularly To xamin and to arrang unintrruptd opration of th blnding opration and loading of tankrs, by maintnanc of control valvs, in cas of malfunctioning / brak down. To carry out tsting, inspction and crtification of all prssur vssls, lifting tackls and storag tanks as pr Factoris Act. To masur th thicknss of piplin and to maintain its propr rcords as pr ruls. To calibrat and to maintain th flow indicator rgularly. To us mchanical sald pumps at th maximum possibl to rduc lakags and fugitiv missions. To prov doubl mchanical sals for agitators To carryout work plac monitoring priodically To rmov combustibl scrap and dbris (wood, claring/grubbing matrial) from th sit daily and to stor it at dsignatd plac. Firfighting: To carry out prvntiv maintnanc of firfighting facilitis (Fir watr pump, driv ngins, hydrants, monitors, alarm systms, tc.) priodically. To kp availabl fir xtinguishrs at all stratgic locations as pr rcommndd gulins. To prov sprinklr systm around flammabl matrial storag tanks for cooling. To prov radily availability of foam systm. Occupational Safty: To prov dyk walls at ach tank. To transfr spillag into vacant tanks to rstrict th sprading of chmical. To kp rady a spill prvntion control and countr masur plan that limits th risk of hazardous matrial rlas into nvironmnt. To us scondary control for matrial transfr in th form of lakag collction tray. To prov alarm systm for incras of high tmpratur masurmnt in storag tanks. To kp cooling arrangmnt by cooling watr circulating pump. 28

29 To prov Earthing systm for tanks, piping and road tankrs. To hav propr labling on all quipmnt and matrials. To chck Safty systm, including Emrgncy Shut Down ( ESD ) switchs at rgular intrvals, for thir propr functioning. ESD may b activatd to stop th unloading opration, if rquird. To chck th sprinklr systm, gas/fir dtctors and Rmot opratd valvs (ROV) priodically for timly actuation of th safty systm. To prov lightning protction systm to covr tank farm. To prov wind socks at various locations to know th dirction of wind in cas of a lak or fir. To kp th MSDS handy for all th hazardous matrials at handling aras. To kp ara wll vntilatd to avo accumulation of gas/ vapors and to kp it blow PEL/ TWL valus. To kp vry floor, working plac and passagway fr from protruding nails, splintrs, hols or loos boards. To kp working surfacs dry to prvnt slips and falls. To prov fully quippd occupational halth cntr to catr any mrgncy. To prov first a boxs at rquird aras. To dploy comptnt and authorizd contractors for transport of hazardous matrial. To follow Th Motor vhicls act strictly for hazardous matrial transportation. To dvlop grnblt around sit priphry. SOP s: To nsur sparat work prmit systm for hot work, cold work, lctrical isolation, vssl ntry, tc. To prpar mrgncy prpardnss documnt covring all th dtails to handl any mrgncy. Training: Priodically training on fir drills by conducting monthly xrcis To conduct Mock drill (Emrgncy Rspons Drill) on yarly basis by kping liaison with local administration and to continu liaison with availabl firfighting facilitis in th ara. To train th workrs on us of slf-containd brathing apparatus (SCBA). To train th drivrs on transportation of hazardous goods Visitor Card: Visitor card to b provd to ach visitor with gat pass & Visitor badg; which will contain th Ruls & Information as blow: ID Badgs: ID Badgs must b worn and visibl at all tims. Thy ar to b rturnd to th rcption dsk/scurity gat whn laving th prmiss. Mobil phon: Mobil phons with a camra function must not b usd on ths prmiss. Th us of mobil phons is strictly prohibitd in dsignatd aras. Elctronic dvics: Elctronic dvics may not b connctd to th company ntwork without authorization. Smoking is prohibitd: Smoking is prohibitd on th company prmiss. Th sal and consumption of tobacco products, alcohol and othr narcotic substancs is forbdn. Prsonal protctiv quipmnt (PPE): PPE must b worn in many aras of our sit. For your own safty you must war th appropriat protctiv quipmnt whn ntring ths aras. Alarm Signal: Oby alarm signals and follow th instructions of th fir safty tam. A triggrd pizo sirn signal indicats a fir systm alarm and alrts th fir safty tam. Howvr, pizo sirns mitting a continuous ton indicat that you must vacuat th building 29

30 immdiatly. Emrgncy Call: To rport an accnt or nvironmntal incnt, plas call our intrnal mrgncy numbr on XXXX/XXXXXX. Plas contact th mrgncy srvics; if thr is any immdiat dangr. Emrgncy prsonnl will prov furthr instructions. Manual call points can b usd to alrt th fir brigad dirctly in th vnt of a fir. Emrgncy Exit: Plas lav th dangr zon immdiatly and warn popl at risk. In th vnt of fir, try to put out th fir with a fir xtinguishr, if possibl. Escap routs ar markd in grn on th mrgncy and vacuation plans displayd ins buildings. In th vnt of an vacuation, plas procd to th appropriat assmbly point. Assmbly Point: Mak your way to on of th dsignatd assmbly points and await furthr instructions. Rport any missing collagus to managmnt at th assmbly point. First a boxs: First a boxs ar provd for trating injuris, and qualif first ars ar on hand during working hours Spcific mitigation masurs for safty at storag ara for Hazardous chmicals Ammonia To prov bullt storag tank with fir watr sprinklr systm around th priphry of storag tank To prov systm to all vnts connctd to scrubbr. Chlorin To prov Onlin Cl 2 Gas dtctors at conspicuous locations ins th plant. To placd Saf Oprating procdurs and Emrgncy Rspons Procdurs and to followd strictly. To prov Chlorin Hood with blowr and scrubbing arrangmnt. Thionyl chlor To prov sufficint distanc btwn tanks To placd fir watr hydrant systm and monitors around th storag ara sufficintly. UPL Ltd. has mad provision of fir watr tank of approx. capacity 316 KL. Watr stord in fir tank will b sourcd from GIDC and will b usd during mrgncy situation only. To prov dump tank, for collction of matrial during mrgncy Conclusion Th ffct of lat pool fir du to 10 mm lak scnario is confind to th sit boundary 30