RISK ASSESSMENT REPORT

Transcription

1 1.0 GENERAL RISK ASSESSMENT REPORT Risk report is for Expansion of Paraffin Wax Manufacturing Plant at Plot No. 57/D/B, 1st Phase, Notified Industrial Area, GIDC Vapi, Tal.: Pardi, Dist- Valsad (Gujarat), by Makwell Plastisizers Pvt. Ltd. (MPPL) with Production Capacity from 250 TPM to 2250 TPM (3000 TPA to TPA). During operation of existing as well as expansion plant there may be chances of damage to nearby area and properties due to any possible accident while handling, storage and operation of plant. Small accident, near miss in plant may lead to high impact accident if not handled with proper mitigation measures. Hence to understand the possible hazards, impacts and their control measures of various toxic, flammable and corrosive chemicals on the study area Qualitative and Quantitative Risk Assessment has been done along with the Disaster Management Plan (DMP). Objective of the Study The principle objective of this study is to identify major risks in the manufacturing process and to evaluate on-site & off-site consequences of identified hazard scenarios. To give effective mitigation of hazards in terms of suggestions for effective disaster management, suggesting minimum preventive and protective measures & change of practices to ensure Occupational Health and Safety. Tools and Software The consequence analysis for the modeled scenarios has been done using DNV s software PHAST Version 6.7(Process Hazard Analysis Software Tool) which allows assessment of situations which present potential hazards to life, property and the environment, and to quantify their severity. PHAST examines the progress of a potential incident from the initial release to far-field dispersion including modeling of pool spreading and evaporation, and flammable and toxic effects. PHAST Professionals sophisticated modeling calculates distances effect produced by hazardous events. With this information, you can evaluate the need for mitigating measures such as changes in design, operation or response. PHAST software can be used to model a proposed facility or operational change to ease the selection of the most effective solutions. With PHAST Professional, you can define special events, model the change in a leak over time, and investigate the details of behavior with special stand-alone models and much, much more. PHAST is integrated into safety and meets regulatory requirements. It uses unified dispersion modeling to calculate the results of the release of material into atmosphere The salient features of this package: It gives the consequence results in terms of Flammable, Toxic and Explosion effects. Flammable parameters covered under this package is- Defines the LEL and UEL zone Jet fire and pool fire scenario along with their respective effect zones (risk contour). Flash fire and fire ball envelope 1 P a g e

2 Toxic parameters- Cloud concentration at user defined time as well as location Categorize the toxic results in terms of ERPG, IDLH and STEL values. Summarize results in terms of equivalent toxic dose along with effect zones. Explosion parameters- Categorize the explosion effects in terms of overpressures levels along with distance covered. BLEVE (Boiling Liquid Expanding Vapor Explosion) 2.0 RISK & HAZARD STUDY Elaborated Qualitative and Quantitative Risk assessment The methodology The methodology includes, Hazard identification, Selection of potential loss scenarios, Simulation of release source model on DNV s PHAST, Version 6.7 Plotting the damage contour on site map These steps undertaken to carry out risk assessment for this project are described below in Chapter. 2 P a g e

3 2.0.1 Chemical Storage Facilities Details of Storage facility of chemicals is shown in Table 1 Table 1: Storage facility of chemicals (Products) # Name of Chemical Physical State Storage Mode (Tank/Bag /Drum) Number of Storage Tanks Capacity of Storage tank KL Each Type of Storag e Tank Above Ground Level/ Underground Tank Height (m) Tank Dia. (m) Storage Temperat ure (oc) Storage Pressure (bar) 1. Chlorinated Paraffin Wax Liquid Tank 50 mt x mt x MT MS Above Ground 1008 x 1 x 5 & 50 x 3 x & 2.5 R/T Atmospheric 2. Sulpho Chlorinated Paraffin Wax Liquid Tank 15 mt x 3 45 MT MS Above Ground R/T Atmospheric Physico-chemical properties of Chemicals Physico-Chemical properties of Chemicals are shown in Table 2 Table 2: Physico-Chemical properties of Chemicals # Raw Materials / Products State Form ula CAS No. Colour Odour Mol. Wt (g/mol e) Flash Point ( C) Boiling Point ( C) Melting Point ( C) IDLH (ppm) Stability Hazard Specif ic Gravit y (g/cc) LEL % UEL % Odour thresho ld (ppm) Vapour Density (air=1) 1. Chlorine Gas Gas Cl Greenish Yellow Gas/ Clear, amber liquid Suffocating pungent odour 70.9 NA Stable Toxic and Irritant 1.41 NA NA Sulphur Dioxide Gas Gas SO NA Pungent, Sulphurous NA Stable Toxic and Irritant 1.39 NA NA NA Hydro chloric Acid Liquid HCL Mixtur e Colorless to light yellow. Pungent. Irritating (Strong.) NA NA Stable Corrosi ve and Irritant NA NA NA- Not Applicable 3 P a g e

4 # Scenarios for Simulation Scenarios for Simulation of chemical is shown in Table 3 Full name of the Raw Material Hazard involved No. and Size of storage tonner Capacity (KL) Nos. each Table 3: Scenarios for Simulation of Chemical Maximum Operating Pressure 1. Chlorine Toxic bar Types of Failure Possible Consequences Considered 2 mm dia hole leak in tank Toxic Dose Catastrophic Rupture of storage tank Toxic Dose 4 P a g e

5 3.0 QUALITATIVE RISK ASSESSMENT Many a times risk involved in various processes / process equipment s cannot be addressed completely by consequence analysis. As a conservative approach, these risks have been considered separately under this topic. The approach is to identify hazards associated in operation of equipment s as well as in processes, assessing its impacts, ranking the risk posed by it and finally to propose remedial actions/mitigation measures such that the risk is minimized to tolerable level. The Risk Matrix presented below should be referred in evaluating this assessment. In Qualitative Risk Assessment, risk has been analyzed using methodology called HIRA- Hazards Identification & Risk Assessment. In HIRA, major manual activities carried out by plant personnel as well as contract labors have been considered. Qualitative Risk Assessment has been carried out for the following areas: Storage and Handling Toxic chemicals like of Chlorine Gas and Sulphur Dioxide Gas. Risk involved in various processes / process equipment cannot be addressed completely by consequence analysis. As a conservative approach, these risks have been considered separately under this topic. The approach is to identify hazards associated in operation of equipment as well as in processes, assessing its impacts, ranking the risk posed by it and finally to propose remedial actions/mitigation measures such that the risk is minimized to tolerable level. The Risk Matrix presented in Table 4, is referred in evaluating the assessment. Risk acceptability criteria given in Table 5. LIKEHOOD/ PROBABILITY Table 4: Risk Matrix for Qualitative Risk Assessment Catastrophic (Death/ System Loss) Major/ Critical (Serious injury/ Illness) SEVERITY Moderate (Less Serious Injury/ Illness) Minor/ Marginal (Minor Injury/ Illness) Insignificant/Negligible (No injury /illness) Almost Certain E H H H M M Likely D H H M M L Possible C H M M M L Unlikely B M M M L L Impossible A M M L L L Risk Range Risk Acceptability Criteria Table 5: Risk Acceptability Criteria Remarks 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. 5 P a g e

6 Severity Likelihood Risk Severity Likelihood Risk # Storage and Handling of Toxic gases like Sulphur Dioxide and Chlorine Process Or Activity Associated Hazards Health & Safety Impact (Risk) Initial Risk Mitigation Measures Residual Risk 1. Working in Storage Area Exposure to fumes (due to leakage from joints, corroded lines failure etc.). Skin burn. Eye irritatio n and respirat ory disorde r. 5 C M SOPs are/will prepared and same will be followed. Will be stored in wellventilated area. Grounding will be provided to storage tanks. Eye wash station and Safety Shower is/will be installed in nearby location. Maintenance of pipelines is/will be carried as per schedule. Employee is/will be provided with impervious clothes, gloves, face shield (eight-inch minimum), dust and safety glasses, vapor-proof goggles, chemically resistant safety shoes, approved/certified respirator etc. Proper trainings is/will be provided to the operators/ workers periodically for handling chlorine 2 B L tonner and SO 2 cylinders. Storage temperature will not exceed 52 C. Leather safety gloves will be provided for handling of Cylinders. 6 P a g e

7 4.0 QUANTITATIVE RISK ASSESSMENT Quantitative Risk Assessment (QRA) is a structured approach to identifying and understanding the hazards and risks associated with Storage and Handling of flammable/ toxic chemicals. The assessment starts by taking into account an inventory of hazardous chemicals stored, likelihood of leakage/ spillage associated with it and selecting the worst case scenario for consequence estimation. Finally, suggesting the measures to minimize or mitigate risks to meet appropriate acceptability criteria. The planning for emergency evacuation shall be borne in mind whilst interpreting the results. Consequence analysis In a plant handling hazardous chemicals, the main hazard arises due to storage and handling of hazardous chemicals as mentioned above. If these chemicals are released into the atmosphere, it may cause damage due to resulting fires or vapor clouds. Blast overpressures depend upon the reactivity class of material between two explosive limits. Damage criteria In consequence analysis studies, in principal three types of exposure to hazardous effects are distinguished: 1. Heat radiation, from jet fire, pool fire, a flash fire or a BLEVE Explosion Toxic effects, from toxic materials or toxic combustion products The chosen damage criteria are given and explained as per the Guidelines for QRA PHAST Software, version 6.7 (DNV) & Purple Book for QRA released by Centre for Chemical Process Safety (CCPS). Planning Hazards that can lead to accidents in operations are discussed in this section. Important hazardous events are classified in Table 6 Type of Event BLEVE Deflagration Detonation Explosion Fire Fireball Flash Fire Table 6: Event Classification Explanation Boiling Liquid Evaporating Vapor Explosion; may happen due to catastrophic failure of refrigerated or pressurized gases or liquids stored above their boiling points, followed by early ignition of the same, typically leading to a fire ball Is the same as detonation but with reaction occurring at less than sonic velocity and initiation of the reaction at lower energy levels A propagating chemical reaction of a substance in which the reaction front advances in the unreacted substance at or greater than sonic velocity in the unreacted material A release of large amount of energy that form a blast wave Fire The burning of a flammable gas cloud on being immediately ignited at the edge before forming a flammable/explosive mixture. A flammable gas release gets ignited at the farthest edge resulting in flash- 7 P a g e

8 Type of Event Jet Fire Pool Fire Spill Release Structural Damage Vapor Cloud Explosion Explanation back fire A jet fire occurs when flammable gas releases from the pipeline (or hole) and the released gas ignites immediately. Damage distance depends on the operating pressure and the diameter of the hole or opening flow rate. Pool fire is a turbulent diffusion fire burning above a horizontal pool of vaporizing hydrocarbon fuel where the fuel has zero or low initial momentum Loss of containment. Release of fluid or gas to the surroundings from unit s own equipment / tanks causing (potential) pollution and / or risk of explosion and / or fire Breakage or fatigue failures (mostly failures caused by weather but not necessarily) of structural support and direct structural failures Explosion resulting from vapor clouds formed from flashing liquids or nonflashing liquids and gases Hazard and Damage Assessment Toxic, flammable and explosive substances released from sources of storage as a result of failures or catastrophes, can cause losses in the surrounding area in the form of: Toxic gas dispersion, resulting in toxic levels in ambient air, Fires, fireballs, and flash back fires, resulting in a heat wave (radiation), or Explosions (Vapor Cloud Explosions) resulting in blast waves (overpressure). Consequences of Fire/Heat Wave The effect of thermal radiation on people is mainly a function of intensity of radiation and exposure time. The effect is expressed in term of the probability of death and different degree of burn. The consequence effects studied to assess the impact of the events on the receptors are: Table 7: Damage due to Radiation Intensity Radiation (kw/m 2 ) Damage to Equipment Damage to People 1.2 Solar heat at noon Minimum level of pain threshold 2.0 PVC insulated cable damage Causes pain if duration is longer than 20 sec. But blistering is unlikely Pain threshold reached after 8 sec. Second degree burns after 20 sec Minimum energy to ignite wood with a 1% lethality in one minute. First degree flame; melts plastic tubing. burns in 10 sec Severe burns after 5 sec Minimum energy to ignite wood at 100% lethality in 1 min. Significant injury identifying long exposure without a flame. in 10 sec Severe damage to plant 100% lethality in 1 min. 50% lethality in 20 sec. 1% lethality in 10 sec. Consequences of Overpressure 8 P a g e

9 The effects of the shock wave vary depending on the characteristics of the material, the quantity involved and the degree of confinement of the vapor cloud. The peak pressures in an explosion therefore vary between a slight over-pressure and a few hundred kilopascals (kpa). Whereas dwelling are demolished and windows and doors broken at overpressures as low as bar. Direct injury to people occurs at greater pressures. The pressure of the shock wave decreases rapidly with the increase in distance from the source of the explosion. Table 8: Overpressure Damage Overpressure Damage (bar) Annoying noise (137 db if of low frequency Hz) Loud noise (143 db, sonic boom glass failure Occasional breaking of large glass windows already under strain Breakage of small windows under strain Typical pressure for glass breakage Projectile limit; some damage to house ceilings; 10% window glass broken Limited minor structural damage Large and small windows usually shattered; occasional damage to window frames to to to Minor damage to house structures Partial demolition of houses, made uninhabitable Corrugated asbestos shattered; corrugated steel or aluminum panels, fastenings fail, followed by buckling, wood panels (standard housing) fastenings fail, panels blown in Steel frame of clad building slightly distorted Partial collapse of walls and roofs of houses Concrete of cinder brick walls, not reinforced, shattered Lower limit of serious structural damage to % destruction of brickwork of houses Heavy machines (3,000 lb) in industrial building suffered little damage; steel frame building distorted and pulled away from foundations. Frameless, self -framing steel panel building demolished; rupture of oil storage tanks Cladding of light industrial buildings ruptured Wooden utility poles snapped; tall hydraulic press (40,000 lb) in building slightly damaged to Nearly complete destruction of houses Loaded train wagons overturned to Brick panels, 8-12 inches thick, not reinforced; heavy machine tools (7,000 lb) moved and badly Loaded trains boxcars completely demolished Probable total destruction of buildings; heavy machines tools (7,000 lb) moved and badly damaged, very heavy machines tools (12,000 lb) survived Limit of crater lip Source: CCPS Consequence analysis of chemical release Consequences of Toxic Release The effect of exposure to toxic substance depends upon the duration of exposure and the concentration of the toxic substance. 9 P a g e

10 Short-term exposures to high concentration give Acute Effects while long term exposures to low concentrations result in Chronic Effects. Only acute effects are considered under hazard analysis. Since they are likely credible scenarios. These effects are: Irritation (respiratory system skin, eyes) Narcosis (nervous system) Asphyxiation (oxygen deficiency) System damage (blood organs) Following are some of the common terms used to express toxicity of materials. Threshold Limit Value (TLV): it is the permitted level of exposure for a given period on a weighted average basis (usually 8 hrs. for 5 days in a week) Short Time Exposure Limit (STEL): It is the permitted short term exposure limit usually for a 15 minutes exposure. Immediately Dangerous to life and health (IDLH): It represents the maximum concentration of a chemical from which, in the event of respiratory failure, one could escape within 30 minutes without a respirator and without experiencing any escape/impairing (eg. Severe irritation) or irreversible health effects. Lethal Concentration Low (LCLo): It is the lowest concentration of a material in air, other than LC50, which has been reported to cause a death in human or animals. Toxic Concentration Low (TCLo): It is the lowest concentration of a material in air, to which humans or animals have been exposed for any given period of time that has produced a toxic effects in humans or produced carcinogenic, neoplastigenic or teratogenic effect in humans or animals. Emergency Response Planning Guidelines 1 (ERPG1): The maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 hour (without a respirator) without experiencing other than mild transient adverse health effects or without perceiving a clearly defined objectionable odor. Emergency Response Planning Guidelines 2 (ERPG2): The maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 hour without experiencing or developing irreversible or other serious health effects or symptoms that could impair their abilities to take protective action. Emergency Response Planning Guidelines 3 (ERPG3): The maximum airborne concentration below which it is believed nearly all individuals could be exposed for up to 1 hour without experiencing or developing life-threatening health effects. Meteorology Atmospheric stability plays an important role in the dispersion of the chemicals. Stability means, its ability to suppress existing turbulence or to resist vertical motion. Atmospheric stability plays an important role in the dispersion of chemicals. Stability means, its ability to suppress existing turbulence or to resist vertical motion. Variations in thermal and mechanical turbulence and in wind speed are greatest in the atmospheric layer in contact with the surface. The air temperature has influenced these 10 P a g e

11 turbulences greatly and air temperature decreases with the height. The rate at which the temperature of air decreases with height is called Environment Lapse Rate (ELR). It will vary from time to time and from place to place. The atmosphere is said to be stable, neutral or unstable according to ELR less than, equal to or greater than Dry Adiabatic Lapse Rate (DALR), which is a constant value of 0.98 ºC per 100 meters. Pasquill Stability Classes Pasquill has defined Six (6) stability classes. A B C D E F - Extremely unstable. - Moderately unstable - Slightly unstable. - Neutral - Slightly stable. - Moderately stable. Three prime factors that defines Stability Solar radiation Night-time sky over Surface wind When the atmosphere is unstable and wind speeds are moderate or high or gusty, rapid dispersion of vapors will occur. Under these conditions, air concentrations will be moderate or low and the material will be dispersed rapidly. When the atmosphere is stable and wind speed is low, dispersion of material will be limited and air concentration will be high. Weather Conditions Following Weather conditions are selected for consequence analysis Time Table 9: Weather Condition Selected Remarks Weather Condition Temperature Wind in C speed m/s Stability Class Day Time Prevalent during the day, most times of the year C Night Time Monsoon Period Consequences Analysis Prevalent during the night, most times of the year E Prevalent during the monsoon months 30 5 D The consequences of the release of Hazardous substances by failures or catastrophes and the damage to the surrounding area can be determined by means of models. Models help to calculate the physical effects resulting from the release of hazardous substances and to translate the physical effects in terms of injuries and damage to exposed population and environment. To assess the damage level caused by the various accidental events, it is essential to firm up the damage criteria with respect to different types of accidents e.g. thermal radiation, toxicity, explosion overpressure etc. 11 P a g e

12 Consequence analysis involves the application of mathematical, analytical and computer models for calculation of effects and damages subsequent to a hydrocarbon release accident. Consequence models are used to predict the physical behavior of the hazardous incidents. The techniques used to model the consequences of hydrocarbon and other hazardous material releases cover the following: Modeling of discharge rates when holes develop in process equipment/pipe work/pipeline. Modeling of the size and shape of flammable and toxic gas clouds from releases in the atmosphere Modeling of the flame and radiation field of the releases that are ignited and burn as jet fire, pool fire, flash fire and BLEVE/ Fire ball Modeling of the explosion fields of releases, which are ignited away from the point of release The information normally required for consequence analysis includes meteorological conditions, failure data of equipment and components, ignition sources, population characteristics within and outside the plant, acceptable levels of risk etc. Assumption 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. Meteorological Paste other tables Atmospheric Conditions: No Inversion Ambient Temperature: 25 C has been considered as MCA approach. Pasquil Stability Classes Pasquil Stability category C, D & E is considered as conservative approach. Other assumptions: Inventory: Release of 100% of the inventory has been considered. For this, failure of the container has been considered from the bottom. Storage conditions: Storage conditions have been considered as they are practically stored at site. Input data for software (modeling) For consequence analysis, input data considered are as below: 1. Volume inventory (Quantity of material) 2. Scenario Leak Catastrophic Rupture 3. Leak size 2 mm hole 4. Storage conditions Pressure Temperature 5. Bund details 12 P a g e

13 Bund height Bund area 6. Weather condition: Wind speed Pasquil stability Atmospheric temperature Relative humidity MCAS Development Techniques As a first step towards risk assessment is to identify the possible release scenarios based on available information about scenario development for Maximum Credible Accident Scenarios (MCAS). Selection of Maximum Credible Loss Scenarios (MCLS ) Following points are considered while selecting the release scenarios: Flash point for flammable chemicals IDLH of Toxic chemicals Operating/ Storage Temperature and Pressure of the material Total inventory of the material Failure Rates A leak or rupture of the tank / pipe, releasing some or all of its contents, can be caused by brittle failure of the tank walls, welds or connected pipework due to use of inadequate materials, combined with loading such as wind, earthquake or impact. The failure rates are the deciding factor for selecting the MCAS. The failure rates for selected MCAS are given in Table Table 10 Categories Table 10: Failure Frequencies for Storage Tanks Catastrophic Rupture Frequency (per tank per year) Leak Frequency (per year) Atmospheric Storage Tank 3.0 x x 10-3 Reference: International Association of Oil & Gas Producers (OGP); Report No , March 2010 Simulation of Release and Development of Contours As the MCLS were developed for the selected set of chemicals, the next step is to carry out the consequence analysis. The consequence analysis results along with their contours are presented in the following sections. Contours are presented on plant layout. 13 P a g e

14 4.0.1 Chlorine Gas Figure 1: Plant Layout Radiation level effect distance, overpressure effect distance and Toxic dose level effect distance due to release of Chlorine gas are presented below: Table 11: Effect Distance due to Release of Chlorine Gas Chemical (Storage Tank) Chlorine Gas Failure Scenario Consequence 2 mm Leak Late pool fire Catastrophic Rupture Late pool fire Met Data Effective Distance in meter to Toxic Level EPRG 1 (1 ppm) EPRG 2 (3 ppm) EPRG 3 (20 ppm) IDLH (10 ppm) 2.7/E /C /D /E /C /D The contour for effect distance generated for the release of Chlorine gas is presented below; 14 P a g e

15 Figure 2: Toxic effect distance Contour due to 2 mm leak in tank at weather condition 2.7/E. 15 P a g e

16 Figure 7.3: Toxic effect distance Contour due to catastrophic rupture of storage tank at weather condition 2.7/E Results of Consequence Analysis Summary of effect distance (in meter) for worst case scenario of hazardous chemical considered for consequence analysis are given below: Chemical/ Scenario Chlorine Gas Effect Distance in Meters at specific Weather condition At IDLH Concentration (in ppm) (2.7/E) The risk of toxic dose is highest in worst case scenario of release of Chlorine Gas in 2.7/E weather condition for maximum IDLH concentration in ppm. 16 P a g e

17 4.0.3 Specific mitigation measures for safety at storage area for Hazardous chemicals CHLORINE Following mitigation measures shall be followed in case of Chlorine Leakage: To provide Online Cl 2 Gas detectors at conspicuous locations inside the plant Evacuate the area in down wind direction: Evacuate area in down wind direction up to 1972 meter. Do not direct water at spill or source of leak. Use Chlorine emergency kit to attend the leak. Absorb the fumes through Chlorine Hood with blower. Only trained workers are allowed to work in this area. Following Safety Measures will be made available to avoid Emergencies related to Chlorine Leakage: Chlorine handling area shall be well ventilated. Chlorine emergency kit shall be kept ready at chlorine shed. Chlorine Hood with blower shall be provided with scrubbing arrangement. SCBA sets shall be kept ready at chlorine handling area. Empty & filled cylinders shall be stored separately. Oxygen Cylinder shall be kept available. Safety shower and eye wash station is/will be available in Chlorine shed area. Online Cl 2 gas detectors shall be installed at conspicuous locations inside the plant. Alarms shall be configured for detection of chlorine in office area and control room. Breathing air network shall be available in entire operational area. Full body protection suite and other PPEs shall be kept ready. Safe Operating procedures and Emergency Response Procedures is/will be followed strictly. Only trained workers and employers shall be allowed to work in this area. Regular worksite inspection is/will be carried out Mitigation Measures against Risk Based on the risk assessment analysis following precautionary mitigation measures are recommended for the project. The installation of all the equipment is/will be as per guidelines of provision of Gujarat Factories Rule For any case of fire emergency, standard type of Firefighting equipment s and fire extinguisher is/will be provided in the storage area as well as required places in the plant. Smoking will be prohibited inside the factory. The adequate and suitable personnel protective equipment s is/will be provide to the operating workers. First Aid facility and First-aid trained person is/will be available at the time of handling operation. 17 P a g e

18 5.0 SAFETY MEASURES FOR TRANSPORTATION, STORAGE AND HANDLING OF CHEMICALS A. General Safety measures for transportation, storage & handling are listed below. Layout and location of hazardous chemical storage area will be based on natural and Mechanical ventilation. Spare barrels of sufficient quantity will be kept ready for any emergency spillage or leakage. Regular inspection of all the drums of hazardous chemicals will be carried out and damaged drums will be separated and disposed to avoid the possibility of catastrophic rupture. Display Boards will be provided on all storage drum which include the name of the chemicals, material of construction, calibration of tanks and date of painting. The level indicators will be placed on all storage drums to know the exact liquid level inside the drum and to avoid the accidental spillage or overflow. All equipment s related to hazardous chemical storage will be maintained and calibrated regularly. Drum trolley will be used for the movement of drums of hazardous chemicals to avoid accident due to manual error. SOP for handling will be displayed in local language for safe operating procedure. Proper inventory of hazardous chemicals will be maintained and buffer stock will be kept as minimum as possible. Standard procedure for unloading will be in place and will be implemented for safe unloading of road tanker. Static earthing provision will be made for tanker unloading. Muffler on the silencer of the tanker during entering in factory premises. Water showering system (Automated sprinkling system) will be provided to the flammable liquid storage area, wherever required to avoid the vaporization due to increase in atmosphere temperature. On site detectors for fire based on heat &/or smoke detection with alarm system will be provided as required. Adequate firefighting system is/will be provided as required. Details of the same are elaborated in related section. First aids boxes will also be provided at prominent places in the plant. Area will be declared as NO SMOKE ZONE. Specific Safety measures for storage and handling of other chemicals and gas cylinders are given as follows. i. Storage and Handling of other Chemicals It will be labeled properly and stored in a cool, well-ventilated and fire resistant area in a tightly closed container. Material Safety Data Sheet will be displayed in front of respective chemicals Proper training and knowledge will be provide to workers for physical and chemical characteristics of the each chemical they are using 18 P a g e

19 ii. Proper PPEs will be provided to the workers Proper firefighting equipment s will be installed at storage yard and maintenance and calibration for that equipment will be carried out on regular basis. Storage and Handling of gas cylinders Store cylinders upright with valve outlet seals and valve protection caps in place. Store cylinders in accordance with ISO Standard Segregate full and empty cylinders. Visually inspect stored cylinders on a routine basis, or at least weekly, for any indication of leakage or problems Use regulators approved for the specific gas. Move cylinders using a suitable hand truck or cart. Secure cylinders when in storage, transit, or use. Use a cylinder cage or cradle to lift a cylinder B. Process Safety Measures Safety measures are the most important aspect of selection of process technology to ensure safety in production unit. For the safety in production area some important critical safety measures must be provided within the process technology/equipment itself. The details of the general safety measures for process unit are as below; Process parameters control is/will be provided vide Standard Operating Procedures. All reaction vents is/will be connected to either vapor condensers system or gaseous scrubber system. Trained person will be engaged for handling of hazardous materials. Proper safety a precaution is/will be taken during handling of hazardous materials. Further all the vessels are/will be examined periodically by a recognized competent person. All the vessels and equipment s is/will be well earthed appropriately and well protected against Static Electricity. Also for draining in drums proper earthing facilities have been provided. Reaction column pressure and temperature data shall be regularly monitored and assessment of properties of flammable chemicals will be evaluated to avoid fire/explosion scenarios. Temperature indicators shall be provided near all reactors. Caution note, safety posters, stickers, periodic training & updating in safety and emergency preparedness plan will be displayed and conducted. Total reaction will be carried out in closed jacketed vessel having cooling water supply to control temperature in case of run-away reaction. Emergency reactor shutdown system will be implemented. 19 P a g e

20 C. Safety Measures for Drum Storage and Handling Drums will be stored at designated location or secured in a safety storage cabinet. Approved methods of equipping a drum and dispensing liquids from it will be followed. Drums, carboys and related accessories will be inspected on regular basis for maintenance purpose. All the vessels and equipment s will be earthed properly and protected against static electricity. Also, proper earthing facilities shall be provided for drums. Materials will be transferred by pumping through pipeline or by vacuum, from drums. Drums for flammable liquids will have proper closures that can withstand the expected handling conditions without leaking. D. Safety Measures for Preventive Maintenance The safety measures in form of the general Do's & Don'ts for safety in process & other plant area are as below: Make sure equipment is empty and fluxed with nitrogen and air. Use proper PPE will be ensured by safety officer. Check VOC content for flammable vapour and make sure that no flammable vapour contents. Keep proper and adequate fire extinguisher near work area. Check all motors are disconnected and fuse pulled out before maintenance. Work in any equipment must be conducted in presence of supervisor. Make sure all process lines are disconnected. Do not work on equipment s without permission from plant head and maintenance head. Do not allow any employment without pre medical checkup or without checking fitness. Additional safety measures in form of the checklist covering Do's & Don'ts of preventive maintenance, strengthening of HSE, manufacturing utility staff for safety related measures is/will be updated timely and will be made available to all concern department & personnel. E. Safety Measures to Prevent Spillage and Leakages The preventive maintenance will be planned and carried out as per plan to avoid the failure of valve, pipe lines and other component of transferring line. The spillage will be confined to the dyke area underneath the vessel. The resultant splash of such chemicals will result in exposure of toxic chemicals to employees. Facilities like Safety shower and eye wash fountains will be provided in the plant area, which can be used to decontaminate the affected employees. The followings are some measures to be taken for handling the toxic chemicals safely; Safety equipment s like electric siren, safety shower etc. is/will be provided at various places in plant and suitable personal protective equipment like splash goggles, gloves and protective clothes are provided while handling the toxic chemicals The storage of corrosive and toxic chemicals will be segregated from each other. The piping will be examined thoroughly every year for finding out any defects; and a defect will be removed forthwith. The record of such examination will be maintained. Smoking will be prohibited inside the factory. Employees will be properly trained for handling of toxic and corrosive chemicals and their training is/ will be ensured by mock practices. 20 P a g e

21 All pipe joints will be provided with heavy duty gaskets to prevent any leakage. Self-breathing apparatus will be provided and workers will be trained about their use also. Dyke wall will be provided to the hazardous chemicals storage area. Spare barrels of sufficient quantity will be kept ready for any emergency spillage or leakage. VOC detectors will be installed. 6.0 FIRE FIGHTING SYSTEM / FIRE CONTROL PLAN By looking to the hazardous nature of process and the chemicals that are handled and processed, the chances of outbreak of fire cannot be totally ignored. Hence to tackle such a situation, company has developed proposed, well-resourced and adequate fire protection system. The management has proposed to keep the following extinguishers at site: Flame detectors, smoke / temperature actuated heat detectors with alarms, automatic sprinkler system, shall be installed at conspicuous locations as per the requirements. Company will have Fire Water Tank of adequate capacity to combat the emergency, if arise, GIDC water reservoir shall also be made available, if required. Working staff will be trained to operate Foam, DCP and CO2 extinguishers. DG set will be available as a separate power backup for fire network. Company has done tie up with GIDC Fire Brigade and nearby companies, for handling emergency situations. Electric driven alarms & sirens will be placed at the conspicuous locations. Hand Bell shall be used in case of power failure. Proponent had provided separate entry and exists with adequate margin all around the periphery for unobstructed easy movement of the emergency vehicle / fire tenders without reversing back. CONCLUSION: Based on the risk assessment analysis it is concluded that the risk of toxic dose is highest in worst case scenario only. In case of any risk, proper mitigation measures are being/will be implemented for the expansion project x x P a g e