RISK ASSESSMENT, DISASTER MANAGEMENT PLAN & HAZOP

Transcription

1 RISK ASSESSMENT, DISASTER MANAGEMENT PLAN & HAZOP M/S. HINDUSTAN PETROLEUM CORPORATION LTD (Construction of New LPG Plant for Bottling & Storage Facilities at Haldia) Haldia LPG Plant, Brindavan Chak (V), Durgachak Tehsil, Purba Medinipur District West Bengal July 2016 PREPARED BY M/s. SV ENVIRO LABS & CONSULTANTS Visakhapatnam Phone: , Fax: Recognized by MoEF, and QCI Accredited, S.No.157 1

2 CHAPTER I INTRODUCTION

3 1.0 INTRODUCTION 1.1 Preamble This Risk Assessment and Onsite & Offsite disaster management plan has been prepared for the Haldia LPG Plant of Hindustan Petroleum Corporation Limited. The Haldia LPG plant of Hindustan Petroleum Corporation Ltd. (HPCL) is situated at Brindavan Chak Village, Durgachak Tehsil, Purba Medinipur District, West Bengal. The plant site along with the surrounding area is shown in Site Plan. Noticing the damage potential and thus risk arising due to transportation, storage and handling of the flammable LPG HPCL, Haldia retained SV Enviro Labs & Consultants, Visakhapatnam, to undertake the Risk Analysis and Disaster Management plan for the LPG Plant. Hindustan Petroleum Corporation Ltd, a Central Public Sector (Govt. of India Undertaking), proposes to setup a 1500MT (3 x 500MT) capacity LPG Plant, bottling capacity of 60,000 MTPA at Haldia, West Bengal, on 18 acres land taken on lease from Kolkata Port Trust. The estimated project cost is Rs Crores. 1.2 Background & Justification of the Project: HPCL has only one LPG Plant in State of West Bengal at Paharpur in an industrial area located in Kolkata City. This project proposed to construct 3x500 MT Mounded Storage Vessels, Bottling Capacity of 60 TMTPA LPG Cylinders in an area of 18 Acres. HPCL has grown only by 14 % during due to bottling capacity constraint. The anticipated market demand shall be 400 TMT by As per Vision 2015 Document of MOP & NG, Govt. of India, the LPG penetration has to be increased so as to achieve 75% penetration of LPG. Therefore,many regular and rural distributors shall be commissioned during next 2-3 years. However, in absence of own additional bottling plants, HPCL is not getting due rural penetration, as per its market potential in the State of West Bengal, as compared to IOC & BPC. It is proposed to attach the Distributors under East and West Midnapur, Howrah &Hoogly districts to new plant on logistic basis, which are presently being fed by Private bottlers and our hospitalityarrangement with IOCL & BPCL. The total supply to these markets during was 41 TMT. However, potential demand was not fulfilled due to non-availability of our own plant, as supplies only to these markets gets affected in adverse situation, since priority is given to Kolkata & it s suburban markets.

4 Project Benefits: Availability to Clean Energy for Domestic Consumption Employment Generation Socio-economic development of the area Educational Facilities in the area 1.3 Design Criteria: The LPG bottling plant will be operated in two shifts /day and 300 days/year to achieve the targeted production by making use of facilities listed Proposed Facilities of the Project: i. 1 no. 24 head fully automatic Flexi-Speed Electronic Carousels with high speed downstream equipment. ii. LPG Cylinder Sheds iii. Filling and testing equipments iv. 3 x 500 MT capacity Mounded storage facilities v. Fire water storage tanks and allied Firefighting facilities, Gas Monitoring system and PPE as per OISD 144 vi. 1 no 8 bay Tank Truck unloading facilities vii. 2 Nos. Manual filling scales for 35 Kg./47.5 Kg. capacity cylinders filling with QC equipment viii. Shed & Testing equipments for Periodic Cylinder Testing Facility. ix. Miscellaneous associated facilities / infrastructure x. Railway siding in future, for unloading of LPG by rakes. Feasibility study included in present scope of project. To analyze Maximum Credible Accident (MCA) Scenarios, following inventory of LPG has been considered:

5 Table: 1.1 Inventory of LPG at HPCL LPG Plant, Haldia Sr. Unit Maximum Inventory (MT) Remark 1. Mounded Bullet Proposed 2. Mounded Bullet Proposed 3. Mounded Bullet Proposed Maximum permissible filling is 85% of the volume (15% is left as vapor space). Major facilities at the LPG Bottling Plant include tank farm comprising of LPG storage, two pump houses one for fire fighting Water and another for LPG, Cylinder Filling shed, Tank Truck loading/ Unloading Gantry, DG room MCC Room, fire water pumps, jockey pumps & two water tanks of capacity 3500KL each for fire fighting. The LPG Bottling Plant has facilities for unloading, storage and loading of LPG. LPG is class A Flammable and hence due care is taken to avoid ignition in the area. Table: 1.2 Work Environment Quality in LPG Bottling Plant, Haldia is given in below table Pollutant Shift PPM Time Weighted Average (TWA)* LPG Less than TWA 1000PPM (1800mg/m3) TWA*= NIOSH Pocket guide to chemical hazards, US Department of Health and Human services, JUNE 1990 Detection of LPG Leakage: If in case leakage of LPG occurs, it is sensed by the sensors and accordingly it will give alarm (20% of LEL: Warning & at 50%LEL: Alarm) Senior Regional Manager/Plant Manager, who would be Site Controller/Chief Coordinator in case of any emergency, manages overall operations of the LPG Bottling

6 Plant. Under his guidance, Fire Fighting Team, Rescue team & Auxiliary team would work in co-ordination during an emergency. In order to identify the nature and extent of impact due to hazards due to the storage & handling of LPG, Risk analysis study has been carried out, which has been covered in the report. Maximum Credible Accident scenarios have been identified and damage distances have been calculated for various damage levels. Though risk of accidents are minimized by sound design and safe operations & maintenance practices, but it has been observed that even after taking all such precautions possibility of occurrence of an accident can not be fully eliminated in such installations. There are number of accident case histories, discussed in the Risk Analysis study, which insist to formulate a functional Disaster Management Plan (DMP). Therefore planning for mitigating the effects of an accident is essential. Mitigation of sufferings due to an accident is achieved by implementing the DMP at the time of emergency. A DMP is prepared by incorporating the results of Risk Analysis study/maximum Credible Accident (MCA) Analysis/Consequence Analysis, which includes identification of the credible accident scenarios and assessment of the consequences of such accidents. Accordingly the emergency operations that would be implemented in the event of an emergency are decided. The requisites for response to an emergency are that the response should be quick, adequate, well devised and properly supervised. Disaster Management Plan for HPCL LPG Plant, Haldia has been prepared in such a way so that loss minimization, hazard control in the quickest possible time and mitigation of the sufferings of the people during a major accident could be achieved. However it is to be noted that Disaster Management Plan is just one aspect of achieving higher levels of safety, which cannot be considered in isolation. In particular, it is not a substitute for maintaining good safety standards in plant operations. Guidelines provided in Manufacture, Storage & Import of Hazardous Chemical Rules 2000 under Environment Protection Act 1987, MoEF, GOI: Schedule 11 & 12 have been used for preparation of On-site Disaster Management Plan.

7 CHAPTER II RISK ANALYSIS

8 2.0 OBJECTIVES & SCOPE OF THE ASSIGNMENT Study Objectives The purpose of carrying out Risk Analysis is to study the nature & impact of hazards due to the handling & storage of LPG and also to analyze the nature of injury & extent of the consequences Off-site the plant so as to facilitate On-site & Off-site Emergency Preparedness Plan. The analysis aims at qualitative & quantitative evaluation of the consequence involved due to location and operation of the LPG bottling plant and also to identify suitable measures to minimize the consequences. The findings result into recommendations for minimization of the existing levels of risk, and provide guidelines for increasing effectiveness of On-site & Off-site Emergency Preparedness Plan. 2.1 IDENTIFICATION OF HAZARDS & ASSESSMENT OF THE CONSEQUENCES LPG are highly inflammable due to low flash point, high volatility, low ignition energy requirement, high burning velocity, higher vapor density than air (due to which the vapor spreads on the ground & thus more susceptible to catch a ignition source), high heat of combustion & concentration in air being within the flammability limits in empty pipelines & tanks. In addition to such intrinsic properties, extrinsic factors like operating conditions & large inventory are considered in the study. (A) Hazard Identification (HAZID) & visualization of MCA Scenarios: 1. Study of ongoing LPG handling & bottling process and engineering information, Piping and Instrumentation (P&I) diagrams, plot and layout plans of the plant 2. Identification of fire & explosion hazards 3. Analysis of inventories in storage units with recourse to manufacture, storage & Import of Hazardous Chemical Rules, 2000 and Fire - Explosion & Toxicity Index (FEI & TI) 4. What- if analysis for all foreseeable deviations in LPG Bullets, LPG Pump & compressor, Bulk Loading/Unloading process, LPG bottling units and various

9 LPG handling processes like LPG unloading from truck tankers, Defective cylinder evacuation, Cylinder filling & Loading of LPG in truck tanker. 5. Identification of accident sequences and consequences with recourse to Event Tree Analysis (ETA) and to evaluate propensity of occurrence of the top event through Fault Tree Analysis (FTA) 6. Past accident data/information analysis in similar installations to develop the credibility of worst come worst accident scenarios 7. Visualization of Maximum Credible Accident (MCA) scenarios (B) Analysis of MCA Scenarios: 1. Analysis of identified MCA scenarios and quantification of primary effects and to evaluate the domino effects with recourse to computerized mathematical models program EFFECTS (Internationally recognized software developed by TNO) pertaining to cases of LPG Outflow and its release Dispersion Heat Radiation Explosion {(Vapor Cloud Explosion, Boiling Liquid Expanding Vapor Explosion (BLEVE)} 2. Application of damage criteria for heat radiation & pressure wave levels with recourse to health criteria, dose-response relations and vulnerability models (C) Consequence Analysis: 1. Study of on-site and off-site population and land usage characteristics. 2. Characterization of Consequence/hazard levels through study of nature of exposure, pathway & consequences of MCA scenarios 3. To provide recommendations to minimize the Consequence and guidelines for On-site & Off-site Disaster Management Plan (DMP).

10 2.2 METHODOLOGY ADOPTED After identifying the study objectives and collection of the data, the team identified the major consequences that are possible due to deviations from design and engineering intentions. The collection of data and information provided familiarity with the facilities to the team carrying out the Risk Analysis study. The Risk Analysis calculations based on the collected data have been carried out by using PHAST LITE 7.11 software. Finally, risk reduction measure has been suggested.

11 Introduction to the study Data collection and discussion with engineers Identification of hazards Data input into Risk Analysis software Processing of risk analysis Calculations and releases Scenarios Risk presentation Recommendation

12 2.3 Properties, Behavior and Hazards of the LPG Properties of LPG are analyzed to identify & quantify the hazards. Material Safety Data Sheets (MSDS) for LPG is given in Table 3. Table 2.1: Material Safety Data Sheet (MSDS) For LPG A. Identification CAS No. : Formula : C 3 H 8 / C 3 H 6 /C 4 H 10 /C 4 H 8 Description : Colourless,Non corrosive, odourless gas when pure. A foul smelling odourant is usually added. B. Physical Properties Molecular weight : 22 to 58 Vapor Pressure : > 1 atm Flammability Limits : Lower (LEL) = 2.1%; Upper (UEL) = 9.5% Category : 1 A Flame able (Osha Classification) Reactivity : Reacts with Strong Oxidizers, Chlorine Dioxide C. Fire/Explosion Hazards Fire Hazard Oxidizing material Explosion Hazards Fire Fighting D. Health Hazards : Highly dangerous when exposed to heat, can react with : Moderate when exposed to heat or flame : Foam, Carbon Dioxide, Dry Chemical Powder, Water Sprays/ Fog can be used. TLV/TWA : 1000 PPM (1800 mg/m 3 ) Target Organs : Respiratory system CNS Pathway : Inhalation Symptoms : Lightheadedness, drowsiness, irritation in eyes, nose, skin, dermatitis.

13 E. First Aid Eye - if this chemical contacts the eyes, immediately wash the eyes with large amount of water, occasionally lifting lower and upper lids. Get medical attention immediately. Contact lenses should not be worn when working with this chemical. Skin - Breath - if this chemical contacts the skin, promptly wash the contaminated skin with soap and water. If this chemical penetrates the clothing, promptly remove the clothing and wash the skin with soap and water. Get medical attention promptly. If a person breathes large amounts of this chemical, move the exposed person to fresh air at once. If breathing has stopped, perform mouthto-mouth resuscitation. Keep the affected person warm and at rest. Get medical attention as soon as possible. 2.4 RISK ANALYSIS Quantitative Risk Analysis Quantitative Risk Analysis has been carried out with the help of world renowned SOFTWARE i.e. PHAST LITE 7.11 Modes of Failure There are various potential sources of large/small leakages, which may release LPG to the surrounding atmosphere. This leakage may be in the form of a small gasket failure in a flanged joint or snapping of hoses, a guillotine failure of a pipeline or any other source of leakage. Damage Criteria The damage effects are different for different types of failure scenarios.the physical effects of ignition of LPG vapours, e.g. blast wave, thermal radiation and BLEVE due to release of LPG from the containment are discussed below: i) LPG vapours released accidentally will normally spread out in the direction of the wind. If it comes into contact with an ignition source before being dispersed below the lower flammability limit (LFL), a flash fire is likely to occur and the flame may travel

14 back to the source of leak. Any person caught in the flash fire is likely to suffer from severe burn injury. Therefore, in consequence analysis, the distance to LFL value is usually taken to indicate the area, which may be affected by flash fires. Any other combustible material within the flash fire is likely to catch fire and may cause secondary fires. In the area close to the source of leakage of LPG there is a possibility of Oxygen depletion since the LPG vapour is heavier than air. A minimum of 19.5% Oxygen in air is considered essential for human lives. ii) Thermal radiation due to pool fire, jet flame or fire ball may cause various degrees of burn on human bodies. Also its effects on inanimate objects like equipment, piping, building and other objects need to be evaluated.

15 Fig: 2.1 Possible Scenario Release of LPG

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20 Fig: 2.2 Leakage from LPG Tanker

21 2.5 HAZARDOUS MATERIAL STORAGE, HANDLING & TRANSPORTATION Maximum inventory of the LPG in the Plant is given in Table 1.1. The storage tanks are fitted with vents, expansion wires, delivery/receipt lines with separate valves & earthing arrangements. At HPCL, Haldia LPG Bottling Plant the bulk LPG will be received at the plant through Road tankers of capacity 18MT. This LPG is then stored in the plant. Bottling of Cylinder is done in the plant through carousel and distributes the filled cylinder to the end users through Dealer network system by truck. 2.6 VISUALIZATION OF MCA SCENARIOS, HAZARD QUANTIFICATION AND ASSESSMENT OF THE CONSEQUENCES A Maximum Credible Accident (MCA) is an accident with maximum damage potential, which is believed to be credible in a hazardous installation. In this Plant, primarily there could be fire (ignition of spilled or leaked LPG), flare (jet fire) or VCE (Vapour Cloud Explosion), BLEVE. VCE is possible at the tank farm only whereas fire, Flare & BLEVE are possible at pipeline, any pipeline containing LPG; Tank farm, Pump House and Truck Tanker. Quantification of heat radiation levels has been carried out for VCE scenarios only as other fires would have comparatively less harmful impacts. In case fire, flare or VCE could not be controlled there is a possibility that fire may propagate from one tank to another. This may further escalate the disaster and BLEVE may occur due to LPG Assessment of the Consequences Primarily there could be fire (ignition of spilled or leaked LPG), flare (jet fire) or VCE in the LPG Bottling Plant. VCE is possible at the Tank farm and Tank Truck whereas fire and flare are possible at any pipeline containing LPG; Tank farm; pump shed and T/T Filling. Quantification of heat radiation levels has been carried out for VCE scenarios only as other fires would have comparatively less harmful impact on the surroundings.

22 Depending on the inter-unit distances, it is quite likely that the fire/explosion in one unit may affect the other nearby units and thus the damage may escalate. A fire, flare or VCE or BLEVE may produce cascading effect (prorogation of an accident) at the tank farm. In case the BLEVE takes inside the plant and could not be controlled in the Area of accident, there is a possibility that the other facility may explode if flame directly impinges on them or any bombing takes place directly on Tank. VCE & Jet Fire will not be as violent as that of BLEVE in Tank Truck. Also, the extent of damage due to VCE or Jet Fire will not be more than that due to BLEVE in LPG Tank Truck. Therefore it could be concluded that BLEVE in a LPG Tank Truck would be worst credible accident scenario for the LPG Bottling Plant and if this accident occurs it may destroy the complete LPG Bottling Plant. However the BLEVE can occur only as secondary effect of VCE or a impinging jet fire on the tank Truck in the TT Gantry, but frequency probability is less than 8.9 x Jet Fire in LPG Pipeline/Product Pump House/Tank Farm/Bulk Loading/Unloading Shed/Truck Tanker If there is a leakage in the pipeline and if there is availability of any ignition source, jet fire may occur. In such cases the leaked LPG may travel up to the ignition source and the fire may travel back to the place of leakage or the leaked LPG may catch fire at the place of leakage it self. The flame impingement and may cause further damage. In this case also there would be sufficient time available for the persons to come out from the affected area, unless they are not trapped due to layout of the plant at that place. In such cases isolating the affected pipeline should be given first priority than extinguishing the fire. The affected equipment (being heated by the heat) should be kept cool with flow of water from monitor/hydrant Vapor cloud Explosion in tank farm Analyzing the damage distances and heat radiation intensities for VCE scenarios, it can be inferred that there will not be any fatality outside the plant as there will be sufficient time to escape. Only burn injuries may occur. If such VCE is extinguished well in time

23 and escalation of accident could be avoided; disaster like Boiling Liquid Expanding Vapor Explosion in Tank Truck could be avoided. Thus damage in the LPG Bottling Plant could be limited to the tank farm only. However, frequency of occurrence of such accidents has been found extremely low. As soon as any such major release of LPG is noticed and LPG cannot be contained in the leaking tank, first efforts should be made to transfer LPG to the other tank in maximum possible quantity. The fire tender & additional fire fighting equipment should be brought to the site. If possible the leakage should be minimized/ stopped and the personnel should ascertain that there is no possibility of any ignition source in the near vicinity. Then the spilled oil should be carefully removed at the earliest. If fire takes place, apart from extinguishing the fire, cooling of nearby tanks containing pipelines & equipment by water monitor/hydrant should be given equal importance SECONDARY OR DOMINO EFFECTS A fire or explosion in one facility may lead to another one; the effects of this nature are called Secondary or Domino effects. The Haldia LPG plant of Hindustan Petroleum Corporation Ltd. (HPCL) is situated at Brindavanchak, Post Box No -6, P.O Durgachak, Purba Medinipur District, West Bengal. However in case of major LPG leakage in the bottling plant and the plume traveling in down wind direction may meet an ignition source and due to backfire phenomenon severe damage to the LPG bottling plant may occur. Referring the damage distances for BLEVE/VCE; it is possible that fire or explosion in one segment of the plant may cause adverse impact to the other segments of the plant. 2.7 DETAILS OF PREVENTIVE MEASURES TO AVOID LEAKAGES & ACCIDENTS FIRE PROTECTION SYSTEM The following fire protection facilities are envisaged as per the requirements of OISD- 117 Portable Fire Extinguishers / Equipments to fight small / approaching fire

24 Fire Fighting system with Automatic Operation to fight Emergency involving major fire Specific norms of various types of fire extinguishers and equipment to be kept at plant has been stipulated in the OISD 144. In case of fire fighting system detailed design and operating parameters have been defined. Provisions for firefighting facilities for plants construction as per OISD 144 is different from plant constructed as per OISD 169. Majority of plants are as per OISD 144. Details of Fire fighting facilities as per OISD 144 Components of fire water system The main components of the system are: - Fire Water Storage - Fire Water Pumps - Fire Hydrant/ Monitor distribution piping network. - Water Sprinkler/ Deluge system. Portable fire extinguisher Portable fire extinguishers shall be located at convenient locations and shall at all times be readily accessible and clearly visible. The maximum running distance to locate an extinguisher in working areas shall not exceed 15 meters HOSES, NOZZLES AND ACCESSOREIS Reinforced rubber lined hoses (63mm) conforming to IS: 636 (type A or B) shall be provided. The hoses shall be of 15 Meters standard length and shall be provided with Gun metal/ Aluminium alloy male & female couplings of instantaneous pattern. The following accessories/ first aid items shall be provided in the plant: 1) Fire hoses 100% of no. of hydrant points. 2) Safety helmets as required (Min. 10 Nos.) 1 no. for each person 3) Hose Boxes Alternate hydrant point. 4) Stretcher with blankets Min. 2 Nos. 5) First aid Box Min. 2 nos. 6) Rubber hand gloves Min. 2 pairs for electrical purpose (BIS approved)

25 7) Low temperature 4 pairs rubber hand gloves for LPG emergency. 8) Low tem. Protective Min. 2 sets clothing for LPG emergency. 9) Explosimeter Min. 2 Nos. 10) Fire proximity suit Min. 1 No. 11) Resuscitator Min. 2 No Fire alarm system Sufficient No. of Manual call points shall be provided in the plant. Electricity operated Fire Siren shall be audible to the farthest distance in the plant (1K.M. from the periphery of the plant). Manually operated fire sirens shall be provided at strategic places. For fire condition the siren shall be wailing sound for minimum 2 minutes and for all clear signals it shall be straight run siren for 2 minutes PREVENTIVE MEASURES: Interlocking shut down device (ISD) will be connected to automatic shutdown and auto operation fire hydrant network. Emergency shutdown will be provided in the control room to stop all dispatch operation Emergency push buttons to stop all loading operations are provided in the control room. Gas Detection system and monitoring system will be provided

26 CHAPTER III DISASTER MANAGEMENT PLAN

27 3.0 OBJECTIVES AND SCOPE OF DISASTER MANAGEMENT PLAN Objectives: The disaster management plan is formulated with the broad objective of safeguarding human life and minimizing human suffering & property loss by localizing the emergency and to eliminate it as far as possible. Elimination of impacts of a foreseeable accident requires prompt action by operators and emergency staff using, e.g., fire-fighting equipment, shut-off valves and water sprays. Minimizing the effects include rescue, first aid, evacuation, rehabilitation & giving prompt information to people in nearby area. The Disaster Management Plan of the company is divided into two parts: 1. Onsite Emergency Plan In this plan, the company officers are given pre-designated responsibilities for dealing with the emergency 2. Offsite Emergency Plan In this, different Govt. agencies will be informed about the emergency for necessary help from them. Scope: 1. To examine the protection measures that are already incorporated and effectiveness of measures in respect of response times, resource mobilization, dispersion etc. and suggest corrective actions to be taken. 2. To develop an effective On-site disaster Management Plan so as to ensure safety by restricting a hazard to not to manifest into an accident. If, at all, a hazard realizes into an accident; to mitigate the consequences to minimum possible level. In order to achieve this, it is required to: 1. Identify the hazards and assess the consequences by carrying out a Risk Analysis Study or MCA Analysis; 2. Evolve guidelines for fire fighting for each perceived accident scenario and to formulate scope of activities for mock drill; 3. Formulate and allocate the actions to be taken during an emergency by every member of the emergency team;

28 4. Evolve procedure for reporting an emergency; 5. To ensure adequacy of proper fire fighting equipments; 6. Ensure quick and proper communication, inside as well as outside the plant during an emergency; 7. Shutdown the Plant operation & isolate storage tanks; 8. Control the situation & contain extent of damage in order to save Plant property & environment; 9. Information to local authorities & associating with them to execute the emergency services 10. Ensure safety of the personnel engaged in control measures and rescue of other plant personnel and to provide first aid & further treatment to the injured; 11. Preserve records & relevant clues to investigate the causes so as to prevent recurrence of such events. 3.1 FORMULATION OF DMP AND EMERGENCY SERVICES In order to cope with the above-identified MCA, it is required to formulate a Disaster Management Plan so that the arised emergency situations could be managed with least possible damage. Following aspects have been considered in preparation of the on-site Disaster Management Plan: 1. Response time of equipments, machinery and fire fighting team any emergency situation 2. Liaison with outside authorities, including the emergency services 3. Procedures for raising the alarm and communications both within and outside the works 4. Appointment of key personnel and their duties and responsibilities, especially for works incident controller and works main controller 5. Emergency Control Centre, its location and infrastructure available 6. Action on-site and off-site

29 7. The time element is of great significance in dealing with most of the dangerous situations in all installations handling hazardous chemicals. Past accidents have shown that this factor is often overlooked. 3.2 EMERGENCY TEAM: In case of any emergency each individual in the LPG Bottling Plant has to act in proper co-ordination to execute specific tasks under the designated team leader. This avoids overlapping of responsibilities & possible chaos at the time of emergency. 3.3 DECLARATION OF EMERGENCY Incidents/scenarios like fires, explosions, natural calamities, sabotage, act of war or negligence may lead to an accident or disaster at the Plant. As soon as any untoward incident is observed which has potential to lead to any emergency situation, it is the responsibility of the observer to rush to the spot of fire (depending on the amount of fire) with the nearest portable extinguisher available to him by shouting FIRE, FIRE, FIRE till he himself (or someone hears and rushes for help and arrange to) sound the siren. Actuation of siren would mean declaration of emergency. A red colored flag would be used to indicate the site of fire. First observer must make sure that Incident Controller or (Fire In-charge) Site Controller/Chief coordinator is informed about the incident and takes overall charge of the situation. Fire in-charge will issue suitable instruction after quickly assessing the situation. The emergency will continue until all fire has been extinguished with no risk of re-ignition. On ensuring normal conditions Site Controller/ Chief coordinator will declare normalcy. Emergency Control Center is the Emergency Response Center of LPG Bottling Plant. 3.4 ACTIONS TO BE TAKEN DURING AN EMERGENCY: The actions that are required to be taken during an emergency in the LPG Bottling Plant have been analyzed and listed below. This includes various information to be made available to Site Controller/ Chief coordinator and the decisions to be taken according to the situation at the time of emergency.

30 Sr. Actions To be Performed by 1. Emergency alarm is to be raised immediately on First Observer observing any type of emergency. In Case of total electricity failure fire bell is to be used 2. What is the exact location of fire/lpg leak in the First observer/ Incident plant and extent/size of LPG leak? Controller 3. Which flammable material is involved? First observer/ Incident Controller 4. What is the nature of emergency? Whether Tank First observer/ Incident overflow / Bund Over-flow / Truck with filled Controller/Site cylinders on fire / LPG Tanker on fire / Fire in Controller/Chief Controller pump house / generator room, dry grass etc., a natural calamity. 5. The Control Systems are to be put into service Incident Controller 6. Fire combating team is to reach to the spot with Fire Combating Team the equipments 7. Fire pump is to be put on & to ensure correct Fire Combating team water pressure in the hydrant line 8. All the LPG transfer pumps are to be stopped & Auxiliary Team the valves are to be closed 9. Fire extinguishers are to be put into operation Fire Combating team immediately 10. Whether the extinguishers are available in Auxiliary Team sufficient Nos. at the site of fire? 11. On Bulk LPG Unloading Shed, unloading operations are to be terminated. Valves in the Bulk Unloading Shed are to be closed and the unloading hoses to be removed from the Tankers under unloading Truck Loading/Unloading In-charge otherwise Auxiliary Team 12. To ensure that all the Tankers are taken out of the Auxiliary Team premises 13. Cash box is to be closed and kept into the safe. Rescue Team Important documents to be kept in safe. 14. Traffic at main gate is to be kept clear Security Staff 15. Whether evacuation of personnel required? If so, then to arrange the evacuation Site Controller/Chief Controller & Rescue Team 16. Entry of unauthorized persons is to be restricted. Security Guard 17. External agencies like fire brigade, Police, Ambulance, etc. are to be informed depending on the Rescue team on instructions from Site Controller/Chief Controller need and necessary help is to be asked. 18. Contractors and visitors are to be taken out of the Rescue Team premises 19. How many vehicles are available? Security 20. To ensure power supply & operation of the generator Auxiliary team 21. Risk to the emergency control center from the incident Fire In-charge (Site Controller/Chief Controller)

31 Every individual worker as well as Fire Incharge, Fire Combating team Incharge and other personnel are expected to use their presence of mind in spite of the duties allotted to them and take prompt action to safe guard lives and minimize the damage to the plant property and environment. Specific duties of the emergency team are as follows. 3.5 APPOINTMENT OF PERSONNEL AND THEIR DUTIES In order to performed the actions listed in item 3.3, duties of all the numbers of the emergency team have been identified and listed below: Table: 3.1 List of Key Personnel Sr no. DESIGNATION OF KEY PERSONNEL 1. SITE CONTROLLER/CHIEF COORDINATOR 2. INCIDENT CONTROLLER 3. ADMINISTRATIVE COORDINATOR 4. FIRE & SAFETY COORDINATOR 5. COMMUNICATION &MAINTAINENCE COORDINATOR 6. SECURITY CONTROLLER NAME OF KEY PERSONNEL Table: 3.2 Details of Manpower Details of Official Staff at Haldia LPG Plant (also to be used as Roll Call List) Sr. Designation/Grade Name of Employee 1. Sr. Regional Manager 2. Sr. Manager Projects 3. Plant Manager 4. Sr Operations Officer 5. Sr Operations Officer 6. Sr Operations Officer

32 Table: 3.3 Details of Clerical Staff at Haldia LPG Plant Details of Clerical Staff at Haldia LPG Plant (also to be used as Roll Call List) Sr. Designation/Grade Name of Employee 1. Sr. Comp. Clerk M Clerk M-10 Table: 3.4 Details of Workmen at Haldia LPG Plant Details of Workmen Staff at Haldia LPG Plant (also to be used as Roll Call List) Sr. Designation/Grade Name of Employee 1. LPG Pump Operator M LPG Operator M LPG Operator M LPG Operator M LPG Operator M LPG Operator M LPG Operator M LPG Operator M LPG Operator M LPG Operator M LPG Operator M LPG Operator M LPG Operator M LPG Operator M LPG Operator M LPG Operator M Fire Incharge (Site Controller/Chief Coordinator): Senior Regional Manager/ Plant Manager will act as Site Controller (Fire Fighting - Chief Co-Ordinator) in the event of an emergency. As soon as emergency is reported, he will rush to the spot & take overall charge of the emergency operations from incident controller. Main duties of Site Controller/Chief Coordinator are: 1. Analyze and review the situation and its possible impacts 2. Clarify and declares emergency

33 3. Assess the magnitude of the situation and decides whether the staff needs to be evacuated from the assembly points 4. Establish contract with District emergency authorities like Police,Fire Brigade, Ambulance, Inspector of factories and mutual Aid partners and alert them for any assistance, if needed 5. Contact with zonal office and HQO and maintain continuous review of possible development in consultation with incident controller and other key personnel to shut down the plant 6. Monitors and review the events and also the possible development in consultation with incident controller, Administrative controller, Safety & Maintenance coordinator 7. Ensure the record of all events, decisions taken, any government directives etc. and are well kept for future reviews & analysis 8. Assess the damage after emergency is over Incident Controller: Senior Operation Officer/ Operation Officer, will act as Incident Controller in the event of emergency. On hearing of an emergency, Incident Controller will rush to the scene of the occurrence and take overall charges and report Site Controller/Chief Coordinator. His other duties include: 1. Direct all operation within the affected area so as to ensure that safety of personnel gets priority over stocks/priority 2. Take assistance from Fire Brigade & mutual Aid Partners in controlling the situation as and when they arrive 3. Collect information regarding the origin and nature of fire 4. Maintain record of all information collected and report all significant development to communication coordinator 5. Ensure that all non essential workers/ staff of the areas affected are evacuated to the appropriate assembly points, and the areas are searched for causalities 6. Pending arrival of Site Controller/Chief Coordinator, assume the duties of his post 7. Direct closure and evacuation of plant areas likely to be affected by the emergency 8. Ensure that all key personnel and outside help are called in

34 3.5.3 Administrative Coordinator Account Officer (JN) will act as a Administrative Controller in the event of emergency. His duties include: 1. Safeguard all document, cash etc 2. Handle under the direction of site Controller, Police, Press and other enquiries 3. Receive report from assembly point and pass on the information to the communication coordinator 4. Ensure stoppage of movement on the highway, inform the railway authorities to stop the rail movement in case of need and ensure that alternate transportation is available when need arises 5. Ensure that causalities receive adequate attention, and arrange additional help, if required and inform the victims relatives 6. Make arrangement for relief of personnel and organize refreshment/catering facility 7. Provide hourly situation reports to the emergency control center indicating men, equipments, materials involved at each area under the influence of emergency Communication & Maintenance Coordinator Senior Operation Officer will act as Communication and maintenance Officer in the event of emergency. His duties include: 1. On hearing the alarm proceed to control center and maintain communication with Incident controller 2. Advice Site Controller/ Chief Coordinator of the situation recommending, if necessary evacuation of staff from Assembly point 3. Recruit suitable staff to act as a runner between Incident Controller and itself (If the telephone and other mode of communication fails) 4. Maintain log of all the incidents, communication etc. 5. In case of prolonged emergency involving risk to the outside areas, contact police & Fire Brigade for warning & if necessary, evacuating the nearby localities

35 3.5.5 Fire and Safety Coordinator: Safety Officer will act as Fire and Safety Coordinator in the event of emergency. His duties include: 1. On hearing the alarm, rush to the emergency spot and report the Site Controller/ Chief Coordinator 2. Organize, plan and give necessary instructions to the plant staff to fight emergency 3. Take care of fire fighting pumps and to get feed back from fire engine shed about, fuel and any other requirement 4. Ensure adequate material and manpower to handle the emergency 5. Review the situation periodically and inform Site Controller/ Chief Coordinator Security Controller: Security Supervisor will act as Security Controller in the event of emergency. His duties include: 1. Ensure protection to all corporation personnel and their property 2. Close public traffic on corporation roads as advised by Site Controller/ Chief Coordinator 3. Assist in evacuation personnel from affected areas 4. Control law and order in law premises Fire Combating Team: This team is lead by Executive operations officer. In his absence Executive Operation Officer will act as a leader. This team will rush to the sight of fire with the fire fighting equipments and put off the fire as early as possible before it could spread to other areas. Responsibilities of this team are:

36 On declaration of emergency/occurrence of fire: 1. The employees will immediately reach the accident place along with the nearest available fire extinguishers. They will immediately be in action under the guidance of chief officer (In charge). In the absence of the chief officer, his representative will look after the emergency operations. 2. The fire fighting team will start fire fighting immediately. 3. The staff will operate sprinkler and release air pressure of the deluge valves. 4. Operate fire hydrant and jet monitor Auxiliary Team: This team is lead by Fire and Safety Coordinator, assisted by LPG Pump Operator, LPG Operator, Security and Electrician. Depending on the nature of emergency Fire Combating Team & Auxiliary Team would merge together or co-ordinate with each other to carry out emergency operations. Functions of this team are as follows: On declaration of emergency/occurrence of fire: 1. The team will put indicator on right place of fire zone indicator. 2. The staff will operate fire siren, break glass of emergency switch. If power fails then operate hand fire siren. The all OK siren will be given on the instruction of the leader. 3. If the fire engine does not start in auto mode then the team will operate it from the Panel. 4. The team will disconnect LPG Unloading hoses from the tankers and move LPG tankers to safe place. 5. All the normal operational activities will be stopped immediately and put-off the valves of storage tank. The main switch of electric supply will be switched-off, so that the electricity distribution to the Plant will be interrupted. 6. All tankers, trucks and other vehicles will be taken to safe zones away from the Loading/Unloading Platform. 7. The team will ensure water supply from bore well to water reservoir.

37 8. All the valves, except that of fire extinguishing networks of pipelines and other appliances, are to be switched-off immediately. 9. The team will arrange for firewater hose pipes nozzles and fire extinguishers. 10. The team will close store and ware house. 11. The free flow of fire extinguishing materials and the appliances is assured. The necessary assistance and help be accorded to the fire fighting team 12. Replace if necessary all equipment used in fire fighting. Specific responsibilities of the team members of auxiliary team are: Sr. Duties During Emergency Operating Personnel 1. Fire Clock Setting Security-A.S.O 2. Operate Electrical Siren/Fire Fighting Engines LPG Pump operator Electrician 3. Removal of Bulk T/T and packed Truck LPG Operator trough emergency gate 4. MCB Shutdown and closing of all valves as instructed by fire chief Security-ULA LPG Pump operator, Electrician will act in absence of LPG Pump Operator) 5. Control Shutdown LPG Operator 6. Closing of Store and Ware Houses Security-TPR * Note: All team members will also report to their team in-charge for further instructions Rescue Team: This team is lead by Accounts Officer (JN). The Team also consists of Clerk, LPG Operator. Responsibilities of this team are: On declaration of emergency/occurrence of fire: 1. Under the instructions of the Chief Officer, they will seek necessary help from external agencies Police, Fire Brigade etc. on telephone. 2. Remove all the important documents, Computer floppies to safe place. 3. The team will stop entry of all the unauthorized persons into the Plant. 4. The team will insist all the persons other then the employees of HPCL to vacate the Plant.

38 5. The team will control the traffic and keep the route open to facilitate external help. 6. The team will provide first aid to the injured persons. 7. Opening of emergency gate. On instruction from the Chief Officer, the team will arrange vehicle to move seriously injured persons to hospital Specific responsibilities of the team members of rescue team are: Sr. Duties During Emergency Operating Personnel 1. Communication with outside agencies like Fire Brigade, Police, Ambulance, Hospital, Accounts Officer (JN) & LPG Operator Other agencies in consultation with chief 2. Bring Stretcher & First Aid Security L/A 3. Guiding external Agency & removal of Clerk, Security- M/G contract lab ours 4. Removal of important document, cash to safe place Accounts Officer (JN) & LPG Operator 5. Shifting of PPF LPG Operator 6. Use of Personnel Protective Equipment LPG Operators There are instructions that whoever detects fire will give a fire alarm and rush to the spot with the Fire Extinguisher and try to extinguish the fire. Fire Hydrant System is operated & water is sprayed to keep the exposed tanks, pipe lines & pumps cool Fire Fighting Organization For The Off-Shift (Night): Only security staff exists during night shift and there are no plant operations. The security people perform all the responsibilities. They are trained to handle the situation of emergency. The security will perform the duty of all the three teams. The security people will rush to the place with the nearest fire extinguisher and try to combat fire. They will operate the siren and operate the fire hydrant and fire monitors. The security will switch off the power supply to all equipments. They will provide first aid to the people injured in the accident and inform the plant manager and safety officer immediately.

39 Specific responsibilities of the team members of night shift and holidays are: Sr. Duties During Emergency Operating Personnel 1. To inform the plant manager / other officers Security A.S.O at residence & contact fire Brigade, Police etc. 2. To blow fire alarm and start fire engines if Security ULA required. 3. Controlling traffic at main gate Security Guard Main Gate 4. Operating Fire Extinguishers / Jet Monitors / Hydrant Hoses. Security guard TPR Security-L/A 3.6 Emergency Equipment & Facilities at the LPG Bottling Plant Emergency Control Center: In the event of an accident Emergency Response Center will be utilized as emergency control center. It is located close to the main exit/entrance of the LPG Bottling Plant and has telephone & the first aid facilities. In the event of an accident all the fire fighting activities and rescue and relief activities will be controlled from this center only. The control center has: 1. Site Plan 2. Telephone nos. of Fire brigade, Police and other organizations at Haldia 3. Chemical Fact Sheet 4. Explosive meter Emergency Assembly Points: People those who are not assigned any work during the period of incident like contractors, workers, and visitors will be taken to assembly point. Care will be taken that it does not hamper the movement of traffic or any other help from outside parties. Following Areas are identified as Assembly Points: 1. Place in front of Administrative Office (Administrative & workers amenity building) 2. Open area opposite to fire fighting Pump house

40 Place in front of the Administrative and worker amenity building is for the Assembly of all outside persons/casual labour/contract worker. At this place, Security incharge in coordination will take stock of all the persons assembled. Open area opposite to fire fighting Pump house will be Assembly point for any group decision during emergency with plant personnel. If Fire is totally control then information is can be passed to this point to declare ALL CLEAR by giving a continuous long alarm and resetting the zone indicator Escape Routes: Following are the escape routes provided for evacuation in case of emergencies: 1. Emergency Gate-I 2. Emergency Gate-II 3. Main Gate Emergency Lighting in critical areas: As the plant operates in one shift there is no need of any emergency lighting. But in case if it is required, the plant have portable emergency lights at MCC room, Office and Main Gate Security Cabin Medical facilities provided at the plant in case of Emergency: Name of the Hospital: - Doctor s Name: Distance from plant: Bed Capacity: Antidotes available: As required First aiders available: Ambulance: o Equipments available in ambulance: Respiratory Equipment o Place of availability: In Hospital & Ambulance o Capacity: As Required o Facilities available e.g. safety equipment Immobilization emergency, medicines etc. in the Ambulance: Available

41 3.6.6 Special Equipment Including Fire Fighting Materials, Damage Control and Repair Items The following are the various fire fighting facilities available in the plant: Water for Fire Fighting (Source & Capacity): Fire Water requirement for Haldia LPG Plant as per OISD-144 is 6660 KL whereas LPG Bottling Plant, Haldia has total Capacity of water available is 7000KL. Hence there is sufficient water storage in Haldia LPG Plant for firefighting purpose. Fire fighting water requirement is 10.2 LPM/m 2 (as per OISD-144 Amended Edition September 2001) and water storage should suffice for 4 hrs. Fire Water Pump House: In Haldia LPG Bottling Plant, Fire Pumps are used for pumping fire water in case of emergency. All pumps is capable of delivering 410 KL/ hour. Also 2 jockey pumps will be available in the LPG Bottling Plant. The availability of fire fighting pumps will be as per OISD 144. In regular surveys, it is assured that the pressure of 7 Kg/Cm 2 is maintained at farthest point. Fire Hydrant/Monitor System: The system is operated manually. Sprinkler System: The system automatically starts as the quartzoid bulb fuse due to heat (at 79 º C), which releases the air pressure and thus actuates the deluge valve, which opens the water flow through the sprinklers. It can also be started manually. As the pressure drops in the system, the fire fighting pumps will automatically start one by one. The sprinkler system will be provided in the following areas: 1. TT Loading/Unloading Gantry (TT Gantry) 2. LPG pump & compressor house 3. LPG bulk storage area

42 4. Filled cylinder shed 5. Empty cylinder cum filling shed 6. Cylinder testing & repairing shed Dry Chemical Powder & CO 2 Type Fire Extinguishers Fire Extinguishers are posted at all places inside the plant. The instructions are about the use of the fire extinguishers is given to all employees. Proper care of the fire extinguishers is taken and the employees are informed about the use of the FE regularly. Sr. Area No. 1. LPG Storage Vessel (Each) 3 Bullets 2. LPG Cylinder filling shed 3000m 2 3. Cylinder Loading / Unloading Shed 600 m 2 Portable fire Extinguisher (F.E.) Required as per OISD-144 Future availability 10 Kg DCP FE 2 in 6 6 number 10 Kg DCP FE 2 in number per 200 m 2 10 Kg DCP FE 2 in 6 6 number per 200 m Kg DCP FE 2 in Filling Cylinder Storage 10 Kg DCP FE 2 in Shed m 2 number per 200 m 2 5. Valve Changing Shed m 2 number per 200 m 2 6. LPG pump House Kg DCP FE 2 in m 2 number per 50 m 2 7. T/T loading /unloading 10 Kg DCP FE 1 in (8 Bays) 2 nos number in each bay 8. Other Pump Houses 10 Kg DCP FE 2 in (Fire H 2 0) number 9. Office/Canteen/stores 10 Kg DCP FE 2 in number in each building 10. MCC/DG Room 4.5 Kg CO 2 2 in numbers in each room or for 100 m Personal Protective Equipments Sr. PPE Equipment Required as per Available No. OISD 1. Safety Helmets Stretchers with Blankets First Aid Box Rubber Hand Gloves for Electrical 02 Sets > 2 Sets purpose Fire Proximity Suit Red / Green Flags As Required 3 Red & 3 Green 7. Breathing Apparatus Safety Goggles Safety Belts - 4