M/s. Gemasko Pharmachem Industries EIA Report: Proposed Expansion of Synthetic Organic Manufacturing Unit GIDC Estate, Vapi, Dist- Valsad, Gujarat. (Category: 5(f)) EIA Consultant: Unistar Environment& Research Labs. Pvt. Ltd. (QCI-NABET Accredited) Chapter 7: Risk Assessment & Disaster Management Page:226 CHAPTER - 7 RISK ASSESSMENT & DISASTER MANAGEMENT PLAN 7.1 BACKGROUND Risk Assessment is a management tool for determining the hazards and risk associated with the various activities of a project and computes the damage potential of these hazards to life and property. Risk Assessment provides basis for determining the safety measures required to eliminate, minimize and control the risks as detailed in Disaster Management Plan (DMP) to handle onsite and offsite emergencies. In Chemical Industry, Risk Assessment is carried out for the various hazards involved in storage and handling of hazardous raw materials, intermediates and finished products as well as for the manufacturing processes used by the unit. 7.2 OBJECTIVES The given study was focused to fulfill the following objectives: Identification of safety areas Ientification of process and storage hazards Visualization of maximum credible accident (MCA) scenarios Consequence analysis of scenarios Determination of quantities released, impact zones Estimation of damage distances for the accidental release scenarios with recourse to Maximum Credible Accident (MCA) analysis Preventive and control measures required for reducing the risk factors Delineation of Disaster Management Plan 7.3 SCOPE OF WORK Based on the objectives as defined above, the scope of work for the given study has been framed as under: 1. Hazard Identification General description of project Study of manufacturing activities Study of plant facilities and layout Hazardous inventory Associated process and storage hazards
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The manufacturing process does not involve high pressure and high temperature reactios or processes.Normal lookout for materials, initiating events and incidents are tabulated in table in following pages.
Process Hazards Initiating Events Incident OutcomeSignificant Inventories of : Equipment Failure Discharge of gas or liquid to
atmosphereFlammable Material Pumps Dispersion of Material(Toxic)Combustible Material Valves FiresUnstable Material Sensors Pool fireCorrosive Material Interlock Jet FireAsyphyxiants Loss Of containment Flash FireShock Sensitive Materials Tanks ExplosionHigly Reactive Materials Vessels Confined ExplosionToxic Materials Pumps Unconfined ExplosionExtreme PhysicalConditions
Heat Exchangers Dust Explosion
High Temperatures System Failure Physical ExplosionHigh Pressures Human ErrorCryogenic Temperatures Design FailureVacuumPressure CyclingTemperature Cycling
Vibration/LiquidHammering
7.5.1 Fire and Explosion HazardsThe unit will handle no. of solvents, few are to be stored in carboys and drums and few in storage tanks.
However, not more than two storage tanks of 10 KL capacity are proposed for any solvent.
7.5.2 Toxic Release HazardsLeakage or rupture in pipelines, valves, and reaction vessels can cause release of toxic gas into the
immediate environment posing serious risk to health and environment.
The unit shall take following measures to prevent such mishap.
The condition of connected piping shall be checked regularly for leakages.
Safety valves are installed at all pressure vessels and shall be periodically calibrated and
maintained.
Interlock devices and cut-off system for critical operations.
8 3" Pipe Leak (1 kg/s) 6 x 10E-5 /yr9 Flange Leak (1 kg/s) 3 x 10E-4 /yr10 Pump Seal Leak (1 kg/s) 5 x 10E-3 /yr
(Source: Dutch Purple book, 2008.)
7.6.1 Failure History DataTable 7.2 Failure History data
Sr.No.
Item International Data Indian Data
1 Process Controller 2.4 x 10-5 hr-1 3.0 x 10-5 hr-12 Process Controller Valve 2 x 10-6 hr-1 2.4 x 10-5 hr-13 Alarm 2.3 x 10-5 hr-1 4.6 x 10-5 hr-14 Leakage at biggest storage tank 5 x 10-5 yr-1 3.0 x 10-5 yr-15 Leakage pipe line 1 x 10-7 m-1yr-1 3.0 x 10-8 m-1yr-16 Human failure 1 x 10-4 (demand)-1 1.8 x 10-3 (demand)-1
7.6.2 Assumed Failure Rate for the StudyTable 7.3 Assumed failure rate for the study
SrNo.
Item Rupture (yr-1) Leakage (yr-1)
1 Pipe lines<3”3”-15”>15
10-610-7--
10-510-610-8
2 Vessel- pressurized- Atmospheric
5 x 10-61 x 10-5
5 x 10-51 x 10-4
7.7 SAFE OPERATING PROCEDURES (SOP)
Preparing safe operating procedures for handling of hazardous chemicals is the first step towards
implementing safety in the production area. The unit shall prepare safe operating procedures for handling
of hazardous chemicals. The information from MSDS is used in preparing SOPs. The material is prepared in
English as well as local language for easy understanding by workers.
The following points shall be included in the SOP:
properties of the chemical
handling and storage instructions
emergency control measures
personal protective equipment
Various possibilities of accident and methods for prevention.
Fire – Fireextinguishers,fire fightingteamToxic control –first-aid andmedical facilitiesOnsite and Off-site Emergencyplan PPE(respiratory aswell as non-respiratory)Spill control kits,and neutralizingmedia
2 Acetone 5 KL0.2 KL
MSDrums
AmbientLiquid
FireIrritative
3 Caustic Flakes 50MT
25 KgHDPE
wovenbags
AmbientSolid
IrritativeCorrosive
4Phthallic
Anhydride3.0MT
25 KgHDPE
wovenbags
AmbientSolid
FlammableIrritative
5Methanol 20 KL
10 KL-Storage
tank
AmbientLiquid Fire
6Toluene 20 KL
10 Kl-Storage
tank
AmbientLiquid Fire
7 Hydrochloricacid 5 KL
0.5 KLHDPE
Carboys
AmbientLiquid
CorrosiveIrritative
8N Hexane 10 KL
10 KL-Storage
tank
AmbientLiquid Fire
9IPA 20 KL
10 KL-Storage
tank
AmbientLiquid Fire
10Liq. Ammonia 5 KL
0.5 KLHDPE
Carboys
AmbientLiquid
Toxic,Irritative
11 Meta Bromoanisole 5 KL
1 KLHDPEDrums
AmbientLiquid
Toxic,Irritative
Suitable PPEprovided,Separatestorage area forflammable andnon-flammablechemicalsStorage andhandlingprocedures asper MSDS,ProperhousekeepingpracticesProper loadingand unloadingpractices
Fire – Fireextinguishers,fire fightingteamToxic control –first-aid andmedical facilitiesOnsite and Off-site Emergencyplan PPE(respiratory aswell as non-respiratory)Spill control kits,and neutralizingmedia
Table 7.7 Other Hazards and their Control Measures
Sr.No.
Name ofpossibleHazards oremergency
Its sources & reasons Its effects onpersons,property andenvironment
Place ofEffect
Control measuresprovided
1 Fire due toNatural gas
Rupture of pipelinecarrying Natural gas fromthe gas station to theboilers
Damage toproperty andperson
Wholefactory
Pressure Relief valveprovided and inspectedregularly. Pipe fittingsand valves checked forleakages, corrosion etc.Fire extinguishersprovided at suitablelocations in the plant andboiler section
2 MechanicalHazards
Rotating Equipments viz.Agitator drives, pumps,centrifuges – accidentalentanglement of clothesor body touch, electricalshockHand Tools and portablepower tools – hit or fallon body part due to mis-operation or suddenstartup or manual error,electrical shock
Damage toperson
Productionarea
Guards are provided onall rotating equipment.The hand tools are keptat specified location sothat they are easilyavailable when required.Proper earthing isprovided to all electricalequipment and checkedregularly
Table 7.9 Details of Personal Protective Equipment
Type of Non-Respiratory PersonalProtective Equipment
To Protect Against -
PVC apron, Cotton Apron Heat and splashing of oil, grease, dust and corrosive chemicalsduring transfer or handling of corrosive Chemicals.
Dust mask Chemical dust while transferring powdered chemicals packedin bags.
Hand gloves (canvas, rubber) Heat and corrosive liquids like acids & alkalis.Safety goggles Liquid chemical splash and dustSafety shoes, Gum boots Contact with corrosive, hot chemicalsFace Shield Damage to face due to splashing of chemicals, hot liquids,
Spark and intense glare during welding, metal dust duringgrinding / cutting
Ear muffs/plugs - damage to hearing due to high noise in boiler, D.G rooms,mechanical work
Safety ShowersChemical splash over full body, clean-up of chemical tracesfrom clothes and body
7.15 VISUALIZATION OF ACCIDENT SCENARIOS
Based on the inventory, physical and chemical properties as well as the activities associated with storage
and handling of hazardous chemicals, the largest potential hazard inventories are considered. Different
release scenarios are visualized for these inventories and short-listed for carrying out the consequence
analysis.
One scenario considered for all is ‘Catastrophic Failure’, which is the worst case (WC) and frequency of
which is very rare in the lifetime of the plant.
Hence most credible accident scenarios (MCA) are also considered primarily leaks from tanks or vessels.
Normally all vessels or tanks have following connections
Inlet Pipe, Outlet Pipe, Level indication connections, Vent pipe, Minimum Flow line(If pump is at
outlet), Pressure indication connection
Leak in the vessel or leak from the flange joints of these connections is possible. The leak through flange
failure is considered from 50% of flange perimeter and accordingly equivalent area is calculated. This area
is approximated to hole of 50mm or 2” diameter. The small bore pipes less than 2” is considered full bore
Emergency equipment Stores (all respiratory/non respiratory PPE/Safetyequipments are stored here)
Medical aid First Aid facilities shall be available at admin blockFire and Toxicity control arrangement :Fire fighting system
Fire extinguishers
Pollution Control arrangement Incident and environment control arrangementinclude efficient control over water, soil/land and airpollution. Appropriate scrubber, exhaust, areinstalled as per requirement and kept ready forimmediate use.
Shutdown process Manual shut down instructions are being prepared
Plant surrounding Necessary information for approaching Authorities in
Villages/city, road approach, medical facility near by,fire service, police station and other aid etc isavailable.
7.17.4 Emergency Alarms & Equipment for Emergency ControlThe type of siren to be sounded major and minor emergencies are given in table below. This will take all
the personal that are present in the plant to become aware about the occurrence. The plant operation
personnel are required to vacate their work spots as early as possible and move to pre-designated safe
places called the assembly points.
CODED SIREN FOR EMERGENCY DECLARATION
NATURE OFEMERGENCY
SIREN CODE SYMBOL
Minor emergency(Fire)
Continuous for 30 seconds ∫∫∫∫∫
Major emergency(Fire or Pressure release)
Long siren followed by short sirenFor 60 seconds with break every 15seconds
All clear signal(When emergency iscontrolled)
Continues siren for 5 [Five] minutes
The control of emergency mainly involves combating the fire/explosion, toxic releases and arresting any
hazardous materials spillages/leakages using the various methods available for risk control as per the
emergency plan. The proper & safer method of handling these hazardous materials is given in MSDS. Also
the personal working in the affected zone should be evacuated and affected persons are to be given
immediate first aid/medical attention. The procedure developed by the unit for performing the above tasks
is dealt in the subsequent sections of this chapter.
7.17.8 Responsibilities Of Emergency Management PersonnelAs said earlier, without a well defined procedure often confusing arises leading to precious loss of
‘’Response Time’’ and loss to human lives, plant & property. Hence the responsibilities/duties of the
emergency management personnel are defined given in table below.
EMERGENCY MANAGEMENTEXECUTIVE/PERSONNEL
RESPONSIBILITY
01. Site main Controller Inform higher management.Inform adjacent industries if necessary.Get in touch with district authorities.Declare the nature of emergency if already has not beendone.Ensure proper coordination amongst variousfunctionaries.Take care of all activities regarding handling ofemergency situation.Give all clear signals when the emergency has beencontrolled.
02. Incident Controller(Shift-in-charge)
On hearing emergency, he will rush To the incident siteand take charge of the overall situation.Instruct for stoppage of the plant if necessaryDecide scale of emergency, direct all operations withinthe affected areas with the priority for safety ofpersonnel, and minimize damage to the plant, propertyand environment.Pending arrival of the site controller, direct shuttingdown plant and evacuation of personnel.Coordinate with fire and security officer and first aidpersonnel as and when they arrive at the incident site.Also designate and coordinate with communicationcontroller.
03. Essential workers(Plant supervisor/operator)
Initiate action to control emergencyEmergency situation to be reported to shift in-charge.It is a task force of trained workers for :Fire fighting, Gas leakage and spill controlHelp fire people and mutual aid teamsShutting down plant and making it safeEmergency engineering work viz. mechanical, electrical,instrumentation, cranes etc.Providing emergency power, water, lighting etc.
04 Telephone operator Maintain communication with incident controller/sitecontrollerInform personnel officerOn instruction from site/incident controller direct staff toact as runners if phone/communication fail.Maintain log of incident report.On instructions from site/incident controller inform allthe local fire brigade and other agencies as instructed.
05. Personnel officer Mobilize transport to meet the requirements ofemergency.Coordinate with police, press and media if required.Receive reports from assembly points and pass on theabsence information to the site controllerOrganize medical camp with adequate medical facultyEnsure adequate supply of medicines and first aidmaterialProvide hourly situation reports to the GM (works)office, indicating men, equipment and materials involvesat each area under the influence of emergency.
05. Personnel officer Arrange for hospitalization and treatment at outsidehospitals as required.Mobilize extra medical help from outside if necessaryInform the incident controller regarding the ambulanceleaving the site, name (s) of patients and destinations,(i.e.) hospitals or first aid centers.
06. Security officer Review emergency situation regarding fire andperiodically report to the site controllerOrganize the group to fight the emergency andcoordinate with them.Ensure equipment and material to extinguish the fireAdvice site controller to call up outside agencies, police,medical and fire bridges when needed and coordinatethem.Assess damages due to fire during and after emergency.Assist in evacuating personnel from the affected area.Cordon the affected zone and not to allow anybody inthe cordoned off area.
07. Safety officer Direct rescue operations in the affected areaEnsure preventive safety measures are initiated inneighboring areas, which are likely to be affected.Replace the used safety equipment like masks, breathingapparatus etc.Invalidate all safety permits in the affected andsurrounding areas.Ensure documentation of the accident information asper statutory requirement.
7.17.9 Standard Operating Procedure (Emergency)As soon as emergency alarm is heard, all essential workers shall report to IC or SMC.
The runner among the workers shall inform SMC / IC and key personnel if they are not at site.
IC shall reach the affected area and evaluate the type of emergency and inform DPMC accordingly.
IC or SMC.
According to the type of emergency / accident, IC or SMC shall instruct the essential workers to get
equipped with PPE / Fire fighting equipment and devices available at the unit to assist the emergency
control team of DPMC.
The messenger amongst the workers shall deliver messages to nearby units as per the instructions of SMC /
IC.
The in-charge of Medical arrangements shall prepare first-aid and other required facilities for the injured.
When DPMC team reaches the site, the other essential workers shall assist them in controlling the
emergency as per their instructions.
IC would keep SMC informed about the status of control measures being taken at the site and ask for other
requirements eg. Mutual aid, equipment etc. if he finds necessary.
SMC would co-ordinate with outside agencies regarding control measures being taken, need for external
help, evacuation, medical treatment, etc.
CHAIN OF COMMAND
08. Key perssonel(Managerial staff)
Ensure that all systems affected or likely to be affectedby the hazardous are safety isolated or shutdown.Coordinate the efforts of operating and maintenancepersonal to contain or arrest or the hazardous.Ensure that adequate safety equipments are availableand are property used.Coordinate with safety officer to ensure that all thepersonnel trapped in the effected area are brought outsafety.
Other outside agencies SMC Mutual aid teamsFire Brigade
7.17.19 Mitigation of Environmental Impact during emergencyIn order to minimize loss or damage to the environment as well as personnel, following instructions shall
be followed during an emergency and after an emergency has been controlled.
Fire
1. Immediately cutoff contact of fire with flammable material or prevent spread of fire by other means
2. Use water or suitable fire extinguisher to extinguish fire
3. Contain the contaminated water or any other liquid to prevent it going to soil or drain and divert it to
ETP storage tank. If required treat it before sending to ETP tank
4. Any solid waste generated should be collected, stored and send to BEIL.
Chemical Spillage
1. In case of Material coming out of the bottom valve due to valve leakage or failure, it shall be contained
in side the dyke wall and will be transferred to HDPE plastic drum by help of pump / piping.
2. The tank shall be emptied by pumping the material into spare tank using extra nozzle. In case of
flammable material, after the tank is emptied, it shall be vented at highest point to vapors. In case of
acids and alkalis, the tank shall be flushed completely with water. Repair or replacement work shall be
started only after confirming that the tank is not contaminated with the chemical.
3. Preventions of failure: Preventive maintenance of bottom value shall be carried out as per schedule. To
prevent any leakage from tank body, thickness checking shall be same as per schedule.