M/s. DIC FINE CHEMICALS PVT. LTD. - Environmental ...

M/s. DIC FINE CHEMICALS PVT. LTD. ENVIRONMENTAL IMPACT ASSESSMENT REPORT

Prepared By: Aqua-Air Environmental Engineers Pvt. Ltd., Surat 164

CHAPTER - 6

___________________________________________________________________________

RISK ASSESSMENT & DISASTER MANAGEMENT PLAN

In order to support the environment impact assessment and environment management

plan, following additional studies have been included in the report.

• Risk assessment

• Disaster Management Plan

• On site and off site emergency action plan

• Occupational Health and Safety Management System

6.1 RISK ASSESSMENT

6.1.1 INTRODUCTION

Hazard analysis involves the identification and quantification of the various hazards (unsafe

conditions). On the other hand, risk assessment deals with recognition and computation of

risks, the equipment in the plant and personnel are prone to, due to accidents resulting

from the hazards present in the plant. Risk assessment follows an extensive hazard analysis.

It involves the identification and assessment of risks the neighboring populations are

exposed to as a result of hazards present. This requires a thorough knowledge of failure

probability, credible accident scenario, vulnerability of population etc. Much of this

information is difficult to get or generate. Consequently, the risk assessment is often

confined to maximum credible accident studies. It provides basis for what should be type

and capacity of its on-site and off-site emergency plan also what types of safety measures

shall be required.

6.1.2 APPROACH TO THE STUDY

Risk involves the occurrence or potential occurrence of some accidents consisting of an

event or sequence of events. The risk assessment study covers the following:

• Identification of potential hazard area;

• Identification of representative failure cases;

• Visualization of the resulting scenarios in terms of fire and explosion;

• Assess the overall damage potential of the identified hazardous events and the

impact zones form the accidental scenarios;



• Furnish the recommendations on the minimization of the worst accident possibilities

• Preparation of Disaster Management Plan;

• Emergency Plan, which includes Occupational and Health Safety Plan;

6.1.3 METHODOLOGY

Quantitative risk assessment (QRA) is a means of making a systematic assessment of the

risks from hazardous activities, and forming a rational evaluation of their significance, in

order to provide input to a decision-making process. The term ‘quantitative risk assessment’

is widely used, but strictly this refers to the purely numerical assessment of risks without

any evaluation of their significance. The study has been conducted based on the premises of

a traditional Quantitative Risk Assessment. The key components of a QRA are explained

below, and illustrated in Figure-6.1 and Figure-6.2.

FIGURE – 6.1

QRA METHODOLOGY



FIGURE–6.2

FLOW CHART FOR QUANTITATIVE RISK ASSESSMENT

Start Identify Risk Areas

Select a Risk Area

Identify Failure Cases

Select a Failure Cases

Identify Consequence Outcomes

Select Consequence Outcomes

Determine Frequency

Estimate Consequence

Record Frequency and Consequence in a summary Table

Have all Consequence outcomes been studied?

Have all failure cases been studied?

Have all risk areas been studied?

Draw Risk Contours Finish

Yes

Next Next



FIGURE–6.3

EMERGENCY ORGANIZATIONAL CHART

Site controller

(GM - Operations)

Amit Upadhayay

Incident Controller

(Production Head & Engg. Head, etc.) Mihir Abhyankar & Ishvar Panchal

EHS Department - Ajay Pancholi - Akash Patel

Fire Fighting Squad (As per

Annex. E-I)

First aid Squad (As per

Annex. E-II)

P & A Dept.

Engineering Security Dept.

Shift In charge



6.1.4 HAZARD IDENTIFICATION

Identification of hazards in the proposed project activity is of primary significance of the

analysis, and quantification. Hazard states the characteristics of system/plant/process that

presents potential for an accident. All the components of a system/plant/process need to be

thoroughly examined to assess their potential for initiating or propagating an unplanned

event/sequence of events, which can be termed as an accident.

6.1.4.1 IDENTIFICATION OF HAZARDOUS AREAS

The procedure for QRA starts with identification of major risk areas in the installation.

Operation carried out in specialty and agrochemical Industries usually come under certain

board, general categories. At M/s. DIC Fine Chemicals Pvt. Ltd., major risk areas are as

follows:

• Bulk storage area for Raw Materials at ambient temperature and atmospheric

pressure.

• Process Plant involving pumping, transportation, reactors, distillation, heating, cooling,

etc.

• Bulk loading and unloading from storage tanks to road takers and vice versa.

6.1.4.2 IDENTIFICATION OF FAILURE CASES FOR HAZARDOUS AREAS

• Release due to catastrophic failure of storage tanks or process vessels.

• Rupture of connected pipe with storage tank or process vessels.

• Continuous release at significant rates for long durations transfer pipelines caused by

sudden, major break of the pipeline.

• Continuous release at low rate through small holes or cracks in piping and vessels, flange

leaks, and leakage from pump glands and similar seals.

It is to be noted that for Quantitative Risk Assessment, worst case scenarios has been

considered, though their frequency of occurrence is much lower than the cases of small

leaks.



6.1.4.3 MAJOR HAZARDOUS AREAS

The hazardous chemical storage area is shown in Figure-6.4. The major Hazardous chemicals

to be stored, transported, handled and utilized within the plot area are summarized in the

Table-6.1. Other hazards and control measures are summarized in Table-6.2. Facilities /

System for process safety, transportation, fire fighting system and emergency capabilities to

be adopted are stated below.

FIGURE-6.4

HAZARDOUS CHEMICAL STORAGE AREA

Antiskin Storage

Maleic Anhydride Storage

Para Formaldehyde Storage



TABLE-6.1

STORAGE AND HANDLING DETAILS OF HAZARDOUS CHEMICALS

Sr.

No. Consumption ( Year wise )

Control

Measure

Provided

Chemicals

(Raw Materials) State

Existin

g

After

Expansi

on

Total

Means

of

Storag

e

Capacity

of

Vessel/P

ack/

Barrel

( Kg)

No.

of

Vess

els

Storage

capacity

(Tonne)

Ink Manufacturing

1 Varnish Liquid 65-

70%

No

change

65-

70% Tanks 60000 9 540

Fire detection

with sprinklers

2

Pigment

(Black/Yellow/Red/Blue/Ex

tender)

Solid 20-

32%

No

change

20-

32% Bags

20/25/400

/

500/800

-- -- Fire detection

with sprinklers

3 Alkyd Resin Liquid 2-20% No

change 2-20% Tanks 60000 3 170

Fire detection

with sprinklers

4 Wax & Additives Paste 2-10% No

change 2-10% Drums 200 -- --

Fire detection

with sprinklers

5 Vegetable oil ester Liquid 2-5% No

change 2-5% Tanks 60000 7 420 Tank farm

6 Tonner Paste 1-10% No

change 1-10% Drum 200 -- -- Tank farm

7 Antiox Liquid 0.5-2% No

change 0.5-2% Tot 1100 -- -- Tank farm

8 Wetting agent Liquid 0.2-1% No

change 0.2-1% Tot 1000 -- -- Tank farm

9 Dryer Liquid 1-4.5% No

change 1-4.5% Drum 200 -- -- Tank farm

Varnish Manufacturing

1 Gum Rosin Solid 22-

35%

No

change

30-

35% Drums 200 -- --

Fire detection

with sprinklers

2 Vegetable oil (Soya/

Linseed/ Wood) Liquid

32-

38%

No

change

42-

58% Tank 60000 -- -- Tank farm

3 Vegetable oil ester Liquid 10-

22%

No

change

10-

22% Tank 60000 -- -- Tank farm

4 Mineral Oil Liquid 16% No

change 16% Tank 60000 -- -- Tank farm

5 Catalyst

(CaO/ZNO2/MgO Solid

0.01-

0.05%

No

change

0.01-

0.05% Bags 20 -- --

Fire detection

with sprinklers

6 PTBP Solid 5-10% No

change 5-10% Bag 25 -- --

Fire detection

with sprinklers

7 Maleic acid anhydride Solid 0.3-2% No

change 0.3-2% Bag 25 -- --

Fire detection

with sprinklers

8 Formaldehyde Solid 2-5% No

change 2-5% Bag 25 -- --

Fire detection

with sprinklers

9 Pentaerytheritol Solid 2-5% No

change 2-5% Bag 25 -- --

Fire detection

with sprinklers

10 Antiox Solid 0.07-

0.21%

No

change

0.07-

0.21 Bag 15 -- --

Fire detection

with sprinklers

11 Resin Solid 2-35% No

change 2-3% Bag 25 -- --

Fire detection

with sprinklers



Additive Manufacturing (wax)

1 Vegetable oil (Soya/

Linseed) Liquid NA 60-70%

60-

70% Tank -- -- -- Tank Farm

2 Wax Solid NA 28-40% 28-

40% Bags -- -- --

Fire detection

with sprinklers

3 Antiox Liquid NA 0-1% 0-1% Drums -- -- -- Fire detection

with sprinklers



TABLE 6.2

OTHER HAZARDS AND CONTROL

SR.

NO.

NAME OF THE POSSIBLE

HAZARD OR

EMERGENCY

ITS SOURCES

&

REASONS

ITS EFFECTS ON

PERSONS, PROPERTY

& ENVIRONMENT

PLACE OF ITS

EFFECT

CONTROL MEASURES PROVIDED

1 BOILER

(1) Burning

(2) Physical injury

(3) Explosion

Over pressure in the boiler if

safety valve not working.

Water level indicator not

working. Low water level

indicator fail. High temp.

System fails.

Minor/Major Injury

Loss of human life

Loss of property (Loss

of Main/ Machine

Material)

Boiler House and

surrounding places

Lower & Upper Level Indication System provision. Safety valves

for pressure control fixed temp. & pressure indicator provided.

Blow down & blowing system provided for cleaning tube and

shell. Soft water used. Inter locking provided on pumps, FD fan, ID

fan. Periodical checking & inspection maintenance done. Yearly

inspection done by Boiler Inspector

2 ELECTRICITY

(1) Burning

(2) Fire

(3) Shock

Loose Contacts, Weak

earthling Short Circuit

Improper Insulation

Burning, Shock,

Death

Surrounding the

accident area

Proper Earthing, Periodical Checking of joints, proper insulations

of Equipments, etc. Flame proof fitting in solvent storage area,

bounding and jumpers to all solvent barrier lines provided.

3 HOUSE KEEPING

(1) Physical

(2) Burning

(3) Fire

(4) Chemical Exposure

Bad House keeping Physical / Chemical

Thermal Burn Injury

(Major / Minor)

In all surrounding

areas i.e. Storage,

Plants

Proper Handling, regular cleaning, Proper placement of material

(RIGHT THING AT THE RIGHT PLACE)

4 PIPE LINE LEAKAGES

Spillages etc.

(1) Corrosion

(2) Toxic gas release

Leaking of pipe line due to

corrosion, Loose contact etc.

Physical / Chemical

Thermal Burn Injury

(Major / Minor)

Plant area Proper maintenance, Proper Selection of Material for pipe lines,

Immediate attention, Earthing provided, flame proof fitting, NO

SMOKING Boards displayed.

5 Structural Failure Inside the factory (Corrosion) Injury/Death to

persons, damage to

property

Within the factory Automatic operation Periodic Testing of safety valves Regular

Inspection and Maintenance

6 Toxic Release from

outside

Outside the factory Injury/Death Within & outside

the unit

Alarm, Evacuation rescue & shelter/ Welfare

7 Natural Calamity Nature Injury / Death to

persons, damage to

property

Within & outside

the unit

Alarm, Evacuation rescue & shelter/ Welfare



TABLE 6.3

HAZARDOUS PROPERTIES OF THE CHEMICALS, COMPATIBILITIES, SPECIAL HAZARD

Liquid Material Flammability Characteristics (Lab Scale – In very small quantities i.e. 2.5 Lit and stored in Flame Proof Storage Cabinets)

S. No. Chemical Appearance Flash Point (°C) Boiling Point (°C) Specific Gravity Vapor Density LEL (%) UEL (%) AIT(°C)

1.

Acetone

Appearance: Liquid.

Color: Colorless.

Clear

Closed Cup: -20°C

Open Cup: -9°C

(Cleveland)

56.2°C

0.79 (Water = 1)

2 (Air = 1)

2.6%

12.8%

465°C

2.

Diesel Oil/HSD

Physical State:

Liquid. Appearance:

Yellowish Brown

32 °C

215 - 376. °C

0.86 - 0.90 At 20

°C

Not Available

0.6%

6%

225 °C

3.

Ethyl Ether

Appearance:

Liquid. (Volatile,

Mobile Liquid )

Color: Clear

Colorless.

-45°C

34.6°C

0.7134 (Water = 1)

2.56 (Air = 1)

1.9%

36%

180°C

4.

Ethanol

Appearance: Liquid.)

Color: Clear

Colorless.

16.6°C

78°C

0.790 At 20°C

1.59

3.3%

19%

363 °C

5.

Hydrazine

Appearance: Liquid.

Color: Not

Available.

Closed Cup:

37.78°C

113.5°C

1 (Water = 1)

1.1 (Air = 1)

2.9%

98%

-




6.

Potassium Hydroxide

Solutions In Ethanol

Appearance: Liquid.)

Color: Clear Colorless

Or Orange.

18°C

78°C

0.8 – 0.9

-

4%

19%

370°C

7.

Methyl Alcohol

Appearance: Liquid.

Color:

Colorless.

Closed Cup: 12°C

(53.6°F). Open

Cup: 16°C (60.8°F).

64.5°C

0.7915 (Water = 1)

1.11 (Air = 1)

6%

36.5%

464°C

8.

Gasoline/Petrol

Physical State: Liquid

Appearance: Orange,

Red

-38 To -42 °C

(Closed Cup)

30 To 215 °C

0.75-0.85 At

20 °C

3-4

1.4%

7.6%

456°C

9.

N-Heptane

Appearance:

Liquid.

Color: Clear

Colorless.

Closed Cup: -4°C

(24.8°F). (Tag)

Open Cup: -

1.1111°C (30°F).

98.4

0.6838

3.5

1.05%

6.7%

203.89°C -223

°C

10.

Phenolphthalein

Appearance: Liquid.

Color: Colorless.

Closed Cup:

12.78°C (55°F).

Open Cup: 12.78°C

78.5°C

0.8

1.59

3.3%

19%

363°C

11. Thinner Appearance: Liquid.

Color: Colorless. -4.°F - 48.°F 133.°F - 232.°F 0.829 Heavier Than Air 1.4% 12.8%

-

12.

Toluene Appearance: Liquid.

Color: Colorless.

7°C

232.°F

0.9

3.1

1.2%

7.1%

422°C

13.

Xylene

Appearance: Liquid.

Color: Colorless.

21 – 27 °C

135 - 155 °C

0.870 Kg/Dm3 At

15°C

3.7

1%

7.1 %

432 - 530 °C




14.

Natural gas

Appearance:

Gas.

Color: Colorless.

Not Available

–161.5ºC

Not applicable

0.53 - 0.7

4%

16.0%

593 ºC

Powder Material Flammability Characteristics

S. No.

Chemical (Pigments)

Minimum Ignition

Energy (mJ)

LEL (%)

AIT (oC)

Pmax (bar)

Kst (bar m/sec)

1.

RED 3164-009

30<MIE<100

60<MIE<70

430

8.3+/- 10%

178+/- 10%

2.

Yellow 1128-D621

1<MIE<3

40<MIE<50

460

8.6+/- 10%

269+/- 10%

3.

SP-004 and SP-005 Cyan

1000

125

350

6.7

77

4.

Black

10000

-

-

-

-



List of Some Hazardous Chemicals & Actions

S.

No

Name of Raw

Material

Hazard

Class

Flash

Point

°C

Melting

Point

°C

Reactivity

Data

Compatibility

Data First Aid

MSDS

AVAILABLE

Precautions

during Handling

1 Butyladed Hydro

toluene (BHT) 118.3 70

Stable,

instable in

excess heat

May react with

oxidizing agent

Skin Contact:

Immediately remove the

contaminated clothing

and flush with plenty of

water. Seek medical

attention

Eye Contact: Immediately

flush with plenty of water

and get medical

attention.

Inhalation: Remove to

fresh air. If not breathing

give artificial respiration.

Seek medical attention

yes

Wear Safety

goggles,

Protective

clothing, Dust

mask, Gloves,

Safety Shoes

2 Calcium Oxide 8 N.A 2572 Stable, Reacts

with water

Reactive with

organic materials,

acids, moisture

Skin Contact:




water. Seek medical

attention



and get medical

attention.





yes

Wear Safety

goggles,

Protective

clothing, Dust

mask, Gloves,

Safety Shoes



S.

No

Name of Raw

Material

Hazard

Class

Flash

Point

°C

Melting

Point

°C

Reactivity

Data

Compatibility

Data First Aid

MSDS

AVAILABLE

Precautions

during Handling

3 Gum Rosin 187 70 - 78 Stable Reactive with

oxidizing agent

Skin Contact:




water. Seek medical

attention



and get medical

attention.





yes

Wear Safety

goggles,

Protective

clothing, Dust

mask, Gloves,

Safety Shoes

4 Magnesium Oxide 2800

Stable,

Hygroscopic,

Air sensitive

Reactive with

oxidizing agent,

acids

Skin Contact:




water. Seek medical

attention



and get medical

attention.





yes

Wear Safety

goggles,

Protective

clothing, Dust

mask, Gloves,

Safety Shoes



S.

No

Name of Raw

Material

Hazard

Class

Flash

Point

°C

Melting

Point

°C

Reactivity

Data

Compatibility

Data First Aid

MSDS

AVAILABLE

Precautions

during Handling

5 Maleic Acid

Anhydrous 103.33 52.8

Stable, May

decompose

on exposure

to moist air

or water

Reactive with

oxidizing agent,

acids, metals,

reducing agent

Skin Contact:




water. Seek medical

attention



and get medical

attention.





yes

Wear Safety

goggles,

Protective

clothing, Dust

mask, Gloves,

Safety Shoes

6 Para Formaldehyde

92 % & 96 % 4.1 70 120 - 170 Stable

Reactive with

oxidizing agent,

acids, metals,

reducing agent

Skin Contact:




water. Seek medical

attention



and get medical

attention.





yes

Wear Safety

goggles,

Protective

clothing, Dust

mask, Gloves,

Safety Shoes



S.

No

Name of Raw

Material

Hazard

Class

Flash

Point

°C

Melting

Point

°C

Reactivity

Data

Compatibility

Data First Aid

MSDS

AVAILABLE

Precautions

during Handling

7 Para Tertiary Butyl

Phenol (PTBP) 9 118 99

Avoid

ignitious

source

May react with

strong oxidizing

agent

Skin Contact:




water. Seek medical

attention



and get medical

attention.





yes

Wear Safety

goggles,

Protective

clothing, Dust

mask, Gloves,

Safety Shoes

8 Pentaerythritol 96

%

N.A 260 Stable Not Available

Skin Contact:




water. Seek medical

attention



and get medical

attention.





yes

Wear Safety

goggles,

Protective

clothing, Dust

mask, Gloves,

Safety Shoes



S.

No

Name of Raw

Material

Hazard

Class

Flash

Point

°C

Melting

Point

°C

Reactivity

Data

Compatibility

Data First Aid

MSDS

AVAILABLE

Precautions

during Handling

9

Pigment:

Black

Blue

Red

Yellow

80 -120 70 - 90

Skin Contact:




water. Seek medical

attention



and get medical

attention.





yes

Wear Safety

goggles,

Protective

clothing, Dust

mask, Gloves,

Safety Shoes



Scenario based Emergency Actions

Based on the reactions involved during the production process and the raw material involved the possible hazards are identified. The action for the emergency situation is

given.

Emergency Situations can cause Occupational Health hazards and Handling Procedure (ESHP)

S. No Name of process

/equipment Type of emergency

Possible Cause for

emergency

Effect of emergency on

process Action after emergency Responsibility

Stoppage of all utility and

agitation of the reactor

Utility dept for giving service

in less time

1.Electric Stoppage Electric main supply cut off Pressure can increase over

specified limit

Keep the pressure lower

than specified limit of 0.35

Mpa if pressure is increasing

above the limit, depressurize

through packed column by

opening manual valve

carefully

Leader/Operator who are

available on place.

1. Motor problem cool the reaction mass by

operating cooling system

2.Seal problem

If not controlled the foam,

slowly depressurize through

manually valve to reduce

pressure 2. Stop of agitation

3.Breakdown in assembly

Foaming in reactor

Try to keep pressure 0.35

Mpa

Operator

3.Stopage of cooling system

Electric main supply cut off

/Breakdown ,leakage in

system

Over pressure

/uncontrolled pressure

,Electrical cut off.

Try to keep the pressure

below 0.35 Mpa and get

electricity on regular with in

less time

Operator

1 Pressurized

reaction process

4. Leakage from agitator

axial seal Miss alignment

Fuming /smell of

formaldehyde as pungent

smell and eye irritation

Put on Air /Gas Mask Operator

M/s. DIC FINE CHEMICALS PVT. LTD. ENVIRONMENT IMPACT ASSESSMENT REPORT


PRECAUTIONS DURING STORAGE AND TRANSPORTATION OF HAZARDOUS CHEMICALS

LIQUIDS

• Always use the road tankers having authorization for transporting the said liquids.

• Vendor will be asked to provide MSDS to Tanker Driver.

• Tankers will have clearly marked identification of material being contained with mentioning

Safety Card.

• Driver to have concerned Safety Officer’s contact details to contact him in case of

emergency.

• Provide muffler on exhaust while entering tanker within premises.

• Ensure Earthing Boss connection before starting any transferring.

• SOP to cover routine checking of Tank farm area to be carried out for checking any spillage /

leakage.

• Tanks will be inspected physically daily for having any visual abnormality.

• Readings of Temperature & Pressure will be noted, recorded & reported immediately for

abnormality.

• Safety instruments like rupture disc, safety valves will be checked at defined duration for

intakeness.

• Scheduled testing of tanks to be done for thickness testing.

• Tanks to be painted on regular interval defined as per laws to protect them from

atmospheric corrosion.

• Barrels to be checked for proper fixing of bungs before sending it outside the premises.

• Barrels to be monitored physically daily for developing any pressure or vacuum within it on

long storage.

• Concerned persons will be trained properly to use spill kit in case of observing any spillage

inside warehouse.

SOLIDS

• Vendor will be asked to provide MSDS to Truck Driver.



• Driver to have concerned Safety Officer’s contact details to contact him in case of

emergency.

• Provide muffler on exhaust while entering truck within premises.

• SOP to cover routine checking of Bags & Containers for checking any damage.

• Containers to be tested for safe racking & transportation.

• Proper PPE to be used while handling the material & concerned persons to be trained for

usage of the same.

• Concerned persons will be trained properly to use spill kit in case of observing any spillage

inside warehouse.

The major hazards in the M/s. DIC Fine Chemicals Pvt. Ltd. are described below.

• Toxic/Corrosive hazards due to leakage of hazardous chemicals from storage tank or

carboys.

• Electrical hazards due to the electrical major equipment/ machinery, operations, welding,

motors, and heavy lift devices, cabling, human intervention (short circuit possibility),

maintenance work (due to machinery breakdown etc.), plant lighting related electrical

hazards.

• Possibility of human injury due to working with mechanical machines, manual handling etc.

• Possibility of injury during chemicals handled, during operations and due to intoxication.

• Major dropped objects hazard due to large number of physical handling steps / operations

involved with overhead lifting/ hoisting equipment.

• Fires in any part of the plant working areas – there is a possibility of rapid escalation if it is

not brought under control quickly.

• Possibilities of fire hazards at transformers, switchgear and other electrical equipment etc.



6.1.4.4 TRANSPORTATION, UNLOADING AND HANDLING PROCEDURE FOR HAZARDOUS

CHEMICALS

Transportation, Unloading and Handling Procedure

SR.

NO.

ACTIVITY TYPE OF POSSIBLE

HAZARD

MITIGATION MEASURES

Leakage& Spillage

• Check the source of leakage point.

• Do not touch damaged containers or spilled material

unless wearing appropriate protective clothing.

• Stop leak if you can do it without risk.

Fire,& explosion • Use water spray to reduce vapors; do not put water

directly on leak, spill area or inside container.

• Keep combustibles (wood, paper, oil, etc.) away from

spilled material.

1 Transportation of Solvents by

road tanker

Toxic release • Isolate the area

• Isolate the container

• Training will be provided to driver and cleaner

regarding the safe driving, hazard of Flammable

chemicals, emergency handling.

• TREM card will kept with TL.

• Fire extinguishers will be kept with TL.

• Flame arrestor will be provided to TL exhaust.

• Instructions will be given not to stop road tanker in

populated area.

• Clear Hazard Identification symbol and emergency

telephone number will be displayed as per HAZCHEM

CODE.

• Appropriate PPEs will be kept with TL.

2 Road tanker unloading at

project site.

Leakage& Spillage





Fire,& explosion • Use water spray to reduce vapors; do not put water



spilled material.

Toxic release • Isolate the area



• Isolate the area


• Spray the water on leakage

• Priority will be given to Tanker to immediately enter the

storage premises at site and will not be kept waiting

near the gate or the main road.

• Security person will check License, TREM CARD, Fire

extinguisher condition; required PPEs as per SOP laid

down.

• Store officer will take sample as per sampling SOP from

sampling point.



• After approval of QC department unloading procedure

will be allowed be started.

Following precautions will be adopted during unloading

• Wheel stopper will be provided to TL at unloading

platform.

• Static earthing will be provided to road tanker.

• Tanker unloading procedure will be followed according

to check list and implemented.

• Flexible SS hose connection will be done at TL outlet

line.

• The quantity remaining in the hose pipeline will be

drained to a small underground storage tank, which will

be subsequently transferred by nitrogen pressure to the

main storage tank thus ensuring complete closed

conditions for transfer from road tanker.

• All TL valves will be closed in TL.

• Finally earthing connection and wheel stopper will be

removed.

• Only day time unloading will be permitted.

Leakage& Spillage • Check the source of leakage point.




Fire, Explosion • Use water spray to reduce vapors; do not put water



spilled material.

3 Storage tank safety

Toxic release. • Isolate the area



• Isolate the area


• Spray the water on leakage

• storage tank will be provided as per IS code.

• Dyke wall will be provided to storage tank.

• Level transmitter will be provided with low level high

level auto cut-off provision.

• Flame arrester and breather valve will be provided to

vent line.

• Fire hydrant monitor with foam attachment facility will

be provided.

• FLP type pump will be provided.

• Nitrogen blanketing will be provided to storage tank.

• Double static earthing will be provided to storage tank.

• Double Jumper clip will be provided to all Solvent

handling pipeline flanges.

4 Solvent transfer from storage

tank to Day tank

Leakage& Spillage due to

Line rupture, Flange

Gasket failure, Fire,

Explosion, Toxic release.

• Double mechanical seal type FLP type pump will be

provided.

• Double on / off switch will provided at tank farm and

process area near day tank. Pump auto cut off with day



tank high level will be provided.

• Flame arrestor will be provided on day tank vent.

• Over flow will be provided for additional safety and it

will be connected to main storage tank.

• NRV will be provided on pump discharge line.

• Double Jumper clip will be provided to all solvent

handling pipeline.

• Double static earthing will be provided to day tank.

5 Solvent transfer from Day

tank to reactor.

Leakage, Spillage due to

Line rupture, Flange

Gasket failure, Fire,

Explosion, Toxic release.

• Gravity transfer.

• Total quantity of day tank material will be charged in to

reactor at a time.

• Static earthing will be provided to storage tank.

• Double Jumpers will be provided to pipeline flanges.

6.1.5 CONSEQUENCE ANALYSIS

In a plant handling hazardous chemicals, the main hazard arises due to storage, handling & use

of these chemicals. If these chemicals are released into the atmosphere, they may cause

damage due to resulting fires or vapour clouds. Blast Overpressures depend upon the reactivity

class of material between two explosive limits.

Operating Parameters

Potential vapour release for the same material depends significantly on the operating

conditions. Especially for any liquefied gas, the operating conditions are very critical to assess

the damage potential. If we take up an example of ammonia, if it is stored at ambient

temperature, say 30oC, and then the vapour release potential of the inventory is much higher as

compared to the case if it is stored at 0oC.

Inventory

Inventory Analysis is commonly used in understanding the relative hazards and short listing of

release scenarios. Inventory plays an important role in regard to the potential hazard. Larger

the inventory of a vessel or a system, larger the quantity of potential release. The potential

vapour release (source strength) depends upon the quantity of liquid release, the properties of

the materials and the operating conditions (pressure, temperature). If all these influencing

parameters are combined into a matrix and vapour source strength estimated for each release

case, a ranking should become a credible exercise.



Loss of Containment

Plant inventory can get discharged to Environment due to Loss of Containment. Certain

features of materials to be handled at the plant need to the clearly understood to firstly list out

all significant release cases and then to short list release scenarios for a detailed examination.

Liquid release can be either instantaneous or continuous. Failure of a vessel leading to an

instantaneous outflow assumes the sudden appearance of such a major crack that practically all

of the contents above the crack shall be released in a very short time. The more likely event is

the case of liquid release from a hole in a pipe connected to the vessel. The flow rate is

depending on the size of the hole as well as on the pressure, which was present, in front of the

hole, prior to the accident. Such pressure is basically dependent on the pressure in the vessel.

The vaporisation of released liquid depends on the vapour pressure and weather conditions.

Such consideration and others have been kept in mind both during the initial listing as well as

during the short listing procedure. In the study, Maximum Credible Loss accident methodology

is to be used, therefore, the largest potential hazard inventories have been considered for

consequence estimation.

6.1.5.1 DAMAGE CRITERIA

Hazard Identification and Consequence Analysis

Background

Key issues in Risk Assessment (RA) of the Ink Plant Manufacturing Unit (M/s DIC Fine Chemicals

Pvt. Ltd.,) i.e. Category 5 (f) of the Schedule to the EIA Notification dated Sept. 14, 2006

(amended till date), for proposed regularize / Amendment of existing EC by addition of Wax &

Additives. The risk assessment process is intended to identify existing and probable hazards in

the work environment and all operations, to quantify the hazards and to assess the risk levels of

those hazards in order to prioritize those that need an immediate attention.

In the unlikely event that an abnormal consequence has occurred, the disaster management

kicks in. This includes prescribing the procedures pertaining to a number of issues such as



communication, encounter, rescue, rehabilitation and further steps to prevent recurrence of

such consequence in future. These issues are addressed in the disaster management plan.

Both, the RA and DMP are living documents and need to be updated whenever there are

changes in operations, equipment or procedures.

Key Definitions

The terminologies used in this Risk Assessment (RA) study are defined below.

Consequence: Magnitude or size of the damage or loss. In terms of health and safety, it is the

degree of harm that could be caused to the people exposed to hazard, the potential severity of

injuries or ill health, and/or the number of people who could be potentially affected.

Consequence of hazard need not only be in terms of human safety criteria, but could also be in

terms of a financial loss due to production and incurred costs due to repairs/replacement,

environmental impacts as well as public outrage.

Disaster: A catastrophic consequence of a major emergency/accident that leads to not only

extensive damage to life and property, but also disrupts all normal human activity for a

significant period of time and requires a major national and/or international effort for rescue

and rehabilitation of those affected.

Emergency: A situation of process deviation that, if uncontrolled, may lead to a major

accident/disaster with potential short term and/or long term risk damage consequence to life

and property in and/or around the workplace.

Emergency Response Planning Guidelines 1 (ERPG 1): 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 odour.


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.




below which it is believed nearly all individuals could be exposed for up to 1 hour without

experiencing or developing life-threatening health effects.

Hazard: Source of potential harm, injury or loss to man and machines.

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 (e.g. severe irritation) or

irreversible health effects.

Lethal Concentration Low (LCLo): It is the lowest concentration of a material in air, other that

LC50, which has been reported to cause death in human or animals.

Risk: Combination of the likelihood of a specific unwanted event and the potential

consequences, if it occurs.

Risk Assessment: A process that involves estimation and measurement of risk to determine

priorities and to enable identification of appropriate level of risk treatment (used also to

describe the overall process of risk management).

Risk Control: Implementation of strategies to prevent, control and minimize hazards.

Risk Management: Overall description of the steps taken to manage risk, by identifying hazards

and implementing controls in the workplace.

Risk Rating: The category, level, or risk assigned following risk assessment (e.g. High, Medium,

or Low).

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.

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 an toxic

effects in humans or produced carcinogenic, neoplastigenic or tetratogenic effect in humans or

animals.



Methodology for Risk 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 (Vapour Cloud Explosions) resulting in blast waves (overpressure).

The scope of work includes site inspection, hazard identification, selection of potential loss

scenarios, and simulation of release source model on DNV’s PHAST Professional 6.54,

consequence analysis and plotting of Damage contour on site map in order to take strategic

decision to mitigate/minimize the level of risk to the facility and to the community. The steps

undertaken to carry out Risk Assessment for the proposed increased capacity are described in

subsequent sections.

MCLS 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 Loss Scenarios

(MCLS).

Basis for Selecting the Material to be studied for Consequence Assessment Following points are

considered while selecting the release scenarios:

• Flammability and the flash point of the material

• Phase of the material i.e. liquid or gas

• Threshold quantity of the chemical as prescribed in MSHIC Rule

• Operating Temperature and Pressure of the material

• Total inventory of the material

MCLS’ Selected from Vessel Source

MCLS’ selected are based on the types of failures discussed in publication World Bank Technical

Paper 55, and TNO purple Book.



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 pipe work 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 MCLS’. The failure rates for selected MCLS’ are given in below

table:

Failure Frequencies for Storage Tanks

Categories

Catastrophic Rupture

Frequency

(per tank per year)

Leak Frequency (per year)

Atmospheric Storage

Tank 3.0 × 10-6 2.8× 10-3

1.2 × 10-5 (for Hole Size 3 to 10 mm) Pressure Vessels 4.7 × 10-7

7.1 × 10-6 (for Hole Size 10 to 50 mm)

Reference: International Association of Oil & Gas Producers (OGP); Report No. 434-3, March

2010

Failure Frequencies for Pipe work

Failure Rates (per meter per year) for Pipe work diameter (mm) Leak Size

0 - 49 50 - 149 150 - 299 300 - 499 500 - 1000

3 mm dia 1 ×10-5 2 ×10-6

4 mm dia 1 ×10-6 8 ×10-7 7 ×10-7

25 mm dia 5 ×10-6 1 ×10-6 7 ×10-7 5 ×10-7 4 ×10-7

1/3 Pipe work

dia 4 ×10-7 2 ×10-7 1 ×10-7

Guillotine /

Full Bore

Rupture

1 ×10-6 5 ×10-7 2 ×10-7 7 ×10-8 4 ×10-8

Reference: Health & Safety Executive, UK

Hazardous Event Classification

Hazards that can lead to accidents in operations due to MCLS’ are discussed in this section.

Important hazardous events are classified as follows:

Event Classification

Type of Event Explanation

BLEVE

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



Type of Event Explanation

Deflagration Is the same as detonation but with reaction occurring at less than sonic

velocity and initiation of the reaction at lower energy levels

Detonation

A propagating chemical reaction of a substance in which the reaction front

advances in the un-reacted substance at or greater than sonic velocity in

the unreacted material

Explosion A release of large amount of energy that form a blast wave

Fire Fire

Fireball

The burning of a flammable gas cloud on being immediately ignited at the

edge before forming a flammable/explosive mixture.

Flash Fire A flammable gas release gets ignited at the farthest edge resulting in flash-

back fire

Jet 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

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

Spill Release

‘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

Structural Damage Breakage or fatigue failures (mostly failures caused by weather but not

necessarily) of structural support and direct structural failures

Vapor Cloud

Explosion

Explosion resulting from vapor clouds formed from flashing liquids or non-

flashing liquids and gases

Consequences of Hazardous Event due to Release of Material into Environment

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:



Damage due to Radiation Intensity

Radiation

(kW/m2)

Damage to Equipment Damage to People

1.2 Solar heat at noon

1.6 - Minimum level of pain threshold

2.0 PVC insulated cable

damage

4.0 - Causes pain if duration is longer than 20 sec.

But blistering is unlikely.

6.4 - Pain threshold reached after 8 sec. Second

degree burns after 20 sec.

12.5

Minimum energy to ignite

wood with a flame; melts

plastic tubing.

1% lethality in one minute. First degree burns

in 10 sec.

16.0 - Severe burns after 5 sec.

25.0

Minimum energy to ignite

wood at identifying long

exposure without a flame.

100% lethality in 1 min. Significant injury in 10

sec.

37.5 Severe damage to plant

100% lethality in 1 min.

50% lethality in 20 sec.

1% lethality in 10 sec.

Consequences of Overpressure

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).

Direct injury to people occurs at pressures of 5-10 (5E-5 to E-4) kPa (with loss of life generally

occurring at a greater over-pressure), whereas dwellings are demolished and windows and

doors broken at pressures of as low as 3-10 kPa. The pressure of the shock wave decreases

rapidly with the increase in distance from the source of the explosion.

Overpressure Damage

Overpressure

(bar) Damage

0.001

0.002

0.003

Annoying noise (137 dB if of low frequency 10-15 Hz)

Loud noise (143 dB, sonic boom glass failure

Occasional breaking of large glass windows already under strain

0.007 Breakage of small windows under strain



Overpressure

(bar) Damage

0.010

0.020

Typical pressure for glass breakage

projectile limit; some damage to house ceilings; 10% window glass

broken

0.027 Limited minor structural damage

0.034

0.034 to 0.068

Large and small windows usually shattered; occasional damage to

window frames

0.048

0.068

0.068 to 0.136

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

0.088

0.136

0.136 to 0.204

Steel frame of clad building slightly distorted

Partial collapse of walls and roofs of houses

Concrete of cinder brick walls, not reinforced, shattered

0.157 Lower limit of serious structural damage

0.170

0.204

0.204 to 0.272

50% 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

0.272

0.340

Cladding of light industrial buildings ruptured

Wooden utility poles snapped; tall hydraulic press (40,000 lb) in building

slightly damaged

0.340 to 0.476

0.476

Nearly complete destruction of houses

Loaded train wagons overturned

0.476 to 0.544

0.612

0.680

20.414

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. 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. These effects are:

• Irritation (respiratory system skin, eyes)

• Narcosis (nervous system)

• Asphyxiation (oxygen deficiency)

• System damage (blood organs)

Wind Direction at Site

Predominant wind direction of the study area is shown as follows:

Predominant Wind Direction

1st

Predominant 2nd

Predominant 3rd

Predominant

Time Direction

Percent No.

of days in a

year

Direction

Percent No.

of days in a

year

Direction

Percent No.

of days in a

year

Day Time SW 40 NE 19 SE 11

Night

Time SW 45 NE 19 NW 13

6.1.5.2 MAXIMUM CREDIBLE LOSS ACCIDENT SCENARIOS

A Maximum Credible Accident (MCA) can be characterised as the worst credible accident. In

other words: an accident in an activity, resulting in the maximum consequence distance that is

still believed to be possible. A MCA-analysis does not include a quantification of the probability

of occurrence of the accident. Another aspect, in which the pessimistic approach of MCA

studies appears, is the atmospheric condition that is used for dispersion calculations. As per the

reference of the study, weather conditions having an average wind speed of 1.40 m/s have

been chosen.

The Maximum Credible Loss (MCL) scenarios have been developed for the Facility. The MCL

cases considered, attempt to include the worst “Credible” incidents- what constitutes a credible

incident is always subjective. Nevertheless, guidelines have evolved over the years and based

on basic engineering judgement, the cases have been found to be credible and modelling for



assessing vulnerability zones is prepared accordingly. Only catastrophic cases have been

considered and not partial or small failures (as is the case in Quantitative Risk Assessment

where contributions from low frequency - high outcome effect as well as high frequency - low

outcome events are distinguished). The objective of the study is emergency planning, hence

only holistic & conservative assumptions are used for obvious reasons. Hence though the

outcomes may look pessimistic, the planning for emergency concept should be borne in mind

whilst interpreting the results.

6.1.5.2.1 CONSEQUENCE ANALYSIS CALCULATIONS

The Consequence Analysis has been done for selected scenarios. This has been done for

weather conditions having wind speed 1.40 m/s. In Consequence Analysis, geographical

location of the source of potential release plays an important role. Consideration of a large

number of scenarios in the same geographical location serves little purpose if the dominant

scenario has been identified and duly considered.

6.1.5.2.2 SOFTWARE USED FOR CALCULATIONS

PHAST MICRO: Phast is the most comprehensive software available for performing Process

Hazard Analysis (PHA), Quantitative Risk Assessment (QRA) and Financial Risk Analysis (FRA).

Our extensively validated software for consequence and risk assessment is used by

governments and industry helping them to comply with local safety regulation and their own

corporate best practice. Phast contains all the discharge, dispersion, effects and risk models you

will need to accurately assess all your major hazards and associated risks. Phast Consequence

provides you with comprehensive hazard analysis facilities to examine the progress of a

potential incident from the initial release to its far-field effects.

TOXIC AND FLAMMABLE IMPACT

It calculates the initial discharge, as the material expands from its storage conditions to

atmospheric, through dispersion, as the material mixes with air and dilutes, and the



subsequent toxic or flammable effects. Phast includes a wide range of models for discharge

and dispersion as well as flammable, explosive and toxic effects.

DISCHARGE

• Phast requires basic information about storage or process conditions and material

properties in order to perform discharge calculations

• The software comes with an integrated material property database containing more

than 1,600 pre-defined pure component chemicals

• Various discharge scenario options have been implemented to represent common

process failures, and model their behaviour. These include:

� Leaks and line ruptures from long & short pipelines

� Catastrophic ruptures

� Relief valve and disc ruptures

� Tank roof collapse

� Vent from vapour spaces

� In building release effects

DISPERSION

The dispersion models within Phast are able to model the following phenomena

• Dispersion of gas, liquid and two-phase releases

• Liquid droplet thermo dynamics calculations and liquid droplet rainout

• Pool spreading and vaporization

• Building wake dispersion effects for vapour releases

FLAMMABLE EFFECTS

For releases of flammable material Phast calculates

• Radiation profiles and contours from a range of fire scenarios including pool fires, flash

fires, jet fires and fire balls, including cross-wind effects on a jet fire



• Vapour Cloud Explosion modeling using industry standards models including the TNO

Multi-energy, Baker Strehlow Tang and TNT Equivalence models

• Overpressure contours from Boiling Liquid Expanding Vapour Explosions

TOXIC EFFECTS

• Graphs of toxic concentration profile

• Indoor and outdoor toxic dose prediction

• Reporting of distance to specific dose and concentration

• Calculated exposure time and use as “averaging time” for passive dispersion effects

PHAST RISK

Phast Risk allows you to combine the flammable and toxic consequences from each scenario in

your QRA model with their likelihood to quantify the risk of fatalities. Phast Risk allows you to

take account of local population distribution, sources of ignition, land usage and local

prevailing weather conditions. It is designed to perform all the analysis, data handling and

results presentation elements of a QRA within a structured framework.

Phast Risk allows you to quickly identify major risk contributors so that time and efforts can be

directed to mitigating these highest risk activities. Based on effects calculations and population

vulnerabilities, Phast Risk can integrate over all scenarios and weather conditions to estimate

the total risk. The established individual and societal risk indicators are predicted by Phast Risk

across your facility and surrounding area using the classical QRA methodology. Risk ranking

reports can be produced at points of strategic importance to show the relative influence of the

various failure scenarios and their contribution to both the individual and societal risk metrics.

A key benefit of Phast Risk is the ability to identify major risk contributors and differentiate

these from incidents with worst case consequences which might otherwise dominate the

safety reviews. Whilst medium scale incidents have lesser consequences, they may have a

higher frequency, which, when combined with their hazardous effects, generate a higher level



of risk. Time and effort directed to mitigating high consequence but often low frequency

events may not be well spent. Phast Risk helps you direct this effort more effectively.

Phast Risk also provides facilities to help you manage large quantities of input data, including

scenarios, parameters, wind roses, ignition and population, and combine these in many ways.

This is critical when looking at sensitivity analyses and assessing the merits of a range of risk

reduction measures.

Benefits

• Facilitates cost reduction in terms of losses and insurance

• Allows optimization of plant and process design

• Assist in compliance with safety regulators

• Enables quicker response to hazardous incidents

• Improve engineer’s understanding of potential hazards

• Regular software upgrades incorporate industry experience and expertise, and

advances in consequence modeling technology

6.1.5.2.3 SCENARIOS

TABLE – 6.4

POSSIBLE ACCIDENT SCENARIOS

Scenario MCL Scenario Pressure & Temp. Quantity

1 10 mm Leak of Antiskin NTP 4 KL

2 Catastrophic Rupture of Antiskin NTP 4 KL

3 Catastrophic Rupture of Para Formaldehyde NTP 10 Tonne

4 Catastrophic Rupture of Maleic Anhydride NTP 20 Tonne



ANTISKIN STORAGE AREA

All anti skin barrel been stored in close air conditioner container with specified temperature

range given is 30 °C, in case of high temperature or malfunctioning of the system hooter is

provided for indication purpose.



Scenario#1: 10 mm Leak of Antiskin

This scenario considers 10 mm Leak of Antiskin:

Results indicate:

10 mm Leak

Input Data

Stored quantity - 4 KL

Results indicate

Pool Fire Scenario

Radiation Level

(KW/m2)

Distance in meter

Effect if IHR at Height of simulation

Early Pool Fire

1.5 F 1.5 D 5 D

4 12.92 12.82 14.85

This level is sufficient to cause personnel if unable to reach

cover within 20s; however blistering of the skin (second degree

burn) is likely; 0: lethality

12.5 8.64 8.54 11.10

This level will cause extreme pain within 20 seconds and

movement to a safer place is instinctive. This level indicates

around 6% fatality for 20 seconds exposure.

37.5 4.49 4.40 6.54 This level of radiation is assumed to give 100% fatality as

outlined above.

Late Pool Fire

1.5 F 1.5 D 5 D

4 39.12 39.01 45.39




12.5 18.63 18.53 26.08




37.5 9.79 9.69 11.00 This level of radiation is assumed to give 100% fatality as

outlined above.

Jet Fire

1.5 F 1.5 D 5 D

4 - - 0.85




Maximum Pool Radius – 6.753 m

Pool Diameter – 1.63 m

Late Pool Fire Diameter – 13.51 m



Antiskin (10 mm Leak)









Early Pool Fire Ellipse

Late Pool Fire Ellipse

Green – 4 KW/m2

Yellow – 12.5 KW/m2

Red – 37.5 KW/m2



Scenario#2: Catastrophic Rupture of Antiskin

This scenario considers Catastrophic Rupture of Antiskin:

Results indicate:


Input Data

Stored quantity - 4 KL

Results indicate

Pool Fire Scenario

Radiation

Level

(KW/m2)

Distance in meter Effect if IHR at Height of simulation

Late Pool Fire

1.5 F 1.5 D 5 D

4 50.16 50.16 64.22




12.5 18.23 18.23 21.28





Pool Diameter – 31.83 m








Late Pool Fire Ellipse

Green – 4 KW/m2

Yellow – 12.5 KW/m2



Scenario#3: Catastrophic Rupture of Para Formaldehyde

This scenario considers Catastrophic Rupture of Para Formaldehyde:

Results indicate:


Input Data

Stored quantity - 10 Tonne

Results indicate

Pool Fire Scenario

Radiation

Level

(KW/m2)

Distance in meter Effect if IHR at Height of simulation

Fireball

1.5 F 1.5 D 5 D

4 158.98 158.98 158.98


cover within 20s; however blistering of the skin (second

degree burn) is likely; 0: lethality

Fireball Radius – 64.98 m



Formaldehyde (Catastrophic)







Radiation Effects: Fireball Ellipse (4 KW/m2)



Scenario#4: Catastrophic Rupture of Maleic Anhydride

This scenario considers Catastrophic Rupture of Maleic Anhydride:

Results indicate:


Input Data

Stored quantity - 20 Tonne

Results indicate


Cloud Segment Duration – 507 s

Pool Vaporization Rate – 0.0148 kg/s







6.1.6 RISK ASSESSMENT SUMMARY

• From the Risk Assessment studies conducted, it would be observed that by and large,

the risks are confined within the factory boundary walls.

• Based on these studies company has been proposed to plan its facility sitting as well as

location of operator cabin, open area, etc.

• Company has to increase awareness programme in the surrounding vicinity and educate

people for safe evacuation at the time of toxic release.

• Induction safety course to be prepared and trained all new employees before starting

duties in plant.

6.1.6.1 PROCESS SAFETY

• Safety measures are adopted & will be adopted from the design stage.

• Safety Valve and pressure gauge are provided on reactor and its jacket (if jacket is

provided).

• Utility like Chilling, cooling, vacuum, steaming and its alternative is provided to control

reaction parameters in a safe manner.

• Free Fall of any flammable material in the vessel is being avoided.

• Static Earthing provision is made at design stage to all solvent handling equipments,

reactors, vessels & powder handling equipments.

• Any reaction upsets will be confined to the reaction vessel itself.

• All emergency valves and switches and emergency handling facilities are easily

assessable.

• Further all the vessels are examined & will be examined periodically by a recognized

competent person under the Gujarat Factory Rules.

• All the vessels and equipments are earthed appropriately and protected against Static

Electricity. Also for draining in drums proper Earthing facilities is provided.

• Materials are transferred by pumping through pipeline or by vacuum from drums.

• Jumpers are provided on all vegetable / solvent handling pipeline flanges.

• Caution note, safety posters, stickers, periodic training & Updation in safety and

emergency preparedness plan is displayed and conducted.

• Flame proof light fittings are and will be installed in the plant.

• All the Plant Personnel are provided with Personal Protection

• Equipments to protect against any adverse health effect during operations, leakage,

spillages or splash. PPE like Helmets, Safety Shoes, Safety

• All employees are given and updated in Safety aspects through periodic training in

safety.

• Material Safety Data Sheets of Raw Materials & Products is readily available that the

shop floor.

6.1.6.2 FOR HAZARDOUS STORAGE TANK FARM

• Tank farm is constructed as per the requirement For HSD & Liq. N2 Storage – Explosive

department) and separation distance will be maintained.



• Tanks are located and marked in designated area of RM storage.

• Static Earthing provision is made for road tanker as well as storage tank.

• Tanks of proper MOC have been selected.

• Flame arrestor with breather valve is provided on vent line.

• Road tanker unloading procedure is prepared and implemented.

• Fire load calculation is done and as per fire load Hydrant System will be provided as per

NFPA std. and Fire extinguishers are provided as per fire load calculation.

• Flame proof type equipments and lighting is provided.

• Trained and experience operator is employed for tank farm area.

• NFPA label (hazard identification) capacity and content is displayed on storage tank.

• Flexible SS hose is used for road tanker unloading purpose and other temperature

connection.

• All tanks are & shall be uniformly tagged.

• Level indicator is provided in tanks.

• Dyke is provided.

• Industrial type electric fittings are provided.

• Adequate fire fighting equipments is provided.

• Anti corrosive paint is done.

• Safety instruction board is displayed.

6.1.6.2 FOR DRUM/CARBOY STORAGE AREA

Some chemicals are received at plant in drums/Carboys by road truck and stored in a

drum/Carboy storage area.

• FLP type light fittings are provided.

• Proper ventilation is provided in RM & FG dome area.

• Proper label and identification board /stickers are provided in the storage area.

• Drum handling trolley /stackers/fork lift is used for drum handling.

• Materials are stored as per its compatibility study and separate area will be made for

flammable, corrosive and toxic chemical drums storage.

• Smoking and other spark, flame generating item is banned from the Gate.

6.1.6.3 TRANSPORTATION

• Road tanker unloading procedure is in place and is implemented for safe unloading of

road tanker.

• Static Earthing provision is made for tanker unloading.

• Earthed Flexible Steel hose is used for solvent unloading from the road tanker.

• Fixed pipelines with pumps are provided for solvent transfer up to Day tanks/reactors.

• Mechanical seal type pumps are installed.

• NRV provision is made on all pump discharge line.



6.1.7 OTHER RISK REDUCTION OPPORTUNITIES

The following opportunities shall be considered as a potential means of reducing identified risks

during the detailed design phase:

• Buildings and plants structures shall be designed for cyclone floods and seismic events to

prevent structural collapse and integrity of weather (water) proofing for storage of goods;

• Provision for adequate water capacity to supply fire protection systems and critical process

water;

• Isolate people from load carrying/mechanical handling systems, vehicle traffic and storage

and stacks locations;

6.1.8 RECOMMENDATIONS FOR ALARP

The following actions are particularly recommended to be implemented in order to ensure

ALARP (As Low As reasonably practical) performance in the operation: Maintain and ensure

effectiveness of all the safety measures, among others through the following actions:

Raw Material Storage Area

• The raw material storage area should be declared as a prohibited area and should be

provided having at least two exits, “No Smoking” and “Prohibited Area” display boards,

as applicable should be provided at site.

• Regular inspection of tanks/drums/carboys containing raw material to be done to take

care.

• Periodic site inspection should be carried out to ensure that there is no leakage from

any of the drums in the ware house.

• Fire hydrant system needs to be provided in storage area as per TAC standards.

• Smoke detector and fire alarm systems need to be provided.

• Provision of fire doors in ware house area.

Fire access for Tank Farm area and Ware Houses

• Fire access roads should be provided to storage area. The storage tanks/area should

have suitable fire protection and fire fighting facility.

The following features are also important for the project by taking the layout into

consideration:

• Hinged doors swing outward in an explosion.

• Window panes (if installed) are shatterproof or plastic in frame.

• Floors, walls and ceilings are designed and installed to limit the generation and

accumulation of static electricity.

• All doors must be fire resistant. Floors, walls and ceilings are designed for at least 2 h of

fire resistance.

• Walls or partitions are continuous from floor to ceiling, and securely anchored.



• Integrity of the wall should be ensured i.e. blast wall not to be broken or drilled as that

can leads to weak spots.

• The building is constructed of non-combustible materials, on a substantial frame.

• Restrained deflagration vent panels are present.

• There is adequate ventilation, and any heating in rooms is limited to steam, hot water,

or other indirect means.

Electrical Safety for Whole Facility

• Electrical Safety: All cables and electric fittings shall be constructed, installed, protected,

operated and maintained in such a manner so as to prevent risk of open sparking.

6.2 DISASTER MANAGEMENT PLAN

Accident

Accidents will an unplanned event which has a probability of causing personal injury or

property damage or both. It may result in physical harm (injury of disease) to personnel and

also damage to property, loss to the company, a new miss or combination of these effects.

Major Accident

It will be a sudden, unexpected, unplanned event, resulting from uncontrolled developments

during an industrial activity, which causes, or has the potential to cause;

• Serious adverse effect immediately or delayed (death, injuries, poisoning or hospitalization)

to number of people inside the installation and/or to persons outside the establishments or,

• Significant damage to crops, plant or animals, or significant contamination of land, water or

air or,

• An emergency intervention outside the establishment (ex. Evacuation of local population,

stopping of local traffic) or,

• Significant changes in the process operating conditions, such as stoppage or suspension or

normal work in the concerned plan for a significant period of time, or

• Any combination of above effects.

Emergency

It could be defined as any situation which presents a threat of safety of persons or/and

property. It may require outside help also. Emergency due to operating conditions

(uncontrolled reaction, small fire, small gas, leak, spill, failure of power, water, air, steam,

cooling media, scrubbing media, etc.) and which can be locally handled by plant personnel

alone (without outside help) will considered as emergency.

Major Emergency

Major Emergency could be defined as any situation which may affect several departments

within and/ or may cause serious injuries, loss of life, extensive damage to property of serious

disruption outside the work. It will require the use of outside resources to handle it effectively.



Usually the result of a malfunction of the normal operating procedure, it may also be

participated by the intervention of an outside agency, such as severs electrical storm, flooding,

crashed aircraft or deliberate acts of arson or sabotage.

Disaster

It will a catastrophic situation in which the day to day patterns of life are, in many instances,

suddenly disrupted and people are plugged into helplessness, suffering and as a result need

protection, clothing, shelter, medical & social care and other necessities of life such as:

• Disaster resulting from natural phenomena like earthquakes, volcanic eruptions, storm,

surges, cyclones, tropical storms, floods, landsides, forest fires and massive infect

infestation. Also in this group, violent drought which will cause a creeping disaster leading

to famine disease and death must be included.

• Second group includes disastrous events occasioned by man or by man’s impact upon the

environment, such as armed conflict, industrial accidents, factory fires, explosions and

escape of toxic gases or chemical substances, rivers, pollution, mining or other structural

collapse, air, sea, rail and road transport accident, aircraft crashes, collisions of carrying

inflammable liquids, oil spills at sea and dam failures.

Risk

It will the likelihood of an undesired event (i.e. accident, injury or death) occurring within a

specified period or under specified circumstances. It may be either a frequency or a probability

depending on the circumstances.

Hazard

Hazard is a physical situation which may cause human injury, damage to property or the

environmental or combination of these criteria.

Objectives of the On Site Emergency Plan

• To define & assess emergencies, including risk & environment impact assessment.

• To control & contain incidents.

• To safeguard employees, visitors & other people in the vicinity.

• To minimize damage to property &/or the environment.

• To inform employees, the general public and the authorities about the hazards/ risk

assessed safeguard provided residual risk if any and the role to be played by them in the

vent of emergency.

• To be ready for the mutual aid if need rises to help the neighboring unit. Normal jurisdiction

of an OEP will the own premises only, but looking to the time factor in the arriving the

external help of off-side plan agency, the jurisdiction must be extended outside to the

extent possible in case of emergency occurring outside.

• To inform authorities and mutual aid centers to come for help.

• To affect rescue and treatment of causalities to count injured.

• To identify and list any dead.



• To inform and help relatives.

• To secure the safe rehabilitation of affected area and to restore normalcy.

• To provide authoritative information to the news media.

• To preserve records, equipments, etc., and to organize investigation into the cause of the

emergency and preventive measure to stop its recurrence.

• To ensure safely of the works before personnel re-enter and resume work.

• To work out a plan with all provisions to handle emergencies and to provide for emergency

preparedness and the periodical rehearsal of the plan.

In order to meet the above objectives, detailed procedure for handling On Site Emergency has

been prepared, which will intended to cover all foreseeable eventualities even those leading to

the evacuation of the site.

SECTION 41B of Factory Act 1948 requires a factory to draw up an Onsite Emergency Plan with

mentioned of all control measures for the industry. It will mandatory for an industry to educate

employees accordingly about the plan.

Rule 13 of Manufacture, Storage and Import of Hazardous Chemical Rules, 1989 says to prepare

an Onsite Emergency Plan.

The enclosed On-site Emergency Plan is made for the Varnish and Ink Manufacturing process

plant of DIC Fine Chemicals Pvt ltd at Dahej. The plant has a manufacturing facility to produce

Printing Ink as final product.

The plant is designed and equipped to handle hazardous chemical and to carry out various

processes and operations on these chemicals. The plant is provided with Fire Hydrant system,

Fire extinguishers and Scrubber system. In addition to this adequate types and number of

Personal Protective Equipment, First Aid Boxes, Eye washers, Ventilation system has been

provided.

Considering the types of operations carried out in the plant and the nature, extent of hazards

existing, the management of M/s. DIC Fine Chemicals Pvt Ltd thought it necessary to have some

system of tackling an emergency. The formulation of this document is an outcome of the above

thought process.

Internal Safety Survey

DICFC will follow a system of Safety survey to prevent emergency situation from being created.

DICFC also intends to employ a system of accepting suggestions from its workforce &

supervisors for continual improvement in its follow up of safety system.



In spite of various preventive and precautionary measures taken in the plant, the possibility of

a mishap cannot be totally ruled out. Hence, the need to prepare a Contingency Plan for

dealing with incidences which may still occur and are likely to affect LIFE and / or PROPERTY,

both within the plant and in the immediate neighborhood.

Such an emergency could be the result of malfunction of the Plant & Equipment or non-

observance of operating instructions. It could, at times, be the consequence of acts outside

the control of plant management like severe storm, earthquake, flooding, or deliberate acts of

arson or sabotage.

A Major Emergency in the plant is one that may cause serious injury or loss of life and damage

to the property.

6.3 ON-SITE EMERGENCY PLAN

This On Site Emergency Plan (OEP) explains the code of conduct of all personnel in the plant &

actions to be carried out in case of an Emergency. This is an indicative guideline for

employees, contractors, transporters, etc. associated directly or indirectly with the emergent

situation. It also covers prompt rescue operations, evacuations, rehabilitation, co-ordination

and communication.

Emergency:

An Emergency is a situation, which may lead to or cause large-scale damage or destruction of

life, property or environment within or outside the Factory. Such non-routine situation may be

out of control of routine staff.

• A hazardous situation (or a threat of hazardous situation) which required actions to control,

correct and return a site to a safe condition and also requires timely actions to protect

people, property and the environment from the harm.

Nature of emergency:

Emergencies are defined according to the type on the basis of the material and activities

involved. The type of emergency will determine the potential impact of the incident on

people, property and the environment.

The emergency specified in the OEP refers to occurrence of one or more of the following

events:

• Fire/Explosion.

• Major accident such as structural or building collapse, overturning of road tanker

containing flammable substances, Electrical emergencies

• Natural calamities like storm, flood, earthquake, etc.,

• Sabotage act of terrorism, civil commotion, air raid etc.

• Medical emergencies heart attack, Brain stroke, cardiac arrest, and fisher



Identification of Hazardous Areas:

Nature of Emergencies:

The emergency has been identified and can be specified in one or more of the followings with

source and effect:

Emergency Source Effect

Fire / Explosion

Electrical Panels, cable trenches,

DG sets, Compressors, welding ,DG Set,

Boiler, Thermic Fluid (Thermopac Area),

Ware house storage, Electrical Substation,

Varnish 12 m (due to Pressure increase),

Emergency venting system

Smoky Fire, flash fire,

Small fires, Total equipment

loss, Major Fire.

Human injury or Death.

Air & soil pollution, Runaway

reaction

Leakages Nitrogen Leakages, Para formaldehyde gas

leakage

Inhalation hazards, fatality as

carcinogen material

Leakages Natural Gas (Emergency shut off valve at

near Diesel tank farm area) Fire

Overturning of the

tanker containing

flammable

Substances / acid.

Diesel Tanks & Other vegetable oil based

Tankers

Major Fire, Burns / Explosion

Injury or Death

Soil , Water & Air Pollution

Spillage of

flammable

substance/ acid

Drums, Diesel tank,

battery acid

Fire, Burns, Death

Soil pollution, Water Pollution,

Air Pollution

Leakage of Ozone

Depleting

substances / CNG

gas

Refrigeration / Cooling System /

Ozone Depletion,

Air Pollution

Confined Space All confined space area in plant layout (as

per list of confined space entry in plant) Oxygen deficiency

Failure of ETP pump ETP Plant Water pollution and

soil pollution

Overflow of ETP

during

heavy rains

ETP Plant Toxic Water Release, water

pollution and Soil pollution.

Food Poisoning Canteen Severe health affect, death

Road Accident Bus Major Accident ,Fatality



6.3.1 EMERGENCY CONTROL CENTRE (ECC):

DICFC Have Designated following as the ECC

• During normal working hours – Director - Operations’ office.

• During hours other than normal working hrs - Ink Incharge act as a Site Incharge

All communications to and from will originate at this CONTROL CENTRE. The Emergency

Control Center will have the following:

• A copy of ON-SITE EMERGENCY PLAN.

• List of important telephone numbers such as Police, Fire

• Brigade, Hospitals, and other outside Emergency Services, etc.

• List of key Personnel with addresses and telephone numbers.

• List of Fire and Rescue Squad Members.

• Plant layout indicating storage of hazardous materials

• List Fire Extinguisher.

• Fire Fighting System (Layout of Fire Hydrants)

• List of Personal Protective Equipment

• First Aid box.

• List of Hazardous Chemicals with MSDS

• Emergency organization Chart

6.3.2 ASSEMBLY POINTS

In case of an EMERGENCY the employees should assemble near the defined Assembly Points,

as indicated below:

• All employees from work place: Area near Canteen and Behind FG Store.

• Others - Area near Security Gate.

Wind socks is installed above Fire Water storage tank and & HT Yard (Opp. Security Gate office)

to indicted the wind direction.

The employees should run perpendicular to the wind direction and not against / along the wind

direction.

Codification of Sirens

S.

No. Sirens Indicates Authority

1.

30 SECOND for

three times

CONTINUOUS

ON SITE

EMERGENCY (ALERT) SITE CONTROLLER

2. 1 MINUTE

CONTINOUS

EMERGENCY

CONTROLLED

(ALL CLEAR)

SITE CONTROLLER



NOTE: 1) EMERGENCY SIREN TO BE SOUNDED ONLY IF REQUIRED

2) ALL EMPLOYEES IN AREAS OTHER THAN AFFECTED TO CONTINUE WORK UNLESS

DISASTER SIREN IS BLOWN.

3) MEMBER OF EMERGENCY RESPONSE TEAM WILL NOT LEAVE THE EMERGENCY SPOT

UNLESS `ALL CLEAR’ SIREN BLOWN.

6.3.3 TRAINING AND EDUCATION

Experience with on site – emergency planning has proved the need of training and rehearsal.

Major emergency procedure should be laid down clearly and convincingly to everyone on site

particularly Key Personnel and Essential workers. It is obvious that in house or outdoor training

is essential. The duties and responsibilities of each person and the emergency procedure to be

followed by him should be very clear.

• Seminar/refresher guidance On Site Emergency Plan.

• Emergency instruction Booklet.

Seminar: Seminar is conducted in house/. Site controller will explain the plan to all associated

concerned employees. Expert from outside explain the plan to all associated concerned

employees. Expert from also may be invited to impart training.

Emergency Instruction Booklet:

Emergency instruction Booklet contains all detailed emergency duties. The booklet contains –

• Emergency duties,

• Reporting relationship.

Thus everyone is conspicuous about his role in the Emergency Plan.

Mock Rehearsal:

DICFC intends to conduct Mock Rehearsals at regular intervals & observations will be analyzed

& acted upon for preparedness to combat emergency. (Once in Six Month)

Updating the Plan:

DICFC intends to review the OEM at regular intervals & during learning lessons, mock rehearsals

& update it after duly analyzing the shortcomings.

Nitrogen Tank:

DO & DON’TS OF VACUUM INSULATED VESSELS

• Please operate the valves as per P & I diagram & Working Instructions.

• Please ensure that Overflow valve is opened during the fill and full quantity delivered

will be when liquid starts flowing out from the overflow valve & not as per the readings

of D.P. Gauge.

• Please observe pressure rise for at least One hour after the fill has been given. In the

event of any excess pressure build up than that of working pressure, release the gas

from vent valve.



• Liquid level gauge is only indicator of approximate quantity available in the vessel and

not accurate.

• Do not change the setting of Pressure raising Regulator. Need base call on BOC

personnel in the event of your requirement of lowering/increasing the working

pressure.

• Do not operate instrumentation valves of Pressure gauge & D.P.Gauge.

• Do not tamper with spring loaded Safety valves and Rupture Discs.

• In the event of pressure build up in the vessel, close the pressure raising valve and

release excess pressure through vent valve.

• In the event of lower pressure than that of working pressure please check pressure

raising valves. If close, please open.

• In the event of failure one rupture disc, reduce the pressure to working pressure than

slowly change over 3 way valve on other side, so that 2nd

Rupture discs remains in

operation.

� Please call on us Tel:080-28396272 and after office hours

� Mobile No:- 9663310093, 9036432246, 09831509713

In the event of any assistance required towards smooth operation of the system

Emergency Organization

Note: Responsibility will be automatically delegated in absence of concern person/s in following

manner.

SITE CONTROLLER: GM - Operations in routine days (other than routine work Ink Incharge shall

act as a Site controller

INCIDENT CONTROLLER: Production Manager in routine days (Other than routine hours both

INK & VARNISH Incharge has to work on a mutual understanding for the responsibilities of a

incident controller

DUTY OFFICER: ON Saturday/SUNDAYS/HOLIDAYS

ADVISORY COMMITTEE: The Advisory committee will comprise of GM - Operations /Head

Production /Head QA/ Head EHS/ Head Maint. & Plant Engineer & Human Resource

Manager/Safety Committee

COMMUNICATION COMMITTEE: Human Resource Manager & Plant Engineers

6.3.4 KEY PERSONNEL & THEIR RESPONSIBILITIES

Key Personnel’s Responsibility during normal working hours:



6.3.4.1 Site Controller:

He will retain overall responsibility for the factory and its personnel. As soon as he is informed

of the emergency his office shall convert into Emergency e control room. His duties shall be:

• Assess the magnitude of the situation and decide if staff needs to be evacuated from

their assembly points.

• Exercise direct operational control over areas other than those affected.

• Maintain a continuous review of possible development and assess in consultation with

Incident Controller and other Key personnel as to whether shutting down of the plant or

any section of the plant and evacuation of persons is required.

• Liaison with Senior Officials of Police, Fire Brigade, Directorate of Industrial Safety,

provide advice on possible effects on areas outside the factory premises.

• Control rehabilitation of affected areas on discontinuation of emergency.

• Issues authorized statements to news media, and ensure that evidence is preserved for

inquiries to be conducted by statutory authorities.

6.3.4.2 Incident Controller:

On hearing of an emergency siren he will rush to the scene of the occurrence and take overall

charge and report to Site Controller. On arrival he will assess the scale of emergency and

decide if major emergency exists or is likely and inform the Communication Officer accordingly.

• Direct all operations within the affected areas with the priorities for safety of personnel

minimize damage to the plant, property and minimize loss of materials.

• Pending arrival of Site Controller, assume the duties of his post and, in particular.

• Direct the shutting down and evacuation of plant and areas likely to be adversely

affected by the emergency.

• Ensure that all Key personnel and outside help are called in.

• Provide advice and information to the Fire squad & Security Officer and the local fire

service as and when they arrive.

• Ensure that all non-essential workers/staff of the areas affected are evacuated to the

appropriate assembly points, and the areas are searched for casualties.

• In the event of failure of electric supply and internal telephones, set up communication

point and establish contact with Emergency Control Centre.

• Report on all significant developments to Director/Site Controller

• Have regard to the need for preservation of evidence so as to facilitate any inquiry into

the causes and circumstances, which caused or escalated the emergency.

6.3.4.3 Human Resources Manager

He will also work as liaison Officer and will be stationed at the Main Entrance (Security Office

near Main Gate) during the emergency. He will under the direction of the site Controller

handle police, press and other inquiries, receive reports from roll-call leaders from assembly

points and pass on the absentee information to the Incident Controller. His responsibilities shall

include:



• To ensure that casualties receive adequate attention, to arrange additional help if

required and information relatives.

• To control traffic movements into the factory and ensuring that alternative transport is

available when need arises.

• When emergency is prolonged, arrange for the relief of personnel and organize

refreshments / catering facility.

• From information received, advise the Site Controller of the situation, recommending (if

necessary) evacuation of staff from assembly points.

• Recruit suitable staff to act as runners between the Incident Controller and himself if the

telephone and other system of communication fails due to whatsoever reasons.

• Maintain prior agreed inventory in the control centre.

• In case of prolonged emergency involving risk to outside areas by wind-blown materials,

contact local Meteorological Office to receive early notification of changes in weather

conditions.

6.3.4.4 Security Officer:

• On hearing alarm advice fire squad and security staff in the factory of the incident zone

and cancel the alarm. He will also announce through telephone or messengers to the

HR Manager, Incident Controller and Site Controller that incident has occurred in such

and such zone. He will open the gates nearest to the incident and stand by to direct the

emergency service.

• If told of a large escape of gas he shall inform the Incident Controller by telephone and

stand-by the telephone to receive further messages.

• On hearing the emergency alarm, he will immediately contact Site Controller and on his

advice call the local fire brigade. In case fire is discovered but no alarm is sounding he

shall receive information about location from the person discovering the fire and

thereafter immediately consult the Site Incident Controller and make announcement on

telephone telling the staff location of the incident and to evacuate to their assembly

points. He will continue to operate the switchboard advising the calls connected with

the incident to the Communications Officer.

6.3.4.5 Departmental Heads:

• The Departmental head wherein the incident has taken place will report to Incident

Controller and provide assistance as required. They will decide which members of their

staff they require at the scene.

6.3.4.6 First-aid Teams:

• The HR Manager shall keep in security the roll call lists for the fire and first-aid teams on

duty. Each Departmental Head for his shift-team appoints roll call leaders and first

aiders. Roll call leaders shall check their roles as members of the services report for

emergency duty. Names of any unaccounted for absentees will be informed to the

Security Officer.



• Members of first-aid Teams will report to the Incident Controller on hearing of the alarm

in day time. The Emergency vehicle driver, if safe to do so, shall collect the emergency

vehicle and park nearest to the scene of the incident. First aider shall inform the

incident controller that the Emergency Vehicle is leaving the site, giving the name of

the patient and destination i.e. hospital or doctor’s room and request the Incident

Controller to inform the destination (hospital, etc.) advising them about the casualties

reaching there.

6.3.4.7 Factory Fire Squad Personnel:

• The duty Fire fighting Squad under the command of the Security Officer shall be

responsible for fire fighting and rescue. On hearing the alarm, they shall proceed to the

place of incident. The men at security gate shall find out the location of the emergency

and proceed to the site of the occurrence.

• At the incident scene, a team members detailed for this purpose will check squad

members against roll-call sheet. At the site, all the squad members will respond to the

advice and information given by the Incident Controller On arrival of the local fire

brigade, they will also assist in fire-fighting work with the advice of the Incident

Controller.

Emergency Action Plan

Anyone noticing emergency situation like fire, explosion, gas etc. must

DO’s

• Attract the nearby person/employee by shouting “FIRE – FIRE – FIRE“

• Seek help from the persons working nearby.

• Try to control the incident at its initial stage with available means/sources quickly.

• Inform Shift In-charge / Duty Officer (In Night Shift) about the Incident.

DON’Ts

• Do not be panicky.

• Do not run – Walk fast.

6.3.4.8 Incident Controller Must

DO’s

A. If Fire / Other Incidents Are Controllable

• Approach the emergency site immediately taking note of wind direction.

• Assess the situation.

• Inform Security Officer, Tell – NAME, TYPE OF INCIDENT, ACTION TAKEN, HELP NEEDED

and Order Security Officer/Guard to inform all KEY persons.

• Take lead in controlling emergency until such time concerned Section Manager takes

over the charge.

DON’TS

• Do not panic.



• Do not lose temperament.

B. If Fire/Other Incidents Are Not Controllable

In Addition to Above (A):

• Order to blow emergency `ALERT’ Siren (30 second continuous).

• Organize Fire fighting / rescue team members to control the Incident.

• Take stock of situation if required shut down the plant / process in affected area.

• Call Fire Brigade if situation demands.

• Evacuate affected area.

• Organize head count of the plant.

• Act as INCIDENT CONTROLLER till such time senior person takes charges as indicated in

Emergency organization

NOTE: 1) Messenger will wait until such time Security Officer arrives.

2) Also inform Telephone Operator.

6.3.4.9 Security Officer / Guard

DO’s

• Do not allow any vehicle to come inside the factory.

• Do not entertain any outside call except for emergency purpose.

• Do not allow visitors to move around.

• Inform all key persons about location and type of emergency.

• Follow this sequence – Inform concerned HOD/Section Head, Main Site Controller, Main

Incident Controller & EHS Dept and other KEY persons.

• Inform Main Site Controller about Government visitors, if any.

• Keep the main Gate open to move the vehicle in out on Emergency

DON’Ts

• Do not entertain any outside call except for emergency purpose.

• Do not allow visitor to move around, from reception.

6.3.4.10 Security Guard

DO’s

• Immediately report at Security Gate in shortest possible time.

• Follow instructions of Officer In-charge.

• Assist in controlling emergency.

• Assist in controlling contractors, vehicle movement and mob.

• Assist in cordoning off the area.

• Take note of wind direction while approaching emergency site.

• Render all possible help for controlling overall situation.

DON’Ts

• Do not leave the site unless asked to do so.



6.3.4.11 Emergency Vehicle Driver

DO’s

• Immediately start vehicle and reach rescue squad assembly point (near Canteen and RM

Store).

• Rescue squad members to emergency site.

• Take vehicle near to emergency site as directed.

• Take note of wind direction.

• Reverse the emergency vehicle for quick transports of injured, if any.

• Keep vehicle engine running.

• Always be on Driver’s seat of the vehicle.

• Take the injured to the hospital as directed.

DON’Ts

• Do not take the vehicle very near to the site.

• Do not leave the vehicle. Do not leave the site unless asked to do so.

6.3.4.12 Incident Controller

DO’s

• Approach emergency site as early as possible taking note of wind direction.

• Take stock of situation.

• Interact with all concerned departments as the situation demands.

• Keep Main Site Controller informed about the latest emergency situation on continuous

basis

6.3.4.13 Site Controller

DO’s

• Will approach emergency site immediately / assess the situation.

• Consult Incident Controller.

• Consult advising Committee Members.

• Instruct Main Incident Controller.

• Communicate to higher ups and Govt. authorities, if required.

• Decide upon need for evacuation and blow `Disaster Siren’.

• After getting satisfied with the situation, give instruction to blow ALL CLEAR Siren.

DON’Ts

• Do not instruct to blow ALL CLEAR siren unless the situation is fully under control.

• Don’t evacuate the entire plant unless the situation demands.

6.3.4.14 Fire Fighting Squad on Hearing Siren

DO’s

• Inform fellow employees/Officers.

• Report to Fire Squad at Incident point.

• Find out emergency location.



• Approach emergency site immediately.

• Take quick action as per the instructions from Incident controller.

• Bring emergency under control as early as possible.

DON’Ts

• Do not leave process/equipment in UNSAFE CONDITION.

• Do not leave emergency site unless ALL CLEAR siren blown.

• Do not use improper fire extinguisher.

• Do not be panic

6.3.4.15 Rescue Squad

DO’s

• Report to assembly point near Canteen or RM Store as per instructed.

• Get in touch with security about location and type of emergency.

• Approach emergency site quickly with Breathing Apparatus set, First Aid Box and

Ambulance.

• Get in touch with incident controller.

• Follow instructions of Incident controller.

• Render first aid to the injured, hospitalize, if required.

• Accompany him to hospital and assist Doctor / Nurse.

• Search for missing person in that area, if required.

• Help in head count

6.3.4.16 All General Employees except Those Who Are In Emergency Organization on Hearing

Siren

DO’s

• Be alert and be available if required.

• Wait for further instructions.

• Bring down the process/plant/equipment in SAFE CONDITION in case of DISASTER siren

as per instructions from Incident Controller.

• Approach respective safe assembling points route as taking note of wind direction.

• Help in taking roll call.

• After hearing ALL CLEAR, go back to the departments.

• Start the work again after setting instruction from Incident controller.

DON’Ts

• Do not be panicky. Do not run.

• Do not approach emergency site unless asked for.

• Do not engage telephone except for emergency purpose. Keep lines free

6.3.4.17 Technical Team: Engineering Department on Hearing Siren

DO’s

• Be available in Engineering Department at respective location for any help.



• Approach emergency site with required with tools and equipments and should work on

instructions of Incident controlled.

• Help Incident Controller to provide technical assistance.

• Isolate lines, process equipments, if required by Incident Controller.

• Provide emergency equipments like Fire Extinguisher, Hoses, etc., if asked by Incident

Controller.

• Provide stop gap arrangements as per the requirement of Incident Controller.

• Carry out electrical isolation of area as per instructions from Incident Controller.

6.3.4.18 Advisory Committee (Environment, Safety and Health Department And All

Department Heads

DO’s

• Approach emergency site as early as possible.

• Render advice to Main Incident Controller and Main Site Controller to control

emergency.

6.3.4.19 Communication Committee – (P&A)

DO’s

• Consult Main Site Controller

• Give necessary instructions to security / Telephone Operator.

• Give instruction to Security to control traffic / crowd.

• Look after injured, communicate with the family members, if situation demands.

• Arrange transportation, if required.

DON’Ts

Do not communicate to any one or brief press without permission of Main Site Controller.

6.3.4.20 General Instructions

DO’S

• Stop work at height. / Stop all hot works.

• Stop all vessel entry.

• Take note of wind direction.

• On hearing Disaster Siren evacuates as per evacuation route without running and

panicky and assembles at respective safe Assembly Points.

DON’Ts

• Do not use telephone except for emergency purpose.

• Do not start work at height, vessel entry, hot work unless permit conditions are verified.

• Do not allow unauthorized person to approach emergency site



TELEPHONE NUMBERS OF POLICE, FIRE BRIGADE, HOSPITALS, AND OTHER OUTSIDE

EMERGENCY SERVICES

DAHEJ / BHARUCH TEL. NOS.

POLICE DEPT-

VAGARA POLICE STATION 02641-225233

DAHEJ POLICE STATION 02641-256233

DSP BHARUCH 02642-269303

COLLECTOR OFFICE 02642-240600

CIVIL HOSPITAL BHARUCH 02642-243515

BLOOD BANK BHARUCH 02642-243603

GRAMPANCHAYAT OFFICE VAGRA :-

SARPANCH VAGARA 02641-256312

TAHASILDAR VAGRA 02641-225221

GRAMPANCHAYAT OFFICE DAHEJ :-

SARPANCH DAHEJ

Fire and Emergency Services of Dahej SEZ Ltd.,

Mr. Jaydeep Bhatt

DSL Fire Station

7874787973

02646-291191, 8347420101

Disaster Management Centre, Dahej (DMC)

Mr. Hitesh Shah

DMC Office

9824475576

02646-256670, 9924937101

DSL Infra – Mr. Niraj Shah 9825740882

MUNICIPAL CORPORATION BHARUCH 02642-241753

Assist. Commissioner MCP bharuch 02642-249389

GPCB OFFICE BHARUCH 02642-246333

FIRE CONTROL ROOM ( MUNICIPAL CORPORATION BHARUCH)

FIRE CONTROL STATION AVAILABLE NEARBY GIDC GACL: 02641-256315/16/17

IPCL: 02641-256401/410

BARODA HEART & MULTI SPECIALITIES HOSPITAL 02642 – 260551, 260552



TELEPHONE NUMBERS AND ADDRESSES OF KEY PERSONNEL LIST OF KEY PERSONS

(EMERGENCY RESPONSE TEAM AT SITE)

NAME RESIDENCE TEL. NO.

Prashant Limaye 09099967101

Vikas ji Agarwal 09099967102

Amit Upadhyay 09099967105

Ishvar Panchal 09099967106

Mihir Abhyankar 09879665537

Ajay Pancholi 09099967117

Mayank Amit 09825337959

Pradosh Mohanty 08000511999

Jatin Patel 09099967113

Avantika Rathod 09429984738

Aarti Vahalia 09099911262

Akash Patel 07573884111

MUTUAL AID SCHEME MEMBERS & MUTUAL AID RESPONSE GROUP

COMPANY OFFICE PHONE

G.A.C.L. 02641-256315/16/17

Birla Copper 02641-256004/5/6

Welspun 02641-256011

IPCL 02641-256401/410

GCPTCL 02641-2566604/05

PIDILITE 022228357558

Dahej Disaster Management Society

For External fire tenders (Hitesh Shah) 09824475576



LIST OF FIRE FIGHTING SQUAD MEMBERS

LIST OF FIRST AIDERS MEMBERS

Name Dept.

Mukesh Solanki INK

Nimesh Patel INK

Sanjay Bhatt INK

Rakesh Biswal INK

Ghanshyam Sindha INK

Mihir Vanza INK

Gaurang Patel INK

Jignesh Vadher INK

Raghuvendra Kumar INK

Nitin Patel INK

Dhruvesh Patel QC

Sandeep Mistry QC

Name Dept. Contact No.

Rakesh Patel Prod. – Varnish 9913613170

Roshan Patel Prod. – Varnish 9426564318

Nitin Patel Prod. – Varnish 9428588477

Pradeep Patel Prod. – Varnish 9427157959

Nimesh Patel Prod. – Ink 9925222907

Jignesh Vadher Prod. – Ink 9898323178

Mukesh Solanki Prod. – Ink 9909956356

Salman Sheikh Prod. – Varnish 9724132706

Gaurang Patel Prod. – Ink 8511190149

Sanjay Bhatt Prod. – Ink 9099956965

Pradosh Mohanty Engg 8000511999

Mayank Amit Engg 9825537959

Ghanshyam Chauhan Logistics 9924199923

Ranvir Rana RM 9924940088

Lotan Patil Qc 7567896983

Manish Patel Logistics 9898029824

Mihir Abhyankar Production 9879665537

Subhash Parekh Engg. 9909148767



Jigar Raj QC

Sagar Parmar ETP

Punit Thakor ENGG

Pradosh Mohanthy ENGG

Parshuram Mahakund ENGG

Subhash Parekh ENGG

Rakesh Patel VARNISH

Salman Sheikh VARNISH

Roshan Patel VARNISH

Ajitendra Ojha VARNISH

Bhavik Kayasth VARNISH

Tushar Parmar HR

Ajay Pancholi EHS

Bhavik Jadav IT

Gaurav Madlani Finance

Ranvir Rana Store

6.4 EMERGENCY CONTROL SYSTEM FIRE HYDRANT SYSTEM

An underground Fire Hydrant System has been installed in the plant with rings around all blocks

to achieve maximum coverage. Fire water reservoir of 650m3

effective capacity for Hydrant as

well as sprinkler system with feed from the GIDC water supply has been provided in the plant.

Following are the details of the system.

• Fire Water Reservoir- 650m3

• Type of Hazard- “High Hazard Occupancies, Category A” as per Fire

• Protection Manual of TAC & “Extra Hazard Occupancies, Gr 2 as per NFPA.

• Design Code-NFPA and TAC”s Fire Protection Manual.

• Total no. of External Fire Hydrant including landing Values, Water monitor - 22 Nos (15

nos of Single hydrants, 7 nos of Double headed hydrants & one no. of foam monitor)

• Automatic Operation-Jockey pump of 50 GPM@88M head capacity with pressure

switches.

• Standby arrangement-Diesel Generator with AMF control panel.



• Nos of Hose Boxes-External-25 nos

• Nos of Hose Boxes- Internal -02 nos

• Total Nos of Hoses- 68 nos

• Nos of Nozzles-20 mm bore-18 nos.

• Hydrant flexible rill - 6 nos.

• Electric Driven main pump - 1500 GPM@88M head capacity with pressure switches.

• One Jockey pump provided of capacity 50 GPM@88M head

List of Fire Extinguishers: Area Wise



List of SCBA Nos. & Trained Manpower

List of PPEs

S. NO. MATERIAL

1. Tough Helmet (Safety)

2. Safety Goggle (anti fog & Scratch resistant)

3. Safety Steel toe Shoes (At present Allen Cooper using)

4. Heat Resistant Hand Gloves ( At present Leather Gloves)

5. PVC Hand gloves

6. Nitrile Hand gloves EFN-15

7. Cotton Knitted Hand gloves 8”

8. Surgical Hand Gloves 7.5”

9. Rubber Hand gloves (Shock proof electric Sub-station/HT)

10. Cut resistant Hand Gloves (Both single side & double side Nitrile coating)

11. Eye washer & Safety shower fountain

12. Steel toe Gum boot

13. Double harness full body Safety Belt (steel scaffold hook)

14. Dust Mask (3M 9004IN P1 at present)

15. Organic Vapour mask

16. SCBA Sets

17. Flame proof Torch

18. Electrical Safety Shoes, Gumboot

19. Aluminized Suit (Fire Entry)

20. Splash Goggle

21. Welding fumes protection mask

22. Ear Plug

23. Ear Muff

24. Chest guard heat resistant

25. Sleeve Heat Resistant

26. Fire water Hose

27. Fire Hose Reel

28. Positive Pressure Suit

29. Convex Mirror

30. Shoe cover

31. Mobile foam unit

32. Disposable Cap

33. Wind shock

34. Oil observer

35. Eye washer bottle

36. Fire Blanket

37. Traffic Cone

38. Barricading tape

39. Spark Arrestor

40. Welding shield



S. No SCBA Set Ident. No. Location

1 SCBA Set – I V1 Varnish 0 Mt

2 SCBA Set – II V2 Varnish 12 Mt

3 SCBA Set - III T1 Thermopack

S. No Name Dept. Contact Details

1 Rakesh Patel Prod. - Varnish 9913613170

2 Roshan Patel Prod. - Varnish 9426564318

3 Nitin Patel Prod. - Varnish 9428588477

4 Pradeep Patel Prod. - Varnish 9427157959

First Aid Medical Facilities

The company has provided “First –AID” boxes at security office. Following are the contents of

First aid.

• Tincture iodine.

• Eye wash solution.

• Soframycin (ointment)

• Sterilized cotton wool.

• Band-aid.

• Antiseptic Solution (Dettol)

• Bandage.

• Paracetamol tablets.

• Iodex

• Pair of scissor

• BP Instrument (Digital & Manual)

• Glucometer

The company has got its own transport facilities to take the injured to the hospital. The nearest

hospitals are in Dahej for Primary treatment & Bharuch for specialized treatment.



List of Emergency Equipments

Smoke Detector List: Area Wise

Smoke Detector List Area Wise

S. No ID No. Area Description Device Type Remark

1 L1/01 Admin Passage Smoke Detector ok

2 L1/02 Admin Purchase manager cabin Smoke Detector ok

3 L1/03 Admin Purchase manager cabin Above Smoke Detector ok

4 L1/04 Admin meeting room Smoke Detector ok

5 L1/05 Admin HR Cabin Smoke Detector ok

6 L1/06 Admin nr. Meeting room Above Smoke Detector ok

7 L1/07 Admin nr. Hr cabin Smoke Detector ok

8 L1/08 Admin GM cabin Smoke Detector ok

9 L1/09 Admin Conference room Smoke Detector ok

10 L1/10 Admin Conference room Smoke Detector ok

11 L1/11 Admin GM cabin Above Smoke Detector ok

12 L1/12 Admin reception Smoke Detector ok

13 L1/13 Admin Lobby D-1 Above Smoke Detector ok

14 L1/14 Admin Lobby D-2 Smoke Detector ok

15 L1/15 Change Room D1 Smoke Detector ok

16 L1/16 Change Room D2 Above Smoke Detector ok

17 L1/17 Admin Ladies change room D1 Smoke Detector ok

18 L1/18 Admin Ladies change room D2 Above Smoke Detector ok

19 L1/19 Plant entry passage - D1 Smoke Detector ok

20 L1/20 Plant entry passage - D2 Smoke Detector ok

21 L1/21 Laboratory D1 Above Smoke Detector ok

22 L1/22 Laboratory D2 Smoke Detector ok

23 L1/23 Prod. Control Room INK D1 Smoke Detector ok

24 L1/24 Prod. Control Room INK D2 Above Smoke Detector ok

25 L1/25 Spare - Printing room Smoke Detector ok

26 L1/26 Lab storage room D1 Above Smoke Detector ok

27 L1/27 Lab storage room D2 Smoke Detector ok

28 L1/28 QC HOD office D1 Above Smoke Detector ok

29 L1/29 QC HOD office D1 Smoke Detector ok

30 L1/30 Engineering HOD office D1 Smoke Detector ok

31 L1/31 Engineering HOD office D2 Above Smoke Detector ok

32 L1/32 Engg. Office D1 Smoke Detector ok

33 L1/33 Engg. Office D2 Smoke Detector ok



Smoke Detector List Area Wise

S. No ID No. Area Description Device Type Remark

34 L1/34 Training Room D1 Smoke Detector ok

35 L1/35 Training Room D2 Above Smoke Detector ok

36 L1/36 Plant Manager office D1 Smoke Detector ok

37 L1/37 Plant Manager office D2 Above Smoke Detector ok

38 L1/38 Engg. Office D3 Above Smoke Detector ok

39 L1/39 Server room D1 Smoke Detector ok

40 L1/40 Server room D2 Above Smoke Detector ok

41 L2/5 Engg. Work Shop D1 Above Smoke Detector ok

42 L2/6 Engg. Work Shop D2 Smoke Detector ok

43 L2/7 Conference Room Smoke Detector ok

44 L2/9 Vanish Control Room D1 Smoke Detector ok

45 L2/10 Vanish Control Room D2 Smoke Detector ok

46 L3/151 Security Visitor Room Smoke Detector ok

47 L3/152 Security Driver Room Smoke Detector ok

48 L3/153 Security Electrical Panel Room Smoke Detector ok

49 L3/154 Security Drinking Water Smoke Detector ok

50 L3/155 Security Reception Smoke Detector ok

51 L3/169 Security OHC Room Smoke Detector ok

52 L3/156 HT Room G.F. D1 Smoke Detector ok

53 L3/157 HT Room F.F. D2 Smoke Detector ok

54 L3/160 Canteen Staff Dining D3 Smoke Detector ok

55 L3/161 Canteen Store Room Smoke Detector ok

56 L3/162 Canteen Staff Dining D4 Smoke Detector ok



Heat Detector List: Area Wise

Heat Detector List Area Wise

S. No ID No. Area Description Device Type

1 L2/1 Elec. Panel D1 HD




5 L2/8 Boiler Room HD

6 L3/158 Canteen Staff Dining D1 HD



9 L3/164 Canteen Kitchen D1 HD

10 L3/165 Canteen Rest Rom HD

11 L3/166 Canteen Executive Dining D1 HD

12 L3/167 Canteen Executive Dining D2 HD


14 L4/151 Substation D1 HD



17 L4/154 Sub Station Battery Room D4 HD



Beam Detector List: Area Wise

Beam Detector List Area Wise


1 L1/131 Ink Plant Beam detector-1 BD-1






7 L2/143 Pigment Area Beam Detector-1 BD-7





Manual Call Point List: Area Wise

Heat Detector List Area Wise


1 L1/102 Dispatch door-1 MCP

2 L1/103 Admin Passage MCP

3 L1/106 Admin Nr. GM Cabin MCP

4 L1/110 Nr. Plant Entry Door-1 MCP

5 L1/112 Lab entry from production MCP

6 L1/115 Nr. Engineer HOD Office MCP

7 L1/120 Engg. Office Dorr-2 MCP

8 L1/127 Ink PlanT E.Exit Door-2 MCP

9 L1/129 Ink PlanT E.Exit Door-1 MCP

10 L1/133 Dispatch E.Exit Door-2 MCP

11 L1/135 Dispatch door-1 MCP

12 L2/102 Ware House Shutter-2 MCP

13 L2/103 Varnish Tank Farm Area MCP

14 L2/106 Varnish Tank Entrance MCP

15 L2/107 Elec. Panel Room MCP

16 L2/111 Compression Room MCP

17 L2/113 Varnish Plant E. Exit Door-2 MCP

18 L2/114 Dilutor Plant MCP

19 L2/117 Reactor Plant E.Exit Door-1 MCP

20 L2/120 Reactor Plant Door-2 MCP

21 L2/122 Reactor plant Nr. Lift MCP

22 L2/125 Varnish control room e. exit MCP

23 L2/128 Nr. Varnish Control room Exit MCP

24 L2/130 Rosin Crusher path way MCP

25 L2/132 Rosin Crusher Plant MCP

26 L2/134 Ware house entrance MCP

27 L2/136 Ware house e. exit door-3 MCP

28 L2/140 Ware house e. exit door-2 MCP

29 L3/178 Security reception MCP

30 L3/176 HT Room GF MCP

31 L3/173 Canteen Entrance Door-2 MCP

32 L3/175 Canteen Entrance Door-1 MCP

33 L3/172 Substation E.Exit Door1 MCP



34 L3/174 Substation Door-2 MCP

35 L3/176 Substation Nr. Shutter MCP

36 L3/178 Utility Entrance MCP

List of Fire Hydrant Nos. & Hose Boxes

List of Fire Hydrant Nos & Hose boxes

S. No Location Fire Hydrant No. Fire Hydrant Box No.

1 Near QC LAB DH-02 HB-05

2 Near Engg Store DH--01 HB-07

3 Near Varnish Main Entrance SH-01 HB-10

4 New E waste room SH-11 HB-18

5 Near Foam Tank DH-04 HB-12

6 Electrical substation main road DH-04 HB-13

7 Entrance of Hazardous waste SH-02 HB-16

8 ETP Garden SH-10 HB-15

9 Near Transformer Area SH-16 HB-14

10 cooling tower Back side SH-08 HB-11

11 Chilling plant Back side SH-07 HB-08

12 Boiler back side DH-03 HB-06

13 Diesel Tank Farm Back Side DH-01 HB-03

14 Near Tank Farm area DH-02 HB-04

15 Near MCC Panel Room SH-04 HB-09

16 Haz. Waste Back Side SH-03 HB-17

17 Near Gum Rosin Dom SH-12 HB-19

18 Near FK Engg SH-03 HB-20

19 FG main Road Back Side SH-09 HB-21

20 Pigment Road back side SH-14 HB-22

21 RM Stores Backside SH-01 HB-24

22 Near Admin Building SH-05 HB-01

23 Near Canteen SH-15 HB-02

24 Ink Plant main road back side SH-15 HB-23

25 Varnish Crushing Area SH-13 HB-25



FIRE HYDRANT DRAWINGS

















Detailed fire control plan for flammable substances and processes showing hydrant

pipeline network, provision of DG Sets, fire pumps, jockey pump, toxic gas detectors etc.



6.5 OFF – SITE EMERGENCY PLAN

6.5.1 NEED OF THE OFF – SITE EMERGENCY PLAN

An off-site emergency plan is prepared to deal with those incidents which have the potential

to harm persons or the environment outside the boundary of the factory premises. A major

accident, major emergency and disaster may affect areas outside the plant. An explosion

can scatter debris over wide areas and its effects of blasts can cover considerable distances.

Wind can spread burning fumes of toxic gases. Thus the events like these described above

can affect outside areas and combating them needs an Off-site Emergency plan.

Envisaging such a rare incident, an off-site emergency plan should be drawn up for the

following purpose.

1. To provide basic information about the risk and environmental impact assessment

related to the unit to local / district authorities, police, fire-brigade, surrounding

units, and the general public. To appraise them of consequences and the protection

/ prevention measures and control actions and to seek their help to communicate

with public in case of a major emergency. The information from all industries shall

enable district authorities to educate public about what could go wrong, and to train

them of measures to be taken as an individual.

2. To enable district authorities to prepare the off-site emergency plan (contingency)

for the district or particular area and to organize rehearsals and initiate actions

learnt from these incidents.

Our Emergency Plan shall be made after considering the all possible effects of incidents on

the neighboring population and the remedial measures will be devised in consultation with

the local authorities and emergency services.

6.6 OCCUPATIONAL HEALTH AND SAFETY

Details of possibilities of occupational health hazards from the proposed manufacturing

activities and proposed measures to prevent them

DICFC is having Health & Hygiene SOP to develop a health and hygiene control program for

the persons on board to ensure that all potential health hazards in work environment are

recognized, evaluated and controlled.



Health & Hygiene is to provide and implement a documented procedure for conducting and

reporting site industrial hygiene risk assessment in order to identify and evaluate potential

community health risks resulting from exposure to physical, chemical, biological,

psychological (i.e. mental stresses) and physiological (i.e. physical stress or ergonomic risk

factors) hazards, as required by the HSE department for identifying and reporting hazards

and mitigating HSE risks, and the HSE Conservation policy for taking foremost account of

employees’ health.

This procedure covers the methodology used for site Industrial Health Hygiene assessment

activities in plant and facilities. The procedure may include desk top review, walk-through

survey and/or exposure assessment, or any combination of these methods. The assessment

activities shall include identifying hazardous tasks or activities, sources of hazardous agents

and potentially exposed workers, followed by evaluating the controls used to prevent or

minimize the exposure, assessing the level(s) of health effects with the associated exposure,

rating the hazards so that the higher risks are addressed first, and recommending additional

controls for preventing or minimizing exposure, as appropriate.

Procedure:

The Health and Hygiene coordinator (EHS Person / Medical Officer), identify and evaluate

occupational health and industrial hygiene hazards that exists in DIC Fine Chemicals Pvt.

Ltd., operations through a structured approach via systematic inspections. The structured

approach can include:

• Review of work activities for all occupations.

• Review of task analysis and technical surveys.

• Review of hazards identified in planned inspections and reported hazards.

• Applicable regulations, legislation, codes and standards.

• Interviews with employees and managers.

These identification surveys are conducted once every year and/ or after major modification

of installation facilities which may result in occupational health and hygiene hazards.



The surveys particularly address the identification and evaluation of the following

occupational health and hygiene hazards:

• Noise Hazards.

• Vibration Hazards.

• Stress related Hazards.

Health Hazard Control

The MR will constitute a team of officers and staff supported by medical officer, which will

• Prioritize the hazards based on their risk potential.

• Identify specific work groups affected by each hazard.

• Determine the controls required to manage these identified hazards. The cost of

each identified control versus benefits of its implementation may be evaluated.

• Develop an action plan identifying

• Work to be done

• Person responsible to complete the work

• target dates of completion

• Develop a follow up system to ensure the action plan is accomplished.

Health Care

The health and hygiene of the personnel at DICFC, Dahej is monitored through periodic

health checks of the persons. All employees undergo a periodic medical examination once in

year. This medical examination focuses on individual medical surveillance of all types of

health hazards covering both occupational and non-occupational issues.

First Aid

First aid boxes are provided at different strategic locations in Site and are regularly checked

for the consumptions by Fire & Safety department in co-ordination with Medical Officer.



Occupational Health of Workers

Noise

Noise will be regularly monitored both at plant boundary for checking compliance against

environmental noise parameters issued by the CPCB. It will also be monitored near noise

generating equipment to ensure that all noise generating equipment do not emit noise in

excess of 85 db (A) 1.0 m from source. All workmen will be provided with required set of

PPEs like ear plug, ear muff etc. where noise levels in excess of 80 db (A) are regularly

generated. Preventive maintenance of noise generating equipment shall be regularly carried

out to ensure that noise levels are minimized to the extent possible. To the extent feasible,

equipment will be purchased considering noise generation as one of the parameters.

Heat

The project does not envisage conditions that could lead to excessive heating.

Consequently, special requirements for protection against heat stress are not anticipated.

However, the following shall be carried out:

• Ventilation shall be provided to take care of heat evacuation. An air-exchange ratio

(ACH: Air changes per hour) of at least 6 will be maintained at all times.

• Drinking water availability shall be ensured at several locations within the plant to

ensure workers have easy access to the same.

• In case of occasional handling of heated equipment or materials, suitable PPEs such as

heat resistant gloves will be used.

Dust, other Chemicals and metals being suspended in the environment

The possibility of suspended particles going into the body of the workmen, either in the

form of inhalation, ingestion or through skin absorption are least and negligible because the

entire operation at the plant will be performed under closed loop condition, right from

charging till discharging, hence it’s a rare possibility that the workmen will come in direct

contact with raw material or final goods, At the same time the level of SPM and RPM will

definitely be of least and nominal value. But even though the same will be under closed

monitoring and periodical surveillance as per GPCB norms and applicable legislations and

any minor deviation from the same will be dealt with immediately and will be corrected.



Further to this all of the workmen will be provided with complete set of appropriate PPEs,

like nose musk / nose respirator, gloves, hard hat or cap, protective uniform and clothing,

eye protections etc.

Steps taken to avoid Musculoskeletal Disorder (MSD), backache, pain in major and minor

joints, fatigue etc.

In past ergonomic studies were carried out at most MSD prone activities / places like ink

filling and raw material charging but associated risk level have been found to be very low.

But in-spite of this as mentioned, the entire new set up will be having the facility of

automation and least involvement of manual handling hence chances of MSD are going to

be almost nil. Further to this some activities like raw material carriage, storage, issuance,

charging etc, all those might lead MSD will also be done through improvised manner by use

of latest / automated lifting and handling equipments, hence the possibility of MSD in these

cases also doesn’t exists.

Occupational Hazards specific pre-placement and periodical monitoring

As per policy and norms all of the workmen are put to medical examination and testing

periodically and at set interval and based on the medical report actions are taken, if at all

anything is necessary and required. Even based on the medical examination report /

feedback, workmen are counseled and put in different area / job rotation kind of activities

For large industries, where multifarious activities are involved during construction, erection,

testing, commissioning, operation and maintenance; the men, materials and machines are

the basic inputs. Along with the boons, industrialization generally brings several problems

like occupational health and safety. The industrial planner, therefore, has to properly plan

and take steps to minimize the impacts of industrialization and to ensure appropriate

occupational health and safety including fire plans. All these activities again may be

classified under construction and erection, and operation and maintenance.



6.6.1 OCCUPATIONAL HEALTH

Occupational health needs attention both during construction & erection and operation &

maintenance phases. However, the problem varies both in magnitude and variety in the

above phases.

6.6.1.1 CONSTRUCTION AND ERECTION

The occupational health problems envisaged at this stage can mainly be due to

constructional accident and noise. To overcome these hazards, in addition to arrangements

to reduce it within TLV's, necessary protective equipments shall be supplied to workers.

6.6.1.2 OPERATION AND MAINTENANCE

The problem of occupational health, in the operation and maintenance phase is primarily

due to noise which could affect consultation. The necessary personal protective equipments

will be given to all the workers. The working personnel shall be given the following

appropriate personnel protective equipments.

• Industrial Safety Helmet;

• Face shield

• Zero power plain goggles with cut type filters on both ends;

• Zero power goggles with cut type filters on both sides and blue color glasses;

• Welders equipment for eye and face protection;

• Cylindrical type earplug;

• Ear muffs;

• Canister Gas mask;

• Self contained breathing apparatus;

• Leather apron;

• Aluminized fiber glass fix proximity suit with hood and gloves;

• Boiler suit;

• Safety belt/line man's safety belt;

• Leather hand gloves;

• Asbestos hand gloves;



• Acid/Alkali proof rubberized hand gloves;

• Canvas cum leather hand gloves with leather palm;

• Lead hand glove;

• Electrically tested electrical resistance hand gloves; and

• Industrial safety shoes with steel toe.

6.6.1.3 HOSPITAL FACILITIES

It is proposed that client will make formal agreements with nearby hospital having facilities

to attend fire and toxic effect cases for attending the affected persons in the emergency

arising out of accidents, if any.

6.6.1.4 FACTORY MEDICAL OFFICER

A qualified doctor is appointed as FMO on visiting basis. Apart from him, Paramedical Staff is

employed.

6.6.1.5 PROPOSED FACILITY TO BE MADE AVAILABLE AT OHC

One Room is proposed to be provided to be operated as OHC. The centre will be equipped

with following medical equipments:—

1. Examination Table

2 Dressing Tables For performing Dressing

3. Glucometer For measurement of Blood Sugar

4 Vision chart To evaluate vision acuity

5. Nebuliser For relieving coughs & Breathing Difficulty

6. Infra red light for relieving muscular pain

7. Suction machine For cleaning airway

8. Autoclave machine For sterilizing cotton &dressing material

9. Weighing Machine For measuring body weight

10. Medical Oxygen Cylinder kit

11. Sphygmomanometer To measure blood pressure

12. Refrigerator To preserve medicines

13. Thermometer



6.6.1.6 AMBULANCE VAN

An ambulance van is proposed to be made available 24 hours at Fire Station.

6.6.1.6 FIRST AID BOX

First Aid Boxes are proposed to be made available at the different location in the plant,

Training to be given to employees for First Aid.

6.6.1.7 PERIODIC MEDICAL EXAMINATION

It is proposed that client will ensure that…

(1) Workers employed shall be medically examined by a qualified medical practitioner/

Factory Medical Officer, in the following manner:

(a) Once in a period of 6 months, to ascertain physical fitness of the person to do the

particular job;

(b) Once in a period of 6 months, to ascertain the health status of all the workers in respect

of occupational health hazards to which they are exposed and in cases where in the opinion

of the Factory Medical Officer it is necessary to do so at a shorter interval in respect of any

workers;

© In periodic and pre-medical examinations, various parameters will be checked. Viz., LIVER

FUNCRION TESTS, Chest X-rays, Audiometry, Spirometry, Vision testing (Far & Near vision,

color vision and any other ocular defect) ECG and other parameters as will be found

necessary as per the opinion of Factory Medical officer.

(2) No person shall be employed for the first time without a certificate of granted by the

Factory Medical Officer.

6.6.1.8 EMP FOR THE OCCUPATIONAL SAFETY & HEALTH HAZARDS SO THAT SUCH

EXPOSURE CAN BE KEPT WITHIN PERMISSIBLE EXPOSURE LEVEL (PEL)/THRESHOLD

LEVEL VALUE (TLV) SO AS TO PROTECT HEALTH OF WORKERS

1. It is proposed to formulate and implement an EMP for Occupational Safety and Health

with following aims…

• To keep air-borne concentration of toxic and hazardous chemicals below PEL and TLV.

• Protect general health of workers likely to be exposed to such chemicals



• Providing training, guidelines, resources and facilities to concerned department for

occupational health hazards.

• Permanent changes to workplace procedures or work location to be done if it is found

necessary on the basis of findings from workplace Monitoring Plan.

2. It is proposed that this EMP be formulated on the guidelines issued by Bureau of Indian

Standards on OH&S Management Systems: IS 18001:2000 Occupational Health and

Safety Management Systems

3. Proposed EMP will be incorporated in Standard Operating Procedure also.

4. The proposed EMP will also include measure to keep air-born concentration of toxic

and hazardous chemicals below its PEL and TLV, like…

a. Leak Surveys

b. Separate storage for toxic chemicals

c. Exhaust Ventilation

d. Proper illumination

e. On-line detectors toxic chemicals like Chlorine and Bromine

f. Close processes to avoid spills and exposures

g. Atomization of process operations to hazards of manual handling of chemicals

h. Supply of proper PPEs like Air mask, Berating canisters, SCBA sets, On-line breathing

apparatus at the places where there is possibility of presence of toxic chemicals

i. Decontamination procedure for empty drums and carboys.

j. Regular maintenance program for pumps, equipment, instruments handling toxic and

corrosive chemicals

k. Display of warning boards

l. Training to persons handling toxic and corrosive chemicals

5. Workplace Monitoring Plan

• It is proposed that a Workplace Monitoring Plan to be prepared & implemented in

consultation with FMO and industrial hygienists.

• Each workplace must be evaluated to identify potential hazards from toxic substances

or harmful physical agents. Air-borne concentration of toxic chemicals will be measured

and record will be kept.

• The current state-of-the-art exposure measurement model is as follows: For purposes of

measuring worker exposure across a single shift it is sufficient t o place a reasonably

accurate exposure measuring device on the worker , within t he worker ’s breathing



zone, and have it operate for nearly the full shift. Client has been proposed to study the

exposure data when the plant is operative.

6. Health Evaluation of Workers

1. It is proposed that management will device a plan to check and evaluate the exposure

specific health status evaluation of workers

2. Workers will be checked for physical fitness with special reference to the possible health

hazards likely to be present where he/she is being expected to work before being

employed for that purpose. Basic examinations like Liver Function tests, chest x ray,

Audiometry, Spirometry Vision testing (Far & Near vision, color vision and any other

ocular defect) ECG, etc. will be carried out. However, the parameters and frequency of

such examination will be decided in consultation with Factory Medical Officer and

Industrial Hygienists.

3. While in work, all the workers will be periodically examined for the health with specific

reference to the hazards which they are likely to be exposed to during work. Health

evaluation will be carried out considering the bodily functions likely to be affected

during work. The parameters and frequency of such examination will be decided in

consultation with Factory Medical Officer and Industrial Hygienists. Plan of monthly and

yearly report of the health status of workers with special reference to Occupational

Health and Safety.

6.6.1.9 MEDICAL SURVEILLANCE PROGRAM

Pre-employment Medical Check Up

1. Chest X-ray

2. Cardiogram

3. Audiometry

4. Hematological Examination:- CBC, SGOT, SGPT, Cholesterol, Blood Sugar etc

5. Urine Examination

6. Vision test

7. Colour blindness test

8. Lung function test- Spirometry

Periodical Medical Check up

1. Lung Function test

2. Cardiogram

3. Audiometry

4. Hematological Examination

5. Urine examination

6. Vision test

7. Colour blindness test

8. Biomarker in Blood & Urine



6.6.2 SAFETY PLAN

Safety of both men and materials during construction and operation phases is of concern.

Safety plan shall be prepared and implemented in the proposed project activity. The

preparedness of an industry for the occurrence of possible disasters is known as emergency

plan. The disaster in the plant is possible due to collapse of structures and fire/explosion etc.

• The proposed project would formulate safety policy keeping in view the safety

requirement during construction, operation, maintenance phases, with the following

regulations:

• To allocate sufficient resources to maintain safe and healthy conditions of work;

• To take steps to ensure that all known safety factors are taken into account in the design,

construction, operation and maintenance of plants, machinery and equipment;

• To ensure that adequate safety instructions are given to all employees;

• To provide wherever necessary protective equipment, safety appliances and clothing and

to ensure their proper use;

• To inform employees about materials, equipment or processes used in their work which

are known to be potentially hazardous to health or safety;

• To keep all operations and methods of work under regular review for making necessary

changes from the point of view of safety in the light of experience and up to date

knowledge;

• To provide appropriate facilities for first aid and prompt treatment of injuries and illness

at work;

• To provide appropriate instruction, training, retraining and supervision to employees in

health and safety, first aid and to ensure that adequate publicity is given to these

matters;

• To ensure proper implementation of fire prevention methods and an appropriate fire

fighting service together with training facilities for personnel involved in this service;

• To organize collection, analysis and presentation of data on accident, sickness and

incident involving people injury or injury to health with a view to taking corrective,

remedial and preventive action;

• To promote through the established machinery, joint consultation in health and safety

matters to ensure effective participation by all employees;

• To publish/notify regulations, instructions and notices in the common language of

employees;

• To prepare separate safety rules for each type of occupation/processes involved in a

plant; and



• To ensure regular safety inspection by a competent person at suitable intervals of all

buildings, equipments, work places and operations.

6.6.3 SAFETY ORGANIZATION

Construction and Erection Phase

A qualified and experienced safety officer shall be appointed. The responsibilities of the

safety officer include identification of the hazardous conditions and unsafe acts of workers

and advice on corrective actions, conduct safety audit, organize training programs and

provide professional expert advice on various issues related to occupational safety and

health. He is also responsible to ensure compliance of Safety Rules/ Statutory Provisions.

Operation and Maintenance Phase

When the construction is completed the posting of safety officers shall be in accordance

with the requirement of Factories Act and their duties and responsibilities shall be as

defined there of.

6.6.4 SAFETY CIRCLE

In order to fully develop the capabilities of the employees in identification of hazardous

processes and improving safety and health, safety circles would be constituted in each area

of work. The circle would consist of about five to six employees from that area. The circle

normally shall meet for about an hour every week.

6.6.5 SAFETY TRAINING

Safety training shall be provided by the Safety Officers with the assistance of faculty

members called from Professional Safety Institutions and Universities. In addition to regular

employees, limited contractor labors shall also be provided safety training. To create safety

awareness safety films shall be shown to workers and leaflets shall be distributed.

Some precautions and remedial measures proposed to be adopted to prevent fires are:

• Compartmentalization of cable galleries, use of proper sealing techniques of cable

passages and crevices in all directions would help in localizing and identifying the area of

occurrence of fire as well as ensure effective automatic and manual fire fighting

operations;



• Spread of fire in horizontal direction would be checked by providing fire stops for cable

shafts;

• Reliable and dependable type of fire detection system with proper zoning and interlocks

for alarms are effective protection methods for conveyor galleries;

• Housekeeping of high standard helps in eliminating the causes of fire and regular fire

watching system strengthens fire prevention and fire fighting; and

• Proper fire watching by all concerned would be ensured.

6.6.6 HEALTH AND SAFETY MONITORING PLAN

The health of all employees shall be periodically monitored for early detection of any

ailment due to exposure to heat and noise.

6.7 TRAINING, REHERASAL & RECORDS

6.7.1 NEED OF TRAINNING & REHEARASAL

Training is important in order to –

• Teach worker’s how to handle chemicals safely, how to act as a runner/messenger, how

to use PPE, how to start and shut down the plant, how to carry out emergency repairs

etc.

• Teach one to be a safe and alert worker.

Rehearsal is essential for -

• Explaining and making key personnel and essential workers aware of their role in case of

an emergency.

• Testing the emergency procedure, emergency arrangements and ability of all involved

with it to grasp the procedure and implement the same.

• Testing the effectiveness of communication system including the alternative

arrangement in case of failure.

• Testing the speed of mobilization of resources, search, rescue and treatment of

casualties, emergency isolation and shut down.

• Detecting the shortcomings in the emergency plan and incorporating remedial measures.



• Allowing professional emergency services to test their parts of the plan and testing co-

ordination.

• Building confidence in workers which is helpful in facing real situations.

Training shall be given to regular employees and contract personnel also. Effective and

latest teaching aids will be used to train workers and supervisory staff. Such training courses

shall be conducted once in a year and co-ordination with offsite personnel shall be sought

during such training. Records will be maintained for training.

6.7.2 SOME CHECK POINTS

Following points can be checked at the time of training/assessing the adequacy of the

Emergency Plan.

� Does the plan cover the range of incidents that can realistically be anticipated?

� Have the consequences of the various incidents considered been adequately assessed?

� Are there sufficient resources in terms of personnel and equipment on the site to carry

out the Emergency Plan for the various incidents in conjunction with the public

emergency services?

� Have the time scales been assesses correctly?

� Is there a logical sequence of actions for each person given a role in the plan? Whether

key personnel, especially the nominated incident controllers, consulted in the

preparation of the plan?

� Is there 24 hours cover, to take account of absences due to sickness and holidays,

minimum shift manning, operator only periods, silent hours, shutdown periods, only

security personnel being present, or for unmanned sites etc.?

� Is there satisfactory co-operation with the local emergency services and district

emergency planning officers?

� At sites where an off-site plan to protect people and the environment outside the site in

the event of an incident is appropriate what is the procedure for initiating the off-site

plan and is this satisfactory?



6.7.3 RECORDS AND UPDATING THE PLAN

All records of On-Site and Off-Site Emergency Plan and modifications by experience and

suggestion, the rehearsals and conclusions of such plans and the enquiries shall be well

maintained and preserved. The necessary data bank shall be also maintained for the utility

of industries and others. New information and the deficiencies identified during the

rehearsal is reviewed and incorporated in the document for continual up dating of the plan

and such information shall be communicated to the concerned authorities.

6.8 HAZOP STUDY

6.8.1 OBJECTIVE

For identifying cause and the consequences of perceived mal operations of equipment and

associated operator interfaces in the context of the complete system. It accommodates the

status of recognized design standards and codes of practice but rightly questions the

relevance of these in specific circumstances where hazards may remain undetected.

6.8.2 PURPOSE OF HAZOP

It emphasizes upon the operating integrity of a system, thereby leading methodically to

most potential and detectable deviations which could conceivably arise in the course of

normal operating routine

- including "start-up” and "shut-down" procedures

- as well as steady-state operations.

It is important to remember at all times that HAZOP is an identifying technique and not

intended as a means of solving problems nor is the method intended to be used solely as an

undisciplined means of searching for hazardous scenarios.

6.8.3 FEATURES OF HAZOP STUDY

Subsystems of interest line and valve, etc

Equipment, Vessels

Modes of operation Normal operation

Start -up mode

Shutdown mode

Maintenance /construction / inspection mode

Trigger events Human failure

Equipment /instrument/component failure

Supply failure

Emergency environment event



Other causes of abnormal operation, including

instrument disturbance

Effects within plant Changes in chemical conditions

Changes in inventory

Change in chemical physical conditions

Hazardous conditions Release of material

Changes in material hazard characteristics

Operating limit reached

Energy source exposed etc.

Corrective actions Change of process design

Change of operating limits

Change of system reliability

Improvement of material containment

Change control system

Add/remove materials

How would hazardous During normal operation

Conditions detected? Upon human failure

Upon component failure

In other circumstances

Contingency actions Improve isolation

Improve protection

6.8.4 HAZOP STUDY PROCEDURE

• Procedure in HAZOP study consists of examining the process and instrumentation (P&I)

line diagram, process line by process line.

• A list of guide words is used to generate deviations from normal operation

corresponding to all conceivable possibilities.

• Guide words covering every parameter relevant to the system under review i.e. flow

rate and quality, pressure, temperature, viscosity, components etc.

• Flowchart for application of HAZOP is shown in figure.



HAZOP STUDY FLOW CHART



GUIDE WORDS

NONE No forward flow when there should be

MORE More of any parameter than there should be, e.g. more

flow, more pressure, more temperature, etc.

LESS As above, but "less of" in each instance

PART System composition difference from what it should be

MORE THAN More "components" present than there should be for

example, extra phase, impurities

OTHER What needs to happen other than normal operation, e.g.

start up, shutdown, maintenance?

NONE e.g., NO FLOW caused by blockage; pump failure; valve

closed or jammed: leak: valve open; suction vessel empty;

delivery side over - pressurized: vapor lock; control failure

REVERSE e.g., REVERSE FLOW caused by pump failure: NRV failure or

wrongly inserted; wrong routing; delivery over pressured;

back- siphoning; pump reversed

MORE OF e.g., MORE FLOW caused by reduced delivery head ; surging

; suction pressurized ; controller failure ; valve stuck open

leak ; incorrect instrument reading.

MORE OF MORE TEMPERATURE, pressure caused by external fires;

blockage ; shot spots; loss of control ; foaming; gas release;

reaction; explosion; valve closed; loss of level in heater; sun.

LESS OF e.g., LESS FLOW caused by pump failure; leak; scale in

delivery; partial blockage ; sediments ; poor suction head;

process turndown.

LESS e.g., low temperature, pressure caused by Heat loss;

vaporization; ambient conditions; rain; imbalance of input

and output; sealing; blocked vent.

PART OF Change in composition high or low concentration of mixture;

additional reactions in reactor or other location; feed

change.

MORE THAN Impurities or extra phase Ingress of contaminants such as

air, water, lube oils; corrosion products; presence of other

process materials due to internal leakage ; failure of

isolation ; start-up features.

OTHER Activities other than normal operation start-up and

shutdown of plant ; testing and inspection ; sampling ;

maintenance; activating catalyst; removing blockage or scale

; corrosion; process emergency ; safety procedures activated

; failure of power, fuel, steam , air, water or inert gas;

emissions and lack of compatibility with other emission and

effluents.



6.8.5 PROCESS HAZARD AND ITS CONTROL

Parameter Guide

Word

Name of

hazardous

process

and

operation

Possible causes Possible

consequences

Measures

safeguard

Action Require

Distillation

More Good Heating 1. No process hazards.

It is part of the

requirement.

2. It will accelerate

the distillation

process.

Temp.

Less Poor Heating No distillation will

take place. Process

delayed.

More Not Possible -- Pressure

Less Not Possible --

More Not Possible --

1. Temperature

gauge &

pressure

gauge

provided.

2. Sight glass

provided.

3. Safety valve

provided .

4. Cooling &

chilling

arrangement

with

alternative

provided.

1. Non return Valve to be provided.

2. Arrow indicator to be provided on

pipeline.

3. Stand by pump to be provided.

4. Pump, storage tank & pipe line

identification to be done.

5. Color code to be provided.

6. Periodic checking of the condenser

to be followed.

Flow

Power

Failure

Distillation

No GEB Supply Distillation will not

achieve.

D.G.Set

provided.

Raw material to the storage tank ( Day Tank ) - Transferring

No 1. No material

in the

storage tank.

2. Pump

tripped.

3. Pump

discharge

valve closed.

4. Heavy

leakage in

pipe line or

chocking the

pipeline.

No material to service

tank.

Pressure gauge

provided on the

pump discharge

valve.

pipeline

arrangement

with alternative

provided.

1. Non-returnable Valve to be

provided.

2. Arrow indicator to be provided on

pipeline.

3. Stand by pump to be provided.

4. Pump, storage tank & pipe line

identification to be done.

5. Color code to be provided.

6. Work permit procedure to be

followed for handling of

hazardous chemicals.

7. PPE compliance to be followed

during handling of acid.

More 1. Valve

opened

more than

set value

2. Human

Error.

More material to the

service tank.

Reverse Not possible

Flow

Pressure

Less

Transferrin

g of Raw

material to

the Storage

Tank

SOP to be prepared.



Transferring of Raw material from storage tank to Process vessel

More 1. Seasonal effect

2. Poor insulation

of pipeline.

3. Falling of hot

water on

uninsulated

line.

4. Incoming

material from

storage tank

itself has high

temperature.

1. More pressure in the

pipeline may give rise

to leakage.

2. From poor flange

joints, valve. Fire &

health hazards.

Insulation on

pipeline &

batch tank

provided.

1. Considering this

sufficient quantity of

water shall be ensured.

2. All flange joints shall be

checked regularly.

Temp.

Less 1. Seasonal effect

2. Leakage of

chilled water

from tank.

No workplace Hazards. Safety valve

provided on

batch tank.

More 1. N2 pressures

more.

2. Valve failure

3. FIC mal

function.

4. Human error.

1. Pressure rise in batch

tank.

2. Leakage in flange joint.

3. Safety valve of batch

tank may popup.

4. Tank filling operation

completed in less

time.

Pressure gauge shall be

provided on batch tank.

Pressure

Less 1. Low pressure of

N2 itself.

No safety hazards but it will

take more time for filling

operation.

More Same as

Pressure

Same as Pressure Same as Pressure

Less 1. Choking in the

excess flow

valve. (Holes are

choked.)

2. Low pressure of

N2 itself.

3. Valve choked.

No safety hazards but it will

take more time for filling

operation.

Flow

Reverse

Transferri

ng of Raw

material

from the

Storage

Tank to

Process

Vessel

No chances 1. NRV

provided.

2. Auto shut

off valve

provided.



Transferring of Raw material from storage tank to Process vessel

More 5. Seasonal

effect

6. Poor

insulation of

pipeline.

7. Falling of hot

water on

uninsulated

line.

8. Incoming

material

from storage

tank itself

has high

temperature

.

3. More pressure in

the pipeline may

give rise to

leakage.

4. From poor flange

joints, valve. Fire

& health

hazards.

Insulation on

pipeline & batch

tank provided.

3. Considering this sufficient

quantity of water shall be

ensured.

4. All flange joints shall be checked

regularly.

Temp.

Less 3. Seasonal

effect

4. Leakage of

chilled water

from tank.

No workplace

Hazards.

Safety valve

provided on

batch tank.

More 5. N2 pressures

more.

6. Valve failure

7. FIC mal

function.

8. Human

error.

5. Pressure rise in

batch tank.

6. Leakage in flange

joint.

7. Safety valve of

batch tank may

popup.

8. Tank filling

operation

completed in less

time.

Pressure gauge shall be provided on

batch tank.

Pressure

Less 2. Low

pressure of

N2 itself.

No safety hazards but

it will take more time

for filling operation.

More Same as

Pressure

Same as Pressure Same as Pressure

Less 4. Choking in

the excess

flow valve.

(Holes are

choked.)

5. Low

pressure of

N2 itself.

6. Valve

choked.

No safety hazards but

it will take more time

for filling operation.

Flow

Reverse

Transferri

ng of Raw

material

from the

Storage

Tank to

Process

Vessel

No chances 3. NRV

provided.

4. Auto shut off

valve

provided.



6.8.6 PLANNING FOR HAZOP

• Safety procedures documents

• Relief/venting philosophy

• Chemical involved

• Piping specifications

• Carry out the study

• Record the results

• Follow-up of actions noted

1. Final report contains resolution of all recommended actions.

2. Must appoint someone as leader to check progress of action.

3. Team may meet again if answers to questions do not simply lead to an action.

Team may meet again if significant design changes in interim report.

M/s. DIC FINE CHEMICALS PVT. LTD. - Environmental ...

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