EIA Report Godrej Agrovet Limited (GAVL) Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 1 RISK ASSESSMENT & DISASTER MANAGEMENT M/s. Godrej Agrovet Limited will execute the proposed project expansion activity at their existing premises located at Plot Nos.: E-24, E-24 (Part) and E-23/1, MIDC Lote Parshuram, Taluka: Khed, District: Ratnagiri, Maharashtra, India. Now, since the unit has been located in Notified MIDC area, as per the OM No. J-11011/321/2016-IA-II(I) dated 27 th April 2018 public hearing is exempted for the industries which are located in industrial estate or parks notified prior to 14.09.2006 i.e. the EIA Notification 2006 coming into force. RISK ASSESSMENT The risk assessment process is intended to identify existing and probable hazards in all operations and work environment, to quantify the hazards and to access the risk levels of those hazards in order to prioritize those that need an immediate attention. 7.1.1 SCOPE OF THIS STUDY The QRA (Quantitative Risk Assessment) study has been conducted considering the Terms of References (TORs) given for Environment Clearance (EC) by SEAC Committee, GoI, New Delhi. The study has been carried out with a view to comply TOR points with respect to Risk assessment 7.1.2 Methodology The following parameters are considered to prepare Quantitative Risk Assessment. Discussions were held with Plant officials on proposed individual safety systems of plant operations. Hazard Identification exercise in coordination with plant officials was conducted taking into consideration the proposed storage of Hazardous Chemicals/ Solvents, operating parameters and proposed safety systems. Containment failure scenarios related to flammable chemicals & hazardous chemicals have been considered for Risk Assessment and consequences in detail. Thus, this study is mainly oriented towards acute risks rather than chronic risks.
77
Embed
RISK ASSESSMENT & DISASTER MANAGEMENT M/s. Godrej …environmentclearance.nic.in/writereaddata/online/... · Godrej Agrovet Limited will handle various chemicals, some of which are
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 1
RISK ASSESSMENT & DISASTER MANAGEMENT M/s. Godrej Agrovet Limited will execute the proposed project expansion activity at their
existing premises located at Plot Nos.: E-24, E-24 (Part) and E-23/1, MIDC Lote Parshuram,
Taluka: Khed, District: Ratnagiri, Maharashtra, India. Now, since the unit has been located in
Notified MIDC area, as per the OM No. J-11011/321/2016-IA-II(I) dated 27th April 2018 public
hearing is exempted for the industries which are located in industrial estate or parks notified
prior to 14.09.2006 i.e. the EIA Notification 2006 coming into force.
RISK ASSESSMENT
The risk assessment process is intended to identify existing and probable hazards in all
operations and work environment, to quantify the hazards and to access the risk levels of
those hazards in order to prioritize those that need an immediate attention.
7.1.1 SCOPE OF THIS STUDY
The QRA (Quantitative Risk Assessment) study has been conducted considering the Terms of
References (TORs) given for Environment Clearance (EC) by SEAC Committee, GoI, New
Delhi.
The study has been carried out with a view to comply TOR points with respect to Risk
assessment
7.1.2 Methodology
The following parameters are considered to prepare Quantitative Risk Assessment.
Discussions were held with Plant officials on proposed individual safety systems of plant
operations.
Hazard Identification exercise in coordination with plant officials was conducted taking into
consideration the proposed storage of Hazardous Chemicals/ Solvents, operating parameters
and proposed safety systems.
Containment failure scenarios related to flammable chemicals & hazardous chemicals have
been considered for Risk Assessment and consequences in detail. Thus, this study is mainly
oriented towards acute risks rather than chronic risks.
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 2
Discussions were held with Plant officials on various Hazards in connection with the plant
operations & their Risks and proposed individual safety systems for plant operations.
Hazard Identification
The project description, and other project related data provided by the client have been
comprehensively reviewed to identify the hazardous operations. Also the information on the
hazardous properties (MSDS) of all the chemicals handled at the site has been reviewed to
identify the hazards associated with the same. Storage of some of the raw material at the site
can lead to uncontrolled release of hazardous material causing hazard. On the basis of this,
the important hazards that can lead to accident in the proposed expansion project are
tabulated below.
TABLE 7.1: TYPE OF HAZARDOUS EVENTS
Type of event Description Explosion A release of large amount of energy that form a blast wave
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 flammable liquid to the surroundings
from unit‘s own Storage containers causing (potential) pollution or risk
of explosion or formation of Toxic vapor cloud
Flammable area
Vapor Cloud
Explosion
Explosion resulting from vapor clouds formed from flashing liquids
Hazard and Damage Assessment
Toxic and flammable 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,
Puddle /pool Fires resulting in a heat wave (radiation), or
Explosions (Vapor Cloud Explosions) resulting in blast waves (overpressure).
Consequences of Fire/Heat Wave
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 3
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 given in the table below.
TABLE 7.2: THERMAL RADIATION INTENSITY AND EXPOSURE TIME-DAMAGE CRITERIA FOR PEOPLE
Thermal Radiation Intensity (KW/m2) Type of Damage
1.6 No harm for long exposures. 4 to 5 Pain for 20 seconds exposure; first degree burn 9.5 Second degree burn after 20 Seconds
10 to 15 Potentially lethal with in 1 minute. 25 Significant injury in 10 seconds; 100 % lethality in 1 minute.
35 to 37.5 1 % lethality in 10 seconds. 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 pressure of the shock
wave decreases rapidly with the increase in distance from the source of the explosion. The
overpressure damage is discussed in table below.
TABLE 7.3: DAMAGE DUE TO OVERPRESSURES
PEAK OVERPRESSURE DAMAGE TYPE
0.83 bar Total destruction
0.30 bar Heavy damage
0.10 bar Moderate damage
0.03 bar Significant damage
0.01 bar Minor damage
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, since they are likely credible
scenarios.
These effects are:
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 4
Hydrogen peroxide which may leads to Air pollution, Water pollution and Soil pollution
The exposure to hazards depends upon the concentration of hazard, Frequency and duration.
The exposure to hazard could be controlled by reducing either the concentration of hazard,
frequency or duration.
After a critical analysis of the chemicals propose to use, stored and for products to
manufacture a defined safe operating procedures will be in place with safety and mitigation
measures to overcome the hazards.
The exposure to the hazard could be controlled by implementing the following:
Engineering controls at the source
Environmental controls that remove the hazard from the environment
Inspection of solvents transfers pipelines conveying lines once in a month.
Earthing to all storage tanks and providing jumpers to transfer pipelines to have continuity of
earthing.
All the process reactors will have temperature control and pressure control system for process
as well as suitable Rupture disc followed by a safety valve to avoid explosion due to excess
pressure.
Details of Process emissions and treatment (Neutralization) methods:
During production of Pyrithiobac sodium, Ammonia and Sulfur dioxide gases will be
released. 6.29 kgs of Ammonia gas and 20.99 Kgs of Sulfur dioxide gas will be released as
process emissions.
The released process emission Ammonia gas from reactor will be sent to double stage
scrubber to scrub ammonia gas with chilled water to convert into 30% Ammonium hydroxide
solution.
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 8
The scrubber will be fitted with Ammonia gas detector to monitor any un scrubbed gases
escaping from scrubber. At any point of time the Ammonia presence in the vent gases will not
be more than 25 ppm.
The released process emission Sulfur dioxide gas from reactor will be sent to double stage
scrubber to scrub the gas with 10% sodium hydroxide solution to convert into Sodium sulfite
salt. The scrubber will be fitted with online PH meter to check continuously the PH of Scrubbing
solution. When solution pH reaches to 8 the scrubbing solution will be changed.
The scrubber will be fitted with Sulfur dioxide gas detector to monitor any un scrubbed gases
escaping from the scrubber. At any point of time the Sulfur dioxide presence in the vent gases
will not be more than 5 ppm
During production of Homobrassinolide, HCl and Sulfur dioxide gases will be released.
2.66 kgs of HCl gas and 4.46 kgs of Sulfur dioxide gas will be released as process emissions.
The released process emission HCl gas from reactor will be sent to double stage scrubber to
scrub HCl gas with chilled water to convert into 10% Hydrochloric acid.
The scrubber will be fitted with HCl gas detector to monitor the any un-scrubbed gases
escaping from scrubber. At any point of time the HCl gas presence in the vent gases will not
be more than 35 mg/m3
The released process emission Sulfur dioxide gas from reactor will be sent to double stage
scrubber to scrub the gas with 10% sodium hydroxide solution to convert into Sodium sulfite
salt. The scrubber will be fitted with online PH meter to check continuously the pH of Scrubbing
solution. When solution pH reaches to 8.0 the scrubbing solution will be changed.
The scrubber will be fitted with Sulfur dioxide gas detector to monitor any un-scrubbed gases
escaping from the scrubber. At any point of time the Sulfur dioxide presence in the vent gases
will not be more than 5 ppm.
During production of Metribuzin Technical, HBr gas and HCl gases will be released.
71.37 kgs of HBr gas and 94.63 kgs of HCl gas will be released as process emissions.
The released process emission HBr gas from reactor will be sent to double stage scrubber to
scrub the gas with 10% sodium hydroxide solution to convert into Sodium bromide salt.
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 9
The scrubber will be fitted with HBr gas detector to monitor the any un-scrubbed gases
escaping from scrubber. At any point of time the HBr gas presence in the vent gases will not
be more than 5 mg/m3
The released process emission HCl gas from reactor will be sent to double stage scrubber to
scrub HCl gas with chilled water to convert into 10% Hydrochloric acid.
The scrubber will be fitted with HCl gas detector to monitor the any un-scrubbed gases
escaping from scrubber. At any point of time the HCl gas presence in the vent gases will not
be more than 35 mg/m3
During production of Quizalofop-p-ethyl, HCl gas will be released.
18.78 kgs of HCl gas will be released as process emission.
The released process emission HCl gas from reactor will be sent to double stage scrubber to
scrub HCl gas with chilled water to convert into 10% Hydrochloric acid.
During production of Trifloxystrobin Technical, HCl gas will be released.
44.25 kgs of HCl gas will be released as process emission.
The released process emission HCl gas from reactor will be sent to double stage scrubber to
scrub HCl gas with chilled water to convert into 10% Hydrochloric acid.
The scrubber will be fitted with HCl gas detector to monitor the any un-scrubbed gases
escaping from scrubber. At any point of time the HCl gas presence in the vent gases will not
be more than 35 mg/m3
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 10
TABLE 7.4: AREA WISE IDENTIFIED HAZARDS, PRECAUTIONS PROPOSED WITH MITIGATION MEASURES
S. No. AREA IDENTIFIED
HAZARD
SEVERITY & NO. OF PERSONS EXPOSED
PRECAUTIONS PROPOSED MITIGATION MEASURES
1]
Raw Material Storage area
Spillage of chemicals
Low to medium & 4 persons
1. Approved layout as per legal requirements.
2. Flame proof electrical fittings will be installed
3. Chemicals will be stored in safe Containers with secondary containment to prevent spillages.
4. Storage quantity is limited 5. Storage area will be well
ventilated by a forced air ventilation system.
6. Material will be accessed only by authorized personnel using mechanized systems
7. Double door entry to ensure a clean atmosphere.
8. Showers will be provided for decontamination.
9. Personnel will be provided with full body protection suits and nose masks to prevent exposure to chemicals.
10. Fire hydrant system with hydrant points with hose reels and nozzles will be installed to mitigate fire hazards
1. Area will be cordoned off. 2. Information will be passed to
Emergency control center is informed.
3. Information will be given to the declarer of emergency on the scale of Leakage.
4. Emergency Response teams will be kept on alert for swift response.
5. All hot works being carried out in the surrounding areas will be stopped
6. Personnel working in the area will be evacuated.
7. Spilled powders will be collected using vacuum cleaners.
8. The spillage will be cleared and the area is made fit work
9. In case of liquid chemical spillage, the container will be shifted from ware house to the outside for arresting the leakage and transferring the contents to another vessel depends on situation.
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 11
S. No. AREA IDENTIFIED
HAZARD
SEVERITY & NO. OF PERSONS EXPOSED
PRECAUTIONS PROPOSED MITIGATION MEASURES
11. Fire extinguishers will be deployed adequately
12. Periodical occupational health checks will be done to personnel working in the area to Access health effects, if any.
13. Liquid chemicals such as HCl, Ethyl acetate, THF, Acetic acid, and Thionyl chloride, Hydrogen peroxide, sulfuric acid will be stored in dedicated area.
Solid chemicals such as, Sodium hydroxide, Potassium hydroxide, potassium carbonate will be stored in dedicated area. Solid and liquid chemicals will not be stored in the same area.
The area where leakage is occurred will be neutralized if necessary and cleaned. The warehouse will have good ventilation so as to minimize the concentration of respective chemical in the working area.
2]
Solvents drums Storage area
Fire, Flammable area of vapor cloud
Medium to High & 2 persons
1. Storage facility will be provided in isolated area to have natural ventilation
2. Flameproof electrical fittings are provided in storage area to prevent any fire hazard.
3. No electrical gadgets or items capable of generating static electric charges will be permitted in the area.
1. Area will be cordoned off. 2. No Hot work will be carried out in
the vicinity to prevent accidental spread of fire.
3. Personnel working in the area will be evacuated
4. Emergency control center will be informed
5. Information will be given to the declarer of emergency on the
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 12
S. No. AREA IDENTIFIED
HAZARD
SEVERITY & NO. OF PERSONS EXPOSED
PRECAUTIONS PROPOSED MITIGATION MEASURES
4. Personnel will be trained about Do‘s & Don‘ts during emergency.
5. No heat sources will be permitted near the Facility.
6. Hot work will be controlled through a work permit system
7. Adequate size collection pit will be provided for containment in case of leakage of solvent.
8. The solvents will be handled by trained and authorized personnel.
9. Mechanical foam type & DCP fire extinguishers are provided at solvent drum storage area as per chief controller of explosives directions.
10. Fire hydrant system with hose reels are provided in the solvents storage area.
11. Hydrocarbon detectors will be provided in the Solvents drums storage area.
scale of Leakage of solvent, Fire. 6. Emergency Response teams will
be kept on alert for swift response.
7. The leakage will be cleared and the area is made fit work
8. In case leakage is found, the contents will be transferred to a in to HDPE drums.
3]
Production Block-Process Reactors
Oxidation/Hydroxylation/Mesylation
Low to medium & 8 persons
1. Flame proof electrical fittings will be installed
2. Jacket chilling/cooling water supply to avoid high
1. Area will be cordoned off. 2. Power supply will be cut off to
the area to prevent accidental fire.
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 13
S. No. AREA IDENTIFIED
HAZARD
SEVERITY & NO. OF PERSONS EXPOSED
PRECAUTIONS PROPOSED MITIGATION MEASURES
exothermic reaction/ Fire
temperature in reactor 3. Material will be stored at
production blocks in safe containers for batch charging with secondary containment to prevent Spillages.
4. Earthing and bonding will be carried out for all reactor vessels and pipelines
5. Nitrogen lines will be provided to reaction vessel to create inert atmosphere inside the reactor to avoid fire and explosion
6. Work permit system will be implemented for hazard assessment in case of any hot work / work at elevated places.
7. Manufacturing area will be ventilated by a Forced air ventilation system to prevent formation of flammable mixture.
8. Fire hydrant system with hydrant points with hose reels and nozzles will be installed to mitigate fire hazards
9. Fire extinguishers are deployed adequately
3. All hot work carried out in the vicinity will be stopped.
4. Emergency control center will be informed.
5. Information will be given to the declarer of emergency on the scale of spillage / fire/Toxic gas release
6. Emergency Response teams will be kept on alert for swift response.
7. Personnel working in the area will be evacuated.
8. Scrubber will be kept in operating condition with caustic scrubbing solution
9. Fire hydrant system will be put in use.
10. If situation beyond control information will be given to Inspector of factories, police, fire department for their assistance.
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 14
S. No. AREA IDENTIFIED
HAZARD
SEVERITY & NO. OF PERSONS EXPOSED
PRECAUTIONS PROPOSED MITIGATION MEASURES
Production block
Ammonia Toxic gas release during production of Pyrithiobac sodium
10 persons
10. Eye wash fountain / Body shower are provided for decontamination at each floor.
11. Limit switches will be provided for centrifuges for safe operation.
12. Nitrogen purging will be arranged for each Centrifuge to prevent formation of explosive flammable mixture.
13. Each reactor will be connected to a scrubber to neutralize or decrease the pressure in case sudden rise in pressure.
Ammonia detector will be installed in the production block with alarm. When Ammonia concentration reaches in the air 25 ppm, immediately alarm will activate.
1. Scrubber will be kept in
operating condition with chilled water circulation during transfer of the material.
2. Emergency Response teams will be kept on alert for swift response
3. Area will be cordoned off. 4. Emergency control center will
be informed
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 15
S. No. AREA IDENTIFIED
HAZARD
SEVERITY & NO. OF PERSONS EXPOSED
PRECAUTIONS PROPOSED MITIGATION MEASURES
5. Information will be given to the declarer of emergency on the scale of Leakage.
6. Neighboring industries and statutory authorities will be informed in case situation is severe.
4] Boiler House
Fire/ Explosion
Low to medium & 2 persons
1. All requirements specified under Boiler Act will be followed
2. All electrical fittings will be of flame proof Type.
3. Entry will be restricted only to trained and authorized personnel to work in the area.
4. Fire extinguishers are positioned at different locations in case of any Emergencies.
5. No material storage will be permitted in the Area.
6. Auto level controller for Water and high temperature alarms will be provided.
7. Water hardness will be checked on shift wise.
8. Area will be well ventilated and illuminated for safe working.
9. 24 x 7 manning of the area is
1. Shutting down the plant, declaring the emergency.
2. Electrical supply will be isolated. 3. Type of emergency will be
informed to the emergency declarer/ central authority.
4. Emergency response teams will be kept on alert for swift action.
5. Movement of personnel and vehicles will be prohibited. Adequate no. of Fire hydrant system will be put in use.
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 16
S. No. AREA IDENTIFIED
HAZARD
SEVERITY & NO. OF PERSONS EXPOSED
PRECAUTIONS PROPOSED MITIGATION MEASURES
done for monitoring of operation.
10. All maintenance /repair works will be carried out after issuing work permits and under constant supervision of experts.
11. Periodical cleaning of soot in furnace to prevent formation of explosive mixtures.
12. Checking of boiler internals as per given schedule to prevent Accidents.
13. Signage‘s will be displayed to
inform personnel about the hazards present in the area
5] Diesel Generator
Noise & Fire Low & 1 person
1. Noise abatement through modular acoustic paneling of D. G. set
2. Secondary containment is done to prevent Diesel leakage from day tanks.
3. Adequate no. of fire extinguishers is kept to handle emergency.
4. Entry access to the area will be only for Authorized personnel.
1. Information will be given to Emergency control center.
2. Power supply will be cut off to the storage area to prevent accidental fire.
3. All hot work around the area will be stopped and the area will be cordoned off
4. The concerned maintenance personnel will be carried repairs to mitigate the leakages.
5. Emergency Response Team will
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 17
S. No. AREA IDENTIFIED
HAZARD
SEVERITY & NO. OF PERSONS EXPOSED
PRECAUTIONS PROPOSED MITIGATION MEASURES
be kept on alert for swift response.
6. Periodical occupational health checks will be done to personnel working in the area to assess exposure to noise.
6]
Electrical sub -station
Electric shock / fire
Low to Medium & 2 persons
1. Layout confirm to legal requirements as per Indian Electrical Rules.
2. Entry will be restricted to licensed and authorized personnel only.
3. Earthing is provided for leakage of stray currents.
4. Electronic mimic panels are installed for fault indication at the entry of the sub-station.
5. Insulating rubber mats confirming to IS: 15652- 2006 will be provided in front of all electrical panel boards.
6. Periodical inspection and maintenance will be carried out to ensure good health of the equipment.
7. CO2 / DCP fire extinguishers are deployed to handle emergency fires
1. Information will be given to Emergency control center.
2. Power supply will be cut off from incoming source.
3. Electricity supply company will be alerted for cut off power supply in case of major risks
4. All hot work around the area will be stopped and the area is cordoned off.
5. The concerned maintenance personnel will be carried repairs to restore normalcy.
6. Emergency Response Team will be kept on alert for swift response
7] Hazardous waste
Fire/Leakage
Low to Medium &
1. Storage shed will be at an isolated location.
1. Information will be given to Emergency control center.
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 18
S. No. AREA IDENTIFIED
HAZARD
SEVERITY & NO. OF PERSONS EXPOSED
PRECAUTIONS PROPOSED MITIGATION MEASURES
storage shed
1 Person
2. Conditions specified in hazardous waste Authorization issued by SPCB will be implemented.
3. Compatible wastes will be stored in separate enclosures
4. Layout provides adequate ventilation and illumination
5. Secondary containment provided to prevent leakages / spillages
6. Storage quantity will be limited. 7. Periodical disposal of
accumulated waste will be sent to authorize landfills.
8. Flame proof electrical fittings will be installed to prevent fire / explosion hazards
9. Eye wash / body shower will be provided for decontamination in case of spillage on body parts.
10. PPE box will be equipped with gum boots, splash proof safety goggles, aprons for use during handling of chemicals.
11. Access to the area will be restricted to authorize personnel
2. Power supply will be cut off from incoming source.
3. All hot work around the area will be stopped and the area is cordoned off
4. The concerned maintenance personnel will be carried repairs to restore normalcy
5. Fire hydrant system will be put in use
6. Emergency Response Team will be kept on alert for swift response.
7. Support of external agencies will be sought in case situation poses major risks and is not controllable by in-house infrastructure
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 19
S. No. AREA IDENTIFIED
HAZARD
SEVERITY & NO. OF PERSONS EXPOSED
PRECAUTIONS PROPOSED MITIGATION MEASURES
only. 12. Fire hydrant point with hose
reels are provided for fire mitigation
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 20
Acetone: It is a clear, volatile, flammable liquid. Vapors may form explosive mixtures with air.
Vapors are heavier than air and may travel along the ground to some distance source of
ignition and flash back.
On combustion may emit toxic fumes of carbon monoxide and CO2.
This product causes irritation of eyes, skin, and mucous membranes in case of contact. It will
cause lung damage if swallowed. Do not breathe vapors.
Use foam, carbon dioxide or dry chemical. Suppress vapors/mists with a water spray jet.
In case of spillage soak up with inert absorbent material such as sand, silica gel, saw dust. Do
not use sparking tools. Do not allow product to enter sewer or waterways.
Store in a well-ventilated place to effectively remove and prevent buildup of any vapors or
mists generated from handling of this product.
While handling wear impervious gloves and anti-static protective clothing. For leak, spills, or
other emergency, use full protective equipment.
Boiling Point: 56.2°C
Flash Point: -20°C
Flammable Limits: LOWER: 2.6% UPPER: 12.8%
Toluene: It is a clear, volatile, flammable liquid. Vapors may form explosive mixtures with air.
Vapors are heavier than air and may travel along the ground to some distance source of
ignition and flash back. Keep away from heat. Keep away from sources of ignition. Ground all
equipment containing material. Do not ingest. Do not breathe gas/fumes/ vapor/spray. Wear
suitable protective clothing. In case of insufficient ventilation wear suitable respiratory. On
combustion may emit toxic fumes of carbon monoxide and CO2.
This product causes irritation of eyes, skin, and mucous membranes in case of contact. It will
cause lung damage if swallowed. Do not breathe vapors.
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 22
Use foam, carbon dioxide or dry chemical. Suppress vapors/mists with a water spray jet. If
ingested, seek medical advice immediately and show the container or the label. Avoid contact
with skin and eyes.
Storage: Store in a segregated and approved area. Keep container in a cool, well-ventilated
area. Keep container tightly closed and sealed until ready for use. Avoid all possible sources of
ignition (spark or flame).
Toluene forms explosive reaction with concentrated nitric acid, sulfuric acid + nitric.
Boiling Point: 110.6 °C
Flash Point: 4.4 °C
Flammable Limits: LOWER: 1.1% UPPER: 7.1%
Methanol: Extremely flammable and vapor may form ignitable vapor air mixtures in storage
tanks or other containers. Ignition and busing can release carbon monoxide, carbon dioxide
and non combustible hydrocarbons (Smoke).
Inhalation can Cause dizziness, head ache and nausea, kidney and liver disorder.
Use foam, carbon dioxide or dry chemical. Suppress vapors/mists with a water spray jet.
In case of spillage soak up with inert absorbent material such as sand, silica gel, saw dust. Do
not use sparking tools. Do not allow product to enter sewer or waterways.
Store in a well-ventilated place to effectively remove and prevent buildup of any vapors or
mists generated from handling of this product.
While handling wear impervious gloves and anti-static protective clothing. For leak, spills, or
other emergency, use full protective equipment.
Boiling Point: 64.7 °C
Flash Point: 12°C
Flammable Limits: LOWER: 6% UPPER: 36%
Hydrochloric acid:
Water Reaction
An aqueous solution. Dilution may generate heat. Fumes in air.
Fire Hazard
Special Hazards of Combustion Products: Toxic and irritating vapors are generated when
heated.
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 23
Health Hazard
Inhalation of fumes results in coughing and choking sensation, and irritation of nose and lungs.
Liquid causes burns.
Reactivity Profile
Hydrochloric Acid is an aqueous solution of hydrogen chloride, an acidic gas. Reacts
exothermically with organic bases (amines, amides) and inorganic bases (oxides and
hydroxides of metals).
Reacts exothermically with carbonates (including limestone and building materials containing
limestone) and hydrogen carbonates to generate carbon dioxide.
Reacts with sulfides, carbides, borides, and phosphates to generate toxic or flammable gases.
Reacts with many metals (including aluminum, zinc, calcium, magnesium, iron, tin and all of
the alkali metals) to generate flammable hydrogen gas.
Protective Clothing:
Skin: If chemical is in solution, wear appropriate personal protective clothing to prevent skin
contact and to prevent skin from becoming frozen from contact with the liquid or from contact
with vessels containing the liquid.
Eyes: Wear appropriate eye protection to prevent eye contact with the liquid that could result in
burns or tissue damage from frostbite.
Wash skin: If the chemical is in solution, the worker should immediately wash the skin when it
becomes contaminated.
Remove: If chemical is in solution, work clothing that becomes wet or significantly
contaminated should be removed and replaced.
Provide: Eyewash fountains should be provided (when chemical is in solution) in areas where
there is any possibility that workers could be exposed to the substance; this is irrespective of
the recommendation involving the wearing of eye protection. Facilities for quickly drenching the
body should be provided (when chemical is in solution) within the immediate work area for
emergency use where there is a possibility of exposure. It is intended that these facilities
provide a sufficient quantity or flow of water to quickly remove the substance from anybody
areas likely to be exposed.
Quick drench facilities and/or eyewash fountains should be provided within the immediate work
area for emergency use where there is any possibility of exposure to liquids that are extremely
cold or rapidly evaporating.
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 24
Sulfuric acid: Water Reaction
Reaction with water is negligible unless acid strength is above 70% then heat from hydrolysis
is extreme, may cause severe burns
Fire Hazard
It is highly reactive and capable of igniting finely-divided combustible materials on contact.
When heated, it emits highly toxic fumes. Avoid heat; water and organic materials. Sulfuric
acid is explosive or incompatible with an enormous array of substances. It can undergo violent
chemical change at elevated temperatures and pressure. It may react violently with water.
Health Hazard:
Corrosive to all body tissues. Inhalation of vapor may cause serious lung damage. Contact
with eyes may result in total loss of vision. Skin contact may produce severe necrosis.
Fatal amount for adult: between 1 teaspoonful and one-half ounce of the concentrated
chemical. Chronic exposure may cause tracheobronchitis, stomatitis, conjunctivitis, and
gastritis. Those with chronic respiratory, gastrointestinal, or nervous diseases and any eye and
skin diseases are at greater risk.
Protective Clothing:
Skin: Wear appropriate personal protective clothing to prevent skin contact.
Eyes: Wear appropriate eye protection to prevent eye contact.
Wash skin: The worker should immediately wash the skin when it becomes contaminated.
Remove: Work clothing that becomes wet or significantly contaminated should be removed
and replaced. Provide: Eyewash fountains should be provided in areas where there is any
possibility that workers could be exposed to the substance; this is irrespective of the
recommendation involving the wearing of eye protection.
Facilities for quickly drenching the body should be provided within the immediate work area for
emergency use where there is a possibility of exposure.
It is intended that these facilities provide a sufficient quantity or flow of water to quickly remove
the substance from anybody areas likely to be exposed.
Thionyl chloride:
A colorless to yellow fuming liquid with a suffocating pungent odor. A lachrymator. Highly
corrosive and toxic.
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 25
Long-term inhalation of low concentrations or short-term inhalation of high concentrations has
adverse health effects.
Emits dense corrosive fumes in moist air. Violently reacts with water to liberate hydrochloric
acid and sulfur dioxide. Based on a scenario where the chemical is spilled into an excess of
water (at least 5 fold excess of water), half of the maximum theoretical yield of Sulfur Dioxide
gas will be created in 0.25 minutes.
Protective Clothing
Skin: Wear appropriate personal protective clothing to prevent skin contact.
Eyes: Wear appropriate eye protection to prevent eye contact.
Wash skin: The worker should immediately wash the skin when it becomes contaminated.
Provide eyewash fountains in areas where there is any possibility that workers could be
exposed to the substance; this is irrespective of the recommendation involving the wearing of
eye protection.
Hydrogen Peroxide 50%: Clear, colorless liquid.
Handling:
Will Use only in well-ventilated areas and Keep away from clothing/ combustible materials.
Wear personal protective equipment. Contamination may cause decomposition and generation
of oxygen gas which could result in high pressures and possible container rupture. Empty
drums should be triple rinsed with water before discarding. Utensils used for handling
hydrogen peroxide will be only be made of glass, stainless steel, aluminum or plastic. Pipes
and equipment should be Passivity before first use. Hydrogen peroxide will be stored only in
vented containers and transferred only in a prescribed manner.
Storage:
Keep containers in dedicated & cool areas out of direct sunlight and away from combustibles.
Will provide local exhaust ventilation to prevent release of vapor or mist into work environment.
Store rooms or warehouses will be made of non-combustible materials with impermeable
floors. In case of release, spillage will flow to safe area.
Boiling Point: 114 °C
Ethanol: Clear, colorless Liquid
Handling and Storage
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 26
Handling: Will use only in a well-ventilated area. Ground and bond containers when transferring Material.
Use spark-proof tools and explosion proof equipment.
Avoid contact with eyes, skin, and clothing.
Keep container tightly Closed.
Keep away from heat, sparks and flame.
Avoid ingestion and inhalation.
Do not pressurize, weld, or expose empty containers to heat, sparks or open flames.
Storage:
Keep away from heat, sparks, and flame. Keep away from sources of ignition. Keep from contact with oxidizing materials.
Store in a cool, dry, well-ventilated area away from incompatible substances. Flammables-area.
Do not store near perchlorates, peroxides, chromic acid or nitric acid.
Spills/Leaks:
Absorb spill with inert material (e.g. vermiculite, sand or earth), then place in suitable container. Remove all sources of ignition. Use a spark-proof tool. Provide ventilation
Boiling Point: 77.1 deg C
Flash Point: 17°C
Flammable Limits: LOWER: 3.3% UPPER: 19%
Chloroform: Colorless Liquid. Handling: Do not get in eyes or on skin or clothing. Do not breathe vapor or mist.
Use only with adequate ventilation. Wear appropriate respirator when ventilation is inadequate.
Kept tightly closed when not in use.
Storage: Store in original container, protected from direct sunlight. Keep container tightly
closed and sealed until ready for use. Containers that have been opened must be carefully
resealed and kept upright to prevent leakage.
Boiling Point: 60.5°C
Flash Point: Not Flammable Methods for cleaning up:
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 27
Spill: Stop leak if without risk. Move containers from spill area.
Prevent entry into sewers, water courses, basements or confined areas.
Contain and collect spillage with non-combustible, absorbent material e.g. sand, earth,
vermiculite or diatomaceous earth and place in container for disposal. Contaminated absorbent
material may pose the same hazard as the spilled product.
Ethyl Acetate: Clear colorless liquid
Precautions for safe handling: Do not breathe vapor or mist.
Wear protective gloves/clothing and eye/face protection.
Wash thoroughly after handling.
Ground and secure containers when dispensing or pouring product.
Avoid contact with incompatible materials.
When handling, DO NOT eat, drink or smoke.
Use in a well ventilated place/Use protective clothing commensurate with exposure
levels.
Storage: Store in a cool, well ventilated place.
Store away from incompatible materials.
Keep container tightly closed.
Keep securely closed when not in use.
Major Spill:
Alert Emergency Responders and tell them location and nature of hazard.
Shut off all possible sources of ignition and increase ventilation.
Wear protective clothing, full boots, impervious gloves, safety glasses and Self
Contained Breathing Apparatus (SCBA), as may be deemed appropriate.
Clear area of personnel and move upwind.
Stop leaks if possible.
Prevent, by any means available, spillage from entering drains or water and
watercourses.
Collect recoverable product into labeled containers for recycling, recovery or disposal.
Contain spill with sand, earth or vermiculite.
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 28
Spread area with lime or absorbent material, and leave for at least 1 hour before
washing.
Clean up all tools and equipment.
Boiling Point: 76.0 °C
Flash Point: -4.4°C
Flammable limits: 2.2% Lower limit,
9% Upper limit
N-Methyl-2-Pyrrolidone: colorless liquid
Precautions for safe handling: Avoid contact with skin and eyes. Avoid formation of dust and
aerosols. Provide appropriate exhaust ventilation at places where dust is formed. Keep away
from sources of ignition.
Conditions for safe storage: Store in cool place. Keep container tightly closed in a dry and
well-ventilated place.
Boiling Point: 202 °C
Flammable Limits: Upper explosion limit: 9.5 %
Lower explosion limit: 1.3 %
Dichloromethane: Colorless liquid
Precautions for safe handling: Work under hood. Avoid generation of vapors
Immediately change contaminated clothing. Wash hands and face after working with material.
Conditions for safe storage: Tightly close. Keep in a well-ventilated place. Protect from light.
Flammable Limits: Upper explosion limit: 13 %
Lower explosion limit: 23 %
Boiling Point: 40 °C
Methyl ethyl Ketone (MEK):
Precautions for safe handling: Keep away from heat, sparks and open flame. Take
precautionary measures against static discharges.
Conditions for safe storage: Ground container and transfer equipment to eliminate static
electric sparks. Store in a cool and well ventilated place.
Boiling Point: 82 °C
Flash Point: -9 °C
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 29
Flammable Limits: 1.5% Lower limit
11.5% Upper limit
Ethylene Dichloride: Colorless Liquid.
Handling and Storage:
Avoid contact with skin, eyes, and clothing. Avoid inhaling vapour and/or mists. Ensure
electrical continuity by bonding and grounding (earthing) all equipment. Restrict line velocity
during pumping in order to avoid generation of electrostatic discharge.
Storage Temperature: Ambient. Must be stored in a well ventilated area, away from sunlight,
ignition sources and other sources of heat.
Vapours from tanks should not be released to atmosphere. Breathing losses during storage
should be controlled by a suitable vapor treatment system.
Clean Up Methods
For large liquid spills (> 1 drum), transfer by mechanical means such as vacuum truck to a
salvage tank for recovery or safe disposal. Retain as contaminated waste. Allow residues to
evaporate or soak up with an appropriate absorbent material and dispose of safely. Remove
contaminated soil and dispose of safely. For small liquid spills (< 1 drum), transfer by
mechanical means to a labelled, sealable container for product recovery or safe disposal.
Allow residues to evaporate or soak up with an appropriate absorbent material and dispose of
safely. Remove contaminated soil and dispose of safely.
Boiling Point: 84 °C
Flash Point: 13 °C
Flammable Limits: 6.2 %LOWER LIMIT
15.9% UPPER LIMIT
Acetic Anhydride: A colorless solution
Precautions to Be Taken: Avoid breathing fume/gas
In Handling: Avoid prolonged or repeated exposure.
Keep away from sources of ignition.
Take precautionary measures against static discharge.
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 30
Precautions to be taken Keep away from heat, sparks, and flame.
In Storing: Keep container tightly closed.
Other Precautions: Reacts violently with water.
Boiling Point: 138 C
Flash Point: 49 °C
Flammable Limits: 2.7% %LOWER LIMIT
10.3% UPPER LIMIT
Dimethyl Formamide: Colorless liquid
Conditions for safe storage: Keep container tightly closed in a cool, well-ventilated place.
Ground container and transfer equipment to eliminate static electric sparks.
Methods and material for containment and cleaning up:
Eliminate all ignition sources if safe to do so. Take precautionary measures against static
discharges.. Use only non-sparking tools. Absorb spill with vermiculite or other inert material,
then place in a container for chemical waste.
Clean surface thoroughly to remove residual contamination.
Precautions for safe handling:
Do not handle, store or open near an open flame, sources of heat or sources of ignition.
Protect material from direct sunlight.
Take precautionary measures against static discharges.
Ground/bond container and receiving equipment.
Use explosion-proof electrical/ventilating/lighting/equipment.
S. No. Risk Significance Criteria Definition & Action Requirements
1 High (16-25)
―Risk requires attention‖ – Project Management need to ensure that necessary mitigation are adopted to ensure that possible risk remains within acceptable limits.
2 Medium (10-15)
―Risk is tolerable‖ – Project Management to adopt necessary measures to prevent any change/modification of existing risk controls and ensure implementation of all practicable controls.
3 Low (5-9)
―Risk is acceptable‖ – Project related risks are managed by well established controls and routine processes/procedures. Implementation of additional controls can be considered.
4 Very Low (1-4)
―Risk is acceptable‖- All risks are managed by well established controls and routine processes/procedures. Additional risk controls need not to be considered.
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 39
The basic physical effect models consist of the following.
Source strength parameters
Calculation of the outflow of liquid, vapor out of a vessel, in case of rupture. Also two-
phase outflow can be calculated.
Calculation in case of liquid outflow, of the instantaneous flash evaporation.
Calculation of the evaporation rate, as a function of volatility of the material, pool
dimensions and wind velocity.
Consequential effects
Dispersion of gaseous material in the atmosphere as a function of source strength,
relative density of the gas, weather conditions and topographical situation of the
surrounding area.
Intensity of heat radiation [in KW / m2] due to a pool fire, as a function of the distance to
the source.
Energy of vapor cloud explosions [in KW / m2], as a function of the distance to the
distance of the exploding cloud.
Concentration of gaseous material in the atmosphere, due to the dispersion of
evaporated chemical. The latter can be either explosive or toxic.
It may be obvious, that the types of models that must be used in a specific risk study strongly
depend upon the type of material involved:
liquid
Inflammable, toxic products
Selection of Damage Criteria
The damage criteria give the relation between extent of the physical effects (exposure)
and the percentage of the people that will be killed or injured due to those effects
The knowledge about these relations depends strongly on the exposure. For instance,
much more is known about the damage caused by heat radiation, than about the
damage due to toxic exposure, and for these toxic effects, the knowledge differs
strongly between different materials.
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 40
In consequence analysis studies, in principle three types of exposure to hazardous effects are
distinguished:
Heat radiation from puddle/pool fire
Vapor cloud Explosion
Toxic effect from toxic materials or toxic combustion products.
Heat Radiation
The consequence caused by exposure to heat radiation is a function of:
The radiation energy onto the human body [KW / m2]
The exposure duration [sec]
The protection of the skin tissue [clothed or naked body]
7.8 DAMAGES TO HUMAN LIFE DUE TO HEAT RADIATION
Injuries to People —Definition of Burn Degrees
First Degree: A mild level of skin burn affecting the epidermis, with persistent redness but no
formation of blisters. More severe first - degree burns will produce some pain, but no
permanent damage. Flaking or scaling of the outer skin layer will occur several days after
exposure.
Second Degree: An intermediate level of skin burn characterized by the formation of blisters.
The blister depth may be shallow (epidermis), with only the surface layers of the skin
damaged, or more severe with nearly the full depth of the skin destroyed (epidermis and
dermis).
Third Degree: Deep burns characterized by the destruction of all skin layers and by charring.
The underlying tissue may also be damaged.
TABLE 7.8: HEAT FLUX INTENSITY AND EXPOSURE TIME-DAMAGE CRITERIA FOR PEOPLE
Thermal Radiation Intensity (KW/m2) Type of Damage
1.6 No harm for long exposures. 4 to 5 Pain for 20 seconds exposure; first degree burn 9.5 Second degree burn after 20 Seconds 10 to 15 Potentially lethal with in 1 minute.
25 Significant injury in 10 seconds; 100 % lethality in 1 minute.
35 to 37.5 1 % lethality in 10 seconds.
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 41
Since in practical situations, only the own employees will be exposed to heat radiation in case
of a fire, it is reasonable to assume the protection by clothing. It can be assumed that people
would be able to find a cover or a shield against thermal radiation in 10 sec. time. Furthermore,
100% lethality may be assumed for all people suffering from direct contact with flames, such
as the pool fire, a flash fire or a jet flame.
Explosion
In case of vapor cloud explosion, two physical effects may occur:
A flash fire over the whole length of the explosive gas cloud;
A blast wave, with typical peak overpressures circular around ignition source.
As explained above, 100% lethality is assumed for all people who are present within the cloud
proper.
The following damage criteria may be distinguished with respect to the peak overpressures
resulting from a blast wave:
TABLE 7.9: DAMAGE DUE TO OVERPRESSURES
PEAK OVERPRESSURE DAMAGE TYPE
0.83 bar Total destruction
0.30 bar Heavy damage
0.10 bar Moderate damage
0.03 bar Significant damage
0.01 bar Minor damage
7.9 MAXIMUM CREDIBLE LOSS ACCIDENT SCENARIOS
A Maximum Credible Accident (MCA) can be characterized 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. 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 judgment, the cases have been found to be credible and modeling for
assessing vulnerability zones is prepared accordingly.
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 42
The objective of the study is Emergency planning, is to prevent by technical and organizational
measures, the unintentional escape of hazardous materials out of the facility and minimize
accidents and losses. Hence, though the outcomes may look pessimistic, the planning for
emergency concept demonstrates the organizational commitment to the safety of employees
and increases organization‘s safety awareness.
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.
The Consequence Analysis has been done for selected scenarios. The details of software
used for MCA analysis are described below.
A computer based version ALOHA is used to calculate toxic and Thermal radiation
effect of the accidental release of liquid chemicals within the plant area.
ALOHA models key hazards-toxicity, flammability, thermal radiation (Heat), and over
pressure (expansion blast force)-related to chemical releases that result in toxic gas
dispersion, fire and/or explosion
The plant is having solvents drum storage shed approved by Chief controller of
explosives.
In the drum storage shed Toluene, Acetone, Methanol, MIBK, THF, Ethyl acetate and
Petroleum ether are being stored. The total solvents quantity is 10600 Lts.
One scenario has been considered that, in case Methanol has leaked from drum &
caught fire and spread to other solvents which resulted in the following consequence.
The total solvents considered as Methanol and its quantity as 10600 Lts.
1. Overpressure (blast force) from vapor cloud explosion
Second Scenario has been considered that, in case the solvents are leaked in the
storage shed and its consequence are:
1. Flammable Area of Vapor Cloud (not burning)
2. Toxic Area of Vapor cloud (not burning)
1. Overpressure (blast force) from vapor cloud explosion
CHEMICAL DATA: Chemical Name: METHANOL CAS Number: 67-56-1
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 43
Molecular Weight: 32.04 g/mol Ambient Boiling Point: 64° C ATMOSPHERIC DATA: Wind: 1.36 meters/second from NW at 3 meters Air Temperature: 38.1° C Relative Humidity: 50% SOURCE STRENGTH: Direct Source: 10.6 cubic meters Source State: Liquid Total Amount Released: 8243 kgs
THREAT ZONE: Threat Modeled: Overpressure (blast force) from vapor cloud explosion Type of Ignition: ignited by spark or flame Level of Congestion: congested Model Run: Heavy Gas Yellow: 234 yards --- (1.0 psi = shatters glass)
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 44
The leakage of solvents and its consequences are considered as Major and its likelihood is
unlikely
Significance = Likelihood X Consequence
=3*4 =12
As defined in Risk Criteria and action requirements
The risk significance is medium.
―Risk is tolerable.‖ –
Mitigation measure: To avoid such incidents day to day the storage shed to be inspected for
any damage of drums and leakage of solvents. In case if any solvent is leaking the particular
drum to be isolated immediately and its contents to be transferred to another empty drum.
While stacking the filled solvents drums, stack the drums solvent wise and maintain at least
three feet distance as free walk way from each group of solvent drums. This facilitates easy
removal of drums from the area.
In case if explosion occurs the impact of over pressure of one psi will be up to a distance of
213 meters.
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 45
2. Flammable Area of Vapor Cloud (not burning)
CHEMICAL DATA: Chemical Name: METHANOL CAS Number: 67-56-1 Molecular Weight: 32.04 g/mol Ambient Boiling Point: 64.0° C ATMOSPHERIC DATA: Wind: 1.4 meters/second from NW at 3 meters Air Temperature: 38.1° C Relative Humidity: 5% SOURCE STRENGTH: Direct Source: 10.6 cubic meters Source State: Liquid Source Temperature: 30° C Total Amount Released: 8326 kgs THREAT ZONE: Threat Modeled: Flammable Area of Vapor Cloud Model Run: Heavy Gas Red : 305 yards --- (43080 ppm = 60% LEL) Yellow: 774 yards --- (7180 ppm = 10% LEL)
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 46
The leakage of solvents and its consequences are considered as Moderate and its likelihood is
unlikely
Significance = Likelihood X Consequence
=3*3 =9
As defined in Risk Criteria and action requirements
The risk significance is low.
―Risk is acceptable.‖ –
Mitigation measure: To avoid such incidents day to day the storage shed to be inspected for
any damage of drums and leakage of solvents. In case if any solvent is leaking the particular
drum to be isolated immediately and its contents to be transferred to another empty drum.
While stacking the filled solvents drums, stack the drums solvent wise and maintain at least
three feet distance as free walk way from each group of solvent drums. This facilitates easy
removal of drums from the area.
In case sudden leakage of solvents on to the ground which results in formation flammable
area of vapor cloud of value of 43080 ppm up to a distance of 278 mts will have 60% lower
explosive limit of leaked solvent .
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 47
(Abnormal) Shower available PPE to be used –Mask / Goggles / Hand gloves
11 Exothermic Reaction (Abnormal)
Injury due to chemical splash, loss of Human efficiency.
3 3 9
MSDS Training & JSA Temp. controller available to Heating Bath Jacket Chilling / cooling supply available Spillage is collected and charged in reactor Spill KIT Use trolley PPE to be used –Mask / Goggles / Hand gloves
1 2 2 Y
12 Fire (Emergency)
Loss of Human efficiency, Skin Injury, Eye Injury, Burn Injury, Body Injury
3 4 12
Temp. controller available to Heating Bath Fire-Fighting equipment available
1 3 3 Y
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 57
Hazard Control Measures
Procedures and actions are well defined and known to all operating personnel for safe
shut down of plant in case of failure of any power, instrumentation, etc.
1. All the motors and other rotating equipment machines have been provided with
suitable safety guards.
2. Suitable fire extinguishers, such as, DCP, CO2 & foam type have been kept in
plant area at easily approachable spots and in sufficient numbers.
3. Fire hydrant points with sufficient length of hose reel have been provided at major
emergency spots.
4. Rupture disc followed by safety valve are provided to prevent over pressurization
5. of process reactors.
6. Safety shower and eye washer are installed at crucial places.
7. Sufficient space has been provided for free movement in the plant area. All piping
and equipment have been provided with earthing connection and it will be tested
regularly.
8. Internal and external inspection of tanks, piping, thickness measurement of
Piping, inspection and testing of lifting tackles, etc, will be carried out as per
Schedule. SOP will be available of safe shut-down of plant during any emergency
Situation.
Operational Safety
1. All operators & maintenance personnel concerned with the plant will be given
Material safety data sheets for hazardous chemicals and will be trained regularly
to combat any leakage spillage, etc.
2. Hydrocarbon (HC) detectors will be provided in Solvents drum storage area.
These detectors shall be placed such a way that entire possible source of leaks is
continuously detected and alarm is set at 20% of lower explosive limit of solvent.
3. Safety appliances like PVC suit, hand gloves, safety goggles, and helmets etc.
being used during material handling. Also, SCBA (Self Contained Breathing
Apparatus) will be kept available all the time.
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 58
4. When in a production area by reason of manufacturing process contaminants are
given off, it shall be necessary to provide an efficient local exhaust ventilation of
the points at which the contaminants are released to reduce their concentration in
the working area below their threshold limit values. Ventilation is expressed as
m3/hr/m2 of floor area. This industry should have ventilation rate of 40 to 60
m3/hr/m2. At present the industry is not having any exhaust fans, only natural
ventilation is available which is insufficient.
As per the area of production block, based on above given ventilation rate the industry
should provide sufficient nos. of Exhaust fans.
Risk Mitigation Measures for Proposed Expansion
1. Hazardous chemicals will be stored in separate storage along with necessary
Safety measures.
2. Enclosures will be provided with vent connected to scrubber for Sulfur dioxide,
Hcl, HBr and ammonia. etc.
3. Safety fittings like safety valve, pressure / temperature indicators, level indicators,
rupture discs etc. will be provided to the concern equipment.
4. Calibration of all instruments in the plant will be carried out periodically.
5. Flameproof fitting, earthing & bonding of equipments & pipelines will be provided
for flammable chemicals.
6. Periodic on site emergency mock drills are being arranged.
7. Safety training‘s are given regularly to the workers for handling of hazardous
Chemicals.
8. Necessary PPE‘s will be readily available. Jobs will be accomplished using
Relevant PPEs
7.11 DISASTER PREPAREDNESS AND EMERGENCY MANAGEMENT PLAN
GAVL has prepared the onsite Disaster Management Plan which is in force for the
existing facility. The purpose of this plan is to provide GAVL with the means to
effectively utilize all the resources at its disposal for the protection of life, environment
and property. GAVL will update existing emergency management system (Onsite
DMP) to tackle any emergency situation for proposed plants expansion. The details of
EIA Report Godrej Agrovet Limited (GAVL)
Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 59
Onsite Emergency plan / Disaster management plan (DMP) are discussed in the
following section.
7.11.1 Objective
To provide detailed guideline in case of emergency situation like major fire, serious
emission of gas, discharge of chemical, liquid fuel & explosion