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6.0 RISK ASSESSMENT AND DAMAGE CONTROL 6.0 Introduction
This chapter presents the risk assessment study results for the
plant operations, transport
and storage of raw materials, and identifies maximum credible
accident scenarios to draw
the emergency management plan addressing various credible
scenarios identified.
6.1. Objectives and Scope
The production of Synthetic Organic chemicals (bulk drug and
intermediates) involves
usage of many chemicals which are both hazardous and toxic in
nature. The risks
associated with the chemical industry are commensurate with
their rapid growth and
development. Apart from their utility, chemicals have their own
inherent properties and
hazards. Some of them can be flammable, explosive, toxic or
corrosive etc. The whole
lifecycle of a chemical should be considered when assessing its
dangers and benefits. In
order to ensure the health and safety of persons at or near the
facilities, Govt. has
approved some regulations. The regulation requires Employers to
consult with employees
in relation to:
- Identification of major hazards and potential major
accidents
- Risk assessment
- Adoption of control measures
- Establishment and implementation of a safety management
system
- Development of the safety report
The involvement of the employees in identification of hazards
and control measures
enhances their awareness of these issues and is critical to the
achievement of safe
operation in practice. In order to comply with regulatory
authorities, M/s Suven Life
Sciences Ltd., have entrusted Team Labs and Consultants,
Hyderabad to review and
prepare Hazard analysis and Risk assessment for their facility
along with an approach to
on-site emergency preparedness plan as required under the acts
and rules. (Manual on
emergency preparedness for chemical hazards, MOEF, New Delhi).
In this endeavor, the
methodology adopted is based on;
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• visualizing various probable undesirable events which lead to
major accidents
• detailed and systematic assessment of the risk associated with
each of those
hazards, including the likelihood and consequences of each
potential major accident
event; and
• identifying the technical and other control measures that are
necessary to reduce
that risk to a level that is as low as reasonably
practicable
The strategy to tackle such emergencies, in-depth planning and
person(s) or positional
responsibilities of employees for implementation and
coordination of timely and effective
response measures are described in onsite detail in Emergency
Plan.
6.2 Project Details
The project site is located at Sy No. 99, 101-109, Dasaigudem
Village, Suryapet Mandal,
Nalgonda district, Telangana. The site is situated at the
intersection of 170 07’ 07” (N)
latitude and 790 38’ 50” (E) longitude. The site elevation above
mean sea level (MSL) is 182
m. The plant is surrounded by National Highway No. 9 in north,
Musi Canal in south,
Tanda road in east and open land in west direction. The nearest
human settlement from
the site is Durajpalli located at distance of 1 km from the site
in east direction. The main
approach road is NH-9 is at a distance of 0.35 km in north
direction. The nearest railway
station is Miryalaguda at a distance of 31 km in SW direction
and the nearest airport is
Shmshabad located at a distance of 128 km in West direction.
Musi River is flowing from
NW to SW direction and passing the study area at a distance of
6.8 km in southwest
direction. There are no national parks, sanctuaries and
ecologically sensitive areas within
the impact area of 10 km radius. There is one reserve forest in
the study area. Indergonda
RF is at a distance of 5 km in southeast direction. The total
site area of the project is 70
acres. The manufacturing capacities of the proposed bulk drug
and intermediates after
expansion and by-products are presented in Table 6.1 and Table
6.2 Chemical inventory is
presented in Table 6.3
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Table 6.1 Proposed Manufacturing Capacity – After Expansion S.No
Name of the Product Capacity
Kg/Day TPM 1 Methyl-2-(Chloromethyl Phenyl)-3-Methoxy-2-Acrilate
(MCPMA) 2168 65 2 5-Cyano pthalide 336 10 3 4-hydroxy-5-methyl
pyrrolo[2,1-f][1,2,4]triazine-6-carboxylic acid ethyl
ester (PTZN) 81 2
4 Gabapentine 96 3 5 Divalproex Sodium 300 9 6 Azacytocine 112 3
7 4,6-dichloro pyrimidine (4,6- DCPY) 227 7 8 Adenine 132 4 9
1-{[5-methyl-3-(trifluoromethyl)-1H-pyrazol-1-yl]acetyl}piperiidne-4-
carbothiomide (MPC) 787 24
10 Losartan potassium (LP) 150 5 11 Theobromine (TBN) 243 7 12
Malonic acid 324 10 13 Cyanoacetamide 380 11 14 Barbituric Acid
(BBA) 500 15 15 Imatanib 299 9 16 5-Fluoro-4,6-Dichloro pyrimidine
(5-Fluro-4,6-DCPY) 303 9 17 1,2,3-Trizole 472 14 18 Chloro Ethoxy
Ethyl Acetate (CEEA) 521 16 19 Entacapone 100 3 20 Calcium Acetate
180 5 21 Carprofen 71 2 22 Tetra hydro ribo furanose 83 2 23
2,4-Dichloro-5-methyl pyrimidine (2,4-DCMPY) 330 10 24 Piperinyl
alcohol 208 6 25 2-Chloro-4-Methyl pyrimidine (CMP) 522 16 26
Chloro ethyliodo pyrimidine 248 7 27 Cyano Acetic Acid (CAA) 1144
34 28 Lamotrigen 188 6 29 Methyl Cyanoaceate (MCA) 1136 34 30 Ethyl
Cyanoaceate (ECA) 2600 78 31 Tomsulosin 30 1 32 Homoveratryl Amine
(HVA) 167 5 33 D-Mannose 410 12 34 Verapamil HCl 182 5 35
Nitazozoxanide 250 8 36 Zolmitripton 100 3 37 2-methyl pyrolidine
carboxilic acid 133 4 38 Hydroxy tetrahydrofuran 213 6 39
2,5-diamino 4,6-dichloro pyrimidine (DADCP) 332 10 40 1-Tert-butoxy
carbonyl amino cyclobutane carboxylic acid (BCAC) 280 8 41
Benzhydrol Thioacetamide (BTA) 285 9
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42 Benzoin 356 11 43 2-n-Butyl-4-formyl-5-chloro imidazole
(BCFI) 297 9 44 Fenoprofen Calcium dihydrate 110 3 45 Capacitabine
170 5 46 Chloro propyl amino pyrazole 99 3 47 Fluoro Phenyl
Methanone 229 7 48 3,5-Diacetoxy acetophenone (DAAP) 521 16 49
1-Bromo -2-iodo benzene (BIB) 474 14 50 L-Xylose 274 8 51
5-Bromo-2-iodo pyrimidine 176 5 52 8-chloro theophylline 259 8 53
S- Indoline-2-carboxilic acid 210 6 54 2,4-Dichloro-5-Nitro
pyrimidine (DCNPY) 116 3 55 Dimethyl thiophenol 311 9 56
2-Amino-5-Chloro Benzoic acid (ACB acid) 267 8 57
Methyl-Napthalene-1-Methyl-amine Hydro chloride (NAP) 382 11 58
3-Hydroxy- N-benzyl pyrrolidine (BHP) 200 6 59 Valsartan 86 3 60
Carbonyl amino cyclo butiric acid 228 7 61 Metane sulfonyl-L-lucyne
202 6 62 2,4-Diamino-6-hydroxy pyrimidine (DAHP) 247 7 63
5-Chlorothiophene-2-carboxylic acid (5-CTA) 396 12 64 3,5-Dibenzoyl
tartaric acid (DBTA) 436 13 65 Pamabromo 332 10 66 2-chloro-5-iodo
benzoic acid 492 15 67 Tetra hydro isoquinoline (THIQ) 153 5 68
2,4-Dichloropyrimidine (2,4-DCPY) 345 10 69 Doxofylline 365 11 70
Dimethyl dithiophosphoric 71 2 71 Aripiprazole 143 4 72 Phentramine
hydrochloride 200 6 73 D-Penicillamine 80 2 74 dimethyl phenyl
isothiocyanate 216 6 75 2-Chlorothioxanthene-9-one (2-CTX) 367 11
76 2,6-dichloro-4,8-dipiperdine-1-yl-pirimido5,4d)pyrimidine (DDH)
250 7 77 Homoveratryl Amine (HOVA) 428 13 78
Thiozole-5-carboxaldehyde 182 5 79 2,5-Dimethylamino-2-phenyl
Butan-1-Ol (RC-105) 267 8 80 Amino Dimaleate (ADM) 418 13 81
2,4,5-Trichloro pyrimidine (TCPY) 198 6 82 4,4-Nitro
phenyl-3-marpholine(NPMP) 116 3 Worst case- 6 Products on campaign
basis 8356 251
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Table 6.2 List of By-Products – After Expansion S.No Name of
Product Stage Name of By-Product Capacity
Kg/day TPM 1 Methyl-2-(Chloromethyl Phenyl)-
3-Methoxy-2-Acrilate IV Sodium Sulfate 1467.9 44.0 V Sodium
hydrogen Sulfate 810.2 24.3 VI Potassium chloride 671.5 20.1
2 5-Cyano Phthalide IV Sodium Sulfate 313.9 9.4 3
4-hydroxy-5-methyl pyrrolo[2,1-
f][1,2,4]triazine-6-carboxylic acid ethyl ester (PTZN)
I Methylamine hydrochloride 43.9 1.3
4 Gabapentine II Ammonium Sulfate 228.8 6.9 5 4,6-Dichloro
pyrimidine crude I Formic acid 81.0 2.4
II Phosphoric acid 301.8 9.1 6
1-{[5-methyl-3-(trifluoromethyl)-
1H-pyrazol-1-yl]acetyl}piperiidne-4-carbothiomide (MPC)
I Sodium Sulfate 415.5 12.5
7 Losartan potassium III 5,5 Dimethyl hydantoin 26.5 0.8 8
Theobromine IV Sodium bromide 154.2 4.6 9 4,6-Dichloro-5-fluoro
pyrimidine
crude I Formic acid 92.8 2.8 II Phosphoric acid 359.2 10.8
10 Entacapone Aluminium hydroxide 28.8 0.9 11 Carprofen I Acetic
acid 30.7 0.9
III Boric acid 5.9 0.2 V Sodium acetate 25.3 0.8
12 2-Chloro-4-Methyl pyrimidine I Sodium Sulfate 337.3 10.1 13
Lamotrigine II Sodium phosphate 39.6 1.2 14 Tamsulosin
Hydrochloride III Potassium chloride 4.5 0.1
IV Sodium Sulfate 18.5 0.6 V Potassium bromide 12.9 0.4
VII Sodium Bromide 8.2 0.2 15 Verapamil Hydrochloride (Pure) III
Sodium bromide 38.7 1.2 16 Zolmitriptan I Sodium Sulfate 164.4 4.9
17 2-methyl pyrolidine carboxilic
acid I Lithium iodide 167.4 5.0
18 3-Hydroxy tetra hydrofuran II Boric acid 314.0 9.4 Sodium
Sulfate 761.6 22.8
19 Benzhydral Thioacetamide II Sodium bromide 79.5 2.4 20
2-Butyl-4-formyl-5-chloro
imidazole II Ammonium phosphate 236.8 7.1
21 Fenoprofen Calcium Dihydrate IV Potassium Sulfate 80.3 2.4
Manganese dioxide 80.1 2.4
22 Capacitabine I Pyridine Hydrochloride 66.0 2.0 II Sodium
acetate 85.2 2.6
23 Chloro propyl amino pyrazole II Lithium chloride 37.4 1.1 24
5-Bromo-2-Iodo benzene I Sodium Sulfate 279.6 8.4 25 2,4-Dichloro-5
nitro II Phosphoric acid 230.0 6.9
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pyrimidine(DCNPY) 26 Dimethyl thiophene II Zinc chloride 306.4
9.2 27 N-Methyl napthalene
methylmamine II Monomethyl amine HCl 148.0 4.4
28 3-Hydroxy- N-benzyl pyrrolidine
II Boric acid 137.0 4.1
29 Valsartan II Triethyl amine HBr 55.1 1.7 III Triethyl amine
HCl 33.8 1.0 IV Succinic acid 59.6 1.8
30 Methane Sulfonyl L-leucyne I Potassium Sulfate 47.8 1.4 III
Boric acid 28.0 0.8
31 2,4-Diamino-6-hydroxy pyrimidine
I Sodium nitrate 166.3 5.0
32 Pamabrom I Sodium bromide 103.4 3.1 33 2-chloro-5-iodo
benzoic acid II Potassium acetate 192.0 5.8 34 Tetra Hydro
Isoquinoline III Hydrobromic acid 83.2 2.5 35
2,4-Dichloropyrimidine I Phophoric acid 453.8 13.6 36 Dimethyl
phenyl isothiocyanate I Sodium Sulfate 123.2 3.7 37
2-Chlorothioxanthene-9-one III Sulfuric acid 145.6 4.4 38
2,6-dichloro-4,8-dipiperdine-1-yl-
pirimido5,4d)pyrimidine (DDH) I Spent Sulfuric acid 400.0
12.0
IV Phosphoric acid 145.3 4.4 39 Thiozole 5 Carboxyaldehyde I
Acetic acid 72.8 2.2
III Phosphoric acid 192.4 5.8 IV Hydrobromic acid 71.6 2.1
40 2,5-Dimethylamino-2-phenyl Butan-1-Ol (RC105)
III Methyl sodium Sulfate 195.3 5.9 IV Aluminium chloride 184.6
5.5
41 2,4,5-Trichloro pyrimidine (TCPY)
II Phosphoric acid 213.7 6.41
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Suven Life Sciences Ltd. Environmental Impact Assessment
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Table 6.3 List of Raw Materials and Inventory (Terms of
Reference No. 18) S.No Name of Raw Material Max Storage
Quantity (Kgs) Physical
State Mode of Storage
Type of Hazard
Mode of Transport
1 (2-Chloroethoxy) Acetic Acid 470 Liquid Drums Irritant By Road
2 (2R)-2-Trichloro methyl Oxazolidine -5-one 375 Liquid Drums
Flammable By Road 3
1-(3-Dimethylaminopropyl)-3-ethylcarbodiimide
HCl 132 Solid Bags Irritant By Road
4 1,1,3,3-Tetra methoxy propane 150 Liquid Drums Flammable By
Road 5 1-(2,3-Dichlorophenyl) Piperazine Hydrochloride 130 Solid
Bags Irritant By Road 6 1,3-dibromo dimethyl hydantoin 210 Powder
Bags Flammable By Road 7 1,3-dibromo propane 350 Liquid Drums
Irritant By Road 8 1,4-Dichlorobutane 75 Liquid Drums Flammable By
Road 9 1-Amino cyclobutane carboxylic acid HCl 170 Solid Bags
Irritant By Road 10 1,4-Dioxane 200 Liquid Drums Flammable By Road
11 2,2-chloromethyl-phenyl(-3-methoxy-Acrylol-
Chloride) 2380 Solid Bags Corrosive By Road
12 2,2,6,6,-Tetramethyl piperidine -1 -Oxyl (TEMPO) 10 Liquid
Drums Flammable By Road 13 2- Amino-5-chloro-2-fluorobenzophenone
285 Powder Bags Irritant By Road 14 2,2-Dipropyl Malonic Acid 420
Liquid Drums Irritant By Road 15 2,3 Dichloro benzoyl cyanide 200
Solid Bags Irritant By Road 16
2,3-Di-O-acetyl-5-deoxy-5-fluoro-N-4-(Pentyloxy
Carbonyl) Cytidine 225 Liquid Drums Corrosive By Road
17 2-Amino-5-nitro thiazole 145 Solid Bags Irritant By Road 18
2-Amino-2-methyl-1-propanol 90 Liquid Drums Irritant By Road 19
2,6-Dimethyl aniline 210 Liquid Drums Irritant By Road 20 2-anilino
ethanol 100 Solid Bags Irritant By Road 21 2-Chloro Acetamide 120
Crystalline HDPE Bags Toxic By Road 22 2-Bromo aniline 380 Solid
HDPE Bags Toxic By Road 23 2-Bromo malonaldehyde 149 Solid Bags
Irritant By Road 24 2-Chloro-5-Iodo benzoic acid 200 Solid HDPE
Bags Toxic By Road 25 2-chlorothiophene 315 Liquid Drums Flammable
By Road 26 2-Chlorobenzonitrile 240 Crystalline Bags Irritant By
Road
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27 2n-Butyl-4-Chloro-5-formyl imidazole 190 Solid Bags Irritant
By Road 28 2-Cyano-N,N-diethyl acetamide 65 Liquid Drums Non hazard
By Road 29 2-keto gulonic acid 415 Liquid Drums Irritant By Road 30
4-(Dimethylamino) Pyridine 2 Solid Bags Irritant By Road 31
3-oxopentanoic acid methyl ester 125 Liquid Drums Flammable By Road
32 3,5-Dihydroxy acetophenone 400 Solid Bags Irritant By Road 33
3-methyl phenyl acetonitrile 205 Liquid Drums Irritant By Road 34
4-Amino-L-Phenyl Oxazolidinone 100 Liquid Drums Corrosive By Road
35 4-Chlorothiophenol 255 Liquid Drums Corrosive By Road 36
4-Hydroxy benzoic acid 200 Solid Bags Irritant By Road 37 4-Cyano
pyridine 310 Crystalline Bags Irritant By Road 38 5-Carboxy
Phthalide 420 Solid Bags Irritant By Road 39 5-Cyanopthalide 352
Solid Bags Irritant By Road 40 4-Nitrobenzoyl chloride 102
Crystalline Bags Corrosive By Road 41 5-Acetonyl-2-methoxy benzene
sulfonamide 25 Solid Bags Toxic By Road 42
7-Sodiumoxy-3,4-Dihydro-1H-quinolin-2-one 110 Solid Bags Toxic By
Road 43 Acetic acid 4300 Liquid Drums Flammable By Road 44 Acetic
anhydride 1350 Liquid Drums Irritant By Road 45 Acetone 15000
Liquid Storage
tanks Flammable By Road
46 Acetonitrile 2220 Liquid Drums Flammable By Road 47 Acetyl
chloride 260 Liquid Drums Flammable By Road 48 Activated Carbon
1850 Solid Bags Non Hazard By Road 49 Alluminium Chloride 500
Powder HDPE Bags Carcinogenic By Road 50 Aminoguanidine bicarbonate
135 Powder Bags Irritant By Road 51 Ammonia 400 Gas Cylinders Toxic
By Road 52 Ammonium chloride 200 Powder Bags Irritant By Road 53
Ammonium Hydroxide 1030 Liquid Drums Toxic By Road 54 Ammonium
thiocyanate 130 Powder Bags Irritant By Road 55 Aniline 150 Liquid
Drums Toxic By Road 56 Aqueous ethanol 2700 Liquid Drums Flammable
By Road 57 Azobis Butyronitrile 10 Crystalline Bags Flammable By
Road
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58 Benzahydrol 235 Solid HDPE Bags Toxic By Road 59 Benzaldehyde
450 Liquid Drums Irritant By Road 60 Benzoyl chloride 1145 liquid
Drums Irritant By Road 61 BOC anhydride 570 Liquid Drums Flammable
By Road 62 Benzylamine 160 Liquid Drums Corrosive By Road 63
Bromine 540 Liquid Drums Toxic By Road 64 Bromobenzene 120 Liquid
Drums Flammable By Road 65 Bromochloropropane 70 Liquid Drums
Flammable By Road 66 Chloro acetaldehyde di methyl acetol (CADMA)
150 Liquid Drums Irritant By Road 67 Calcium Acetate 200 Solid Bags
Irritant By Road 68 Calcium hydroxide 120 Solid Bags Irritant By
Road 69 Calciumoxide 125 Powder Bags Corrosive By Road 70 Carbazole
100 Powder HDPE Bags Carcinogenic By Road 71 Carbon tetra chloride
215 Liquid Drums Toxic By Road 72 Celite 10 powder Bags Irritant By
Road 73 Chlorine 2270 Gas Cylinders Irritant By Road 74 Chloro
acetaldehyde dimethyl acetal 350 Liquid Drums Flammable By Road 75
Chloroacetyl chloride 390 Liquid Drums Toxic By Road 76 Chloro
ethoxy ehanol 430 Liquid Drums Corrosive By Road 77 Chloroform 3000
Liquid Drums Irritant By Road 78 chlorosulfonic acid 290 Liquid
Drums Corrosive By Road 79 Copper powder 25 Solid Bags Flammable By
Road 80 Cuprous chloride 200 Solid Bags Irritant By Road 81 Cyano
Acetic Acid 4450 Crystalline Bags Corrosive By Road 82
Cyanoquanidine 110 Powder Bags Non Hazard By Road 83 Cyclohexane
2000 Liquid Drums Toxic By Road 84 Cyclohexanone 100 Liquid Drums
Irritant By Road 85 Cyclopropane carboxylic acid 100 Liquid Drums
Corrosive By Road 86 Darco 12 Powder Bags Non hazard By Road 87
Dibromo ethane 25 Liquid Drums Toxic By Road 88 Diethanol amine HCL
355 Liquid Drums Carcinogenic By Road 89 Diethoxy dimethyl
butanamine 100 Liquid Drums Corrosive By Road
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90 Diethyl ether 1500 Liquid Drums Flammable By Road 91 Diethyl
Maleate 40 Liquid Drums Carcinogenic By Road 92 Diethyl Malonate
1060 Liquid Drums Irritant By Road 93 Diethyl sulfate 70 Liquid
Drums Toxic By Road 94 Dimethyl formamide 3050 Liquid Drums
Flammable By Road 95 Dimethyl acetamide 500 Liquid Drums
Carcinogenic By Road 96 Dimethyl sulfate 1600 Liquid Drums Toxic By
Road 97 Dimethyl sulfone 50 Crystalline Bags Non Hazard By Road 98
Dimethylsulfoxide 870 Liquid Drums Non Hazard By Road 99 D-ribose
50 Powder Bags Non Hazard By Road 100 D-tartaric acid 310
Crystalline Bags Irritant By Road 101 Ethylene Dichloride (EDC)
3870 Liquid Drums Flammable By Road 102 EDTA 10 Powder Bags
Irritant By Road 103 Ethyl alcohol 10000 Liquid Storage
tanks Flammable By Road
104 Ethyl Acetate 20000 Liquid Storage tanks
Flammable By Road
105 Ethyl cyano acetate 1260 Liquid Drums Irritant By Road 106
Ethyl aceto acetate 80 Liquid Drums Non Hazard By Road 107 Ethylene
glycol 95 Liquid Drums Carcinogenic By Road 108 Flourodiethyl
malonate 400 Liquid Drums Corrosive By Road 109 Flourobenzene 700
Liquid Drums Flammable By Road 110 Formaldehyde 100 Liquid Drums
Toxic By Road 111 Formamide 2000 Liquid Drums Carcinogenic By Road
112 Formic acid 330 Liquid Drums Flammable By Road 113 Glycine 140
Solid Bags Non Hazard By Road 114 glycine ethylester hydrochloride
85 Crystalline Bags Corrosive By Road 115 Guanidine nitrate 620
Crystalline Bags Irritant By Road 116 Hexane 8100 Liquid Drums
Flammable By Road 117 Homoveratronitrile 650 Solid Bags Irritant By
Road 118 Hydrazine 85 Liquid Drums Flammable By Road 119 Hydrazine
hydrate 210 Liquid Drums Irritant By Road
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120 Hydrobromic acid 100 Liquid Drums Irritant By Road 121
Hydrochloric acid 3870 Liquid Drums Irritant By Road 122 Hydrogen
55 Gas Cylinders Flammable By Road 123 Hydrogen chloride 210 Gas
Cylinders Flammable By Road 124 Hydrogen perroxide 140 Liquid Drums
Corrosive By Road 125 Hydroxylamine Hydrochloride 40 Crystalline
HDPE Bags Carcinogenic By Road 126 Hydroxylamine sulfate 100
Crystalline HDPE Bags Carcinogenic By Road 127 Hyflow 60 Solid Bags
Non hazard By Road 128 Indole-2-carboxylic acid 250 Solid Bags Non
hazard By Road 129 Isatoic Anhydride 700 Powder Bags Irritant By
Road 130 Iso propyl Alcohol .HCL 740 Liquid Drums Irritant By Road
131 Isobutyraldehyde 130 Liquid Drums Flammable By Road 132
Isopropyl Acetate 260 Liquid Drums Flammable By Road 133 Isopropyl
alcohol 20000 Liquid Storage
tanks Irritant By Road
134 Isopropyl Bromide 51 Liquid Drums Flammable By Road 135
Isovanillin 89 Powder Bags Irritant By Road 136 Lithium
bis(trimethyl silyl) amide 160 Powder Bags Crystallline By Road 137
Lithium Diisopropylamide (LDA) 165 Liquid Drums Toxic By Road 138
L-Malic acid 770 Powder Bags Irritant By Road 139 L-Valine methyl
ester HCl 70 Crystalline Bags Non hazard By Road 140 Malano nitrile
105 Solid HDPE Bags Toxic By Road 141 Manganese Dioxide 40 Solid
Bags Irritant By Road 142 Mannose syrup 1000 Solid Bags Irritant By
Road 143 Methanesulfonic acid 110 Liquid Drums Corrosive By Road
144 Methanol 2 x 30000 Liquid Storage
tanks Flammable By Road
145 Methyl amine 150 Liquid Drums Flammable By Road 146 Methyl
formate 950 Liquid Drums Flammable By Road 147 Methyl iodide 200
Liquid Drums Toxic By Road 148 Methyl tert butyl ether 2150 Liquid
Drums Flammable By Road 149 Methylene Dichloride (MDC) 20000 Liquid
Storage
tanks Carcinogenic By Road
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150 m-Hydroxy Acetophenone 100 Crystalline Bags Irritant By Road
151 Methyl Iso Butyl Ketone 2000 Liquid Drums Flammable By Road 152
Monochloro benzene 1800 Liquid Drums Flammable By Road 153
Monomethyl Urea 140 Crystalline Bags Non hazard By Road 154
M-xylene 270 Liquid Drums Flammable By Road 155 N,N-dimethyl
aniline 1400 Liquid Drums Toxic By Road 156 N,N diethyl aniline 180
Liquid Drums Toxic By Road 157 N-Acetyl-L-leucine 90 Crystalline
Bags Non hazard By Road 158 Naphthalene 360 Solid Bags Flammable By
Road 159 N-Bochydroxyl amine 75 Crystalline Bags Non Hazard By Road
160 n-Butyl Cyanide 160 Liquid Drums Flammable By Road 161
n-Butyllithium 35 Liquid Drums Flammable By Road 162 Nickel 60
Powder HDPE Bags Carcinogenic By Road 163 N-Iodo succinamide 220
Crystalline Bags Irritant By Road 164 Nitric acid 580 Liquid Drums
Toxic By Road 165 Nitro vanillin 95 Powder Bags Irritant By Road
166 Nitromethane 60 Liquid Drums Flammable By Road 167
N-Methylpyrolidinone 400 Liquid Drums Flammable By Road 168
NN-Dimethylformamide dimethylacetal 75 Liquid Drums Flammable By
Road 169 n-Pentylchloroformate 105 Liquid Drums Flammable By Road
170 n-Propanol 1760 Liquid Drums Flammable By Road 171 O- Xylene
10000 Liquid Storage
tanks Flammable By Road
172 O-Acetyl salicyl chloride 200 Solid Bags Corrosive By Road
173 Orotic acid 150 Solid Bags Irritant By Road 174 Ortho dichloro
benzene 400 Liquid Drums Irritant By Road 175 O-Tolyl Benzonitrile
100 Liquid Drums Flammable By Road 176 Oxalylchloride 85 Liquid
Drums Toxic By Road 177 Palladium 10 Solid Bags Flammable By Road
178 Palladium on Carbon 70 Solid Bags Non Hazard By Road 179
Palladium hydroxide (20%) 6 powder Bags Irritant By Road 180
Paraformaldehyde 160 Solid Bags Flammable By Road
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181 Phentermine 180 Liquid Drums Irritant By Road 182 Phenyl
ethylamine 10 Liquid Drums Toxic By Road 183 Phenyl Hydrizine 15
Liquid Drums Toxic By Road 184 Phosphoric acid 375 Liquid Drums
Toxic By Road 185 Phosphorus oxychloride 5340 Liquid Drums Toxic By
Road 186 Phosphorus pentachloride 170 Powder HDPE Bags Toxic By
Road 187 Phosphorus pentasulfide 250 Solid Bags Flammable By Road
188 Phosphoryl trichloride 130 Liquid Drums Toxic By Road 189
Piperonal 220 Solid Bags Irritant By Road 190 Potassium Carbonate
175 Crystalline Bags Irritant By Road 191 Potassium hydroxide 860
Flakes Bags Corrosive By Road 192 Potassium iodate 90 Solid Bags
Oxidizer By Road 193 Potassium iodide 710 Crystalline HDPE Bags
Toxic By Road 194 Potassium Permanganate 145 Solid Bags Irritant By
Road 195 potassium tert-butoxide 60 Solid Bags Irritant By Road 196
Propiophenone 240 Liquid Drums Irritant By Road 197 P-Toluene
sulfonic acid(PTSA) 50 Solid HDPE Bags Carcinogenic By Road 198
Pyridine 100 Liquid Drums Flammable By Road 199 R+ (a) methyl
benzyl amine 175 Liquid Drums Toxic By Road 200 Raney Nickel 130
Solid Bags Flammable By Road 201 Silica gel 745 Solid Bags Irritant
By Road 202 Sodium azide 400 Crystalline HDPE Bags Toxic By Road
203 Sodium bicarbonate 625 Crystalline Bags Irritant By Road 204
Sodium Borohydride 545 Powder Bags Flammable By Road 205 Sodium
carbonate 140 Crystalline Bags Irritant By Road 206 Sodium chloride
50 Solid Bags Non Hazard By Road 207 Sodium cyanate 60 Solid Bags
Irritant By Road 208 Sodium cyanide 860 Crystalline HDPE Bags Toxic
By Road 209 Sodium hydro sulfide, NaSH 140 Liquid Drums Toxic By
Road 210 Sodium hydroxide 20000 Liquid Storage
tanks Corrosive By Road
211 Sodium Hypochlorite 890 Liquid Drums Corrosive By Road
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212 Sodium methoxide 1950 Solid Bags Corrosive By Road 213
Sodium nitrite 780 Solid Bags Irritant By Road 214 Sodium sulfate
30 Solid Bags Irritant By Road 215 Sodium Sulfite 290 Solid Bags
Irritant By Road 216 sodium thiosulfate 40 Powder Bags Non hazard
By Road 217 Sulfamide 228 Powder Bags Irritant By Road 218
Sulfolane 1900 Crystalline Bags Irritant By Road 219 Sulphuric Acid
4200 Liquid Drums Irritant By Road 220 Sulphur 28 Flakes Bags
Irritant By Road 221 t-butanol 220 Liquid Drums Flammable By Road
222 Triethylamine Hydrochloride 80 Crystalline Bags Irritant By
Road 223 Tetra-n-butyl ammonium bromide(TBAB) 20 Solid Bags
Irritant By Road 224 Tri ethyl benzyl ammonium chloride(TEBAC) 35
Crystalline Bags Irritant By Road 225 Tetrahydrofuran 3600 Liquid
Drums Irritant By Road 226 Theophylline 750 Powder HDPE Bags Toxic
By Road 227 Thio Urea 100 Crystalline Bags Irritant By Road 228
Thionyl chloride 2500 Liquid Drums Toxic By Road 229 Thymine 300
Powder Bags Non Hazard By Road 230 Toluene 2 x 30000 Liquid
Storage
tanks Toxic By Road
231 Tributyl tin chloride 80 Liquid Drums Toxic By Road 232
Trichloroisocyanuric Acid 120 Powder Bags Oxidizer By Road 233
Triethyl amine 2220 Liquid Drums Flammable By Road 234 Triethyl
orthoformate 170 Liquid Drums Irritant By Road 235 Uracil 545
Powder Bags Non Hazard By Road 236 Urea 580 Solid Bags Irritant By
Road 237 Valeryl Chloride 37 Liquid Drums Flammable By Road 238
Valproic Acid 300 Solid Bags Irritant By Road 239 Vitride 395
Liquid Drums Irritant By Road 240 Xylene 1460 Liquid Drums Toxic By
Road 241 Zinc 155 Solid HDPE Bags Toxic By Road
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6.3 Process Description
The manufacturing process for all the products is presented in
Chapter 2. (Page No. 2-6 to
2-253) of the report.
6.4 Plant Facilities
The manufacturing facility shall be provided with
1) Production blocks 2) Utilities 3) Quality Control, R&D
lab 4) Effluent treatment plant 5) Warehouses
6) Tank farm area 7) Cylinder Storage 8) Administrative Office
9) Solvent recovery area
The production facilities shall be designed for proper handling
of materials and machines.
Safety of operators, batch repeatability and process parameter
monitoring shall be the
major points of focus in the design of facility. The current
Good Manufacturing Practices
(GMP) guidelines shall be incorporated as applicable to
synthetic organic chemicals
manufacturing facilities.
6.4.1 Production Blocks:
The Production blocks will consist of SS and glass lined
reactors, storage tanks, shell &
tube heat exchangers, evaporators, vacuum pumps, packed columns,
Agitated Nutche
Filter and Dryers, crystallizers, layer separators etc. The area
shall be provided with
proper concealed drainage facility and all process facilities
shall be performed under
protective environment.
6.4.2 Utilities:
The proposed expansion requires additional steam. It is proposed
to establish 2 x 10 TPH
coal fired boilers in addition to existing 3 TPH and 4 TPH coal
fired boilers boilers to meet
the steam requirement both for process and ZLD system. It is
proposed kept 1 x 10 TPH
boiler as standby. The DG sets required for emergency power
during load shut down is
estimated at 2100 KVA and accordingly 1 x 1000 Kva DG sets are
proposed for expansion
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6-16 Team Labs and Consultants
in addition to existing 500 KVA and 600 KVA DG sets. The list of
utilities is presented in
the following Table 6.4.
Table 6.4 List of Utilities S. No Description Capacity
Existing Proposed Total after Expansion 1 Coal Fired Boilers 1 x
3 TPH
1 x 4 TPH 2 x 10 TPH* 2 x 10 TPH
1 x 3 TPH and 1 x 4 TPH 2 Thermic Fluid Heater --- 1 lac
K.cal/hr 1 Lac K.Cal/hr 3 DG Set** 500 KVA
600 KVA 1000 KVA 1 x 1000 KVA
1 x 600 KVA 1 x 500 KVA
* 1 x 10 TPH boiler shall be kept as standby **DG sets will be
used during load shut down periods only.
6.4.3 Quality Control, R&D Lab
The QC department shall comprise of an in-process lab with
instruments like HPLC, GC
etc. It will be maintained by highly qualified and trained
people. The activities include:
• In-process quality check during manufacturing • Validation of
facilities • Complaint handling
Also a process development laboratory shall be provided for
in-house process
development , initial evaluation of process technology in case
of technology transfer, back-
up for production department to address any issues arising
during commercial production
6.4.4 ETP and Solid waste storage
The total effluents segregated into two streams High COD/ TDS
and Low COD/ TDS
streams based on source of generation. These effluents are
treated in Zero Liquid
Discharge system and the treated effluents are reused for
cooling towers make-up.
6.4.5 Ware Houses:
The plant shall have sufficient storage facility for safe
handling of raw materials. All solid
raw materials shall be stored in marked areas with proper
identification. Liquid raw
materials and solvents like which are available in drums will be
stored according to
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material compatibilities and flammability. Adequate fire
fighting facilities shall be
provided as per NFPA norms.
6.4.6 Tank Farm Area:
A separate tank farm area shall be provided for storing liquid
raw materials, especially
solvents with high inventory and also for toxic, corrosive
chemicals. Dykes shall be
provided to ensure safety in case of tank failure. Acid proof
lining for the dykes shall be
provided for acid storage tanks. Condensers for low volatile
solvent storage tanks vents.
6.4.7 Cylinders storage Area:
Gas cylinders storage should conform to SMPV-Unfired rules-1981.
Hydrogen cylinders
should be stored in approved Gas Storage pad. Chained and capped
when not in use.
Operational cylinder should be firmly secured. Pressure
regulator, metal piping, non-
return valve, and safe residue bleed off arrangement should be
incorporated in installation
design. Strict hot work control and display of danger signs
should be ensured.
6.4.8 Administrative Office:
An Administrative office shall be provided at the entrance of
the factory to ensure the
entry of authorized personnel only into the premises.
6.4.9 Water Sump:
Water sump of 200 Kl capacity shall be provided for fire
fighting in case of emergencies.
6.4.10 House Keeping:
A regular house keeping schedule with adequate preventive
maintenance shall be ensured
so that the plant is consistently maintained as per GMP
standards.
6.4.11 Facility layout and design:
The layout of all the various areas required for the facility,
as mentioned above is
considered. In laying out the above areas, isolation of the
various process areas from the
utilities and non-process areas is considered in view of both
containment and cGMP. A
tentative plant layout is shown in Fig 6.1.
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Suven Life Sciences Ltd. Environmental Impact Assessment
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6-18 Team Labs and Consultants
Fig 6.1 Plant Layout of Suven Life Sciences Ltd.
Green Belt
DESCRIPTION
MAINTENANCE ENGG.OFFICE
3 B , 3 C , 3 D
GATE
Gate
SOLVENT STORAGE TANKS
SVL
285A
3B
SOLVENT DRUMS STORE
Gate
01
4.5 M WI
DE RO
AD
Q.C.D
MAIN EN
TRANCE
STORE
Storm Water
18
12.0
GREEN BELT
SVL
26
22
DRY HCL.PLANT
GMP BLOCK
11SVL
WASH AREA
27
Storm
Water
Green Belt
Road
TIME OFFICE & PERSONAL DEPT.
SVL
Future
SOLVENT STORAGE YARD.
WATER SUMP
PLANT LAYOUT
CT-1001
10A
35
18
15
SVL
25.0
Storage Pond
27
24
SVL
10
Green Belt
FABRICATION SHED
30
4A
2.4
1B
29
DM WATER PLANT & OFFICE
6.0 M WID
E ROAD
11
DRUMS STORAGE SHED
3C
22
09
02
17A
4.5 M WID
E ROAD
13
ENGG.STORE & CONF.HALL
ROAD
24
NATION
AL HIG
H WAY
NO.9
VIJAYAW
ADA T
O HYD
ERABADSECURITY
SVL
DRYING & PACKING SVL
CANTEEN & MAINTANCE DEPT.
05
36
20 & 21
PRODUCTION BLOCK -2
Gate
17A
06
GATE
3A
EFFLUENT TREATMENT PLANT
Storage
Pond
MMA. Tan
ks
33
ELECTRICAL PANEL ROOM FOR
34
DS TANKS
03
Stora ge Tank
25
26
6.0 m Road
NALA
16
TANDA ROAD
SVL
GREEN BELT
6
UNIT - 1, DASAIGUDEM VILLAGE,SURYAPET(M) , NALGONDA ( D.T),
A.P
SVL
12
BLOCK
N
19
PARKING SHED
ROAD
23
SVL
ROAD
2
14
104.0
Road
SVL
4.5 M WID
E ROAD
23
TOILLETS
Road
PRODUCTION BLOCK - 3 A
Green Belt
R.M.STORE & BONDED STORE
1033
Storm Water
ROA
D
17 GateABSORPTION SYSTEM
Checked by :
QCD
Prepared by:
35Gree
n Belt
TANKS
07
Approved by :
CYCLE S
HED
ROAD
4.5 M WI
DE RO
AD
Storage Tank
08
14
34
134.5 M
WIDE
ROAD
GATE
DISPENSARY & TIME OFFICE
ROAD
QA & ADMINISTRATIVE OFFICE
CYLINDER STORAGE SHED
17
Open Area
GATE
29
Effective Date :
3508
ENT
21
12
Title:
16
32
04
SVL
BLOCK -3 MCC PANEL ROOM
AMMONIA VAPOUR
DWG.No : SUVEN- 01-001
28
OFFICE
Store
LIQUID RAW MATERIAL TANKS
4.5 M WI
DE RO
AD
UTILITY BLOCK
SVL
ELECTRICAL TRANSFORMER
Rev.0
GENERATOR ROOM
ROAD
5.0 M W
IDE RO
AD
PRODUCTION BLOCK -4 , 4A, 4B
SVL
Storm Water
6.0 m Road
NO
Green Belt
25
SVL
15
PRODUCTION BLOCK -1, 1A,1B
SVL
3D
1A
0709
4B
Open Area
1
BOILER HOUSE 4T/ 5T
DRYING & PACKING AND
20
19
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6.5 Hazard Analysis and Risk Assessment
6.5.1 Introduction.
Hazard analysis involves the identification and quantification
of the various hazards
(unsafe conditions) that exist in the plant. On the other hand,
risk analysis deals with the
identification and quantification of risks, the plant equipment
and personnel are exposed
to, due to accidents resulting from the hazards present in the
plant.
Hazard and risk analysis involves very extensive studies, and
requires a very detailed
design and engineering information. The various hazard analysis
techniques that may be
applied are hazard and operability studies, fault-tree analysis,
event-tree analysis and
failure and effects mode analysis.
Risk analysis 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's etc. Much of this
information is difficult to get or
generate. Consequently, the risk analysis is often confined to
maximum credible accident
studies.
In the sections below, the identification of various hazards,
probable risks, maximum
credible accident analysis, consequence analysis are addressed
which gives a broad
identification of risks involved in the plant.
6.5.2 Hazard Identification
The Hazard identification process must identify hazards that
could cause a potential major
accident for the full range of operational modes, including
normal operations, start-up,
and shutdown, and also potential upset, emergency or abnormal
conditions. Employers
should also reassess their Hazard identification process
whenever a significant change in
operations has occurred or a new substance has been introduced.
They should also
consider incidents, which have occurred elsewhere at similar
facilities including within the
same industry and in other industries.
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Hazard identification and risk assessment involves a critical
sequence of information
gathering and the application of a decision-making process.
These assist in discovering
what could possibly cause a major accident (hazard
identification), how likely it is that a
major accident would occur and the potential consequences (risk
assessment) and what
options there are for preventing and mitigating a major accident
(control measures). These
activities should also assist in improving operations and
productivity and reduce the
occurrence of incidents and near misses.
The chemical and process industries have been using a variety of
hazard identification
techniques for many years, ranging from simple screening
checklists to highly structured
Hazard and Operability (HAZOP) analysis. Each technique has its
own strengths and
weaknesses for identifying hazards. It is impossible to compare
hazard identification
techniques and come to any conclusion as to which is the best.
Each technique has been
developed for a specific range of circumstances taking many
factors into account including
the resources required to undertake the analysis, expertise
available and stage of the
process. While HAZOP is primarily a tool for hazard
identification, the HAZOP process
can also include assessment of the causes of accidents, their
likelihood and the
consequences that may arise, so as to decide if the risk is
acceptable, unacceptable or
requires further study. Moreover, a formal guidance for applying
this technique is
available. Collaboration between management and staff is
fundamental to achieving
effective and efficient hazard identification and risk
assessment processes.
After identifying hazards through a qualitative process,
quantification of potential
consequences of identified hazards using simulation modeling is
undertaken. Estimation
of probability of an unexpected event and its consequences form
the basis of quantification
of risk in terms of damage to property, environment or
personnel. Therefore, the type,
quantity, location and conditions of release of a toxic or
flammable substance have to be
identified in order to estimate its damaging effects, the area
involved, and the possible
precautionary measures required to be taken.
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Considering operating modes of the facility, and based on
available resources the following
hazard identification process chosen are:
a) Fire Explosion and Toxicity Index (FETI) Approach; b) HAZOP
studies; c) Maximum Credible Accident and Consequence Analysis
(MCACA); d) Classification of Major Hazard Substances; e)
Manufacture Storage and Import of Hazardous Chemical Rules, 1989
(GOI Rules,
1989); f) Identification of Major Hazardous Units.
The physical properties of solvents used in the process are
presented in Table 6.2 which
forms the basis for identification of hazards during storage and
interpretation of the
Manufacture, Storage and Import of Hazardous Chemical Rules,
1989 (GOI Rules, 1989)
The interpretation of “The Manufacture Storage and Import of
Hazardous chemicals”
issued by the Ministry of Environment and Forests, GOI, which
guides the preparation of
various reports necessary for safe handling and storage of
chemicals shows that the
present project requires preparation of safety reports before
commencing operation and
risk assessment is not mandatory. The applicability of various
rules is presented in Table
6.5.
Table 6.5 Applicability of GOI Rules to Storage/Pipeline S.
No
Chemical Inventory KL
Threshold Quantity (T) For Application of Rules Applicable Rules
5,7-9, 13-15 10-12
1 Acetone 15 1500 10000 4 (1) (a), (2), 5,15 2 Dichloromethane
20 1500 10000 4 (1) (a), (2), 5,15 3 Isopropyl alcohol 15 1500
10000 4 (1) (a), (2), 5,15 4 Methanol 2 x 30 1500 10000 4 (1) (a),
(2), 5,15 5 Toluene 2 x 30 1500 10000 4 (1) (a), (2), 5,15 6
Ethanol 10 1500 10000 4 (1) (a), (2), 5,15 7 Ethyl Acetate 20 1500
10000 4 (1) (a), (2), 5,15 8 O-Xylene 10 1500 10000 4 (1) (a), (2),
5,15
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Table 6.6 Physical Properties of Raw Materials and Solvents S.No
Name of Raw material TLV
(ppm) Toxicity Level Flammable Limit Chemical Class
(As per MSIHC Rules)
LD50 LD50 LC 50 (mg/1) Oral
(mg/kg) Dermal (mg/kg)
LEL (%)
UEL (%)
FP (OC)
BP (OC)
Class (As per Petroleum
Classification 1 Acetic Acid 10 3310 1060 88 4.0 19.9 39 118 C
Flammable 2 Acetic anhydride 5 1780 4320 4200 2.0 10.2 49 138 C
Flammable 3 Acetone 1000 5800 20000 5540 2.6 13.0 20 1.0 8.1 -22 69
B Flammable 15 Isopropyl alcohol 400 5045 12800 100000 2.0 12.7 12
82.4 B Flammable 16 Isopropyl ether 500 8470 14480 162000 1.0 21.0
-28 67 C Flammable 17 Methanol 200 5628 15800 64000 5.5 36.5 11
64.5 A Flammable 18 Methyl isobutyl ketone 100 2737 6480 23500 1.8
10.0 -4 79.64 C Flammable 19 Methyl t-butyl ether 50 4000 10000
23576 1.6 15.1 -33 55.2 C Flammable 20 n-Heptane 400 15000 9750
4900 1.0 7.0 -4 98.4 B Flammable 21 N-methyl-2-pyrrolidone 50 3914
5100 8000 1.3 9.5 91 82 B Carcinogenic 22 Tetrahydrofuran 200 1650
2000 2160 1.5 12.4 -21.5 66 B Flammable 23 Toluene 200 636 12124
313 1.2 8.0 4 110.6 B Flammable 24 Xylene 100 50 1 7 24 138.5 B
Flammable
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6.5.3 Fire & Explosion Index (F & EI):
6.5.3.1 Methodology
Dow Chemical Company issued a guideline for hazard determination
and protection. By
this method a chemical process unit is rated numerically for
hazards. The numerical
value used is the Fire and Explosion Index (F&EI) which is
most widely used for hazard
evaluation in chemical process industries.
The guide applies to process unit only and not to auxiliary
units such as power
generating stations, plant water systems, control rooms, fired
heaters, structural
requirements, corrosive nature of material handled and personal
safety equipment. These
are regarded as basic features that do not vary according to the
magnitude of the fire and
explosion hazard involved. The guide also does not cover the
processing and handling of
explosives such as dynamite, TNT etc.
Computation of F&EI
The F&EI is calculated as a product of Material factor,
General process hazard factor, and
special process hazard factor The Material factor is a measure
of the intrinsic rate of
potential energy release from fire or explosion of most
hazardous material or mixture of
materials present in significant quantity, whether it is raw
material, intermediate,
product, solvent etc, by combustion or chemical reaction. “In
significant quantity” here
means such quantity that the hazard represented by the material
actually exists. The
National Fire Protection Agency of USA (NFPA) have specified
standard values for
material factor which should be used for F&EI calculations
and are available in Dow’s
Hazard Classification Guide. In case it is not readily
available, it can be calculated using
the heat of combustion, flammability indices etc.
General process hazards are factors that play a primary role in
determining the
magnitude of loss of incident. It takes into account the nature
of the reaction, ventilation
of the unit, accessibility of the unit, drainage facilities
etc., Special process hazards are
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Suven Life Sciences Ltd. Environmental Impact Assessment
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6-24 Team Labs and Consultants
factors that contribute primarily to the probability of a loss
of incident. They consist of
specific process conditions that have shown themselves to be
major causes of fire and
explosion incidents. It takes into account toxicity of the
material, operating pressure,
operation near flammable range, quantity of material, joints and
packing, use of hot oil
exchange system etc., The F&EI index is calculated as a
product of Material factor,
General process hazard factor, and Special process hazard
factor.
Hazard Ranking
The hazard ranking based on F&EI value is presented in Table
6.7. Table 6.7 Degree of Hazard for F&EI
F&EI Index Range Degree of Hazard 1 – 60 Light
61 – 96 Moderate 97 – 127 Intermediate 128 – 158 Heavy
159 & above Severe The estimated values of F&EI and
hazard ranking are given in the Table 6.8. The radius
of exposure is determined by 0.26 meter x respective F&EI.
The estimated values of F&EI
reflect light hazard in view of the low volume of chemicals.
The fire and explosion index evaluation can be very useful in
developing plant layouts or
adding equipment and buildings to existing plants. Evaluation of
the F&EI calculations
and layout considerations will result a safe, operable,
maintainable and cost-effective
arrangement of equipment and buildings.
Table 6.8 Fire & Explosion Index for Tank farm S. No. Name
of the Solvent Fire &
Explosion Index (F1*F2*MF)
Radius of Exposure (m)
F&EIx0.26
Degree of Hazard
1 Acetone 73.77 19.18 Moderate 2 Dichloromethane 93.62 24.34
Moderate 3 Ethanol 64.48 16.76 Moderate 4 Ethyl acetate 72.48 18.84
Moderate 5 Isopropyl alcohol 72.34 18.81 Moderate 6 Methanol 74.17
19.28 Moderate 7 Toulene 86.82 22.57 Moderate 8 O-Xylene 78.69
20.46 Moderate
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F& E index value is found to be moderate reflecting the
threshold limits as prescribed in
MSHC rules. Both MSHC rules and F & E index indicate that
the present facility does not
require a detailed risk assessment.
6.5.4 Hazard and Operability Study (HAZOP)
Hazard and Operability Study (HAZOP) is a highly structured and
detailed technique,
developed primarily for application to chemical process systems.
A HAZOP can generate
a comprehensive understanding of the possible ‘deviations from
design intent’ that may
occur. However, HAZOP is less suitable for identification of
hazards not related to
process operations, such as mechanical integrity failures,
procedural errors, or external
events. HAZOP also tends to identify hazards specific to the
section being assessed, while
hazards related to the interactions between different sections
may not be identified.
However, this technique helps to identify hazards in a process
plant and the operability
problems. It is performed once the engineering line diagrams of
the plant are made
available. It is carried out during or immediately after the
design stage. The purpose of
the study is to identify all possible deviations from the way
the design/operation is
expected to work and all the hazards associated with these
deviations. A multi-
disciplinary team was constituted with chemical, mechanical and
instrumentation
engineers, R&D chemist and production manager.
The preparative work for HAZOP studies consisted of four stages
i.e., obtaining the data,
converting into usable form, planning the sequence of the study
and arranging the
necessary meetings. The documents referred to for the study
include process description,
process flow diagrams, P&I diagrams plant layout, operating
manuals including startup
& shutdown, safety instructions etc., The parameters such as
temperature, pressure, flow,
level were investigated for deviation and hazard situations are
identified.
Some basic definitions of terms frequently used in HAZOP studies
are deviation, causes,
consequences and guide words etc., Deviations are departures
from the design intent
which are discovered by systematically applying the guide words.
Causes are the reasons
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why deviations might occur. Consequences are the reasons why
deviations should they
occur. Guide words are simple words used to understand a
particular plant section in
operating condition in order to guide and simulate the creative
thinking process and so
discover deviations. NO, less, more, as well as, part of,
reverse, other than are guide
words used.
6.5.5 Hazard Factors
A study of past accident information provides an understanding
of failure modes and
mechanisms of process and control equipment and human systems
and their likely effects
on the overall plant reliability and safety. Some of the major
contributing factors for
accidents in chemical industries are:
S. No Contributing Factor Percent Loss 1 Equipment design faults
41 2 Process design faults 10 3 Operator errors 31 4 Maintenance
deficiencies 12 5 Material hazards 6
A study by AIChE (1972) indicates that majority of equipment of
component failures
involve compressors, furnaces and heat exchangers as there are
lesser opportunities to
take them off for maintenance. The frequency of equipment or
component failures is
observed as follows:
S. No Equipment Frequency (%) 1 Compressors 30 2 Furnaces 18 3
Heat Exchangers 17 4 Process Vessels 18 5 Others 17
However, failures of storage vessels and those during
transportation have been reported
more frequently than cases of plant failures. The failure rate
of various equipment in a
typical power plant is provided in the following table.
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Equipment Failure Rates Failure rate Failures 10-6/h Electric
motors (general) 10 Transformers (
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Failure rate Failures 10-6/h Magnetic clutches 6 Fixed orifices
1 Variable orifices 5 Nozzle and flapper assemblies: Blockage 6
Breakage 0.2 Filters: blockage 1 Leakage 1 Rack-and-pinion
assembles 2 Knife-edge fulcrum: wear 10 Springs (heavily stressed)
1 (Lightly stressed) 0.2 Hair springs 1 Calibration springs: creep
2 Breakage 0.2 Vibration mounts 9 Mechanical joints 0.2 Grub screws
0.5 Pins 15 Pivots 1 Nuts 0.02 Bolts 0.02 Boilers (all types) 1.1
Boilers feed pumps 2.5 Cranes 7.8
6.5.6 Common Causes of Accidents
Engineering and Instrumental
Based on the analysis of past accident information, common
causes of major chemical
plant accidents are identified as:
• Poor house keeping • Improper use of tools, equipment,
facilities • Unsafe or defective equipment facilities • Lack of
proper procedures • Improving unsafe procedures • Failure to follow
prescribed procedures • Jobs not understood • Lack of awareness of
hazards involved
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• Lack of proper tools, equipment, facilities • Lack of guides
and safety devices • Lack of protective equipment and clothing
Failures of Human Systems
An assessment of past chemical accidents reveals human factor to
be the cause for over
60% of the accidents while the rest are due to other plant
component failures. This
percentage will increase if major accidents alone are considered
for analysis. Major
causes of human failures reported are due to:
• Stress induced by poor equipment design, unfavorable
environmental conditions, fatigue, etc.
• Lack of training in safety and loss prevention. • Indecision
in critical situations. • Inexperienced staff being employed in
hazardous situations.
Often, human errors are not analyzed while accident reporting
and accident reports only
provide information about equipment or component failures.
Hence, a great deal of
uncertainty surrounds analysis of failure of human systems and
consequent damages.
The number of persons/materials are potentially exposed to a
specific hazard zone is a
function of the population density and distribution near the
accident location. The failure
rate data and ignition sources of major fires are presented in
the following Tables 6.9 and
6.10.
Table 6.9 Failure Rate Data
S.No Item International Data 1. Process Controllers 2.4 x 10-5
hr-5 2. Process control valve 2.0 x 10-6 hr-1 3. Alarm 2.3 x 10-5
hr-1 4. Leakage at biggest storage tank 5.0 x 10-5 yr-1 5. Leakage
of pipe line 1 x 10-7 m-1 yr-1 6. Human Failure 1 x 10-4
(demand)-1
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Table 6.10 Ignition Sources of Major Fires S.No Ignition Source
Percent 1. Electrical (wiring of motors) 23% 2. Smoking 18% 3.
Friction 10% 4. Over heated material 8% 5. Burner flames 7% 6.
Combustion sparks 5% 7. Spontaneous ignition 4% 8. Cutting &
welding 4% 9. Exposure (fires jumping into new areas) 3% 10.
Incendiarism (fires maliciously set) 2% 11. Mechanical sparks 2%
12. Molten substances 1% 13. Chemical actions 1% 14. Static sparks
1% 15. Lightening 1% 16. Miscellaneous 1%
6.6 Maximum Credible Accident and Consequence Analysis
(MCACA)
The potential hazards due to toxic and inflammable nature of the
raw materials, process
streams and products can be quantified. However, it is necessary
to carry out a hazard
analysis study to visualize the consequences of an unexpected
release from chemical
plant, which consists of a number of process units and tank farm
facilities. The present
study provides quantified picture of the potential hazards and
their consequences
6.6.1 Methodology
MCACA aims at identifying the unwanted hazardous events, which
can cause maximum
damage to plant and personnel. At the first instance, all
probable accident scenarios are
developed. Scenarios are generated based on properties of
chemicals, physical conditions
under which reactions occur or raw materials stored, as well as
material strength of
vessels and conduits, in-built valves and safety arrangements,
etc. Creating a scenario
does not mean that it will occur, only that there is a
reasonable probability that it could. A
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scenario is neither a specific situation nor a specific event,
but a description of a typical
situation that covers a set of possible events or
situations.
This is the basis of the risk study; it tells us what may happen
so that ways and means of
preventing or minimizing the possibility can be devised. The
next step is estimation of
the probability of each accident scenario. A credible accident
is one within the realm of
possibility and is likely to be severe enough to cause
significant damage. This concept
comprises of two parameters- probable damage caused by an
accident and probability of
occurrence of an accident .There may be types of accidents that
may occur frequently, but
would cause very little damage. And there may be other types
that may cause great
damage, but would have a very low probability of occurrence.
Both are important and
need to be considered, even if they are later discarded. A host
of probable accident
scenarios are visualized examined and credibility of probable
events is established based
on engineering judgment, past accident data and expertise in the
field of risk analysis.
The following steps are involved in identifying the maximum
credible accident scenarios.
a. A detailed study of the process and plant information
including process flow diagrams
and piping & instrumentation diagrams.
b. Hazard classification of chemicals, operations and
equipment.
c. Identification of representative failure cases of vessels and
pipelines and the resulting
release scenarios
d. Establishment of credibility of visualized scenarios based on
past accident data.
6.6.2 Identification of Vulnerable Areas
The unit operations in the process and storage areas involve
mass and energy transfer
operations to effect the necessary physical changes. Nature of
chemicals and the
operating conditions create special hazardous situations. In the
present case the chemicals
handled are flammable and toxic in nature. With these factors in
mind a thorough
examination of the process information is carried out and a list
of inventories of the
hazardous chemicals is prepared to identify the hazardous
situations. Based on the raw
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material consumptions determined from the pilot scale studies,
experience in handling
commercial scale processes and logistics in procurement of raw
materials, the inventories
to be maintained for each of the raw material and its mode of
storage is determined. High
inventory liquid raw materials like solvents are usually stored
in tank farms, while solids
and other low inventory liquids are stored in ware house based
on compatibility,
reactivity, toxicity etc. with appropriate safety and fire
fighting facilities to handle any
kind of emergencies. The solvent tank farm and the capacity of
each tank is mentioned
in table 6.4.
6.6.3 Representative Accident Scenarios
A study of past accidents, which took place in similar process
units and the present plant,
provides reasons and course of accidents and there by focusing
on most critical areas. A
thorough examination of engineering details indicated many
possible scenarios like
gasket leak, pinholes in pipes and vessels apart from rupture of
pipelines and vessels
and catastrophic failure of vessels resulting in a pool. Heat
radiation damage distances
for Pool fire was considered.
Failure Frequency:
The release scenarios considered above can be broadly divided in
to two categories
(i) Catastrophic failures which are of low frequency and
(ii) Ruptures and leaks which are of relatively high
frequency
Vapor or liquid release from failure of gasket, seal and rupture
in pipe lines and vessels
fall in second category whereas catastrophic failure of vessels
and full bore rupture of
pipe lines etc., fall in to first category. Typical failure
frequencies are given in Table 6.11.
Table 6.11 General Failure Frequencies Item Mode of failure
Failure frequencies Pressure Vessel
Serious leak 1.0*10-5/Year Catastrophic 3.0*10-6/Year
Pipe lines =50 mm dia
Full bore rupture 8.8*10-7/m.year Significant leak
8.8*10-6/m.year
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>50 mm =150 mm dia
Full bore rupture 2.6*10-7/m.year Significant leak
5.3*10-6/m.year
>150 mm dia
Full bore rupture 8.8*10-8/m.year Significant leak
2.6*10-6/m.year
hose Rapture/Failure 4.0*10-5/hr Unloading arm Rapture/Failure
3.0*10-8/hr Check valve Failure on demand 1.0*10-4/on demand motor
operated valve Failure on demand 1.0*10-3/ on demand Flange Leak
3.0*10-4/ Year Pump seal Leak 5.0*10-3/ Year Gasket failure Failure
5.0*10-5/ Year Process safety valve(PSV)
Lifts heavily 4.0*10-3/ Year Blocked 1.0*10-3/ Year Lifts
lightly 6.0*10-2/ Year
6.7 Consequence Analysis
The accidental release of hazardous chemicals leads to
subsequent events, which actually
cause the damage. The damages are of three types.
1) Damage due to heat radiation.
2) Damage due to Over pressure effects subsequent to
explosion
3) Damage due to toxic effects
The type of damage and extent of damage depends on nature of
chemical, the conditions
of release, atmospheric conditions and the subsequent events.
The sequence of probable
events following the release of a hazardous chemical is
schematically shown in Figure
6.2. The best way of understanding and quantifying the physical
effects of any accidental
release of chemicals from their normal containment is by means
of mathematical
modeling. This is achieved by describing the physical situations
by mathematical
equations for idealized conditions and by making corrections for
deviation of the
practical situations from ideal conditions. In the present study
ALOHA software from
USEPA. These models for various steps are described in the
following sub-sections.
6.7.1 Release Models and Source strength
This depends on the nature of failure of the unit and the
content of the unit and operating
temperature and pressure of the unit. The release may be
instantaneous due to total
failure of storage unit or continuous due to leakage or rupture
of some component of the
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storage facility. The material discharged may be gas or liquid
or the discharge could be
manifested through two phase flow. The models that are used to
calculate the quantity of
liquid/vapor released are:
Fig 6.2 Steps in Consequence Calculations
The following criteria tables present heat radiation intensities
(Table 6.12), radiation
exposure and lethality (Table 6.13), and damage due to peak over
pressure is presented
in Table 6.14.
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Table 6.12 Damage Due to Incident Radiation Intensities S. No
Incident
Radiation (KW/m2)
Type of Damage Intensity Damage to Equipment Damage to the
People
1 37.5 Damage to process Equipment 100% lethality in 1 min.
1% lethality in 10 sec.
2 25.0 Minimum energy required to ignite wood at indefinitely
long exposure without a flame
50 % lethality in 1min.
Significant injury in 10 sec.
3 19.0 Maximum thermal radiation intensity allowed n thermally
unprotected adjoining equipment.
---
4 12.5 Minimum energy to ignite with a flame, melts plastic
tubing
1% lethality in 1 min.
5 4.0 -- Causes pain if duration is longer than 20 sec, however
blistering is unlikely ( First degree burns)
6 1.6 -- Causes no discomfort on Longer exposure
Source: Techniques for Assessing Industrial Hazards by World
Bank
Table 6.13 Radiation exposure and lethality
Radiation Intensity (KW/m2)
Exposure Time (seconds)
1% Lethality Degree Burns
1.6 -- 0 No Discomfort even after longer exposure
4.5 20 0 1st 4.5 50 0 1 st 8.0 20 0 1 st 8.0 50
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Table 6.14 Damage Due to Peak Over Pressure Human Injury
Structural Damage
Peak Over Pressure (bar)
Type of Damage Peak over Pressure (bar)
Type of Damage
5 – 8 100% lethality 0.3 Heavy (90%Damage) 3.5 – 5 50% lethality
0.1 Repairable (10%Damage) 2 – 3 Threshold lethality 0.03 Damage of
Glass
1.33 – 2 Severe Lung damage 0.01 Crack of Windows 1 – 11/3 50%
Eardrum rupture - -
Source : Marshall, V.C.(1977)’ How lethal are explosives and
toxic escapes. 6.7.2 Results of Consequence Analysis (Terms of
Reference No.57)
The damages due to the accidental release of chemicals are of
three types. a) Damage due to heat radiation b) Damage due to Over
pressure effects subsequent to explosion c) Damage due to Toxic
effects 6.7.2.1 Analysis of Hazardous Scenarios
The hazardous chemicals involved are stored within the threshold
limits of storage and
hence few representative chemicals mainly solvents were
studied.
6.7.2.1.1 Heat radiation effects
When a non-boiling liquid spills, it spreads into a pool. The
size of the pool depends on
the availability of the bund and obstacles. The heat load on
objects outside a burning pool
of liquid is calculated with the heat radiation model. The
average heat radiation intensity,
the diameter-to-height ratio dependent on the burning liquid,
geometric view, distance
from the fire, relative humidity of air, horizontal or vertical
orientation of the object
radiated with respect to fire are factored. All storage tanks in
tank-farm area are provided
with dykes. For each of the hazardous chemicals involved various
scenarios such as pipe
line leaks of 5mm or pipeline ruptures or catastrophic vessel
ruptures of the inventories
as outlined have been considered and damage distances for Lower
Flammability Limits
(LFL) and heat radiation effects for the three levels of
intensity are calculated and
presented in Table 6.15 . Heat radiation damage distances for
most of the scenarios are
not occurring in the case of release from 25 mm holes at a
height of 0.1 m from the bottom
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of the tank for one hour, in the solvent stroage tanks. In case
of pipeline leaks, 5 mm
leaks are considered for 15 mm and 50 mm pipe sizes. The release
rates from 5 mm leaks
are observed to be low, and these leaks have low incident
hazard. The concentration of
the flammable material in the vapor cloud was found to be below
the lower flammability
limits.
Table 6.15 Heat Radiation Damage Distances – Tank Farm S.
No Name of Solvent Tank
Capacity (KL)
Dia (m)
Height (m)
Hole Dia
(mm)
Release Rate
(Kg/sec)
Heat radiation damage distances in m for KW/m2
37.5 12.5 4.0 1 Acetone 15 2.3 3.8 25 0.38
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LDlo - Lethal dose low The lowest concentration of a chemical at
which some test animals die following
inhalation exposure.
IDLH- Immediate Danger to Life and Health The maximum
concentration limit to which a healthy worker can be exposed for
30
minutes and escape without suffering irreversible health effects
or escape impairing
symptoms.
LD50 – Median lethal dose The dose at which 50 percent of test
animals die following exposure. Dose is usually
expressed as milligrams for kilogram of body weight of test
animal. The most popular
way of expressing lethality of toxic loads is to use probit
functions.
P = A + B ln (Cn t) where P is probit value, A , B, n –
constants specific to the chemical t -- time of exposure in
seconds, c – concentration in mg /m 3 or ppm
Knowing the concentration level and time of exposure, the
percentage lethality may be
estimated. However for most of the chemicals the characteristic
constants are not available
and in such cases IDLH values are used.
The storage of toxic chemicals was evaluated with respect to
failure of containment
resulting in toxic dispersion and the toxic damage distances
were calculated using
ALOHA software. The results of the same are presented in Table
6.16.
Table 6.16 Toxic Dispersion Damage Distance S.No Name of Raw
material Diameter
(m) Height
(m) Storage Pressure
Release Rate
(Kg/sec)
IDLH (ppm)
Distance (m)
1 Ammonia (50Kg) 0.87 0.27 7.86 Bar 0.004 300 17 2 Hydrogen
Chloride (1000Kg) 0.30 0.65 42.26 Bar 0.066 50 117
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Fig 6.3 Toxic Dispersion of Ammonia Cylinder
Fig 6.4 Toxic Dispersion of 1Ton HCl Cylinder.
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6.7.2.1.2 Overpressure effects:
When an unignited gas cloud mixes with air and reaches the
flammable range and if the
cloud ignites wither a flash fire or flash fire explosion can
occur. Since the burning time is
shorter, instead of heat radiation from a flash fire, peak
overpressure as a function of
distance from the centre of the cloud is derived. In case of
pipeline leaks, damage
distances due to overpressure effects are not observed. The
values are found to be similar
as there are no pressurized storage tanks in the tank farm, and
the over pressure
distances are contingent on the tank capacity.
6.7.3 Observations:
From the previous incident records published in literature and
hydrocarbon release data
bases, it has been observed that pinhole leaks contribute
highest percentage where as the
second cause is small sized leaks of 25 mm diameter in tank
farm. Accordingly the
consequence analysis was carried out for 25 mm sized leaks in
the tank farm.
6.7.4 Recommendations:
The following are the recommendations to minimize the hazards
and improve the safety
of the proposed plants. Plants of this nature, which handle a
variety of chemicals, face
problems of fire and vapor cloud explosions. It has been
observed that for the proposed
plants the damage distances are more or less confined to the
plant area only. Taking
precautionary safety measures as outlined below can further
minimize these effects.
• In view of hazardous nature of operations, it is recommended
to adopt best practices
with respect to design, operation and maintenance.
• It is recommended that all flammable areas and process area be
maintained free of
ignition sources. Ensure that sources of ignition, such as pilot
lights, electrical
ignition devices etc., at strategic locations like solvent
storage areas are avoided.
• All electrical fittings involved in and around the pipeline
and operation system
should conform to flame/explosion proof regulations.
• Strict hot work control and display of danger signs should be
ensured.
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• It is recommended to provide one fire hydrant point in the
tank-farm area to take
care of any emergency. Installation of fire water hydrant net
work is suggested.
• It is suggested to provide fire extinguishers in process plant
at solvent storage area
and the vents of solvent tanks to be provided with PESO approved
flame arrestors.
• Fire protection equipment should be well maintained so that it
is available when
required. They should be located for quick accessibility.
Provide carbon dioxide fire
extinguishers and DCP extinguishers for Electrical fires.
• It is suggested to have a periodical review of safety
awareness and safety training
requirements of plant employees with respect to hazards present
in the plant.
• In general, all pipelines carrying flammable liquids/vapor are
periodically checked
for their integrity. Spillages have to be avoided and disposal
should be done
quickly.
6.7.5 Toxic Management Plan (Terms of Reference No.Add. TOR 5
& 6)
The list of chemicals identified to have toxic or carcinogenic
nature is presented in Table
6.17.
Table 6.17 List of Toxic/Carcinogenic Chemicals and Mode of
Storage/Transport S.No Name of Raw
Material Max
Storage Quantity
(Kgs)
Physical State
Mode of Storage
Type of Hazard
Mode of Transport
1 2-Chloro Acetamide 120 Crystalline HDPE Bags Toxic By Road 2
2-Bromo aniline 380 Solid HDPE Bags Toxic By Road 3
2-Chloro-5-Iodo
benzoic acid 200 Solid HDPE Bags Toxic By Road
4 5-Acetonyl-2-methoxy benzene sulfonamide
25 Solid Bags Toxic By Road
5 7-Sodiumoxy-3,4-Dihydro-1H-quinolin-2-one
110 Solid Bags Toxic By Road
6 Alluminium Chloride 500 Powder HDPE Bags Carcinogenic By Road
7 Ammonia 400 Gas Cylinders Toxic By Road 8 Aniline 150 Liquid
Drums Toxic By Road 9 Benzahydrol 235 Solid HDPE Bags Toxic By Road
10 Bromine 540 Liquid Drums Toxic By Road 11 Carbazole 100 Powder
HDPE Bags Carcinogenic By Road
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12 Carbon tetra chloride 215 Liquid Drums Toxic By Road 13
Chloroacetyl chloride 390 Liquid Drums Toxic By Road 14 Cyclohexane
2000 Liquid Drums Toxic By Road 15 Dibromo ethane 25 Liquid Drums
Toxic By Road 16 Diethyl Maleate 40 Liquid Drums Carcinogenic By
Road 17 Formaldehyde 100 Liquid Drums Toxic By Road 18 Formamide
2000 Liquid Drums Carcinogenic By Road 19 Hydroxylamine HCl 40
Crystalline HDPE Bags Carcinogenic By Road 20 Hydroxylamine
sulfate 100 Crystalline HDPE Bags Carcinogenic By Road
21 Lithium Diisopropylamide
165 Liquid Drums Toxic By Road
22 Malano nitrile 105 Solid HDPE Bags Toxic By Road 23 Methyl
iodide 200 Liquid Drums Toxic By Road 24 Methylene Dichloride 20000
Liquid Storage
tanks Carcinogenic By Road
Handling: Storage & handling in compliance with MSDS. The
transfer of solvents shall be
mainly by closed pipeline systems, while solvents are
transferred from drums by using
air operated diaphragm pumps in closed hoods. Solid phase raw
materials are charged
by using closed hoppers to avoid dust emissions and hazard of
static electricity. SOP’s
for better operational control.
Engineering Control Measures: All the operations filtration,
centrifugation, drying is
conducted in closed conditions. Forced dry ventilation system to
hoods. Vent condensers
in series to reactors, distillation columns, driers and
centrifuge to mitigate atmospheric
emissions of toxics. Solvents with low boiling point will be
stored in double limpet coil
storage tanks with coolant circulation.
Vents of secondary condensers connected to vacuum pumps followed
by tertiary
condenser. Common headers connecting all the process vents and
the same are connected
to scrubbers. Low boiling solvents tanks are connected with
reflux condensers to
minimise the loss. The transfer pumps shall be provided with
mechanical seals.
Personnel Protective Equipment: Personal protective equipment
shall be provided to all
employees including contract employees. All the employees shall
be provided with
gumshoe, helmet, masks, goggles. The other equipment like ear
muffs, gloves, respirators,
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aprons etc., will be provided to employees depending on the work
area allocated to them.
The PPE selection shall strictly follow the prescribed
guidelines of MSDS.
Health Monitoring of Employees: The pre employment screening and
periodic medical
examination shall follow the guidelines of factories act. The
pre employment screening
shall obtain medical history, occupational history followed by
physical examination and
baseline monitoring for specific exposures.
Pre employment check up will be made mandatory and following
test will be conducted:
• Plan of evaluation of health of workers
Chest x rays ECG Haemogram (examination of the blood) Urine
(Routine and Microscopic) Complete physical examination
- Musculo-skeletal disorders (MSD) - Backache - Pain in minor
and major joints - Fatigue, etc.
Frequency of Health Monitoring Occupation Type of evaluation
Frequency Process area Complete blood count, platelet count,
and
measurement of kidney and liver function, and medical
examination with focus on liver, kidney, nervous system and
skin,
Every 5 years to age
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Transportation of raw materials may result in accidents due to
high speed collision, low
speed collision, overturning and non-accident-initiated release.
The initiating and
contributing causes are presented in Table 6.18
Table 6.18 Truck Incidents – Initiating and Contributing Causes
Human Errors Equipment Failures System or Procedural
Failures External Events
Driver Impairment
Non-dedicated trailer Driver incentives Vandalism/ Sabotage
Speeding RR crossing guard Driver training Rain Driver Overtired
Failure Carrier selection Fog Contamination Leaking Valve Container
Specification Wing Overfilling Leaking Fitting Route selection
Flood/washout Other Vehicle's Driver
Brake Failure Emergency response training
Fire at rest areas/parking reas
Taking Tight Insulation/Thermal Protection Failure
Speed Enforcement Earthquake
Unsecured Load Relief device failure Driver rest periods
Existing accident Tire failure Maintenance Inspection Soft shoulder
Overpressure Time of day Restrictions Material defect Steering
failure Sloshing High center of gravity Corrosion Bad Weld
Excessive Grade Poor Intersection design Suspension system
The scenarios presented for storages are calculated for
transport related
incidents/accidents and presented in Table 6.19.
Table 6.19 Transportation Specific Concerns
Concern Road Spill on Water Over or near a body of water
Unconfined Pools In an undisturbed flat area BELVE-Induced
catastrophic vessel failure
Possible if sufficient quantity in car with small leak to feed
fire or if double tank trailer or burning fuel leak
Toxic products of combustion or reaction
Dependent on material and whether ignition occurs
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6.7.7 Control Measures for Accidental Spillage of Chemicals Name
of the Chemical Stored
Storage Details Hazard Rating Systems Type of Hazards Involved
Persons Effected
Control Measures Quantity
(KL) Pressure/
Temp TLV
(PPM) STEL (PPM)
FP (OC)
Acetone 30 NTP 1000 500 -20 Highly flammable liquid and vapor.
Causes serious eye irritation. May cause drowsiness or
dizziness.
Operators Maintenance Technicians
Keep away from heat/sparks/open flames/hot surfaces. - No
smoking. Avoid breathing dust/ fume/ gas/ mist/ vapors/ spray. IF
IN EYES: Rinse cautiously with water for several minutes. Remove
contact lenses, if present and easy to do. Continue rinsing. Safety
board’s displayed on the tank. Effective ventilation must be
provided. For accidental contact if you feel unwell, seek medical
advice immediately. Handling of Acetone with Safety gloves and
protective clothing
Dimethyl Formamide
30 NTP 10 58 Flammable liquid and vapor Harmful in contact with
skin Causes serious eye irritation Harmful if inhaled
Operators Maintenance Technicians
Avoid exposure - obtain special instructions before use. Avoid
contact with skin and eyes. Avoid inhalation of vapor or mist. Keep
away from sources of ignition - No smoking. Take measures to
prevent the buildup of electrostatic charge. Wear respiratory
protection. Avoid breathing vapors’, mist or gas. Ensure adequate
ventilation.
Methanol 20 NTP 1000 1000 14 Highly flammable liquid and
vapor.
Operators Maintenance Technicians
Keep away from heat/sparks/open flames/hot surfaces. Use
personal protective equipment. Avoid breathing vapors, mist or gas.
Ensure adequate ventilation. Remove all sources of ignition.
Evacuate personnel to safe areas.
Methylene Dichloride
20 NTP 50 13 Limited evidence of a carcinogenic effect.
Operators Maintenance Technicians
Do not breathe gas/fumes/vapour/spray. Avoid contact with skin
and eyes Wear suitable protective clothing and
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gloves. Store in cool place. Keep container tightly closed in a
dry and well-ventilated place. Containers which are opened must be
carefully resealed and kept upright to prevent leakage
Toluene 20 NTP 200 4 Highly flammable liquid and vapor. May be
fatal if swallowed and enters airways. Causes skin irritation May
cause drowsiness or dizziness. May cause damage to organs through
prolonged or repeated exposure
Operators Maintenance Technicians
Keep away from heat/sparks/open flames/hot surfaces. - No
smoking. Avoid breathing dust/ fume/ gas/ mist/ vapours/ spray. Use
personal protective equipment as required. IF SWALLOWED:
Immediately call a POISON CENTER or doctor/ physician. Do NOT
induce vomiting. Use personal protective equipment. Avoid breathing
vapors, mist or gas. Ensure adequate ventilation
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6.8 Disaster Management Plan (Terms of Reference No.57)
6.8.1 Introduction
A disaster is a catastrophic situation in which suddenly, people
are plunged into
helplessness and suffering and, as a result, need protection,
clothing, shelter, medical and
social care and other necessities of life.
Disasters can be divided into two main groups. In the first, are
disasters resulting from
natural phenomena like earthquakes, volcanic eruptions, storm
surges, cyclones, tropical
storms, floods, avalanches, landslides, and forest fires. The
second group includes
disastrous events occasioned by man, or by man's impact upon the
environment.
Examples are armed conflict, industrial accidents, radiation
accidents, factory fires,
explosions and escape of toxic gases or chemical substances,
river pollution, mining or
other structural collapses, air, sea, rail and road transport
accidents and can reach
catastrophic dimensions in terms of human loss.
There can be no set criteria for assessing the gravity of a
disaster in the abstract since this
depends to a large extent on the physical, economic and social
environment in which it
occurs. However, all disasters bring in their wake similar
consequences that call for
immediate action, whether at the local, national or
international level, for the rescue and
relief of the victims. This includes the search for the dead and
injured, medical and social
care, removal of the debris, the provision of temporary shelter
for the homeless, food,
clothing and medical supplies, and the rapid re- establishment
of essential services.
An emergency may be said to begin when operator at the plant or
in charge of storage of
hazardous chemicals cannot cope up with a potentially hazardous
incident, which may
turn into an emergency. The emergencies could be a major fire or
explosion or release of
toxic gas or a combination of them.
The proposed plant will store fuels, which are flammable in
nature, and the storage will be
as per the Controller of Explosives and OISD norms. The
hierarchy of the employees is
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yet to be determined and the project is still in the initial
stages of designing. Hence a
tentative disaster management plan is prepared to be suitably
modified before
commissioning of the plant.
6