CHAPTER - 7 ADDITIONAL STUDIES

CHAPTER - 7

ADDITIONAL

STUDIES

Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat

(EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)

EN-VISION ENVIRONMENTAL SERVICES, SURAT. JUNE -2018 7-148

Report No. 1718A058

CHAPTER – 7

ADDITIONAL STUDIES

7.1 PUBLIC HEARING

Public hearing is applicable for the proposed unit as stipulated in ToR Letter No: IA-J-11011/517/2017-IA-

II(I) Dated: 9/12/2017 issued by MoEF. Public hearing was conducted on 25th

May 2018, at Palsana, Surat

and MOM of public hearing, issues raised and commitments made by the project proponent during public

hearing with action plan in tabular chart Annexure- XLII.

7.2 GENERAL

M/s. Spectrum Dyes & Chemicals Private Limited was incorporated in the year 1989 for manufacturing Disperse Dyes. Spectrum has a fully integrated installed plant for manufacturing Disperse dyes and

Intermediates and is the second largest disperse dyestuff manufacturing company in India. Spectrum has a

strong customer base. Besides the local Surat market, the company is selling its products all across India and

abroad. Spectrum follows stringent quality controls in the manufacturing process and sourcing of all the raw materials.

These products are manufactured in compliance to the international standards acceptable in Dyes and Intermediates industry. Spectrums’ Research & Development Department is equipped with the latest equipments. In a proactive measure, experienced scientists continually research on improvements in existing

products and processes as well as innovation for higher efficiency and newer products. One such step is to

improve technologies to minimize impact on environment.

7.3 RISK ASSESSMENT AND DISASTER MANAGEMENT PLAN AND OBJECTIVE

Industrial accidents results in great personal and financial loss. Managing these accidental risks in today’s

environment is the concern of every industry, because either real or perceived incidents can quickly jeopardize

the financial viability of a business. Many facilities involve various manufacturing processes that have the

potential for accidents which may be catastrophic to the plant, work force, environment, or public. The main

objective of risk assessment study is to propose a comprehensive but simple approach to carry out risk

analysis and conducting feasibility studies for industries and planning and management of industrial prototype

hazard analysis study. It is essential to achieve and maintain high standards of plant integrity through good

design, management and operational controls. However, accidents do occur and these can cause serious injury

to employees or to the public, and damage to property. Most disastrous events like the Bhopal tragedy have

emphasized the need to address both on-site and off-site safety. The public concern at such events invariably

leads to call for additional control at national and international levels. It is against this background that the

various Section and Rules under the Environment Protection Act, 1986, the Factories Act, 1948 and other

Acts specify the requirements for a safe and reliable working of an industry. These require carrying out

various studies and analysis to assess and mitigate hazards prevalent in the factory in line with the above goal

of safe and reliable working.

The main objectives of the Risk Assessment Studies are :

1. To define and assess emergencies, including risk hazard assessment.

2. To control and contain incidents.

3. To safeguard employees and people residing in vicinity of the company.

4. To minimize damage to property and environment through appropriate installed mitigating procedures.

5. To be ready for mutual aid if need arise to help neighboring units. Normal jurisdiction of an OEP (ON-

SITE EMERGENCY PLAN) is to control events in own premises only. When it comes to the mutual

aid it requires catering to Mutual Aid Partners also.

The study includes predictions of the WORST CASE SCENARIO (catastrophic failure) and MAXIMUM

CREDIBLE ACCIDENT SCENARIO along with damage distances and preparedness plan for effectively

combating such situations. The report also discusses and demarcates the vulnerable zones.

No plan is complete or total of its requirements and its scope of improvement is a continuous process. Hence,

the Risk Assessment Report is to be reviewed and updated as and when:

• Any expansion, alteration, or extension of the plant is planned / implemented




Report No. 1718A058

• An incident has occurred and been dealt with, based on feedback gathered on any shortcomings in the

handling of the situation

• Any feedback is received from the users of the report

Risk Assessment is therefore defined as a continuous and integrated process of identification, evaluation, and

measurement of risks, along with their potential impact on the organization.

7.4 TOOLS & SOFTWARE USED FOR CALCULATIONS

7.4.1 ALOHA (Areal Locations of Hazardous Atmospheres): ALOHA is a computer program designed especially for use by people responding to chemical accidents, as well as for emergency planning and training. ALOHA can predict the rates at which chemical vapors may

escape into the atmosphere from broken gas pipes, leaking tanks, and evaporating puddles. It can then predict

how a hazardous gas cloud might disperse in the atmosphere after an accidental chemical release.

ALOHA is an air dispersion model, which one can use as a tool for predicting the movement and dispersion of

gases. It predicts pollutant concentrations downwind from the source of a spill, taking into consideration the physical characteristics of the spilled material. ALOHA also accounts for some of the physical characteristics of the release site, weather conditions, and the circumstances of the release. Like many computer programs, it

can solve problems rapidly and provide results in a graphic, easy-to-use format. This can be helpful during an

emergency response or planning for such a response.

ALOHA provides output as amount of chemical discharged from the source as well as its concentration in air it takes in to account different levels of concentrations for a specified chemical. Different concentration levels

are given below:

ERPG 1: is the maximum airborne concentration below which it is believed that nearly all individuals could

be exposed for up to 1 hour without experiencing other than mild transient adverse health effects or perceiving a clearly defined, objectionable odor.

ERPG 2: is the maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 hour without experiencing or developing irreversible or other serious health effects or

symptoms which could impair an individual's ability to take protective action.

ERPG 3: is the maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 hour without experiencing or developing life-threatening health effects.

IDLH: The Immediately Dangerous to Life or Health (IDLH) level. A chemical's IDLH is an estimate of the maximum concentration in the air to which

7.5 ELEMENTS OF THE RH STUDY

7.5.1 ELABORATED QUALITATIVE & QUANTITATIVE RISK ASSESSMENT

(METHODOLOGY)

Identification, analysis and assessment of hazard and risk are very useful in providing information to risk management. It provides basis for what should be the type and capacity of its, on-site and off-site emergency

plans. Risk analysis is carried out considering storage and handling of various hazardous raw materials,

manufacturing process and storage of hazardous finished goods.

7.5.2 TOXIC EFFECTS OF CHEMICAL SUBSTANCES. WHAT ARE THE LIMITS? Toxic chemicals are substances that may cause harm to an individual if it enters the body. Toxic chemicals

may enter the body in different ways. These ways are called the route of exposure. The most common route of exposure is through inhalation (breathing it into the lungs). Another common route of entry is through skin

contact. Some chemicals can easily pass through unprotected skin and enter the body. Ingestion is another, less common, route of exposure in the workplace. Ingestion often occurs accidentally through poor hygiene practices. Below shows Toxicity limits by enters the body in different ways.

SR.

NO TOXICITY

ORAL

TOXICITY

LD50(MG/KG)

DERMAL

TOXICITY

LD50(MG/KG)

INHALATION

TOXICITY

LC50(MG/L)

1. Extremely toxic > 5 <40 < 0.5




Report No. 1718A058

2. Highly toxic >5-50 >40-200 < 0.5 - 2.0

3. Toxic >50-200 > 200-1000 >2-10

7.5.3 ASSESSMENT OF FLAMMABILITY & EXPLOSIVE PROPERTIES.

FLAMMABLE CHEMICALS: what law interprets and gives limits. (1) Flammable gases: Gases which at 20

oC and at standard pressure of 101.3KPa are :-

(a) Ignitable when in a mixture of 13 percent or less by volume with air, or;

(b) Have a flammable range with air of at least 12 percentage points regardless of the lower flammable limits.

Note: The flammability shall be determined by tests or by calculation in accordance with methods

adopted by International Standards Organization ISO Number 10156 of 1990 or by Bureau of Indian Standard ISI Number 1446 of 1985.

(2) Extremely flammable liquids: Chemicals which have flash point lower than or equal to 23oC and

boiling point less than 35oC.

(a) Very highly flammable liquids: Chemicals which have a flash point lower than or equal to

23oC and initial boiling point higher than 35oC.

(b) Highly flammable liquids : Chemicals which have a flash point lower than or equal to 60oC

but higher than 23oC.

(c) Flammable liquids : Chemicals which have a flash point higher than 60oC but lower than

90oC.

(3) Explosives: Explosives mean a solid or liquid or pyrotechnic substance (or a mixture of substances) or

an article.

(a) Which is in itself capable by chemical reaction of producing gas at such a temperature and pressure and at such a speed as to cause damage to the surroundings?

(b) Which is designed to produce an effect by heat, light, sound, gas or smoke or a combination of these as the result of non-detonative self sustaining exothermic chemical reaction?

7.5.3.1 TOXIC HAZARDS OF SUBSTANCES Toxic substances affect in three ways by ingestion, absorption & inhalation. Adequate provision of safety

along with personal protective equipment will be made; emergency kit shall be provided at various locations of the installation.

Intoxication – Analytical Analysis. The consequences from inhalation of a toxic vapour/gas are determined by the toxic dose.

This dose D is basically determined by:

- Concentration of the vapour in air; - Exposure duration.

Furthermore, of course, the breathing rates of the victim, as well as the specific toxic mechanism unto the metabolism play an important role.

The dose is defined as D = Cn

.t, with: C = concentration of the toxic vapour, in [ppm] or [mg/m3];

t = exposure duration, in [sec] or [min]; n = exponent, mostly > 1.0; this exponent takes into account the fact that a high concentration

over a short period results in more serious injury than a low concentration over a relatively

longer period of exposure. The value of n should be greater than zero but less than 5. The given definition for D only holds if the concentration is more or less constant over the exposure time; this

may be the case for a (semi) continuous source. In case of an instantaneous source, the concentration varies

with time; the dose D must be calculated with an integral equation:

D = Cn.dt

For a number of toxic materials, so-called Vulnerability Models (V.M.) have been developed. The general equation for a V.M. (probit function) is:

Pr = a + b.ln (Cn.t), with

Pr = probit number, being a representation of the percentage of people suffering a certain kind of damage, for instance lethality

Pr = 2.67 means 1% of the population;

Pr = 5.00 means 50% of the population; a and b material dependent numbers; Cn.t = dose D, as explained above.




Report No. 1718A058

The values for a and b are mostly derived from experiments with animals; occasionally, however, also human

toxicity factors have been derived from accidents in past. In case only animal experiments are available, the

inhalation experiments with rats seem to be best applicable for predicting the damage to people from acute intoxication. Although much research in this field have been done over the past decades, only for a limited number of toxic materials consequence models have been developed. Often only quite scarce information is

available to predict the damage from an acute toxic exposition. Data transformation from oral intoxication data to inhalation toxicity criteria is sometimes necessary. Generally, in safety evaluations pessimistic

assumptions are applied in these transformation calculations. The calculated damage (distance) may be

regarded as a maximum. For the purposes of a response to a major incident, the IDLH value level has been

chosen for the ‘wounded‘ criteria. This type of injury will require medical attention.

7.5.3.2 FLAMMABILITY HAZARDS OF SUBSTANCES Since the Stone Age term 'fire' is associated with fear. Fire destroys everything when not controlled. It is very dangerous if occurs in uncontrolled manner. It should be clearly understood that when a liquid is used having

flash point (Beginning of transformation phase from liquid to vapor) below the normal ambient temperature, it

could, in suitable circumstances, liberate a sufficient quantity of vapor to give rise to flammable mixtures with air. Any source of ignition will transform the vapor to fire.

Heat Radiation – Analytical Analysis Parameters. 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).

The limits for 1% of the exposed people to be killed due to heat radiation, and for second-degree burns are given in the table herein:

Damages to Human Life Due to Heat Radiation

Exposure

Duration

Radiation for 1%

lethality (kW/m2)

Radiation for 2nd

degree burns(kW/m2)

Radiation for first

degree burns, (kW/m2)

10 Sec 21.2 16 12.5

30 Sec 9.3 7.0 4.0

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. The effects

due to relatively lesser incident radiation intensity are given below.

Effects Due To Incident Radiation Intensity

INCIDENT RADIATION –

kW/m2

TYPE OF DAMAGE

0.7 Equivalent to Solar Radiation

1.6 No discomfort for long exposure

4.0 Sufficient to cause pain within 20 sec. Blistering of skin (first degree burns are likely)

9.5 Pain threshold reached after 8 sec. second degree burns after 20 sec.

12.5 Minimum energy required for piloted ignition of wood, melting plastic tubing etc.

7.5.3.3 EXPLOSION HAZARDS Release of energy in a rapid and uncontrolled manner gives rise to explosion. Explosion is very dangerous

because it has the potential to spread the flammable material and fire on low flammable substances also. This

effect of spreading fire instantaneously at different installations due to explosion is called “DOMINO EFFECT”.




Report No. 1718A058

Explosion –Analytical Analysis Parameters In case of vapour 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. For the blast wave, the lethality criterion is based on:

* A peak overpressure of 0.1 bar will cause serious damage to 10% of the housing/structures. * Falling fragments will kill one of each eight persons in the destroyed buildings.

The following damage criteria may be distinguished with respect to the peak overpressures resulting from a

blast wave:

Damage Due To Overpressures

PEAK OVERPRESSURE DAMAGE TYPE

0.83 bar Total Destruction

0.30 bar Heavy Damage

0.10 bar

0.03 bar

Moderate Damage

Significant Damage

0.01 bar Minor Damage

From this it may be concluded that p = 0.17 E+5 pa corresponds approximately with 1% lethality.

Furthermore it is assumed that everyone inside an area in which the peak overpressure is greater than 0.17 E+

5 pas will be wounded by mechanical damage. For the gas cloud explosion this will be inside a circle with the ignition source as its centre.

7.5.3.4 CORROSION HAZARDS Corrosion is a chemical reaction-taking place at the surface of metal. It is also the effects of tissue damage

caused to human beings when contacted accidentally. All substances pH 0-5 & 8.0-12.0 are corrosive. Most

corrosive substances will produce chemical burns, while certain chemical substances produce deep ulceration. The effect will be for internal organs also when the fumes are inhaled/ ingested. Other damages are, has a detailing effect on skin and may cause dermatitis.

On contact with metals, corrosive substances will oxidize the load bearing columns, beams and truss structure

and bring down the stability factor of the buildings.

7.5.3.5 REACTIVITY HAZARDS Reactivity is a property of causing a violent chemical reaction when TWO OR MORE compatible materials coming in contact. The resulting impetus shall release energy in the form of heat, detonation, vapors/gases.

The criteria of avoiding reactivity type hazards is to follow the REACTIVITY MATRIX for storing materials.

(Enlarge to view and read)




Report No. 1718A058

INCOMPATIBLE STORAGE RECOMMENDATIONS.

CHEMICAL

SEGREGATION BY CHEMICAL

GROUP

CLASS 1 2 3 4 5 6

EXPLOSIVES 1

1.0

EXPLOSIVE

SEGREGATE

FROM

SEGREGAT

E FROM

SEGREGAT

E FROM

SEGREGAT

E FROM

SEGREGAT

E FROM

SEGREGAT

E FROM

SEGREGATE FROM SEGREGA

E FROM

FLAMMABLE LIQUIDS

2

SEGREGATE

FROM

KEEP

APART KEEP APART

KEEP

APART

FLAMMABL

E SOLIDS 3

READILY

COMBUSTIBLE

SEGREGAT

E FROM

KEEP

APART

KEEP APART

SPONTENEOUSL

Y COMBUSTIBLE

SEGREGATE

FROM

SEGREGATE

FROM

KEEP

APART KEEP APART

KEEP

APART

DANGEROUS

WHEN WET

SEGREGATE

FROM

SEGREGATE

FROM

OXIDIZING

SUBSTANCE

S

4

OXIDIZING

SUBSTANCE

SEGREGAT

E FROM

SEGREGAT

E FROM KEEP APART

KEEP

APART

ORGANIC

PEROXIDE

SEGREGATE

FROM

SEGREGATE

FROM

KEEP

APART

KEEP APART KEEP

APART

TOXIC

SUBSTANCE

S

5

SEGREGATE

FROM

KEEP

APART

KEEP

APART

KEEP

APART

KEEP

APART

KEEP

APART

SEGREGATE

FROM

KEEP

APART

KEEP

APART

KEEP

APART

KEEP

APART

KEEP

APART

CORROSIVE

SUBSTANCE

S

6

SEGREGATE

FROM

KEEP

APART

KEEP

APART

KEEP

APART

KEEP

APART

KEEP

APART




Report No. 1718A058

7.6 STORAGE AND HANDLING OF HAZARDOUS MATERIALS

Both hazardous and non-hazardous materials generated within the project facility shall be temporarily

accommodated in designated storage units within the project facility built/made in line with the safety, health

and environmental standards.

Size of these temporary units would depend on the quantity and type of hazardous waste materials with

appropriate storage capacities placed in the project facility in compliance with the Hazardous Waste

Management and Handling Rules. Each unit in the facility should have fire hydrant system to handle fire

hazards.

A. LIQUID RAW MATERIALS A.1 IN STORAGE TANKS - Stored in multiple units of same chemical when the quantity is very large in

a tank-farm.

A.2 IN STORAGE TANKS - Stored in a single tank, with other material tanks in a tank –farm. (Mixed

materials tank-farm.

A.3 IN STORAGE TANKS - Specific material stored in A TANK / TANKS in a tank-farm demarcated

and isolated storage ,Licensed and separated with minimum safe distances.

A.4 IN STORAGE SHEDS- Separate storage sheds made for storing specifically raw materials in drums and carboys.

B. SOLID RAW MATERIALS B.1 IN SILOS - Large quantities of powder / Granules are stored in silos. The handling of materials

are done pneumatically. The quantity dispatch in terms of weight are measured with the provision of load cells.

B.2 IN BAGS & - Solid raw materials are received in bags and boxes are stored in closed sheds as per

the BOXES compatibility norms.

C. GASEOUS RAW MATERIALS C.1 IN TONNERS & GAS CYLINDERS.- Flammable and toxic raw materials are stored in demarcated

and isolated storage in Licensed premises.

C.2 IN PIPELINES - Received in pipelines up to the unit and parameters processed in the skid for end

use.

All the above systems of storage are practiced in M/s. SPECTRUM DYES&CHEMICALS PVT.LTD.

Materials that are employed in different processes of Spectrum Dyes & Chemicals Pvt. Ltd., Palsana, Surat

plant, together with their hazardous characteristics are listed in following table 7.1.




Report No. 1718A058

TABLE 7.1 PHYSIO-CHEMICAL PARAMETERS OF HAZ-CHEM: RAW MATERIALS IN TANKFARMS HAZARDOUS CHEMICALS USED IN M/S.

SPECTRUM DYES & CHEMICALS PVT. LTD, PALSANA, SURAT.

HAZARD PARAMETERS CHART.- RAW MATERIALS IN TANKFARMS.- HAZARD PARAMETERS

HIGHLY FLAMMABLE HIGHLY TOXIC

S.NO NAME TPQ LIQUID/

VAPOR

TANK

FARM/

YES/NO

NFPA

LABEL

F-H-R-O

VD LEL

UEL%

F.P

°C B.P °C

TLV

ppm/mg/m³

IDLH

ppm/mg/m³ CAS. NO UN NO

1 Acetic acid 55 L YES 2-3-0-X 2.07 5,0

16.0 40.0 118 5 50 64-19-7 2789

2 Acetic

anhydride 18 L YES 2-3-1-X 3.52

2.7

10.3 49.0 139 0.5 200 108-24-7 1715

3 Acetone 33 L YES 3-1-0-x 2 2.6

12.8 -19 56.0 200 NA 67-64-1 1090

4 Acrylonitrile 13 L YES 3-4-2-X 1.9 3 17 0 77.3 107-13-1 1093

5 Ammonia 25% 9 L YES 0-2-0-X 0.62 NA NA 100 25 300 7766-41-7 1760

6 Aniline Oil 12 L YES 2-3-0-x 3.22 1.3

25 70 184.1 2 100 62-53-3 1547

7 Caustic soda

Lye 48% 40 L YES 0-3-1-X 0.62 NA NA NA 2mg/m3 NA 1310-73-2 1824

8 DMF 75 L YES 2-2-0-X 2.51 2.2

15.2 67 156 2 500 68-12-2 2265

9 Formaldehyde 32 L YES 2-3-2-x 1.06 6

36.5 56-63 NA 1 20 50-00-0 1198

10 Hydrochlo ric

acid 87 L YES 0-3-1-x 1.267 NA NA 110 5 NA 7647-01-0 1789

11 Methanol 34 L YES 3-1-0-x 1.1 5.5

36.5 11.1 64.5 200 6000 67-56-1 1230

12 Oleum 23% 152 L YES 0-3-2-X 2.76 NA NA 142 0.2mg/m³1 NA 8014-95-7 1831




Report No. 1718A058

13 O-Phosphoric

acid 42 L YES 0-3-0-x 3.4 NA NA 158 1mg/m3 NA 7664-38-2 1805

14 Liquid Phenol

94% 19 L YES 2-3-0-x 3.2

1.7

8.6 79 100 6.3 250 108-95-2 2821

15 Sulphuric acid 206 L YES 0-3-2-w 3.4 NA NA 554 1mg/m3 15mg/ m3 7664-93-9 1830

16 NSL 30 L YES NA NA NA NA NA 1.2mg/m³ NA 7782-78 -7 2308

LIST OF HAZARDOUS LIQUID CHEMICALS STORED IN DRUMS AND CARBOYS- HAZARD PARAMETERS

S.NO NAME TPQ/M LIQUID/ VAPOR

TANK

FARM/

YES/NO

NFPA

LABEL

F-H-R-O

VD LEL UEL%

F.P °C

B.P °C TLV ppm IDLH CAS. NO UN NO

1 TOULENE 10 L NO 3-2-0-X 3.14 1.27

7.1 4.4 110.5 50 500 108-88-3 1294

2 BROMINE 6 L NO 0--3-0-0X 5.5 X X 59.4 0.033 3 7726-95 -6 1744

3 BENZOYL

CHLORIDE 36 L NO 2-3-2-W 4.8

1.2

4.9 162 387 X X

4 HYDROGEN

PEROXIDE 5 L NO 0-3-1-0X X X NA 150 10 75 7722-84 -1 2014

5. ALLYL

CHLORIDE 30 L NO 3-3-1-X 2.64

3.3

11.2 3.8 45 2.8 250 107-105 -1 1100

LIST OF HAZARDOUS COMPRESSED GAS STORED IN TANKS & TONNERS

1

ETHYL

CHLORIDE

(EC)

45 GAS

COMP. TONNER 4-2-0-X 2.22

3.8

15.4

(-)

14.4 12.2 300 3800 75-00-3 1037

2 ETHYLENE

OXIDE (EO) 7.5

GAS

COMP. TANK 4-3-3-X 1.49

3

100 -20 10.7 5 800 75-21-8 1040




Report No. 1718A058

LIST OF HAZARDOUS SOLID CHEMICALS STORED IN DRUMS –HAZARD PARAMETERS

S.NO NAME TPQ/M SOLID TANK FARM/ YES/NO

NFPA LABEL F-H-R-O

VD LEL

UEL% F.P °C B.P °C

TLV

ppm IDLH CAS. NO UN NO

1 Caustic soda

flakes 13 YES NO x x x x x 0.5mg/m3 10 mg/m3 1310-73-2 1823

2 Copper cyanide 5 YES NO NA x x x x 21mg/m3 NA 544-92-3 1587

3 Sodium cyanide e 5 Y NO 0-3-0-X x x x x 4mg/m³ 25mg/m³ 143-33-9 1689

4 Zinc cyanide 5 Y NO 0-3-0-X X X X x 14mg/m³ x 557-21-1 1713

5 Hydroquinone 1 Y NO 1-2-0-X x x 168 287 3.0 mg/

m³ NA 123-31-9 1713

6 Naphthalene 250 Y NO 2-2-X-0 4.4 0.9 5.9 87.7 218 15 250 91-20-3 1334

7 Iodine 0.05 Y NO X x x x 185 0.1 2 7553-56-2 3495

8 Para nitrile

Aniline 36 Y NO 1-3-2-X 4.8 X 390 637 9mg/m3

300

mg/m³ 100=01-6 1661

9 P Chloro Aniline 30 y NO NA 4.41 2.2

- 113 232

6.1 mg /

m3 NA 106-47-8 2018

TPQ - THRESHOLD PLANNED QUANTITY, FP – FLASH POINT, BP – BOILNG POINT, VD – VAPOR DENSITY , SG- SPECIFIC GRAVITY, LEL/UEL – EXPLOSIVE LIMITS, TLV – THRESHOD

LIMIT VALUE , IDLH – IMME. DANGER TO LIFE & HEALTH, NFPA –HAZARD PARAMETERS LABEL

TABLE 7.2 STORAGE HAZARDS & MITIGATION MEASURES (QUANTITIES AND TOXICOLOGICAL DATA):

Sr.

No.

Name of

the

Hazardous

Substance

No. of

Container

with

Quantity.

(MT)*

Place of

its

Storage

State and

operating

Pressure&

Temp.

Types of hazards

Possible

(Fire,

Explosion on,

Toxic

Release

, Spill etc.)

Control Measures Provided

1 2 3 6 7 8 9

1 Acetic

Acid

25 MT + 35

MT

EO

RM

Liquid,

Pr. & Temp.

Fire,

Corrosive,

1) Dyke wall having sufficient size is provided.

2) Tank, valve, pipeline are checked and maintain, in good condition.




Report No. 1718A058

2 St. Tank

SS 316

Tank

Farm

Atm. Toxic 3) All Gaskets are checked periodically & being replaced by new one if found defective.

4) Joints are checked regularly for any Leakages.

5) Adequate PPEs are kept to handle the Hazard.

6) ISI Portable fire extinguisher & Hydrant line is provided.

7) Sufficient amount of sand/soil are kept to control any spillage. 8) Flame proof fitting provided.

9) Eye washer cum shower is provided near Tank-farm area.

10) Level indicator provided.

11) Spark arrester are installed on all vehicles inside the premises.

12) SCBA set, Canister mask and airline mask is provided.

13) Earthing& bonding on Tanks is provided.

14) Vent line dipped in water is provided.

15) Tanks kept on sound foundation.

2 Acetic

Anhydride

18 MT

1 Tank

SS 316

EO RM

Tank

Farm

Liquid,

Pr. &

Temp.

Atm.

Fire,

Corrosive

1) Dyke wall having sufficient size is provided.


3) All Gaskets are checked periodically & being replaced by new one if found defective. 4) Joints are checked regularly for any Leakages.

5) Adequate PPEs are kept to handle the Hazard.


7) Sufficient amount of sand are kept to control any spillage.

8) Flame proof fitting provided.







15) Tanks kept on sound foundation.

3 Acetone 33 MT

1 Tank

M S

Methanol

Tank

Farm

Area

U/ G

Liquid,

Pr. &

Temp.

Atm.

Fire 1) Separate storage Tank.

2) Flame proof fittings provided.

3) Fire hydrant & extinguishers provided.

4) Sufficient amount of sand are kept.

5) Apron, Hand gloves, gumboot, helmet, goggles provided

4 Acrylonitr

ile

13 MT

1 Tank

Acrylon

itrile

Tank

Liquid,

Under N2

Blanketing,

Explosive,

Toxic

1) Tank, valve, pipeline are checked and maintained, in good condition.

2) All Gaskets are checked periodically & if being replaced by new one if found defective.




Report No. 1718A058

M S Farm

Area

U/ G

pressure 0.1

Kg/Cm2 &

Temp.

Atm.


4) ISI Portable fire extinguishers are provided.

5) Sufficient amount of sand are kept to control any spillage 6) Flame proof fitting

provided.


8) Proper Earthing& Bonding provided. Earth pit resistance is checked on regular basis and records are maintained.

9) Flame arrester with breather valve is provided on the vent line.

10) Apron, Hand gloves, gumboot, goggles and helmet provided.

11) NRV provided on Tanks.

12) Trained operators are employed to handle the Acrylonitrile under the supervision of

Chemist.

13) Eye washer & shower are provided near the Tank farm area 14) Tank is kept on RCC foundation.

15) Good ventilation in the area. 16) Area declared as “NO SMOKING ZONE”.

17) All vehicles are allowed to enter in the premises after installing spark arrester on

exhaust pipe.

5 Liquor

Ammonia

– 25 %

9 MT

1 Tank

M S

NKS/

M.N.

LIQUI

D T F

A

Liquid,

Pr. &

Temp.

Atm.

Toxic,

Corrosive

1) Dyke wall of sufficient size is provided.


3) All Gaskets are checked periodically & being replaced by new one if found defective.


5) Adequate PPE is kept to handle the Hazard.

6) ISI Portable fire extinguisher is provided.








14) RCC foundation is provided.

15) Sprinkler system provided

6 Aniline

Oil

12 MT

1 Tank

M S

EO RM

Tank

Farm

Liquid,

Pr. &

Temp.

Atm.

Fire, Toxic 1) Dyke wall of sufficient size is provided.

2) Tank, valve, pipeline are checked and maintain, in good condition 3) All Gaskets are checked periodically & being replaced by new one if found defective.





Report No. 1718A058











7 A S C

Acetanilide

SULFONY

L

Chloride

5.4 MT

0.050 X 108

Bags

RM

Store

Solid,

PR. &

Temp.

Atm.

Flammable 1) Separ ate place provided in store

2) Flame proof fittings provided

3) Fire hydrant & extinguishers provided

4) Apron , Hand gloves, gumboot, helmet , goggles provided

8 Benzene

Sulphonyl

Chloride

6 MT

0.250 x 24

M S

DRUM

RM

Store

Liquid,

Pr. &

Temp.

Atm.

Corrosive 1) Separate place provided in store.



4) Sufficient amount of sand are kept


9 Benzoyl

Chloride

36 MT

0.250X 144

P P

DRUM

RM

Store

Liquid,

Pr. &

Temp.

Atm.

Toxic 1) Separate place provided in store 2) Flame proof fittings provided.




10 Benzyl

chloride

7.920

MT0.220 X

36

Drums

RM

Store

Liquid ,

Pr. &

Temp

Atm.

Corrosive

&

Toxic

1) Separate place provided in store


3) Apron , Hand gloves, gumboot, helmet, goggles & Gas mask provided

11 Bromine 6 MT

3 KG X

In

Bromin

e

Liquid,

Pr. &

Temp.

Toxic,

Corrosive

1) Separate place provided in store.






Report No. 1718A058

2000

Bottles

Store

Area

Atm. 4) Sufficient amount of sand are kept.

5) Apron, Hand gloves, gumboot, helmet, goggles provided.

12 Caustic

soda

Flakes

13 MT

0.050 X

260

Bags

RM Store Solid,

Pr. &

Temp.

Atm.

Toxic,

Corrosive

1) Separate place provided in store 2) Fire hydrant & extinguishers provided.


4) Apron, Hand gloves, gumboot, helmet, and goggles provided.

13 Caustic

Soda Lye

48%

68 MT

40 MT

1 Tank

M S

28 MT

1 TANK

MS

N K S

TFA

EO RM

TFA

Liquid,

Pr. &

Temp.

Atm.

Toxic,

Corrosive





5) Apron, Hand gloves, gumboot, goggles and helmet provided. 6) ISI Portable fire extinguisher & Hydrant line is provided.

7) Sufficient amount of sand are kept to control any spillage

8) Eye washer cum shower is provided near Tank-farm area

9) Level indicator provided

10) Vent line provided at sufficient height

14 Copper

Cyanide

0.050 x

120

M S

DRUM

RM

Store

Powder,

Pr. &

Temp.

Atm.

Toxic 1) Separate storage room with lock & key arrangement is provided.


3) Apron, Hand gloves, gumboot, helmet, goggles provided.

4) No acid handling nearby storage area.

15 D 129 3.6 MT

0.150 X 48

M S Drum

RM

Store

Liquid ,

Pr.& Temp

Atm.

Corrosive 1) Separate place provided in store


3) Fire hydrant

4) Sufficient amount of sand are kept 5) Apron , Hand gloves, gumboot, helmet , goggles provided

16 D E S 17 MT

1 Tank

M S

N K S

Tank

Farm

Area

Liquid ,

Pr. & Temp

Atm.

Toxic 1) Dyke wall of sufficient capacity provided.


3) Apron, Hand gloves, gumboot, goggles, canister gas mask and helmet provided.



6) Eye washer cum shower is provided near Tank farm area. 7) Level indicator provided


17 DMF 9.6 MT

RM Liquid,

Pr.

Fire 1)Tank, Valve, pipeline , joint leakage checked & maintain in good condition

through preventive maintenance




Report No. 1718A058

M S

Drum

0.190 x 80

MS Tank

U/G

34 MT

&

A/G

30 M.T.

Store

&

U/G

Tank

farm

area

&Temp.

Atm.

2) Fire extinguishers & fire Hydrant line are provided.

3) Flame proof electrical fittings/ installation provided

4) Proper earthing, Bonding & flange to flange jump ring is provided.

5) Flame arrester provided on vent line

6) CCE approved Separate Storage area with door having locking arrangement is provided.

7) Spark arresters are installed on all vehicles inside the premises.

8) Apron, Hand gloves, gumboot, goggles & helmet provided.

9) Trained operator employed

10) Eye washer & shower provided

11) Tank's thickness measured on regular interval 12) Good ventilation provided in the

area. 13) Mayura water curtain,3% AFFF solution & Foam gun available

18 Dispersant

B/

REAX

89L

35 MT

0.025 X

1400

Bags

RM

Store

Liquid ,

Pr. & Temp

Atm.

Toxic, Fire 1) Separate place provided in store





19 Ethylene

Oxide

15.8 MT

2 Tanks

M S + S S

E.O.

Tank

Yard

Liquid,

Temp.

2oC-

8oC and

under N2

Blanketing

,

Pr.-3.5

Kg/Cm2

Fire,

Toxic, &

Explosion

1) Dyke wall having sufficient size - filled with sufficient water is provided.

2) Tank, valve, pipeline are checked and maintain, in good condition through preventive

maintenance.

3) All Gaskets are checked periodically & if found, defective are replaced by new one,

under preventive maintenance schedule.

4) Joints are checked regularly to detect any leakage under preventive maintenance schedule

5) ISI Portable fire extinguisher & Fire Hydrant line is provided.

6) Flame proof electrical fittings / installation provided.

7) Proper earthing, bonding & flange to flange jump ring is provided. Earth pit resistance

is checked on regular basis and records are maintained

8) Sprinkler System is provided.

9) 1 No. Water monitor is provided.

10) Double Safety valve installed on each Tank. Vent line of safety valve is connected

with water pit.

11) Excess flow checks valve and NRV Provided on EO transfer line.

12) EO are always stored under Inert Gas (N2) atmosphere Blanketing

13) All vehicles are allowed to enter in the premises after installing spark arrester on




Report No. 1718A058

exhaust pipe.

14) Brine cooling system provided and alternative arrangement of child water-cooling system is also provided to maintain temperature bellow 10

oc.

15) Double Temp. & Pressure Indicator provided and maintained good condition.

16) Magnetic level indicator provided.


18) Trained operators are employed to handle EO under the supervision of Chemist.

19) Eye washer & shower provided near EO storage and handling area. 20) Tank’s

thickness measured on regular interval.

21) One Tank out of two Tanks is always kept empty for emergency purpose. 22) RCC foundation provided.

23) Railing with toe guard provided and maintained.

24) Water pit provided and maintain. Vent line connected to water pit.

25) Logbook is maintained for pressure and temperature & to verify quantity on regular

basis.

26) Good ventilation in the area.

27) Lighting arrestor is provided at the roof of tank yard. 29) Area declared as “NO

SMOKING ZONE”.

30) Auto Earthing system installed for EO Tanker Unloading.

31) Mayura water curtain,3% AFFF solution & Foam gun for any type of serious Emergency

32) Emergency Alarm System is installed at 1st & 2nd floor

20 ET 87 3.6 MT

0.150 x 24

M S Drum

RM

Store

Liquid,

Pr.

&Temp. Atm.

Fire &

Corrosive





5)Apron , Hand gloves , gumboot , helmet & goggles provided.

21 Formaldeh

yde 37%

35 MT

1 Tank

MS

NKS

TFA

Liquid,

Pr. &

Temp.

Atm.

Fire, Toxic 1) Dyke wall is provided.



4) Apron, Hand gloves, gumboot, goggles and helmet provided. 5) ISI Portable fire extinguishers & Hydrant line is provided.







Report No. 1718A058

22 H R D

(n Hexayl

Bromide)

19.2

MT

0.200 X 96

M S Drum

RM

Store

Liquid ,

Pr. & Temp

Atm.

Hygro

scopeopic




4) Sufficient amount of sand/soil are kept


23 Hydrochlor

ic Acid

63 MT

2 Tanks

PP

40 MT

23MT

NEW

DD – 1

TFA

DD – 2

TFA

Liquid,

Pr. &

Temp.

Atm.

Toxic,

Corrosive

1) Dyke wall will be provided.

2) Dyke wall of sufficient size will be provided in DD1 TFA.




6) Separate storage area are provided.

7) Scrubber system provided

24 Hydro

quinone

1 M T

0.025 x 40

Bags

RM

Store

Powder,

Pr. &

Temp.

Atm.

Toxic, 1) Separate place provided in store



25 Hydrogen 2 Cylinder

Near

Engg.

Worksh

op

Area

Gas,

Under

pressure

150

Kg/Cm2

& Temp. Atm.

Explosive 1) Apron, Hand gloves, gumboot, goggles & helmet provided

2) ISI Portable fire extinguisher & Hydrant line is provided. 3) Flame proof fitting provided.

4) Sufficient Nos. of SCBA sets & 2 No. of Air line mask.

5) Preventive maintenance on regular basis.

6) Cylinder will be stored and used under Shed to protect from direct sun light.

26 Hydrogen

Peroxide

6.0 MT

0.050X120

Carboys

PP

RM Store Liquid,

Pr. &

Temp.

Atm.

Toxic,

Corrosive






27 Iodine 0.050

0.050 x 1

RM

Store

Solid,

Pr. &

Toxic, 1) Separate place provided in store





Report No. 1718A058

Corr. Box Temp.

Atm.


28 Malano

Nitrile

19.2 MT

0.200 X 96 Drum

MS

RM

Store

Solid,

Pr. &

Temp.

Atm.

Toxic 1) Separate place provided in store



4) Sufficient amount of sand/soil are kept.


29 M E A

70%

Mono

Ethyl

Amine

70%

14.4 MT

0.150 X 96

M S

Drum

RM

Store

Liquid ,

Pr. &

Temp

Atm.

Toxic, Fire 1) Separate place provided in store





30 Methanol 34 MT

1 Tank

M S

Methanol

Tank

Yard

Area.

Liquid,

Pr. &

Temp.

Atm.

Fire &

Explosion

1) Tank, valve, pipeline are checked and maintain, in good condition through preventive maintenance.

2) Joints are checked regularly to detect any Leakage.

3) ISI Portable fire extinguishers & Fire Hydrant line are provided. 4) Flame proof electrical fittings / installation provided.

5) Proper Earthing, Bonding & flange-to-flange jump ring is provided. 6) Flame arrester provided on vent line.

7) CCE approved Separate Storage area with door having locking arrangement.

8) Spark arrester are installed on all vehicles in side the premises. 9) Apron, Hand gloves, gumboot, goggles and helmet provided.

10) Trained operator employed.

11) Eye washer & shower provided.

12) Good ventilation in the area.

13) Tanks are kept under RCC dyke.

14)Mayura water curtain,3% AFFF solution & Foam gun for any type of serious

Emergency

31 Mono

Ethyl

Aniline

10 MT

1 Tank

M S

E.O.

R M

Tank

Yard

Liquid,

Pr. &

Temp.

Atm.

Toxic 1) Dyke wall of sufficient size is provided.





6) ISI Portable fire extinguishers & Hydrant line are provided.





Report No. 1718A058







32 M.M.A. 40%

Mono

Methyl

Amine

8.160 MT

0.170 x

48

Drum

MS

RM

Store

Liquid,

Pr. &

Temp.

Atm.

Fire, Toxic 1) Separate place provided in store 2) Flame proof fittings provided. 3) Fire hydrant & extinguishers provided.



33 MSC

MethaneSulphonyl

Chloride

21 MT

0.250x84 MS Drums

RM

Store

Liquid,

Pr. &

Temp

Atm.

Corrosive,

Toxic




4) Apron, Hand gloves, gumboot , helmet & goggles provided.

34 MNBA

Mono N

Butyl

Amine

14.4 MT

0.150 X 96

M S Drum

RM

Store

Liquid,

Pr.

&Temp

Atm.

Fire,

Toxic

Corrosive

1) Separate storage godown




5) Apron , Hand gloves , gumboot , helmet & goggles provided.

35 M 108 1.8 MT

0.200 X 9

P P Drum

RM

Store

Liquid ,

Pr. & Temp

Atm.

Flammable 1) Separate place provided in store




36 Naphthalen

e

250 MT

0.025 X 10000

Bags

Naphthal

e

ne

Godown

RM Store

Solid, PR.

& Temp.

Atm.

Toxic,

Flammable

1) Separate storage godown



4) Apron , Hand gloves, gumboot, helmet , goggles & cartridge mask for organic vapour

provided

37 N S A

35%

98 MT

52 MT

DD2

Acid

Liquid ,

Pr. & Temp

Atm.

Corrosive

Acidic



3) Apron, Hand gloves, gumboot, goggles and helmet are provided.

4) ISI Portable fire extinguisher.




Report No. 1718A058

1 Tank

S S

+

46 MT

1 Tank

S S

TFA

MONO

AZO

TFA





9) Vent line dipped in H2So4 are provided.


38 Oleum

23%

86 MT

2 Tanks

MS

40 MT

+

48 MT

NKS

TFA

MONO

AZO

TFA

Liquid,

Pr. & Temp.

Atm.

Toxic,

Corrosive


2) Tank, valve, pipeline are checked and maintain, in good condition. 3) Apron, Hand gloves, gumboot, goggles and helmet are provided.

4) ISI Portable fire extinguisher.





9) Vent line dipped in H2So4 are provided.

10) RCC foundation will be provided.

39 Ortho

Phosphori

c Acid

25 MT

1 Tank

SS 316

JARRY

CANS

1.5 MT X

8

12 MT

DYTOL

DF

TFA

RM

Store

Liquid,

Pr. &

Temp.

Atm.

Corrosive 1) Dyke wall will be provided.





6) Separate storage area will be provided.





40 Para Nitro

Aniline

36 MT

0.025 x

1440 Bags

RM

Store

Solid,

Pr. &

Temp.

Atm.

Fire, Toxic 1) Separate place provided in store



41 Para

Chloro

Aniline

7 MT

0.050 x 140

Bags

RM

Store

Solid,

Pr. &

Temp.

Atm.

Fire 1) Separate place provided in store



42 P C O N A 9 MT RM Solid, Corrosive 1) Separate place provided in store




Report No. 1718A058

Para

Chloro

Ortho

Nitro

Aniline

0.025 X 360

Bags

Store PR.

& Temp.

Atm.

2) Apron, Hand gloves, gumboot, helmet, cartridge mask, goggles provided.

43 Phenol

90%

Liquid

37 MT

1 Tank

M S

NKS

Tank

Farm

Area.

Liquid,

Pr. &

Temp.

Atm.

Fire, Toxic 1) Dyke wall of sufficient size is provided.



4) ISI Portable fire extinguisher & Hydrant line is provided

5) Flameproof electrical connection will be provided.

6) Separate storage area will be provided.

7) Sufficient amount of sand are kept to control any spillage



44 Phosphoro

us Oxy

Chloride

15 MT

0.050 X

300

PP Carboys

RM

Store

Liquid,

Pr. &

Temp.

Atm.

Toxic 1) Separate storage godown.



4) Sufficient amount of sand/soil are kept.


45 Piperidine 2.112 MT

0.176 x 12

PP Drum

RM

Store

Liquid,

Pr. &

Temp.

Atm.






46 Pyridine 0.200

MT

0.200 x 1

PP DRUM

RM

Store

Liquid,

Pr. &

Temp.

Atm.

Fire, Toxic 1) Separate place provided in store





47 PC0808 4.8 MT

0.200 X 24

PP Drum

RM

Store

Liquid,

Pr.

&Tem

p Atm.

Fire

Toxic





5) Apron, Hand gloves, gumboot, helmet & goggles provided.

48 P N B C 0.520 RM Solid, Corrosive 1) Separate place provided in store




Report No. 1718A058

P Nitro

BenzoyL

Chloride

MT

0.065 X

8

Carboys

Store PR.

& Temp.

Atm.

2) Apron, Hand gloves, gumboot , helmet , cartridge mask , goggles provided.

49 Propionic

Acid

2.4 MT

0.200 X 12

M S Drum

New

RM

Store

Liquid ,

Pr. & Temp

Atm

Flammable 1) Separate place provided in store




50 Propionic

Anhydride

2.4 MT

0.200 X 12

M S Drum

New

RM

Store

Liquid ,

Pr. & Temp

Atm

Flammable 1) Separate storage godown




51 Sodium

Cyanide

10 MT

0.050 x

200

M S

DRUM

RM

Store

Solid,

Pr. &

Temp.

Atm.

Toxic 1) Separate storage room with lock & key arrangement is provided. 2) Fire hydrant & extinguishers provided.


4) No acid handling nearby storage area.

52 Sodium

Hydro

Sulphite

3 MT

120 X 2 5

M S Drum

RM

Store

Solid,

PR.

& Temp.

Atm.

Combustible 1) Keep in a separate place which should be clean , dry &dark place



4) SCBA Set & Fire Suit should be provided

53 Solvent 87 7.2 MT

0.160 X 45

M S Drum

New

RM

Store

Liquid ,

Pr. & Temp

Atm.

Flammable 1) Separate storage godown




54 Sulfuric

Acid 98%

100

MT

1 Tank

M S

46 MT

+

54 MT

MONO

AZO

TFA

DD 2

Acid

TFA

Liquid,

Pr. & Temp.

Atm.

Corrosive,

Toxic

1) Dyke wall sufficient capacity is provided.






7) Level indicator provided

8) Vent line dipped in H2So4 will be provided.


55 Sulfamic 15 MT New Solid, Corrosive 1) Separate place provided in store




Report No. 1718A058

Acid 0.050X360

Bags

RM

Store

PR.

& Temp.

Atm.

Hygro

scopic

2) Apron, Hand gloves , gumboot , helmet , cartage mask , goggles provided.

56 Sulfuryl

Chloride

5 MT

0.100 X 50

Carboy

RM

Store

Liquid ,

Pr. &

Temp

Atm.

Corrosive & Toxic



3) Apron , Hand gloves, gumboot, helmet, goggles & Gas mask provided

57 T C A 2 MT

0.050 X 40

Bags

New

RM

Store

Solid,

PR.

& Temp.

Atm.

Corrosive

Hygroscopic


2) Apron, Hand gloves, gumboot , helmet , cartage mask , goggles provided.

58 Zinc

Cyanide

4 MT

0.030 x 133

M S Drum

RM

Store

Solid,

Pr. &

Temp.

Atm.

Toxic 1) Separate storage room with lock & key arrangement is provided.



4) No acid handling nearby storage area .

59 3 AC 3 MT

0.050 x 60

P P Drum

New

RM

Store

Liquid ,

Pr. & Temp

Atm.

Flammable

Liquid





60 3 M P A

3 Methoxy

Propyl

Amine

3.96 MT

0.165 X 24

M S Drum

New

RM

Store

Liquid ,

Pr. & Temp

Atm.

Flammable

Liquid

1) Separate space provided in store



4) Apron, Hand gloves, gumboot, helmet , goggles provided

61 2 Amino

Thio

Phenol

2.640 MT

0.220 X 12

Drums

RM

Store

Liquid ,

Pr. & Temp

Atm.


2) Apron, Hand gloves, gumboot, helmet, cartridge mask, goggles provided.

62 2 Ethyl

Hexa

Amine

0.8 MT

0.160 M.T.

X 5 Drums

RM

Store

Liquid ,

Pr. & Temp

Atm

Corrosive

Flammable





63 3:4

Di chloro

Aniline

6 MT

0.050 M.T.

X 120 Bags.

RM

Store

Solid, Pr.

& Temp

Atm.

Toxic 1) Separate place provided in store


3) Apron , Hand gloves, gumboot, helmet, goggles & Dust mask provided




Report No. 1718A058

TABLE 7.3 PROCESS HAZARD & MITIGATION MEASURES:

Sr.

No.

Name of

Plant,

Dept.

or place

Name of the

Hazardous

Process and

Operation

Materials in the

process /operation

with their

quantity.

Name of the

Vessel and its

Location

Operating

Parameter

- pressure,

temp., flow etc.

Types of hazards

Possible

(Fire, Explosion,

Toxic Release,

Spill etc.)

Control Measures Provided

1

BROMIDE

PLANT

1) Sulphonation

2) Condensation

TK - 28

OLEUM -6000 Kgs

H2SO4

DMF

Pocl3

MS- 5,6,7

NGL - 1,2,3

GL – 4,5,6

CT – 1 to CT - 3

FP-1 to FP-3

P = ATM

T = 90OC

Toxic Release

Corrosive

Spill

1) Temp. Gauge Are Provided

2) Scrubber Unit Provided

3) All Required PPEs Are Provided

4) Fire Extinguishers Are Provided

5) Fire Hydrant Points Are Provided. 6) Sand & Lime Drums Are Kept On Each

Floor 7) Emergency Alarm System Is Provided

2

SOLVENT

- 1

PLANT

1) Cyanation

2) Condensation

3) Oxidative

Bromination

METAL

CYANIDE - 190

Kgs

METHANOL -

1500

Kgs

MONO AZO DYE

DMF

SS - 1,2,3,4

SS - 5,6,7,8,9

NUTSCHE

SS – 1 to 9

P = ATM

T = 110OC

Toxic Sludge

Fire

1) Toxic Sludge Collect. Detoxified and Solvent recover In Recovery Plant.

2) All Electrical Gadgets are provided. 3) Scrubber Unit Provided.

4) Spark Arrester are Provided on The Vent

Line.

5) All Required PPEs are provided 6) Fire Extinguishers Are Provided

7) Fire Hydrant Point are provided

8) Sand & Lime Drums are kept on each Floor

3 SOLVENT

- 2

PLANT

Condensation SD – 31

POCL3

DMF

METHANOL

SS – 1 TO 12

GL- I TO 6

P = ATM

T = RM to 90OC

Toxic

Sludge

Fire

Toxic

1) Toxic sludge collect. detoxified and

Solvent recover in recovery plant.

2) All electrical gadgets are provided.

3) Scrubber unit provided.

4) Spark arrester are provided on the vent line.

5) all required PPEs are provided




Report No. 1718A058

Sr-30

Sludge

Fire

6) Fire extinguishers are provided

7) Fire hydrant point are provided

8) sand & lime drums are kept on each floor

4

AQ-1

PLANT

Bromination

Condensation

METHANOL -

2000

Kgs

BROMINE - 330

Kgs

POCl3,, EC, SOL-

87,

A.ACID, HCL,

H2SO4

ACETIC

ANHYDRIDE,

H2O2

ST-1 to ST-10

CT-1 to CT-4

FP-1 to FP-4

P = ATM

T = 50oC - 120OC

Toxic release,

Corrosive,

spill

1) Temp.gauges are provided.

2) Scrubber unit are provided.

3) all require PPE's are provided 4) Safety valves are provided.

5) Fire extinguishers are provided.

6) Fire hydrant points are provided. 7) sand & lime drums are kept on each floor 8) emergency alarm system is provided

5

AQ-2

PLANT

Condensation

MSC,BSC,

HAC

MAA-

ESTER,ECA

CAME,MMA,

METHYL AMINE,

ETHYL AMINE,

BUTYL AMINE,

3 METHOXY

PROPILE AMINE

ST –1 to ST-10

CT-1

P = 1-2 Kg/Cm2

T = 90oC

Toxic release,

Corrosive,

spill

1) Temp.gauges are provided.


3) All require PPE's are provided 4) Safety valves are provided.


9) Fire hydrant points are provided. 10) sand & lime drums are kept on each

floor

11) Emergency alarm system is provided.

6

RECOVERY

1, 2& 3

PLANT

1) Distillation

2) Vacuum

Distillation

METHENOL

DM

AQ-1

ST – 11,12

SOLVENT – 2

SS - 8

P=ATM

T = 65OC

P=ATM

T = 110OC

Toxic Sludge,

Fire

1) All electric gadgets are flame proof.


3) Water Ejectors are provided.

4) Spark arrestors are provided on the vent line.

5) All require PPE’s are provided.




Report No. 1718A058

SOLVENT – 3

RC – 101,102

P=ATM

T = 180OC

6) Fire hydrant points are provided.


8) Emergency alarm system is provided

7

DD-1

PLANT

(DISPERSE

DYES)

Diazotization

HCL

NaNO2

SODIUM

ACETATE

AMINES

DYTOL DF

OPA

ACETIC ACID

DV – 1 TO 11

CR – 1 TO 8

CT – 1 TO 8

FP - 1TO 8

CFP – 1 TO 8

ST – 1 TO 7

HV – 1 TO 11

PADDLE

DRYER – 1

TRAY DRYER

– 4 TO 8

P=ATM

T = <5OC

Toxic

Exothermic

1) All required PPE’s are provided.



4) Temperature indicators are provided. 5) Fire hydrant points are provided.


8

DD-2

PLANT

(DISPERSE

DYES)

Diazotization

H2SO4

HCL

NSA

NaNO2

SODIUM

ACETATE

DYTOL DF

OPA

ACETIC ACID

MSGL 1 TO 12

CT - 1 TO 7

SL – 1 TO 7

FP – 1 TO 7

P=ATM

T = <5OC

Toxic

Exothermic

1) All required PPE’s are provided. 2) Scrubber unit are provided.


4) Temperature indicators are provided.

5) Fire hydrant points are provided. 6) sand & lime drums are kept on each floor

9 NKS

(DISPERSI

1) Naphthalene

Melting

NAPTHALENE, M

N LIQUID.

MELTERS

1,2,3

P=ATM

T = <80O

C

Toxic


2) Temperature indicator & pressure gauge is




Report No. 1718A058

NG

AGE)&

MAA

PLANT

2) Sulphonation

3) Condensation

4) Nutralisation

5) Filtration

6) Condensation

MAA PLANT

:-

7) Des

Condensation

8) Acetylation

9) Filtration

10) Bromination

OLEUM / H2SO4

FORMALDEHYD

E

CAUSTIC LYE

PHENOL

FORMALDEHYD

E

CAUSTIC LYE

DI ETHYL

SULPHATE

MPDA, META

TOLUDINE

N HSXYAL

BROMIDE

H2SO4,HCL,AMI

NE,

BROMINE,H2O2

3rd

FLOOR

R - 109,110 ,111

2nd

FLOOR

R -

103,104,108,113

1st FLOOR

R -

101,102,105,112

1st

FLOOR

FP - 1, FP - 2,

FP - 3,

FP - 6

R - 106,107

1st

FLOOR

R - 122

1st

FLOOR

R - 117,

118,119,120,

121,122

ANF,FP - 4,

FP - 5

R – 119

P=ATM

T =<150OC

P= < 2.0

Kg/Cm2

T =<135OC

T = <60OC

P= < 3.5

Kg/Cm2

T=< 150OC

P=ATM

T = <100OC

P=ATM

T = 10OC

P = ATM

T = 30OC

Exothermic

Exothermic

Pressure

Release

Toxic

Toxic

Exothermic

Toxic

Toxic

Exothermic

Toxic

provided.

3) Safety valves are provided.

4) Pressure reducing valve are provided.

5) Vent line dip in water provided.

6) Alternate cooling arrangement is

provided

7) All required PPE’s are provided


9) Fire hydrant points are provided. 10) Sand & lime drums are kept on each floor.

10 EO PLANT

ETHYLEN

E

OXIDE

PLANT

Ethoxylatioin

Acetylation

Condensation

Filtration

EO,AMA,MAA,M

T,

MCA,ACN,MEMT

,MEA

ACETIC

ANHYDRIDE

1st FLOOR

R - 1 TO 9

GROUND

FLOOR

NUTSCHE - 1

TO 3

P= 3.5

Kg/Cm2

T = <

120OC

Explosive

Fire

Toxic

Exothermic

Pressure


2) Temp & pressure gauges are provided.

3) Safety valves are provided.

4) Vent line dip in water provided.

5) Alternate cooling arrangement is

Provided.

5) Fire extinguishers are provided. 6) Fire hydrant points are provided.

7) Emergency alarm system is provided

8) Sand & lime drums are kept on each floor.




Report No. 1718A058

ACETIC ACID

ANILINE OIL

ALLYL

CHLORIDE

BENZYL

CHLORIDE

CAUSTIC LYE

9) Sprinkler system is

provided in plant.

11 FORMULA

TION

- 1 PLANT

Grinding

Milling

Spray Drying

DYTOL - DF

NKS

TKS / TKM

OPA

ACETIC ACID

REAX 89 L

HEDP

SPD - 4

2nd

FLOOR

PV - 1 TO 16

HOMO - 6,

HV12A,12B,12C

HV - 1B

G FLOOR

SM -

1AB,2AB,3AB,

4AB

SM- 5AB

6AB,7AB,8AB,

9AB,10AB

SM - 11,12

SM -

13AB,14AB,15

AB,16AB

FT BOX – 1 TO

3

ALL AT

FORM - 1

SPD - 3,5

HV - 1,2,3,4 2nd

FLOOR

ALL AT NKS

P=ATM

T = <50OC

1) All required PPE’s are provided. 2) Temp. Gauges are provided.







Report No. 1718A058

SIDE

12 FORMULA

TION

- 2 PLANT

Grinding

Milling

Spray Drying

DYTOL – DF

NKS

TKS

OPA

ACETIC ACID

SPRAY

DRYER - 6,7,8

TANK – 1 TO4

1st FLOOR

SM -

1AB,2AB,3AB,

4AB,

5AB,6AB

FILTER BOX -

1,2,3,4

2nd FLOOR

TURBO-

1,SMV-1 TO 6

MRV-1,2,3

CV 1TO 6

EXV-1,2,3

G FLOOR AT

DD - 2

MR-1A,B,C

MR2A,B,C,D

MR - 3A,B,C

MR -

4A,B,C,D,E


2) Temp. Gauges are provided.


4) Fire hydrant points are provided. 5) Sand & lime drums are on kept on each

floor.

13

PT P

PLANT

&

AMINO

PLANT

Amination

&

Reduction

EFFLUENT

WATER

8, 50,000 LITS.

LIME - 700 MT

FERRIOUS

SULPHATE 80

MT

LIQ. AMMONIA

QUNIZILINE

HYDRO

NT – 1&2

EQUILIZER

TANK

1000KL

AMINO

PLANT

AR-

101,102,103,104

DISTILATION

R - 101 TO 103

P=ATM

T = <50OC

P= 3.0 Kg/Cm2

T= 70OC

Fire

Toxic


2) Temp. Gauges are provided.







Report No. 1718A058

DISTILATION

C-101, R-105

FILTER

PRESS

AFT-102

AR - 106

14 SOLVENT

– 3

PLANT

Chlorosulfonatio

n

&

Condensation

ODCB

SULPHURYL

CHLORIDE

LEUCO

VIOLET 28

PHENOL

POTASSIUM

CARBONATE

R – 102 to R -

108

FP – 2 / FP – 3

P=ATM

T = 50OC

to

80OC

P=ATM

T = RT to

180OC

Toxic

Release

Corrosive

Spill



3) Fire extinguishers are provided. 4) Fire hydrant points are provided.



15 MONO

AZO

Diazotization

Coupling

Bromination

NSA, H2SO4,

WEAK AMINE,

DBPNA, DCPNA,

SD – 12,

SD - 7

SV – 1 to DV –

6

CT – 1 to CT –

4

FP – 1 to FP - 4

P=ATM

T = 80OC

Toxic

Release

Corrosive

Spill




4) Fire hydrant points are provided. 5) Sand & lime drums are kept on each floor.


The major anticipated hazards in the SDCL are described below.

Electrical hazards due to the electrical major equipment/ machinery, operations, welding, motors, heavy lift devices, cabling, human intervention (short circuit

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

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

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

Major dropped objects hazard due to large number of physical handling steps / operations involved with crane/ overhead lifting/ hoisting equipment.

Fires in any part of the plant working areas; there is a possibility of rapid escalation if it is not brought under control quickly.




Report No. 1718A058

TABLE 7.4 GENERAL HAZARDS AND ITS CONTROL

S.

NO

HAZARD

EMERGENCY

POSSIBLE

REASON

RISK/

IMPACT

CONTROL MEASURES

AVAILABLE/REQUIRED

1 Hazardous gases

exposure Failure of equipment

Toxicity

poisoning

Application of gas masks

advised

2 High temperature

contact

Slips,

Falls,

Burn injuries Application of aprons, gloves

and facemasks advised.

3 High noise Hearing impairment Inability in

communication application of ear plugs advised

4 Fire, explosion Unforeseen material

in wastes

Physical injuries,

loss of equipment,

Application of fire

extinguishers, fire hydrant

system advised

5 Movement of

vehicles Accidental impacts

Physical injuries,

damage to

equipment

Speed limit of vehicles and

routes for plying to be fixed.

6 Electrical hazards Contacts/overloads Flash fires,

electrocutions

Application of hand gloves,

face mask, safety shoes advised.

7 Scaffold failure Insufficient props Physical injuries Application of props and

leveling of scaffold

8 No work permits No proper work

procedures/controls

Failures, physical

injuries

Implementation of a work

permit system.

SAFETY MEASURES FOR TRANSPORTING OF HAZARDOUS CHEMICALS:

Transporter to be provided with transport emergency card (TREM) with detailed instructions in case

of accident and/or emergency situation;

Driver & cleaner to be provided training to handle the emergency situation;

Transport vehicle will be equipped with fire fighting gadgets;

SAFETY MEASURES FOR STORING AND HANDLING OF HAZARDOUS CHEMICALS:

All the hazardous chemicals are provided with Safety instruction sheets.

All the user departments are provided with the sheets and regular training imparted to the employees.

Visuals are also displayed to understand the do’s and don’ts of the chemicals.

The monitoring of implementations is done through safety inspections. (Near Miss incidents)

A model safety instruction sheet is given below for scrutiny.

Continued…….

Project: M/s. Spectrum Dyes and Chemicals Pvt. Ltd, Palsana, Surat, Gujarat (EIA/EMP Report for Proposed Expansion of Dyes and Chemicals Manufacturing Unit)

SUBSTANCE: ETHYLENE OXIDE.

SAFETY INSTRUCTIONS – HAZCHEM: ETHYLENE OXIDE (EO) CAS NO: 75-21-8

COMPANY: SPECTRUM DYES &CHEMICALS PVT.LTD. DATE: 02.07.2017

WORKING AREA: EO

RESPONSIBLE PERSON: Mr. HUSMUKH PATEL SIGNATURE :

HAZARD TO HUMAN HEALTH AND THE ENVIRONMENT

FLAMMABLE LIQUID/GAS : Extremely flammable liquid and vapor. Freely soluble in water. Gas is heavier

than air. Chemically unstable. Kept in liquefied state under Nitrogen pressure at lower temperatures. (-5°C)

FP = (-57) °C BP= 10.5 °C LEL = 2.6 % VD = 1.925kg/cm2 at 15°C ,VP = 2.1 bar at 30°C, Auto

Ignition Temp. = 435°C Density of liquid = 0.8866 kg/l. Explosion group = II B TWA = 1.0 ppm

HEALTH: Acute and Chronic health hazards form the substance. Lowest inhalation concentration causing

toxic effects is 1.44 mg/l for 4 hours. It is a strong skin irritant. Neurological disorders and even death have

been reported. Confirmed carcinogen.

REACTIVITY : The auto ignition temperature may be as low as 140° C in presence of rust. Rapid compression

of the vapor with air causes explosion. Ethylene oxide vapor may be initiated into explosive decomposition

in the absence of air. Metal fittings containing magnesium, copper or silver should be avoided. Tends to

polymerize spontaneously due to impurities & application of heat.

Avoid spills and process water in drains. This substance is Eco toxic.

PROTECTIVE MEASURES AND RULES OF CONDUCT

Provision of good ventilation in the working area.

Avoid inhalation of vapor or cold mist. Stay upwind and uphill. Deny entry.

Avoid contact with skin and eyes. In case of contact wash skin and eyes with water.

Store liquefying the gas and cooling to (-5°C). Protect it from heat and heat loss.

Fill in a designated labeled container/vessel.

Evacuate downwind areas for large release of HAZCHEM.

When on large releases, notify the fire and health officials and pollution control agencies.

Avoid long term spills un-cleaned. Vapor formation will result in ignition and flashbacks.

Empty the containers as soon as they are taken for process applications.

Restricted entry. Entry only to authorized personnel.

CONDUCT IN CASE OF DANGER

Suitable dry extinguishing media. Dry extinguishing powder, dry sand.

The flammable gases are highly toxic. Use appropriate gas masks/SCBA set during fire fighting.

Provide sprinkler system, FFF Foam system, fire hydrant system for mitigating fires.

Use water spray to cool and dilute the gas leakages.

In case of large fire use copious amount of water to fight fire.

Use appropriately the fire suits / Proximity suits/ depending on the intensity of the situations.

In any case personal safety shall be the guiding point during fire fighting.

Avoid fire prone liquids and gases entering closed enclosures/ drains. The substance is hazardous to aquatic

environment.

FIRST-AID

EMERGENCY

INHALATION: Remove the casualty from the hazardous area and take him to the fresh air. Arrange medical treatment.

SKIN: Remove the contaminated clothing. Immediately cleanse the affected skin areas with soap under running water.

If irritation persists arrange for medical treatment.

EYES: Rinse the affected eyes with widely spread lids for 10 minutes with running water. Take him to an eye doctor.

SWALLOING: Rinse the mouth and spit the fluids out. If the person is conscious, make him to drink copious amounts of

liquids. Arrange medical treatment.

PROPER DISPOSAL

Carefully absorb the spilled liquid, place into sealed containers, and send to the competent authority for proper

disposal. If the quantity is small dissolve it with plenty of water and dispose it off.




Report No. 1718A058

7.7 TRANSPORTATION

All the raw materials and finished are transported through by road only.

7.8 RISK ASSESSMENT AND CONSEQUENCE ANALYSIS

In a plant handling hazardous chemicals, the main hazard arises due to storage, handling and use of these

chemicals. If these chemicals are released into the atmosphere, they may cause damage due to resulting fires

or vapour clouds.

Operating Parameters: Potential vapour release for the same material depends significantly on the operating

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

potential.

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

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

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

operating conditions (pressure, temperature).

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

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

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

be either instantaneous or continuous. Failure of a vessel leading to an instantaneous outflow assumes the

sudden appearance of such a major crack that practically all of the contents above the crack have to released in

a very short time.

7.8.1 SELECTION OF INCIDENTS AND CONSEQUENCE CALCULATIONS

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

having wind speed 1.2 m/s. In Consequence Analysis, geographical location of the source of potential release

plays an important role. Consideration of a large number of scenarios in the same geographical location serves

little purpose if the dominant scenario has been identified and duly considered.

7.8.2 MAXIMUM CREDIBLE LOSS ACCIDENT SCENARIOS

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

accident in an activity, resulting in the maximum consequence distance that is still believed to be possible. A

MCA-analysis does not include a quantification of the probability of occurrence of the accident. Another

aspect, in which the pessimistic approach of MCA studies appears, is the atmospheric condition that is used

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

Facility. The MCL cases considered, attempt to include the worst “Credible” incidents- what constitutes a

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

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

vulnerability zones is prepared accordingly. Only catastrophic cases have been considered and not partial or

small failures (as is the case in Quantitative Risk Assessment where contributions from low frequency-high

outcome effect as well as high frequency - low outcome events are distinguished). The objective of the study

is emergency planning, hence only holistic and conservative assumptions are used for obvious reasons. Hence

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

whilst interpreting the results.

7.8.3 SCENARIOS (VULNERABILITY AREA IDENTIFICATION)

Identification of risks is done qualitatively and quantitatively through the selection of hazardous substances

and by studying process, to arrive at possible failures and their inherent causes. Probability of risk occurrence

is also ascertained in order to determine the MAXIMUM CREDIBLE ACCIDENT SCENARIO and the

WORST CASE SCENARIO. Hazardous substances have been identified as follows considering the applicable

criteria laid down under the Chemical Accident (Emergency Planning, Preparedness and Response) Rules,

1996, as well as other relevant guidelines.

The handling, processing, and storage of Hazardous chemicals were analyzed and the risks as shown in Table

7.1 had been identified. The risks are then analyzed quantitatively in terms of probability, and severity. The

risks have also been rated according to the matrix R = Probability x Severity.




Report No. 1718A058

Based on generally accepted definitions, the MAXIMUM CREDIBLE ACCIDENT SCENARIO (MCAS)

indicates most likely or possible accident scenario, taking into account the effect of existing control measures

also.

Possible accident scenarios at SDCL are given in following table 7.5

TABLE 7.5 POSSIBLE ACCIDENT SCENARIOS

S.

No Source Scenarios

Failure

Mechanism

RISK

Consequences Probability

¹

Severity 2

Risk

Rating3

1

FIRE IN OUTSIDE

SURFACE OF

ETHYLENE OXIDE STORAGE TANK DUE TO LEAKAGE

FROM THE TANK

(WORST CASE SCENARIO)

WELD CRACK ON THE WELD

SEAMS OF STORAGE TANK.

BIG FIRE, BLEVE, DOMINO

EFFECTS OF FIRE IN OTHER

AREAS OF THE

PREMISES.

2 5 10

2

ETHYLENE OXIDE LEAKAGE FROM

THE TANKER UNLOADING HOSE

PIPE CONNECTION. FLAMMABLE VAPOURS

ENGULFING THE

AREA.

LEAKAGE FROM THE

UNLOADING HOSE PIPE JOINTS.

FIRE ACCIDENTS AND PHYSICAL INJURIES TO THE

OPERATING PEOPLE IN THE

PLANT. DAMAGE

TO PLANT AND EQUIPMENT.

2 4 8

3

LEAKAGE IN THE

UNDERGROUND METHANOL TANK. OUT FLOWN

MATERIAL EMITS

FLAMMABLE

VAPOUR.

STORAGE TANK WELD

JOINT CRACK.

METHANOL VAPOURS ARE HIGHLY

FLAMMABLE. LIKELYHOOD OF

FLAMMABILITY.

DUMPING ARRANGEMENT IN OTHER

TANKS TO

MITIGATE EMERGENCY.

2 4 8

4

OVERFLOW OF

METHANOL FROM

THE RECEIVER IN THE PLANT.

FLAMMABLE

VAPOURS INSIDE THE PLANT PREMISES.

(MAXIMUM

CREDIBLE

ACCIDENT

SCENARIO)

OVERFLOW

RETURN LINE

NOT AVAILABLE. OVER FLOWN

METHANOL

SPILLS ON THE PLANT

FLOOR AND

PROCESS EQUIPMENT

POSSIBILITY OF MOJOR FIRE

2 4 8

5

OLEUM STORAGE TANK INFLOW LINE

VALVE LEAKAGE.

INFLOW LINE DIPPED IN THE

STORAGE

MATERIAL.

VALVE SEAT

ERODED AND LEAKED.

OULEUM FUMES SPREAD IN THE

FACTORY

PREMISES AND THE NEARBY

NATIONAL

HIGHWAY.

3 3 9

6 OVERTURNING OF FORKLIFT WHILE

CARRYING

WHILE TURNING

ROUND A

BREAKAGE OF BOTTLES AND

LIBERATION OF 3 3 9




Report No. 1718A058

BROMINE BOTTLE

CRATES.

CORNER FORKLIFT

OVERTURNED.

THICK BROMINE TOXIC VAPORS

END LEGEND

1PROBABILITY: 2SEVERITY: 3RISK RATING:

1 – HIGHLY UNLIKELY 1 – EXTREMELY MILD PROBABILITY x SEVERITY

2 – UNLIKELY 2 – MILD

3 – SOMEWHAT LIKELY 3 – MODERATE 4 – LIKELY 4 – SEVERE

5 – VERY LIKELY 5 – MOST SEVERE

There are more numbers of TOXIC SEVERITY SCENARIO RISKS from the following chemicals,

(OLEUM, ACETIC ACID, ACETIC ANHYDRIDE, HCL, H2SO4, NSA, ANILINE) , on the Bulk

storage and transfer of chemicals.

There are VERY HIGHLY FLAMMABLE GASES in compressed form (ETHYLENE OXIDE,

ETHYL CHLORIDE), very highly flammable liquids ( METHANOL, DMF, ACRYLONITRILE,

ACETONE)

The worst case scenario is also well within the reach of fire protection/mitigation measures, planned for

installation.

Fire protection/ control / mitigation measures are fully incorporated.

7.8.4 VULNERABILITY ANALYSIS A vulnerability analysis is carried out on the MAXIMUM CREDIBLE ACCIDENT SCENARIO and the WORST CASE SCENARIO. The analysis is carried out using the help of sophisticated computer

software which provides the zone of influence as well as the geographical risk contours. The

calculations are complex in nature, and various parameters are defined to assist the software in simulating the risk contours. The parameters include details such as the size of the leakages / holes,

quantity of materials released, duration of the release, weather and geographical conditions. The

simulations are generated under standard operating conditions. Data given in the reports and manuals are taken as correct information.

The weather conditions are taken as per Table 7.6 for all simulations.

TABLE 7.6 WEATHER CONDITIONS

PARAMETERS CONDITION D CONDITION F

Wind Speed 10.0 m/s 3.0 m/s

Wind Direction 225° true at 3 m 45° true at 3 m

Pasquill Stability D F

Ground Roughness Open country Open country

Air Temperature (°C) 32 25

Surface temperature 32 25

Relative Humidity 75% 50%

Cloud Cover 70% 50%

7.8.4.1 MAXIMUM CREDIBLE ACCIDENT SCENARIO The MAXIMUM CREDIBLE ACCIDENT SCENARIO was analyzed based on flammable vapor and toxic

vapor risks. The ALOHA simulation software was used to obtain the risk contours and the zone of influence,

as well as levels of risk associated with each zone. The calculations performed are based on Unified Dispersion Modeling and provide the foot prints of hazardous chemical dispersion and the distances of critical concentrations for flammability and toxicity. The

model considers a three stage method as given in the following illustration:

POOL SPREADING AND VAPORIZATION The release containing liquid droplets forms a pool. Any

evaporation from this pool will contribute to the dispersing pool.

Evaporation

↓




Report No. 1718A058

DISPERSION The vapor cloud disperses in the atmosphere until it has

reached harmless concentration.

Calculation of the concentration profile of the cloud ↓

FLAMMABILITY AND TOXICITY

The results of the ALOHA simulation as well as the parameters used for carrying out the simulations is given

below. Downwind concentrations of chemicals are shown.

7.8.4.2 The latitude for Surat - Palsana, Surat, Gujarat, India is:

Latitude DMS: 21°5'7.09" N

Longitude DMS: 72°56'30.69" E

7.8.5 WORST CASE SCENARIO:

TABLE 7.7 WORST CASE SCENARIOS SIMULATION FOR WEATHER CONDITIONS ‘D’, ‘F’

PARAMETERS RISK

THREAT

ZONES

‘D’

THREAT

ZONES

‘F’

PSI

AFFECTED

POPULATION

THREAT AT

POINT:

DW:50M,

CW30M

ETHYLENE OXIDE (BLAST

FORCE IN THE

TANKS)

BLEVE

14 m 19 m 8.0 Employees in the plant shall assemble at safe

Assembly points. The

Assembly points shall

be located in UPWIND

SIDE. Minor damages

are possible in the

works premises. No off

site emergency

foreseen.

‘D’Stability:0.676

psi.

‘F’ Stability :

1.04 psi

20m 27 m 3.5

44 m 61 m 1.0

7.8.5.1 DISPERSION CALCULATIONS:

1) Fire in outside Surface of Ethylene Oxide Storage Tank due to leakage from The Tank.

(WORST CASE SCENARIO)

Ethylene Oxide – 3 m/s, Stability Condition: “F”

SITE DATA:

Location: PALSANA, SURAT,GUJARAT, INDIA

Building Air Exchanges Per Hour: 12 (user specified) Time: January 9, 2018 1342 hours ST (using

computer's clock)

CHEMICAL DATA:

Chemical Name: ETHYLENE OXIDE

Molecular Weight: 44.05 g/mol AEGL-1 (60 min):

N/A AEGL-2 (60

min): 45 ppm AEGL-3 (60 min): 200 ppm IDLH: 800 ppm LEL: 30000 ppm

UEL: 1000000 ppm

Carcinogenic risk - see CAMEO

Chemicals

Scenario:

Fire in outside Surface Of Ethylene Oxide Storage Tank

due to leakage from the tank.




Report No. 1718A058

Ambient Boiling Point: 10.5° C

Vapor Pressure at Ambient Temperature: greater than 1 atm Ambient Saturation Concentration:

1,000,000 ppm or 100.0%

ATMOSPHERIC DATA: (MANUAL

INPUT OF DATA)

Wind: 3 meters/second from 45° true at 3 meters

Ground Roughness: open country

Cloud Cover: 5 tenths

Air Temperature: 25° C

Stability Class: F (user override)

No Inversion Height

Relative Humidity: 50%

SOURCE STRENGTH:

Direct Source: 2000 kilograms/hr

Source Height: 0

Release Duration: 60 minutes Release Rate: 33.3 kilograms/min

Total Amount Released: 2,000 kilograms

Note: This chemical may flash boil and/or result in two phase flow.

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

Red : 19 meters --- (8.0 psi = destruction of buildings)

Orange: 27 meters --- (3.5 psi = serious injury likely) Yellow: 61 meters --- (1.0 psi = shatters glass)

THREAT AT POINT: Overpressure Estimate at the point:

Downwind: 50 meters Off Centerline: 30 meters

Overpressure: 1.04 psi




Report No. 1718A058

Ethylene Oxide– 10 m/s, Stability Condition: “D”

SITE DATA:

Location: PALSANA, SURAT,GUJARAT, INDIA Building Air Exchanges Per Hour: 12 (user

specified)

Time: January 9, 2018 1342 hours ST (using computer's clock)

CHEMICAL DATA:


Molecular Weight: 44.05 g/mol AEGL-1 (60 min):

N/A AEGL-2 (60 min): 45 ppm AEGL-3 (60 min): 200 ppm

IDLH: 800 ppm LEL: 30000 ppm

UEL: 1000000 ppm

Carcinogenic risk - see CAMEO

Chemicals


Vapor Pressure at Ambient Temperature: greater

than 1 atm Ambient Saturation Concentration: 1,000,000 ppm or 100.0%

ATMOSPHERIC DATA:

Wind: 10 meters/second from 225° true at 3 meters

Ground Roughness: open country Cloud Cover: 7 tenths

Air Temperature: 32° C Stability Class: D

No Inversion Height Relative Humidity: 75%

SOURCE STRENGTH:


Source Height: 0



Note: This chemical may flash boil and/or result in two phase flow.

Scenario:

Fire in outside Surface Of Ethylene Oxide Storage Tank

due to leakage from the tank.

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

Red : 14 meters --- (8.0 psi = destruction of buildings)

Orange: 20 meters --- (3.5 psi = serious injury likely)

Yellow: 44 meters --- (1.0 psi = shatters glass)

THREAT AT POINT:

Overpressure Estimate at the point:

Downwind: 50 meters

Off Centerline: 30 meters

Overpressure: 0.676 psi

Discussion / Interpretation:

• Ethylene Oxide is stored under the nitrogen pressure due to its highly reactive & explosive nature.

• Here, we have considered the Fire in outside Surface of Ethylene Oxide Storage Tank due to

leakage from the tank.

• Analysis shows, The maximum overpressure (8.0 psi = destruction of buildings) is experienced up to

19 meter & 14 meter from the source for stability class 3F & 10D respectively.

• EO should be handled with care & control measures shall be regularly checked & maintained.




Report No. 1718A058

7.8.5.2 MAXIMUM CREDIBLE ACCIDENT SCENARIO (MCAS) :

TABLE 7.8 MAXIMUM CREDIBLE ACCIDENT SCENARIO (MCAS) SIMULATION FOR

WEATHER CONDITIONS ‘D’, ‘F’

PARAMETERS

–RELAESE OF

GAS

RISK

THREAT

ZONES

‘D’ in ‘m’

THREAT

ZONES

‘F ’in

‘m ‘

PPM/

PSI ACTIONS TO REDUCE

SEVERITY

THREAT

AT

POINT:

DW 10M,

CW 5 M

ETHYLLENE

OXIDE: Storage

tank Failure (Flammable area

vapor cloud)

FLAM MABLE

Vapor Cloud

10 NA

18000 Cover the spilled liquid

with sand. Dilute the

liquid pool with 1:25

ration water

No

significant

effect. XX NA XX

30 NA 3000

METHANOL:

storage tank

failure .(Flammable area

vapor cloud)

FLAM MABLE Vapor

Cloud

11 NA 43080

Cover the spilled liquid

with sand. Use PPEs.

No

significant

effect.

xx NA XX

28 NA 7180

METHANOL: Pipeline Transfer failure.

(Flammable area

vapor cloud)

FLAM

MABLE

Vapor Cloud

27 NA 43080


with sand. Use PPEs.

No

significant

effect.

XX NA XX

97 NA 7180

OLEUM :

Leakage from the inlet filling line valve(Toxic

cloud effect)

Toxic Vapor Cloud

<1O NA 160mg

m3


with sand. Then apply

neutralizers (Soda ash/

Lime) over the sand. The

toxic effect will be

reduced to 10%.Use

PPEs.

No

significant

effect.

11 NA xx

80 NA

xx

BROMINE:

Forklift capsizing

and bottles broken. (Toxic

cloud effect)

Toxic

Vapor Cloud

27 NA 8.5 All the crates shall be

placed in a open container

to avoid fall and

breakage.

No

significant

effect.

164 NA 0.24

486 NA 0.033




Report No. 1718A058

1) Ethylene Oxide: Storage tank failure (Flammable area vapor cloud)

(MAXIMUM CREDIBLE ACCIDENT SCENARIO)

Ethylene Oxide – 3 m/s, Stability Condition: ‘D’

SITE DATA:

Location: PALSANA, SURAT,GUJARAT,

INDIA

Building Air Exchanges Per Hour: 12 (user specified) Time: January 9, 2018 1503 hours ST

(using computer's clock)

CHEMICAL DATA:


Molecular Weight: 44.05 g/mol AEGL-1 (60 min): N/A

AEGL-2 (60 min): 45 ppm AEGL-3 (60 min): 200 ppm

IDLH: 800 ppm LEL: 30000 ppm

UEL: 1000000 ppm Carcinogenic risk - see CAMEO

Chemicals


Vapor Pressure at Ambient Temperature:

greater than 1 atm

Ambient Saturation Concentration:

1,000,000 ppm or 100.0%

ATMOSPHERIC DATA:

Wind: 10 meters/second from 225° true

at 3 meters

Ground Roughness: open country Cloud

Cover: 7 tenths


Stability Class: D

No Inversion Height


SOURCE STRENGTH:

Evaporating Puddle (Note: chemical is

flammable)

Puddle Diameter: 3 meters Puddle Mass: 500 kilograms

Ground Type: Default soil Ground Temperature: 32° C Initial Puddle Temperature: 10.5° C

Release Duration: ALOHA limited the

duration to 1 hour

Max Average Sustained Release Rate: 29.8 kilograms/min (averaged over a minute or

more) Total Amount Released: 321 kilograms

Scenario:

Storage tank failure (Flammable area vapor cloud)

THREAT ZONE: Threat Modeled: Flammable Area of Vapor Cloud

Model Run: Gaussian

Red : less than 10 meters(10.9 yards) --- (18000 ppm = 60% LEL = Flame Pockets)

Note: Threat zone was not drawn because effects of near-field patchiness make dispersion predictions less reliable for short distances.

Yellow: 30 meters --- (3000 ppm = 10% LEL)

Note: Threat zone was not drawn because effects of near-field patchiness make dispersion predictions less

reliable for short distances.

THREAT AT POINT: Concentration Estimates at the point: Downwind: 10 meters


Note: Concentration not drawn because there is no

significant concentration at the point selected.




Report No. 1718A058

2) Methanol: Storage tank failure (Flammable area vapor cloud)


METHANOL – 10 m/s, Stability Condition: ‘D’

SITE DATA:

Location: PALSANA, SURAT,GUJARAT,

INDIA

Building Air Exchanges Per Hour: 12 (user

specified) Time: January 9, 2018 1503 hours ST


CHEMICAL DATA:

Chemical Name: METHANOL Molecular Weight: 32.04 g/mol

AEGL-1 (60 min): 530 ppm

AEGL-2 (60 min): 2100 ppm AEGL-3 (60 min): 7200 ppm

IDLH: 6000 ppm

LEL: 71800 ppm UEL: 365000 ppm


Vapor Pressure at Ambient temperature: 0.24 atm

Ambient Saturation Concentration: 237,713

ppm or 23.8%

ATMOSPHERIC DATA:


at 3 meters


Cover: 7 tenths


Stability Class: D

No Inversion Height


SOURCE STRENGTH:


Source Height: 0



Scenario:

Storage tank failure (Flammable area vapor cloud)

THREAT ZONE: Threat Modeled: Flammable Area of Vapor Cloud Model Run: Gaussian

Red: 11 meters --- (43080 ppm = 60% LEL = Flame Pockets)

Note: Threat zone was not drawn because effects of

near-field patchiness make dispersion predictions less






THREAT AT POINT: Concentration Estimates at the point:

Downwind: 10 meters Off Centerline: 5 meters






Report No. 1718A058

3) METHANOL: Pipeline Transfer failure (Flammable area vapor cloud)


METHANOL – 10 m/s, Stability Condition: ‘D’

SITE DATA:




CHEMICAL DATA:

Chemical Name: METHANOL Molecular Weight: 32.04 g/mol

AEGL-1 (60 min): 530 ppm AEGL-2 (60 min): 2100 ppm AEGL-3 (60 min): 7200 ppm

IDLH: 6000 ppm

LEL: 71800 ppm

UEL: 365000 ppm Ambient Boiling Point: 64.7° C Vapor Pressure at Ambient temperature: 0.24

atm Ambient Saturation Concentration: 237,713

ppm or 23.8%

ATMOSPHERIC DATA:


at 3 meters


Cover: 7 tenths


Stability Class: D

No Inversion Height


SOURCE STRENGTH:

Direct Source: 200 kilograms/min Source Height: 15

Release Duration: 60 minutes Release Rate: 200 kilograms/min


Scenario:

Pipeline Transfer failure (Flammable area vapor cloud)

THREAT ZONE:

Threat Modeled: Flammable Area of Vapor Cloud

Model Run: Heavy Gas Red: 27 meters --- (43080 ppm = 60% LEL = Flame

Pockets)






Downwind: 10 meters

Off Centerline: 5 meters Max Concentration: Outdoor:1.89 ppm Indoor:1.89 ppm




Report No. 1718A058

4) OLEUM: Leakage from the inlet filling line valve (Toxic cloud effect)


OLEUM – 10 m/s, Stability Condition: ‘D’

SITE DATA:




CHEMICAL DATA:

Warning: OLEUM can react with water and/or water vapor. This can affect the

evaporation rate and downwind dispersion. ALOHA cannot accurately predict the air hazard if this substance comes in contact with

water.

Chemical Name: OLEUM

Solution Strength: 23% (by weight) Ambient Boiling Point: 131.6° C Partial Pressure at Ambient Temperature:

0.0035 atm Ambient Saturation Concentration: 3,535

ppm or 0.35%

Hazardous Component: SULFUR TRIOXIDE Molecular Weight: 80.06 g/mol

AEGL-1 (60 min): 0.2 mg/(cu m)

AEGL-2 (60 min): 8.7 mg/(cu m) AEGL-3 (60 min): 160 mg/(cu m)

ATMOSPHERIC DATA:


at 3 meters


Cover: 7 tenths


Stability Class: D

No Inversion Height


SOURCE STRENGTH:

Evaporating Puddle: Puddle Diameter: 1 meters

Puddle Mass: 200 kilograms

Ground Type: Concrete Ground Temperature: 32° C Initial Puddle Temperature: Ground

temperature Release Duration: ALOHA limited the

duration to 1 hour

Max Average Sustained Release Rate: 10.8

grams/min (averaged over a minute or more) Total Amount Hazardous Component

Released: 642 grams

Scenario:

Leakage from the inlet filling line valve (Toxic cloud effect)

THREAT ZONE:

Model Run: Gaussian Red: less than 10 meters (10.9 yards) --- (160 mg/(cu m)

= AEGL-3 (60 min))



reliable for short distances. Orange: 11 meters --- (8.7 mg/(cu m) = AEGL-2 (60 min))




Yellow: 80 meters --- (0.2 mg/(cu m) = AEGL-1 (60 min))

THREAT AT POINT: Concentration Estimates at the point: Downwind: 10 meters

Off Centerline: 5 meters Max Concentration: Outdoor:1.89 ppm Indoor:1.89 ppm






Report No. 1718A058

05) BROMINE: Forklift capsizing and bottles broken. (Toxic cloud effect)


BROMINE – 10 m/s, Stability Condition: ‘D’

SITE DATA:




CHEMICAL DATA:

Chemical Name: BROMINE Molecular Weight: 159.81 g/mol

AEGL-1 (60 min): 0.033 ppm AEGL-2 (60 min): 0.24 ppm AEGL-3 (60 min): 8.5 ppm

IDLH: 3 ppm


Vapor Pressure at Ambient Temperature: 0.38 atm Ambient Saturation Concentration: 376,061

ppm or 37.6%

ATMOSPHERIC DATA:

Wind: 10 meters/second from 225° true at 3 meters Ground Roughness: open country Cloud

Cover: 7 tenths

Air Temperature: 32° C Stability Class: D

No Inversion Height Relative Humidity: 75%

SOURCE STRENGTH:

Direct Source: 20 kilograms/hr Source Height: 0

Release Duration: 60 minutes Release Rate: 333 grams/min

Total Amount Released: 20.0 kilograms

Scenario:

Leakage from the inlet filling line valve (Toxic cloud effect)

THREAT ZONE:

Model Run: Gaussian

Red : 27 meters --- (8.5 ppm = AEGL-3 (60 min))




Orange: 164 meters --- (0.24 ppm = AEGL-2 (60 min))

Yellow: 486 meters --- (0.033 ppm = AEGL-1 (60 min))


Downwind: 10 meters







Report No. 1718A058

7.8.6 RISK ASSESSMENT AND MITIGATION MEASURES

RISK ASSESSMENT MITIGATION MEASURE & ITS MANAGEMENT

FORMALDEHYDE, PHENOL, AQUOUS AMMONIA are

highly toxic Materials.

Whenever there is spillage on the ground the pool has to be immediately covered with sand and neutralizers like SODA ASH/LIME shall be

spread on the spillage. 90% of the potential harm will be reduced.

FORMALDEHYDE , PHENOL, AMMONIA,OLEM in the gaseous form are very dangerous.

All the chemicals are both

flammable and highly toxic.

Leaks have to be isolated by closing the control valves SWIFTLY. No

body shall stay in the down wind direction. SCBA set shall be used and skilled manpower shall be used to control the effects of these chemicals.

METHANOL, ACETONE,

ACRYLONITRILE,

ETHYLENE OXIDE, ETHYL CHLORIDE are highly flammable chemical with low flash point and

boiling point. These chemicals are a potential source of major fires.

The storage area shall be well protected from any ignitable substances.

All the electrical fittings shall be flameproof. Only qualified /trained

persons shall be used to operate in the tank farm. The tank farm shall be

monitored all the 365 days including nights. Major accident scenarios have to be planned and MOCK DRILLS conducted.

Unsafe practices in the Tank-Farm

areas

All the storage tanks facilities shall have dumping arrangements

planned for reducing the severity during emergencies.

Dumping arrangement is a spare tank facility kept empty and ready to

receive the chemical from the tank with an emergency.

Quantity requirement of

Formaldehyde and Methanol are

very high.

It is preferable to have tanks with medium capacity (more in number) in

the tank farm.

Toxic Chemicals tank farm It shall be separated from flammable chemical tank farm. They have to

be separated by at least 15m away.

Rise in Exothermic reaction

temperature in Reaction vessels.

The cooling arrangements for the Reaction vessels shall be with standby

system. This will control the rise in Exothermic reaction temperatures.

There shall be also two Temperature indicators for monitoring temperature rise in the Reaction vessels.

In case of pressure reactors where

the pressures of operations are greater than atmospheric pressure, the overrun of exothermic reactions

control is very critical.

In addition to the safety devices, there must be arrangement to dislodge

the reaction mass through the bottom discharge valve. There shall be a provision of remote controlled discharge valves for the purpose.

7.8.7 SPECIFIC GUIDELINES FOR HANDLING OF HAZARDOUS CHEMICALS 7.8.7.1 SPECIFIC GUIDELINES FOR ETHYLENE OXIDE:

Guideline for Potential Hazards: Health & Safety • TOXIC; may be fatal if inhaled or absorbed through skin.

• Contact with gas or liquefied gas may cause burns, severe injury and/or frostbite.

• Fire will produce irritating, corrosive and/or toxic gases.

• Runoff from fire control may cause pollution.

• Flammable; may be ignited by heat, sparks or flames.

• May form explosive mixtures with air.

• Those substances designated with a (P) may polymerize explosively when heated or involved in a fire.

• Vapors from liquefied gas are initially heavier than air and spread along ground.

• Vapors may travel to source of ignition and flash back.

• Some of these materials may react violently with water.

• Cylinders exposed to fire may vent and release toxic and flammable gas through pressure relief

devices.

• Containers may explode when heated.




Report No. 1718A058

• Ruptured cylinders may rocket.

• Runoff may create fire or explosion hazard.

• CALL EMERGENCY RESPONSE Telephone Number on Shipping Paper first. If Shipping Paper not

available or no answer, refer to appropriate telephone number listed on the inside back cover.

• As an immediate precautionary measure, isolate spill or leak area for at least 100 meters (330 feet) in

all directions.

• Keep unauthorized personnel away.

• Stay upwind.

• Many gases are heavier than air and will spread along ground and collect in low or confined areas

(sewers, basements, tanks).

• Keep out of low areas.

• Ventilate closed spaces before entering.

• Wear positive pressure self-contained breathing apparatus (SCBA).

• Wear chemical protective clothing that is specifically recommended by the manufacturer. It may

provide little or no thermal protection.

• Structural firefighters' protective clothing provides limited protection in fire situations ONLY; it is not

effective in spill situations where direct contact with the substance is possible.

Guideline for Emergency Response: Fire

• DO NOT EXTINGUISH A LEAKING GAS FIRE UNLESS LEAK CAN BE STOPPED. Dry

chemical, CO2, water spray or alcohol-resistant foam.

Large Fire

• Water spray, fog or alcohol-resistant foam.

• FOR CHLOROSILANES, DO NOT USE WATER; use AFFF alcohol-resistant medium expansion

foam.

• Move containers from fire area if you can do it without risk.

• Damaged cylinders should be handled only by specialists.

Fire involving Tanks

• Fight fire from maximum distance or use unmanned hose holders or monitor nozzles.

• Cool containers with flooding quantities of water until well after fire is out.

• Do not direct water at source of leak or safety devices; icing may occur.

• Withdraw immediately in case of rising sound from venting safety devices or discoloration of tank.

• ALWAYS stay away from tanks engulfed in fire.

• ELIMINATE all ignition sources (no smoking, flares, sparks or flames in immediate area).

• All equipment used when handling the product must be grounded.

• Fully encapsulating, vapor protective clothing should be worn for spills and leaks with no fire.

• Do not touch or walk through spilled material.

• Stop leak if you can do it without risk.

• Do not direct water at spill or source of leak.

• Use water spray to reduce vapors or divert vapor cloud drift. Avoid allowing water runoff to contact

spilled material.

• FOR CHLOROSILANES, use AFFF alcohol-resistant medium expansion foam to reduce vapors.

• If possible, turn leaking containers so that gas escapes rather than liquid.

• Prevent entry into waterways, sewers, basements or confined areas.

• Isolate area until gas has dispersed.

• Move victim to fresh air. • Call 911 or emergency medical service.

• Give artificial respiration if victim is not breathing.

• Do not use mouth-to-mouth method if victim ingested or inhaled the substance; give artificial

respiration with the aid of a pocket mask equipped with a one-way valve or other proper

respiratory medical device.

• Administer oxygen if breathing is difficult.




Report No. 1718A058

• Remove and isolate contaminated clothing and shoes.

• In case of contact with substance, immediately flush skin or eyes with running water for at least 20

minutes.

• In case of contact with liquefied gas, thaw frosted parts with lukewarm water.

• In case of burns, immediately cool affected skin for as long as possible with cold water. Do not

remove clothing if adhering to skin.

• Keep victim warm and quiet.

• Keep victim under observation.

• Effects of contact or inhalation may be delayed.

• Ensure that medical personnel are aware of the material(s) involved and take precautions to protect

themselves.

7.8.7.2 SPECIFIC GUIDELINES FOR CYANIDES: Cyanides – Hazards - Curatives. Cyanides are considered to be one of the highly poisonous chemicals. It can produce severe undesirable health

effects when in direct contact with them. The write up highlights how much we are prepared for handling it. Any fresh suggestions on SAFETY ENHANSEMENT are welcome. Cyanides are supplied as white crystalline solid, lump solid or in powder form. Cyanides are deadly human

poison by ingestion, Toxic by skin absorption through open wounds, Toxic by ingestion, and by inhalation of

dust.

In M/s. Spectrum Dyes & Chemicals Pvt. Ltd, PALSANA. We use sodium Cyanide, Copper Cyanide and Zinc Cyanide in the Cyanation process. Sodium Cyanide is supplied in the form of tablets coated with soda ash, while the copper cyanide and zinc cyanide are supplied in the powder form.

This paper was discussed with Mr.Hardutt singh Tarar, Mr.K.B.Vishwakarma, Mr. Milind Joshi, Mr. Balbirsingh and all their suggestions incorporated.

PRECAUTIONS AT PROPDUCTION UNITS: The supply of cyanides is done in thick metal containers, the lids in sealed condition. The cyanide materials

are supplied in 25kgs, 30kgs and 50kgs tins. Inside the containers the cyanide material is again packed in thick

polythene bags sealed after packing. The packing is usually good and no accidents reported by damage of containers. The average consumption of cyanides in our company is 100 metal tins in each category.

1. All the Cyanides when accidentally come in contact with Acids (Even diluted acids) will puff out

copious amount of hydrogen cyanide gas which is a deadly poisonous gas associated with flammability.

2. Whenever there is a spillage of cyanides in the liquid form they have to be neutralized with

ALKALINE FERROUS SULPHATE solution. The neutralization process will prevent the

generation of hydrogen cyanide gas, hence will reduce the risk of poisoning and fire. 3. The cyanation process begins with addition of sodium cyanide in DMF liquid already charged inside

the reaction vessel. Addition of sodium cyanide tablets are done only when the DMF is tested alkaline. The mixture is stirred for 12-14 hrs prior to the addition of MONOAZODYE solutions.

4. Similarly the addition of copper cyanide and zinc cyanide is done in DMF when the vessel is taken on

vacuum. Due to vacuum the cyanide powders does not spill outside or spread. Designated PPEs are

used during cyanides handling. 5. In our company the CYANIDE material is used for almost 25 years and there is no damage of cyanide

containers during handling. This is due to clear demarcation of responsibility. All the handling and

manipulations are done by designated employees who are well trained for the purpose. 6. After the transfer of cyanide material the containers are washed with ferrous sulphate solution and

disposed off.

7. Throughout the period of association with cyanides, wearing of the designated PPEs are made

mandatory. 8. The track record of cyanide operations is good in M/s. Spectrum Dyes & Chemicals Pvt Ltd,

PALSANA. For the past 25 years there is no single incident on CYANIDE handling and usage. These

chemicals are handled by ONLY SOLVENT-1 group.


PRECAUTIONS AT OHC:

CYANIDES anti dote kit is kept in Occupational Health Centre. They contain SODIUM NITRITE – INJECTION, SODIUM THIOSULPHATE-INJECTION., AMYL NITRITE –inhalant. Shift Nurses are well

aware of the procedure during emergencies.

MATERIAL SAFETY DATA SHEET (MSDS) An extract of the MATERIAL SAFETY DATA SHEET (MSDS) is given for Cyanides used in

M/s. Spectrum Dyes & Chemicals Pvt Ltd, PALSANA. This will give a ready reference and actions to be

taken during emergencies. 1. Sodium Cyanide

2. Copper Cyanide

3. Zinc Cyanide

1.SODIUM CYANIDE

CAS Number UN/NA Number DOT Hazard Label CHRIS Code

143-33-9 1689 Poison SCN

NFPA 704

Diamond Hazard Value Description

0 3

0

Health 3 Can cause serious or permanent injury.

Flammability 0 Will not burn under typical fire conditions.

Instability 0 Normally stable, even under fire conditions.

Special Source: (NFPA, 2010)

General Description

A white crystalline solid, lump solid or powder. A deadly human poison by ingestion Toxic by skin absorption through open wounds, by ingestion, and by inhalation of dust.

Reactivity Alerts : Water-Reactive

Air & Water Reactions

Soluble in water. Slowly decomposed by water and very rapidly by acids to give off hydrogen cyanide, a flammable poison gas. 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 Hydrogen Cyanide gas will be created in 12

minutes.

Fire Hazard

Sodium cyanide is not combustible itself, but contact with acids releases highly flammable hydrogen cyanide

gas. Fire may produce irritating or poisonous gases. Runoff from fire control water may give off poisonous

gases. Container may explode in the heat of fire. Avoid strong oxidizers such as nitrates and chlorates; acids and acid salts. Avoid contact with acids. Aqueous solutions rapidly decompose.

Health Hazard

Super toxic; probable oral lethal dose in humans is less than 5 mg/kg or a taste (less than 7 drops) for a 70 kg (150 lb.) person. Sodium cyanide is poisonous and may be fatal if inhaled, swallowed or absorbed through the

skin. Contact with sodium cyanide may cause burns to skin and eyes. Individuals with chronic diseases of the kidneys, respiratory tract, skin, or thyroid are at greater risk of developing toxic cyanide effects.

Reactivity Profile




Report No. 1718A058

SODIUM CYANIDE produces deadly and flammable hydrogen cyanide gas upon contact with acids, even

very weak acids, e.g., carbon dioxide dissolved in water (soda pop). Reacts violently with fluorine,

magnesium, nitric acid, nitrates and nitrites Incompatible with strong oxidizing agents.

Belongs to the Following Reactive Group(s) : Cyanides, Inorganic

First Aid

Headache, vertigo (dizziness), agitation, and giddiness may be followed by combative behavior, dilated and

unreactive pupils, convulsions, paralysis, and coma. Sodium cyanide is irritating to the skin and mucous membranes. Lacrimation (tearing) and a burning sensation of the mouth and throat are common. Increased

salivation, nausea, and vomiting are often seen.

Emergency Life-Support Procedures: Acute exposure to sodium cyanide may require decontamination and life support for the victims. All exposed persons should be transported to a health care facility as quickly as

possible. Emergency personnel should wear protective clothing appropriate to the type and degree of

contamination. Air-purifying or supplied-air respiratory equipment should also be worn as necessary. Rescue vehicles should carry supplies such as plastic sheeting and disposable plastic bags to assist in preventing

spread of contamination.

INHALATION EXPOSURE: 1. Move victims to fresh air. Emergency personnel should avoid self-exposure to sodium cyanide.

2. Evaluate vital signs including pulse and respiratory rate, and note any trauma. If no pulse is detected, provide CPR. If not breathing, provide artificial respiration. IMMEDIATELY begin administering 100% oxygen to all victims. Monitor victims for respiratory distress. Warning: To prevent self-poisoning, avoid

mouth-to-mouth breathing; use a forced-oxygen mask. Direct oral contact with sodium cyanide-contaminated

persons or their gastric contents may result in self-poisoning. 3. RUSH to a health care facility!

DERMAL/EYE EXPOSURE: 1. Remove victims from exposure. Emergency personnel should avoid self- exposure to sodium cyanide.

2. Evaluate vital signs including pulse and respiratory rate, and note any trauma. If no pulse is detected,

provide CPR. If not breathing, provide artificial respiration. IMMEDIATELY begin administering 100%

oxygen to all victims. Monitor victims for respiratory distress. Warning: To prevent self-poisoning, avoid mouth-to-mouth breathing; use a forced-oxygen mask. Direct oral contact with sodium cyanide-contaminated

persons or their gastric contents may result in self-poisoning. 3. RUSH to a health care facility! 4. Remove contaminated clothing as soon as possible.

5. If eye exposure has occurred, eyes must be flushed with lukewarm water for at least 15 minutes.

6. Wash exposed skin areas twice with soap and water.

INGESTION EXPOSURE: 1. Evaluate vital signs including pulse and respiratory rate, and note any trauma. If no pulse is detected,

provide CPR. If not breathing, provide artificial respiration. IMMEDIATELY begin administering 100% oxygen to all victims. Monitor victims for respiratory distress. Warning: To prevent self-poisoning, avoid mouth-to-mouth breathing; use a forced-oxygen mask. Direct oral contact with sodium cyanide-contaminated

persons or their gastric contents may result in self-poisoning. 2. RUSH to a health care facility!

3. DO NOT induce vomiting. Ipecac is not recommended for ingestion of sodium cyanide.

4. Obtain authorization and/or further instructions from the local hospital for administration of an antidote or

performance of other invasive procedures. 5. Activated charcoal may be administered if victims are conscious and alert. Use 15 to 30 g for children, 50

to 100 g for adults, with 125 to 250 ml of water.

Exposure Period AEGL-1* AEGL-2 AEGL-3

30 minutes 5 mg/m3 20 mg/m3 42 mg/m3

IDLH (Immediate Danger to Life and Health) : 25 mg/m3

Permissible Exposure Limit (PEL) : 8 hours 2 mg/m3


2. COPPER CYANIDE


544-92-3 1587 Poison CCY

NFPA 704

General Description

A green powder. Insoluble in water. Toxic by skin absorption, through open wounds, by ingestion, and by inhalation of hydrogen cyanide that arises from slight decomposition. Produces toxic oxides of nitrogen in fires.

Hazards:

Reactivity Alerts: None

Air & Water Reactions : Insoluble in water.

Fire Hazard

Non combustible. Special Hazards of Combustion Products: Toxic hydrogen cyanide gas may form in fires.

Health Hazard

Following severe exposure to dust, symptoms of cyanide poisoning may develop (see ingestion). Ingestion causes anxiety, confusion, dizziness, sudden loss of consciousness, odor of bitter almonds on breath or in

vomits, rapid weak pulse, convulsions, and paralysis. Contact with eyes causes irritation. Air & Water Reactions : Insoluble in water.

Fire Hazard

Non combustible. However mixed during combustion can release poisonous hydrogen cyanide gas.

Health Hazard

Following severe exposure to dust, symptoms of cyanide poisoning may develop (ingestion). anxiety,

confusion, dizziness, sudden loss of consciousness, odor of bitter almonds on breath or in vomits, rapid weak pulse, convulsions, and paralysis. Contact with eyes causes irritation.

Reactivity Profile

COPPER CYANIDE is decomposed by acids to give off hydrogen cyanide, a flammable poisonous gas. Tends to explosive instability. Capable of violent oxidation under certain condition: fusion with metal

chlorates, per-chlorates, nitrates or nitrites can cause explosions. Reacts with incandescence with magnesium.

COPPER CYANIDE is decomposed by acids to give off hydrogen cyanide, a flammable poisonous gas. Tends to explosive instability. Capable of violent oxidation under certain condition: Fusion with metal

chlorates, per-chlorates, nitrates or nitrites can cause explosions. Reacts with incandescence with magnesium

Belongs to the Following Reactive Group(s): Cyanides, Inorganic.

First Aid EYES: First check the victim for contact lenses and remove if present. Flush victim's eyes with water or

normal saline solution for 20 to 30 minutes while simultaneously calling a hospital or poison control center.

Do not put any ointments, oils, or medication in the victim's eyes without specific instructions from a

physician. IMMEDIATELY transport the victim after flushing eyes to a hospital even if no symptoms (such as redness or irritation) develop.

SKIN: IMMEDIATELY flood affected skin with water while removing and isolating all contaminated clothing. Gently wash all affected skin areas thoroughly with soap and water. If symptoms such as redness or

irritation develop, IMMEDIATELY call a physician and be prepared to transport the victim to a hospital for

treatment.

INHALATION: IMMEDIATELY leave the contaminated area; take deep breaths of fresh air.

IMMEDIATELY call a physician and be prepared to transport the victim to a hospital even if no symptoms


(such as wheezing, coughing, shortness of breath, or burning in the mouth, throat, or chest) develop. Provide

proper respiratory protection to rescuers entering an unknown atmosphere. Whenever possible, Self-Contained

Breathing Apparatus (SCBA) should be used; if not available, use a level of protection greater than or equal to that advised under Protective Clothing.

INGESTION: CYANIDES ARE EXTREMELY TOXIC AND FAST-ACTING POISONS. Even though the

induction of vomiting is not usually recommended outside of a physician's care if the victim is conscious and not convulsing, it may be worth the risk if cyanide has been ingested. Ipecac syrup or salt water may be used

to induce vomiting in such an emergency. IMMEDIATELY call a hospital or poison control center and transport the victim to a hospital. If the victim is convulsing or unconscious, do not give anything by mouth,

assure that the victim's airway is open and lay the victim on his/her side with the head lower than the body. DO NOT INDUCE VOMITING. IMMEDIATELY transport the victim to a hospital.

IDLH(Immediate Danger to Life and Health): Data unavailable

3. ZINC CYANIDE


557-21-1 1713 Poison ZCN

NFPA 704

Diamond Hazard Value Description

0

3

0

Health 3 Can cause serious or permanent injury.

Flammability 0 Will not burn under typical fire conditions.

Instability 0 Normally stable, even under fire conditions.

Special (NFPA, 2010)

General Description: A white powder. Insoluble in water. Toxic by inhalation (dust and the hydrogen cyanide from slight

decomposition) and by ingestion. Produces toxic oxides of nitrogen in fires. Used in medicine, in metal

plating, and in chemical analysis.

Hazards:

Reactivity Alerts : None Air & Water Reactions : Insoluble in water.

Fire Hazard Non-combustible, substance itself does not burn but may decompose upon heating to produce corrosive and/or toxic fumes. Containers may explode when heated.

Health Hazard EYES: Causes eye burns. SKIN: Irritation. INGESTION OR INHALATION: A bitter, acrid burning taste is sometimes noted followed by a feeling of constriction or numbness in the throat. Salivation and nausea are not

unusual, but vomiting is rare. Anxiety, confusion, vertigo, giddiness and often a sensation of stiffness in the

lower jaw.

Reactivity Profile ZINC CYANIDE is decomposed by acids to give off hydrogen cyanide, a flammable poisonous gas. Tends

to explosive instability. Capable of violent oxidation under certain condition; fusion with metal chlorates, per chlorates, nitrates or nitrites can cause explosions. Reacts incandescence (Glow) with magnesium.

First Aid EYES: First check the victim for contact lenses and remove if present. Flush victim's eyes with water or

normal saline solution for 20 to 30 minutes while simultaneously calling a hospital or poison control center. Do not put any ointments, oils, or medication in the victim's eyes without specific instructions from a

physician. IMMEDIATELY transport the victim after flushing eyes to a hospital even if no symptoms (such as redness or irritation) develop.




Report No. 1718A058

SKIN: IMMEDIATELY flood affected skin with water while removing and isolating all contaminated

clothing. Gently wash all affected skin areas thoroughly with soap and water. If symptoms such as redness or

irritation develop, IMMEDIATELY call a physician and be prepared to transport the victim to a hospital for treatment.

INHALATION: IMMEDIATELY leaves the contaminated area; take deep breaths of fresh air. IMMEDIATELY call a physician and be prepared to transport the victim to a hospital even if no symptoms

(such as wheezing, coughing, shortness of breath, or burning in the mouth, throat, or chest) develop. Provide

proper respiratory protection to rescuers entering an unknown atmosphere. Whenever possible, Self-Contained

Breathing Apparatus (SCBA) should be used; if not available, use a level of protection greater than or equal to that advised under Protective Clothing.

INGESTION: CYANIDES ARE EXTREMELY TOXIC AND FAST-ACTING POISONS. Even though the induction of vomiting is not usually recommended outside of a physician's care if the victim is conscious and

not convulsing, it may be worth the risk if a cyanide has been ingested. Ipecac syrup or salt water may be used

to induce vomiting in such an emergency. IMMEDIATELY call a hospital or poison control center and transport the victim to a hospital. If the victim is convulsing or unconscious, do not give anything by mouth,

assure that the victim's airway is open and lay the victim on his/her side with the head lower than the body.

DO NOT INDUCE VOMITING. IMMEDIATELY transport the victim to a hospital

IDLH: Not available.

7.9 DISASTER MANAGEMENT PLAN

7.9.1 INTRODUCTION: The term ‘Disaster’ owes its origin to the French word ‘desastre’, which is a combination of two words ‘des’

meaning bad and ‘aster’ meaning star. Thus, the term ‘disaster’ refers to ‘Bad or Evil Star’. In earlier days

disasters were considered to be an outcome or outburst of some unfavorable star.

Ideally, a disaster may be defined as “an event concentrated in time and space which threatens a society or a relative self sufficient subdivision of a society with major unwanted consequences as a result of the collapse

of precautions which had hitherto been culturally accepted as adequate”.

Disaster according to the Disaster Management Act, 2005 means “a catastrophe, mishap, calamity or grave

occurrence in any area, arising from natural or man made causes or by accident or negligence which results in substantial loss of life or human suffering or damage to, and destruction of property, or damage to, or

degradation of, environment, and is of such a nature or magnitude as to be beyond the coping capacity of the

community of the affected area”;

Disasters are extreme events which cause great loss to life and property. They pose a serious threat to the

normal life as well as the process of development and strike with sudden violence, tearing bodies, destroying lives and structures and throwing apart families. Natural disasters, which are both sudden and powerful,

damage national economy and cause hardships to a large section of the population. They are the single largest concern for most of the nations as they take a heavy toll of human life, destroy belongings and infrastructure and have far reaching economic and social consequences for communities. Thus, the impact of disasters on

human life is multi – dimensional, affecting it in all aspects- domestic, social, economic etc.,

Disaster Management Act:

The DM Act, 2005 provides for the requisite institutional mechanism for drawing up and monitoring the implementation of the DM Plans ensuring measures by various wings of government for prevention and

mitigation effects of disasters and for undertaking a holistic coordinated and prompt response to any disaster situation. The Act seeks to institutionalize the mechanisms at the national, state and district levels to plan,

prepare and ensure a swift response to both natural calamities and man-made disasters/accidents IN THREE LEVELS.

1. NATIONAL LEVEL

2. STATE LEVEL

3. DISTRICT LEVEL (In a state) - Local level in a district

Types of Disasters: Generally, disasters are of two types – Natural and Manmade. Based on the devastation, these are further




Report No. 1718A058

classified into major/minor natural disaster and major/minor man-made disasters. Some of the disasters

are listed below:

Major natural disasters: Flood

Cyclone Drought,

Earth quake

Minor natural disasters: Cold wave

Thunderstorms Heat waves Mud slides

Storm

Major man-made disaster: Setting of fires Epidemic Deforestation

Wars

Pollution due to prawn cultivation

Industrial disaster/ crisis

Chemical disaster/pollution.

Minor man-made disaster: Road / train accidents, riots Food poisoning Environmental pollution

Industrial hazards are threats to people, and life-support systems that arise from the mass production of goods

and services. When these threats exceed human coping capabilities, or the absorptive capacities of environmental systems, they give rise to industrial disasters.

Industrial hazards can occur at any stage in the production process, including extraction, processing,

manufacture, transportation, storage, use, and disposal. Losses generally involve the release of damaging substances (e.g. chemicals, radioactivity, and genetic materials) or damaging levels of energy from industrial facilities or equipment into surrounding environments.

The growth of chemical industries has led to an increase in the risk of occurrence of incidents associated with hazardous chemicals (HAZCHEM). A chemical industry that incorporates the best principles of safety can

largely prevent such incidents. Common causes for chemical accidents are deficiencies in safety

management systems and human errors, or they may occur as a consequence of natural calamities or sabotage activities. Chemical accidents result in fire, explosion and/or toxic release.

The nature of chemical agents and their concentration during exposure ultimately decides the toxicity and damaging effects on living organisms in the form of symptoms and signs like irreversible pain, suffering, and

death. Meteorological conditions such as wind speed, wind direction, height of inversion layer, stability class,

etc., also play an important role by affecting the dispersion pattern of toxic gas clouds.

The Bhopal Gas tragedy of 1984—the worst chemical disaster in history, where over 2000 people died due to the accidental release of the toxic gas Methyl Iso-cyanate, is still fresh in our memories. Such accidents are

significant in terms of injuries, pain, suffering, loss of lives, damage to property and environment. A small

accident occurring at the local level may be a prior warning signal for an impending disaster. Chemical disasters, though low in frequency, have the potential to cause significant immediate or long-term damage.

DISASTER MANAGEMENT IS WITH THE GUIDELINES OF

1. ON –SITE EMEGENCY PLAN - prepared by the plant

2. OFF-SITE EMERGENCY PLAN- Prepared by DDMA

ON-SITE EMERGENCY: Disaster within the premises of the PLANT / FACTORY describes the action scenarios, complying with a documented Plan, to manage and eliminate the Disaster by the Plant personnel.

OFF-SITE EMERGENCY: Disaster spilled outside the factory premises, describes the action scenarios,

complying with a documented plan to manage and eliminate the disaster, by both the plant personnel and District Disaster Management Authorities. This plan will be prepared by DDMA seeking the details from plant authorities.




Report No. 1718A058

7.9.2 GLOSSARY: TERMS AND INTERPRETATIONS:

DISASTER: “means a catastrophe, mishap, calamity or grave occurrence in any area, arising from natural or man-made causes, or by accident or negligence which results in substantial loss of life & sufferings or damage & destruction of property, or damage & degradation of environmental systems, and is of such a

magnitude as to be, beyond the coping capacity of the community of the affected area”;

MANAGEMENT: “means a group of employees unifying to mitigate the undesirable effects of a disaster,

controlling and eliminating its effects fully to bring back to erstwhile normal operating conditions.”

EMERGENCY: “an undesirable state of events of LOSS, beyond the coping capacity of the designated

operating personnel of the plant”.

PLAN: “means set of activities laid in series, arrangements made in advance with internal trained personnel & external agencies, to perform them in a systematic way to mitigate, control and eliminate an EMERGENCY”

ON-SITE EMERGENCY: “means an EMERGENCY SITUATION – Radiation, Toxicity, impact on environment , confined to the plant premises” to cause LOSS.

OFF-SITE EMERGENCY: “means an adverse EMERGENCY SITUATION- Radiation, Toxicity, impact

on environment, spilling outside the plant premises to cause LOSS.

LOSS: “means - ill health to people, destruction to property, stoppage of plant operations, forced layoff to

employees, increased debt burden of loans on purchase of plant & machinery, good will loss, loss of employee’s confidence level, impact on environmental systems which supports life in the area. (Loss of greenery, loss of cattle, and loss of aquatic life, land and water pollution and ……..)

EMERGENCY CONTROL ROOM: “means designated room for the “INCIDENT CONTROLLER” to

perform his role on mitigating, controlling, eliminating the emergency and bring the plant back to normal

working environment.” INCIDENT CONTROLLER (IC): “means a designated person, vested with OVERALL responsibility &

authority to mitigate, control and eliminate emergency and put the plant in normal working condition.”It

includes controlling the entire operations as a team leader and reporting to TOP MANAGEMENT/ OWNERS of the plant. Normally this position is given to the plant CEO or NO.1 POSITION HOLDER of the plant.

ACCIDENT SITE CONTROLLER (ASC): “means a designated person, vested with overall responsibility to mitigate, control and eliminate emergency from the designated site / sites inside the plant premises. He

mitigates, controls, and eliminates the actual accident which has later become an emergency. (Engineering

team, Rescue & Relief team, Fire fighting team, and other miscellaneous services will report to him.)”.

Normally this position is held by CONCERNED PLANT HEAD.

RESCUE & RELIEF HEAD (RRH): “means a designated person, who will perform rescue operations, take relief measures to the injured, co-ordinates with Liaison officer. Rescue operations in the entire plant being a big operation he will have a fairly big team to perform this operation.” This position is given to the HEAD -

CIVIL DEPARTMENT.

ENGINEERING HEAD (EH): “means a designated person, who will advice operations to save damages to Plant & Machinery, operations to mitigate and control processes, performs safe shutdown operations, safely operating the utility services (Electricity, Instrument air, various water systems, waste water systems,). This

position is given to the HEAD - MAINTENANCE (MECHANICAL, UTILITY, ELECTRICAL & INSTRUMENTATION).

LAISION HEAD (LH): “means a person authorized by INCIDENT CONTROLLER for coordinating the external resources & services. He interacts with INCIDENT CONTROLLER, and communicates to mainly District Disaster Management Authorities. He receives the requirements from IC, analyses and coveys the

same to his SPOKES PERSON, who in turn, contacts the concerned external agency, and gets the required

external resources sought.”




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SPOKES PERSON: “means a person authorized by LAISION HEAD to contact and arrange for external

resources / help (like district administration-collector, commissioner of police, commissioner of labor, Factory

Inspectorate, Health inspector, Fire Brigade Head, Local panchayat head, District transport officer……etc”).

KEY EMERGENCY PERSONNEL: “means employees, who take responsibilities and take positions to mitigate, control and eliminate EMERGENCY. They report to their respective team HEADS. During the

entire course of EMERGENCY these personnel will be inside the plant to perform above operations. They will note down the REAL performance of operations carried out, analyze the gaps in the performance and

discuss the same in the post emergency feedback meeting.”

NON-EMERGENCY PERSONNEL: “means employees, visitors, contractors and other outsiders required to be evacuated from the factory premises on “declaration of emergency”.

SAFETY MATERIALS: “means additional materials, tools, PPEs and appliances required for use during EMERGENCY operations by the persons inside the factory.” Also the additional safety materials required to

be provided to district administration in the event of an OFF SITE EMERGENCY”.

EMERGENCY PLAN: “means an authorized document (preconceived, discussed and agreed methodology

of operations and responsibilities) having clear cut action scenarios without aberrations, to be performed by

key emergency personnel, during MOCK DRILLS or REAL EMERGENCY situations.”

SITE PLAN: “means a print copy of the layout of the plant / factory displaying the locations of different

buildings, facilities, storage locations, roads, referred for easy communication and action during EMERGENCY.

AREA PLAN: “means plan showing the area e.g., JOLWA INDUSTRIAL AREA to scale. Useful for

assessing the affected area in the event of an OFF-SITE EMERGENCY and preparations for evacuation of people till the emergency is over.

TOXICITY: “ means - Toxicity is, the degree to which a substance can damage an organism. Three types of toxicity are 1. CHEMICAL, 2. BIOLOGICAL, 3. PHYSICAL. The entry routes for damage of the organism are 1. INHALATION, 2. INGESTION, 3. SKIN ABSORPTION. Isolation from the source of

origination is the effective way of safe guard. The degree of toxicity is given by the Threshold Limit Value

(TLV), Immediate Danger to Life & Health (IDLH).

FLAMMABILITY: “means- Flammability is, as how easily matter will burn or ignite, causing FIRE or COMBUSTION.” The degree of flammability is determined by the explosion limits of the hazardous

chemical, and its quantity & calorific value determines the “thermal radiation flux” liberated on combustion.

SPOT FIRE: “means fire liberated from a point or line opening of a container due to leakage of a flammable

gas.” FLASH POINT/ FIRE POINT: - “the flash point of a volatile liquid is the lowest temperature at which it

can vaporize to form an ignitable mixture in air”. The fire point, a higher temperature, is defined as the temperature at which the vapor continues to burn after being ignited.

THRESHOLD LIMIT VALUE: “means -The threshold limit value (TLV) of a chemical substance, is a

level to which it is believed, a worker can be exposed day after day, for a working lifetime without adverse health effects.” It is expressed in ppm or mg/kg of body weight.

TRESHOLD QUANTITY: “means the highest quantity of a HAZCHEM (in m³ or MT) of liquid or solid stored in a manufacturing unit storage area (In one or more vessels) at any point of time throughout the year,

above which certain regulatory compliance's are required.

SCENARIO: “means the mathematically arrived “virtual physical effects” of an accident, for the input conditions given.” It is presented in the form of a x-y graph.

DISPERSION: “means the spread of any flammable combustible vapor or toxic cloud of vapor, in the atmosphere for a given set of wind speed and atmospheric stability conditions.”




Report No. 1718A058

DISPERSION FOOT PRINTS: “means graphical mapping of the dispersion clouds in the x-y-z coordinates

with respect to distance traveled and over a said period of time.

THERMAL RADIATION FLUX: “means the amount of thermal energy released by a flammable cloud of vapor in the atmosphere on a unit area, and its radiation effects, at a particular distance in the hazardous zone.

SAFE ZONE: “means a safe limit of TOXIC VAPOUR CLOUD existing in an area where there is no damage to human beings or environment when they live in a free exposed condition for an hour or more.

“Means a safe limit of THERMAL RADIATION FLUX existing in an area, where there is no damage to

human beings or environment when they live in a free exposed condition.”

EMERGENCY SIREN: “means a siren with a blowing range of 1 km radius, all around the source, and

capable of giving long and short variances sound for a period of minimum 3 minutes.”

ALL CLEAR SIREN: “means a siren with a blowing range of 1km radius, all around the source, and capable

of giving a continuous non-variant sound for 5 minutes.”

7.9.3 ORGANISATION SET UP:

PLAN: 1. Approved ON-SITE, OFF-SITE EMERGENCY plans shall be available with OH&S Head.

2. All plant personnel have to be trained on the Emergency Plans.

3. Rescue members have to be additionally trained as per the TEAM responsibility.

4. Mock drills have to be performed once in every 6 Months. The drills shall be witnessed by DISH

officials OR Senior management members of same group of Industries. The EXTERNAL

OBSERVERS concept in MOCKDRILLS will improve the quality of drills.

5. All the improvements suggested in the Mock Drills have to be implemented through a MOM.

6. The reports of MOCKDRILLS have to be sent to DISH officials as a record.

7. A list of Risk Scenarios has to be identified and listed for performing the Mock Drills at periodic

intervals.

7.9.4 TEAMS FITMENT PLAN:

S.NO TEAM TEAM LEADERS

1 INCIDENT CONTROLLER SENIOR MANAGEMENT PERSON

2 ACCIDENT SITE CONTROLLER

IN CHARGE OF ACCIDENT PLANT

SR. SUPERVISOR /CHEMIST

(II SHIFT & III SHIFT)

3 LIAISON HEAD HOD -HR

4 ENGINEERING TEAM

SENIOR MANAGEMENT PERSONNEL FROM

PROJECTS, DESIGN , MAINTENANCE

5 RESCUE &RELIEF TEAM SENIOR MANAGEMENT PERSONNEL FROM

PERSONNEL, ACCOUNTS

6 FIRE TEAM SAFETY PERSONNEL

7 MEDICAL TEAM OHC PERSONNEL

8 SECURITY TEAM SECURITY OFFICERS SECURITY GUARDS


ORGANISATIONAL SET UP FOR EMERGENCY:

7.9.5 RESPONSIBILITIES OF KEY EMERGENCY PERSONNEL / TEAMS: INCIDENT CONTROLLER – RESPONSIBILITIES

The head of the PLANT will be normally the Incident Controller(IC). Ensures the emergency is

properly dealt with, eliminated and normal operating conditions are restored as soon as possible.

Ensures all the managers and officers of the plant are included as “key emergency personnel.”

Ensures the On-site Emergency Plan is prepared, and general training is given to all the employees of

the plant. On-site Emergency Plan is submitted to Department of Industrial safety & Health for review.

Ensures Mock drills (Virtual Emergency) are conducted quarterly in different shifts as per the provisions of On-Site Emergency plan.

Ensures one or two District disaster management Authority (DDMA) personnel are invited to

participate in the mock-drills.




Report No. 1718A058

Ensures On site Emergency Plan is revised, based on the Mock-drill feed backs, till he is satisfied,

that the plan is acceptable to all key emergency personnel.

To officiate a person responsible to co-ordinate with District Disaster Management Authorities to prepare OFF-SITE EMERGENCY PLAN for the plant. The LIASION HEAD may be the appropriate

person for the same.

Ensure the fire fighting system, safety materials required for use during real emergency, and first-aid

medical facilities, are in order by review of documents, inspections and trials.

Ensures to name the alternate key emergency personnel IC, ASC, LH, EH, RRH in case the

emergency is reported after general shift hours .The key emergency personnel will take positions as

soon as possible and replace the alternate team. (Mock drills conducted in II & III shifts will give

necessary guidance to select the personnel)

ON DECLARATION OF REAL EMERGENCY

Soon after hearing the emergency from the Main gate security or SMS –Emergency, INCIDENT

CONTROLLER rushes to ECC.

He takes control on all operations to deal with the EMERGENCY from ECC.

He ensures all the team leaders are in their respective positions of operation, soon after ordering to

blow the emergency siren.

On the advices of ASC, LH, EH, RRH analyzes the actual situation at periodic intervals and declares

OFF-SITE EMERGENCY if required.

He ensures through Liaison Head, external emergency services are informed and called for help in

time.

Take periodic rounds to provide guidance and help to team leaders for effectively discharging their

duties. Notes down the short comings in the operations.

Once the Risk is eliminated completely as declared by ACCIDENT SITE CONTROLLER, he orders

to blow “All clear siren”.

He calls a FEED BACK meeting at ECC. All the key emergency personnel are to attend the meeting

and participate in the deliberations.

He CO-ORDINARES with department heads to normalize the plant for regular production activities

and support services.

ACCIDENT SITE CONTROLLER - RESPONSIBILITIES

Coordinates with ENGG TEAM, FIRE TEAM, RESCUE &RELIEF TEAM to mitigate emergency

conditions’

Ensures to finally eliminate the Emergency condition completely inside the plant.

Ensures after eliminating emergency the area/s worked, are kept clean for normal operations.

Ensures the required number of teams and personnel are kept ready for eliminating the emergency.

Ensures all required materials, equipment and resources are available for eliminating the emergency.

Is requested and brought in time.

Ensures right information is given to IC at periodic intervals.


Soon after hearing the emergency siren or SMS Emergency, ACCIDENT SITE CONTROLLER rushes and takes control of the site inside the plant, which created an emergency situation.

He assesses the risk, computes the requirements of teams, the requirement of key emergency

personnel for each team, requirement of reserve teams in case the risk spreads, and orders them to

take their positions.

He assesses the complete scenario, and decides whether to declare OFF-SITE EMERGENCY and

informs to IC accordingly.

Ensures all the requirements for fighting the Emergency is available to eliminate the emergency at the

shortest possible time.

Ensures all requirements of external resources are informed in time to LIAISON TEAM.

He takes regular rounds and gives necessary guidance and help to teams to deal with emergency.

He applies strategies, and tries all possible permutations & combinations to LIMIT the Emergency as ON-SITE EMERGENCY.

Ensures all the key emergency personnel, are operating strictly complying safety parameters.

Gives constant feedback on the Emergency situation, and post his requirements to IC.




Report No. 1718A058

He ensures emergency conditions are completely eliminated, areas are cleared, and informs to IC for

blowing all clear siren.

Notes down the short comings in the operations performed for eliminating the emergency, during his rounds.

LIAISON HEAD - RESPONSIBILITIES

Head – HR department is nominated as Liaison Head.

ENSURES district disaster administration authorities are informed about the declaration of emergency

and constantly keeps in touch with them. Informs the actions initiated by district administration

officials to IC.

Ensures local in habitations are well informed and measures taken for their safety.

Ensures the external resource help is given in time to ASC.

Ensures the medical assistance for the injured, in nearby Hospitals, and transport for non-emergency

personnel movement.

Ensures constant dialogue with nearby industries and arranges all possible help through district

administration.

Ensures proper gate security is maintained for preventing outside persons unauthorized entry inside

the industry.


Soon after hearing the emergency siren or SMS Emergency, Liaison Head rushes to main gate.

Briefly informs the district administration of the Emergency situation and the help required.

Informs the Fire Brigade for fire tenders and transport department for buses to evacuate the non

emergency employees.

Informs the nearby industries about the impact and precautions to be taken by them. On request

distribute chemical masks for the employees inside factory.

Takes periodic rounds of the affected areas and studies the situation. Notes down the points of

concern of the Egg. Team, Fire mitigation Team, Rescue & Relief teams.

Asks his spokes person to meet the nearby village head and brief the actions taken for the safety of the

people of that village.

Keeps the district administration informed about the latest situation and the help required.

ENGINEERING TEAM- RESPONSIBILITIES

Engineering team head is nominated from Maintenance Department.

Mechanical, Electrical & Instrumentation & Utility Maintenance Head will be the team leaders.

Ensures the Plant & Machinery inside the plant are protected from damages.

Isolates EB power and takes essential operations on standby power.

Ensures the plant with minimum required illumination to carryout emergency operations.

Ensures the systematic stoppage of plant and machinery to cause minimum LOSS, and pave way for

easy restart conditions.

Ensures isolation of systems which can otherwise raise the risk level of emergency.

Ensures the semi finished products on the process line are protected from unwanted reactions and

prevent it from becoming a waste.

Ensures all the machines are in shut- off condition.

Ensures the unaffected storage locations are well protected, using the built in safety protection

systems.


Soon after hearing the emergency siren or SMS - emergency, Engineering Heads rushes and takes

control of his key personnel to deal with the conditions of emergency.

Associates with the site controller wherever he demands help in controlling the emergency.

Isolates EB power and takes the unit on standby power.

Provides minimum illumination required for the control of emergency operations throughout the

plant.

Puts off all running equipment and shuts off the continuous process plant following emergency shut-

down procedures.

Ensures unwanted chemicals are drained off the reactor vessels, heat exchangers and other systems as

the plant demands.




Report No. 1718A058

Keeps the waste water treatment plant running to clear off the excess load on the system?

In the Tank storage farms take appropriate actions like – draining the Hazchem in the dyke,

transferring from one vessel to another standby vessel, additional cooling arrangements of the equipment wherever required.

RESCUE AND RELIEF TEAM – RESPONSIBILITIES

On receiving information from SMS emergency rushes to accident site and coordinates activities with

ASC.

Group the team members and inform all non-emergency personnel to assemble at assembly points

(Assembly points are located near main security gate).

Subdivide the group and perform intensive search operation at all location to find out the injured.

Make arrangements to transport to injured on stretcher to the medical team stationed at medical

center.

Search for the missing person given in the list by LH. Give periodic feedback to ASC.


Soon after hearing the emergency siren or SMS - emergency, Rescue and Relief Team Head rushes

to accident site.

Associates with the accident site controller wherever he demands help in controlling the emergency.

Makes arrangements to search employees, contract persons and visitors missing in the HEAD

COUNT.

Search teams go all around the plant to search for the missing persons in the head count.

FIRE TEAM – RESPONSIBILITIES Fire Team head is nominated from Safety Department.

Fire Team consists of Key emergency personnel from safety Department, First aid centre, process department and security departments.

He ensures all electrical systems are isolated except emergency lighting systems.

He ensures all the fuel /heating systems are isolated from both the ends of flow.

He ensures required numbers of fire mitigation equipment are fully operational. He ensures all fire fighting persons are performing the operations safe.

He ensures all external help required is informed to ASC in time.

He ensures the water resources are fully operational. He ensures smooth co-ordination with external Fire Mitigation Agencies.

ON DECLARATION OF REAL EMERGENCY 1. Soon after hearing the emergency siren or SMS Emergency FIRE Team Head rushes to Accident site

and takes Instructions from ASC.

2. He plans with ASC and EH to isolate systems prior to start of fire extinguishing operations. 3. He takes note of wind direction and proper ventilation systems prior to start of fire fighting.

4. He ensures the required number of fire fighting teams is kept for fire fighting and preventing fire

spreading.

5. He ensures appropriate extinguishing systems are optimally used for controlling the situation. 6. He ensures wherever inert gases are used for controlling the fire, safe systems of operations are

adopted.

7. He ensures personal safety is given utmost importance. 8. After ensuring complete extinguishment reports to ASC.

9. He ensures complete clean up operations are performed prior to allowing persons for inspection.

SECURITY TEAM – RESPONSIBILITIES

Security Team head is nominated from Security Department. Security Team reports to Liaison Head. It is divided into three divisions

a. Gate security Team b. Team to associate fire team

c. Team to perform inside factory security and cordoning operations.

He ensures overall assistance is given to all teams. He ensures non emergency persons are guided to Assembly points.




Report No. 1718A058

He ensures traffic regulation inside the plant is done to the requirement.

He ensures gate security team protects all inside plant persons. Records the in time of key emergency

personnel.

Stops all persons/ vehicular movements as soon as Emergency Call is received. Allows DDMA vehicles , emergency service vehicles and guides them properly. He ensures all instructions given by Liaison Head are strictly followed.

ON DECLARATION OF REAL EMERGENCY a. Soon after hearing the emergency call OR SMS-emergency, Security Team Head rushes and takes

Instructions from LH.

b. He plans his persons for various operations and assigns a security supervisor for the same.

c. He takes note of wind direction and guides the persons to Assembly point/s.

d. He controls the gate operations and records the movement of vehicles and persons after the declaration of emergency.

e. He interacts with LH and performs his instructions.

MEDICAL TEAM – RESPONSIBILITIES Medical Team head is nominated from OHS Department. He ensures the ambulance and one male nurse is kept in the accident site. Ensures CPR is given to unconscious persons in the accident site.

Depending on the requirement requests LH for additional ambulances.

He ensures proper prearrangements are done at nearby hospitals for treatment of injured. Keeps records of injured persons and monitor the progress of injured regularly.

ON DECLARATION OF REAL EMERGENCY a. Soon after hearing the emergency call OR SMS - emergency, Medical Team Head rushes and takes

Instructions from LH. b. He will be stationed in OHS centre and monitor the medical needs of the injured.

c. He will ensure the required medicine, fire blankets, first aid boxes, and other essentials are kept ready for the injured persons.

d. One additional ambulance will always be kept at OHC depending on the emergency conditions.

He will have constant interactions with LH on the medical treatment to injured persons

7.9.6 COMMUNICATION SYSTEM:

Communication will be exchanged mainly from team to team or person to person using

Mobile cell phones, Group SMS for Key emergency personnel. Land line phones wherever available. Designated intercom cell phones.

Public Address system installed in offices & Plants.

FIRST - INCIDENT INFORMATION: The first incident information about, informing an incident/accident will be given by an employee, who has seen the incident. He will give the information to the main Security Main Gate/ Fire Room, giving his identity

in full.

The security officer on duty/ Safety Person on duty, who receives the information informs to their Heads. Both the fire team lead by safety supervisor/ security persons will rush to incident site immediately for

mitigating the emergency. The Head of Safety/Security passes information by flashing SMS message (Template) to all the KEY EMERGENCY PERSONNEL by group SMS using Mobile Cell phone. For easy

sending, each group is recommended to have 10 persons. The person informed is requested to REPLY positively.

By this system all the Key members of the emergency will be officially informed about the emergency. Their replies will confirm their receipt. The replies shall be as concise as ‘YES’.




Report No. 1718A058

7.9.6.1 INCIDENT CONTROLLERS

Sr.

No.

Shifts Incident Controller's Runner's

Name & Designation Qualification

Place of availability Phone No.

Name & Designation

Place of

availability

in Plant

Phone

No. In the

Factory

(Plant)

Residence

Address In the

Factory Residence

1 2 3 4 5 6 7 8 9 10 11

2 First

&

General

1) HardattSinghTarar B.A. Form - 2 347 9924903599 1) Hithart Pathak ADM

Building

310

2) K.B. Vishwakarma M.Sc. ADM Building 224 9879323596 2) Sanjay Patil AQ 245

3) Mukesh Patel B.E.Che DD - 1 324 9824724340 3) JanakMaisuriya DD - 1 258

4) Hasamukh Patel B.Sc. EO 362 9825376478 4) Snehal Patel EO 363

5) Mukesh Patel B.E.Che NKS 324 9824724340 5) Sanjay Rathod NKS 319

6) Mukesh Patel B.E.Che MAA 324 9824724340 6) Naresh Tandel MAA 266

7) Yogesh Sonani M.Sc. DD – 2 353 9825242182 7) Rajesh Patel DD – 2 352

8) Yogesh Sonani M.Sc. DD – 2 353 9825242182 8) EknathSonawane Form - 2 341/349

9) K.B. Vishwakarma M.Sc. ADM Building 224 9879323596 9) RajendraPrajapati Solv - 2 336

10) K.B. Vishwakarma M.Sc. ADM Building 224 9879323596 10) RasikSutariya Solv - 3 366

11) K.B. Vishwakarma M.Sc. ADM Building 224 9879323596 11) S Chandran Mono Azo 297

12) K.B. Vishwakarma M.Sc. ADM Building 224 9879323596 12) Rajendra Patel AQ- 2 251

13) K.B. Vishwakarma M.Sc. ADM Building 224 9879323596 13) Rajesh Patel AQ - 1 389

14) S K Jha M.Sc. PTP 231 9714999336 14) Vipul Patel PTP 339

15) S K Jha M.Sc. PTP 231 9714999336 15) Vipul Patel AMINO 365




Report No. 1718A058

Sr.

No.




Name &

Designation

Place of

availability

in Plant

Phone No. In the

Factory

(Plant)

Residence

Address In the

Factory Residence

1 2 3 4 5 6 7 8 9 10 11

2 Second 1) Shift Executive Min. B. Sc. DD - 1 374 1) Shift Executive DD - 1 374/262

2) Shift Executive AQ 274 2) Shift Executive AQ 251

3) Shift Executive Form - 1 259 3) Shift Executive Form - 1 235

4) Shift Executive NKS/MAA 319/266 4) Shift Executive NKS/MAA 319/266

5) Shift Executive EO 263 5) Shift Executive EO 263

6) Shift Executive DD - 2 358 6) Shift Executive DD - 2 358

7) Shift Executive Form - 2 349/348 7) Shift Executive Form - 2 349/348

8) Shift Executive Sol - 2 264 8) Shift Executive Sol - 2 264/334

9) Shift Executive Sol – 3 368 9) Shift Executive Sol – 3 368

10) Shift Executive ETP /PTP 218 10) Shift Executive ETP /PTP 218

11) Shift Executive Mono Azo 292 11) Shift Executive Mono Azo 292

12) Shift Executive AQ - 2 251 12) Shift Executive AQ - 2 251

13) Shift Executive AQ – 1 389/390 13) Shift Executive AQ - 1 390

14) Shift Executive AMINO 218 / 339 14) Shift Executive AMINO 365




Report No. 1718A058

Sr.

No.




Name &

Designation

Place of

availabilit y

in Plant

Phone No. In the

Factory

(Plant)

Residence

Address In the

Facto ry Residence

1 2 3 4 5 6 7 8 9 10 11

3 Third 1) Shift Executive Min. B. Sc. DD - 1 374 1) Shift Executive DD - 1 374/262











12) Shift Executive AQ - 2 251 12) Shift Executive AQ - 2 251






Report No. 1718A058

NOTE:–

1. If IC is not available, for deputy IC see 7.3

2. The shift may change but the person will be available against each shift.

3. Prepare 2 to 3 IC even if there is only one or two shifts

Sr.

No.




Name &

Designation

Place of

availabilit y

in Plant

Phone No. In the

Factory

(Plant)

Residence Address In the

Factory Residence

1 2 3 4 5 6 7 8 9 10 11

4

Holiday

1) JanakMaisuriya Min. B. Sc. DD - 1 258 1) Devang Desai DD - 1 377

2) Sanjay Patil AQ 245 2) Rajendra Patel AQ 251

3) Paresh Mistry Form - 1 259 3) Mukesh Patel Form - 1 235

4) Sanjay Rathod NKS/MAA 319 4) Naresh Tandel NKS/MAA 266

5) Snehal Patel EO 362 5) Dharmesh Mehta EO 363

6) Rajesh Patel DD - 2 352 6) Rakesh Patel DD - 2 358

7) EknathSonawane Form - 2 341 7) Kamlesh Patel Form - 2 349/348

8) RajendraPrajapati Sol - 2 363 8) Rakesh Desai Sol - 2 364

9) RasikSutariya Sol – 3 366 9) DhavalThakor Sol-3 366/368

10) Vipul Patel ETP /PTP 218/339 10)Dilip Mistry ETP /PTP 218/339

11) Vinod Sonwane Mono Azo 297 11) Rajendra Mono Azo 292

12) Rajendra Patel AQ - 2 251 12) Ajay Mishra AQ - 2 251

13) Vinod Sonwane AQ – 1 389/390 13) R I PATEL AQ - 1 390

14) Dilip Mistry AMINO 218 / 339 14) Pavan Mishra AMINO 365




Report No. 1718A058

7.9.6.2 DEPUTY INCIDENT CONTROLLERS:

Shifts

Sr. No.

(Any one shall

be

available in

each

shift & on

holidays on

call)

Deputy Incident Controller's Persons to be called if IC & Dy. IC both are

not available

Name & Designation Qualifi

cation


Name & Designation

Place of

availability

In

Plant Phone No. In the

Factory

Residence

Address

In the

Factory Residence

1 2 3 4 5 6 7 8 9 10 11

First &

General

1 1) Sanjay Patil B.Sc. AQ 245 1) RajendraPatel AQ - 1 251

2) JanakMaisuria M.Sc. DD - 1 258 2) Gunvant Tank DD - 1 258

3) Snehal Patel B.Sc EO 362 3) Kirit Desai EO 363

4) Naresh Tandel B.Sc MAA 266 4) PrafulRathod MAA 266

5) Sanjay Rathod B.Sc NKS 319 5) Sakir Patel NKS 319

6) Rajesh Patel B.Sc DD - 2 352 6) Chhotu Ram DD - 2 358

7) Kamlesh Patel B.Sc Form - 2 341 7) Bhudhu ram Form - 2 349

8) Paresh Mistry B.Sc Form - 1 259 8) Mukesh Patel Form - 1 235

9) RajendraPrajapati M. Sc. Solv - 2 336 9) Rakesh Desai Solv - 2 336

10) RasikSutariya B. Sc. Solv - 3 366 10) DhavalThakor Solv - 3 368

11) S Chandran M. Sc Mono Azo 297 11) Rajendra Mono Azo 292

12) Dilip Mistry B.Sc. ETP/PTP 218/339 12) BALVANT ETP / PTP 218/339

13) Vipul Patel B. Sc. Amino 218/365 13) Balvent Amino 218/365

14) Rajesh Patel B. Sc. AQ - 1 389 14) Vinod Sonwane AQ - 1 390

15) Rajendra Patel B. Sc. AQ - 2 251 15) Ajay Mishra AQ - 2 279




Report No. 1718A058

Shifts

Sr. No.

(Any one

shall be

available in

each

shift & on

holidays on

call)

Deputy Incident Controller's Persons to be called if IC & Dy. IC both

are not available

Name & Designation Qualifi

cation


Name & Designation

Place of availability

In

Plant Phone No. In the

Factory

Residence

Address

In the

Factory Residence

1 2 3 4 5 6 7 8 9 10 11

3 Third 1) Shift Executive Min. B.

Sc.

DD - 1 374 1) Shift Executive DD - 1 374/262











12) Shift Executive AQ - 2 251/279 12) Shift Executive AQ - 2 251/279



Note:

1. The shift may change but the person will be available against each shift

2. Prepare 2 to 3 Dy. I.C. even if there is only one or two shifts.




Report No. 1718A058

7.9.6.3 SITE MAIN CONTROLLERS:

Sr.

No.

Site Main Controller's Runner's

Name in priority

order Designation Qualification

Place of availability Phone No. Name &

Designation

Place of

availability Phone No. In the

Factory

Residence

Address

In the

Factory Residence

1 2 3 4 5 6 7 8 9 10 11

1

Mr. Hardattbhai

General

Manager

B. A.

Form - 2

101, ShreejiVihar Apt. VyashFalia,

Palsana

343

9924903599 Mr. Balbirbhai Factory

Manager cum

P.R.O.

ADM

Building

230

2

Mr. K B

Vishwakarma

DGM

M Sc. AQ Plant Peradise

Tower, Station

Road, Navsari

224

9879323596

Mr.Omprakash

Godara

Sr. Manager P &

A

ADM

Building

216

3 Mr. Balbir Singh

Pilania

AGM EHS B.A. ADM

Building

VyashFaliaPalsana 230 9824106565 Mr. Shasikant

Jha

Manager EHS

EHS

Department

231, 234

4 Mr. Milind.Joshi AGM

MMS

M.Sc. R.M. Store 72, Sant Shri

Asharam

Nagar,Jiyav,

Budiya road,

Bhestan.

257 9825127741 Mr. Utkarsh

Kapadia

Manager EHS

EHS

Department

231, 234

5 Mr .Mukesh.Patel AGM B.E. (Chemical) NKS Plant F.No. -702

Nandini Apt.

Vesu

324 9824724340 DalsukhbhaiKakani

Manager EHS

EHS

Department

231, 234




Report No. 1718A058

7.9.6.4 KEY PERSONS:

Sr.

No.

Key Person's Next Person's

Departme

nt

Name (He may

be called at any

time for this

plan)

Designation Qualificati

on


Name &

Designation


In the

Factory

Residence

Address

In the

Factor

y

Reside nce In the

Factory

Residence Address

In the

Factory

Residence

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1

Safety,

Fire

& Gas

Control

Mr.

DalsukhKakani

EHS

Manager

MSc.

EHS

Dept.

MotaVarachha

Surat

231

234 99250

67074

Mr.Utkarsh

Kapadia

EHS

Dept.

Juna

Thana,

Navsari

231

234 99241

02389

2 Security Mr.Ram

Naresh Siswar

Security.

Officer

B.A. Main

Gate

As per List

Attached

203 /

240

82642

82638

Mr. Bhola Singh Main

Gate

Bharmin

Falia,

Kiritbhainichali,

palsana

203

99048

52592

3 Pollution

Control

Mr.ShasikantJha

Mr. Hardik

Masuria

ManagerEHS

Env. Eng.

M.Sc.

B.Sc.Enviro

EHS

Dept.

Rudhrax

Apt.,

Surat.

231,

234,

218,

365

238

97149

99336

98790

07233

Mr.Vipul Patel ETP

Plant

Panghat,

Vishakap ark Society,

Dudhiya

Talav ,

Navsari

218/365

94283

80236

4 Medical Dr.

GanpatTandel

Doctor MBBS,

AFIH

IPHA

Medical

Center

25, Sanskar

Nager Society,

Bhatar Road,

Surat

239

98791

31394

MrOmprakash

Godara

Main

Building

Nava

Falia,

Palsana

216

98244

77072

5 Transport Mr. Ram Singh Kulharia

Manager B.Com. Finish

Godown

Desai Falia,

Palsana

318 98244

77071

Mr.Banwari Bhai Finish

Godown

VareliPalsana 222 98244

77092

6 Production Mr. KB

Vishwakarma

D.G.M. M.Sc. ADM

Office

204,

Paradise Tower,Statio n

224 98793

23596

Mr.

RajendraPrajapati

Solvent -

2

336 98792

28458




Report No. 1718A058

Road, Navsari

Mr. KB

Vishwakarma

D.G.M. M.Sc. ADM

Office

204,


Road, Navsari

224 98793

23596

Mr. Sanjay

Patil

Solv-1,

Bromide

245 98796

43415

Mr. KB

Vishwakarma

D.G.M. M.Sc. ADM

Office

204,

Paradise

Tower,Statio n Road,

Navsari

224 98793

23596

Mr. Rajendra Patel AQ-2

251 96241

73705

Mr. KB

Vishwakarma

D.G.M. M.Sc. ADM

Office

204,

Paradise

Tower,Statio n Road,

Navsari

224 98793

23596

Mr. S Chandran Mono

Azo

297 70969

14701

Mr. KB

Vishwakarma

D.G.M. M.Sc. ADM

Office

204,


Road, Navsari

224 98793

23596

Mr. Rajesh Patel AQ - 1

389 94277

84648

Mr. KB

Vishwakarma

D.G.M. M.Sc. ADM

Office

204,


Road, Navsari

224 98793

23596

Mr. Rashik

Sutasriya

Solv - 3

366 98259

48810

Mr. Yogesh

Sonani.

Sr. Manager M.Sc. DD - 2 45,

Ankita Park

Surat

353 98252

42182

Mr.Rajesh

Patel

DD - 2 352 99255

56174

Mr. Yogesh

Sonani.


Ankita Park

Surat

353 98252

42182

Mr. Eknath

Sonawne

Form - 2

341 95101

92866

Mr. Hasmukh Sr. Manager B.Sc. EO LuharFalia, 362 98253 Mr.Snehal EO 363 99096




Report No. 1718A058

Patel Undach,

Gandevi,

Bilimora

76478

Patel

79864

Mr. Mukesh

Patel

AGM B.E.

(Chemical)

DD -1 702

Nandini Apt.

Vesu Surat

324 98247

24340

Mr.JanalMaisuriya DD - 1

258 98258

60271

Mr. Mukesh

Patel

AGM B.E.

(Chemical)

NKS 702

Nandini Apt.

Vesu Surat

324 98247

24340

Mr. Sanjay

Rathod

NKS

319 96389

11955

Mr. Mukesh

Patel

AGM B.E.

(Chemical)

MAA 702 Nandini Apt.

Vesu Surat

324 98247

24340

Mr. Naresh

Tandel

MAA

266 98792

55136

Mr. Yogesh

Sonani.


Ankita Park

Surat

353 98252

42182

Mr. Paresh

Mistry

Form - 1

259 97234

25602

Mr. S K Jha Sr. Manager M.Sc. ETP Rudhrax

Apt., Surat.

231 97149

99336

Mr. Vipul

Patel

ETP

366

218

94283

80236

Mr. S K Jha Sr. Manager M.Sc. AMINO Rudhrax

Apt., Surat.

231 97149

99336

Mr. Vipul

Patel

ETP

366

218

94283

80236

7 Technical

Services

Dr. Mininath

Desmukh

Dr. B.B.Chauby

Manager

R&D LAB

Sr. Manager

Phd.

Phd.

R&D

LAB

QA &

QC Lab.

601, Amrapli

Apt., Umra,

SURAT. 104, Paradise

Tower,Statio n

Road, Navsari

253

209

97302

05057

94268

69076

Dr. Anand

Jain

Mr. Umesh

Patel

R&D

Lab.

QA & QC

Lab.

277

320

99704

10410

96016

02975

8 Stores Mr.Milind Joshi A.G.M. M.Sc.

R.M.S.

72, Shree

Yashanker, Sant

Shree Asaram

Nagar, Bhestan,

Surat

257

98251

27741 Mr. Ram

Sudhirsingh R.M.S.

204

9 Personnel Mr.Omprakash Sr.Manager M.Com. Main

Building

NavaFaliaPalsana 216

98244

77072 Mr.PundlikBhavsar H.R.

219

98241

19577

10 D&L Mr. Ramesh

Mishra Sr. Manager M.A., LLB

Finish

Store

Raj Abhishak

Sachin 316 98241

02259 Mr.Banwari D&L 222

98244

77092




Report No. 1718A058

7.9.7 EMERGENCY SIREN:

EMERGENCY ‘ON’ SIREN: FIRE MODE / TOXIC MODE 0-0-0-0-0-0-0-0 WAILING SIREN

(10 SEC)(5 SEC) (10 SEC)(5 SEC)……UP-DOWN-UP-DOWN - FOR THREE MINUTES

ALL CLEAR SIREN:

CONTINUOUS SIREN FOR 5 MINUTES

7.9.8 EMERGENCY CONTROL CENTRE (ECC):

ECC will be occupied by INCIDENT CONTROLLER... It will have provisions to sit for five persons, a

conference room to house 15 persons, and a store to accommodate safety materials storage required during EMERGENCY. The following documents, (latest revisions) will be kept in the emergency Control Center, for immediate reference and use, in the event of an EMERGENCY. A key will be kept with IC.

REFERENCE DOCUMENTS

1. On-site Emergency Plan – 5 copies

2. Off-site Emergency Plan – 5 copies 3. Plant - site plan - 5 copies 4. Area plan (SPECTRUM Palsana plant)- 5 copies

5. MSDS of all HAZCHEMS – Each chemical.

6. Short note books -25 no’s 7. Ball pens, Pencils, erasers, sharpeners -25+10 + 10+ 2 no’s

8. Digital Cameras – 2 no’s

9. Laptops – 2 no’s network connected.

LIST OF SAFETY MATERIALS:

1. Self Contained Breathing Apparatus- 10kg - 10 no’s

2. Full Face masks - 25 no’s 3. Trolley mounted oxygen cylinders - 5 no’s 4. Full body chemical protection suits - 10 no’s

5. Chemical splash proof goggles - 50 no’s

6. Aluminized fire fighting suits - 10 no’s 7. 25mm hose clips with screw clips - 10 no’s

8. Gum boots full length - 25 pairs

9. Leather hand gloves - 50 pairs 10. Electrical hand gloves - 5 pairs 11. Non permeable hand gloves - 25pairs

12. Safety helmets - 50 no’s 13. Safety shoes sizes - 60 pairs

14. Pick axles - 2 no’s

15. Shovels - 5 no’s 16. Rain coats full size - 10 no’s 17. Stretchers - 2 no’s

7.9.9 FIRST- AID MEDICAL SERVICES: First –Aid service center is available in the Main gate of plant. There is a doctor and qualified medical nurses.

They will be assisted by trained first aiders where- ever there is an urgent need.

Medical examinations are out sourced, and reports are maintained by the HR department. EHS manager has a formal agreement, with “Full fledged hospitals” in the nearby area of the plant, for

immediate admission and treatment to the injured.




Report No. 1718A058

7.9.10 ASSEMBLY POINT/s: Assembly point is the place, where the non-emergency employees are assembled for a head count. Later they

are kept at the same place OR shifted to a safer place on the advice of IC. Two assembly points are planned.

Assembly point is located inside the site of the plant. Normally assembly points are away from the bulk storage locations, near to the plant main security gate, and located in upward side of the predominant wind

direction. The wind sock is installed, for instantly knowing the current wind direction, is located on the top of the plant building, and is clearly seen from the assembly points.

Assembly point No. Location

Assembly point No-1 Near. Main Gate

Assembly point No-2 In front north side of Main Building

Assembly point No-3 Near Emergency gate ( Formulation – 2 plant)

7.9.11 FIRE FIGHTING BUILT IN FACILITIES:

Fire hydrant system – Fire water storage, Fire Pump, Jockey pump, PP Power / DG Power, Fire

Room, systems to control water supply and power.

Hydrant Pipes, Risers, Spray Nozzles, control gate valves, Hydrant boxes, Hydrant control valves.

DCP, CO₂, FOAM portable fire extinguishers of different capacity.

Water and Foam Fire Tender stationed at CP.

7.9.11.1 AVAILABILITY OF FIRE FIGHTING FACILITES:

S.NO. PERTICULARS PARTICULARS

1. Fire Water Total Qty. = 1000 KL 3 Nos. of Reserviors

5 Nos. of overhead tanks

2. Other source & Capacity

Water reservoir having

345 m3 Capacity.

Water reservoir having 550 m3 Capacity.

3. No. of Hydrant Points 97

4. No. of fire pumps, type & capacity Jockey pump -2

Electric pump -2 Diesel pump -2

(171m3 /hours)

5. No. of Hose Reel & total

length

Hose Reel : 212 Nos.

Length : 15 m & 30 m

6. No. of Sprinklers Lifting height : 30 m Pressure : 7 kg/cm2

7. No of CO2 Extinguishers

53 Nos. (4.5 kgs) 42 Nos. (2.0 kgs)

8. Dry Powder Type Extinguishers

Type : DCP/ABC (2/5/6/10/25 Kgs Capacity)

Total : 223 Nos.

9. Form Type Extinguishers

Type: Mech. Foam (9 Lts. & 50Lts. ), Total: 24 Nos.

Type: 3% AFFF Solution 3360 Ltrs., Total : 168 Nos.

10. PPE’s : Respiratory: Self Breathing Apparatus: 11 Nos. Air Line Respirator : 10 Nos.

Gas Masks = 30 Nos.

Dust mask = 500 Nos. Non – respiratory:

Hand Gloves = 300 Nos. Goggles = 100 Nos.

Gum Boots = 50 Nos. Helmet = 50 Nos.

Ear plug = 25 Nos.




Report No. 1718A058

Ear muff = 05 Nos. PVC suit = 10 Nos.

PVC apron = 10 Nos.

Fire suit = 02 Nos.

7.9.11.2 Fire Pumping Capacity M/s Spectrum Dyes & Chemicals Pvt. Ltd., Palsana Manufacturing Division is a dyes manufacturing, so

it is categorized under High HAZARD OCCUPANCIES, Sub Category –A as per Fire Protection Manual of TAC.

Under High Hazard Occupancy,Sub Category –A, Hydrant post (point) shall be provided for every 30

meter on the fire hydrant ring mains. This is in addition to required number of Fire Hydrant points for each

floor on risers at plant and other buildings.

7.9.11.3 Pump House details:

Reservoir Capacity 895 m3 dedicated for fire hydrant system

Main Pump Capacity 171 m3/hr. (1 nos.)

273 m3/hr. (1 nos.)

Jockey Pump Capacity 30 m3/hr. (1 nos.)

11 m3/hr. (1 nos.)

Diesel Pump Capacity 171 m3/hr. (1 nos.)

273 m3/hr. (1 nos.)

7.9.11.4 Fire Water Storage

Reservoir Capacity for Fire hydrant system is 895 m3 is also available for process water which can be used for fire hydrant system during fire emergency.

So, Time Duration for Fire Fighting = 895 m3/hrs. ≈ 2hrs

7.9.11.5 Booster Pump

The capacity of the Jockey Pumps shall neither be more than 5 % of the installed pumping capacity nor less

than 3 % thereof (with a minimum of 10.8 m3/hrs) as per TAC guidelines. Company has one Jockey

pump with capacity of 25 m3/hrs each. Hence, capacity of Jockey Pump has been found adequate.

7.9.11.6 POLLUTION CONTROL:

The water used for firefighting will be diverted to ETP

The wastes collected at the site of accident will be sent to waste yard in designated packages. EHS environment department will do the necessary formalities for its disposal.

7.9.11.7 WIND SOCKS:

Wind socks are installed on buildings to instantly catch up the wind direction. The sock flying indicates the DOWNWIND direction.

FOUR wind socks are installed. One at the top of the EO building Second SOLVENT-2 SHOP. Third

on the R.M Stores Fourth on ADMIN building.

7.9.11.8 RESCUE TEAMS:

The positions of RESCUE TEAM MEMBERS are created in all plants, departments and service

centers. They are given a RED HELMET for east identification. They are being trained in different

aspects of activities involving emergencies. They are from workers, operators, supervisors and chemists. They are well distributed in the shifts so that their availability is felt, round the clock.

On hearing the emergency siren the RESCUE team members (Respective shift) are requested to rush to the emergency site location and assemble at the Ground floor. Information will be given about their

arrival to ACCIDENT SITE CONTROLLER. They will form the team members for performing necessary activities as per the directions of their

respective team leaders.

Both during accidents and BIG events like EMERGENCIES they will be fully utilized.




Report No. 1718A058

7.9.11.9 IMPORTANT EXTERNAL TELEPHONES NUMBERS

Sr.

No.

Name & address of the Telephone

Sr.

No.

Name & address of the Telephone

Dept. /service/Person

(including external

emergency services)

Numbers

Dept. /service/Person

(including external

emergency services)

Numbers

(external)

(external)

1 2 3 1 2 3

1

Disaster Management 0261 2471121 41

Medical Surgeon DISH 9904593112

Cell, 2472471 Surat 7383812981

Collector Office

42 Regional Transport

Officer, Surat

02612472436,

2472185

2 Additional Collector Surat

0261 2471121 43 State Manager Transport

Office, Surat 0261 2543365

2463819 44 Dy. Controller Of

Explosive, Vadodara 0265 2420512

2651060

45

Pollution Control Board 0261 – 2442696 ,

9978405520 ( Regional Officer ) 2429733

3 Disaster Management

Cell,

0261 2465112,

2465118 7574827586

4 Emergency Control Room,

SMC

0261 242350-55 46 Fire & Accident 0261 101

2451765/55,

2422285-87 47 Ambulance (SMC) 0261 102

Ext. 318,

9724346021 48 Ambulance 0261 – 102,108

5 Policy Control Room

0261 100, 2462100, 49 New Civil Hospital 0261 2208448

2462318 50 Old Civil Hospital 0261 2479311,

2479175

Fax- 2462200, 2462600

51 Mahavir Hospital

SURAT 0261- 2332829-32

6 Emergency Ambulance 108 52

Surat General Hospital 0261- 2479791

7 Mamlatdar Palsana 02622 264 SURAT

8 Commissioner, Surat

Municipal

9825144800, 0261

2422244 53 ESIC General Hospital

0261- 2244110

9 PSI Palsana 02622 264227 Majura Gate SURAT

10 DY SP 02622 226861 54 BASPS SURAT 0261-2781000

11 CPI 02622 220670

55

Mody General Hospital 02622 271621

12 DSP Palsana 02622 2651832,

2651833 Kadodara 02622 272345




Report No. 1718A058

98784 05082 56 (CHC) Central Health

Center, Palsana 02622 264232

13 IG Surat 0261

2668666,2650332

57

Khusi Hospital

02622 272023

14

Jt. Director Industrial 0261 2473501,

2472422

Kadodara

Safety & Health, (Surat

Region) Palsana

15

Dy. Director Industrial

0261 2472422 58

Snjeevni Hospital 02622 281184

Safety & Health, (Surat Region)

Chalthan 02622 281253

16 Chief Fire Officer, SMC,

Surat

0216 2414195-96,

2414139

59

Punit Hospital 02622 271454

17

Executive Engineer,

Public Health & Mechanical Division,

Gujarat Water Supply &

Several Board, Surat

0261 2687376 Kadodara 98251 67137

18 Dy. Director of

Information, District 0261 2479172 Palsana

19 Chief Civil Defense, Surat 0261 2472043

60

Omshivam Hospital 0261 2390290

20 Medical Superintendent,

NewCivilHospital, Surat

0261 2244456,

2244459 Sachine 0261 2396551

21 District Health Officer,

Surat

94285 09526,

9374146464

0261 2430589 61 Omshivam Hospital

Palsana 92280 86670

22 Reliance Fire Station 3035068, 3035555 62 Unity Orthopedic

Hospital 92280 77567

23 KRIBHCO Fire Station 0261 2802122 63

Garg Eye Hospital 02622 271073

24 ONGC Fire Station 0261 2840026 Kadodara

25 PEPLFire Station

Kadodara

9909904111 64

RevivaL Hospital 95377 90081

02622 291108,109 Kadodara

02637 75554,75678 65

Dhruv Hospital 02622 274671

26 BardoliFire Station 02622 220101 Kadodara

27 NavsariFire Station 02637 259001,

66 Care Hospital

02622 273108 245101 Kadodara

28 Colourtax Industries Pvt.

Ltd.

0261 239 9666 67

OMShivam Hospital 91739 99158

0261 224 0568 Kadodara

98250 56865

68

ESIC Dispensary

02622 282385

29 Navin Florine International

0261 2890326 – 329 Kadodara

9924822099 69

SMC, Fire Control Room

101, 0261 2414195,

30 Reliance Industries Ltd.

0261 4135999 Surat 2414196, 2414139

9998011387 70 Chief Fire Officer,

Surat, SMC

0261 2436636,2414195-

96

31 Goyal Knit Fab Pvt Ltd. 02622 - 265266

32 Noble Tax 02622 - 264032,




Report No. 1718A058

02622 - 264632

33 Laxmi Narayan Dyeing 02622 - 264501,

02622 - 264502

34 Vishnu Priya 02622 - 264164

35 T M Patel Dyeing 02622 - 264444

36 VirDev Pharma 02622 - 264504

37 GPPL 9824102606

38 Kotex Industries 9824102615

9824166165

39 Anubha Industries

9924028887

9826028887

9824700400

40 Spectrum Auxi Chem. 98241 06781

7.9.12 OCCUPATIONAL HEALTH AND SAFETY PROGRAM - MITIGATIVE MEASURES: Health hazards associated with the occupation are called occupational hazards. In chemical industry due to handling of toxic and hazardous chemicals there are possibilities of developing occupational diseases. The

manufacturing process does not involve hazardous chemicals of high health effects.

These diseases are caused due to

1. Acute exposure of chemical fumes.

2. Chronic effects of exposure of chemical fumes

M/s. Spectrum Dyes & Chemicals Pvt. Ltd, has planned for the following checks to curb the problem:

Pre - employment medical checkup at the time of employment.

Annual medical check must be done for all employees in once every year.

i. Occupational Health center for rendering immediate first aid prior to sending to nearby hospitals.

First aid training must be given to “a section” of employees.

ii. Monitoring of occupational hazards like noise, ventilation, chemical exposure shall be carried out at

frequent intervals, the records of which shall be documented. iii. Suitable PPEs have to be provided and application enforced. All the PPEs procured are of BIS

approved products. Work place enforcement of wearing is done regularly. The same will be followed

in the extension unit also. iv. All the hazardous chemicals are to be identified by the hazchem visuals. All the workmen have to be

properly trained.

v. Evaluation of health of workers viz. chest x ray, Audiometry, Spirometry Vision testing (Far and Near vision, color vision and any other ocular defect) ECG, during pre-employment and periodical examinations must be carried out.

vi. The injuries record and the gas effect record shall be maintained for assessing the controls at the

workplace monitoring.

7.9.12.1 Occupational Health Centre (OHC):

The OHC shall be maintained and controlled by qualified medical team consisting of doctors, nurses

and other Para medical staff.

The OHC shall be maintained for 24x7 – 365 days operation.

All the available antidotes as available shall be maintained by the OHC personnel.

A fully loaded ambulance shall be maintained for carrying persons to nearby Hospitals.

The safety officer shall maintain the legal requirement records in the prescribed formats as called in different laws.

Symptomatic treatment is given to the persons affected by chemicals by the authorized Medical

Practitioner.




Report No. 1718A058

HSE monthly reports have to be maintained.

7.9.12.2 HSE ORGANIZATION.

The systems to be maintained by HSE department shall be taken from BIS 14489 1998. There shall be

appropriate staff qualified as per the requirement of law, has to be maintained in the HSE department.

Periodic reports shall be sent to DIRECTOR OF INDUSTRIAL SAFETY &HEALTH (DISH) authorities

as specified in the law books.

The Inspection book remarks made by the Factory Inspector shall be fully complied and records

maintained.

7.9.13 DO’S &DON’T’S TO BE FOLLOWED:

DO’S:

All the machines are to undergo Preventive Maintenance latest by once in a year. Productive

maintenance rounds (Daily visual rounds) have to be undertaken periodically to assess the healthiness of the machines. Records to be maintained.

For critical machines: All fasteners, gaskets, oil rings, lubricating oils, plastic parts , hose

pipes etc., have to be changed at the time of maintenance.

All load bearing members of the machine parts have to be thoroughly cleaned and visually inspected for any cracks and other defects.

All the PPEs procured shall conform to BIS or other equivalent standards.

Use of PPEs in the form of visuals has to be displayed at appropriate places.

All Hygiene practices are to be followed; restrictions for entry to specified places have to be

displayed.

Emergency escape routes and exit points have to be vividly displayed.

Near- miss inspections have to be carried out, discussed with area owners and hazards to be mitigated.

Ammonia used in the chilling plants have to be suitably disposed, when there is leakage.

REUSE, RECYCLE, RECOVERY of chemicals and liquids shall be devised and practiced.

All hazardous wastes in the form of solids and liquids shall be disposed off as per the

stipulated regulations.

EMERGENCY mitigation equipment locations and routing has to be displayed at prominent

locations.

Pressure and temperature parameters have to be monitored and records maintained wherever

called for.

All cooling arrangements for controlling temperatures shall have standby arrangements.

All continuous processing facilities shall have power backup facility.

Emergency lighting system shall be available during emergencies.

DONT’S:

Mix different chemicals or other treatment products prior to adding to pool water.

Dispose of chemical product container without washing & drying completely.

Use dry chemical fire extinguishers (use water only!).

Dispose of spilled material or unused product in the TRASH or SEWER (use or dispose per

label directions).

Store liquid materials above solid materials.

Allow product to contact oil, grease, acid or organic material.

Smoke where pool chemicals are stored or used.

Use floor sweeping compounds when cleaning up pool chemicals.

Put spilled materials back in the original container.

Use temporary wiring.

Overload motors, circuits, or outlets.

Leave circuit breakers blocked in a closed position.

Overheat transmission shafts or bearings, especially if they're in an area with dust or lint.

smoke, lit fire or spark in the identified hazardous area




Report No. 1718A058

panic, evacuate calmly and quickly perpendicular to wind direction through the designated

escape route

pay attention to the rumors and don’t spread rumors.

Provide housing near the industries producing or processing the hazardous chemicals, if

possible.

Sensitize the community living near the industrial units and they should be more vigilant about the nature of industrial units and associated risks.

CHAPTER - 7 ADDITIONAL STUDIES

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Transcript of CHAPTER - 7 ADDITIONAL STUDIES