chapter - 7 additional studies -...

Environmental Impact Assessment Report

M/s. NN Polymers

Survey No. 1458, Village: Panshina,

Taluka: Limbdi, District: Surendranagar, Gujarat.

T. R. Associates (Ahmedabad)

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Chapter‐7: Additional Studies

7.1

CHAPTER - 7 ADDITIONAL STUDIES

A. PUBLIC CONSULTATION

All the aspects of the TORs are incorporated in the draft EIA/EMP report, the same

may be submitted to the Gujarat Pollution Control Board (GPCB) for conducting public

hearing/public consultation as per EIA Notification, 2006 and its subsequent

amendments.

Minutes of Public Consultation / Public Hearing will be included in final EIA report with

suggestions/recommendations, if any after public consultation.

B. RISK ASSESSMENT STUDY

The said study report is presented in next page.

C. SOCIAL IMPACT ASSESSMENT, R & R ACTION PLAN

The socio‐economic study of the study area is carried out and details are presented in

the Chapter‐3/Section‐ 3.9. It may be noted that the proposed project is to be

established on Non Agricultural land. The project site is intended for the industrial

purpose and thus no displacement of villagers/people will take place. Therefore, the

R&R (Rehabilitation & Resettlement)policy/plan is not undertaken. However, the

direct financial and social benefits with specialemphasis on the benefit to the local

people will be preferred and the proposed budgets for corporate social responsibility

(CSR) activities are summarized in Chapter‐ 8 /Section‐ 8.5.


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B. RISK ASSESSMENT

7.1 Overview of Project

M/s. NN Polymers is proposing to manufacture Melamine Formaldehyde Resin,

Phenol Formaldehyde Resin & Urea Formaldehyde Resin as well as Laminated Sheets

at Survey No.: 1458, Village: Panshina, Taluka: Limbdi, District: Surendranagar,

Gujarat. The total production capacity of proposed unit for all resins is 900 MT/Month

and laminated sheets 1,50,000 Nos./Month. Total land area of 17,705 m2. Out of the

above stated land area approximately 6,915 m2 is green belt area (approx. 39.1 % of

the total land area).

The total estimated cost of the proposed project is Rs. 8.5 Crores out of which resin

plant cost will be approx. Rs. 1.1 Crore. Major plant machinery to be installed are

storage tanks, reactors (MOC:MS), utilities which includes Thermic Fluid Heater (TFH),

Steam Boiler and Cooling Towers. Hazardous chemicals mainly Phenol, Formaldehyde

(37%), Methanol will be stored and used in the process for manufacturing resins.

7.2 Surrounding Area

The proposed unit will be set – up in village: Panshina in Limbdi Taluka. No major

industries are situated within 10 km radius form the project site. Only one small scale

unit named Accurate Infra Industries (P) Ltd. manufacturing fly ash bricks and

Autoclaved Aerated Concrete (AAC) block is situated within 10 km radius area. The

google image showing proposed unit is given in Chapter: 2 (Figure No. 2.2). Proposed

project site is adjacent to the National Highway No. 8A which is well connected to

other state highways as well as national highway. There is no protected area notified

under the Wild Life (Protection) Act (1972) & Eco‐sensitive area notified under the

Environment (Protection) Act‐ 1986 exists within 10 km radius area from the project

site.

7.2.1 Objective and Scope

Risk Assessment is used for determining the risk of chemicals in use, handling,

transport and storage of dangerous substances. QRAs are done if dangerous

substances are thought to be present at a location (e.g. industrial sites and

transportation routes) in amounts that can endanger the environment. Due to storage

risk posed to people who work inside or live near hazardous facilities, and to aid in


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preparing effective emergency response plans by delineating a Disaster Management

Plan (DMP) to handle onsite and offsite emergencies.

Scope of the Study:

Hazard Identification ‐ Identifying sources of accidents involving release of

hazardous material in the atmosphere and the various ways (that is scenarios)

they could occur.

Consequence Assessment ‐ Estimating the probable zone of impact of accidents as

well as the scale and/or probability of damages with respect to human beings and

plant equipment and other structures.

Accident Frequency Assessment ‐ Computation of the average likelihood of

accidents.

7.2.2 Risk Analysis Methodology:

Information on Location, Layout, Process Parameters

Hazard Identification

Quantification of Hazards

Select Most Credible Scenario which can convert into an accident out of several

major and minor.

Select Worst Case Scenario which has the highest potential to cause an accident

of maximum damage

Estimate Consequences: in the plant in the form of fire, explosion and toxic

effects

Estimate Frequency of Occurrence

Estimate effect of damage

7.3 Hazard Identification and Risk Analysis

The Hazard identification and risk analysis is used to identify possible accidents and

estimate their frequency and consequences. While identifying hazards only those

areas of plants having potential risk are used further for risk analysis. Hazard is

considered as characteristic of system/plant/process that presents potential for an

accident. Hence, all the components of a system/plant/process are thoroughly

examined to assess their potential for initiating or propagating an unplanned

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


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7.3.1 Hazard Identification Methods

The proposed project of setting – up resin manufacturing unit comprises of a

numbers of stages from site selection, conceptualization to decommissioning. Each

stage of plant possesses hazards. In case of proposed project during the stage of

Environmental Clearance the proposed project is considered at predesign stage.

Hazard identification method used or the proposed plant is given below.

o Identification of major hazardous units based on Manufacture, Storage and

Import of Hazardous Chemicals Rules, 1989 of Government of India (as amended

in 2000); and

o Preliminary Process Hazard Analysis: Hazard associated with raw materials,

intermediates, by‐ products, final products, plant equipment.

o Hazard Indices: Identification of hazardous units and segments of plants and

storage units based on relative ranking technique, viz. Fire‐Explosion and Toxicity

Index (FE&TI).

7.3.2 Identification of Hazardous Chemicals used within Premises

Following chemicals to be stored and utilized within the premises falls under

Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 (as amended

in 2000). List of Hazardous Chemicals is given below:

Amongst the below described raw materials and products, some are the hazardous

chemicals as per the MSIHC rule 2000. Chemical and physical properties of raw

materials are given in Table 7.1.


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Table 7.1 Chemical Properties of Hazardous Chemicals

Sr. No.

Chemicals TLV

Toxicity Level Flammable Limit Chemical Class (As per MSIHC

Rules)

LD50 Oral mg/Kg

LD50 Dermalmg/Kg

LC50 mg/l

LEL% UEL% FP 0C BP0C

Class (As per

petroleum classification)

1. Phenol* 5 ppm 317 669 125 1.8 8.6 790C (CC) 850C (OC)

182 C Flammable,

Toxic, Hazardous

2. Formaldehyde* (37%)

0.75 ppm 100 15800 64000

ppm/4 hr 6 36.5

500C (CC) 600C (OC)

98 B Flammable,

Toxic, Hazardous

3. Methanol* 200 ppm 5628 15800 64000

ppm/4 hr 6 36.5

120C (CC) 160C (OC)

64.5 A Very high flammable

4. Caustic Soda* 2 mg/m3 N.A N.A N.A N.A N.A N.A 1388 ‐‐ Hazardous

5. Melamine N.A 3161 1000 N.A N.A N.A 93.3 0C N.A C Slightly

flammable

6. Urea 10 mg/m3 8471 ‐‐ ‐‐ N.A N.A N.A N.A ‐‐ N.A

Note: * Hazardous chemicals as per MSIHC rule, 2000 ‐‐ Note: CC: Close Cup; OC: Open Cup; N.A.: Not Available.

The toxicity level of hazardous chemicals as per Manufacture, Storage and Import of Hazardous Chemical (Amendment) Rules, 2000 (MSIHC) is

shown as below:

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

2 Highly Toxic >5‐ 50 >40‐200 <0.5‐2

3 Toxic >50‐200 >200‐1000 >2‐10


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7.3.3 Storage Details of Raw Material and Products:

Details of the raw materials and products with storage are given in Table 7.2.

Table 7.2: Storage Details of Raw Materials

Sr. No.

Name of Raw Material

Consumption per Month

Consumption Per Day

Physical State

Mode of Storage

Material of Construction

Capacity of

Storage Unit

No. of Units

Total Storage Capacity

Storage Inventory (days)

1 Melamine 120 MT 4.8 MT Solid Bags HDPE 25 kg 600 nos.

15 MT 3

2 Urea 120 MT 4.8 MT Solid Bags HDPE 25 kg 600 nos.

15 MT 3

3 Phenol (94%) 145 MT 5.8 MT Liquid Tank MS 30 MT 1 nos. 30 MT 5

4 Formaldehyde

(37%) 524 MT 21 MT Liquid Tank

HDPE MS

10 MT 30 MT

1 nos. 1 nos.

40 MT 2

5 Methanol 75 MT 3 MT Liquid Tank MS 10 MT 1 nos. 10 MT 3

6 Caustic Soda

(Flakes) 4.5 MT 0.18 MT Solid Bags HDPE 25 kg 50 nos. 1.25 MT 7

7 Acetic Acid 1.5 MT 0.06 MT Liquid Tank HDPE 1 MT 1 nos. 1 MT 16

8 Kraft Paper 236.3 MT ‐ Solid Raw Material Storage Area ‐

9 Design Paper 33.7 MT ‐ Solid Raw Material Storage Area ‐


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Table 7.2 (A): Storage Details of Products

No. Description Physical Form Mode of storage Transportation Capacity of

storage

1 Phenol Formaldehyde Resin Semi Solid MS tank (1 No.) Captive consumption & sale.

Quantity will be transported by

road, rail & ship.

30 MT

2 Melamine Formaldehyde Resin Semi Solid MS tank (1 No.) 30 MT

3 Urea Formaldehyde Resin Semi Solid MS tank (1 No.) 30 MT

Table 7.3: Identification Hazard Associated with Storage of Raw Materials:

Sr. No.

Name of material stored

Hazard Rating Systems

Type of hazard / Risk involved

Causes Effect Control Measures proposed

(1)

Phenol

30 MT tank Ambient

TLV – 5 PPM STEL‐10 PPM NFPA Ratings: Health:4; Flammability: 2; Instability: 0 Flash Point: 79.440C

Toxic Chemicals Exposure Risks Fire /Explosion

Glands/seal leaks in valves, pumps,

Hose/pipe failure, leakage from flanged joints carrying phenol

Overflow from storage tanks

Toxic when contact with Skin

Causes burns Toxic if swallowed Irritating to Skin,

Eyes and Respiratory System

Dyke wall shall be provided to all above ground storage tank.

Separate from strong oxidant. Fire hydrant system shall be

installed. Safety shower and eye washer

shall be installed near storage area.

Flame proof Electrical fittings shall be provided at flammable storage area.

Proper selection of MOC for chemicals storage tank.

Earthing/bonding shall be

(2)

Formaldehyde (37%)

30 MT tank & 10 MT tank

TLV – 0.3 PPM (1 ppm)

NFPA Ratings: Health ‐ 3

Flammability ‐ 2Reactivity ‐ 0

Toxic Chemicals Exposure Risks

Glands/seal leaks in valves, pumps

Hose/pipe failure, leakage from flanged joints carrying Formaldehyde (37%)

Very toxic by inhalation, in contact with skin, Very toxic if swallowed.

Causes burns.


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Sr. No.

Name of material stored

Hazard Rating Systems

Type of hazard / Risk involved

Causes Effect Control Measures proposed

Flash Point: 500C

Fire /Explosion

Overflow from storage tanks

Limited evidence of a carcinogenic effect.

Risk of serious damage to the eyes.

May cause sensitization by skin contact.

provided for static charges. Flame arrestor shall be

provided on flammable material storage tank vent.

Level gauge and level measurement instrument shall be provided on material storage tank.

Lightening arrestor on all chimney and building shall be provided.

Hazardous material should be stored away from the plant and safe distance shall be maintained.

Safety permit system shall be followed for loading, unloading of hazardous chemical.

Fencing, caution note, hazardous identification board should be provided.

Only authorized person shall be permitted in storage tank area and register will be maintained.

(3) Methanol 10 MT tank

TLV – 200 PPM (8‐hr TWA) STEL‐250 PPM NFPA Ratings: Health: 1 Flammability: 3

Fire /Explosion

Glands/seal leaks in valves, pumps

Hose/pipe failure, leakage from flanged joints carrying Methanol

Loading and unloading process

Nearby ignition sources

Fire due to Bottom nozzle failure

Damage of storage tank Pump discharge nozzle failure

Unloading road tanker hose rupture

Highly Flammable Toxic by inhalation Toxic when

contact with Skin Toxic if swallowed Danger of very

serious irreversible effects.


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A. Identification of Process hazards:

Name of

hazardous

process and

operation

Material in the

process /

operation

Type of hazard possible toxic

gas release / fire / explosion

/ run away reaction /

rupture, etc.

Causes

Control Measures to be provided

Thermic Fluid

Heater Oil

Fire/Explosion

Heat burns

Flash point variation of thermal

fluid/oil over a period of time

(Thermal fluids which were not

flammable at the operating

temperature when they were

initially installed but over time

become flammable at the operating

conditions)

Mist Formation around leak points

such as flagged joints, around valves

and connection points in the pipe

line. These may create explosive

atmospheres being formed outside

the pipework where ignition sources

such as motors pumps and electrical

equipment are present

Regularly replacement of thermic

fluid

Monitoring of flashpoint of thermic

fluid heater regularly

Installing Fluid conditioning

equipment in the thermal fluid

system

Reduce the extent of mist formation

by fiting mist guards

Avoiding lagging fires

Following type of instrumentation

suggested:

Install temperature indicator cum

Controllers to indicate temperature

and prevent undesired overheating at

the inlet and outlet of the system

Photo cell to sense flame failure, give

alarm and switch off the burner.


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Name of

hazardous

process and

operation

Material in the

process /

operation




rupture, etc.

Causes


Lagging Fire – leak and dispersion of

oil within insultation leads to fire

Magnetic levels switch in the

deaerator cum expansion tank to cut

off the burner if the thermic fluid

level falls below the minimum level.

Synchronising mechanism exists

between the hot oil circulation pump

and burner, so that the burner will

not be switched on until the

circulation pump reached the full

speed.

Reactor

Vessel

Formaldehyde

(37%),

Melamine,

Urea, Phenol

Fire/Explosion

Release of Heat and Flammable gases

Fire, Toxic gas release and Explosion Failure of agitator, heating and

cooling system in the reactor

Failures of external boiler, condenser and piping system

Raw Materials quantity must be

controlled either volumetrically or

gravimetrically.

Process control devices must be

installed includes the use of sensors,

alarms, trips and other control

systems that either take automatic

action or allow for manual

intervention to prevent the

conditions for uncontrolled reaction


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Name of

hazardous

process and

operation

Material in the

process /

operation




rupture, etc.

Causes


occurring.

High Temperature indicator valve and

alarm system must be provided

Auto cut off system must be provided

after reaching of predetermined

maximum safe temperature.

Pressure gauge is must provided.

Safety Control valve is must be

provided.

The Vessel Emergency Relief vent

should discharge to a suitably

designed catch pot or should be so

positioned that people working in the

area and members of the public will

not be in danger if the contents of the

vessel are discharged.

Use skilled worker Proper selection of MOC

Mechanical seal in all pumps and

reactors


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Name of

hazardous

process and

operation

Material in the

process /

operation




rupture, etc.

Causes


Transportation of finished product from vessel to storage tank through

close pipe.

Boiler Heat burns

Thermal radiation

Explosion Heat burns

Leaking safety and or safety relief valves

Malfunctioning of Water level

indicator

Steam leaks (steam systems)

High stack temperatures (excess of

350ºF)

Condensate dripping down stack or out the front of the boiler

Constantly resetting of controllers and safety devices

Annual inspections Safety interlocks to be provided Safety and pressure gauge valves fitted Properly supported and protected

against corrosion

Testing of Jackets and joints of tubes regularly


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B. General hazards and controls

Type of

Emergency

Identification

of Area Possible Causes Possible Results

Material

handling In Plant

Flammable, eye irritating &

accidently leakages Fire and health Hazards

7.3.4 Hazard Indices:

Hazard indices are used as relative ranking of hazard potential of proposed plant. The method used DOW fire and explosion index, Mond

Toxicity index provide direct and easy approach to a relative ranking of the risks in process plants.

DOW index : Fire‐Explosion and Toxicity Index (FE&TI)

The Fire and Explosion Index (FE&TI) calculation is a tool to help determine the areas of greatest loss potential in a particular process. It also

enables one to predict the physical damage that would occur in the event of an incident. For the proposed project storage tanks are considers

to know fire and explosion potential of each tank.

To calculate the Fire and Explosion Index, however, only storage tanks having storage capacity of 30 MT which have an impact from a loss

prevention standpoint has been evaluated. These are known as Pertinent Process Units.

Important factors for selecting Pertinent Process Units include:

a. Chemical energy potential (Material Factor)

b. Quantity of hazardous material in the Process Unit

c. Process pressure and process temperature

d. Units critical to plant operation, e.g. Reactor, storage tank


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Table ‐7.4: Fire & Explosion Index

Sr.

No.

Material

Stored

Storage

Qty.

Nh Nf Nr MF GPH SPH FEI Degree of

hazard

Th Ts Ti Degree

of

Hazard

Radius

of expo.

(ft.)

1 Phenol 30 MT 4 2 0 10 1.93 2.12 45 Low 325 125 10.2 high 34

2 Methanol 10 MT 1 3 0 16 2.05 3 93 High 250 50 5.2 Low 83

3 Formaldehyde (37%)

30 MT 3 2 0 10 2.20 2.50 60 Low 250 125 10.0 high 46

Note: MF=Material Factor, GPH= General Process Hazardous, SPH= Special Process Hazardous, FEI: Fire and Explosion index

Based on F & EI and toxicity index TI, following categories are available:

Sr.

No.

Category F & EI TI Degree of

Hazard

1 I F<65 T<6 Low

2 II 65<F<95 6<T<10 Medium

3 III F>95 T>10 High

From the above stated toxicity index, it is evident that methanol storage tank has high potential physical damage and loss.


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7.3.5 Credible Accident Sources/Worst Case Scenarios

Maximum Credible Accident (MCA) scenario indicates most believable, reasonable,

likely or possible accident scenario and damage distance based on it. MCA scenario

takes into account the effect of existing control measures also. It considers the

malfunctioning of the control system, opening of safety valve/failure of safety valve,

leakages from flange joint, pipe line etc. and failing of some safety devise.

Worst‐case scenario (rarely possible) is defined as the release of the largest quantity

of a regulated substance from a single vessel or process line failure that results in the

greatest distance to an end point, e.g. catastrophic failure. It considers the failure of

all control systems and release of the whole mass resulting in maximum damage.

Based on the storage and properties of the chemicals at the proposed resin

manufacturing unit, the some typical scenarios relevant for MCA analysis is given in

the following Table.

Table ‐7.5: Scenarios Considered for MCA Analysis

Sr.

No.

Chemical Storage

Quantity

Pool Fire Flash fire Toxic

Dispersion

Worst case

scenario

1 Methanol 10 MT

MS tank

2 Phenol 30 MT

MS tank

‐ ‐ ‐

3 Formaldehyde

(37%)

30 MT

MS tank

& 10 MT

HDPE tank

‐

4 Causitc soda

(Flakes)

25 Kg HDPE

Bags

‐ ‐ ‐ ‐

The above table indicates that major material storage is flammable liquid. Fires could

occur due to presence of ignition source at or near the source of leak or could occur

due to flashback upon ignition of the traveling vapour cloud.

Tank fires may occur due to the following: ̇ Ignition if rim seal leak leading to rim seal

fire and escalating to full‐fledged tank fire.


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Lighting is a major source of ignition of tank fires; and ̇ Overflow from tank leading to

spillage and its subsequent ignition, which flashes back to the tank leading to tank

fire. The chance of overflow should be less unless operator has grossly erred.

Spillage due to overflow may result in a dyke fire if ignition occurs after sufficiently

long period.

For radiation calculations, pool fire is important and the criteria of 4.5 kW/m2

selected to judge acceptability of the scenarios. The assumptions for calculations

are: ̇ It is not continuous exposure ̇ It is assumed that no fire detection and mitigation

measures are initiated

7.4 Consequence Modeling

Hazardous incidents start with a discharge of a flammable or toxic material from its

normal containment. Discharge can take place from a crack or fracture of process

vessels or pipe work, an open valve or from an emergency vent. The release may be in

the form of gas, liquid, or two phase flashing of gas‐liquid.

7.4.1 Damage Criteria:

The storage and unloading at the storage facility may lead to fire and explosion

hazards. The damage criteria due to an accidental release of any hydrocarbon arise

from fire and explosion.

A. Fire Damage

Table 7.6 tabulates the damage effect on equipment and people due to thermal

radiation intensity whereas; the effect of incident radiation intensity and exposure

time on lethality is given in Table 7.6.

Table 7.6: Damage Due to Incident Radiation Intensities

Sr. No.

Incident Radiation

(kW/m2)

Type of Damage Intensity

Damage to Equipment Damage to People

1 37.5 Damage to process equipment 100 % lethality in 1 min. 1% lethality in 10 sec.


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Sr. No.

Incident Radiation

(kW/m2)

Type of Damage Intensity

Damage to Equipment Damage to People

2

25.0

Minimum energy required to ignite wood at indefinitely long exposure

without a flame

50% Lethality in 1 min. Significant injury in 10 sec.

3

19.0

Maximum thermal radiation intensity allowed on thermally

unprotected adjoining equipment

‐‐

4 12.5 Minimum energy to ignite with a

flame; melts plastic tubing 1% lethality in 1 min.

5

4.5

‐‐

Causes pain if duration is longer than 20 sec ,however

blistering is un‐likely (First degree burns)

6 1.6 ‐‐

Causes no discomfort on long exposures

Source: Techniques for Assessing Industrial Hazards by World Bank.

Table 7.7: Radiation Exposure and Lethality

Radiation Intensity

(kW/m2)

ExposureTime (seconds)

Lethality (%)

Degree of Burns

1.6

‐‐

0 No Discomfort even

after long exposure

4.5 20 0 1st 4.5 50 0 1st 8.0 20 0 1st 8.0 50 <1 3rd 8.0 60 <1 3rd 12.0 20 <1 2nd 12.0 50 8 3rd 12.5 ‐‐ 1 ‐‐ 25.0 ‐‐ 50 ‐‐

37.5 ‐‐ 100 ‐‐


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B. Damage due to explosion

Explosion is a sudden and violent release of energy accompanied by the generation of

pressure wave and a loud noise. The rate of energy release is very large and has

potential to cause injury to the people, damage the plant and nearby property etc.

BLEVE ‐ fireball

A Boiling Liquid Expanding Vapour Explosion (BLEVE) occurs when there is a sudden loss

of containment of a pressure vessel containing a superheated liquid or liquified gas. It is

sudden release of large mass of pressurized superheated liquid to atmosphere. The

primary cause may be external flame impinging on the shell above liquid level

weakening the vessel and leading to shell rupture. Calculations are done for diameter

and duration offer ball and the incident thermal flux.

Pool fires and jet fires are common fire types resulting from fires over pools of liquid or

from pressurized releases or gas and/or liquid. They tend to be localised in effect and

are mainly of concern in establishing potential for domino effects and employee safety.

ALOHA Models are used to calculate various components ‐ burning rate, pool size,

flame height, In jet fire modelling the steps followed for the thermal effects are

calculation of the estimated discharge rate, total heat released, radiant fraction/source

view fraction, transmissivity and thermal flux and thermal effects.

Vapour cloud explosion

When gaseous flammable material is released a vapour cloud forms and if it is ignited

before it is diluted below its lower explosive limit, a vapour cloud explosion or a flash

fire will occur. Insignificant level of confinement will result in flash fire. The vapour

cloud explosion will result in overpressures.Table 7.6 tabulates the damage criteria as a

result of peak over pressure of a pressure wave on structures and people.

Table 7.8: Damage Due to Peak Over Pressure

Human Injury StructuralDamage

Peak Over

Pressure (bar)

Type of Damage Peak Over

Pressure (bar)

Type of Damage

5 ‐ 8 100 % lethality 0.3 Heavy (90% damage)

3.5 – 5 50 % lethality 0.1 Repairable (10% damage)

2 ‐3 Threshold lethality 0.03 Damage of Glass


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Human Injury StructuralDamage

Peak Over

Pressure (bar)

Type of Damage Peak Over

Pressure (bar)

Type of Damage

1.33 ‐ 2 Severe lung

damage

0.01 Crack of Windows

1 ‐ 11/3 50% Ear drum rupture

‐ ‐

Source: Marshall, V.C. (1977)' How lethal are explosives and toxic escapes'.

C. Effect due to toxic gas release

Various approaches are used to determine the consequences of toxic gases:

• IDLH

• ERPG

IDLH (Immediate Danger to Life or Health) is the maximum concentration from which

escape is possible within 30 minutes without any escape‐impairing symptoms or

irreversible health effects.

7.4.2 Details of Model Used for Consequence Analysis

ALOHA provide output as amount of chemical discharged from the source as well as

its concentration in air it takes into account different levels of concentrations for a

specified chemical.

Software used for calculation ‐ ALOHA (Areal Locations of Hazardous Atmospheres) 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 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.


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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.


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 a healthy worker

could be exposed without suffering permanent or escape‐impairing health effects.

Input data for ALOHA are as below:

Weather Data:

Average Wind Speed: 5 m/sec, 3m/sec & 1.5 m/sec

Average Ambient Temperature: 400C, 350C, 210C

Average Humidity: 21 %, 58 %, ,68 %

Atmosphere Stability Class: D (windy day time), B (moderate wind, day time), F

(extreme calm, night time)

Chemical Properties:

Chemical properties of each hazardous chemical stored within premises is given in Table

No.: 7.1

Storage Details:

Storage quantity and type of storage of chemicals is given in Table No.: 7.2


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Table 7.9: Consequence analysis and Damage Distance (Failure of raw material storage tanks)

Name of Chemical

Type of Impact Flammable (Distance in meter) Toxic Dispersion

Pool Fire (meter)

Fire Ball (BLEVE)(meter)

Worst Case Scenario

Flash fire(Flammable Area of Vapor

Cloud)(meter)

ERPG(3)/ IDLH ERPG(2) ERPG(1)

Radiation Intensity(kW/m2)

37.5 25 4.5 37.5 25 4.5 UEL LEL

Fatalities 100% 50% 100% 50% ‐ ‐

Wind Speed

Stability Class

Methanol (10 MT x 1)

5 D <10m <10m <15m 68 100 270 19 meters ‐‐‐(43080 ppm =

60% LEL = Flame Pockets)

39 meters ‐‐‐ (7180 ppm = 10% LEL)

15 meters ‐‐‐(6000 ppm =

IDLH)

32 meters ‐‐‐(1000 ppm = ERPG‐2)

130 meters ‐‐‐ (200 ppm = ERPG‐1)

1.5 F <10m <10m <12m 68 99 270 19 meters ‐‐‐(43080 ppm =

60% LEL = Flame Pockets)

39 meters ‐‐‐ (7180 ppm = 10% LEL)

30 meters ‐‐‐(6000 ppm =

IDLH)


329 meters ‐‐‐ (200 ppm = ERPG‐1)

Formaldehyde (37% solution) (30 MT x 1)

5 D ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ 118 meters ‐‐‐(20 ppm = IDLH)


547 meters ‐‐‐ (1 ppm = ERPG‐1)

1.5 F ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ 693 meters ‐‐‐(20 ppm = IDLH)

1.0 kilometers ‐‐‐ (10 ppm = ERPG‐2)

3.4 kilometers ‐‐‐ (1 ppm = ERPG‐1)

Phenol (30 MT x 1)

5 D ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ 18 meters ‐‐‐(250 ppm =

IDLH)


55 meters ‐‐‐ (10 ppm = ERPG‐1)

Note: Phenol is stored below its flash point. It is unlike to catch fire in case of BLEVE worst case scenario. Formaldehyde (37%): For modeling toxic dispersion 37 % of formaldehyde in total quantity stored in tank is considered with direct source modeling

E

Environmental Imp

T. R. As

NABET

pact Assessment Re

sociates (Ahmedab

Accredited

port

bad)

Taluka: Limb

Figure 7.1: Me

M

Survey No. 1458, V

bdi, District: Surend

Chapter‐7: A

ethanol Pool Fire

M/s. NN Polymers

Village: Panshina,

dranagar, Gujarat.

dditional Studies

7.22

e (Threat Zone)

N

E

Environmental Imp

T. R. As

NABET

pact Assessment Re

sociates (Ahmedab

Accredited

port

bad)

Figure 7.

Taluka: Limb

2: Methanol BL

M

Survey No. 1458, V


Chapter‐7: A

EVE ‐ Worst Cas

M/s. NN Polymers

Village: Panshina,

dranagar, Gujarat.

dditional Studies

7.23

se Scenario (Thrreat Zone)

N

E

Environmental Imp

T. R. As

NABET

pact Assessment Re

sociates (Ahmedab

Accredited

port

bad)

Taluka: Limb

Figure 7.3:

M

Survey No. 1458, V


Chapter‐7: A

Methanol Toxic

M/s. NN Polymers

Village: Panshina,

dranagar, Gujarat.

dditional Studies

7.24

c Dispersion

N

E

Environmental Imp

T. R. As

NABET

pact Assessment Re

sociates (Ahmedab

Accredited

Fig

port

bad)

ure 7.4: Methan

Taluka: Limb

nol Toxic Dispers

M

Survey No. 1458, V


Chapter‐7: A

rsion (1.5 m/s w

M/s. NN Polymers

Village: Panshina,

dranagar, Gujarat.

dditional Studies

7.25

eather conditionn – stability classs F)

N

E

Environmental Imp

T. R. As

NABET

pact Assessment Re

sociates (Ahmedab

Accredited

port

bad)

F

Taluka: Limb

Figure 7.5: Form

M

Survey No. 1458, V


Chapter‐7: A

maldehyde (37 %

M/s. NN Polymers

Village: Panshina,

dranagar, Gujarat.

dditional Studies

7.26

%) Toxic Dispersioon (Threat Zonee)

N

E

Environmental Imp

T. R. As

NABET

pact Assessment Re

sociates (Ahmedab

Accredited

port

bad)

Taluka: Limb

Figure 7.6

M

Survey No. 1458, V


Chapter‐7: A

6: Phenol Toxic D

M/s. NN Polymers

Village: Panshina,

dranagar, Gujarat.

dditional Studies

7.27

Dispersion

N


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7.28

7.5 Failure Frequency

Fire under a tank may lead to the instantaneous release of the complete inventory of

the tank. Various causes of failure may lead to a fire under a tank:

Leakage of the connections under the tank followed by ignition. This event only

occurs for tanks loaded with flammable substances. The frequency is equal to 1

× 10‐5 per year for atmospheric tanks. (Reference Purple book: Guidelines for

quantitative risk assessment)

The best available estimates of leak frequencies for atmospheric tanks are

summarised in Table 7.10.

Reference: Storage incident frequencies International Association of Oil and Gas

Producers (UK: HSE)

Table 7.10: Atmospheric Storage Tank Leak/ Tank Fire Frequencies

Type of Tank Type of Release Leak Frequency (Tank/Year )

Fixed/ floating roof Liquid spill outside tank 2.8 × 10‐3

Tank rupture 3.0 × 10‐6

Atmospheric storage tank Fire Frequency

Type of Fi r e Fi x e d Roof Tank (Tank/Year)

Internal explosion & full surface fire 9.0 × 10‐5

Internal explosion without fire 2.5 × 10‐5

Vent fire 9.0 × 10‐5

Small bund fire 9.0 × 10‐5

Large bund fire (full bund area) 6.0 × 10‐5


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7.6 Estimation of Effect of Damage / Impact Identification

The results of consequence modeling reveal that the maximum intensity of heat

radiation is experienced for Methanol pool fire having a radius of 15 meters. This is

mainly due to the large radius of the storage tank and comparatively high heat of

combustion and heat of vaporization values of Methanol. From the dispersion

modeling of Phenol and Formaldehyde (37%), it is observed that the threat zone is

maximum for Formaldehyde (37%) from storage tank, for the atmospheric conditions

during morning and night. Threat zone distance given below are considered for

Temperature: 220C, Velocity: 1.5 m/sec, Humidity: 71%, Atmospheric stability Class:‐

F considering winter night time. Percentage fatality from different incident outcome

cases and level of concerns are given below:

Table 7.11: Estimation of Fatality

Chemical Incident outcome case

Level of concern

Treat zone

distance

% fatality(pfi)

Likely hood of

occurrence

Magnitude of Impact/Damage

Methanol Pool fire 25 kW/m2

<10 meters

50% Likely Moderate

BLEVE 25 kW/m2

100 meters

50% Unlikely high

Formaldehyde (37%)

Toxic dispersion

IDLH 20 ppm

118 meters

‐ Very Unlikely

Moderate

Phenol Toxic dispersion

IDLH : 250 ppm

18 meters

‐ Likely Moderate

All the threat zones in the proposed unit are super imposed on google image. Figure

7.1 to 7.6 shows the map of vulnerable areas corresponding to different individual

outcome cases. Figure 7.2 gives the location, where individual risk is found to be a

maximum at locations within premises as well as outside of premises. The reason for

high individual risk at this location is due to considering BLEVE scenario as worst case

scenario resulting from the catastrophic failure of storage tank. Abroadly acceptable

level of individual risk as per the ALARP (As Low As Reasonably Practicable) concept

of HSE, UK is 10‐6/year.

7.7 Summary

It may be noted that in dispersion modeling, the wind direction and air temperature,

atmospheric stability are found to be the deciding factors for the threat zones.


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The present risk assessment study shows that proposed unit of M/s. N N Polymers

having storages of hazardous chemicals mainly Methanol could have potential for

damage to those inside and outside the industry.

Fire modeling shows that the hazardous distances for methanol storage tank

extended up to 100 meters in worst case scenario, In case of pool fire it is within 15

meters which might prevent effective fire‐fighting arrangements to be provided .

A maximum threat zone of approximately 693 meters is observed in the case of

release of Formaldehyde (37%). This threat zone can be shortened by reducing the

inventory or storing Formaldehyde (37%) in smaller tanks.

7.8 Proposed Risk Reduction Measures

Storage tank of Formaldehyde 37% / Methanol / Phenol should be installed away

from the plant area.

Wind indicator should be provided at the highest level of the plant to know the

wind direction.

Automatic sprinkler system for the flammable material tanks (over ground tanks

only) may be provided as knock on effect in case of fire is possible.

Containment dykes with proper sloping and collection sumps should be provided so

that any spillages in the bulk storage and other handling areas shall not stagnate

and shall be quickly lead away to a safe distance from the source of leakage. This

reduces the risk of any major fire on the bulk storages and the risk to the

environment shall be minimized/ eliminated.

Inspection of the storage tanks as per prefixed inspection schedule for thickness

measurement, joint and weld efficiency etc.

Provision of flameproof electrical fittings / equipment’s.

Proper maintenance of earth pits.

Strict compliance of security procedures like issue of identity badges for outsiders,

gate passes system for vehicles, checking of spark arrestors fitted to the tank lorries

etc.

Strict enforcement of no smoking.

Periodic training and refresher courses to train the staff in safety fire fighting.

Employee training and education is carried out.

Structural fireproofing in the process area could be considered as a safety measure

in the light of probable spill and fires in the area.

Emergency drills should be carried out periodically to ensure preparedness must

continue.


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7.31

Wind indicator should be provided at the highest level of the plant to know the

wind direction.

Many operations involve use of highly toxic/flammable materials and these needs

to be documented as SOPs. These must be made and kept updated on priority.

Extensive training on use of Self Contained Breathing Apparatus (SCBAs) must be

ensured for emergency control.

Many of the raw materials used for resin are either toxic or flammable. It is

therefore important to ensure that these materials are stored in closed, well

ventilated totally safe areas. A fire alarm system (heat and smoke detection) should

be provided for the storage area where the material is stored as toxic fumes arise

on combustion.

Loose drums of waste materials, often solvent laden, must be removed from the

working areas and close watch kept.

Proper Earthing needs to be provided through plug type systems or through the

agitators/liquid.

Ventilation should be provided for any enclosed are where hydrocarbon or toxic

vapors may accumulate. Several such areas were noticed‐ these may be surveyed

and tackled accordingly.

All personnel should be trained in handling emergency situations and should be

apprised of their role in handling emergency situation and to ensure adequacy of

the emergency procedures simulated exercise should be carried out. This was

found wanting.

Flame arrestor should be provided.

Adequate number of caution boards highlighting the hazards of chemicals should

be provided at critical locations.

Monitoring of occupational hazards like noise, ventilation, chemical exposure etc. is

carried out regularly and its record is maintained.

Good housekeeping, use of PPE, Engineering controls, Enclosure processes,

scrubber system, display of safety boards, SOP of loading / unloading, local exhaust

ventilation, safety shower etc. are important safety measures have taken to keep

these chemicals within TLV.

Appropriate personal protective equipment is provided & ensure the usage of

them.

Workers are trained for safe material handling of hazardous chemicals.

Prepare & display the safe operating procedure for hazardous chemicals storage,

handling & transporting or using.

Local Exhaust ventilation and scrubber should be installed where it is required to

reduce fumes, vapors, temperature and heat stress.


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7.32

Reduce the level of physical activity by sharing workload with other or by using

mechanical means.

Following FIRE safety devices should be provided to protect from any malfunctioning of

plant equipments.

Water storage of adequate capacity to meet the requirements of water for fire

fighting purposes.

Fire hydrants and automatic sprinkler system. Diesel driven pumps and headers to

supply water to fire hydrant network.

Adequate Portable fire extinguishers, sand bucket, wheeled fire & safety

equipment should be provided at the required places.

Equipment required for personal safety like blankets, gloves, apron, gum boots,

face mask helmets, safety belts, first aid boxes etc. are provided. Proximity suits

and self‐contained breathing apparatus to be provided.

7.9 Occupational Health Surveillance Programme

Introduction:

Medical surveillance program (also termed as medical surveillance for workers) can

aid in the early recognition of a relationship between exposure to a hazard and

disease, in the assurance of the safety of new substances, and as an indicator of the

effectiveness of existing control measures. It is the systematic collection, analysis, and

dissemination of disease data on groups of workers and is designed to detect early

signs of work‐related illness..

The Factories Act, 1948 and the rules framed thereunder provide for pre‐employment

and periodical medical examinations of workers employed in industries with

hazardous processes and dangerous operations under section 41‐C and section 87

respectively. Chemicals exposed to workers directly or indirectly are Phenol,

Formaldehyde (37%) and Methanol. Pre‐employment medical checkup and

periodically medical examination will be done. Liver function testis will be carried out

during pre‐placement and periodical examination. In addition to the above, following

safety equipment will be provided.

Action plan for Occupational Health and safety for workers:

Monitoring of occupational hazards like noise, ventilation, chemical exposure etc.

will be carried out regularly and its record will be maintained.


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7.33

Good housekeeping, use of PPE, Engineering controls, Enclosure processes, display of

safety boards, SOP of loading / unloading, local exhaust ventilation, safety shower

etc. All necessary safety measures will be taken to keep all chemicals within TLV.

Appropriate personal protective equipment will be provided & ensure the usage of

them.

Workers will be trained on safe material handling of hazardous chemicals.

Prepared & display the safe operating procedure for hazardous chemicals storage,

handling & transporting or using.

Periodical medical examination of the workers & Liver Function Testes will be done.

Register (form no.37) for work place air monitoring will be done regularly.

Employee training and education will be carried out regularly.

Control the noise at source by substitution, isolation, segregation, barriers will be

done.

Local Exhaust ventilation will be installed where it is required to reduce fumes,

vapors, temperature and heat stress.

7.9.1 Treatment Facilities Provided to Workers affected by accidental Spillage of

Chemicals

Hazards with Acute Exposure

Contact with skin may cause severe burns or systemic poisoning.

Systemic effects may occur from any route of exposure, especially after skin

absorption.

Hazards with Chronic Exposure

Repeated or prolonged exposure may harm the respiratory system. Can irritate

and inflame the airways.

Methanol affects the central nervous system, liver, and kidneys.

Special Safety Precautions

Prevent contact with skin by wearing neoprene gloves, lab coat, and resistant

apron.

Wear safety glasses or a face shield if splashing may occur.

Store in a cool, dry, well‐ventilated area, away from heated surfaces or ignition

sources.

Skin contact requires immediate washing of the affected area with soap and

water.

Remove contaminated clothing and launder before wearing again.


M/s. NN Polymers




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7.34

Procedure for treating workmen after skin contact:

Skin contact requires immediate flushing of the contaminated area with soap and

water at a sink or emergency shower for a good fifteen minutes. Remove

contaminated clothing. In case of eye contact, promptly flush the eyes with

copious amounts of water for 15 minutes (lifting upper and lower lids

occasionally) and obtain medical attention. If methanol is ingested, obtain

medical attention immediately. If large amounts of methanol are inhaled, move

the person to fresh air and seek medical attention at once. It is recommended to

provide the safety shower and eyewash station in plant.

7.9.2 Minimization of the Manual Handling of Hazardous Substance

Employers and employees should examine their workplaces to detect any unsafe or

unhealthful conditions, practices, or equipment and take corrective action. Provide

flameproof electrical motor & transfer chemicals through the pipelines. Use

specially designed pallets to hold, move raw materials, finished products through

work areas. Minimize lifting of raw materials, heavy loads by using appropriate

platforms, trolleys etc. Avoid the moving, manual handling of hazardous material.

7.9.3 DO’S and DONT’S

Handling of Chemicals

Do’s Dont’s

Know the hazards of the chemical before

handling.

Know the antidotes for chemical, which you

are handling.

Do keep material safety data sheet in

locations where chemicals are being handled

and study it.

Use appropriate personal protective

equipment like gloves, aprons, and respirator;

face shield etc. depending upon nature of the

work.

Label every chemical that you use and tightly

close the container.

Use eye wash fountain / safety shower in case

of splash of chemicals in the eye or body for

at least 15 minutes.

Segregate toxic, flammable chemicals and

keep them under control.

Do not store the chemicals that are

incompatible with other chemicals.

Do not spill the chemicals.

Do not dispose chemical without

neutralizing.

Do not keep large inventory of

chemicals.

Do not allow empty containers of

hazardous chemicals to be used by

others.

Do not use compressed air for

transferring chemicals.

Do not stand near chemical transfer

pump while it is in operation with

temporary hose connection.

Pouring of chemicals by hand or doing

siphoning by mouth should never be

adopted.


M/s. NN Polymers




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7.35

In addition to draining and closing valves,

lines should be blanked before taking up

maintenance work.

Provide proper ventilation at the chemical

handling area to limit their concentration

within prescribed level.

Chemicals drums should never be

moved without protection.

Do not attempt to neutralize the acid /

alkali on the skin. Use water only.

Do not use solvent for cleaning hands.

Material Handling

Do’s Don’ts

Use proper lifting tool and tackle having

adequate capacity.

Only authorized persons should operate

material handling equipments.

Each tool, tackle or equipment should have

number and safe working load (SWL) marked

on it.

Assess weight of the material, distance to be

carried and hazards etc. before lifting the

load.

Inspect and test all the lifting tools and tackles

regularly as per Factory Rules.

Wear Personal Protective Equipments while

handling of material.

Wherever possible, mechanized material

handling shall be adopted.

While lifting a load physically, keep the load

as near as possible to the body with feet

properly placed for body balance.

Bend knees, keep back straight, keep the load

closed to the body and lift the load.

Do not use the equipment for the

purpose other than its design intention.

Do not allow personnel to move

underneath lifted load.

Do not load the equipment above its

safe working load.

Do not use makeshift arrangements for

lifting equipment without inspection

and test.

Do not use defective tool and tackles.

Keep the tools & tackles free from

adverse effect of atmosphere by

applying suitable protective coating.

The angle between the legs of two leg

sling should not exceed 90 degree.

Do not allow male and female adult to

lift a load manually higher than 55 kgs

and 30 kgs respectively.

Do not hold the load with tip of the

fingers; grasp the load firmly with palm.

Fire Prevention

Do’s Don’ts

Follow ‘NO SMOKING’ sign.

Deposit oily rags and waste combustible material

in the identified containers and dispose them

suitably.

Fire Hose used for any other purpose should be

Do not leave flammable material like

acetone, kerosene etc. used as

cleaning agent at the work area.

Do not over tighten fire hydrant

valves with F‐lever.


M/s. NN Polymers




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7.36

permanently marked and taken out of fire

hydrant system.

Keep minimum inventory of flammable and

combustible substances.

Take permission before breaking or removal of

fire barrier and ensure subsequent relocation of

fire barrier.

Check periodically the operability of fixed fire

fighting system.

Attend any abnormality / deficiency with fire

protection system promptly.

Provide earthling or bonding to prevent

accumulation of static charges to tanks where

flammable chemicals are stored / handled.

Use instruments that are intrinsically safe in

explosive atmosphere.

Do not allow wild grass growth

around storage of the gas cylinders

and switchyard.

Do not obstruct accessibility to the

fire related equipment.

Do not destroy the inspection tag

provided with the fire equipment.

Do not misuse fire‐fighting

equipment other than intended

purpose.

Do not store the flammable material

in the open container.

Do not use instruments that are not

intrinsically safe in the explosive

atmosphere.

House Keeping

Do’s Don’ts

Assign places for everything and maintain things

at assigned places.

Clean the area after completion of work.

Use aisle space free for personnel and material

movement.

Ensure adequate illumination and ventilation for

the job.

Drop paper, plastic, glass, metal and bio‐medical

waste in a separate bin kept for this purpose.

Know the location where emergency equipment

such as first aid box, firefighting equipment,

SCBA, Stretchers are kept.

Arrest all types of spills such as chemical, water,

oil, air / gas, steam etc. and clean up the area

immediately.

Ensure exits are indicated / painted for use

during emergency.

Do not leave combustible materials

in the work area.

Do not smoke in the area of work.

Do not allow dust bin to overflow.

Do not generate extra waste.

Do not disturb the safety equipment

from assigned location.

Do not block emergency switches

and on/off switches of the

equipment by storming of materials

in front of work.

Do not leave cleaning agent like

acetone, isopropyl alcohol, kerosene

etc. at the work area after

completion of work.

Do not block fire exit point by storing

materials or by means.

Do not leave a spillage unattended.


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7.37

7.10 Disaster Management Plan

7.10.1 Disaster

Disaster , A disaster is a catastrophic situation in which the day‐to‐day patterns of life

are, in many instances, suddenly disrupted and people are plunged into helplessness

and suffering and as a result need protection, clothing,, shelter, medical and social

care and other, necessities of life.

Advance emergency planning and proper training of every employee in the

'emergency function is very essential to make emergency control measures more

effective. It is not possible to completely eliminate emergency situations, but it is

definitely possible to control them. An emergency, if uncontrolled may cause a

disaster which in turn may create a catastrophe.

There are two types of emergency control plans (1) On site emergency plan and (2) Off

site emergency or disaster plan.

7.10.2 Statutory Provisions:

Section 41B(4) of the Factories Act, 1948 requires an on‐site emergency plan and

detailed disaster control measures for the safety of the factory workers and the

general public living in the vicinity of the factory. The occupier is required to inform

the workers and the public about the safety measures to be taken in the event of an

accident.

Rule 13, 14 and Schedule II & 12 of the Manufacture; Storage and Import of Hazardous

Chemicals Rules, 1989 and Rule 5,7,9 and 10 of the Chemical' Accidents (Emergency

Planning, Preparedness and Response) Rules, 1996 also provide for on‐site and off‐site

emergency plans

7.10.3 On‐Site Emergency Plan :

Objectives of the Plan

1. To protect persons and properly of your factory in case of all kinds of accidents,

dangerous occurrences (Rule 103, Gujarat Factories Rules), emergencies and

disasters happening in or affecting your plant at any time.


M/s. NN Polymers




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7.38

2. To inform people and surroundings about above happening if it is likely to adversely

affect them.

3. To inform authorities including helping agencies (doctors, hospitals, fire, police,

transport etc.) in advance, and also at the lime of actual happening.

4. To identify, assess, foresee and work out various kinds of possible hazards, their

places, potential and damaging capacity and area in case of above happenings.

Review, revise, redesign, replace or reconstruct the process, plant, vessels and

control measures if so assessed.

5. To work out a plan with detailed instructions to cope up with above happenings,

based on your personnel, equipment and records. Necessary requirements shall be

added if not already available. Levels of hazardous substances shall be minimised to

the extent possible. Establish machinery for rescue and recuperation operations,

total loss control and prevention of harms and recurrence of above happenings.

Ensure that absolute safety and security is achieved within the shortest time.

7.10.4 Site Plan of the Factory and Surrounding:

Proposed unit has prepared a plan of the factory premises and surroundings showing

therein the areas of various hazards such' as fire, explosion, toxic release etc., and

also location of assembly points, equipment room, personal protective equipment

room, telephone room, first aid or, emergency control room, main gate, emergency

gates, normal wind direction, north direction.

The same has been given in Chapter No.2; Figure No.2.5 of EIA report

7.10.5 Types of Overall Emergencies

In the risk assessment study section no. 7.3 describes all type of hazards are listed

along with its causes in or near plant. Fire (small and big), explosion, toxic exposure,

strike, storm, flood and other hazardous possible situations shall be described with

reasons. Sources of hazard from outside or neighboring plants, tanks, structure etc.

shall be mentioned.

Table 7.12: Types of Emergencies

Sr.

No.

Type of emergency

including disaster

(Major Class)

May arise due to

At (Place)

People and area

likely to be

affected

1 Fire

Methanol spillage or

leakages at storage tank

Leakages: Pipeline

carrying Methanol

Storage area of

raw materials

Plant Operator,

Labors, workers

Admin staff


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7.39

Sr.

No.

Type of emergency

including disaster

(Major Class)

May arise due to

At (Place)

People and area

likely to be

affected

2 Explosion

Failure of the safety

valve/pressure relief

valve, corrosion of

critical parts of the

boiler, or low water

level.

Boiler and

Thermic Fluid

Heater

3 Release of Toxic

Gas/Vapour

Leakages from

tank/pipes/valves

Tank farm

area, process

area

4 Spillage of flammable liquid

/gas

Loading and unloading Tank farm

area, process

area

5 Deliberate Sabotage,

Terrorism, Air Raid etc.

‐ ‐

6 Natural Calamities: ‐

Lightening, Storm,

Earthquake, Flood etc.

‐ ‐

7 Collapsing of structure

Overturning of tanker

containing flammable /

toxic substances

‐ ‐

7.10.6 Assessment of In‐plant Hazards

Detailed hazard assessment of in‐plant and control measures provided in section

no.7.3 & 7.4 of EIA report. Storage Hazards and Controls, Process Hazards and

Controls are described in same topic.

7.10.7 Emergency Control System:

A. Emergency Organizations and Functions

The organizational set‐up necessary for chain of commands during emergency situation,

which may arise in the premises. The system is described in following Subsections.

Organizational Set‐up


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7.40

Members of above teams will be available during all shifts and holidays. Protective

equipment, lifting gears, fire control points etc.; will be provided in sufficient numbers

and their locations will be well informed. Necessary vehicles will be kept ready to shift

persons 'in case of emergency.

B. Emergency Control Room (Safety officer room)

The place identified as Emergency Control Center is considered as safety officer room..

The facilities available at the Emergency Control Center shall include:

i. Internal Telephone& External Telephone:

Address and Telephone numbers of the Factory Inspectorate, Gujarat Pollution

Control Board, Police, Fire Brigade, Hospitals and OEP Team Members

ii. Manual Fire/Emergency Siren

iii. Siren Actuation Switch

iv. Important Address and Telephone Numbers

v. Emergency Vehicles

vi. Confined Space Entry Procedure

vii. List of Antidote/actions to be taken in case of hazardous chemical/materials.

viii. Material Safety Data Sheets of chemicals

ix. A copy of On‐Site Disaster Management Plan

x. Plant layout‐indicating storage of hazardous materials, layout of fire

Hydrants/extinguishers, entrances/exits, roads etc.

xi. Portable P.A. System, Manual Siren, flood lights, Torches, Pickaxe, Saw, Nylon

Ropes.

xii. Fire Blankets / Fire Proximity Suit, Breathing Apparatus, First Aid Box etc.

Plant Manager

EHS/Safety Officer

SupervisorPlant Chemist

Director

Skilled workers Security staff


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7.41

xiii. List of employees with address, telephone number, blood group etc.

All communications after General Shift working hours and on Sundays/ Holidays are

to be routed through the Security Gate Office.

C. On – site facilities for emergency control

Fire Emergency: Trained personnel will be employed in all the shifts. The responsibilities

and duties include:

To fight the fire with available internal firefighting equipment and to stop leakage of

liquid etc.

To provide personal protective equipment to the team.

To cordon the area and inform incident controller or site main controller about the

development of emergency.

To train the persons (essential workers) to use personal protective equipment and

fire‐fighting equipment.

D. Fire Fighting Facilitiesto be provided on ‐ site:

1. Fire Buckets / Fire Extinguishers

Fire buckets and portable fire extinguishers will be provided in all the areas depending

upon the specific needs of the area. Some spare equipment will also be maintained in

the inventory at an identified fire & safety equipment store.

2. Fire Alarm Sirens

It will be provided to alert all the employees inside the premises about the situation of

an emergency.

3. Sand Buckets

5 nos. of sand buckets will be provided within the industrial premises in case of

emergency fire.

4. Oxygen Cylinder

Oxygen cylinder will be provided for emergency.

5. Safety Equipment

All types of personnel protective safety equipment required for handling the emergency

will be arranged in the proposed unit. Some of the protective equipment is as follow:

o Canister/Cartridge type masks

o Dust Masks

o PVC suits, Aprons

o Safety showers/ Eye Wash fountains

o Other personnel protective appliances, like safety glasses, gumboots, helmets, hand

gloves, face shields, safety belts, safety ladders, safety torches, blankets.


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6. Details of fire extinguishers

Table 7.13: Details of Fire Extinguishers

Sr. No. Type Capacity Qty.*

1. Jockey Pump 250 RPM 1

2. Dry Chemical Powder 2 Kg. 15 Nos.

3. Capacity CO2 type Fire Extinguisher 3 Kg 10 Nos

4. Water storage tank (For Fire) 1. 5 KL 01 Nos

Note: * Quantity of is assumed, however these number of cylinders may changes

after commissioning of project

E. Assembly Points:

The assembly points for gathering workers / Admin staff is fixed and clearly marked as

per the wind direction on plant layout as well as on site. In case of emergency some

locations are considered as Assembly Points. Depending on the wind direction and

location of emergency, Assembly Point is declared. The employees should run across the

wind direction and not against the wind direction.

F. Medical Arrangement:

First Aid Boxes will be provided at various strategic locations. Requisite number

employees will be trained about First Aid, Liaison with nearest hospitals.

Antidotes

Antidotes for Methanol

Ethanol (30 % solution from inside, 5 % solution from outside i.e. by intravenous

injection)

Epicake syrup

In case of acidosis give sodium bicarbonate

In case of delirium give diazepam 10 mg by intravenous injection

Folinic acid (leucovorin 1 mg/kg iv, 4 hourly)

Antidotes for Formaldehyde

Milk

Activated Charcoal or Water


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Antidotes for Phenol

Polyethylene glycol 300 or 400

Activated Charcoal and 240 ml Milk

7.10.8 General Procedures and Responsibilities:

Mock drill: Mock drills will be carried out regularly to familiarize the staff with their

roles, fire protection equipment/system installed in the plant and use of personnel

protective equipment. Senior officials

Wind Socks: Wind direction will be determined with the help of installed windsocks.

Procedure on Noticing an Emergency

If anybody notices any situation, which may lead to a disaster, should be

immediately inform the Shift In‐charge / site controller / Incident Controller / Fire &

Safety Supervisor / Security.

Take charge of the situation as Incident Controller.

Rush to the site of emergency to get the correct picture and then to Emergency

Control Center for speedy control over the situation by making an arrangement for

raising the alarm.

On arrival of Team members, he shall assign duties as required and activate the On‐

Site Emergency Plan.

Ensure safety of the plant and the personnel in the plant. He will make an

assessment of the emergency and decide on external assistance.

Communicate and Coordinate among the Incidents Controller/ Site Controller/

Factory manager/ fire safety supervisor etc. and is final authority on all matters

related with management of emergency such as:

Firefighting Welfare and rescue operations.

Arrange for Civil/Mechanical/Electrical work during emergency.

Transport.

EHS/Safety Officer & Security staff:

Rush immediately to the scene of the fire/emergency, select and set out appropriate

fire/emergency equipment. He will take the below mentioned actions at the earliest

opportunity, if the fire/emergency is not controlled.


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He will

Call the security personnel from their residences for additional manpower if

required.

Regulate entry and exit of personal required for controlling the fire/emergency.

Restrict exit of personal required for controlling the fire/emergency.

Arrange for Personnel Protective Equipment required for the emergency.

Call, the local Fire Brigade, Police in case of necessity in consultation with the

Incident controller.

Arrange transport facilities for removal of causalities to dispensary / hospital.

Take responsibility of law and order.

Keep detailed records of the incident and progress of operations to fight the

emergency.

Factory manager:

He will rush to the Emergency Control Centre and collect the information from the Incident

Controller. Further he will,

Announce the location of the Assembly Point after getting information from Incident

Controller / site controller.

Take the list of persons to be communicated internally and externally.

Maintain liaison with the press, government agencies i.e. Police, Fire Brigade etc.

and the neighborhood regarding the emergency under instructions from Incident

Controller.

Courteously Receive officers from the State Government or neighbors to the

Administration Block only and inform to Incident Controller that they can be taken

care off.

Take all the steps required for the welfare such as providing tea, snacks, emergency

temporary Medical Center in consultation with the incident controller/site

controller.

Disclose all the necessary information in the plant and media so as to avoid rumors

and Confusion.

Also be responsible for the head counts at the Assembly Points.

Supervisor/ shift in charge & security:

Proceed to the scene; establish contact with firemen and incident controller to

supplement efforts in fire fighting.

Assist in searching casualties and help to remove them to the medical center.


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Organize outside assistance in fire fighting and rescue operations if required.

Mobilize personal protective equipment and safety appliances and assist

personnel handling emergency in using them.

Keep and check on any new development of unsafe situation and report the

same to Site Main Controller.

Effectively cordon off the emergency area and will prevent unauthorized people

entering the scene.

Permit the Fire tenders or Ambulance requisitioned by Incident Controller to the

plant.

Ensure that vehicles and trolleys are sent out of the plant premises.

Ensure that all the employees are conducted out of plant and assembled at

Assembly Point.

Control Traffic Movement. Remove tankers, tanker drivers outside.

Entry of unauthorized public to be prevented.

Arrange for vehicles for shifting casualties and essential workers to safe assembly

points.

Collect and preserve evidence to facilitate future inquiries.

7.11 Offsite Emergency Preparedness Plan

Offsite emergency plan would follow the onsite emergency plan. When the

consequences of an emergency situation go beyond the plant boundaries, it

becomes an offsite emergency.As the off‐site emergency plan is to be prepared by

the Government, a Central Control Committee or Group shall be formed under the

Chairmanship of the area head. For example we assume a district structure and

District Collector (is the Chairman of the District Control Committee (DCC). Other

officers from police, fire, factory, medical, engineering, social welfare, publicity,

railway, telephone, transport and requisite departments shall be incorporated as

members.

However, the plant management will provide the public administration with the

technical information relating to the nature, quantum and probable consequences

on the neighboring population. The offsite plan in detail is based on those events,

which are most likely to occur, but other less likely events, which have severe

consequence, will also be considered. Incidents which have very severe

consequences yet have a small probability of occurrence would also be considered

during the preparation of the plan.

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Voluntary Organizations:Details of organizers, telephone numbers, resources etc.

Fuel Information:Details of the hazardous substances stored and a summary of the risk

associated with them.

Meteorological Information:Arrangements for obtaining details of weather forecasts and

weather conditions prevailing at that time

Humanitarian Arrangements:Transport, evacuation centres, emergency feeding, treatment

of injured, first aid, ambulances and temporary mortuaries.

Public Information: Arrangements for (a) Dealing with the media press office; (b) Informing

relativesAssessment of Emergency Plan

Arrangements for: Collecting information on the causes of the emergency; and Reviewing

the efficiency and effectiveness of all aspects of the emergency plan.

Role of the Emergency Co‐ordinating Officer

The various emergency services would be coordinated by an Emergency Coordinating

Officer (ECO), who is designated by the District Collector. The ECO would liaison closely with

the Factory Manager/Safety officer. The ECO has been equipped with address and phone

numbers of important agencies.

a. Role of the Local Authority

The duty to prepare the offsite plan lies with the local authorities. The emergency

planning officer (EPO) appointed should carry out his duty in preparing for a whole range

of different emergencies within local authority area. This liaison should ensure that plan

is continually kept up to date. It is responsibility of the EPO to ensure that all those

organizations which has been involved offsite in handling the emergency, know of their

role and are able to accept it by having for example, sufficient staff and appropriate

equipment to cover their particular responsibilities. Rehearsals for offsite plans should

be organized by the EPO.

b. Role of Police

Formal duties of the police during an emergency include protecting life and property and

Controlling traffic movements. Their functions should include controlling bystanders,

evacuating the public, identifying the dead and dealing with casualties, and informing

relatives of death or injury.


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c. Role of Fire Authorities

The control of a fire should be normally the responsibility of the senior fire brigade

officer who would take over the handling of the fire from the site incident controller on

arrival at the site. The senior fire brigade officer should also have a similar responsibility

for other events, such as explosions. Fire authorities in the region should be appraised

about the location of all stores of flammable materials, water and foam supply points,

and firefighting equipment. They should be involved in onsite emergency rehearsals

both as participants and, on occasion, as observers of exercises involving only site

personnel.

d. Role of Health Authorities

Health authorities, including doctors, surgeons, hospitals, ambulances and so on, should

have a vital part to play following a major accident, and they should form an integral

part of the emergency plan. For major fires, injuries should be the result of the effects of

thermal radiation to a varying degree, and the knowledge and experience to handle this

in all but extreme cases may be generally available in most hospitals.

Major off site incidents are likely to require medical equipment and facilities additional

to those available locally, and a medical "mutual aid” scheme should exist to enable the

Assistance of neighboring authorities to be obtained in the event of an emergency.

e. Role of Government Safety Authority

This will be the factory inspectorate available in the region. Inspectors are likely to

satisfy themselves that the organization responsible for producing the offsite plan has

made adequate arrangements for handling emergencies of all types including major

emergencies. They may wish to see well documented procedures and evidence of

exercise undertaken to test the plan. In the event of an accident, local arrangements

regarding the role of the factory inspector will apply. These may vary from keeping a

watch, to a close involvement in advising on operations.

Table 7.14: Offsite Action Plan

Sr.

No.

Action Required to be taken to

Mitigate Disaster by Aid giving

agency

Responsible

Agencies for

Taking action

Equipment/Material facilities

required at site to mitigate

Emergency

A

1

Arrangements for evacuation

Rescueof personsfrom zoneof

influence to predetermined camps

Police

Department

Self‐Breathing apparatus

With spare cylinder


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Sr.

No.



agency

Responsible

Agencies for

Taking action



Emergency

2 Caution to public by announcement

Chemical gas mask with

sparecanister

Vehicle with PA system

Transportation for evacuation

of people

3 Traffic control by cordoning of the

area

4 Law & order

5 Request to railway authority for

Keeping the nearest railway gate

open & to stop the trains at the

nearest railway station

B Control of fire District Fire

Brigade

Self‐breathing apparatus with

spare cylinders

Foam /water fire tenders

Gas mask with spare canisters

Limewater

Neck to toe complete Asbestos

suit, PVC hand gloves,

gumboots, safety goggles

Mobile scrubbing system

Along with suction

arrangement.

1 Scrubbing of the flashed off gas

Cloud with water curtain

2 To rescue trapped persons

3 If fire is big, keep surrounding

Area cool by spraying water

4 Communication to State

Electricity Board to continue or

cut off electric supply

5 Communication to water supply

Department for supplying water

C Medical facilities for affected

Persons (first aid and treatment)

Hospital and

Public health

Ambulance with on board

resuscitation unit, first aid,

stretchers

D Identification of concentration of

Gas in zone of influence

Pollution

Control Board

Gas detector

E Removal of debris and damaged

structures

Municipal

corporation

Provide bulldozers

Provide cranes

F

1

Monitor the incoming and out

Going transports

Transport

department

Provide traffic police at site

Provide emergency shifting

vehicles at site

Provide stock of fuel for

vehicles.

2 Arrange emergency shifting of

affected persons and non

Affected per son to specified area

3 Arrange diesel/petrol for needed

vehicles

G

1

Give all information related to

Meteorological aspects for safe

Meteorological

Department

Provide wind direction and

velocity instruments with


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Sr.

No.



agency

Responsible

Agencies for

Taking action



Emergency

handling of affected area for living

beings

temperature measurements

2 Forecast important weather

changes,ifany

Mobile van for Meteorological

parameter measurements

H

1

Representatives of all

Departments are in the local crisis

group; therefore they are

expected to render services

available with them. Since It is a

group of experts with authority,

the mitigating measures can be

implemented speedily. The

representatives from locals are

also there so that communication

with local people is easy and quick.

Local Crises

Group

Must have all resources at hand,

specially disaster management

plan and its implementation

method.

All relevant information

Related to hazardous industry

with crisis group Newspaper

editor shall be a part of the

group so that right and timely

media release can be done

2 The district emergency or

Disaster control officer/collector

shall be the president and he shall

do mockdrill etc. so that action can

be taken in right direction in time

I

1

Collector shall be the President

Of District Crisis Group therefore all

district infrastructure facilities are

diverted to affected zone

District Crisis

Group

All necessary facilities

Available at district can be made

available at affected zone

Control of law and order

situation 2 All other functions as mentioned

For local crisis group

chapter - 7 additional studies -...

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