M/S. TRIDEV INDUSTRIES

Transcription

RISK ASSESSMENT STUDY REPORT
FOR
M/S. TRIDEV INDUSTRIES
Plot No. D-2/CH/134, GIDC Industrial Estate, Dahej,
Taluka: Vagra - 392130, Dist.: Bharuch, Gujarat.
PREPARED BY
BHAGWATI ENVIRO CARE PVT. LTD.
[ISO 9001, ISO 14001 & OHSAS: 18001 CERTIFIED COMPANY]
CORPORATE OFFICE
28, 29, 30, Parmeshwar Estate II, Opp. AMCO Bank,
Phase I, GIDC Estate, Vatva, Ahmedabad – 382445. Gujarat, India
Phone No: +91 79 29295043, 40083051/52 Fax: +91 79 40083053
, Email: [email protected] , [email protected]
URL: www.bhagwatienviro.com Risk Assessment Study Report of
Tridev Industries at
Plot No.D-2/CH/134, GIDC Estate, Dahej, Ta – Vagra, Dist –Bharuch, Gujarat.
INDEX
Sr. No.
Chapter
Page No.
1.
Introduction
240
2.
Risk Assessment Process
243
3.
Basic Environment
249
4.
Storage & Handling of Hazardous
274
Chemicals
5.
Various Hazards & its control
281
6.
Health & safety measures
286
7.
Occupational health scheme for the
289
workers
8.
Risk Reduction Measures
290
9.
Fire Fighting system
293
10.
Hazards Identification, major hazards &
294
Damage criteria
11.
Risk Analysis & Consequence analysis
308
Prepared By M/s. Bhagwati Enviro Care Pvt Ltd.
239 Risk Assessment Study Report of
CHAPTER: 1
INTRODUCTION
M/s. Tridev Industries has decided to start manufacturing activity of “various kinds of
Resins” at Plot. No. D-2/CH/134, GIDC Estate, Dahej, Ta – Vagra, Dist- Bharuch,
Gujarat.
As a manufacturer, the management’s objective is to build confidence among their
customers by regular and reliable supplies at competitive prices and consistent quality,
complying with their technical requirements.
Company’s purpose is to build a comprehensive range of products for each specific
market segment with the objective to be the most reliable manufacturer in the market.
The company is intending to start proposed manufacturing facility by new products which falls
under Category “B” of Project Activity 5(f) – ‘Synthetic Organic Chemicals Industry’ of EIA
Notification issued in September – 2006. For this the unit needs environmental clearance from
Ministry of Environment & Forests. New Delhi.
As per the TOR no. 24 of the said letter, the Risk Assessment with following emphasis is
required to be carried out:
Purpose
The purpose of this risk assessment is to evaluate the adequacy of the proposed products and
raw materials which is used as raw material to ink, Paint and coating industries. This risk
assessment provides a structured qualitative assessment of the operational environment. It
addresses sensitivity, threats, vulnerabilities, risks and safeguards. The assessment
recommends cost-effective safeguards to mitigate threats and associated exploitable
vulnerabilities.
Scope
The scope of this risk assessment assessed the system’s use of resources and controls
(implemented or planned) to eliminate and/or manage vulnerabilities exploitable. This Risk
Assessment Report evaluates the confidentiality (protection from unauthorized disclosure of
system and data information), integrity (protection from improper modification of information),
and availability (loss of system access) of the system. Recommended security safeguards will
allow management to make decisions about security-related initiatives.
Mission
The production plant of resin manufacturing is basically used as raw material for the production
of ink, Paint and coating industries.. Proposed project will require some chemical like
Cyclohexanone, Formaldehyde, Xylene, N –Butryaldehyde, Butanol, etc. our main aim to focus
the entire plant to estimate the risk assessment of all hazardous chemical and try to avoid some
consequences accident in internal premises of surrounding area of production plant.
Geographical Information of Project Site
Latitude
: 21O 43' 34. 428 ’’ N
Longitude : 72O 37' 17. 472 ” E
LOCATION MAP OF THE COMPANY ON GOOGLE MAP
Layout Plan
CHAPTER :2
RISK ASSESSMENT PROCESS
RISK ASSESSMENT Identification analysis and assessment of hazard and risk are very useful in providing
information to risk management. It provides basis for what should be type and capacity
of its on-site and off-site emergency plan also what types of safety measures are
required. Risk and consequence analysis is carried out considering storage and
handling of various hazardous raw materials, intermediates and product as well as
manufacturing process.
This section details the risk assessment process performed during this effort. The process is
divided into pre-assessment, assessment, and post assessment phases.
PHASE I – PRE-ASSESSMENT
Step 1: Define the Nature of the Risk Assessment
This initial risk assessment provides an independent review to help Centers for Disease Control
and Prevention (CDC) determine the appropriate level of security required for the system to
support the development of a System Security Plan for intermediate chemical resin plant. The
risk assessment is based on interviews, documentation and, as necessary, some automated
technical review.
Step 2: Data Collection
The data collection phase included identifying and interviewing key personnel within the
organization and conducting document reviews. Interviews focused on the operating
environment. Document reviews provided the risk assessment team with the basis on which to
evaluate compliance with policy and procedure.
Step 3: Templates
The following templates were used by the risk assessment team and are
included in the appendices:
•
Security Baseline Worksheet:
Completed by the analysts using information extracted from questionnaires and interviews.
•
Risk Calculation Worksheet:
Converts the raw vulnerabilities into risks based on the following methodology:
•
Risk Mitigation Worksheet:
Lists the risks and the associated recommended controls to mitigate these risks for the
Business Steward to review.
PHASE II – ASSESSMENT
Step 1: Document Review
The assessment phase began with the review of documents provided by the members of the
various Resin manufacturing system team. Detailed interviews with members of the CDC
Resins manufacturing system team allowed completion of the system questionnaire and
identification of specific threats inadequately identified in the Enterprise Threat Statement.
Step 2: System Characterization
In this step, the analyst defined the boundaries of the IT system, along with the resources that
constitute the system, its connectivity, and any other elements necessary to describe the
system. Dependencies were clarified. Sensitivity of the system and data was discussed in the
final section of the characterization.
Step 3: Threat Identification
Through the interview process, it also identified “most likely” system and location-specific
threats.
Step 4: Vulnerability Identification
In this step, the risk assessment team developed a list of system vulnerabilities (flaws or
weaknesses) that could be exploited by the potential threat vectors.
Step 5: Risk Determination (Calculation/Valuation)
In this step, the risk assessment team determined the degree of risk to the system. In some
cases, a series of vulnerabilities combined to create the risk. In other cases, a single
vulnerability created the risk. The determination of risk for a particular threat source was
expressed as a function of the following:
•
•
•
•
•
Likelihood Determination:
The following governing factors were considered when calculating the likelihood of the
probability that a potential vulnerability might be exploited in the context of the associated
threat environment:
Threat source motivation and capability
Nature of the vulnerability
Existence and effectiveness of current controls
The following table defines the likelihood determinations.
Table1. Likelihood Definition
Level
Likelihood Definition
High
The threat source is highly motivated and sufficiently capable, and
controls to prevent the vulnerability from being exercised are
ineffective.
Moderate
The threat source is motivated and capable, but controls are place
that may impede successful exercise of the vulnerability.
Low
The threat source lacks motivation or capability, or controls are in
place to prevent, or at least significantly impede, the vulnerability
from being exercised.
Impact Analysis:
The next major step in measuring level of risk was to determine the adverse impact resulting
from successful exploitation of vulnerability. The adverse impact of a security event can be
described in terms of loss or degradation of any, or a combination of any, of the following three
security goals:
•
Loss of Confidentiality – Impact of unauthorized disclosure of sensitive information (e.g.,
Privacy Act).
•
Loss of Integrity – Impact if system or data integrity is lost by unauthorized changes to
the data or system.
•
Loss of Availability – Impact to system functionality and operational effectiveness.
Table 2. Impact Definition
Magnitude
of Impact
High
Impact Definition
Exercise of the vulnerability (1) may result in the highly costly loss of
major tangible assets or resources; (2) may significantly violate, harm,
or impede an organization’s mission, reputation, or interest; or (3) may
result in human death or serious injury.
Moderate
Exercise of the vulnerability (1) may result in the costly loss of tangible
assets or resources; (2) may violate, harm or impeded an
organization’s mission, reputation, or interest; or (3) may result in
human injury.
Low
Exercise of the vulnerability (1) may result tangible assets or
resources; (2) may organization’s mission, reputation, or interest.
in the loss of some noticeably affect an
•
Risk Determination:
The following were used to assess the level of risk to the IT system:
•
•
•
The likelihood of a given threat source’s attempting to exercise a given vulnerability.
The magnitude of the impact should a threat-source successfully exercise the
vulnerability.
The adequacy of planned or existing security controls for reducing or eliminating risk.
The following table provides a definition for the risk levels. These levels represent the degree or
level of risk to which an IT system, facility, or procedure might be exposed if a given vulnerability
were exercised.
Table 3. Risk Level Definition
Magnitude
of Impact
Risk Level Definition
High
There is a strong need for corrective measures. An existing system may
continue to operate, but a corrective action plan must be put in place as soon
as possible.
Moderate
Corrective actions are needed and a plan must be developed to incorporate
these actions within a reasonable period of time.
Low
The system’s Authorizing Official must determine whether corrective actions
are still required or decide to accept the risk.
Step 6: Risk Mitigation Recommendations:
During this step of the process, controls that could mitigate or eliminate the identified risks, as
appropriate to the organization’s operations, were provided. The goal of the recommended
controls is to reduce the level of risk to the IT system and its data to an acceptable level. The
risk assessment team considered the following factors when recommending controls and
alternative solutions to minimize or eliminate identified risks:
•
•
•
•
•
•
Sensitivity of the data and the system
Effectiveness of recommended options
Legislation and regulations
Organizational policy
Operational impact
Safety and reliability
PHASE III – POST ASSESSMENT
Risk Mitigation
The elimination of all risk is usually impractical, senior management and business stewards
should assess control recommendations, determine the acceptable level of residual risk, and
implement those mitigations with the most appropriate, effective, and highest payback.
CHAPTER :3
BASIC ENVIRONMENT
Details of Products: No.
Name of Product
Total Quantity
MT/MONTH
01
Drying of Ketonic Resin
100
02
Drying of poly Vinyl Butyl Resin
50
03
Printing Ink & Coatings
300
04
Ketonic Resin
250
05
Polyamide Resin
100
06
Maleic Resin
100
07
Poly Vinyl Butyl Resin
100
08
Adhesion Permoter (TA-10)
50
09
MF Resin
100
10
Water Based Additive
200
Total
1350
NAME OF BY – PRODUCT:
No.
Name of By Product
Total Quantity
MT/MONTH
01
Turpentine (From Maleic Resin)
2.0
PROPERTIES OF PRODUCTS Name of the Products State B.P. º C Sr. No. Drying of Ketonic Solid Resin 1 2 Main Properties (refer MSDS) Flash Point º C LEL UEL % TLV ppm or mg/m3 LD50 mg/kg NA 95 > 149 NA NA NA NA 105‐
125 300 F ND NA 10000 mg/kg Rat NA NA NA NA NA ND Drying of Poly Vinyl Solid Butyl Resin 3 Printing Coatings 4 Ketonic Resin Solid NA 95 >149 NA NA NA 5 Polyamide Resin Solid NA NA NA NA NA NA Solid 100‐
110 NA NA NA NA NA NA 105‐
125 300 F ND NA 10000 mg/kg Rat NA NA 30 NA NA NA NA >200 F NA 0.75 ppm 500 mg/Kg NA NA >100 C NA NA NA 6 Maleic Resin ink& M.P. º C Liquid 7 Poly Vinyl Resin 8 Adhesion Permoter Liquid (TA‐10) 9 Powde
r MF Resin Water Additive 10 Butyl Solid Based Liquid Prepared By M/s. Bhagwati Enviro Care Pvt Ltd.
Sr.
No.
1
2
Full Name of the
Products
State
Main Properties (refer MSDS)
Pressure
mm/Hg
Drying of Ketonic
Resin
Drying
Vinayl
of
Solid
poly
Temp
ºC
Ambient
Ambient
Ambient
Ambient
Ambient
Specific
Gravity
Vapour
Density
Odour
Threshold
(water =1)
(air
1)
ppm
or
mg/m3
¾ 1
=
NA
NA
NA
NA
NA
Ambient
--
NA
NA
Solid
Butyl Resin
3
Printing
Coatings
4
Ketonic Resin
Solid
Ambient
Ambient
>1
NA
NA
5
Polyamide Resin
solid
Ambient
Ambient
0.97
NA
NA
6
Maleic Resin
Solid
Ambient
Ambient
NA
NA
NA
7
Poly Vinyl Butyl
Resin
Solid
Ambient
Ambient
NA
NA
NA
8
Adhesion
Permotor(Ta-10)
Liquid
Ambient
Ambient
0.98
NA
NA
Ambient
Ambient
0.6-0.7
NA
NA
Ambient
Ambient
NA
NA
NA
9
10
Ink&
MF Resin
Water
Additives
Liquid
Powder
Based
Liquid
PACKING AND FINAL APPLICATION OF PRODUCTS & BY-PRODUCTS
Sr. No
1
2
Name of proposed
Product
Drying of Ketonic Resin
Type of
Packing
25 kg Paper bag
3
Drying of poly Vinyl Butyl 10 kg Paper bag
Resin
Printing Ink & Coatings
15 kg Drum
4
Ketonic Resin
15 Kg Paper bag
5
Polyamide Resin
20 Kg Paper bag
6
Maleic Resin
25 kg Paper bag
7
Poly Vinyl Butyl Resin
10 Kg Paper bag
8
Adhesion Permoter(TA-10
9
MF Resin
200 kg HDPE
Drum
25 kg Paper bag
10
Water Based Additive
200 kg Drum
Final application of
Product
Ink, paint & coating
industries
NAME AND QUANTITY OF RAW MATERIAL CONSUMPTION
Sr. No. Name of product Capacity TPM 1 Drying of Ketonic Resin Drying of poly Vinyl butyrl Resin Printing Ink & Coating 100 Wet Ketonic resin 50 Wet Poly Butyl Resin Vinyl 1.176 58.8 300 4 Ketonic Resin 250 5 Polyamide Resin 100 6 Maleic Resin 100 7 Poly Vinyl Butyl Resin 100 8 Adhession Permoter (TA‐10) 50 Dry Pigment Solvent Varnish Additives Cyclohexanone Formaldehyde Caustic Soda Dimmer Amine Fatty Acid Xylene Gum Rosin Fumeric acid Penta erythritol Poly Vinyl alcohol n‐Butryaldehyde Additives Acetyl aceton t‐Iso propyl titanate Additives Melamine Formaldehyde Butanol Xylene Butyl acrylate Methyl acrylic acid Acrylic acid Vinyl acetate 0.15 0.4 0.4 0.05 0.7737 1.1315 0.05 0.5806 0.339 0.113 0.032 0.800 0.125 0.125 0.75 0.4 0.08 0.53 0.4 45 120 120 15 193.425 282.875 12.5 58.06 33.9 11.3 3.2 80.0 12.5 12.5 75 40 8 26.5 20 0.07 0.219 0.756 0.405 0.081 0.367 0.0128 0.0285 0.19 3.5 21.9 75.6 40.5 8.1 73.4 2.56 5.7 38 2 3 9 M F Resin 10 Water additives 100 based 200 Name of R.M. Raw Material Consumption MT /MT of MT per product Month 1.176 117.6 Prepared By M/s. Bhagwati Enviro Care Pvt Ltd.
DIbutyl maleate Additives 0.0928 0.022 18.56 4.4 CHEMICAL NAME & PHYSICAL FORM OF RAW MATERIAL:
Cyclohexanone
Physical
Form
Liquid
Container
Type
Tank
MOC of
container
SS 304
Formaldehyde
Formaldehyde
Liquid
Tank
HDPE
Sodium Hydroxide
solid
Bags
HDPE
4.
Caustic soda
Flakes
Dimmer
------
Liquid
Tank
SS
5.
Amine
------
Liquid
Tank
HDPE
6.
Fatty acid
Carboxylic Acid
Liquid
Tank
HDPE
7.
Xylene
xylene
Liquid
Tank
HDPE
8.
Gum Rosin
Rosin
solid
Drum
HDPE
9.
Fumeric acid
(E)-Butenedioic acid
solid
Bags
HDPE
10.
Penta Erythritol
solid
Bags
HDPE
11.
solid
Bags
HDPE
12.
Poly vinyl
Alcohol
n- Butaldeyade
n- Butaldeyade
Liquid
Tank
HDPE
13.
Acetyl acetone
2,4-Pentanedione
Liquid
Tank
HDPE
14.
t-Iso propyl titrate
Liquid
Tank
HDPE
15.
t-Iso propyl
titrate
Melamine
solid
Bags
HDPE
16.
Butanol
1,3,5Triazine2,4,6
triamine
Butanol
Liquid
Drum
HDPE
17.
Butyl acrylate
Butyl acrylate
Liquid
Tank
HDPE
18.
Methyl acrylic acid
Methacrylllic Acid
Liquid
Drum
HDPE
19.
Acrylic acid
Prop-2-enoic acid
Liquid
Drum
HDPE
20.
Vinyl acetate
Vinyl Acetate
Liquid
Tank
HDPE
21.
DIbutyl maleate
DIbutyl maleate
Liquid
Drum
HDPE
No.
1.
Name of Raw
Material
Cyclohexanone
2.
3.
Chemical Name
-----Ethanolhomo polymer
PROPERTIES OF RAW MATERIAL
1. Cyclohexanone :
01
Full Name of Raw
Material
:
Cyclohexanone
02
State
:
Liquid
No. of Containers & Size
MS Tank
03
No.
:
01
04
MT
:
10 KL
:
Keep container in cool ,well ventilated areas
Storage Parameters
05
Pressure kg /cm2
:
Atm
06
Temp 0C
:
Ambient
07
Boiling Point
:
155 0C
08
Flash Point
:
43.880 C
09
LEL , UEL %
:
LEL:1.1%
UEL:9.4 %
10
TLV ppm or mg /NM3
:
Not Available
11
LD50 mg /Kg,
:
1516 mg /Kg (Oral – Rat)
12
Specific Gravity (water
= 1)
:
0.9478
13
Vapor Density (Air =
1)
:
3.24
14
Odour Threshold ppm
or mg /NM3
:
0.88 ppm
2. Formaldehyde:
01
Full Name of Raw Material
:
Formaldehyde
02
State
:
Liquid
MS Tank
03
No.
:
01
04
MT
:
10 KL
:
Keep away from heat, flame and
oxidizer
Pressure kg /cm2
:
Atm
Temp 0C
:
Ambient
Boiling Point
:
960C
Flash Point
:
600C
LEL , UEL %
:
LEL :7 %
UEL :73 %
Storage Parameters
3.
4.
05
5.
6.
7.
06
8.
9.
07
10.
11.
08
12.
13.
09
14.
3
3
10
TLV ppm or mg /NM
:
1.5 mg/m
11
LD50 mg /Kg,
:
800 mg /Kg (Oral – Rat)
12
Specific Gravity (water = 1)
:
1.038
13
Vapor Density (Air = 1)
:
NA
14
Odour Threshold ppm or mg
:
2 PPM
3
/NM
3. Sodium Hydroxide:
01
:
Sodium hydroxide
02
State
:
Solid
HDPE bags
03
No.
:
100
04
MT
:
2.5
:
keep in cool dry well ventilated places
Storage Parameters
05
Pressure kg /cm2
:
Atm
06
Temp 0C
:
Ambient
07
Boiling Point
:
318.4 0C
08
Flash Point
:
NP
09
LEL , UEL %
:
NP
10
TLV ppm or mg /NM3
:
2 mg/m3
11
LD50 mg /Kg,
:
NL
12
:
2.12
13
:
NA
14
Odour Threshold ppm or
mg /NM3
:
Odorless
4. Dimmer
01
:
Dimmer
02
State
:
Liquid
Tank
03
No.
:
1
04
MT
:
10
:
Keep tightly closed
ventilated place
Storage Parameters
05
Pressure kg /cm2
:
Atm
06
Temp 0C
:
Ambient
07
Boiling Point
:
NA
08
Flash Point
:
NA
09
LEL , UEL %
:
NA
10
TLV ppm or mg /NM3
:
NA
11
LD50 mg /Kg
:
NA
12
:
NA
13
:
NA
14
/NM3
:
Odorless
in
dry
well
5. Amine
01
Full Name of Raw
Material
:
Amine
02
State
:
Liquid
Drum
03
No.
:
25
04
MT
:
0.2
:
Store in original container in locked storage
areas
Storage Parameters
05
Pressure kg /cm2
:
Atm
06
Temp 0C
:
Ambient
07
Boiling Point
:
214 0F
08
Flash Point
:
1250F
09
LEL , UEL %
:
NL
10
TLV ppm or mg /NM3
:
NA
11
LD50 mg /Kg,
:
NA
12
Specific Gravity (water
= 1)
:
1.16
13
Vapor Density (Air =
1)
:
>1
14
Odour Threshold ppm
or mg /NM3
:
NA
6. Fatty Acid ;
01
:
Fatty acid
02
State
:
Liquid
Drum
03
No.
:
10
04
MT
:
200 Kgs x 10 drum = 2.0 Mt
:
Store in accordance with local regulation. Store
in original
Protected from direct sunlight in a dry, cool,
well ventilated
area
Storage Parameters
05
Pressure kg /cm2
:
Atm
06
Temp 0C
:
Ambient
07
Boiling Point
:
>300
08
Flash Point
:
185
09
LEL , UEL %
:
NA
10
TLV ppm or mg /NM3
:
10 mg/m3
11
LD50 mg /Kg,
LC50 mg /L
:
4640mg /Kg
12
:
NA
13
:
NA
14
/NM3
:
NA
7. Rosin:
01
:
Rosin
02
State
:
Solid
Bags
03
No.
:
200
04
MT
:
25 kgs x 200 bags = 5.0 MT
:
Keep Container tightly closed, keep container in
cool, well
-ventilated area
Storage Parameters
05
Pressure kg /cm2
:
Atm
06
Temp 0C
:
Ambient
07
Boiling Point
:
NA
08
Flash Point
:
187
09
LEL , UEL %
:
NA
10
TLV ppm or mg /NM3
:
NA
11
LD50 mg /Kg,
:
3805 mg /Kg
12
Specific Gravity (water =
1)
:
1.06-1.07
13
:
NA
14
mg /NM3
:
odorless
8. Polyvinyl Alcohol :
01
:
Polyvinyl alcohol
02
State
:
Powder
Bags
03
No.
:
100
04
MT
:
25 kgs x 100 bags = 2.5 MT
:
Store in cool dry well –ventilated place
area
Storage Parameters
05
Pressure kg /cm2
:
Atm
06
Temp 0C
:
Ambient
07
Boiling Point
:
NA0C
08
Flash Point
:
79 0C
09
LEL , UEL %
:
NA
10
TLV ppm or mg /NM3
:
NA
11
LD50 mg /Kg,
:
14700 mg /Kg
12
:
1.19-1.31
13
:
NA
14
/NM3
:
NA
9. Xylene :
01
:
Xylene
02
State
:
Liquid
Drum
03
No.
:
5
04
MT
:
200 Kgs x 05 drum = 1000 Kgs
:
Storage in well ventilated, dry area, away from
heat, flame
And oxidizing materials
Storage Parameters
05
Pressure kg /cm2
:
Atm
06
Temp 0C
:
Ambient
07
Boiling Point
:
1400C
08
Flash Point
:
1870C
09
LEL , UEL %
:
NA
10
TLV ppm or mg /NM3
:
100 PPM
11
LD50 mg /Kg,
:
4300mg /Kg
12
:
0.864
13
:
NA
14
mg /NM3
:
NA
10. Fumeric Acid :
01
:
Fumeric Acid
02
State
:
Solid
Drum
03
No.
:
10
04
MT
:
200 Kgs x 10 drum = 2000 Kgs
:
Keep container dry, keep in a cool
place
Storage Parameters
05
Pressure kg /cm2
:
Atm
06
Temp 0C
:
Ambient
07
Boiling Point
:
NA
08
Flash Point
:
NA
09
LEL , UEL %
:
NA
10
TLV ppm or mg /NM3
:
NA
11
LD50 mg /Kg,
:
10700 mg /Kg
12
:
1.635
13
:
NA
14
/NM3
:
NA
11. N Butryaldehyde ;
01
:
N- Butryaldehyde
02
State
:
Liquid
Drum
03
No.
:
50
04
MT
:
200 Kgs x 50 Nos. = 10 MT
:
Protect cylinder from physical
damage
Storage Parameters
05
Pressure kg /cm2
:
Atm
06
Temp 0C
:
Ambient
07
Boiling Point
:
75.6o C
08
Flash Point
:
-10.15 o C
09
LEL , UEL %
:
NA
10
TLV ppm or mg /NM3
:
11
LD50 mg /Kg,
:
NA
12
:
0.803
13
:
2.48
14
Odour Threshold ppm or mg /NM3
:
NA
12. Butanol
01
:
Butanol
02
State
:
Liquid
Drum
03
No.
:
5
04
MT
:
200 Kgs x 5 drums = 1000 Kgs
:
Store in cool in a dry, cool, well ventilated
area, away from heat and frame
Storage Parameters
05
Pressure kg /cm2
:
Atm
06
Temp 0C
:
Ambient
07
Boiling Point
:
117.7 o C
08
Flash Point
:
36.1
09
LEL , UEL %
:
LEL:1.4%
UEL:11.2%
10
TLV ppm or mg /NM3
:
50 ppm
11
LD50 mg /Kg,
:
790 mg /Kg
12
:
0.81
13
:
2.55
14
/NM3
:
2.5ppm
13. Butyl Acrylate:
01
:
Butyl Acrylate
02
State
:
Liquid
Drum
03
No.
:
5
04
MT
:
200 Kgs x 05 Nos. = 1000 Kgs
:
Store in a cool, dry, well ventilated,
away from heat, frame,
Oxidizer materials
Storage Parameters
05
Pressure kg /cm2
:
Atm
06
Temp 0C
:
Ambient
07
Boiling Point
:
148.8o C
08
Flash Point
:
48.80C
09
LEL , UEL %
:
NA
10
TLV ppm or mg /NM3
:
10 ppm
11
LD50 mg /Kg,
:
900 mg /Kg
12
:
0.899
13
:
4.42
14
:
NA
14. Acetyl Acetone
01
:
Acetyl Acetone
02
State
:
Liquid
Drum
03
No.
:
5
04
MT
:
200 Kgs x 05 Nos. – 1.0 Mt
:
Keep tightly closed, keep away from
heat
Storage Parameters
05
Pressure kg /cm2
:
Atm
06
Temp 0C
:
Ambient
07
Boiling Point
:
136o C
08
Flash Point
:
38o C
09
LEL , UEL %
:
LEL:1.7%
UEL;11.2%
10
TLV ppm or mg /NM3
:
NA
11
LD50 mg /Kg,
:
55mg /Kg
12
:
NA
13
:
3.5
14
:
NA
15. T- Iso Propyl Titanate
01
:
T- Iso Propyl Titanate
02
State
:
Liquid
Drum
03
No.
:
5
04
MT
:
200 Kgs x 05 = 1000 Kgs
:
Keep away from heat, keep away from
source of ignition
Storage Parameters
05
Pressure kg /cm2
:
Atm
06
Temp 0C
:
Ambient
07
Boiling Point
:
163 0C
08
Flash Point
:
77 0C
09
LEL , UEL %
:
LEL-1.6%,
UEL-8.1%
10
TLV ppm or mg /NM3
:
NA
11
LD50 mg /Kg,
:
2600mg /Kg
12
:
0.82
13
:
3.18
14
/NM3
:
NA
16. Methacrylic Acid
01
:
Methacrylic Acid
02
State
:
Liquid
Drum
03
No.
:
5
04
MT
:
200 Kgs x 05 Nos. = 1000 Kgs
:
Store in metallic or coated fiber board
drum
Storage Parameters
05
Pressure kg /cm2
:
Atm
06
Temp 0C
:
Ambient
07
Boiling Point
:
163 0C
08
Flash Point
:
77 0C
09
LEL , UEL %
:
LEL:1.6%
UEL-8.1%
10
TLV ppm or mg /NM3
:
NA
11
LD50 mg /Kg,
:
1060mg /Kg
12
:
1.015
13
:
2.97
14
:
NA
17. Acrylic Acid :
01
:
Acrylic acid
02
State
:
Liquid
Drum
03
No.
:
5
04
MT
:
200 Kgs x 05 Nos. = 1000 Kgs
:
Keep container cool, well ventilated
area, keep container
Tightly closed
Storage Parameters
05
Pressure kg /cm2
:
Atm
06
Temp 0C
:
Ambient
07
Boiling Point
:
141 0C
08
Flash Point
:
50 0C
09
Melting Point
:
14 0C
10
LEL , UEL %
:
NA
11
TLV ppm or mg /NM3
:
NA
12
LD50 mg /Kg
:
1060 mg /Kg
13
:
1.05
14
:
2.97
15
:
0.092
18. Vinyl Acetate :
01
:
Vinyl acetate
02
State
:
Liquid
Drum
03
No.
:
5
04
MT
:
200 Kgs x 05 = 1000 Kgs
:
Store in a cool, dry and wellventilated area, away from heat,
flame, and oxidizing agent
Storage Parameters
05
Pressure kg /cm2
:
Atm
06
Temp 0C
:
Ambient
07
Boiling Point
:
730C
08
Flash Point
:
-50C
09
LEL , UEL %
:
LEL -2.6%
UEL-13.4%
10
TLV ppm or mg /NM3
:
10 ppm
11
LD50 mg /Kg,
:
2920 mg /Kg
12
:
0.934
13
:
3.0
14
:
0.12ppm
CHAPTER: 4
STORAGE AND HANDLING OF HAZARDOUS CHEMICALS The properties of the important raw materials and the safety precautions to be taken to
prevent an accident are detailed in ‘Material Safety Data Sheets’ and described in
Chapter: 02.
The details of storage of Hazardous chemicals along with measures taken during
storage are given in Table.
HAZARDOUS CHEMICALS
Details of raw material, which are termed as Hazardous Chemicals as per Manufacture,
Storage and Import of Hazardous Chemical (Amendment) Rules 2000 are given in the
below table
Toxicity details of raw materials are given in the below Table.
TABLE
DETAILS OF HAZARDOUS CHEMICALS
Hazardous
Chemicals
Reference
The Manufacturer, Storage & Import
of Hazardous chemical Rules 1989
Maximum
Quantity to be
Stored at a
time
Threshold
Storage quantity
in MT as per
schedule 3 for
application
Rules 10-12
Cyclohexanone
Sr.No. 162 (part II, Sch 1 of MSIHCR,
1989
19.5 MT
---
Formaldehyde
1989
37 MT
---
Caustic Soda
1989
0.5 MT
---
STORAGE FACILITY OF RAW MATERIAL
Sr.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Name of Raw
Material
Container
Type
MOC
Container
Physical form
Max.
Storage
Capacity
in MT
At a time
storage
in MT
Cyclohexanone Formaldehyde Caustic Soda Dimmer Amine Fatty Acid Xylene Gum Rosin Fumeric Acid Penta Erythritol Poly Vinyl Alcohol N – Butryaldehyde Acetyl Acetone T – Iso propyl titanate Melamine Butanol Butyl Acrylate Methyl Acrylic Acid Tank
Tank
Bags
Tank
Tank
Tank
Tank
Drum
Bags
Bags
Bags
Tank
Tank
Tank
Bags
Drum
Tank
Drum
SS 304
HDPE
HDPE
SS
HDPE
HDPE
HDPE
HDPE
HDPE
HDPE
HDPE
HDPE
HDPE
HDPE
HDPE
HDPE
HDPE
HDPE
Liquid
Liquid
solid
Liquid
Liquid
Liquid
Liquid
solid
solid
solid
solid
Liquid
Liquid
Liquid
solid
Liquid
Liquid
Liquid
25 40 3 16 1 1 1 10 1 1 20 16 1 1 5 10 20 1 19.5 37 0.5 5 0.2 0.2 0.2 2 0.1 0.1 10 5 0.2 0.2 10 10 20 5 Acrylic Acid Vinyl Acetate Di Butyl Maleate Drum
Tank
Drum
HDPE
HDPE
HDPE
Liquid
Liquid
Liquid
5 20 10.0 5 20 20.0 Prepared By M/s. Bhagwati Enviro Care Pvt Ltd.
Sr. No. 1 Name of R.M. Cyclohexanone Place of Its storage State Operating Pressure, Temp. Possible Type of hazards Storage Tank Norma( Liquid) at RT
Flammable Normal(Liquid) at RT
Skin sensitivity, SS 304 2 Formaldehyde Storage Tank HDPE Control measures provided Fire extinguisher, double earthing, bonding on flange joint, level indicator, flame proof fitting, water shower etc. provided. Wear gloves, goggles, gas mask, closed system Suspected 3 Caustic Soda RM Storage Normal(Solid) at RT 4 Dimmer Yard/bags RM Storage Normal (Liquid) Carcinogen Skin sensitivity None Wear gloves, goggles, gas mask, closed system Use Rubber gloves goggles Yard/SS Storage tank RM Storage at RT Normal (Liquid) Irritant Wear gloves, Safety goggles, dust mask 5 Amine 6 Fatty Acid Yard/Storage tank RM Storage at RT Normal (Liquid) None Use Rubber gloves &goggles Xylene Yard/Storage tank RM Storage at RT Normal (Liquid) Flammable Yard/Storage tank at RT RM Storage Normal(Solid) at RT Fire existingusher, double Earthing, bonding on flange joint, level indicator, flame proof fitting, water shower etc Wear Gloves ,safety goggles, dust mask 7 8 Gum Rosin None Yard/ drum Prepared By M/s. Bhagwati Enviro Care Pvt Ltd.
9 Fumeric Acid RM Storage Normal(Solid) at RT Irritant Wear gloves, safety goggles, dust mask 10 Penta Erythritol Yard/bags RM Storage Normal(Solid) at RT Irritant Wear gloves, Safety goggle, dust mask 11 Poly Vinyl Alcohol Yard/bags RM Storage Normal(Solid) at RT None Use Rubber gloves 12 N – Butryaldehyde Yard/bags RM Storage Normal (Liquid) Flammable Yard/Storage tank at RT RM Storage Normal (Liquid) None Fire extinguisher, double earthing, bonding on flange joint, level indicator, flame proof fitting, water shower etc Use Rubber gloves & goggles Yard/Storage tank RM Storage at RT Normal (Liquid) None Use Rubber gloves & goggles Yard/Storage tank Bags at RT Normal (Powder) Toxic Wear gloves, goggles, gas mask, closed system 13 Acetyl Acetone 14 T – Iso propyl titanate 15 Melamine at RT 16 Butanol Drum Normal (Liquid) Non flammable Flammable at RT 17 Butyl Acrylate Tank Normal (Liquid) Flammable Monomer Non Flammable Non Flammable 18 Methyl Acrylic Acid Drum at RT Normal (Liquid) 19 Acrylic Acid Drum at RT Normal (Liquid) 20 Vinyl Acetate Tank at RT Normal (Liquid) Flammable at RT monomer Fire extinguisher, double earthing, bonding on flange joint, level indicator, flame proof fitting, water shower etc Wear gloves, goggles, gas mask ,closed system Wear gloves, goggles, gas mask ,closed system Wear gloves, goggles, gas mask ,closed system Fire extinguisher, double earthing , bonding on flange joint, level indicator, flame proof fitting, Prepared By M/s. Bhagwati Enviro Care Pvt Ltd.
Di Butyl Maleate 21
Drum
Normal (Liquid) Flammable at RT monomer water shower etc
Fire extinguisher, double earthing , bonding on flange joint, level indicator, flame proof fitting, water shower etc
SAFETY PRECAUTIONS DURING STORAGE OF CHEMICALS Storage & Handling of Hazardous Chemicals:
•
•
•
•
•
•
•
•
Company will do planning to stock all the necessary material as
minimum as possible.
All containers with hazardous chemicals have labels indicating
the contents and warning of the hazard.
Necessary information on safe handling and first aid measures
and antidotes of major hazardous material will be available on
the label.
Workers dealing with hazardous chemicals will be trained on
health risks and safe handling.
Exposure to hazardous chemicals will be minimized.
Liquid Hazardous chemicals will be transferred in closed
piping system.
Separate storage section will be provided for storage of
hazardous and non-hazardous raw materials.
Flame arrestors are provided to all hazardous storage
equipment.
Vessel and other Equipment related:
•
•
Checking of process vessels and equipment will be carried out
regularly.
Records related to maintenance and its planning schedule will
be maintained.
Fire related
• Overhead water storage tank with adequate capacity will be
provided to ensure 24 hr. supply.
• Fire water tank with sufficient capacity of 100 KL will be
provided with fire pump (02 Nos.). One no. being diesel
operated pump and another is operated by power.
• Fire hydrant piping will be provided with water ring man
covering all individuals’ plants and tank farms.
• Adequate hydrant points will be provided at specific locations.
• Sprinkler system will be provided over hazardous area.
•
•
•
•
•
•
•
•
•
•
•
Emergency power supply to EMS and also for storage tanks
will be ensured.
Fire extinguisher will be provided. Contact numbers of nearest
fire agency will be provided.
Electrical related
All electrical fitting and motors in the tank farm areas will be
flameproof.
Checking of all earthings, wiring & connection will be carried
out regularly.
Proper earthing will be provided at all equipments.
Adequate Nos. of earth pits will be provided.
Lighting arrestors will be provided at peak points.
Safety related
Adequate types of personal protective equipment will be
provided. And also safety training will be provided to workers.
Emergency showers and eye wash stations will be available at
the worksite.
Arrangement for 24 hr. medical facilities by contact with
nearest health care centre/ hospital.
Pre-employment medical check-up and annual medical check
up will be carried out and its records will also properly
maintained.
Monitoring of occupational hazards like noise, ventilation,
chemical exposure etc. will be carried out regularly and its
records will be maintained.
CHAPTER: 5
VARIOUS HAZARDOUS & ITS CONTROL
Sr. No. 1 Name of R.M. Cyclohexanone Place of Its storage State Operating Pressure, Temp. Possible Type of hazards Storage Tank Norma( Liquid) at RT
Flammable Fire extinguisher, double earthing, bonding on flange joint, level indicator, flame proof fitting, water shower etc. provided. Normal(Liquid) at RT
Skin sensitivity, Wear gloves, goggles, gas mask, closed system SS 304 2 Formaldehyde Storage Tank HDPE Suspected Control measures provided Carcinogen 3 Caustic Soda RM Storage Normal(Solid) at RT Yard/bags 4 Dimmer 5 Amine 6 Fatty Acid 7 Xylene RM Storage Normal (Liquid) Yard/SS Storage tank at RT RM Storage Normal (Liquid) Yard/Storage tank at RT RM Storage Normal (Liquid) Yard/Storage tank at RT RM Storage Normal (Liquid) Skin sensitivity Wear gloves, goggles, gas mask, closed system None Use Rubber gloves goggles Irritant Wear gloves, Safety goggles, dust mask None Use Rubber gloves &goggles Flammable Fire existingusher, double Earthing, bonding on flange Prepared By M/s. Bhagwati Enviro Care Pvt Ltd.
8 Gum Rosin Yard/Storage tank at RT joint, level indicator, flame proof fitting, water shower etc RM Storage Normal(Solid) at RT None Wear Gloves ,safety goggles, dust mask Normal(Solid) at RT Irritant Wear gloves, safety goggles, dust mask Normal(Solid) at RT Irritant Wear gloves, Safety goggle, dust mask Normal(Solid) at RT None Use Rubber gloves Flammable Fire extinguisher, double earthing, bonding on flange joint, level indicator, flame proof fitting, water shower etc None Use Rubber gloves & goggles None Use Rubber gloves & goggles Toxic Wear gloves, goggles, gas mask, closed system Yard/ drum 9 Fumeric Acid RM Storage Yard/bags 10 Penta Erythritol RM Storage Yard/bags 11 Poly Vinyl Alcohol RM Storage Yard/bags 12 13 14 15 N – Butryaldehyde Acetyl Acetone T – Iso propyl titanate Melamine RM Storage Normal (Liquid) Yard/Storage tank at RT RM Storage Normal (Liquid) Yard/Storage tank at RT RM Storage Normal (Liquid) Yard/Storage tank at RT Bags Normal (Powder) at RT 16 Butanol Drum Normal (Liquid) at RT Non flammable Flammable Fire extinguisher, double earthing, bonding on flange joint, level indicator, Prepared By M/s. Bhagwati Enviro Care Pvt Ltd.
flame proof fitting, water shower etc 17 Butyl Acrylate Tank Normal (Liquid) at RT 18 19 Methyl Acrylic Acid Acrylic Acid Drum Drum Normal (Liquid) Vinyl Acetate Di Butyl Maleate 21
Tank Drum
Monomer Non Wear gloves, goggles, gas mask ,closed system Wear gloves, goggles, gas mask ,closed system at RT Flammable Normal (Liquid) Non Flammable Wear gloves, goggles, gas mask ,closed system Normal (Liquid) Flammable at RT monomer Fire extinguisher, double earthing , bonding on flange joint, level indicator, flame proof fitting, water shower etc Normal (Liquid) Flammable at RT monomer at RT 20 Flammable Fire extinguisher, double earthing , bonding on flange joint, level indicator, flame proof fitting, water shower etc
TABLE OTHER HAZARDS AND CONTROL SR. NO. ITS SOURCES NAME OF THE & POSSIBLE HAZARD OR REASONS EMERGENCY 1 BOILER Over pressure (1) Burning in the boiler if (2) Physical safety valve injury not working. (3) Explosion Water level indicator not working. Low water level indicator fail. High temp. System fail. 2 ELECTRICITY (1). Burning (2). Fire (3). Shock ITS EFFECTS ON PERSONS, PROPERTY & ENVIRONMENT Minor/Major Injury Loss of human life Loss of property (Loss of Main/ Machine Material) Loose Burning, Shock, Death
Contacts, Weak earthling Short Circuit Improper PLACE OF ITS EFFECT CONTROL MEASURES PROVIDED
Boiler House and surrounding places Lower & Upper Level Indication System provision. Safety valves for pressure control fixed temp. & pressure indicator provided. Blow down & blowing system provided for cleaning tube and shell. Soft water used. Inter locking provided on pumps, FD fan, ID fan. Periodical checking & inspection maintenance done. Yearly inspection done by Boiler Inspector Surrounding the accident area Proper Earthing, Periodical Checking of joints, proper insulations of Equipments, etc. Flame proof fitting in solvent storage area, bounding and jumpers to all solvent barrier lines provided. Prepared By M/s. Bhagwati Enviro Care Pvt Ltd.
Insulation 3 Bad House Physical / Chemical Thermal HOUSE Burn Injury (Major / Minor) KEEPING keeping (1). Physical (2). Buring (3) Fire (4) Chemical Exposure In all surrounding areas i.e. Storage, Plants Proper Handling, regular cleaning, Proper placement of material (RIGHT THING AT THE RIGHT PLACE) 4 PIPE LINE Leakages of Physical / Chemical Thermal pipe line due Burn Injury (Major / Minor) LEAKAGES Spillages to corrosion, etc. Loose contact (1) Corrosion etc. (2) Toxic gas release Plant area Proper maintenance, Proper Selection of Material for pipe lines, Immediate attention, Earthing provided, flame proof fitting, NO SMOKING Boards displayed. Prepared By M/s. Bhagwati Enviro Care Pvt Ltd.
CHAPTER: 6
HEALTH & SAFETY MEASURES
For handling hazardous chemicals and to take care of employees’ health, M/s. Tridev
Industries shall adopt a practice of preventive and predictive maintenance looking to the
nature of hazardous chemicals being handled / processed. All the equipments in the
plant areas shall be inspected/ tested by an outside agency.
The various safety equipments like breathing apparatus and critical instrumentation
provided on various equipments will be inspected and tested frequently to ensure their
operability all the time. Besides, all the first aid, fire fighting devices shall also be
inspected, tested and maintained by a competent third party and kept all the time in
ready to use condition.
Health of all the employees in plant area shall regularly monitor by outside physician. If
any abnormality shall found necessary treatment shall be given. Necessary history
cards, records will be maintained and up-dated time to time.
Some of the safety measures shall carry out by M/s. Tridev Industries. to ensure
prevention of occupational hazards is delineated below.
¾ Flameproof equipments and fittings will be provided for handling of hazardous
chemicals.
¾ Tanks and all pump motors shall be earthed.
¾ Road tanker earthing lines shall provide near the unloading pumps.
¾ Independent dykes will provide for hazardous chemicals storage to contain
leakages. Floors of the dyke area shall of impervious finish.
¾ Housekeeping of the plant shall as per prescribed norms. Floors, platforms,
staircases, passages will be kept free of any obstruction.
¾ All hazardous operations shall explain to the workers. They will periodically
trained on the hazardous processes.
¾ Dedicated supply of firewater shall available in the plant.
¾ Only authorized persons shall be allowed inside the plant.
¾ All instrument and safety devices will be checked and calibrated during
installation. They will also be calibrated, checked at a frequent interval.
Calibration records shall maintain.
¾ All electrical equipments will be installed as per prescribed standards.
¾ All the equipments of the plant shall periodically tested as per standard and
results shall documented. All equipments undergo preventive maintenance
schedule.
¾ The area will fence to isolate the same from all other departments.
¾ Proper Earthing will be provided to each tank. Also earthing would be taken care
during solvent transfer from tanker into the underground vessel.
¾ Flame arrestors shall provide on each tank.
¾ Flameproof pumps & motors shall provide for solvent transfer.
¾ D.G. Set will be available which can supply power in case of grid power failure.
¾ In addition to fire hydrant system, nos. of fire extinguishers will be installed at
different locations within premises.
¾ Adequate ventilation arrangement shall provide for safe and better working in the
plant as per the standard.
¾ Process, equipments, plant involving serious fire hazards are designed as per
prescribed guideline.
¾ Sufficient access for firefighting shall provide in the plant.
¾ Protection against lightning will be taken care in the plant.
¾ Precautions against ignition will be taken.
ANTIDOTES OF CHEMICALS
Sr. No.
Name of Chemical
Antidotes
1
Formaldehyde
Milk, Activated Charcoal or
water
2
Caustic Soda Lye (48%)
Apply Water
3
Xylene
Wash the skin area plenty of
water if affected. Fresh air or
Oxygen, 0.1 mg/kg slowly
through injection rest in bed.
Don’t apply Epinefrin, Ifridin
etc.
Don’t
apply
milk,
vegetable oil or alcohol.
4
Sodium Hydroxide
Wash with plenty of water if
eyes or skin is affected.
Do not give chemical antidotes
because it increases heat and
injury with reaction. Do not
induce vomiting.
Milk, Lemon Water or milk of
magnesia can be given.
5
Xylene
Skin is affected then washes
with plenty of water. Administer
Oxygen in case of breathing
operation.
Diazepam 0.1 mg /Kg, bed rest.
CHAPTER: 7
OCCUPATIONAL HEALTH SCHEME FOR THE WORKERS
M/s. Tridev industries shall carry out following occupational health scheme for workers; •
Personal protective equipment such as safety shoes, safety goggles, hand gloves, gum boots, safety helmet, air line mask, Breathing Apparatus set kit have been given to each workers & staff and additional PPE’s are kept in all related area, Fire fighting facilities, etc.. •
Safety awareness training programmes are arranged regularly for staff & contractor workers working in the factory premises. •
On site – Off site emergency plan shall be available. •
Medical Examination as per GFR guidelines •
Work Permit system procedure shall be adopted. Prepared By M/s. Bhagwati Enviro Care Pvt Ltd.
CHAPTER: 8
RISK REDUCTION MEASURES
TRAINING AND EDUCATION OF EMPLOYEES:
Safety awareness training programmes are arranged regularly and safety-training
programme are also arranged for workers & staff working in the factory premises.
M/s. Tridev Industries shall give training on the following subjects;
¾ Accident Prevention Technique
¾ Basic fire fighting
¾ Use of Respiration PPE
¾ Handling of Hazardous chemicals
¾ First Aid program
¾ Breathing Apparatus practical programme
¾ General safety regulation
¾ Work Permit system
¾ Electrical safety
¾ On site emergency plan training
¾ MSDS Awareness
Once in a month workmen shall be grouped together & practical classes shall be held to train
them how to operate various types of fire extinguisher to wear the mask, SCBA apparatus, use
of cylinder handling kits. Usefulness of each part of the chlorine kits is also explained. Fire dill is
also conducted regularly. Personal protective equipment such as safety shoes, safety
googles, hand gloves, gum boots, safety helmet have been given to each workers &
staff.
RISK REDUCTION MEASURES:
Design:
•
Plant operator and staffs shall be selected well experience and qualified for
chemical plant operation.
•
All key personals shall be trained for emergency handling procedures and regular
Mock Drills will be conducted on various scenarios.
•
At design stage adequate care shall be taken for design, selection, fabrication,
erection and commissioning of facilities and other equipment piping, pipe fittings,
electrical equipment etc.
Safety Devices at Storage Tanks:
•
Level gauge on storage tank.
•
Static bonding of pipeline flanges.
•
Dyke wall shall be provided above ground storage tank.
•
Safety valve rupture and other venting system will be provided on pressure
storage vessels.
•
All pumps shall be provided flame proof type and double mechanical seal type.
•
All pipeline and tanks shall be painted as per IS color code.
•
Caution note and material identification, capacity will be displayed on all storage
tanks.
Safety at Pumps:
•
Required outlet valve and NRV provided on pump outlet.
•
Modular fire extinguisher shall be provided near of most of pumps.
•
FLP type and mechanical seal type pump will be installed for flammable
chemicals.
Safety at Pipelines:
•
Jumper connections on flanges to prevent build up of static electricity
charge.
•
Proper supports and clamping are provided.
•
Double earthing provided to all electrical motors.
•
Color code as per IS standard will be maintained.
Safety during Operation & maintenance:
•
Periodic testing of hoses for leakages and continuity.
•
Earthing of all plant equipment and earthing of all vehicles of vehicles
under unloading operation.
•
Annual testing of all safety relief valves.
•
Planned preventive maintenance of different equipment of their safety and
reliable operations.
•
•
Strict compliance of safety work permits system.
•
Proper maintenance of earth pits.
Periodic training and refresher courses to train the staff in safety, fire fighting and
first aid.
CHAPTER: 9
FIRE FIGHTING SYSTEM
M/s. Tridev Industries. Will take into consideration fire prevention measures during the
project expansion planning to avoid any outbreak of fire. But looking to the hazardous
nature of process and the chemicals that are handled and processed, the chances of
outbreak of fire cannot be totally ignored. Hence to tackle such a situation a good well
laid fire protection system will be provided in the factory.
Overhead water tank storage capacity: 50 KL
Underground water tank storage capacity: 50 KL
No. of Fire Sand Storage: 25 No.
The unit will provide fire extinguishers based on probability and type of fire hazards at
strategic locations. The unit will install approximately 25 fire extinguishers (Dry
powder type) to tackle the fire hazards of Class A, B & C at different levels of the
plant.
The unit will also provide fire protection arrangements in the form of fixed water spray
system (1 No.) and fire hydrant systems (2 Nos.) to tackle any fire emergency arising
due to storage of hazardous chemicals.
CHAPTER: 10
HAZARDS IDENTIFICATION, MAJOR HAZARDS & DAMAGE
CRITERIA
HAZARDS IDENTIFICATION:
Hazard is defined as a chemical or physical condition that has a potential of causing
damage to the people, property or the environment. Hazard identification is the first step in
the risk analysis and entails the process of collecting information on:
•
•
•
•
The types and quantities of hazardous substances stored and handled,
The location of storage tanks & other facilities,
potential hazards associated with the spillage and release of hazardous
Chemicals.
Hazard is the associated term with material, which is a measure or the likely hood of the
damage to human working with, or studying the material in question. The potential
hazard and major risks associated with the plant will be identified using Hazard &
operability study (HAZOP).
MAJOR HAZARDS:
A brief description of the following hazards generally encountered in handling hazardous
chemicals is given in the section.
•
•
•
•
•
•
•
Pool Evaporation
Vapor Cloud Explosion
Vapor Cloud Dispersion
Pool Fire
Jet Fire
BLEVE
Toxic Release
Pool Evaporation
If the fluid, which escapes from containment, is a liquid, then vaporization must occur before
a vapor cloud is formed. The rate at which vaporization takes place determines the
formation of such a vapor clouds.
Vaporization scenarios
Vaporization can occur when there is a leak in any of the following situations:
a) A liquid at atmospheric temperature and pressure.
b) A liquid under pressure and above normal boiling point. The rates of vaporization of the
liquid are different for each of the two cases. In the case
•
•
The liquid after spillage is approximately at equilibrium and evaporates relativity
slowly.
In the case, the liquid flashes off when released, and the liquid remaining then
undergoes slow evaporation.
(I) Evaporation of a liquid at atmospheric temperature and pressure.
Evaporation from a pool of liquid is essentially a mass transfer process that depends on the
vapor pressure of the liquid, wind velocity across the surface of the pool and ambient
weather condition.
A spillage of this kind constitutes a steady continuous source of vapor. Unless the rate of
evaporation due to the combination of vapor pressure and wind velocity is high enough, it is
usually assumed that the heat transfer from the air and the ground is sufficient to provide
the latent heat of vaporization.
(II) Evaporation of a liquid under pressure and above normal boiling point
When a pressurized liquid is released from containment a portion flashes off. This heat is
obtained by cooling the remaining liquid to its boiling point thus reaching a state of
equilibrium from the high in equilibrium prevalent immediately on loss of containment. In
practice, it frequently happens that there is a significant amount of spray formation caused
by the sudden release of pressure and the violent boiling of liquid. This spray vaporizes
rapidly by taking heat for vaporization from air. This spray liquid formation is assumed to
equal to the gas fraction generated by flash. The proportion of liquid airborne is thus
considerably high. Following flashing, the residual liquid is at its boiling point. Vaporization
then continuous by gaining heat from surrounding as an essentially heat or mass transfer
limited process. This secondary stage of rate limited vaporization is usually relatively less
important compared with the flash off, particularly with respect to formation of flammable
gas clouds.
Vapor Cloud dispersion
Following a continuous leak and formation of gas cloud, if cloud does not ignite it undergoes
atmospheric dispersion in accordance with the prevalent wind direction, speed and stability
category. The objective of carrying out analysis of cloud dispersion is two fold. First, it
provides the distance (from the leak) at which the concentration of flammable material falls
below the lower flammability limit (LEL). Second it provides the concentration of the toxic
substance to which people may be exposed for short time, at varying distance (from the
leak).
Vapor cloud Explosion
Release of energy in a rapid and uncontrolled manner gives rise to explosion. Identified
locations having explosion hazards shall in tank farm and storage area (warehouse).
Extra care shall be taken by providing rupture disc, Pressure release valve, and
temperature controller. In addition to that Fire and explosion hazard will identified as
catastrophic failure of storage tanks in solvent storage yard.
Explosion is a sudden and violent- release of energy which may be in the form of physical
energy or chemical energy. In case where a major leak continues from some time without
ignition a substantial mass of the gas from a vapor of cloud which on finding a source of
ignition may result in an vapor cloud explosion (VCE) before a cloud is diluted to the
concentration below the lower explosion limit in air. The explosion will cause overpressure
resulting in to damage to the surrounding area.
Pool fire
Since the Stone Age term 'fire' is associated with fear. It is very dangerous if occurs in
uncontrolled manner. It should be clearly understood that when a liquid is used having
flash point below the normal ambient temperature, it could, in suitable circumstances,
liberate a sufficient quantity of vapour to give rise to flammable mixtures with air.
Following an accidental release, chemicals will form either a confined pool within the bund
area or an unconfined pool. Should the vapor above the pool ignite, the liquid will burn as a
pool fire. The pool fire will result in thermal radiation. It cloud also damage all the storage
tanks within the confined area of the dyke. In the present study, impact distances for various
scenarios have been calculated.
Jet fire
After a minor or major loss of containment following hardware failure, chemicals which are
stored under high pressure would escape as liquid/ gas spray or jet which undergoes
flashing evaporation and forms a dense flammable gas could in the air. The cloud, which
initially moves forward in the spatial direction of the spray till the kinetic energy, is lost and
gravity slumping of cloud occurs if the gas is heavier than the air. Should the flammable jet
ignite very soon after development of leak? A jet fire will commence. The jet fire could
damage the neighboring tanks by direct flame impingement. It would also cause thermal
radiation in the surrounding area.
Fire Ball / BLEVE
Any fire in the vicinity of storage tank containing a liquefied gas may cause Boiling
Expanding Vapor Explosion (BLEVE). Due to simultaneous increase of pressure as well as
weakening of the material of the vessel because of a fire in the vicinity the tank. It may fail
resulting in release of the entire inventory suddenly and result in a BLEVE and fireball.
BLEVE results in serious thermal radiation to the plant equipment and surroundings.
Damage may also result to the debris of the shattered vessel being thrown about.
The major hazards in the M/s. Tridev Industries. are described below.
•
Toxic hazard due to leakage of hazardous chemicals.
•
Fire hazard due to leakage of flammable chemicals.
•
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.
Toxic hazards
Toxic substances affect in three ways by ingestion, absorption & inhalation. Adequate
provision of safety along with personal protective equipment will be made, breathing
apparatus and emergency kit shall be provided at various locations of the installation.
Corrosion hazards
Corrosion is a chemical reaction-taking place at the surface of metal. Corrosive
chemicals have their typical hazard when it comes in contact with human tissues. Most
corrosive substances will produce chemical burns, while certain chemical produce deep
ulceration. Other has detailing effect on skin and may cause dermatitis. This has also
adverse effects on weakening the strength of material in contact.
M/s. Tridev Industries shall take due care to overcome the hazard. The complete
structure of the manufacturing area shall be painted with special type of anticorrosive
paint. Good quality materials will be used for transferring corrosives. Regular thickness
testing of equipment, pipelines etc. shall carry out to have the exact picture of effect of
corrosion.
Biological hazards
Effluent treatment process involves the biological activities so biological hazard’s can
not be eliminated. The way of biological hazards is by hand to mouth contact during
eating, drinking or by wiping the face with contaminated hands or gloves or by licking
splashes from the skin or by breathing them in, as dust, aerosol or mist. The major
source of biological hazard on site is biological sludge drying bed, filter press, biological
storage sump etc. Practically, complete elimination of biological hazard can not be
possible but it will be reduce by adopting the safe practice guards.
DAMAGE CRITERIA:
Damage estimates due to thermal radiations and overpressure have been arrived at by
taking in to consideration the published literature on the subject. The consequences can
then be visualized by the superimposing the damage effects zones on the proposed plan
site and identifying the elements within the project site as well as in the neighboring
environment, which might be adversely affected, should one or more hazards materialize in
real life.
In consequence analysis, use is made of a number of calculation models to estimate
the physical effects of an accident (spill of hazardous material) and to predict the
damage (lethality, injury, material destruction) of the effects. The calculations can
roughly be divided in three major groups:
a)
Determination of the source strength parameters;
b)
Determination of the consequential effects;
c)
Determination of the damage or damage distances.
The basic physical effect models consist of the following.
Source strength parameters
*
Calculation of the outflow of liquid, vapour or gas out of a vessel or a pipe, in
case of rupture. Also two-phase outflow can be calculated.
*
Calculation, in case of liquid outflow, of the instantaneous flash evaporation and
of the dimensions of the remaining liquid pool.
*
Calculation of the evaporation rate, as a function of volatility of the material, pool
dimensions and wind velocity.
*
Source strength equals pump capacities, etc. in some cases.
Consequential effects
*
Dispersion of gaseous material in the atmosphere as a function of source
strength, relative density of the gas, weather conditions and topographical
situation of the surrounding area.
*
Intensity of heat radiation [in kW/ m2] due to a fire or a BLEVE, as a function of
the distance to the source.
*
Energy of vapour cloud explosions [in N/m2], as a function of the distance to the
distance of the exploding cloud.
*
Concentration of gaseous material in the atmosphere, due to the dispersion of
evaporated chemical. The latter can be either explosive or toxic.
It may be obvious, that the types of models that must be used in a specific risk study
strongly depend upon the type of material involved:
-
Gas, vapour, liquid, solid
-
Inflammable, explosive, toxic, toxic combustion products
-
Stored at high/low temperatures or pressure
-
Controlled outflow (pump capacity) or catastrophic failure?
Selection of Damage Criteria
The damage criteria give the relation between extent of the physical effects (exposure)
and the percentage of the people that will be killed or injured due to those effects. The
knowledge about these relations depends strongly on the nature of the exposure. For
instance, much more is known about the damage caused by heat radiation, than about
the damage due to toxic exposure, and for these toxic effects, the knowledge differs
strongly between different materials.
In Consequence Analysis studies, in principle three types of exposure to hazardous
effects are distinguished:
1. Heat radiation, from a jet, pool fire, a flash fire or a BLEVE.
2. Explosion
3. Toxic effects, from toxic materials or toxic combustion products.
In the next three paragraphs, the chosen damage criteria are given and explained.
Heat Radiation
The consequence caused by exposure to heat radiation is a function of:
2
•
The radiation energy onto the human body [kW/m ];
•
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
Radiation
Duration
1%
for Radiation
lethality 2nd
(kW/m2)
for Radiation
degree first
for
degree
burns, (kW/m2)
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
RADIATION
KW/m2
DAMAGE TO EQUIPMENT
DAMAGE TO PEOPLE
Equivalent to Solar Radiation
0.7
1.2
Solar heat at noon
1.6
***
No discomfort for long exposure ,
2.0
PVC insulated cables damaged
Minimum level of pain threshold
***
4.0
***
Causes pain if duration is longer than
20 secs. But blistering is unlikely.
6.4
***
Pain threshold reached after 8 secs.
Second degree burns after 20 secs.
9.5
Minimum energy to ignite wood
Minimum energy required for piloted
ignition of wood, melting plastic
tubing etc. Pain threshold reached
after 8 sec. second degree burns
after 20 sec.
12.5
With a flame; Melts plastic tubing.
1% lethality in one minute.
First degree burns in 10 secs.
16.0
***
Severe burns after 5 secs.
25.0
Minimum energy to ignite wood at
identifying long exposure without a
flame.
100% lethality in 1 minute.
Significant injury in 10 secs.
37.5
Severe damage to plant
100% lethality in 1 minute.
50% lethality in 20 secs.
1% lethality in 10 secs.
Explosion
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:
FATAL RADIATION EXPOSURE LEVELS:
RADIATION
FATALITY
LEVEL
kW/m2
1%
50%
99%
EXPOSURE IN SECONDS
4.0
150
370
930
12.5
30
80
200
37.5
8
20
50
Damage Due To Overpressures
Peak Overpressure
OVER
PRESSURE
mbar
300
Damage Type
0.83 bar
Total Destruction
0.30 bar
Heavy Damage
0.10 bar
Moderate Damage
0.03 bar
Significant Damage
0.01 bar
Minor Damage
MECHANICAL DAMAGE TO
EQUIPMENTS
DAMAGE TO PEOPLE
1% death from lung damage
>50% eardrum damage
Heavy damage to plant & structure
100
>50% serious wounds from
flying objects
>1% eardrum damage
Repairable damage
>1% serious wounds flying
objects from
30
Major glass damage
10
10% glass damage
Slight injury from flying
glass
***
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 pa will be wounded by mechanical damage. For
the gas cloud explosion this will be inside a circle with the ignition source as its centre.
Intoxication
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.
n
The dose is defined as D = C .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.
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.
Toxic Effects:
The effect of exposure to a toxic substance depends upon the duration of exposure and the
concentration of the toxic substance. Short-term exposures to high concentration give Acute
Effects while long term exposures to low concentrations result in Chronic Effects.
Only Acute Effects are considered under hazard analysis, since they are likely credible
scenarios. These effects are:
a) Irritation (respiratory system skin, eyes)
b) Narcosis (nervous system)
c) Asphyxiation (oxygen deficiency)
d) System damage (blood organs)
Following are some of the common terms used to express toxicity of materials:
TLV: Threshold Limit Value – is the permitted level of exposure for a given period on a
weighted average basis (usually 8 hrs.for 5 days in a week).
STEL: it is permitted Short Time Exposure Limit usually for a 15-minute exposure.
IDLH: Immediately Dangerous To Life & Health
LCLo: Lethal Concentration Low
TCLo: Toxic Concentration Low
CHAPTER: 11
CONSEQUENCE ANALYSIS & RISK ANALYSIS
CONSEQUENCE ANALYSIS In a plant handling hazardous chemicals, the main hazard arises due to storage, handling & use of these chemicals. If these chemicals are released into the atmosphere, they may cause damage due to resulting fires or vapour clouds. Blast Overpressures depend upon the reactivity class of material between two explosive limits. Operating Parameters Potential vapour release for the same material depends significantly on the operating conditions. Especially for any liquefied gas, the operating conditions are very critical to assess the damage potential. If we take up an example of ammonia, if it is stored at ambient temperature, say about 28oC, and then the vapour release potential of the inventory is much higher as compared to the case if it is stored at 0oC. Inventory Inventory Analysis is commonly used in understanding the relative hazards and short listing of release scenarios. Inventory plays an important role in regard to the potential hazard. Larger the inventory of a vessel or a system, larger the quantity of potential release. The potential vapour release (source strength) depends upon the quantity of liquid release, the properties of the materials and the operating conditions (pressure, temperature). If all these influencing parameters are combined into a matrix and vapour source strength estimated for each release case, a ranking should become a credible exercise. Prepared By M/s. Bhagwati Enviro Care Pvt Ltd.
Loss of Containment Plant inventory can get discharged to Environment due to Loss of Containment. Certain features of materials to be handled at the plant need to the clearly understood to firstly list out all significant release cases and then to short list release scenarios for a detailed examination. Liquid release can be either instantaneous or continuous. Failure of a vessel leading to an instantaneous outflow assumes the sudden appearance of such a major crack that practically all of the contents above the crack shall be released in a very short time. The more likely event is the case of liquid release from a hole in a pipe connected to the vessel. The flow rate is depending on the size of the hole as well as on the pressure, which was present, in front of the hole, prior to the accident. Such pressure is basically dependent on the pressure in the vessel. The vaporisation of released liquid depends on the vapour pressure and weather conditions. Such consideration and others have been kept in mind both during the initial listing as well as during the short listing procedure. In the study, Maximum Credible Loss accident methodology is to be used, therefore, the largest potential hazard inventories have been considered for consequence estimation. MAXIMUM CREDIBLE LOSS ACCIDENT SCENARIOS A Maximum Credible Accident (MCA) can be characterised as the worst credible accident. In other words: an accident in an activity, resulting in the maximum consequence distance that is still believed to be possible. A MCA‐analysis does not include a quantification of the probability of occurrence of the accident. Another aspect, in which the pessimistic approach of MCA studies appears, is the atmospheric condition that is used for dispersion calculations. As per the reference of the study, weather conditions having an average wind speed of 2.18 m/s have been chosen. The Maximum Credible Loss (MCL) scenarios have been developed for the Facility. The MCL cases considered, attempt to include the worst “Credible” incidents‐ what constitutes a credible incident is always subjective. Nevertheless, guidelines have evolved over the years and based Prepared By M/s. Bhagwati Enviro Care Pvt Ltd.
on basic engineering judgement, the cases have been found to be credible and modelling for assessing vulnerability zones is prepared accordingly. Only catastrophic cases have been considered and not partial or small failures (as is the case in Quantitative Risk Assessment where contributions from low frequency ‐ high outcome effect as well as high frequency ‐ low outcome events are distinguished). The objective of the study is emergency planning, hence only holistic & conservative assumptions are used for obvious reasons. Hence though the outcomes may look pessimistic, the planning for emergency concept should be borne in mind whilst interpreting the results. CONSEQUENCE ANALYSIS CALCULATIONS The Consequence Analysis has been done for selected scenarios. This has been done for weather conditions having wind speed 2.18 m/s. In Consequence Analysis, geographical location of the source of potential release plays an important role. Consideration of a large number of scenarios in the same geographical location serves little purpose if the dominant scenario has been identified and duly considered. 6.7.3.1 SOFTWARE USED FOR CALCULATIONS Aloha 5.1.1.2 is the most comprehensive software available for performing Process Hazard Analysis (PHA), Quantitative Risk Assessment (QRA) and Financial Risk Analysis (FRA). Our extensively validated software for consequence and risk analysis is used by governments and industry helping them to comply with local safety regulation and their own corporate best practice. Aloha 5.1.1.2 contains all the discharge, dispersion, effects and risk models you will need to accurately assess all your major hazards and associated risks. Aloha 5.1.1.2 Consequence provides you with comprehensive hazard analysis facilities to examine the progress of a potential incident from the initial release to its far‐field effects. Prepared By M/s. Bhagwati Enviro Care Pvt Ltd.
6.7.4 SCENARIOS TABLE ‐ 6.5 POSSIBLE ACCIDENT SCENARIOS AT M/s. Tridev Industries Scenario 1 MCL Scenario
Release of Cyclohexanone
Pressure & Temp.
Stored qty in MT Normal Liq. At Rom 19.5 Temperature 2 Release of Formaldehyde
Normal Liq. At Rom 37 Temperature 3 Release of Xylene Normal Liq. At Rom 0.2 Temperature 4 Release of N – Butryaldehyde
Normal Liq. At Rom 05 Temperature 5 Release of Butanol Normal Liq. At Rom 10 Temperature Prepared By M/s. Bhagwati Enviro Care Pvt Ltd.
1. Release of Cyclohexanone (Pool Fire):
SITE DATA:
Location: Tridev Industries, Plot No. D-2 CH-134, GIDC, Dahej
Building Air Exchanges per Hour: 0.69 (unsheltered double storied)
Time: October 16, 2013 1410 hours MST (using computer's clock)
CHEMICAL DATA:
Chemical Name: CYCLOHEXANONE
Molecular Weight: 98.14 g/mol
PAC-1: 20 ppm
PAC-2: 20 ppm
PAC-3: 5000 ppm
IDLH: 700 ppm
LEL: 13000 ppm
UEL: 94000 ppm
Ambient Boiling Point: 311.2° F
Vapor Pressure at Ambient Temperature: 0.0062 atm
Ambient Saturation Concentration: 6,198 ppm or 0.62%
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)
Wind: 5.55 meters/second from ESE at 3 meters
Ground Roughness: open country
Air Temperature: 27° C
No Inversion Height
Cloud Cover: 5 tenths
Stability Class: D
Relative Humidity: 50%
SOURCE STRENGTH:
Leak from hole in vertical cylindrical tank
Flammable chemical escaping from tank (not burning)
Tank Diameter: 3 meters
Tank Length: 3 meters
Tank Volume: 21.2 cubic meters
Tank contains liquid
Internal Temperature: 27° C
Chemical Mass in Tank: 5,016 kilograms
Tank is 25% full
Circular Opening Diameter: 0.5 inches
Opening is 5 inches from tank bottom
Ground Type: Concrete
Ground Temperature: equal to ambient
Max Puddle Diameter: Unknown
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 2.38 pounds/min
(Averaged over a minute or more)
Total Amount Released: 82.0 pounds
Note: The chemical escaped as a liquid and formed an evaporating puddle.
The puddle spread to a diameter of 10.6 yards.
THREAT ZONE:
Threat Modeled: Flammable Area of Vapor Cloud
Model Run: Gaussian
Red : less than 10 meters(10.9 yards) --- (13000 ppm = LEL)
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
2.
Leak from Formaldehyde Tank:
CHEMICAL DATA:
Chemical Name: FORMALDEHYDE
LEL: 7 ppm
UEL: 73 ppm
Normal Boiling Point: 204.8° F
Note: Not enough chemical data to use Heavy Gas option
No Inversion Height
Stability Class: D
SOURCE STRENGTH:
Direct Source: 100 kilograms/sec
Source Height: 0
Release Duration: 60 minutes
Release Rate: 13,200 pounds/min
Total Amount Released: 793,664 pounds
THREAT ZONE:
Model Run: Gaussian
Red : greater than 6 miles --- (10 mg/(cu m))
Orange: greater than 6 miles --- (10 ppm)
THREAT AT POINT:
Concentration Estimates at the point:
Downwind: 100 meters
Off Centerline: 100 meters
Note: Concentration not drawn because
there is no significant concentration at the point selected.
3. Leak from XYLENE Tank:
CHEMICAL DATA:
Chemical Name: XYLENE
AEGL-1 (60 min): 130 ppm AEGL-2 (60 min): 920 ppm AEGL-3 (60 min): 2500 ppm
LEL: 10000 ppm
UEL: 70000 ppm
Normal Boiling Point: -unavailNote: Not enough chemical data to use Heavy Gas option
No Inversion Height
Stability Class: D
SOURCE STRENGTH:
Direct Source: 100 kilograms/sec
Source Height: 0
Release Duration: 60 minutes
Release Rate: 13,200 pounds/min
THREAT ZONE:
Model Run: Gaussian
Red : 413 yards --- (2500 ppm = AEGL-3 (60 min))
Orange: 729 yards --- (920 ppm = AEGL-2 (60 min))
Yellow: 1.4 miles --- (130 ppm = AEGL-1 (60 min))
4.
Leakages from Butryaldehyde Tank :
CHEMICAL DATA:
Chemical Name: BUTYRALDEHYDE
PAC-1: 0.0014 ppm PAC-2: 0.016 ppm PAC-3: 2.8 ppm
LEL: 19000 ppm
UEL: 125000 ppm
No Inversion Height
Stability Class: D
SOURCE STRENGTH:
Flammable chemical is burning as it escapes from tank
Tank Diameter: 3.0 meters
Tank Length: 3.0 meters
Chemical Mass in Tank: 5000 kilograms
Tank is 30% full
Circular Opening Diameter: 0.5 meters
Opening is 10 inches from tank bottom
Max Flame Length: 30 yards
Burn Duration: 4 minutes
Max Burn Rate: 4,840 pounds/min
Total Amount Burned: 7,937 pounds
Note: The chemical escaped as a liquid and formed a burning puddle.
The puddle spread to a diameter of 31 yards.
THREAT ZONE:
Threat Modeled: Thermal radiation from pool fire
Red : 63 yards --- (10.0 kW/(sq m) = potentially lethal within 60 sec)
Orange: 81 yards --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)
Yellow: 113 yards --- (2.0 kW/(sq m) = pain within 60 sec)
THREAT AT POINT:
Thermal Radiation Estimates at the point:
Downwind: 100 meters
Off Centerline: 100 meters
Max Thermal Radiation: 0.907 kW/(sq m)
5.
Leakages from Tank of Butyl Alcohol: :
CHEMICAL DATA:
Chemical Name: N-BUTYL ALCOHOL
PAC-1: 20 ppm
PAC-2: 50 ppm
IDLH: 1400 ppm
LEL: 17000 ppm
PAC-3: 8000 ppm
UEL: 113000 ppm
No Inversion Height
Stability Class: D
SOURCE STRENGTH:
Flammable chemical escaping from tank (not burning)
Tank Diameter: 2.5 meters
Tank Length: 3.0 meters
Chemical Mass in Tank: 10 tons
Tank is 77% full
Circular Opening Diameter: 0.5 meters
Opening is 1 feet from tank bottom
Ground Type: Default soil
Ground Temperature: equal to ambient
Max Puddle Diameter: Unknown
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 73.5 pounds/min
(averaged over a minute or more)
Note: The chemical escaped as a liquid and formed an evaporating puddle.
The puddle spread to a diameter of 55 yards.
Source Strength of Cyclohexanone:
Source strength – Burn rate of Butryaldehyde:
Thermal Radiation of Butryaldehyde:
Thermal Radiation – Threat Zone of Butryaldehyde:
Toxic Threat Zone of Butanol:
Xylene – Source strength – Release Rate:
Xylene – Direct – Release Rate:
327 Annexure: 02
National Ambient Air Quality Standards
Annexure 2 of M/s. Tridev Industries.
328
Annexure: 02
National Ambient Air Quality Standards
329
Annexure: 03
Drinking Water Quality Standards
DRINKING WATER QUALITY STANDARDS AS PER IS NO. 10500 (1991)
Substance or characteristics
Colour Hazen units
Odour
Taste
Turbidity NTU, Maximum
PH
Total Hardness (as CaCO3) mg/l
Iron (as Fe) mg/l
Chlorides (as Cl) mg/l
Residual Free Chlorine, mg/l
Dissolved Solids, mg/l
Calcium (as Ca) mg/l
Magnesium (as Mg), mg/l
Copper (as Cu), mg/l
Manganese (as Mn), mg/l
Sulphate (as SO4), mg/l
Nitrate (as NO2 mg/l)
Fluoride (as F), mg/l
Phenolic Compound, mg/l
Mercury, mg/l
Cadmium, mg/l
Selenium, mg/l
Arsenic, mg/l
Cyanide, mg/l
Lead, mg/l
Zinc, mg/l
Anionic detergent, mg/l
Chromium (as Cr+6), mg/l
Polynuclear Aromatic Hydrocarbons, mg/l
Mineral Oil, mg/l
Pesticides, mg/l
Radioactive materials
1 Alpha emitters Bq/l
2. Beta emitters Bq/l
Alkalinity, mg/l
Aluminum, mg/l
Boron , , mg/l
Permissible Limit
25
Unobjectionable
Agreeable
10
6.5-8.5
600
1
1000
0.2
2000
200
100
1.5
0.3
400
100
1.5
0.002
0.001
0.01
0.01
0.05
0.05
0.05
5
0.2
0.05
-0.03
0.001
0.1
1
600
0.2
5
330
Annexure: 04
National Ambient Noise Quality standards
NATIONAL AMBIENT NOISE QUALITY STANDARDS
(CENTRAL POLLUTION CONTROL BOARD, INDIA)
Area code
A
B
C
D
Category of areas
Industrial Area
Commercial Area
Residential Area
Silence zone
Leq in db(A)
Day time
Night Time
75
70
65
55
55
45
50
40
Note:
1)
Daytime is reckoned in between 6 am and 10 pm
2)
Night time is reckoned in between 10 pm and 6 am
3)
Silence zone is defined as areas upto 100 meters around such premises
as hospitals, educational institutes and courts. The silence zones are to
be declared by the competent authority.
4)
Mixed categories of areas should be declared as one of the four
above mentioned categories by the competent authority and the
corresponding standards shall apply.
331
Annexure: 05
SSI Certificate
SSI Certificate of M/s. Tridev Industries
332
Annexure: 06
CA Certificate
CA Certificate of M/s. Tridev Industries.
333
Annexure: 07
Undertaking
Undertaking of M/s. Tridev Industries.
334
Annexure: 08
Proof of water supply
Proof of Water supply for M/s. Tridev Industries.
335
Annexure: 09
Land Possession Documents
Land Possession Documents of M/s. Tridev Industries.
336
Annexure: 09
337
Annexure: 09
338
Annexure: 09
339
Annexure: 09
340
Annexure: 09
341
Annexure: 09
342
Annexure: 09
343
Annexure: 09
344
Annexure: 09
345
Annexure: 09
346
Annexure: 09
347
Annexure: 09
348
Annexure: 09
349
Annexure: 09
350
Annexure: 09
351
Annexure: 10
Treatability Study Report
Treatability Study Report of M/s. Tridev Industries.
352
Annexure: 10
353
Annexure: 10
354
Annexure: 10
355
Annexure: 10
356
Annexure: 10
357
Annexure: 10
358
Annexure: 10
359
Annexure: 10
360
Annexure: 10
361
Annexure: 10
362
Annexure: 10
363
Annexure: 11
Adequacy Certificate
Annexure 11 : Adequacy Certificate of M/s. Tridev Industries.
364
Annexure: 11
365
Annexure: 11
366
Annexure: 11
367
Annexure: 11
368
Annexure: 11
369
Annexure: 11
370
Annexure: 11
371
Annexure: 11
372
Annexure: 12
NOC application copy for TSDF & CHWIF Membership
373

M/S. TRIDEV INDUSTRIES

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