1. Art and Diseño

PAVAN ENVITECH CONSULTANT PVT. LTD.
CHAPTER - 6
ADDITIONAL STUDIES
6.1 PUBLIC HEARING / PUBLIC CONSULTATION:
Publ ic Hearing is a pplicable as per obtained TOR (Terms of Reference). Public Hearing was
ca rri ed-out for the proposed expansion project of synthetic organic chemicals (emulsi fi e r
& de -e mulsifier) of Shree Vallabh Che mi cal a t Surve y No.: 163, 174/2 & 175/4, Vi l l age :
Ahmedpura-Sampa, Taluka: Dehgam, Di s tri ct: Gandhi na ga r unde r cate gory – A of the
s che duled at 5(f) on 20/12/2014 at 16:00 hrs at Yogi Satsang Hall, Nr. Nilkanth Mahadev T emple,
Dehgam-Modasa Road, Village: Palaiya, T aluka: Dehgam, District: Gandhinagar. An advertisement
in English waspublished in “T he Indian Express” dated 19-11-2014 & 19-12-2014 and in Gujarati in
“Gujarat Samachar” dated 19/11/2014 & 19-12-2014. Dr. M. D. Modiya (GAS), Resident Additional
Collector and Additional District Magistrate, Gandhinagar as representative of District Magistrate
and District Collector Gandhinagar supervised and presided over the entire public hearing
proceedings with Mr. B. R. Gajjar, Regional Officer, GPCB, Gandhinagar.
The public hearing presentati on and ques ti on ans we r s e s s i on e nded wi th pos i tive
re s ponses from the local people a bout the project. They we re sati s fi e d wi th mi ti ga tion
me a sures a nd e nvironmental manage me nt pl a n of the propos e d e xpa ns i on project.
Ra i sed queries during the public hearing were a lso adequately a ddressed. The minutes of
me e ting of the public hearing proceeding is e nclos e d as Annexure – 5. In vie w of the
a bove, it was concluded that no change is re quired i n EMP of the propos e d expa ns ion
proje ct. Industry will p rovide 5% (Rs.4 lac) of the expansion cost (Rs.80 lac) towards
CSR:
S r. No.
CS R Activity
Budgetary Amount
1.
Comp uters for school
Rs.2,50,000/-
2.
Public health p rogramme / seminar
Rs.1,50,000/TOTAL
Rs.4,00,000/-
Chap ter 6-1
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ESSMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
6.2 RISK ASSESSMENT:
A. Raw Material Handling and Storage :
Table 6.1 give s a list of the monthl y re qui re ment of ea ch ra w ma teri a l tha t wi l l be
consumed to manufacture the maximum quantity. All the ra w ma terial s s hal l be firs t
re cei ved by the s tores department and samples of ra w materials s hallbe s ent to quali ty
control laboratory wherein the qua l i ty of ra w ma te ria l s ha ll be tes te d. Onl y a fte r
confi rmation of quality by the QC l a b, the ra w material shall be transferred / unl oa de d
a t the re spective storage area in the factory wi th proper labeling. The ra w ma te ri a l i n
ge ne ra l wil l be rece i ve d i n ba gs , ca rboys , drums as we l l a s through tanke rs .
Table : 6.1 : LIST OF RAW MATERIALS WITH CONSUMPTION
Sr.
No.
Raw Materials
Consumption
MT / MT of product
MT / Month
1.0
Nonyl Phenol Ethoxylate : 160 MT / Month
1.1
Nonyl Phenol
1.2
Ethylene Oxide
1.3
NaOH / KOH
1.4
Water
2.0
Octyl Phenol Ethoxylate : 30 MT / Month
2.1
2.2
Octyl Phenol
Ethylene Oxide
2.3
2.4
NaOH / KOH
Water
3.0
Dodesyl Phenol Ethoxylate : 10 MT / Month
3.1
Dodesyl Phenol
3.2
Ethylene Oxide
3.3
NaOH / KOH
3.4
Water
4.0
Castor Oil Ethoxylate : 100 MT / Month
4.1
4.2
Castor Oil
Ethylene Oxide
4.3
4.4
NaOH / KOH
Water
5.0
Poly Ethylene Ethoxylate : 80 MT / Month
5.1
Poly Ethylene (Di – Ethylene) Glycol
0.332
0.666
0.002
0.008
53.220
106.46
0.320
1.280
0.318
0.680
0.002
0.008
9.556
20.384
0.060
0.240
0.229
0.769
0.002
0.008
2.290
7.690
0.020
0.080
0.508
0.490
0.002
0.008
50.765
49.035
0.200
0.800
0.194
15.501
Chap ter 6-2
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ESSMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
5.2
5.3
Ethylene Oxide
NaOH / KOH
5.4
Water
6.0
Fatty Alcohol Ethoxylate : 120 MT / Month
6.1
6.2
Fatty Alcohol
Ethylene Oxide
0.296
0.702
35.584
84.176
6.3
6.4
NaOH / KOH
Water
0.002
0.008
0.240
0.960
7.0
Hydrogenated Castor Oil (HCO) : 20 MT / Month
7.1
Hydrogenated Castor Oil (HCO)
7.2
7.3
Ethylene Oxide
NaOH / KOH
7.4
Water
8.0
Poly Ol Ethoxylate (De – Emulsifier) : 40 MT / Month
8.1
Poly Ol
8.2
Ethylene Oxide
8.3
8.4
NaOH / KOH
Water
0.804
0.002
0.008
0.319
0.681
0.002
0.008
0.693
0.305
0.002
0.008
64.339
0.160
0.640
13.587
6.373
0.040
0.160
27.198
12.198
0.008
0.320
Chap ter 6-3
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ESSMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
Storage and Transportation of Liquid Raw Materials
Al l liquid raw material s wi l l be store d in s torage ta nks a nd i n Drums /Carbouys a t
s e parate storage area. The storage a rea for hazardous chemicals will be located wi thi n
the boundary wa llwi th a constant wa tch by s ecurity round the clock. Proper enclosures
s hall be provided for a ll s torage tanks . Al l ne ces s a ry fi re fi ghti ng s ys te m and s a fety
a rrangements s hal l be provi de d ne a r the s tora ge are a to combat a ny eme rge ncy
a ccident. The liquid chemicals shall be transported through pipes vi a rack to production
a re a from s tora ge ta nks. The sa me s ys te m is provide d for e xi ti ng a cti viti e s .
Storage and Transportation of other Raw Materials
The ra w mate ri a l s whi ch a re procure d i n drums /ca rboys /ba gs s ha l l be s tore d i n
s e parate storage area i n stores department and tra nsported from the s tora ge a re a to
the production plant by hydraulic lift/trolley/forklift as applicable. The s a me s ys te m i s
provi de d for e xi ting a ctivi ti e s .
Table 6.2 & Table6.3 s hows the details on Tra ns portati on, Stora ge a nd Handl i ng of
products and ra w ma te ri a l s , res pe ctive l y.
Table : 6.2 : TRANSPORTATION DETAILS ON FINISHED PRODUCTS
Sr.
No.
Product
Physical
State
Dispatch
1.
Means of
Nonyl Phe nol Ethoxylate
Li quid
Loca l / Export Truck / Conta iner
2.
Octyl Phe nol Ethoxylate
Li quid
Loca l / Export Truck / Conta iner
3.
Dode syl Phenol Ethoxylate
Li quid
Loca l / Export Truck / Conta iner
4.
Ca s tor Oi l Ethoxylate
Li quid
Loca l / Export Truck / Conta iner
5.
Pol y Ethyl e ne Ethoxylate
Li quid
Loca l / Export Truck / Conta iner
6.
Fa tty Al cohol Ethoxylate
Li quid
Loca l / Export Truck / Conta iner
7.
Hydroge nated Castor Oil (HCO)
Ethoxyl a te
Li quid
Loca l / Export Truck / Conta iner
8.
Pol y Ol Ethoxylate (De – Emulsifier)
Li quid
Loca l / Export Truck / Conta iner
Transportation
Chap ter 6-4
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ESSMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
Table – 6.3 : DETAILS ON RAW MATERIALS – TRANSPORTATION
Sr.
No.
Raw Material
1.
2.
Nonyl Phenol
KOH
3.
NaOH
4.
5.
6.
7.
8.
9.
10.
11.
Octyl Phenol
Dodesyl Phenol
Castor Oil
Di – Ethylene Glycol
Fatty Alcohol
Hydrogenated Castor Oil
Poly Ol
Ethylene Oxide
Physical
State
Liquid
Flakes
Liquid/
Flakes
Flakes
Liquid
Liquid
Liquid
Liquid
Flakes
Liquid
Liquid
Source of
Supply
Means of
Transportation
(by road)
Distance of
Supplier from
Project Site (km)
Local
Local
200 kg drum
25/50 kg bags
50 - 500
50 - 500
Local
25/50 kg bags
50 - 500
Local
Local
Local
Local
Local
Local
Local
Local
25/50 kg bags
200 kg drum
200 kg drum
200 kg drum
200 kg drum
25/50 kg bags
200 kg drum
7 T Tanker load
50 - 500
50 - 500
50 - 500
50 - 500
50 - 500
50 - 500
50 - 100
50 - 100
Safety Procedures for Transfer of Raw Materials
All the lines shall be metallic and provided with jumpers for the conductivity of each
flames zones
All the day tanks shall be provided with level indicators and an overflow line which will
come back to the tank
Action plan for the transportation of raw material and products
1. The following major ra w materials and products being tra nsported to the facility a nd from
the fa cility
1.1 Ethyl e ne Oxi de
1.2 Hydroge n Pe roxide
1.3 Fa tty Alcohols
1.4 Nonyl Phenol, Octyl Phenol & Dodecyl Phenol
1.5 Ca s tor oil & Hydrogenated Castor oil
1.6 Pol ye thylene Glycol ( PEG)
1.7 Pota s sium Hydroxide (or Sodium Hydroxide ) Fl akes as a catalyst
1.8 The e thylene oxide condensates ( Ethoxylated Products) of all the above
1.9 Di e sel
1.10 Coal – Anthracite coal
Chap ter 6-5
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ESSMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
2. Transportation and handling of Ethylene oxide
Of a l l the above products e thylene oxide transportation is mos t ha za rdous a s i t i s both
fl a mmable a nd toxic. It is transported in a pressured tanker at a pressure of 4 to 5 Kg/cm 2.
The tra nsportation of this materiali s done i n a l iquefied stage at higher pressure a nd low
te mperature of about 4 to 6 °C, i n an insulated ta nker. Following pre cautions are taken for
tra ns porta tion of thi s mate ri a l .
2.1 The res ponsi bi l i ty of the tra ns porta ti on l i e s wi th the s uppl i e r onl y.
2.2 The roa d ta nker i s filled at a temperature of 2 to 4°C a nd a t a pre s s ure of 4 to 5
kg/cm2
2.3 The tanker i s fully i nsulated to minimize the heat gain during tra ns portati on. The
ma te ri a l of ins ul a ti on s houl d be compa ti bl e wi th EO.
2.4 The tanker i s fully e quipped with safety e quipme nt a nd acce s s ori e s l ike s a fety
va l ve , pre s s ure ga uge , te mpe ra ture ga uge a nd fi re exti ngui s he r.
2.5 The dri ver a nd cleaner a re fully tra ined in ha ndl i ng the Ethyl e ne Oxi de re l a te d
e me rge nci e s whi ch a re l ike l y on the roa d.
2.6 The route of the ve hicle is planned in such a way that busy a nd popul a te d a rea s
a re a voi de d.
2.7 The ethylene oxide is purchased and transported from the nearest location (From
Va doda ra faci l i ty of RIL) as fa r as pos si bl e .
2.8 The es timated tra nsportation time is 6 to 8 hours (The di s ta nce from Va dodara
ma nufa cturing fa cil i ty of RIL i s about 125 km).
2.9 In ca se there is any mishap on the road or the tanker develops the leak, the n i t i s
ha ndled by supplier i .e. (RIL) for which they have a 24 hr e me rge ncy a nd re s cue
te a ms a re ava i l a ble a t the i r Va doda ra pl a nt.
2.10 The material of construction: of the ta nke r i s s ta i nle s s s te e l onl y a s any
contamination of tanker ca n re sult in initiating polymerizati on rea cti on whi ch i s
e xothe rmi c and ca n ca us e burs ting of the conta i ne r/ta nker.
2.11 Ta nk fittings and attachments i n contact with Ethylene Oxi de shall a l s o be of the
a bove-mentioned materi a ls , a nd ma y not contai n coppe r or a l l oys of coppe r
a nd/or ma gne s i um.
2.12 The tanker i s never filled up to the bream. Some empty s pace i s l e ft to a l l ow for
the e xpa ns i on of the l i qui d.
2.13 The roa d ta nker is not a llowed to keep waiting i n the open sun either on the roa d
or i n the fa ctory premi s e s to mi ni mi ze the hea t ga i n.
2.14 The tanker i s emptied i n the Ethylene Oxi de s torage ta nk onl y whe n the ta nk i s
e mpty.
2.15 The unloading is done by nitrogen pressure. The pumpi ng of Ethyl e ne Oxi de i s
a voi de d i n orde r to control fugi ti ve e mi s s i ons of EO.
Chap ter 6-6
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ESSMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
2.16 Use of dedicated tankers: The EO ta nkers are dedicated for the tra nsporta ti on of
EO onl y. Thi s i s to avoi d conta mi na ti on a nd pol yme ri za ti on of EO. If i t gets
pol yme ri ze d i t wi l l choke the i nle t outle t l i nes a nd s a fe ty va l ve .
2.17 Parking the vehicle - Dri ve rs must ensure that the ve hicle is either s upervised or is
pa rked in a secure place. No pote nti a l s ource of he a t or fi re mus t e xi s t i n the
vi ci nity, a nd the ve hicle must be capable of being easily removed i n a n emergency.
2.18 The pa rking of the ve hicle is to be avoided a s far as possible. Drivers mus t i nform
the haul e r of the i r ove rnight pa rki ng l oca ti on.
2.19 Delays or accidents: - Al l delays during tra nsport, whether due to s evere we a the r
conditions, breakdown or other re asons mus t be re porte d to the cons i gnor a s
s oon as possible. Transport a ccidents must also be re porte d to the cons i gnor a s
s oon a s poss i bl e
2.20 Pressure and temperature checks :- For roa d tra ns port the pre s s ure a nd/or
te mperature of the tank contents should be checked re gularly a nd re corde d on a
che ckl i s t or i n a l ogbook
2.21 Emergency procedure: - Dri ve rs should be give n precise i ns tructi ons a s to the
a cce ptable pressure and te mperature rise during the journey, a nd the eme rge ncy
a cti on to be ta ken i n the e vent that re adings in e xce s s of a cce pta bl e le ve l s are
obs e rve d.
2.22 The design of the road tankers / tank conta i ne rs mus t gua ra nte e a compl ete
unl oadi ng of the roa d ta nke rs /tank conta i ne rs . Cri teri on: l es s than 5 l i tre s
re ma ini ng product.
2.23 The ethylene oxide tanker is padded with nitrogen to avoid self-polymerizati on of
EO vapour.
2.24 The l oading and unloading operation of the ta nker s hould be situated a t the s afe
di s ta nce from the stora ge ta nks.
2.25 Afte r loading the ta nke r i s pre s s ure d with ni troge n to e ns ure the ga s phas e
re ma ins i nert e ve n up to 50 °C.
2.26 The dri vers of the tanker to che ck that the press ure of the ta nke r does not ri ze
a bove 10 Kg/cm 2 or te mp do not ri s e a bove 50 °C.
2.27 The val ves of the tanker may ge t choked due to polymerization of EO, hence the y
s hould be cle a ne d pe ri odi ca l l y.
2.28 The tanker s hould not be kept empty containi ng va pour of EO for l ong ti me s to
a voi d polymerization of EO. It s hould be purged a nd mainta i ne d unde r ni troge n
pre s sure .
Chap ter 6-7
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ESSMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
2.29 Precautions while unloading the tanker
2.29.1. Duri ng loading or unloading the ve hicle must be earthed. Ensure double
ea rthing to avoid a ny static charge a ccumulation
2.29.2. The oxyge n content of the ta nker should be l ess than 0.3% by vol . before
loa ding of EO
2.29.3 The operator should wear breathing apparatus before l oading or unloading
ethyl ene.
2.29.4 Afte r conne ction the hose must be purged with nitrogen to ma ke it fre e from
Oxyge n
2.29.5 The fl ange joints and other connections to be checked with s oap s olution for
l e akage. It should be ke pt in mind that the thresh hold limit for EO i n air is 1
ppm only.
2.29.6 The key of the ve hicle should be re moved
2.29.7 The ve hicle hand brake is to be put on.
2.29.8 The wheel chocks s hould be applied during loading unloading to s top
a cci dental move ment of ve hicle.
2.29.9 Ha nd brake s hould be applied when the tanker is getting loaded or
unl oaded.
2.29.10 The dri ver s hould be near the ve hicle during l oading unloading operation.
2.29.11 The vehicle should be parked i n the shed when it is l oaded or unloaded.
Company has obtained renewal license for Ehylene Oxide Storage license from
Petroleum and Explosives Safety Organisation (PESO), West Circle, Ministry of
Commerce & Industry, Govt. of India, vide License No.: S/HO/GJ/03/210(S1368) Date
of Issue: 13-04-2011, Validity upto: 31-03-2014 and Renewal License vide License No.:
S/HO/GJ/03/210(S1368) Date of Issue: 17-02-2014, Validity up to 31-03-2017 (Please
Refer Annexure – 1) vide compliance of their requirements.
3. Storage and handling of Hydrogen Peroxide
3.1 The hydrogen peroxide is used i n the process as a bleaching a gent. Wheneve r the
product has a ye llowish tinge a bout 1litre of hydrogen peroxide is added to the
re a ctor to ma ke a colourless liquid.
3.2 The hydrogen peroxide is brought in a 50 l itre carboys
3.3 It i s stored i n a s hed away from the other ma terial as i t is a s trong oxidizing agent.
Chap ter 6-8
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ESSMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
4. Storage and handling of alkyl phenols
4.1 The a lkyl phenols a re the main ra w materials for the facility. The alkyl phenols
ma i nly used are Nonyl Phe nol, Dodesyl Phenol a nd Octyl Phenol.
4.2 The s e are mostly a vailable in liquid form
4.3 The y a re purchased in the 200 l itres HDPE drums or MS Drums and brought to the
fa ctory i n the tra nsport truck.
4.4 The y a re s tored i n the factory main storage area.
4.5 The l iquid from the drums is tra nsferred to the re actor by a portable pump, the
pump i s mounted on the top of the drum and the suction pipe is dipped in the drum
upto the bottom.
4.6 The re maining liquid is manually poured in a small container of a bout 10 to 20 l i tres
in s ize and is pumped to the reactor.
4.7 Se condary containment in the form of a tra y is used to control the s pillage of the
ma te rial
4.8 Al l the used drums a re sold to the authorized a nd GPCB a pprove d re cyclers
5. Storage and handling of castor oil, hydrogenated castor oil and fatty alcohol
The castor oila nd fatty alcohol a re liquids with a similar properties like a lkyl phenols and
the y a re brought i n 200 l itres MS or HDPE drums by roa d trucks.
The y are handled in the s imilar wa y like an a lkyl phenols.
6. Storage and Handling of PEG (polyethylene glycol)
6.1 PEG i s the main ra w material for the production of Poly-Sol a de-emulsifier used in
crude oil processing to separate oil from the wa ter.
6.2 PEG i s the higher boiling glycol. It is in liquid form. It is procured i n 200 l iters MS or
HDPE drums .
6.3 The drums are transported i n the road truck a nd s tored i n a separate area i n the raw
ma te rial storage shed.
6.4 Occa s ionally the material is s upplied i n the road ta nker. The road tanker material is
empti ed in the 200 l itres HDPE drums. They are stored i n the shed a way from the
di re ct sunlight.
Chap ter 6-9
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ESSMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
6.5 The PEG i s transferred to the reactor from the drum by the portable pump which can
be mounted on the drum top.
6.6 The us ed drums are sold to the a uthorized recyclers.
7. Storage and handling of potash flakes or caustic flakes
7.1 The ca ustic or potassium hydroxide i s used as a ca talyst for the i nitiation of
ethoxylation reaction
7.2 The material is purchased a nd is a vailable i n 25 kg or 50 kg HDPE l ined woven s acks.
7.3 Thi s is transported by the road truck.
7.4 Si nce the material is highly hygroscopic, the bags a re tightly cl osed a fter taking out
the ma terial.
7.5 A 30 % or 50 % ca us tic or potash s olution i s made in water for use as a ca talyst.
7.6 Ade quate PPE is used while handling the flakes, especially the use of hand gloves
and goggles is must while handling.
7.7 Si nce the material is harmful to skin and eyes a dequate tra ining in handling this
ma te rial is given to workers.
7.8 The e mpty bags a re fully washed and decontaminated before s elling or recycling
the m for s torage of other product.
8.
Diesel
8.1 Di e sel will be used as fuel for running the DG set i n case of power failure.
8.2 The quantity of diesel required is depends on the running of DG s et. But i t is about
100 l i ters per month.
8.3 . Di e selis a vailable on the nearby petrol pump
8.4 It i s brought in a 35 or 50 l i ters ca rboys and is tra nsferre d to the tank i n the DG set.
8.5 The ca rboys are dedicated for diesel
8.6 Al l necessary safety pre cautions are ta ken as diesel is a flammable l iquid.
9.
Coal
9.1 The fa cility will be set up a coal fi red boiler for production of s team
9.2 The coal re quirement is a bout 2 MT pe r day.
Chap ter 6-10
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ESSMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
9.3 Imported coal or Anthracite coal is procured through the dealers is delivered to the
si te by Road Lorri es.
9.4 The coal is stored i n shed near the boiler and is manually fed to the boiler to
ma i ntain boiler pressure.
9.5 Bi g l umps of coal are broken into small pieces manually for fe eding to the boiler.
9.6 Si nce coal ca n ca tch fire on its own in the open s torage, re gular water s praying is
done the coal.
9.7 Bi g heaps of coal is avoided to re duce chances of fire.
10.
Stora ge and handling of ethoxyl ate products: All e thoxylate products are in liquid form
a nd near to similar properties and sell in 200 l iters capacity HDPE drums by road.
Ha ndling of product like similar way of ra w ma terial.
Chap ter 6-11
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ESSMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
DETAILS OF OCCUPATIONAL HEALTH PROGRAMME
1. To which chemicals, workers are exposed directly or indirectly
The following chemicals are being used as ra w materials i n the plant
I)
Ethyl e ne Oxide
II)
Hydroge n Pe roxide
III)
Fa tty a l cohols
IV)
Nonyl Phe nol, Octyl Phenol & Dodecyl Phenol
V)
Ca s tor oil & Hydrogenated Ca stor oil.
VI)
Pol ye thylene Glycol (PEG)
VII)
Potas sium Hydroxide (or Sodium Hydroxide) Flakes as a catalyst.
VIII) The Ethyl ene Oxi de condensates ( Ethoxylated Products of all the above)
2. Whether these chemicals are within Threshold Limit Values (TLV) / Permissible
Exposure Levels as per ACGIH recommendation?
In the e xpanded facility of Shree Vallabh Chemical. The most hazardous chemical
ha ndled is Ethylene oxide. The TLV a nd PEL va lues of the Ethylene Oxi de a re
I. A. TLV – 8 Hour we ighted a verage (TWA) Value – 1.8 mg/M3 or 1 ppm
B. TLV – Imme diate Danger to l ife or health (IDLV) va lue – 800 ppm
The a bove values a re as per the US notification of Jan 2009. (ACGIH)
II. The PEL e xposure value as per OHSA , Uni ted states Nov 2006 i s
A STEL– Short te rm Exposure limit is 5 ppm for 15 mi nutes & 1 ppm for 8 Hrs (TWA)
The other ma terials are mostly in liquid form a nd mostly with high boiling points
he nce their concentration in the working a tmosphere is ve ry l ow and do not pose
any he alth danger to the persons working.
3. What measures company has taken to keep these chemicals within PEL/TLV.?
The following measures and precautions will be taken to keep the concentrations of EO
i n the working atmosphere below the PEL / TLV
3.1 The ma in s torage tank (pressurized ve ssel) is i nstalled i n the open outside the
bui lding a nd is under the shed.
3.2
The tra nsfer of Ethylene Oxi de material to the reactor and to the measuring tank
i s by pi pe line a nd is under nitrogen pressure.
3.3 Ma nual handling of the hazardous material like Ethylene Oxi de is not there.
3.4 Mi nimum flange joints are used in the pipeline to minimize the chances of
Ethyle ne Oxide leakage.
3.5 The joi nts are re gularly checked with s oap s olution for l eakages.
3.6 The area where e thylene oxide is handled i s wellve ntilated. The use of Eco
ve ntilators is being done.
Chap ter 6-12
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ESSMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
Exhaust fans a nd windows are fitted on the wall at lower l evel to keep the area
fre e from pollutants. (EO vapour are heavier than air try to s ti ck to the lower
l e ve ls.)
Re gular monitoring of the workplace is done by using drägar tubes a nd monitors.
The workers have been provided adequate PPE’s like breather mask, face mask to
ca rry out criti cal operations l ike shut down, or maintenance of equipments where
the re i s chance of exposure.
Pe rmi t s ystem is strictly e nforced for ca rrying out maintenance and non-routine
jobs .
Sta ff a nd workers are well tra ined i n the operations a nd to a void exposure to
da ngerous che micals.
The ve nt of the condensation re actor is dipped i n the water bath. The water i n
the wa ter bath is changed daily. Ethyl ene Oxide va pour if any i n the ve nt gases
a re absorbed i n the water. The water i n the water bath is s ent to the waste water
tre a tment facility.
The re is a double mechanical sealon the agitator of the reactors. This ensure that
the re i s no fugitive e mission of Ethylene Oxi de
The re is a safety valve on the reactor which i s set at 7 Kg pre ssure ( g)
The re a ctor a nd other ve ssels containing EO a re purged thoroughly to ma ke them
fre e from EO be fore opening
LDAR program is enforced for Ethylene Oxi de a nd s team lines (Leak Detection and
Re pair) program.
Fugi tive e mission control – Si nce the Ethylene Oxi de s torage i s under pressure
a nd no dire ct ve nt is provided the fugitive e mission of e thyl ene oxide is ze ro.
Company has obtained renewal license for Ehylene Oxide Storage license from
Petroleum and Explosives Safety Organisation (PESO), West Circle, Ministry of
Commerce & Industry, Govt. of India, vide License No.: S/HO/GJ/03/210(S1368) Date
of Issue: 13-04-2011, Validity upto: 31-03-2014 and Renewal License vide License No.:
S/HO/GJ/03/210(S1368) Date of Issue: 17-02-2014, Validity up to 31-03-2017 (Please
Refer Annexure – 1) vide compliance of their requirements.
4. How the workers are evaluated concerning their exposure to chemicals during preplacement and periodical medical monitoring?
As pe r policy a nd norms all of the workmen are put to medical examination a nd te sting
pe riodically a nd a t set i nterval a nd based on the me dical re port actions are taken, i f at
a l l anything i s necessary and re quired. Eve n based on the medical e xamination re port /
Chap ter 6-13
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ESSMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
fe e dback, workmen are counselled a nd put in different a rea / job rotation kind of
a ctivi ties. Me dical re cord should be maintained i n office.
The pre -placement and periodical medical examination re cords a re to be maintained i n
the pre scribed format as per the Factories Act 1948 a nd Gujarat Factories Rules 1963.
5.
What are onsite and offsite emergency plan during chemical disaster
5.1 Onsite Emergency Response
The following types of emergencies are possible in the facility which handling flammable
a nd dangerous material like Ethylene Oxide
a . Fi re
b. Ga s leak / toxic re lease.
c. Spi llage of liquid chemical from 200 l iters drums.
d. Acci dent i nvolving human injury
In ca s e of the a bove emergencies the company has well defined and documented
e me rgency management procedure, this procedure is described in s hort i n the
fol lowing paragraphs
5.1.1 Shut down and Isolation: Ra i sing the alarm, followed by i mmediate safe s hut
down of the processes, reactors, power s upply, a nd isolation of a ffected a reas
5.1.2 Escape, Evacuation and Rescue: Sa fe guarding human lives at s ite by
comme ncement of the Eme rgency Eva cuation and Rescue Plan. Ensuring that
a l l personnel are a ccounted for a nd ca rrying out a head count of persons
e vacuated. Notification and commencement of offsite e mergency plan in case
offs ite i mpacts are possible The persons s hould be asked to gather a t the
des ignated place.(Emergency a ssembly Poi nts)
5.1.3 Stopping the development of the emergency: Control or re sponse to the
e me rgency depending upon its nature (fire, toxic re lease or explosion). Fire ca n
be s omewhat better controlled through fire fighting, while toxic re lease
i mpacts can be partially controlled through proper communication with
a ffe cted population. Impacts of e xplosions i mpacts cannot be controlled once
they occur, he nce efforts will require focusing on provision of re lief or control
of s e condary i mpacts (such a s property da mage or fires) resulting from
e xpl osions.
5.1.4 Treatment of injured: Fi rs t aid and hospitalization of injured persons
5.1.5 Protection of environment and property: During mitigation, efforts should be
made to prevent impacts on environment and property to the e xtent possible.
5.1.6 Welfare of the personnel managing the emergency: Cha nge over, fi rst aid a nd
re fre s hments for the persons managing the e mergency
Chap ter 6-14
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ESSMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
5.1.7 Informing and assisting relatives of the victims
5.1.8 Informing the news a nd e lectronic me dia
5.1.9 Preserving all evidences and records: Thi s s hould be done to e nable a thorough
i nve stigation of the true causes of the emergency
5.1.10 Investigation and follow up: This re quires to be carried out to e stablish
preve ntive measures for the future a nd a re view of the DMP and its annexure
to fi l l up the deficiencies i n the emergency planning procedures
5.1.11 Ensuring safety of personnel prior to restarting of operations: Efforts re quire
to be ma de to ensure that work e nvironment is safe prior to re starting the
work.
5.1.12 In case of fire: If the re is a fire and there is little personal risk, use a ppropriate
e xti nguisher i f you have been trained i n i ts proper use. If the fi re is very small, it
may be e xtinguished by smothering it with a non flammable material such as a
s and, watch glasses or me tal s heet. Turn off electrical circuit and gas lines.
5.2 Off-site Emergency Response Plan
5.2.1 An e me rgency may a ffect a reas offsite of the works as for e xample, an
e xpl osion can s catter debris over wide areas and the effects of blast can cover
cons iderable distances, wind ca n s pread burning brands of gases.
5.2.2 In s ome cases e.g. as the re sult of a n e xplosion, outside damage will be
i mme diate and part of the a vailable re sources of the emergency servi ces may
nee d to be deployed in the a ffected areas. In any ca se, the possibility of further
damage may re main, e.g. as the re sult of further e xplosion or by the e ffect of
wind spreading burning brands of hazardous material.
5.2.3 It wi l l be necessary to pre pare in adva nce simple charts or ta bles relating the
l i kely s pread of the va pours cl oud taking into account its e xpected buoyancy,
the l ocal topography and all possible weather conditions during the time of
re le ase.
5.2.4 It ma y a lso be desirable to i nstall instruments indicating wind speed and
di re ction, which could be done jointly wi th surrounding i ndustries.
5.3 First aid treatment plan should be taken if any employee get injured in any
emergency situation as follows:
5.3.1. In a ll a ctual or suspected cases of exposure to EO, me dical attention should be
obta ined at once and the patient s hould always be remove d from the
conta minated a rea.
5.3.2. Al l contaminated cl othing s hould be remove d immediately.
5.3.3. Remove from e xposure. If unconscious s ecure airway and place in semi prone
re cove ry position. If not breathing give artificial re spiration.
Chap ter 6-15
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ESSMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
5.3.4. If he art beat a bsent give exte rnal cardiac compression.
5.3.5. If the re is cya nosis (blueness of the lips) administer oxygen by fa ce mask. If
there i s breathing difficulty or cough keep patient at rest seated i n position of
maxi mum comfort. Re fer to hospital or doctor ri sk of delayed s ymptoms.
5.3.6. Remove all contaminated clothing to a safe ve ntilated place or a sealed
conta iner.
5.3.7. In ca s e of s kin contamination wash i mmediately wi th plenty of cl ean, gently
fl ow water.
5.3.8. In ca s e of e ye contamination wash the eye i mmediately with plenty of cl ean,
gentl y flow water for 10 mi nutes. Then send promptly to a doctor or hospital.
5.3.9. Cove r s ki n burns with a sterile dressing.
5.3.10. If pa tient appears confused, excited or uncoordinated use only mi nimal
re stra int necessary for s afety a nd treatment.
5.3.11. If pa tient is conscious permit water to drink.
6.
Liver function tests (LFT) during pre-placement and periodical examination
Ethyl e ne Oxide may also damage the live r and kidneys i n case of chroni c expos ure .
He nce Le ver function and kidney te sts wi l l be done duri ng pre –pl a ceme nt and
duri ng periodical me dical checkup once in a ye ars for those workers who a re l i ke l y
to ge t exposed to Ethylene Oxide. More detailed i nformation on various tes ts to be
pe rforme d for thos e worki ng i n EO ha ndl i ng are a s i s gi ve n i n ne xt pa ra on
occupati ona l he a l th s urve il l a nce program.
7. Details of occupational health surveillance program
7.1 Medical surveillance program
The EO ha s been l inked to an i ncreased ri sk of cancer a nd re productive e ffects
i ncluding decreased male fertility, fe totoxicity, and spontaneous a bortion. At the
pre sent, l imited s tudies of chronic e ffects in humans re sulting from e xpos ure to
EO suggest a causal association wi th l e uke mi a. Ade qua te s cre e ni ng te s ts to
de termine a n e mploye e's potential for developing s erious chronic diseases, s uch
a s ca ncer, from e xposure to EO do not presently e xist. Laboratory te sts may gi ve
e vi dence to suggest that an e mploye e i s pote nti a l l y ove re xpos e d to EO. The
physician must become familiar wi th the si gns and s ymptoms tha t indi ca te a
worke r i s receiving otherwise unre cognized and unaccepta bl e e xposure to EO.
The e mployer i s required to i nsti tute a me di cal s urvei l l a nce progra m for a l l
e mpl oyees who are or will be e xposed to EO a t or a bove the a cti on l e ve l (0.5
ppm) for at l e a s t 30 da ys pe r yea r, without re ga rd to re s pi ra tor us e .
Al though broad latitude in prescribing s pecific tests to be included i n the medical
s urve illance program is exte nded to the e xa mi ni ng phys i ci a n, OSHA re qui re s
i nclus i on of the fol l owing e l e me nts in the routi ne e xa mina ti on:
Chap ter 6-16
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ESSMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
(i ) Me dicala nd work histories with s pe ci a l e mpha s i s di re cte d to symptoms
re l a te d to the pul mona ry, he ma tol ogi c, ne urol ogi c, and re producti ve
s ys te ms a nd to the eye s a nd s ki n.
(i i ) Physicale xamina ti on wi th parti cul ar e mpha s i s gi ve n to the pul monary,
he ma tologic, neurologic, and re productive systems a nd to the e yes a nd skin.
(i i i) Complete blood count to i ncl ude at l e a s t a whi te ce l l count (i ncl uding
di ffe renti a l ce l l count), re d ce l l count, he ma tocri t, a nd he mogl obi n.
(i v) Any l a boratory or other test which the e xamining physician deems necessary
by s ound me di ca l pra cti ce .
The e mployer i s required to make the prescribed te sts available a t least annuall y
to empl oyees who are or will be exposed at or above the a cti on l e ve l, for 30 or
more da ys pe r yea r; more ofte n than s pe ci fi e d if re comme nde d by the
e xa mining physician; a nd upon the employe e's te rmi nati on of e mpl oyme nt or
re a ssignment to another work area. While l ittle i s known a bout the l ong term
consequences of high s hort-term e xposures, i t appears prudent to monitor s uch
a ffected e mployees cl osely i n light of existing health data . The e mpl oye r s ha l l
provi de physician re commended examinations to any employee e xpos e d to EO
i n emergency conditions. Li kewise, the employer shall make a va i l a bl e me dica l
consultations i ncludi ng phys i ci an re comme nde d e xams to e mpl oye e s who
be l ie ve they a re suffe ri ng s i gns or s ymptoms of e xpos ure to EO.
The e mpl oye r i s re qui re d to provi de the phys i cia n wi th the fol l owing
i nformation: a description of the affected e mployee's duties as they relate to the
e mpl oyee exposure leve l; and information from the e mployee's pre vious medical
e xa minations which is not readily a vailable to the examining phys i ci a n. Ma king
thi s information a vailable to the phys i ci a n wi ll a i d i n the eva l ua tion of the
e mpl oyee's health i n re lation to assigned duties a nd fi tne s s to we a r pe rs ona l
prote cti ve e qui pme nt, whe n requi re d.
The e mpl oye r i s re qui red to obta i n a wri tte n opi nion from the exa mi ni ng
physician containing the results of the me dical exa mi na ti ons ; the phys i ci a n's
opi nion as to whether the e mployee has any detected me dicalconditions whi ch
woul d place the e mploye e at i ncreased risk of material i mpairment of his or he r
he alth from exposure to EO; a ny re commended restrictions upon the employee's
e xposure to EO, or upon the use of protecti ve cl othi ng or e qui pme nt s uch a s
re s pirators; a nd a s ta te me nt tha t the empl oye e ha s be e n i nforme d by the
physi ci a n of the re s ul ts of the me dica l e xami na tion a nd of a ny me dica l
condi tions which require further explanation or tre atment. This written opi nion
must not reve a l spe ci fi c fi ndi ngs or di a gnose s unre l a te d to occupa ti ona l
Chap ter 6-17
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ESSMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
e xposure to EO, a nd a copy of the opi nion must be provi de d to the a ffe cte d
e mpl oye e .
The a nnexure below i s the formats for me dical checkup as per the factori e s act.
7.2 Details of occupational Health/Safety surveillance Requirements:
Provi s i on for fol l owi ng ma tte rs ne e d to be ma de :
• Che cki ng packaging or container labels and materia l s a fe ty da ta she e ts ; on
regul a r ba s i s .
• Re gular communication between workers, supervisors a nd empl oye rs a bout
l ikely hazards; Regular tra ining to a l l conce rne d peopl e on the ha za rdous
i nvol ve d e s pe ci a l l y of the EO e xpos ure
• Re gular i nspection of workplaces, pl ant a nd e qui pme nt; for l e a ka ge s and
spi llages. The flange joints and other joints to be e xamined with soap solution
for a ny le a ka ges of EO.
• The pl ant and process area i s well ve ntilated by us e of e co –ve nti la tors and
exha us t fa ns mounted on the l ower s i de of the wa l l .
• Re gular monitoring of workplace by dragger tube for presence of EO. The EO
l eve l should be l ess than 1 ppm which is a threshold limit. The desired l evel of
EO i n the worki ng a tmos phere s houl d be l e s s tha n 0.5 ppm
• Re gul a r re vi e w of ta sks a nd proce dure s ; and
• Che cki ng of previous i nci de nt a nd i njury records for re curri ng s itua ti ons .
• Job ri s k a na l ysi s / job s a fe ty a na l ysi s
• Encl osed sys tems for chemicals, re location of e mployees or physical ba rri ers
• Stori ng hazardous substances in a locka bl e , e ncl ose d a re a wi th a de quate
venti l a ti on
• Limi ti ng a cce s s to chemi ca l s tora ge a re a s to a uthori zed pe opl e onl y
• Ens uri ng a l l l abe l s rema i n inta ct on conta i ne rs a nd packa gi ng
• Whe re possible, pump chemicals into reactors or ta nks ra the r than pouri ng
ma nua ll y from conta ine rs .
• Mi ni mi zi ng ri sk of i tems a cci de ntal l y droppi ng into ta nks , s pl a s hi ng.
Chap ter 6-18
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ESSMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
PRE-PLACEMENT FORM
ANNEXURE-1
FORM NO: 27-A
(Prescribed under Rule 102)
CERTIFICATE OF FITNESS
1. Seri al number:
I ce rti fy that I have personally e xamined ______________________________________ son of
(Fa ther’s name) _________________________________________________________ re siding
a t (address)_________________________________________________________ who is
de sirous of being employed as (designation) ________________________________ in (process,
de partment a nd factory) ____________________________________________ and that his
a ge, a s nearly a s can be ascertained from my e xamination, is ______________ ye ars, and that
he is i n my opinion, fit/unfit for employment i n the a bove mentioned factory as me ntioned
a bove .
2. He ma y be produced for further e xamination after a period of
________________________________________months
3. The s erial number of the previous certificate is __________________________
Si gnature or l eft hand
thumb i mpression of
pe rson examined:
Si gnature of Ce rtifying
Surge on :Na me __________
Da te: _____________
I ce rtify tha t I
e xa mined the person
me ntioned above on
I exte nded this certificate
unti l (If certificate is not
e xte nded, the period for
whi ch the worker i s
cons idered unfit for work is to
be me ntioned)
Si gns and
s ymptoms
obs erve d during
e xa mination
Si gnature of the
Ce rti fyi ng
Surge on
Da te –
PRE-PLACEMENT FORM
ANNEXURE-2
Chap ter 6-19
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ESSMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
FORM NO: 33
(Prescribed under Rule 68-T and 102)
Certificate of fitness of employment in hazardous process and operations.
(TO BE ISSUED BY FACTORY MEDICAL OFFICER)
1. Se rial number i n the re gister
Of adult workers
:
2. Na me of the person e xamined
:
3. Fa the r’s Name
:
:
:
4. Se x
5. Re sidence
:
:
6. Da te of Birth
7. Na me & a ddress of the factory
8. The worker i s employe d/proposed
a. Ha za rdous process
b. Da ngerous operation
:
:
:
I ce rti fy tha t I have personally e xamined the a bove named person whose i dentification
ma rks are _________ a nd who is desirous of bein g e mployed in a bove mentioned
proce ss/operation and that his/her, a ge, as nearly a s can be ascertained from my e xamination,
i s ________ ye a rs.
In my opi nion he/she i s fit for e mployment in the s aid manufacturing process/operation.
In my opi nion he/she i s unfit for e mployment i n the said manufacturing process/operation
for the re ason ______________. He /she is re ferred for further e xamination to the certifying
Surge on.
The s erial number of previous certificate is ______________.
Si gnature or l eft hand thumb
i mpression of the person examined:
Si gnature of the Factory Me dical Office r:
Stamp of factory: _______________
Me di cal officer with Name of the Factory: ___________
Chap ter 6-20
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ESSMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
QUANTITATIVE RISK ASSESSMENT
1.0 INTRODUCTION
QRA s tudy for, M/s . Shree Vallabh Chemical has been ca rried out based on data provi ded by
them. The s tudy ha s been ca rri ed out i n a ccorda nce wi th the Interna ti ona l codes of
pra cti ces using PHAST (Process Hazard Analysis Software Tool) – 6.53 s oftwa re. The l a tes t
vers i on of the renowned PHAST Risk software package of DNV is us ed for ca rryi ng out the
ri s k a na l ys i s .
The full terms of potential hazardous s cenarios and consequence events associated with the
i ns tallation a nd operation was considered i n the analysis. Ba s ed on the opera ti ons to be
ca rri ed a t the plant, the Risk Analysis, affected distances a nd the da ma ge of property a nd
population from the identified s cenarios considering the Maximum Credible Los s Scena ri o
(MCLS) & Wors t ca se s cenario of the phenomenon occur. Ma ximum credible loss s cena ri os
ha ve been worked based on the i nbui l t s a fety s ys tems a nd protecti on mea s ures to be
provi ded for the operation of the facility & the Worst case s cenario i .e. 100% ca ta s trophi c
rupture ha ve been worked out ba s ed on fa i l ure of the i nbui l t s a fety s ys tem.
We ha ve assumed Ma ximum credible loss s cenario (MCLS) i .e. Nozzle failure and Worst case
Scena rio i.e. ca tastrophic rupture as per the guidelines s ugges ted by DNV – UK. Si mi l a rl y,
ma xi mum i nventory a t the ti me of fa i l ure i s a s s umed.
1.1 OBJECTIVE OF THE STUDY
The ma in objective QRA (Quantitative Risk Analysis) is to determine the potenti a l ri s ks of
ma jor disasters having damage potential to life and property a nd provide a scienti fi c ba s i s
for deci sion makers to be s atisfied about the safety l evels of the fa cilities to be s et up. This is
a chi eved by the fol l owi ng:
Identi fi ca ti on of ha za rds tha t coul d be rea l i zed from proces s pl a nt.
Identi fy the potenti a l fa i l ure s cena ri os tha t coul d occur wi thi n the fa ci l i ty.
To As s es, the potential risks associated with identified ha za rds to whi ch the pl a nt
a nd i ts personal and community outside may be s ubjected. Consequences analysis of
va ri ous hazards is ca rried out to determine the vulnerable zones for ea ch proba bl e
a cci dent s cena ri o.
Eva l uate the process hazards ema na ti ng from the i denti fi ed potenti a l a cci dent
s cena ri os .
Ana l yze the da ma ge effects to the s urroundi ngs due to s uch a cci dents .
Concl usion a nd Recommendation to mitigate measures to reduce the hazard / ri s ks .
To provi de gui del i nes for the prepa ra ti on of On-s i te res pons e pl a n.
Chapter 6-21
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ES SMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
1.2 SCOPE OF THE STUDY
Fol lowing flammable chemicals or s ol vents s tored, us ed a nd ha ndl ed i n the premi s es .
S. No
Flammable
solvents/Material
Hazards
Flash Point Approx
(°C)
Quantity (MT)
1
Ethyl ene Oxi de
Hi ghly Flammabl e (Pool fi re,
Jet fi re, fl a s h fi re)
-20
9
2
Ethyl ene Oxi de
Hi ghly Flammabl e (Pool fi re,
Jet fi re, fl a s h fi re)
-20
4.4
3
Ethyl ene Oxi de
Hi ghly Flammabl e (Pool fi re,
Jet fi re, fl a s h fi re)
-20
3
1.3 USE OF QRA RESULTS
The techniques us ed for ri s k predi cti on wi thi n the QRA ha ve i nherent uncerta i nti es
a s sociated with them due to the neces s a ry s i mpl i fi ca ti ons requi red. In a ddi ti on, QRA
i ncorporates a certain a mount of s ubjecti ve engi neeri ng judgment a nd the res ul ts a re
s ubject to l evels of uncertainty. For this reason, the results should not be us ed a s the s ol e
ba s is for decision making a nd s hould not drive deviations from sound engineering pra cti ce.
The res ults s hould be used as a tool to aid engineering judgment a nd, i f used in this way, can
provi de va l ua bl e i nforma ti on duri ng the deci s i on ma ki ng proces s .
The QRA res ults are dependent on the assumptions ma de i n the ca l cul a ti ons , whi ch a re
cl ea rl y documented throughout the fol l owi ng s ecti ons of thi s report. Cons erva ti ve
a s sumptions have been used, which helps to remove the requirement for detailed a na l ys i s
of the uncertainty. The results show the significa nt contri buti ons to the overa l l ri s k a nd
i ndicate where worthwhile gai ns ma y be a chi eved i f further enha ncement of s a fety i s
deemed neces s a ry.
1.4 SOFTWARE USED
PHAST 6.53 (l a test version) has been used for consequence a nalysis include di s cha rge a nd
di s pers i on ca l cul a ti ons .
1.5 METEOROLOGICAL CONDITIONS
The consequences of released toxic or flammable material a re l a rgel y dependent on the
preva iling weather conditions. For the assessment of ma jor scenarios i nvol vi ng rel ea s e of
toxi c or fl ammable materials, the most important meteorological parameters a re those that
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a ffect the a tmospheric dispersion of the escaping material. The crucial va ri a bl es a re wi nd
di rection, wind s peed, a tmospheric stability a nd temperature. Rainfa l l does not ha ve a ny
di rect bearing on the results of the ri sk a nalysis; however, i t ca n have benefi ci a l effects by
a bs orption / washout of released materials. Actual behavior of a ny rel ea s e woul d l a rgel y
depend on preva i l i ng wea ther condi ti on a t the ti me of rel ea s e.
1.6 ATMOSPHERIC PARAMETERS
The Cl i ma tol ogi ca l da ta whi ch ha ve been us ed for the s tudy i s s umma ri zed bel ow:
Table 1.1: Climatological data
S. No.
Parameter
Max
Min.
Annual Average
1.
Ambi ent Tempera ture (°C)
35
25
33.6
2.
Rel a ti ve Humi di ty (%)
60
27
38.5
The a verage value of the a tmospheric parameters is assumed for the study.
1.6.1 Wind Speed and Wind Direction
The wi nd speed and wind direction data which have been used for the s tudy i s summarized
bel ow:
Wi nd Speed : 1.5 m/s & 5 m/s
Atmos pheric Stability : F a nd D
Wi nd Direction : SW.
1.6.2 Weather Category
One of the mos t i mporta nt cha ra cteri s ti cs of a tmos phere i s i ts s ta bi l i ty. Sta bi l i ty of
a tmosphere is i ts tendency to resist vertical motion or to s uppress existing turbulence. Thi s
tendency directly i nfluences the a bility of a tmosphere to disperse pollutants emitted i nto i t
from the fa cilities. In most dispersion s cena ri os , the rel eva nt a tmos pheri c l a yer i s tha t
nea rest to the ground, va rying in thickness from a few meters to a few thous a nd meters .
Turbul ence induced by buoyancy forces i n the a tmosphere is cl osely related to the verti ca l
tempera ture gra di ent.
Temperature normally decreases with increas i ng hei ght i n the a tmos phere. The ra te a t
whi ch the temperature of air decreases with hei ght i s ca l l ed Envi ronmenta l La ps e Ra te
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(ELR). It wi ll va ry from time to ti me a nd from place to place. The atmosphere i s s a i d to be
s ta ble, neutral or uns ta bl e a ccordi ng to ELR i s l es s tha n, equa l to or grea ter tha n Dry
Adi a ba ti c La ps e Ra te (DALR), whi ch i s a cons ta nt va l ue of 0.98°C/100 meters .
Pa s -qui l l s ta bi l i ty pa ra meter, ba s ed on Pa s -qui l l – Gi fford ca tegori za ti on, i s s uch a
meteorological parameter, which describes the s tability of a tmosphere, i .e., the degree of
convecti ve turbulence. Pa s-quill has defined six stability classes ranging from `A' (extremel y
uns table) to `F' (moderately s table). Wind s peeds , i ntens i ty of s ol a r ra di a ti on (da yti me
i ns ulation) and nighttime sky cover have been i dentified a s pri me fa ctors defi ni ng thes e
s ta bi l i ty ca tegori es .
When the a tmosphere is unstable a nd wind speeds a re modera te or hi gh or gus ty, ra pi d
di s persion of pollutants will occur. Under these conditions, pollutant concentra ti ons i n a i r
wi l l be moderate or low a nd the material will be dispersed ra pidly. When the a tmosphere i s
s ta ble a nd wi nd s peed i s l ow, di s pers i on of ma teri a l wi l l be l i mi ted a nd pol l uta nt
concentration i n air will be high. In general, worst dispersion conditions (i.e. contributi ng to
grea ter hazard distances) occur during l ow wind s peed a nd very s table weather condi ti ons .
1.7 METHODOLOGY ADOPTED FOR CONSEQUENCE ANALYSIS
Cons equences of loss of conta i nment ca n l ea d to ha za rdous s i tua ti on i n a ny i ndus try
ha ndl i ng potenti a l l y ha za rdous ma teri a l s . Fol l owi ng fa ctors govern the s everi ty of
cons equence of the l os s of conta i nment.
Intri nsic properties; flammability, i nstability a nd toxicity.
Di s persive energy; pressure, temperature and state of ma tter.
Qua ntity present
Envi ronmental factors; topography a nd weather.
Cons equence analysis a nd calculations a re effecti vel y performed by computer s oftwa re
us i ng models va lidated over a number of applications. Consequence modeling is ca rried out
by PHAST (vers i on 6.53) of DNV Softwa re, UK.
PHAST us es the Unified Dispersion Model (UDM) ca pable of describing a wide ra nge of types
of a cci dental releases. The Model uses a particularly flexible form, allowing for s harp-edged
profi l es , whi ch become more di ffus e downwi nd.
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PHAST conta ins data for a large number of chemicals and allows defi ni ti on of mi xtures of
a ny of these chemicals i n the requi red proporti on. The ca l cul a ti ons by PHAST i nvol ve
fol l owi ng s teps for ea ch model ed fa i l ure ca s e:
Run di s cha rge ca l cul a ti ons ba s ed on phys i ca l condi ti ons a nd l ea k s i ze.
Model fi rs t s ta ge of rel ea s e (for ea ch wea ther ca tegory).
Determine va por relea s e ra te by fl a s hi ng of l i qui d a nd pool eva pora ti on ra te.
Di s pers i on model i ng ta ki ng i nto a ccount wea ther condi ti ons .
In ca s e of flammable release, calculate size of effect zone for fi re a nd expl os i on.
The ha zardous materials considered in this s tudy a re mostly fl ammable liquids. Flow
cha rt for consequence a nalysis is s hown i n the form of event tree for rel ea s e of
fl a mma bl e l i qui d.
1.8 HAZARDS OF MATERIALS
Definitions
The rel ease of flammable gas or l i qui d ca n l ea d to di fferent types of fi re or expl os i on
s cenarios. These depend on the material released, mechanism of release, temperature a nd
pres sure of the material a nd the point of ignition. Types of flammable effects a re as follows.
a.
Pool fire
The rel eased flammable material which i s a liquid stored below its normal boiling point, will
col l ect in a pool. The geometry of the pool will be dictated by the s urroundings. If the liquid
i s s tored under pressure a bove its normal boiling point, then a fra cti on of the l i qui d wi l l
fl a sh i nto va por and the remaining portion will form a pool i n the vi ci ni ty of the rel ea s e
poi nt. Once s ustained combusti on i s a chi eved, l i qui d fi res qui ckl y rea ch s tea dy s ta te
burni ng. The heat release ra te is a function of the liquid s urfa ce a rea expos ed to a i r. An
unconfined s pill will tend to have thin fuel depth (typically l ess than 5 mm) which will res ul t
i n s lower burning rates. A confined spill is limited by the boundaries (e.g. dyked a rea ) a nd
the depth of the res ul ti ng pool i s grea ter tha n tha t for a n unconfi ned s pi l l .
b.
Flash fire:
It occurs when a va por cl oud of flammable material burns. The cl oud i s typically i gni ted on
the edge and burns towards the rel ea s e poi nt. The dura ti on of fl a s h fi re i s very s hort
(s econds), but it ma y continue a s jet fi re i f the rel ea s e conti nues . The overpres s ures
generated by the combustion are not considered significant in terms of damage potential to
pers ons , equi pment or s tructures . The ma jor ha za rd from fl a s h fi re i s di rect fl a me
i mpingement. Typically, the burn zone is defined as the area the va por cl oud covers out to
ha l f of the LFL. This definition provides a conservative estimate, allowing for fluctuations i n
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model i ng. Even where the concentra ti on ma y be a bove the UFL, turbul ent i nduced
combus ti on mi xes the ma teri a l wi th a i r a nd res ul ts i n fl a s h fi re.
c.
Jet Fire:
Jet fl a mes are characterized a s high-pressure release of gas from limited openings (e.g. due
to s ma ll leak i n a vessel or broken drain va lve). Boiling l i qui d expa ndi ng va por expl os i on
(BLEVE) or fi reball: A fi reball is a n i ntense spherical fire resulting from a sudden rel ea s e of
pres surized liquid or gas that is immediately i gnited. The best known ca use of a fireball i s a
boi ling liquid expandi ng va por expl os i on (BLEVE). Fi reba l l dura ti on i s typi ca l l y 5 – 20
s econds .
d.
Vapor cloud explosion
When a large quantity of flammable va por or ga s i s rel ea s ed, mi xes wi th a i r to produce
s ufficient mass in the flammable ra nge and is i gnited, the result is a va por cl oud expl os i on
(VCE). Wi thout s ufficient air mi xing, a di ffus i on-control l ed fi reba l l ma y res ul t wi thout
s i gnificant overpressures developing. The s peed of flame propagation mus t a ccel era te a s
the va por cl oud burns . Wi thout thi s a ccel era ti on, onl y a fl a s h fi re wi l l res ul t.
1.8.1 HAZARDS ASSOCIATED WITH TOXIC MATERIALS
It i s necessary to s pecify s uitable concentration of the toxic substance under s tudy to form
the end-point for consequence calculations . The cons i dera ti ons for s peci fyi ng the endpoi nts for the hazardous material invol ved i n the fa i l ure s cena ri o a re des cri bed i n the
fol lowing paragraphs. American Industrial Hygiene Association (AIHA) has issued Emergency
Res pons e Pl a nni ng Gui del i nes (ERPG) for ma ny chemi ca l s .
•
ERPG-1 i s the maximum airborne concentra ti on bel ow whi ch i t i s bel i eved tha t
nea rly a ll i ndividuals could be exposed for up to 1 hour wi thout experi enci ng other tha n
mi l d tra nsient a dverse health effects or perceiving a cl early defined, objecti ona bl e odour.
•
ERPG-2 i s the maximum airborne concentra ti on bel ow whi ch i t i s bel i eved tha t
nea rly a ll i ndividuals could be exposed for up to 1 hour without experiencing or devel opi ng
i rreversible or other serious health effects or s ymptoms, which could impair an individua l 's
a bi l i ty to ta ke protecti ve a cti on.
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•
ERPG-3 i s the maximum airborne concentra ti on bel ow whi ch i t i s bel i eved tha t
nea rly a ll i ndividuals could be exposed for up to 1 hour without experiencing or devel opi ng
l i fe-threa teni ng hea l th effects .
Toxi c l imit values a s Immediately Dangerous to Li fe or Hea l th (IDLH) concentra ti ons a re
i s sued by US National Institute for Occupational Safety a nd Hea l th (NIOSH). An IDLH l evel
represents the maximum airborne concentration of a substa nce to whi ch a hea l thy ma l e
worker ca n be exposed as l ong as 30 mi nutes a nd s till be able to escape without l oss of l i fe
or i rreversible organ s ystem damage. IDLH values a lso take into cons i dera ti on a cute toxi c
rea cti ons such as s evere eye i rritation, which could prevent escape. IDLH values a re used in
s el ecti on of brea thi ng a ppa ra tus .
TLV: Thres hold Limit Value – i s the permi tted l evel of expos ure for a gi ven peri od on a
wei ghted a vera ge ba s i s (us ua l l y 8 hrs for 5 da ys i n a week).
STEL: A Short Term Exposure Li mit (STEL) is defined by ACGIH as the concentration to whi ch
workers ca n be exposed continuously for a s hort peri od of ti me wi thout s ufferi ng from:
Irri ta ti on
chroni c or i rrevers i bl e ti s s ue da ma ge
Na rcos is of sufficient degree to increase the likelihood of a cci denta l i njury, i mpa i r
s el f-res cue or ma teri a l l y reduce work effi ci ency.
It i s permi tted Short Ti me Expos ure Li mi t us ua l l y for a 15-mi nute expos ure.
IDLH: IDLH i s a n a cronym for Immedia tel y Da ngerous to Li fe or Hea l th. Thi s refers to a
concentration, formally s peci fi ed by a regul a tory va l ue, a nd defi ned a s the ma xi mum
exposure concentration of a given chemical i n the workplace from which one could es ca pe
wi thin 30 mi nutes without a ny es ca pe-i mpa i ri ng s ymptoms or a ny i rrevers i bl e hea l th
effects . Thi s va l ue i s norma l l y referred to i n res pi ra tor s el ecti on.
LCLo: Letha l Concentration Low (LCLo) value is the lowest concentration of a material i n a i r
reported to have ca used the death of a nimals or huma ns . The expos ure ma y be a cute or
chroni c. This i s also called the l owest concentration ca using death, lowes t detected l etha l
concentra ti on, a nd l etha l concentra ti on l ow.
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LDLo: LDLo i s cl osely related to the LC50 va l ue which is the concentration which kills ha l f of
the tes t animals under controlled conditions. This va lue a pplies to va pors, dusts, mi s ts a nd
ga s es. Solids and liquids use the cl osely related LDLo va lue for routes other than inha l a ti on
TCLo: Toxi c Concentra ti on Low qua nti ty a t whi ch a wa ter-s ol ubl e, l i qui d, or ga s eous
s ubstance produces harmful effects in specified test s pecie over a certain exposure peri od.
1.8.2 Damage Criteria
Da mage estimates due to thermal ra diations a nd overpres s ure ha ve been a rri ved a t by
ta ki ng in to consideration the published literature on the s ubject. The cons equences ca n
then be visualized by the s uperimposing the damage effects zones on the proposed plan site
a nd i denti fyi ng the el ements wi thi n the project s i te a s wel l a s i n the nei ghbori ng
envi ronment, which might be adversely a ffected, s hould one or more hazards materialize i n
rea l l i fe.
1.8.3 Thermal Damage
The effect of thermal ra diation on people is mainly a function of intensity of ra di a ti on a nd
exposure time. The effect is expressed i n terms of the proba bi l i ty of dea th a nd di fferent
degrees of burn. The fol l owi ng ta bl es gi ve the effect of va ri ous l evel s of hea t fl ux.
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1.8.3.1 Damage Due to Radiation Intensity
Table 1.2: Damage Due to Radiation Intensity
RADIATION
KW/m2
1.2
DAMAGE TO EQUIPMENT
DAMAGE TO PEOPLE
Sol a r hea t a t noon.
1.6
***
Mi ni mum l evel of pa i n thres hol d.
2.0
PVC i ns ul a ted ca bl es da ma ged
Mi ni mum l evel of pa i n thres hol d.
4.0
***
Ca us es pain if duration i s longer than 20
s ec. But bl i s teri ng i s unl i kel y.
6.4
***
Pa i n thres hol d rea ched a fter 8 s ec.
Second degree burns a fter 20 s ec.
12.5
Mi ni mum energy to i gni te wood 1% l etha l i ty i n one mi nute.
wi th a flame; Melts plasti c tubi ng. Fi rs t degree burns i n 10 s ec.
16.0
25.0
37.5
***
Severe burns a fter 5 s ec.
Mi ni mum energy to i gnite wood a t
100% l etha l i ty i n 1 mi nute.
i dentifying long exposure without a
Si gni fi ca nt i njury i n 10 s ec.
fl a me.
Severe da ma ge to pl a nt
100% l etha l i ty i n 1 mi nute.
50% l etha l i ty i n 20 s ec.
1% l etha l i ty i n 10 s ec.
1.8.3.2 Fatal radiation exposure levels
Table 1.3: Fetal radiation Exposure Level
RADIATION LEVEL
kW/m2
FATALITY
1%
50%
99%
EXPOSURE IN SECONDS
4.0
150
370
930
12.5
30
80
200
37.5
8
20
50
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1.8.4 Overpressure Damage:
Table 1.4: Overpressure Damage Criteria
OVER PRESSURE
(mbar)
MECHANICAL
EQUIPMENTS
DAMAGE
TO
DAMAGE TO PEOPLE
1% dea th from l ung da ma ge
300
Hea vy da mage to pl a nt & s tructure
>50% ea rdrum da ma ge
>50% s eri ous wounds from
fl yi ng objects
Repa i ra bl e da ma ge
>1% ea rdrum da ma ge
>1% s eri ous wounds from
30
Ma jor gl a s s da ma ge
fl yi ng objects
Sl i ght i njury from fl yi ng gl a s s
10
10% gl a s s da ma ge
***
100
1.8.4.1 Over pressure damage: (In Details)
Table 1.5: Over pressure Damage
OVER PRESSURE
Bar
KPa
MECHANICAL DAMAGE TO EQUIPMENTS
0.0014
0.0021
0.14
0.21
Annoyi ng noise (137 dB if of low frequency 10–15 Hz).
Occa s ional breaking of large glass wi ndows already under s train.
0.0028
0.0069
0.28
0.69
Loud noise (143 dB), sonic boom, glass failure.
Brea kage of small windows under s train.
0.0103
0.0207
1.03
2.07
Typi ca l pressure for glass breakage.
Sa fe distance" (probability 0.95 of no s erious damage below this va lue);
projectile limit; some damage to house ceilings; 10% wi ndow glass
broken.
0.0276
0.030.069
2.76
3.4-6.9
Li mi ted minor s tructural damage.
La rge a nd small windows usually s hattered; occasional .damage to
wi ndow frames.
0.048
0.069
4.8
6.9
Mi nor da mage to house structures.
Pa rti al demolition of houses, made uninhabitable.
0.0690.138
6.913.8
Corruga ted asbestos s hattered; corrugated steel or aluminum panels,
fa s tenings fail, followed by buckling; wood panels (standard
housing)fastenings fail, panels blown in.
0.09
9.0
Steel fra me of clad building slightly distorted.
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0.138
0.1380.207
13.8
13.820.7
Pa rti al collapse of walls and roofs of houses.
Concrete or ci nder block walls, not reinforced, s hattered.
0.158
15.8
Lower l imit of s erious structural damage.
0.172
17.2
50% des truction of brickwork of houses.
0.207
20.7
0.2070.276
20.727.6
Hea vy ma chines (3000 l b) i n i ndustrial building s uffered little damage;
s teel fra me building distorted a nd pulled away from foundations.
Fra meless, self-framing s teel panel building demolished; rupture of oil
s tora ge tanks.
0.276
0.345
27.6
34.5
Cl a dding of light i ndustrial buildings ruptured.
Wooden utility poles s napped; tall hydraulic press (40,000 l b) i n
bui lding slightly damaged.
0.3450.482
34.548.2
Nea rly complete destruction of houses.
0.482
48.2
Loa ded, lighter weight (British) tra in wagons overturned.
0.4820.551
0.62
48.255.1
62.0
Bri ck pa nels, 8–12 i n. thick, not reinforced, fail by s hearing or flexure.
0.689
68.9
0.689
68.9
20.68
2068
Loa ded train boxcars completely demolished.
Proba ble total destruction of buildings; heavy ma chine tools (7,000 l b)
moved a nd badly damaged, very heavy ma chine tools (12,000 l b)
s urvi ve.
Proba ble total destruction of buildings; heavy ma chine tools (7,000 l b)
moved a nd badly damaged, very heavy ma chine tools (12,000 l b)
s urvi ve.
Li mi t of cra ter lip.
1.9 CONSEQUENCE ANALYSIS
1.9.1 Introduction
The consequence a nalysis is ca rried out to determine the extent of s prea d (di s pers i on) by
a cci dental release which ma y lead to jet fire, pool fire, ta nk fi re res ul ti ng i nto genera ti ng
hea t ra di a ti on, overpres s ures , expl os i ons etc.
In order to form a n opi ni on on potenti a l l y s eri ous ha za rdous s i tua ti ons a nd thei r
cons equences, consequence anal ys i s of potenti a l fa i l ure s cena ri os i s conducted. It i s
qua litative analysis of hazards due to va rious failure s cenari os . In cons equence a na l ys i s ,
Chapter 6-31
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ea ch failure case i s considered i n isolation a nd damage effects predicted, wi thout taking into
the a ccount of the secondary events or fa ilures i t may ca use, leading to a major di s a s trous
s i tuation. The results of consequence analysis are useful in developing disaster management
pl a n a nd i n developing a sense of awareness among operating and maintenance personnel .
It a l so gives the operating personnel and population living i n i ts vi cinity, a n understanding of
the ha za rd they a re pos ed to.
1.9.2 Event Outcomes
Upon release of flammable / toxi c gas & l i quids, the hazards coul d l ea d to va ri ous events
whi ch are governed by the type of release, release phase, ignition etc. PHAST has a n i n-built
event tree for determining the outcomes which are based on two types of releases na mel y
conti nuous a nd i nstantaneous. Leaks a re considered to be continuous rel ea s es wherea s ,
ruptures are considered to be i nstantaneous releases. These types of rel ea s es a re further
cl a ssified i nto those which have a potential for rain-out and thos e whi ch do not. Whether
the rel ease would l eak to a ra in-out or not depends upon dropl et model i ng whi ch i s the
ma i n ca use of formation of pools. Fig 6.1, 6.2, 6.3 a nd 6.4 presents the event trees uti l i zed
by PHAST to genera te the event outcomes .
Fi gure 1.1: Event Tree for conti nuous rel ea s e wi thout ra i n-out (from PHAST)
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Fi gure 1.2: Event Tree for Ins ta nta neous rel ea s e wi thout ra i n-out (from PHAST)
Fi gure 1.3: Event Tree for conti nuous rel ea s e wi th ra i n-out (from PHAST)
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Fi gure 1.4: Event Tree for Ins ta nta neous rel ea s e wi th ra i n-out (from PHAST)
1.9.3 Modes of Failure
There a re va rious potential causes a nd s ources of leakage. This may be by way of failures of
equipment or piping, due to pump seal failure, i nstrument tubing giving way, fa i l ure of the
pi pes, failure of process vessels etc. Following Table represents general mechanism for l oss
of conta i nment for Pi pi ng a nd fi tti ng, i ns truments , a nd huma n error.
(A). Piping and Fitting
Ref.
LOSS OF
Table 1.6: Piping and Fitting
EXAMPLES OF POSSIBLE BASIC
No.
CONTAINMENT
CAUSE
A.1
REMARKS
Fl a nge/Gasket Leaks - Incorrect ga s ket i ns ta l l ed, e.g. Pos s i bl e
fl a me
i ncorrect ma teri a l , i ncorrect s i ze i mpi ngement
a nd
(thi cknes s a nd di a meter).
l oca l i zed hea ti ng of
- Incorrect i nstallation, e.g. fl a nge a dja cent equi pment.
fa ces not cl ea ned, fl a nged fa ce
da maged, i ncorrectly ti ghtened bolts,
i ncorrect bol ts us ed.
- Fl a nge repl a cement wi thout
ga s ket.
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Ref.
No.
A.2
LOSS OF
CONTAINMENT
Pi pe
Overs tres s
EXAMPLES OF POSSIBLE BASIC
REMARKS
CAUSE
- Ina ppropri a te us e of des i gn Pi pe s tres s es woul d
Ca us i ng Fra cture
codes .
- Error i n s tres s
a na l ys i s
ca l cul a ti ons .
- La ck of i ns pecti on duri ng pi pe
mos t l i kel y ca us e a
fl a nge l ea k, unl es s
there
exi s ted
a
combi nation of errors ,
erecti on, e.g. exces s i ve col d pul l .
- Pi pe tes ti ng i ncorrectl y ca rri ed
out.
- Incorrect s etti ng of s pri ng
e.g. i ns ta l l a ti on of
rogue ma teri a l s a nd
uns ui ta bl e
pi pe
s upport, or error i n
ha ngers a nd pi pe s upports a nd s tress ca lcula ti on pl us
s l i di ng s hoes not free to move.
fa i lure to pressure tes t.
- Pi pe not hydro tested because of
bore s ize (or considered not cri ti ca l )
a nd no s econda ry tes t procedures
ca rri ed out.
- Omi s sion to test because s ystems
not cl ea rl y i denti fi ed, or error i n
documenta ti on.
- Extreme temperature differential
i n pi pe work not ca tered for i n
des i gn, i .e. col d a nd hot s trea ms
A.3
Over pres surizati on a) Ina dequa te Pres s ure Rel i ef
of
Pi pe
work - Rel i ef va l ve ‘s i mmeri ng’ a nd
Ca us i ng Fra cture
hydra ti ng, i ci ng.
- Incorrect s etting of RV pres s ure.
- Incorrectl y s i zed RV.
Ca reful
a ttenti on
requi red for ha ndl i ng
hydroca rbons
wi th
“free” wa ter.
- Wrongl y i nstalled RV, e.g. due to
tra ns ferred ta g No. : or i nstallation of
i ncorrect s pri ng ma teri a l .
- Abus e of locking s ys tem a nd a l l
RVs i s ol a ted from s ys tem
Ri gorous adherence to
- Exces sive back pres s ure ca us ed procedures is essential .
by bl ocka ge of rel i ef s ub-hea ders
wi th s l udge, i ce/hydra te, etc.
Chapter 6-35
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ES SMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
Ref.
No.
LOSS OF
CONTAINMENT
EXAMPLES OF POSSIBLE BASIC
REMARKS
CAUSE
- Hi gh pressure breakthrough i nto
l ow pres s ure s ys tems , whi ch ha ve
i na dequa te rel i ef ca pa ci ty.
- Bl ockage of RVs with debris/fines,
e.g. mol si eve dus t, or brea ka ge of
s creens /pa cka ge/demi s ter.
b) Exces s i ve
Ha mmer
Surge
Pres s ure
Rel ief ca pa ci ty s houl d
a l ways be adequa te or
hi gh i ntegri ty tri p
s ys tem i ns ta l l ed.
Potenti a l
probl em
a round mol s i eve
/ ves s el s , a bs orbers ,
col umns a nd RVs .
- Too ra pid isolation or blockage of
l i quid full l ines, i.e., operator cl os i ng Cons i der needs to
i s ol a ti on va l ve.
ha ndle l iquid slugs from
feed line when pi ggi ng
- Ra pid blockage of l iquid lines, e.g. recommended.
NRV fa i l ure.
Pa rti cular ca re required
- Li nes not or i na dequa tel y a t pi g tra ps and at i nl et
des igned for two pha s e/s l ug fl ow. PCVs /bypa s s .
- Too ra pid opening of va l ves a nd
l etdown of l i qui d under hi gh No
remote
di fferenti a l pres s ure.
depressuri zi ng s ys tem
- Ra pid va porization of cold l i qui d a va i l a bl e; requi res
i n conta ct wi th hot fl ui d. (Ra pi d revi ew.
pha s e tra ns i ti on).
Potenti a l
for
ca ta strophic rupture of
c) Rupture Under Fi re Condi ti ons equi pment,
- Di rect fi re impingement wi thout fra gmenta ti on
a ny cooling (internal or externa l ) or fi reba l l effects .
fa i l ure to effecti vel y depres s ure
equi pment.
A-4
a nd
Fa i lure of piping due - Fa i lure due to a cous ti c fa ti gue Vul nera bl e a rea s a re
to
fa ti gue
or a ri s i ng from:pi ping downs trea m of
vi bra ti on.
E.g. fa i l ure to recogni ze probl em PCVs a nd RVs operating
exi s ts i n particula r a rea s , fa i l ure to a t very hi gh pres s ures .
ta ke a dequate precautions (selection Pa rti cularly s usceptibl e
Chapter 6-36
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ES SMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
Ref.
No.
LOSS OF
CONTAINMENT
EXAMPLES OF POSSIBLE BASIC
REMARKS
CAUSE
of i ncorrect valve at desi gn s ta ge or i s s mall bore pipe work
duri ng maintenance, inadequate line
s upport).
Improper
tes ting/inspection when i n s ervi ce,
fa i l ure to report a bnorma l l y hi gh
a s s oci a ted
wi th
pres sure l etdown a nd
two pha se flow systems
a nd
compres s ors /
noi se levels (during normal and upset pumps .
condi ti ons ).
- Fa i l ure due to mecha ni ca l
vi bra ti on a ri s i ng from:
Regeneration ga s pi pe
e.g. fa i l ure to recogni ze probl em, work a nd connecti ons
i na dequate s upport, failure to report to mol s i eve ves s el s
a nd mi nor exces s i ve vi bra ti ons meri t
pa rti cul a r
(under a l l pl a nt condi ti ons ), a ttenti on.
ma i ntena nce error, (fa i l ure to
correctl y a l i gn rota ti ng equi pment
a nd tes t for vi bra ti on pri or to
rei ns ta tement?
- Fa i l ure due to pres s ure or
therma l cycl i ng.
A.5
A.8
Fa i lure of Pi pe due
to Stres s Corros i on
of Embri ttl ement
Fa i lure of piping Due
to i ns ta l l a ti on of
Wrong Ma teri a l s
- Hydrogen
embri ttlement/blistering. (Hydrogen
i nduced cra cki ng).
- Incorrect materials s election, e.g.
a t des ign stage, from supplier or site
s tores .
Onl y s ta i nl es s s teel
equi pment.
Stri ct
s ys tem
for
s upervision, inspecti on
a nd veri fi ca ti on of
- Incorrect material ins ta l l ed, e.g. ma teri a l s
requi red
i mproper
s upervi s i on
a nd duri ng all modifications.
i denti fi ca ti on of ma teri a l s a fter
wi thdra wa l from s tores .
A.9
Fa i lure of Piping Due to l ow Temperature
Bri ttl e fra cture
Rogue
ma teri a l
us ed
i n A number of s ys tems
cons tructi on, wrong
ma teri a l ha ve been identified a s
s peci fi ed, or uncerta i nti es i n
bri ng
vul nera bl e,
ma teri a l s peci fi ca ti on.
pa rti cul a rl y
where
-
Error i n ca l cul a ti ng mi ni mum condens a te a t hi gh
Chapter 6-37
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ES SMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
Ref.
No.
LOSS OF
CONTAINMENT
EXAMPLES OF POSSIBLE BASIC
CAUSE
l ower des i gn tempera tures .
-
A.10
Fa i lure of Pi ping (or -
REMARKS
pres s ure
ma y
be
Sys tems not des i gned for l ow depres s uri zed.
temperature, (e.g. on emergency
depres s uri ng) a nd i mmedi a te
repres s uri s i ng.
Impa ct from equi pment bei ng Hi s tori ca l l y, fa i l ure of
nozzl es ) Due to moved duri ng ma i ntena nce.
Externa l Forces or - Impa ct of heavy l ifti ng gea r, e.g.
Impa ct.
cra nes .
- Impa ct from s i te tra ns port, e.g.
HP proces s pi pi ng due
to mecha nical i mpact i s
confi ned ma i nl y to
s ma l l bore pi pi ng.
cons tructi on tra ffi c, fi re tender.
Stri ct control over s i te
- Impa ct on rei nforced nozzl e cons tructi on wi l l of
ca us i ng fra ctures el s ewhere, e.g. cours e be neces s a ry.
va l ve, pump ca s i ng ves s el .
Any i nci dent of i mpa ct
on pi pe work duri ng
cons tructi on mus t be
reported a nd da ma ge
i nves ti ga ted.
Chapter 6-38
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ES SMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
(B) Human Error
Table 1.7: Human Error
Ref. LOSS
OF EXAMPLES OF POSSIBLE BASIC REMARKS
No.
CONTAINMENT
CAUSE
Los s of containment through human error has been assumed i mpl i ci tl y i n the s tora ge a rea
however examples or some typical operating and maintena nce errors a re i ncl uded bel ow:B.1
Opera ti ona l Error
- Fa i l ure or i na bi l i ty to cl os e
i ns trument or s a mpl e va l ves .
- Fa i lure or i nability to cl ose dra i n
a nd vent va l ves .
- Lea vi ng safety tri ps/sys tems out
of commi s s i on a fter tes ti ng or
i ns pecti ng.
B.2
- Intenti ona l l y defea ti ng tri p
s ys tems for reas ons of producti on.
Error
in
De- - Ina dvertent or una uthori zed
commi s s i oni ng
opening of a pressurized system, e.g.
fi l ters , ves s el s .
- Improver depres s uri zi ng a nd
purgi ng of a s ystem prior to isolation
or s pa di ng.
- Fa i lure to effecti vel y i s ol a te a l l
process (and uti l i ty) a nd el ectri ca l
connecti ons .
B.3
Error
Ma i ntena nce
i n - Fa i l ure to ma i nta i n effecti ve
i s ol a ti on.
- Fa i l ure to report da ma ge to
equi pment duri ng repa i r or
modi fi ca ti on.
- Ma i ntenance a ctivities extended
to s ys tems , whi ch a re `l i ve’.
- Improper supervision of contra ct
ma i ntena nce
s ta ff, i mproper
ma i ntena nce.
B.4
Error
in
Re- - Fa i l ure to cl os e vents /dra i ns ,
commi s s i oni ng
repl a ce pl ugs .
Chapter 6-39
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ES SMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
Ref.
No.
LOSS
CONTAINMENT
OF EXAMPLES OF POSSIBLE BASIC REMARKS
CAUSE
- Improper or l a ck or purgi ng of
equi pment e.g. s phere recei ver
furna ces .
B.5
Supervi s i on Error
- Des ign error for modi fi ca ti ons .
- La ck of s upervi s i on a nd control
e.g. Authori za ti on of permi ts
i s ol a ti on.
- Fa i lure to regularl y tes t/i ns pect
e.g. tri p/a l a rm s ys tem, s a fety
equi pment.
Al l ure to regularly monitor e.g. noise
vi bra ti on,
corros i on,
s trea m
compos i ti on
1.9.4 Selected Failure Cases
Ea rl ier, i t was the practice to select a particular item i n a unit a s failure scenario, e.g. rupture
of rea ctor outlet pipe. Such selecti on i s norma l l y s ubjecti ve on fol l owi ng pa ra meters :
Properti es of ma teri a l na mel y Toxi c or Fl a mma bl e.
The l ikely severity of consequence i n the event of a cci denta l rel ea s e ba s ed on
i nventory, opera ted pres s ure & opera ted tempera ture.
The probability of fail ure of va ri ous equi pments s uch a s va l ves , fl a nges , pi pe,
pres s ure ves s el s etc. us ed i n the pl a nt.
Si ze of Release: For accidental releases i dentified for consequence analysis i s 50mm leakage.
The s cenarios are considered to be confined to those equipment failures which i nvol ve the
l eakage of flammabl e or toxi c products , of whi ch the frequency of occurrence a nd the
s everity of the consequences have been ta ken i nto consideration a nd which may have a low
proba bi l i ty of ea rl y detecti on.
Ta ki ng this factor into consideration, a list of selected failure cases was prepared ba s ed on
process knowledge, i nventory, engi neeri ng judgment, a nd experi ence, pa s t i nci dents
a s socia ted wi th s uch fa ci l i ti es a nd cons i deri ng the genera l mecha ni s ms for l os s of
conta i nment. Ca s es ha ve been i denti fi ed for the cons equence a na l ys i s .
Chapter 6-40
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ES SMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
Cons equence analysis a nd calculations a re effecti vel y performed by computer s oftwa re
us i ng models va lidated over a number of applications. Consequence modeling is ca rried out
by PHAST (vers i on 6.53) of DNV Softwa re, UK.
PHAST us es the Unified Dispersion Model (UDM) ca pable of describing a wide ra nge of types
of a cci dental releases. The Model uses a particularly flexible form, allowing for s harp-edged
profi l es , whi ch become more di ffus e downwi nd.
PHAST conta ins data for a large number of chemicals and allows defi ni ti on of mi xtures of
a ny of these chemical s i n the requi red proporti on. The ca l cul a ti ons by PHAST i nvol ve
fol l owi ng s teps for ea ch model ed fa i l ure ca s e:
1.9.4.1 Effect of Release
When hazardous material is released to a tmosphere due to a ny rea s on, a va por cl oud i s
formed. Direct cl oud formation occurs when a gaseous or fl a s hi ng l i qui d es ca pes to the
a tmosphere. Release of hydrocarbons a nd toxic compounds to a tmosphere may usually lead
to the fol l owi ng:
(a) Di s persion of hydrocarbon va por with wi nd till i t reaches i ts l ower flammability l imit (LFL)
or fi nds a s ource of i gnition before reaching LFL, which will result in a flash fire or explosion.
(b) Spi llage of liquid hydrocarbons will result in a pool of liquid, which will evaporate ta ki ng
hea t from the surface, forming a flammable a tmosphere a bove it. Ignition of thi s pool wi l l
res ul t i n pool fi re ca us i ng therma l ra di a ti on ha za rds .
(c) Li ghter hydrocarbon va por (e.g. Na tura l Ga s ) or Hydrogen di s pers es ra pi dl y i n the
downwind direction, being lighter than air. But comparativel y hea vi er hydroca rbon va por
cl oud like that of LPG, Propylene or Ammonia will tra vel downwind a l ong the ground. If i t
encounters a n i gni ti on s ource before i t i s di s pers ed bel ow the LFL, expl os i on of a n
unconfi ned va por cl oud wi l l genera te bl a s t wa ves of di fferent i ntens i ti es .
(d) A fi reball or BLEVE (Boiling Liquid expandi ng Va por Expl os i on) occurs when a ves s el
conta ining a highly vol atile liquid (e.g. LPG, Propylene etc) fails a nd the released large ma s s
of va por cl oud gets i gnited immediately. It has damage potenti a l due to hi gh i ntens i ty of
Chapter 6-41
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ES SMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
ra di ation a nd generation of the overpressure waves, causing large-scale dama ge to nea rby
equi pment a nd s tructures .
(e) Ca ta s trophic failure of tanks/ pressurized vessels, rotary equipment and va l ves etc. ca n
res ul t i n equi pment fra gments fl yi ng a nd hi tti ng other equi pment of the pl a nt.
(f) Rel ea s e of toxi c compounds res ul ts i n the toxi c va pour cl oud tra vel i ng over l ong
di s tances, affecting a large area, before i t gets sufficiently diluted to harmless concentration
i n the a tmos phere.
(g) The ma terial i s in two phases i nside the containment - l iquid & va por. Depending on the
l oca tion of the leak liqui d or va por wi l l be rel ea s ed from the conta i nment. If va por i s
rel eased a va por cloud will form by the mixing of the va por a nd a i r. The s i ze of the va por
cl oud will depend on the rate of release, wind speed; wi nd direction & a tmospheric s tabili ty
wi l l determi ne the di s pers i on a nd movement of the va por cl oud.
(h) If l i quid is released there will be s ome flashing as the boiling point of liquid is bel ow the
a mbient temperature. The vapor formed by i mmedi a te fl a s hi ng wi l l beha ve a s va pors
rel ease. The liquid will fall on the ground forming a pool. There will be va porization from the
pool due to the heat gained from the atmosphere & ground. There will be di s pers i on a nd
movement of va por cl oud formed by eva pora ti on of l i qui d.
The behavior of material released by l oss of containment depends on the following fa ctors :
(1) Phys i ca l properti es of the ma teri a l .
(2) Condi ti ons of ma teri a l i n conta i nment (pres s ure a nd tempera ture).
(3) Pha s e of ma teri a l rel ea s ed (l i qui d or ga s ).
(4) Inventory of ma teri a l rel ea s ed.
(5) Wea ther parameters (tempera ture, humi di ty, wi nd s peed, a tmos pheri c s ta bi l i ty).
(6) Ma teri a l wi th boi l i ng poi nt bel ow a mbi ent condi ti on.
Sta ti stical reports of consequence a nalys i s a re s umma ri zed bel ow i n Ta bl e 7. Si mi l a rl y
pi ctorial pres enta ti ons of cons equence res ul ts a re s hown bel ow the ta bul a r report.
Chapter 6-42
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ES SMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
Ethylene Oxide Tank Scenario (Dia 1.5 × 5.6,m Horizontal Tank)
Scenario
1.5 F @ 50 mm Leak & 5 D @ Catastrophic Rupture
description
Distances (m)
Weather data
Concentration
(ppm)
Early Pool
Fire(kW/m2)
Flash Fire (ppm)
2
Jet Fire (kW/m )
Late Pool Fire
(kW/m2)
Late Ignition (bar)
Early Explosion
Fire Ball Ellipse
1.5 F
5D
UFL (1e+006)
Not Set
0
LFL (30000)
10.6493
192.788
LFL Fra c (15000)
23.7713
268.681
Ra di a ti on Level (4)
---
---
Ra di a ti on Level (12.5)
---
---
Ra di a ti on Level (37.5)
Furthes t Extent
(15000)
Furthes t Extent
(30000)
Ra di a ti on Level (4)
Ra di a ti on Level (12.5)
Ra di a ti on Level (37.5)
Ra di a ti on Level (4)
---
--268.681
60.7334
15.5397
Not Rea ched
---
Ra di a ti on Level (12.5)
Ra di a ti on Level (37.5)
Overpressure(0.02068)
Overpres s ure(0.1379)
Overpres s ure(0.2068)
Overpressure(0.02068)
Overpres s ure(0.1379)
Overpres s ure(0.2068)
Ra diation l evel (4)
Ra diation l evel (12.5)
Ra diation l evel (37.5)
----116.081
44.8778
39.2499
-------------
23.7713
10.6493
192.788
------122.067
110.732
97.0362
623.654
314.144
297.371
357.079
92.4567
71.5409
117.991
30.8741
Not Rea ched
Chapter 6-43
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ES SMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
Ethylene Oxide Measuring Tank 1 Scenario (Dia 1.6× 2.7,m Vertical Tank)
Scenario
1.5 F @ 50 mm Leak & 5 D @ Catastrophic Rupture
description
Distances (m)
Weather data
Concentration
(ppm)
Early Pool
Fire(kW/m2)
Flash Fire (ppm)
Jet
Fire (kW/m2)
Late Pool Fire
(kW/m2)
Late Ignition (bar)
Early Explosion
Fire Ball Ellipse
1.5 F
5D
UFL (1e+006)
Not s et
0
LFL (30000)
9.73722
145.388
LFL Fra c (15000)
23.0778
206.804
Ra di a ti on Level (4)
---
---
Ra di a ti on Level (12.5)
---
---
Ra di a ti on Level (37.5)
Furthes t Extent
(15000)
Furthes t Extent
(30000)
Ra di a ti on Level (4)
Ra di a ti on Level (12.5)
Ra di a ti on Level (37.5)
Ra di a ti on Level (4)
Ra di a ti on Level (12.5)
Ra di a ti on Level (37.5)
Overpressure(0.02068)
Overpres s ure(0.1379)
Overpres s ure(0.2068)
Overpressure(0.02068)
Overpres s ure(0.1379)
Overpres s ure(0.2068)
Ra diation l evel (4)
Ra diation l evel (12.5)
Ra diation l evel (37.5)
---
--206.804
23.0778
9.73722
58.7377
14.6909
Not Rea ched
------112.749
44.0151
38.5823
-------------
145.388
------94.4049
85.9069
74.8145
489.517
241.214
227.342
281.299
72.8353
56.3583
91.548
21.2599
Not Rea ched
Chapter 6-44
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ES SMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
Ethylene Oxide Measuring Tank 2 Scenario
Scenario
1.5 F @ 50 mm Leak & 5 D @ Catastrophic Rupture
description
Distances (m)
Weather data
Concentration
(ppm)
Early Pool
Fire(kW/m2)
Flash Fire (ppm)
Jet
Fire (kW/m2)
Late Pool Fire
(kW/m2)
Late Ignition (bar)
Early Explosion
Fire Ball Ellipse
1.5 F
5D
UFL (1e+006)
Not Set
0
LFL (30000)
10.6114
125.035
LFL Fra c (15000)
23.7701
177.341
Ra di a ti on Level (4)
---
---
Ra di a ti on Level (12.5)
---
---
Ra di a ti on Level (37.5)
Furthes t Extent
(15000)
Furthes t Extent
(30000)
Ra di a ti on Level (4)
Ra di a ti on Level (12.5)
Ra di a ti on Level (37.5)
Ra di a ti on Level (4)
Ra di a ti on Level (12.5)
Ra di a ti on Level (37.5)
Overpressure(0.02068)
Overpres s ure(0.1379)
Overpres s ure(0.2068)
Overpressure(0.02068)
Overpres s ure(0.1379)
Overpres s ure(0.2068)
Ra diation l evel (4)
Ra diation l evel (12.5)
Ra diation l evel (37.5)
---
--177.341
23.7701
10.6114
60.7524
15.5587
Not Rea ched
------116.022
44.8625
39.238
-------------
125.035
------80.3497
71.8507
60.7208
427.961
208.149
195.072
247.585
64.1059
49.6037
79.727
16.8565
Not Rea ched
Chapter 6-45
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ES SMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
1.10 MITIGATION MEASURES
Mea s ures a nd recommenda ti ons for the propos ed Ta nk Fa rm a rea a re a s fol l ows :Offs i te preca uti on mea s ures a re to be prepa red.
Adherence of international engineering s tandards in the Des i gn, Cons tructi on a nd
tes ti ng of the s tora ge ta nks , equi pments a nd other ha rdwa re.
Al l ta nks to be provided with a utomatic s prinkler s ys tem i nterl i nked wi th fus i bl e
bul bs , the s pri nkl er s ys tem to confi rm to TAC des i gn gui del i nes .
Al l s torage tanks to have level i ndicators, flame arrestors, breather va lves a nd foa m
i njecti on s ys tem wherever requi red.
The pumps used for tra nsferring the s olvents s hall be not i n the ma i n dyke but i n a
s epa ra te dyke.
Al l pumps used to have mechanical seal to prevent l eakages a nd fugiti ve emi s s i on.
Spi llages a nd l eaks from the storage ta nks ca n be collected a nd tra nsferred out a nd
trea ted for s a fe di s pos a l .
Stora ge a rea s s ha l l be free from a ccumul a ti on of ma teri a l s .
Al l electrical a nd instrumentation equipment used in the tank farm area to be ra ted
for the s ol vent pres ent a s per ATEX s ta nda rds .
There s hould be good communication system available nea r ta nk fa rm a rea to the
control room, a nd i t s houl d be fl a meproof.
The ta nk farm s hould be protected with upwind a nd downwind foam moni tors , the
s pa ci ng of the s a me i s to be a s per TAC s ta nda rds .
A good layout should provi de for adequate fire-fighting access, means of es ca pe i n
ca s e of fire a nd also segrega ti on of fa ci l i ti es s o tha t a dja cent fa ci l i ti es a re not
enda ngered duri ng a fi re.
Routi ne Ins pecti on of Fl a me a rres tor a nd brea thi ng va l ve s houl d be done.
At every ta nk farm its license number, s tora ge ca pa ci ty & na me of the chemi ca l s
s houl d be di s pl a yed a t the entra nce.
Fl a meproof Motors for unloading near flammable storage tank s houl d be provi ded
wi th doubl e ea rthi ng.
Al l el ectri c fi tti ngs us ed i n the ta nk fa rm s houl d be fl a me proof type.
Condi ti on of N2 bl a nketi ng s houl d be checked regul a rl y, i f provi ded.
Fi re protecti on s ys tem s ha l l be provi ded on ea ch ta nk, a fi xed foa m pouri ng
a rra ngement to tackle a ny duke s pil l a ges s houl d a l s o be cons i dered. The foa m
bl a nket prevents s urfa ce eva pora ti on form l i qui d pool .
Chapter 6-46
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ES SMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
Devel op deta i l ed ma i ntena nce/contra ctor procedures requi ri ng phys i ca l
i dentification of ta nk vents during walk-through a nd other devi ces whi ch ha ven’t
cover duri ng ma i ntena nce a cti vi ti es .
Emergency cupboards containing self contained breathing a pparatus, fires suits a nd
chemi ca l s ma s ks a nd s ui ts to be kept nea r the ta nk fa rm a rea s .
Outs i de shaded or detached storage areas are preferred for Metha nol . A deta ched
s tora ge area is either an outside shaded area or a separate bui l di ng conta i ni ng no
i ncompa ti bl e ma teri a l s a nd l oca ted a wa y from a l l other s tructures .
In the ca se of detached storage the building construction should be fire resistant and
provi sions made for potential fire-fighting activities. The fi re-fi ghti ng i ns ta l l a ti on
s hould include provision for a n a dequate s uppl y of wa ter. Fi re exti ngui s hers a nd
hydra nts should be distributed around the area. Fire-fighting water run-off should be
prevented from pol l uti ng wa ter s ources .
A tel ephone should be provided which is freely a vailable and readil y a cces s i bl e for
the reporting of a cci dents or emergency s i tua ti ons . The emergency tel ephone
numbers s houl d i ncl ude the fi re depa rtment, a mbul a nce s ervi ce, emergency
res pons e tea m, hos pi ta l a nd pol i ce.
Emergency respirator equipment ca binets s houl d be i ns ta l l ed not more tha n 30
meters or ten seconds wa l ki ng di s ta nce from a ny l oca ti on i n the s tora ge a rea .
Non-freeze safety s howers a nd eyewash fountains shall be provided, clearly marked,
wel l lit a nd with unobstructed a ccess. They s hould be installed close to the bromi ne
s tora ge area and not more than 30 meters or ten seconds walking distance from any
l oca ti on i n the s tora ge a rea . Provi de a l terna ti ve s ources of wa ter s uppl y.
Lea d detector s ys tem s houl d be i ns ta l l ed.
Company has obtained renewal license for Ehylene Oxide Storage license from
Petroleum and Explosives Safety Organisation (PESO), West Circle, Ministry of
Commerce & Industry, Govt. of India, vide License No.: S/HO/GJ/03/210(S1368)
Date of Issue: 13-04-2011, Validity upto: 31-03-2014 and Renewal License vide
License No.: S/HO/GJ/03/210(S1368) Date of Issue: 17-02-2014, Validity up to 3103-2017 (Please Refer Annexure – 1) vide compliance of their requirements. Our
suggestion is to maintain Compliance of conditions given by PESO for storage and
handling of Ethylene Oxide.
Chapter 6-47
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ES SMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
1.11 REFERENCES
Qua ntitative Ris k As s es s ment-M.J Borys i ewi ez, M.A. Borys i ewi ez, L.Ga ra nty, A.
Kozuba l .
Gui de to Ma nufacture, Storage a nd Import of Hazardous Chemical s Rul es (MSIHC),
1989 i s sued by the ministry of envi ronment a nd fores ts , (MoEF) Govt.of Indi a a s
a mended up to da te.
Worl d Bank Technical pa pers rel a ti ng to “Techni ques for a s s es s i ng Indus tri a l
Ha za rds ”.
Ma jor Ha za rd Control by ILO.
Ri s k Ma na gement Progra m gui del i nes by EPA (US).
Worl d Bank Technical Paper no. 55 – Technica l td. For assessing hazards – A Ma nual.
PHAST v 6.53-Softwa re.
Overa l l pl ot pl a n.
Chapter 6-48
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ES SMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
6.3 CREP GUIDELINES:
There a re 17 types of industrial s ector for which CREP guideline have been given. Si nce
Shree Va l labh Chemical is a Syntheti c orga ni c chemi ca l i ndus try of emulsifier and deemulsifier, the gui delines are not applicable to them. The list of 17 types of i ndus tri es
for whi ch CREP gui del i nes ha ve been formed i s gi ven bel ow.
1. Al uminium
2. Cement
3. Chl or – Al kali
4. Copper
5. Di s tillery
6. Dyes & dye i ntermediates
7. Ferti lizer
8. Iron & Steel
9. Oi l Refineries
10. Pes ti cides
11. Petrochemicals
12. Pul p & Pa per
13. Suga r
14. Ta nnery
15. Thermal Power Pl ants
16. Zi nc
Even though the CREP guide lines are not yet established for this kind of indus try, Shree
Va l labh Chemical has i nitiated number of measures to keep the pol l uti on l evel to the
mi nimum. Following actions a re ta ken as s elf-initiated Responsibility for Envi ronmenta l
Protecti on a nd Pol l uti on preventi on. .
1. The a sh from boiler wi l l be s old to cement ma nufa cture or wi l l be s old to bri ck
ma nufa cturer.
2. The hei ght of the boi l er chi mney will keep 31 meters to di s pers e fl ue ga s es .
3. A M ulti-cone type cyclone separator will be provi ded to removed PM a nd SPM from
boi l er fl ue ga s es
4. Ethyl ene Oxide (EO) storage tank vent i s di pped i n wa ter to control EO pol l uti on.
5. The us ed drums of raw materia l s wi l l be s ent to the GPCB a uthori zed recycl ers .
6. The us ed oil from engines a nd pump/a gi ta tor s ea l wi l l be col l ected a nd s ent to
a uthori zed recycl ers .
7. Effluent will be treated in effluent treatment pl a nt a nd will be evaporated.
8. The pumps agitator a nd fl a kers us e energy effi ci ent motor to cons erve energy.
9. Eco venti lators will be used to maintain the EO l evel bel ow thres h hol d l i mi t of 1
ppm.
10. Acous tic enclosure will be installed in DG s et to minimize noise pollution.
Chapter 6-49
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ES SMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
COMPLIANCE OF CREP GUIDELINES
Sr.
No.
1.
Action Point
Segregation of waste stream
•
2.
Waste streams should be segregated •
into high COD waste, toxic waste, low
COD waste, inorganic waste etc. for •
the purpose of providing appropriate
treatment
No high COD streams / toxic streams shall be
generated from the unit.
Effluent shall be treated in the Primary Effluent
Treatment Plant before sending it to in-house
Evaporator for evaporation, thus achieving “Zero
Discharge”.
Management of solid waste
•
•
•
•
3.
Compliance
Proper facilities should be provided for
handling and storage of hazardous
waste.
For final disposal of hazardous waste,
recycling and reuse should be given
priority, either within the premises or
outside with proper manifest system.
In case of incinerable waste, properly
designed incinerator should be
installed within the premises or
outside as a common facility.
The non-incinerable hazardous waste
should be disposed of in properly
designed secured landfill either within
the industry’s premises or in a
common facility.
•
•
•
•
•
•
Sepa rate s olid & ha zardous wastes s tora ge
a rea havi ng impervious bottom, pucca roof
a nd l eachate col l ecti on s ys tem ha s been
provi ded. Leachate, i f a ny, wi l l be ta ken to
ETP for trea tment a nd di s pos a l .
Al l ha za rdous wa s tes wi l l be s epa ra tel y
s tored at this s ite in a ppropriate conta i ner.
ETP s l udge wi l l be di s pos ed-off to TSDF.
Us ed Oil will be given to CPCB registered reproces s or of oi l .
Di s ca rded conta i ners wi l l be gi ven to
regi stered vendor a fter deconta mi na ti on.
Proces s wastes/ used Softner res i n wi l l be
di s pos ed-off a t CHWIF.
Minimum scale of production to afford
cost of pollution control
•
•
For new i ndustri es whi ch a re not •
connected wi th CETP & TSDF a nd
whi ch do not have the economi cs
to i ns tall treatment fa ci l i ti es ma y •
not be cons i dered for gra nti ng
cons ent to es ta bl i s hment.
Industry association s ha l l s ubmi t
propos a l to SPCB / CPCB
The Unit will install an in-house ETP cum
evaporation system, thus achieving “Zero
Discharge”.
Unit is in procedure to obtain TSDF membership.
Chapter 6-50
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ES SMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
4.
Long term strategies for reduction in
waste
•
•
5.
Consent for establishment and •
Consent for operation under Water
Act will be based on pollution load and
concentration of pollutants.
Each industry will submit pollution •
load, concentration of final discharge
alongwith
water
balance
to
SPCB/CPCB for formulation of strategy
7.
The unit will strive to reduce polluti on l oa d
through optimum uti l i za ti on of res ources
l i ke ra w ma teri a l , energy, etc.
Control of air pollution
•
6.
Necessary details will be provi ded to GPCB
a t a ppropri a te s ta ge of project
i mpl ementa ti on.
Indus try wi l l ta ke up on pri ori ty, •
the control of ha za rdous a i r
pol l uta nts (s uch a s Benzene,
Ca rbon Tetrachloride, 1 – 4 Di oxi n,
Metha nol , Tol uene, Methyl
Chl ori de etc.) a nd odorous
compounds (Merca pta nts &
Hydrogen Sul phi de)
Self-Regulation by Industry though
regular monitoring and environmental
auditing
•
• Industries on thei r own wi l l ca rry
out monitoring of envi ronmenta l
pa ra meters , a udi t i t i n regul a r
i ntervals and s ubmi t the s a me to
SPCB.
•
There a re no proces s rel a ted emi s s i ons
genera ted from the uni t.
Al l a pplicable environmental parameters will
be regul a rl y moni tored a s per the
Envi ronmental Monitoring Pl an formul a ted
by the uni t.
Envi ronmental Statement (i n Form-V) will be
regul a rl y s ubmi tted to GPCB.
Organisational
restructuring
and
accreditation
of
Environmental
Manager of Industry
•
Envi ronment Ma nagement Cell will •
be crea ted for ea ch i ndus try
reporti ng to CEO di rectl y.
•
There s houl d be a certi fi ca ti on •
s ys tem for the envi ronmenta l
ma nagers at i ndi vi dua l l evel a nd
common facility l evel . BDMA ma y
evol ve the programme a l ongwi th
SPCB/CPCB
The uni t s ha l l s et-up a n Envi ronment
Ma na gement Cell consisting of well-qualified
a nd experienced professionals from the field
of s a fety a nd envi ronment.
The uni t wi l l s tri ve to obta i n ISO : 14001
certi fi ca ti on.
Chapter 6-51
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ES SMENT REPORT – EXPANS ION PROJECT
PAVAN ENVITECH CONSULTANT PVT. LTD.
8.
Optimising the inventory of hazardous
chemicals
•
The i nformation shall be submitted •
to SPCB regul a rl y a l ongwi th
ra ti ona l a cti on pl a n
•
•
Al l rul es a nd regul a ti ons of Fa ctory
Ins pectora te wi l l be compl i ed wi th.
On-s ite emergency pl a n wi l l be prepa red
ba s ed on ri sk assessment s tudy a nd s tri ctl y
i mpl emented.
Al l details will be submitted to all concerned
a uthori ti es a s per MSIHC Rul es .
Chapter 6-52
S HREE VALLABH CHEMICAL
ENVIRONMENTAL IMPACT AS S ES SMENT REPORT – EXPANS ION PROJECT