9.0 RISK ASSESSMENT & ON SITE/OFF SITE EMERGENCY...
Transcript of 9.0 RISK ASSESSMENT & ON SITE/OFF SITE EMERGENCY...
REIA of Kusa Chemicals Pvt. Ltd. S. No. 126/1,2,3, Godhra-Halol Highway, Vi: Popatpura, Ta: Godhra, Di:
Panchmahal, Gujarat
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September - 2014
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9.0 RISK ASSESSMENT & ON SITE/OFF SITE EMERGENCY PLAN
Risk Assessment (RA) is a method that has proven its value as an all-round tool for
improving the safety standards prevalent in every hazardous industry. With advancements in
in-built and inherent safety systems, accident rates have come down, but still persist at
un-acceptable levels for newer technology and new process plants. Risk Assessment is a
structured safety assessment tool designed for high hazard industries such as chemical,
petrochemical, pesticides, pharmaceuticals etc., supplementing other safety system tool such
as HAZOP, safety audit, and regular incident analysis to identify the potential for incidents
(near-miss, unsafe conditions) and to evaluate the necessary control measures.
9.1 OBJECTIVE
The main objective of the Risk Assessment study is to determine damage due to major
hazards having damage potential to life and property and provide a scientific basis to assess
safety level of the facility.
The secondary objective is to identify major risk in manufacture of chemicals, storage of
chemicals and provide control though assessment. To prepare on- site, off site, disaster
management plan for control of hazards.
9.2 PHILOSOPHY
The main philosophy of risk assessment is to find out the real cause of accident and then
based on it to suggest appropriate remedial measures to prevent its recurrence. To find out
unsafe action negligence, omission or personal fault.
Software used for calculation- ALOHA (Areal locations of Hazardous atmospheres):
Aloha is a computer program designed especially for use by people responding to chemical
accidents, as well as for emergency planning and training. ALOHA can predict the rates at
which chemical vapors may escape into the atmosphere from broken gas pipes, leaking tanks
and evaporating puddles. It can then predict how a hazardous gas cloud might disperse in the
atmosphere after an accidental chemical release.
ALOHA is an air dispersion model, which you can use as a tool for predicting the movement
and dispersion of gases. It predicts pollutant concentrations downwind from the sources of a
spill, taking into consideration the physical characteristics of the spilled material. ALOHA
also accounts for some of the physical characteristics of the release site, weather conditions,
and the circumstances of the release. Like many computer programs, it can solve problems
REIA of Kusa Chemicals Pvt. Ltd. S. No. 126/1,2,3, Godhra-Halol Highway, Vi: Popatpura, Ta: Godhra, Di:
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rapidly and provide results in a graphic, easy to use format. This can be helpful during an
emergency response or planning for such a response.
ALOHA provide output as amount of chemical discharged from the source as well as its
concentration in air it takes into account different levels of concentrations for a specified
chemical.
9.3 METHODOLOGY
Design data, built in safety systems to be provided are studied. Discussions are held with
officials. Safety related individual system is discussed.
Hazard identification exercise is conducted taking into consideration of materials, material
handling methods, operating procedures, built in safety in reactors, operating parameters
and safety measures to be taken in proposed plant. Few areas like process building, storage
of hazardous chemicals, to evaluate safety systems in the event of any abnormalities
occurring. Containment failure scenario related to storage area is considered for hazard
Analysis and consequences of such containment failures are considered in detail. Thus, this
study is mainly oriented towards actual risks rather than chronic risks.
Based on the data furnished and the study of the proposed installation, certain hazards have
been identified and their consequences are modeled mathematically using ALOHA
software.
9.4 PROJECT SETTING
The site is located at S. No.126/1,2,3, Godhra-Halol Highway, Vi: Popatpura, Ta: Godhra,
Di: Panchmahal. Other locational details are as follows:
The site is located:
o Approximately 10.0 km South of Godhra Town
o The site is on State Highway (Halol-Godhra).
o Geographical Location & Area of the Premises are displayed below:
o Latitude : 22° 42’ 50.57” N Longitude: 73° 34’ 49.17"E
o The total area of the site is 132905.63 m2.
REIA of Kusa Chemicals Pvt. Ltd. S. No. 126/1,2,3, Godhra-Halol Highway, Vi: Popatpura, Ta: Godhra, Di:
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9.5 ORGANOGRAM OF THE COMPANY
DIRECTOR
UNIT HEAD
PRODUCTIO MANAGER
MAINTENANCE
ENGINEERSHIFT EXECUTIVE
ELECTRICAL
ENGINEERSTORE
SUPERVISOR
OPERATORS
HELPERS
REIA of Kusa Chemicals Pvt. Ltd. S. No. 126/1,2,3, Godhra-Halol Highway, Vi: Popatpura, Ta: Godhra, Di:
Panchmahal, Gujarat
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9.6 DETAILS OF STORAGE OF RAW MATERIALS/HAZ. MATERIALS
SR.NO
RAW MATERIALS
STATE
Mol. Formula
Mol.
Weight
Storage MOC
Storage
Capacity
No. of containe
r
Total
Quantity of
Storage
MT MT
1 MINERAL OIL LIQUI
D - - TANK SS 20 KL 5 100 KL
2
DIETHYLENE GLYCOL
LIQUI
D C4H10O3 106
DRUM
S
HDP
E 200 KG 50 10
3 DIETHANOLAMINE
LIQUID C4H11NO2 105
DRUMS
HDPE 200 KG 50 10
4
ETHYLENE OXIDE
GAS, LIQUI
D C2H4O 44 TANKS SS 7 KL 2 14 KL
5
2-
ETHYLHEXANOL
LIQUI
D 4R-OH 100
DRUM
S
HDP
E 200 KG 25 5
6 ETHYL ACRYLATE
LIQUID
CH₂CHCO₂CH₂C
H₃ 940 DRUM
S HDP
E 200 KG 25 5
7
FATTY ALCOHOL 16,18 SOLID R-CO-R - BAGS
HDP
E 25 KG 800 20
8
FATTY ALCOHOL
12, 14 LIQUI
D R-CO-R - TANK SS 15 KL 2 30 KL
9 METHACRYLIC ACID
LIQUID C4H6O2 86 TANK SS 15 KL 1 15 KL
10
METHYL METHACRYLATE
LIQUID C5H8O2 100 TANK SS 15 KL 1 15 KL
11 CASTOR OIL
LIQUID R-CO-R 910 TANK SS 10 KL 1 10 KL
12 NONYL PHENOL
LIQUID C9H19C6H4OH 220 TANK SS 15 KL 1 15 KL
13 OELIC ACID
LIQUI
D C18H34O2 282 TANK SS 15 KL 2 30 KL
14
PHOSPROUS PENTASUL SOLID P2S5 222
DRUMS
HDPE 300 KG 10 3
15 PHENOL SOLID C6H50H 94 TANK SS 15KL 1 15 KL
16 SOYA OIL
LIQUI
D R-CO-R - TANK SS 10 KL 1 10 KL
17 TOLUENE
LIQUID C6H5CH3 92 TANK SS 10 KL 1 10 KL
18 ZINC OXIDE SOLID ZnO 39 BAGS 50 KG 80 4
19 DIISOBUTYLENE Liquid C8H17 112.21 TANK SS 10 KL 1 10 KL
20 NONENE Liquid C9H18 126.24 TANK SS 10 KL 1 10KL
21
α-METHYL
STYRENE Liquid C9H10 118.18
DRUM
S
HDP
E 200 KG 25 5
22 STYRENE
Liquid C8H8 104 TANK SS 10 KL 1 10 KL
23 PHENOL Solid at
R.T C6H6O 94 TANK SS 20 KL 1 20 KL
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SR.NO
RAW MATERIALS
STATE
Mol. Formula
Mol. Weight
Storage
MOC
Storage Capacity
No. of containe
r
Total Quantit
y of
Storage
MT MT
26 P- CRESOL
Solid C7H8O 108.1 DRUM
S HDP
E 200 KG 50 10
27 MIX XYLENOL
Solid C7H10O 110 DRUM
S HDP
E 200 KG 25 5
28
BUTYLENE
OXIDE Liquid C4H8O 72 TANK SS 5 KL 1 5 KL
31 CATALYST
32 1) CLAY
Solid Clay - BAGS HDP
E 25 KG 120 3
33 2) ALCL3
Solid AlCl3 133.34
DRUM
S
HDP
E 25 KG 40 1
34
FORMALDEHYDE Liquid
CH2O+H2
O 30 DRUM
S HDP
E 200 KG 50 10
35 FO Liquid - - TANK SS 10 1 10KL
36 CHLORINE
GAS Cl2 70 Tonner
s MS 900 KG 3 2.7
REIA of Kusa Chemicals Pvt. Ltd. S. No. 126/1,2,3, Godhra-Halol Highway, Vi: Popatpura, Ta: Godhra, Di:
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9.7 DETAILS OF STORAGE OF PRODUCTS
SR.NO
PRODUCTS STATE Mol. Formula
Mol.
Weight
Storage
MOC
Storage
Capacity
No. of container & size
Total
Quantity of
Storage
MT MT
1 Oil Additives Liquid
-( R-CO-R)n -
DRUMS
HDPE 200 KG 50 10
2 Emulsifer
Liquid (CH2CH2O)n
H - DRUM
S HDP
E 200 KG 50 10
3 Monomer
Liquid -
-
DRUM
S
HDP
E 200 KG 50 10
4
Zinc Di Alkyl Di
Thio Phosphate (ZDDP) Liquid
((RO)2PSS)2Zn
- DRUM
S HDP
E 200 KG 50 10
5 POLYAMIDES Solid(powde
r) -
- DRUM
S HDP
E 200 KG 25 5
6
ACRYLIC
EMULSION Liquid
(C5H8O2)n
(C4H6O2)n -
DRUM
S
HDP
E 200 KG 25 5
7
PIBSA(Polyisobutyle
ne Succenic Anhydride) Liquid
- -
DRUMS
HDPE 200 KG 25 5
8
Mix of Di Octyl
Mono Tri Octyl Di Phenyl Amine Liquid
C8H17(C12H11
N) 208
DRUM
S
HDP
E 200 KG
9
Mix of Di, Tri, Mono Octyl Phenyl-a-
Naphtalamine Liquid
C8H17(C16H13
N) 332
DRUMS
HDPE 200 KG
10
Mix of Mono, Di, Tri
Nonylated Diphenyl Amine Liquid
C9H18(C12H11
N) 295
DRUM
S
HDP
E 200 KG
50 10
11
Styrene Diphenyl
Amine Liquid
C8H8(C12H11N
) 273
DRUM
S
HDP
E 200 KG
12
Methyl Styrene
Diphenyl Amine Liquid
C9H10(C12H11
N) 287 DRUM
S HDP
E 200 KG
13 Nonylated p-Cresol
Liquid C9H18(C7H8O)
234
DRUM
S
HDP
E 200 KG
14 Styrenated Phenol
Liquid C8H8(C6H6O)
198
DRUM
S
HDP
E 200 KG
15 Tetra Methyl Bisphenol-F Liquid
(C7H9O)CH 122
DRUMS
HDPE 200 KG
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9.8 PROPERTIES OF HAZARDOUS CHEMICALS AS PER MSIHC RULES
Sr.
No
Full name Of the raw
materials
Main properties (refer MSDS, Sch-9 of MSIHC Rules)
B.P. °C
F.P. °C
LEL
UEL %
TLV ppm
or mg/m
3
LD50
mg/Kg LC50 mg/l
Specific
Gravity (water
=1)
Vapor
density (air=1)
Odour
threshold ppm or
mg/m3
Chemical
Class (As per MSIHC
Rules)
1. Di isobutylene 102 - - - - 0.708 - - Flammable
2. Nonene 150 26 0.9 - -- 0.73 4.35 -- Flammable
3. α-methyle
styrene 165.
4 44(CC) 52 (OC)
1.9 100 ppm
4500 mg/kg
0.909 4.1 50 ppm Flammable
4. Styrene 145.
2
31.1CC)
36.7(OC)
1.1/6.
1
50
ppm 316 mg/kg 0.906 3.59 0.1 ppm Flammable
5. Phenol 182 79(CC)
85(OC)
1.7/8.
5 5 ppm 317/125 1.057 3.24 0.48 ppm
Flammable, Toxic,
Hazardous
6. Butylene oxide 63 -17 -- --
50 mg/kg/
1000 ppm/7 hr
0.837 2.2 - Flammable
7. Formaldehyde
37% 98
50(CC)
60(OC) 6/36.5
0.3
ppm 100 mg/kg 1.08 1.03 10 ppm Flammable
8. Ethylene Oxide 10.4 -20 3/100 1 ppm --/72
mg/kg - 1.52 - Flammable
9. Methacrylic
Acid 163
77(CC)
1.6/8.1
20 ppm
1250 mg/kg
1.015 2.97 - Flammable
10. Toluene 110.
6
4.4(CC) 16(OC)
1.1/7.
1
200
ppm
--/50
mg/kg 0.8636 3.1 1.6 ppm Flammable
11. FO 339 54
1.3/7.
5 100 ppm
-- 0.83 - <0.16 ppm Flammable
12. Coal-Anthrasite -- -- -- 10
ppm -- 2-3 - - --
13. Chlorine -35 -- -- 0.5 ppm
293 ppm/1 hr
-- 2.49 0.01 ppm combustible
Note: CC: Close Cup, OC: Open Cup, N.A.: Not Available
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9.9 OCCUPATIONAL HEALTH SURVEILLANCE PROGRAMME
Health surveillance is the monitoring of a person’s health to identify changes in health status
due to occupational exposure to a hazardous substance. It includes biological monitoring.
Ideally, the avoidance of work-related diseases should be achieved by the prevention or
controlling exposures to hazardous substances in the workplace. Where a process cannot be
designed or maintained to eliminate the risk of exposure, it may be necessary for workers to
undergo health surveillance.
9.9.1 AIMS OF HEALTH SURVEILLANCE
• Identify those at increased risk
Health surveillance is used to identify workers who have an increased risk of developing an
occupational disease. For example, people who have asthma are at increased risk of being
severely affected if exposed to potent respiratory irritants such as chlorine.
• Compliance with regulations
Health surveillance is sometimes required by laws and codes of practice (for example, a
worker exposed to lead in battery manufacture or a spray-painter exposed to isocyanates in
two-pack paints). Each state or territory has regulations containing a schedule of hazardous
substances for which health surveillance is mandated.
• Early detection
The major purpose of health surveillance is to detect adverse health effects at an early stage
so that the worker may be protected from further injury, either by control of the process or by
removal from exposure.
• Evaluating effectiveness of control measures
Health surveillance is not a control measure in itself and should not be the sole means of
determining whether control measures are effective. However, it can provide useful
information on the effectiveness of safe working practices.
• Epidemiology and disease
REIA of Kusa Chemicals Pvt. Ltd. S. No. 126/1,2,3, Godhra-Halol Highway, Vi: Popatpura, Ta: Godhra, Di:
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Health surveillance can be used to evaluate the health experiences of groups of workers
exposed to specific hazardous agents or working within a particular industry.
Workers should be made aware that health surveillance is sometimes necessary to ensure
their ongoing health. Health surveillance is often used in addition to workplace monitoring.
Workplace monitoring will only indicate the potential for exposure of workers to a hazardous
substance. It can never be an indication of the actual amount of substance absorbed or the
effect on the body of absorbing the hazardous substance.
When a toxic substance (such as an industrial chemical) is present in the environment, it
contaminates air, water, food, or surfaces in contact with the skin: environmental monitoring
evaluates the amount of toxic agent in these media.
As a result of absorption, distribution, metabolism, and excretion, a certain internal dose of
the toxic agent (the net amount of a pollutant absorbed in or passed through the organism
over a specific time interval) is effectively delivered to the body and becomes detectable in
body fluids.
Subsequent interaction with a receptor in the critical organ (the organ which, under specific
conditions of exposure, exhibits the first or the most important adverse effect) leads to
biochemical and cellular events. Both the internal dose and the elicited biochemical and
cellular effects may be measured through biological monitoring.
• Mission
The overall mission of the Occupational Health Surveillance Program is to promote the
health, safety and quality of life of working people will be achieved:
9.9.2 SURVEILLANCE PROGRAM CAN BE IMPROVED BY FOLLOWING
ACTION
• Pre-placement examination and periodic examination must be carried out at workplace.
• Emergency/exposure examination and test should be carried out. Examination is based on
irritation, sensitization of skin, respiratory system, eye , shortness of breath.
• Maintain the work profile and medical history of employee/workers.
• Pulmonary function test must be carried out in case handling of formaldehyde.
• Written medical opinion must be maintained by industry.
REIA of Kusa Chemicals Pvt. Ltd. S. No. 126/1,2,3, Godhra-Halol Highway, Vi: Popatpura, Ta: Godhra, Di:
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• Examination must be certify by qualified medical practitioners
9.9.3 OCCUPATIONAL HEALTH PROGRAMME
• The health & physical hazards caused due to toxic, irritant, corrosive, flammable materials. All
chemicals are within Threshold Limit Value as per ACGIH.
• Monitoring of occupational hazards like noise, ventilation, chemical exposure etc. will be
carried out regularly and its record will be maintained.
• Good housekeeping, use of PPE, Engineering controls, Enclosure processes, scrubber system,
display of safety boards, SOP of loading / unloading, local exhaust ventilation, safety shower
etc. are important safety measures have taken to keep these chemicals within TLV.
• Appropriate personal protective equipment will be provided & ensure the usage of them.
• Workers will be trained on safe material handling of hazardous chemicals.
• Prepare & display the safe operating procedure for hazardous chemicals storage, handling &
transporting or using.
• Periodical medical examination of the workers & Liver Function Testes will be done.
• Register (form no.37) for work place air monitoring will be done.
• Employee training and education will be carried out.
• Control the noise at source by substitution, isolation, segregation, barriers etc.
• Local Exhaust ventilation and scrubber should be installed where it is required to reduce
fumes, vapors, temperature and heat stress.
• Reduce the level of physical activity by sharing workload with other or by using mechanical
means.
• Pre-employment medical checkup and periodically medical examination will be done.
• Emergency /exposure examination and test should be carried out. Examination is based on
irritation, sensitization of skin, respiratory system, eye, shortness of breath
• Test must be carried out as per handling of chemicals as per OSHA guideline.
• Check the previous medical opinion of worker/employee as well as history.
• Safety showers is being placed within premises.
REIA of Kusa Chemicals Pvt. Ltd. S. No. 126/1,2,3, Godhra-Halol Highway, Vi: Popatpura, Ta: Godhra, Di:
Panchmahal, Gujarat
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9.9.4 MEASURES TO KEEP CHEMICALS WITHIN PEL/TLV.
• Process should be carried out in isolated area or closed system.
• Dilution ventilation/local exhaust ventilation system should be provided.
• Chemical handled by competent person
• MSDS of hazardous substance must be maintained by company.
• Quantity of substance should kept to absolute minimal.
• Flame proof electric fitting should be provided.
• Safety devices like temp. Control and pressure control must be provided to vessel
• Labeling and sign board should be provided.
• Fire fighting, sprinkling system and emergency exit should be provided.
• PPE must be used during handling of chemicals.
9.9.5 PRECAUTIONS DURING STORAGE & TRANSPORTATION OF
HAZARDOUS CHEMICALS
For Storage:
• Storage shall be in cool, dry well-ventilated location away from any area where the fire
hazard may be acute.
• Outside or detached storage shall be done for solvents storage and separate from
incompatible.
• Storage and use area shall be No smoking area.
• Use non-sparking type tools and equipment, including explosion proof ventilation.
• Dyke wall shall be provided to all storage tanks.
• Fire hydrant system has been installed and Mock drill is regularly conducted..
• Safety shower and eye washer shall be installed near storage area.
• Flame proof light fitting shall be provided at flammable storage area.
• Sprinkler system shall be installed at flammable material storage area.
• Earthing / bonding shall be provided for static charges.
• Level gauge and level measurement instrument shall be provided on material storage tank.
• Lightening arrestor on all chimney and building shall be provided.
• Safety permit system shall be followed for loading, unloading of hazardous chemical.
REIA of Kusa Chemicals Pvt. Ltd. S. No. 126/1,2,3, Godhra-Halol Highway, Vi: Popatpura, Ta: Godhra, Di:
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• Fencing, caution note, hazardous identification board should be provided.
• Only authorized person shall be permitted in storage tank area and register will be
maintained.
• Quantity should be kept to minimum.
For Transportation:
• Solvent shall be received by road tanker and stored in above ground storage tank in
separated bulk storage area.
• Loading and unloading procedure shall be prepared for material received through road
tanker.
• Earthing/bonding shall be provided for static charges.
• Container shall be bonded and grounded for transfer to avoid static sparks.
• Flexible steel hose shall be used for unloading from the road tanker.
• Flame proof electric motor shall be used during loading/unloading.
• NRV shall be provided on pump discharge line.
• Fixed pipeline with pumps shall be provided for transfer to vessel.
• TERM CARD will be provided to all transporters and shall be trained for transportation
Emergency of hazardous chemicals.
• Personal Protective Equipment (safety goggles, hand gloves, apron, masks, gum boots etc.)
shall be provided.
Step if a spill Occurs:
• Stop or reduce the release of material , if it can be done safely.
• If there are noxious vapors, evacuate and notify supervisor or emergency coordinator.
• Eliminate all sources of ignition.
• Evacuate all person not wearing protective equipment from the area of the spill or leak until
cleanup is complete.
• Notify supervisor or emergency coordinator of the spill.
• Do not walk through spilled product. Avoid skin contact and inhalation.
• Stay upwind and keep out of low lying area.
• For large spills and fires , immediately call your fire department.
• Earthing/bonding shall be provided for static charges.
• Container shall be bonded and grounded for transfer to avoid static sparks.
Following emergency equipment shall be present on site.
REIA of Kusa Chemicals Pvt. Ltd. S. No. 126/1,2,3, Godhra-Halol Highway, Vi: Popatpura, Ta: Godhra, Di:
Panchmahal, Gujarat
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• Fire extinguishers
• Industrial first aid kit
• Safety Shower.
• Emergency shower
• Ample supply of potable water for washing as well as for drinking purpose.
• Emergency communication devices, such as mobile phone, or two way radios
• Vehicle suitable for emergency transport
9.10 RISK ASSESSMENT FOR STORAGE CHEMICALS
The worst case scenario of chemical release has been tabulated below
TABLE 9.1 WORST CASE SCENARIO OF CHEMICAL
Sr.No. Short description
of scenario
Chemical
involved
Type of
Risk
Probability Concentration Damage
Distance from
source
1 Release from
damage of Phenol
tank ( 20 KL)
Phenol Toxic
effect
Very
unlikely
15 ppm
23 ppm
200 ppm
1.6 Km
1.2 Km
339 meter
2 Release from
damage of Toluene storage tank
(10 KL)
Toluene Thermal
Radiation from pool
fire
Very
unlikely
2 kw/sqm
5 kw/sqm 10 kw/sqm
137 meter
95 meter 73 meter
3 Release from
damage of chlorine
tonner
( 900 kg)
chlorine Toxic
effect
Very
unlikely
0.5 ppm
2 ppm
20 ppm
2.4 Km
1.2 Km
343 meter
4 Release from
damage of Ethylene oxide
storage tank
(7 KL)
Ethylene
oxide
Toxic
effect
Very
unlikely
45 ppm
200 ppm
3.8 Km
2.0 Km
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9.10.1 SCENARIO 1: PHENOL
LOCATION: KUSA CHEMICALS, INDIA
TIME: FEBRUARY 14, 2014 20:00 HOURS
CHEMICAL DATA:
CHEMICAL NAME: PHENOL
MOLECULAR WEIGHT: 94.11 G/MOL
AEGL-1 (60 MIN): 15 PPM
AEGL-2 (60 MIN): 23 PPM
AEGL-3 (60 MIN): N/A
IDLH: 250 PPM
LEL: 1.7 PPM
UEL: 8.6 PPM
AMBIENT BOILING POINT: 182.0° C
VAPOR PRESSURE AT AMBIENT TEMPERATURE: 0.032 ATM
AMBIENT SATURATION CONCENTRATION: 31,731 PPM OR 3.17%
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)
WIND: 5 METERS/SECOND FROM N AT 3 METERS
GROUND ROUGHNESS: OPEN COUNTRY
CLOUD COVER: 3 TENTHS
AIR TEMPERATURE: 25° C
STABILITY CLASS: D
NO INVERSION HEIGHT
RELATIVE HUMIDITY: 52%
SOURCE STRENGTH:
DIRECT SOURCE: 320 KILOGRAMS/MIN
SOURCE HEIGHT: 0
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RELEASE DURATION: 60 MINUTES
RELEASE RATE: 320 KILOGRAMS/MIN
TOTAL AMOUNT RELEASED: 19,200 KILOGRAMS
THREAT ZONE:
MODEL RUN: GAUSSIAN
RED : 339 METERS --- (200 PPM = ERPG-3)
ORANGE: 1.2 KILOMETERS --- (23 PPM = AEGL-2 (60 MIN))
YELLOW: 1.6 KILOMETERS --- (15 PPM = AEGL-1 (60 MIN))
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9.10.2 SCENARIO 2: TOLUENE
LOCATION: KUSA CHEMICALS, INDIA
TIME: FEBRUARY 14, 2014 20:45
CHEMICAL DATA:
CHEMICAL NAME: TOLUENE
MOLECULAR WEIGHT: 92.14 G/MOL
AEGL-1 (60 MIN): 200 PPM
AEGL-2 (60 MIN): 1200 PPM
AEGL-3 (60 MIN): 4500 PPM
IDLH: 500 PPM
LEL: 11000 PPM
UEL: 71000 PPM
AMBIENT BOILING POINT: 110.6° C
VAPOR PRESSURE AT AMBIENT TEMPERATURE: 0.038 ATM
AMBIENT SATURATION CONCENTRATION: 37,542 PPM OR 3.75%
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)
WIND: 5 METERS/SECOND FROM N AT 3 METERS
GROUND ROUGHNESS: OPEN COUNTRY C
LOUD COVER: 3 TENTHS
AIR TEMPERATURE: 25° C
STABILITY CLASS: D
NO INVERSION HEIGHT
RELATIVE HUMIDITY: 52%
SOURCE STRENGTH:
LEAK FROM HOLE IN VERTICAL CYLINDRICAL TANK
FLAMMABLE CHEMICAL IS BURNING AS IT ESCAPES FROM TANK
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TANK DIAMETER: 2 METERS
TANK LENGTH: 3 METERS
TANK VOLUME: 9,425 LITERS
TANK CONTAINS LIQUID
INTERNAL TEMPERATURE: 25° C
CHEMICAL MASS IN TANK: 8.57 TONS
TANK IS 95% FULL
CIRCULAR OPENING DIAMETER: 1 FEET
OPENING IS 2 FEET FROM TANK BOTTOM
MAX FLAME LENGTH: 34 METERS
BURN DURATION: 5 MINUTES
MAX BURN RATE: 2,970 KILOGRAMS/MIN
TOTAL AMOUNT BURNED: 6,168 KILOGRAMS
NOTE: THE CHEMICAL ESCAPED AS A LIQUID AND FORMED A BURNING PUDDLE.
THE PUDDLE SPREAD TO A DIAMETER OF 28 METERS.
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THREAT ZONE:
THREAT MODELED: THERMAL RADIATION FROM POOL FIRE
RED : 73 METERS --- (10.0 KW/ (SQ M) = POTENTIALLY LETHAL WITHIN 60
SEC)
ORANGE: 95 METERS --- (5.0 KW/ (SQ M) = 2ND DEGREE BURNS WITHIN 60
SEC)
YELLOW: 137 METERS --- (2.0 KW/ (SQ M) = PAIN WITHIN 60 SEC)
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9.10.3 SCENARIO 3: CHLORINE
LOCATION: KUSA CHEMICALS, INDIA
TIME: FEBRUARY 14, 2014 21:03 HOURS
CHEMICAL DATA:
CHEMICAL NAME: CHLORINE
MOLECULAR WEIGHT: 70.91 G/MOL
AEGL-1 (60 MIN): 0.5 PPM
AEGL-2 (60 MIN): 2 PPM
AEGL-3 (60 MIN): 20 PPM
IDLH: 10 PPM
AMBIENT BOILING POINT: -34.0° C
VAPOR PRESSURE AT AMBIENT TEMPERATURE: GREATER THAN 1 ATM
AMBIENT SATURATION CONCENTRATION: 1,000,000 PPM OR 100.0%
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)
WIND: 5 METERS/SECOND FROM N AT 3 METERS
GROUND ROUGHNESS: OPEN COUNTRY
CLOUD COVER: 3 TENTHS
AIR TEMPERATURE: 25° C
STABILITY CLASS: D
NO INVERSION HEIGHT
RELATIVE HUMIDITY: 52%
SOURCE STRENGTH:
DIRECT SOURCE: 8 LITERS/MIN
SOURCE HEIGHT: 0
SOURCE STATE: LIQUID
SOURCE TEMPERATURE: EQUAL TO AMBIENT
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RELEASE DURATION: 60 MINUTES
RELEASE RATE: 11.2 KILOGRAMS/MIN
TOTAL AMOUNT RELEASED: 669 KILOGRAMS
THREAT ZONE:
MODEL RUN: HEAVY GAS
RED : 343 METERS --- (20 PPM = AEGL-3 [60 MIN])
ORANGE: 1.2 KILOMETERS --- (2 PPM = AEGL-2 [60 MIN])
YELLOW: 2.4 KILOMETERS --- (0.5 PPM = AEGL-1 [60 MIN])
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9.10.4 SCENARIO 4: ETHYLENE OXIDE
LOCATION: KUSA CHEMICALS, INDIA
BUILDING AIR EXCHANGES PER HOUR: 1 (USER SPECIFIED)
TIME: FEBRUARY 14, 2014 21:10 HOURS
CHEMICAL DATA:
CHEMICAL NAME: ETHYLENE OXIDE
MOLECULAR WEIGHT: 44.05 G/MOL
AEGL-1 (60 MIN): N/A
AEGL-2 (60 MIN): 45 PPM
AEGL-3 (60 MIN): 200 PPM
IDLH: 800 PPM
LEL: 30000 PPM
UEL: 1000000 PPM
CARCINOGENIC RISK - SEE CAMEO CHEMICALS
AMBIENT BOILING POINT: 10.5° C
VAPOR PRESSURE AT AMBIENT TEMPERATURE: GREATER THAN 1 ATM
AMBIENT SATURATION CONCENTRATION: 1,000,000 PPM OR 100.0%
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)
WIND: 5 METERS/SECOND FROM N AT 3 METERS
GROUND ROUGHNESS: OPEN COUNTRY
CLOUD COVER: 3 TENTHS
AIR TEMPERATURE: 25° C
STABILITY CLASS: D
NO INVERSION HEIGHT
RELATIVE HUMIDITY: 52%
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SOURCE STRENGTH:
LEAK FROM HOLE IN HORIZONTAL CYLINDRICAL TANK
FLAMMABLE CHEMICAL ESCAPING FROM TANK (NOT BURNING)
TANK DIAMETER: 1.8 METERS
TANK LENGTH: 2.8 METERS
TANK VOLUME: 7,125 LITERS
TANK CONTAINS LIQUID
INTERNAL TEMPERATURE: 25° C
CHEMICAL MASS IN TANK: 6.50 TONS
TANK IS 95% FULL
CIRCULAR OPENING DIAMETER: 1 FEET
OPENING IS 1 FEET FROM TANK BOTTOM
RELEASE DURATION: 1 MINUTE
MAX AVERAGE SUSTAINED RELEASE RATE: 96.3 KILOGRAMS/SEC
(AVERAGED OVER A MINUTE OR MORE)
TOTAL AMOUNT RELEASED: 5,779 KILOGRAMS
NOTE: THE CHEMICAL ESCAPED AS A MIXTURE OF GAS AND AEROSOL (TWO
PHASE FLOW).
THREAT ZONE:
MODEL RUN: HEAVY GAS
RED : 2.0 KILOMETERS --- (200 PPM = AEGL-3 [60 MIN])
ORANGE: 3.8 KILOMETERS --- (45 PPM = AEGL-2 [60 MIN])
YELLOW: NO RECOMMENDED LOC VALUE --- (N/A = AEGL-1 [60 MIN])
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9.11 ACTION PLAN FOR HANDLING & SAFETY SYSTEM
• Wind indicator should be provided at the highest level of the plant to know the wind
direction.
• Sprinkler system for the flammable material tanks (over ground tanks only) may be
provided as knock on effect in case of fire is possible.
• Containment dykes with proper sloping and collection sumps should be provided so that
any spillages in the bulk storage and other handling areas shall not stagnate and shall be
quickly lead away to a safe distance from the source of leakage. This reduces the risk of
any major fire on the bulk storages and the risk to the environment shall be minimized/
eliminated.
• Inspection of the storage tanks as per prefixed inspection schedule for thickness
measurement, joint and weld efficiency etc.
• Provision of flameproof electrical fittings / equipment’s.
• Proper maintenance of earth pits & Regular check of Resistance.
• Strict compliance of security procedures like issue of identity badges for outsiders, gate
passes system for vehicles, checking of spark arrestors fitted to the tank lorries etc.
• Strict enforcement of no smoking.
• Periodic training and refresher courses to train the staff in safety fire fighting.
• Employee training and education will be carried out.
• Emergency drills should be carried out periodically to ensure preparedness must continue.
• Many operations involve use of highly toxic/flammable materials and these needs to be
documented as SOPs. These must be made and kept updated on priority.
• Extensive training on use of Self Contained Breathing apparatus (SCBAs) must be
ensured for emergency control.
• Many of the raw materials used for resin are either toxic or flammable. It is therefore
important to ensure that these materials are stored in closed, well ventilated totally safe
areas. A fire alarm system (heat and smoke detection) should be provided for the storage
area where the material is stored as toxic fumes arise on combustion.
• Loose drums of waste materials, often solvent laden, must be removed from the working
areas and close watch kept.
• Proper Earthing needs to be provided through plug type systems or through the
agitators/liquid.
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• Ventilation should be provided for any enclosed are where hydrocarbon or toxic vapors
may accumulate. Several such areas were noticed- these may be surveyed and tackled
accordingly.
• All personnel should be trained in handling emergency situations and should be apprised
of their role in handling emergency situation and to ensure adequacy of the emergency
procedures simulated exercise should be carried out. This was found wanting.
• Flame arrestor should be provided.
• Adequate number of caution boards highlighting the hazards of chemicals should be
provided at critical locations.
• The health & physical hazards caused due to toxic, irritant, corrosive, flammable materials.
All chemicals are within Threshold Limit Value as per ACGIH.
• Monitoring of occupational hazards like noise, ventilation, chemical exposure etc. will be
carried out regularly and its record will be maintained.
• Good housekeeping, use of PPE, Engineering controls, Enclosure processes, scrubber
system, display of safety boards, SOP of loading / unloading, local exhaust ventilation,
safety shower etc. are important safety measures have taken to keep these chemicals
within TLV.
• Appropriate personal protective equipment will be provided & ensure the usage of them.
• Workers will be trained on safe material handling of hazardous chemicals.
• Prepare & display the safe operating procedure for hazardous chemicals storage, handling &
transporting or using.
• Local Exhaust ventilation and scrubber should be installed where it is required to reduce
fumes, vapors, temperature and heat stress.
• Reduce the level of physical activity by sharing workload with other or by using mechanical
means.
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� FOLLOWING FIRE SAFETY DEVICES WILL BE PROVIDED TO PROTECT FROM ANY
MALFUNCTIONING OF PLANT EQUIPMENTS. FOLLOWING FIRE PROTECTION SYSTEMS WILL
BE PROVIDED.
• Water storage of adequate capacity to meet the requirements of water for firefighting
purposes.
• Fire hydrants and sprinkler system, Diesel driven pumps and headers to supply water to
fire hydrant network.
• Adequate Portable fire extinguishers, sand bucket, wheeled fire & safety equipment
should be provided at the required places.
• Equipment required for personal safety like blankets, gloves, apron, gum boots, face mask
helmets, safety belts, first aid boxes etc. are provided. Proximity suits and self-contained
breathing apparatus to be provided.
9.12 ON SITE EMERGENCY PLAN& OFF SITE EMERGENCY PLAN
9.12.1 OBJECTIVES
The overall objectives of are:
• To control the situation and if possible eliminate as quickly as possible.
• To avoid confusion/panic and to attend the emergency with clear-cut line of action.
• To minimize the loss of property to the plant as well as to our neighborhood.
• To safe guard the non-affected areas.
• To alert the neighborhood.
• To arrange head-count and rescue operations.
• Treatment of the injured.
• To safeguard others by timely evacuation.
• To prevent any cascade of emergencies.
9.12.2 EMERGENCY
An emergency is the situation, which has potential to cause a large-scale damage or
destruction to life or property or Environment or combination of these within or outside the
factory. Therefore it is essential to have a laid down procedure to meet emergency
systematically.
In any industry, emergency can arise at any moment and this depends on the type of:
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• Structure
• Raw materials
• Machines
• Nearby Industries
• Location of the Industry etc.
9.12.3 TYPES OF EMERGENCY:
The "Emergency" specified in this plan will refer to occurrence of one or more of the
following natural/manmade events.
• Fire
• Explosion
• Release of Toxic Gas/Vapour
• Spillage of flammable liquid /gas
• Deliberate Sabotage, Terrorism, Air Raid etc.
• Natural Calamities: - Lightening, Storm, Earthquake, Flood etc.
• Collapsing of structure
• Overturning of tanker containing flammable / toxic substances.
9.12.4 NATURE OF EMERGENCY
If there is any emergency in part of the plant / work place / industry due to any
reason, the area which may be affected due to the emergency can be divided in the
following two natures
Nature – I (On Site Emergency)
Effects remain limited to plants / industry boundary.
Nature – II (Off Site Emergency)
Effect spread to neighboring industry / population.
9.13 OFF SITE EMERGENCY
Events likely to endanger the human lives, plant and equipment within the factory and also
in the neighborhood and is not possible to control with the resources available within the
factory.
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Requires mobilization of outside resources from Local / District Authorities such as
Hospital Facilities, Civil Defense, District Magistrate, Police, Army, Air Force, and other
agencies (may be called into control and contain the emergency).
A. Functions of the State Crisis Group
The State Crisis Groups shall –
• Review all district off-site emergency plans in the State with a view to examine its
adequacy in accordance with the Manufacture, Storage and Import of Hazardous
Chemical, Rules and forward a report to the Central Crisis Group once in three months;
• Assist the State Government in managing chemical accidents at a site;
• Assist the State Government in the planning, preparedness and mitigation of major
chemical accidents at a site in the State;
• Continuously monitor the post accident situation arising out of a major chemical
accident in the State and forward a report to the Central Crisis Group;
• Review the progress report submitted by the District Crisis Groups;
• Respond to queries addressed to it by the District Crisis Groups; and
• Publish a list of experts and officials in the State who are concerned with the
management of chemical accidents.
B. Functions of the District Crisis Group
The District Crisis Group shall –
Assist the preparation of the district off-site emergency plan;
• Review all the on-site emergency plans prepared by the occupier of Major Accident
Hazards installation for the preparation of the district off-site emergency plan;
• Assist the district administration in the management of chemical accidents at a site lying
within the district;
• Continuously monitor every chemical accident;
• Ensure continuous information flow from the district to the Centre and State Crisis
Group regarding accident situation and mitigation efforts;
• Forward a report of the chemical accident within fifteen days to the State Crisis Group;
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and
• Conduct at least one full scale mock-drill of a chemical accident at a site each year and
forward a report of the strength and the weakness of the plan to the State Crisis Group.
C. Functions of the Local Crisis Group
The Local Crisis Group shall -
• Prepare local emergency plan for the industrial pocket;
• Ensure dovetailing of the local emergency plan with the district off-site emergency
plan;
Train personnel involved in chemical accident management;
• Educate the population likely to be affected in a chemical accident about the
remedies and existing preparedness in the area;
• Conduct at least one full scale mock-drill of a chemical accident at a site every six
months and forward a report to the District Crisis Group; and
• Respond to all public inquiries on the subject.
The Off-site Emergency Plan shall be contains up-to-date details of outside emergency services and resources such as Fire Services, Hospitals, Police etc. with telephone number.
a. Police Department.
b. Revenue Department.
c. Fire Brigade.
d. Medical Department.
e. Municipality.
f. Gram Panchayat.
g. Railway Department.
h. Telephone Department.
i. Factory Department.
j. Electricity Department.
k. Pollution Control Department.
l. Explosive Department.
m. Press and Media.
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9.14 ON SITE EMERGENCY
Events likely to endanger human lives, plant and equipment, and is beyond the control of
shift personnel and facilities available in the plant.
Requires mobilization of additional resources of other plant / department to handle the
emergency.
Require help under mutual aid scheme for fire fighting and rescue operation from nearby
industries.
9.14.1 DEFINITION:
Environment as defined u/s 2(a) of the environment Protection Act includes water, air and
land and the inter relationship which exists among and between water, air and land and
human beings, other living creatures, plants, micro organism and property.
Environment pollutant defined by the same Act as any solid, liquid or gaseous substances
present in such concentration as may be tend to injurious to atmosphere.
Hazardous substance is also defined by the same Act and hazardous process is defined by
sec.2 (cb) of the Factories Act. 1948.
Hazard is a physical situation, which may cause human injury, damage to property or the
environment or any combination of these criteria.
Chemical Hazard is a hazard due to chemical (including it’s storage, process, handling etc.)
and it is realized by fire, explosion, toxicity, corrosivity, radiation etc.
Risk is a likelihood of an undesired event (i.e. accident, injury or death) occurring within a
specified period or under specified circumstances.
Individual risk is the frequency at which any individual may be expected to sustain a given
level of harm from the realization of specific hazards.
Social risk is a measure of chances of a number of people being effected by a single event or
set of events and is often presented as f/n curves (i.e. frequency v/s number of people
effected)
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The on-site emergency plan will deal with measures to prevent and control emergencies
affecting public and the environment outside the premises. The manufacturer should provide
the necessary information on the nature, extent and likely effects of such incidents.
Disaster is a catastrophic situation in which the day-to-day patterns of life are, in many
instances, suddenly disrupted and people are plunged into helplessness and suffering and as a
result need protection, clothing, shelter, medical and social care and other necessities of life,
such as: -
• Disasters resulting from natural phenomenon like earthquake, volcanic eruptions,
storm, surges, cyclones, tropical storms, floods, landslides, forest fires and massive
insect infestation. Also in this group, violent draught which will cause a creeping
disaster leading to famine, disease and death must be included.
• Second group includes disastrous events occasioned by man, or by man’s impact
upon the environment, such as armed conflict, industrial accidents, factory fires,
explosion and escape of toxic gases or chemical substances, river pollution, mining
and other structural collapses; air, sea, rail and road transport accidents, aircraft
crashes, collision of vehicles carrying inflammable liquids, oil, spills at sea, and dam
failures.
9.14.2 ACCIDENT:
An accident is an unplanned event, which has a probability of causing personal injury or property
damage or both. It may result in physical harm (injury or disease) to person (s), damage to
property, loss to the company, a near miss or any combination of the effect.
A Major accident is a sudden, unexpected, unplanned event, resulting from uncontrolled
developments during and industrial activity, which causes or has a potential to cause
• Serious adverse effects immediate or delayed (death, injuries, poisoning or
hospitalization) to a number of people inside the installations and/ or to persons
outside the establishment.
• Significant damage may be caused to crops, plants or animals or significant
contamination of land waters or air.
• An emergency intervention outside the establishment (evacuation of local
population, stopping of local traffic).
• Any combination of above.
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9.14.3 MEDICAL HELP:
First Aid Boxes have been provided at various strategic locations. Requisite number
employees are trained about First Aid, Liaison with nearest hospitals.
9.14.4 COMMUNICATION SYSTEM:
• Alarm Raising for Emergency by blowing the sirens installed
• The siren will be used for raising the emergency alarm and also for all clear signals.
• Emergency Siren: The wailing alarm will be sounded intermittently at fixed interval of 30
seconds for a period of two minutes in case of emergency, such alarm will signify the
employees that an emergency has occurred and that the emergency services should be put
into operation.
• Incident Controller after assessing the situation will declare that emergency is over. Till the
Incident Controller issues the declaration, all the leaders will adhere to the task and be
present at the prescribed location.
• All clear signal will be sounded through continuous siren for 1 minute. Even after the
emergency is over a skeleton staff of the Rescue/Evacuation Team will be available at the
site of emergency for at least 30 minutes to ensure that the situation is absolutely free from
danger.
• After the emergency is over, all the team leaders should meet at the Emergency Control
Center and each team leader should submit a report to the Incident Controller about team
performance and other details observed.
• In addition to the above systems, internal telephones, P.A.System, Mobile telephones,
Computer System etc. will be used for communication.
• If situation is beyond the control, the external agencies will be informed accordingly and
asked for the help. Direct telephone, cell phone or messengers / runners may achieve this.
9.14.5 ASSEMBLY POINT:
In case of emergency some locations are considered as Assembly Points. Depending on the
wind direction and location of emergency, Assembly Point will be declared. The employees
should run across the wind direction and not against the wind direction.
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Depending upon the location of the emergency the Incident Controller will fix the Assembly
Point and Officer will announce the location of the Assembly Point. Employee’s attendance,
visitors and contractors workmen register will be made available at the Assembly Point for
head count.
EMERGENCY CONTROL CENTER:
Factory Manager Office will be declared as an Emergency control center. Emergency control
center is facilities with:
• Address and Telephone numbers of the Factory Inspectorate, Gujarat Pollution Control
Board, Police, Fire Brigade, Hospitals and OEP Team Members
• Plant layout-indicating storage of hazardous materials, layout of fire
Hydrants/extinguishers, entrances/exits, roads etc.
• Portable P.A. System, Manual Siren, flood lights, Torches, Pickaxe, Saw, Nylon Ropes.
• Fire Blankets / Fire Proximity Suit, Breathing Apparatus, First Aid Box etc.
• List of employees with address, telephone number, blood group etc.
• Material Safety Data Sheets of all chemicals handled.
9.14.6 WIND SOCKS:
Wind direction will be determined with the help of installed windsocks.
9.14.7 MOCK DRILL:
Mock drills are carried out regularly to familiarize the staff with their roles, fire protection
equipment/system installed in the plant and use of personnel protective equipment. Senior
officials monitor this and shortcomings are thoroughly studied and necessary corrective
measures are taken.
PROCEDURES FOR MOCK DRILLS
• Inform all the employees about mock drills and the signal to be given.
• Fix the date and location of the emergency for mock drills.
• Mock drills will be monitored by observers.
• Raise the siren for emergency.
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• After hearing the siren the Incident Controller, Site Controller, Officers and Team Members
should actuate the “On-site Emergency Plan”.
PROCEDURE ON NOTICING AN EMERGENCY
• If anybody notices any situation, which may lead to a disaster, should be immediately
inform the Shift In-charge / site controller / Incident Controller / Fire & Safety Supervisor /
Security.
• Take charge of the situation as Incident Controller.
• Rush to the site of emergency to get the correct picture and then to Emergency Control
Center for speedy control over the situation by making an arrangement for raising the alarm.
• On arrival of Team members, he shall assign duties as required and activate the On-Site
Emergency Plan.
• Ensure safety of the plant and the personnel in the plant. He will make an assessment of the
emergency and decide on external assistance.
• Communicate and Coordinate among the Incidents Controller/ Site Controller/ Factory
manager/ fire safety supervisor etc. and will be the final authority on all matters related with
management of emergency such as:
• Fire fighting.
• Welfare and rescue operations.
• Arrange for Civil/Mechanical/Electrical work during emergency.
• Transport.
9.14.8 INCIDENT CONTROLLER / SITE CONTROLLER:
Rush immediately to the scene of the fire/emergency, select and set out appropriate
fire/emergency equipment. He will take the below mentioned actions at the earliest
opportunity, if the fire/emergency is not controlled.
He will
• Call the security personnel from their residences for additional manpower if
required.
• Regulate entry and exit of personal required for controlling the fire/emergency.
• Restrict exit of personal required for controlling the fire/emergency.
REIA of Kusa Chemicals Pvt. Ltd. S. No. 126/1,2,3, Godhra-Halol Highway, Vi: Popatpura, Ta: Godhra, Di:
Panchmahal, Gujarat
Chapter 9 Additional Studies
Prepared By: ECO-CARE SOLUTIONS, Vadodara,
September - 2014
232
• Arrange for Personnel Protective Equipment required for the emergency.
• Call, the local Fire Brigade, Police in case of necessity in consultation with the
Incident Controller.
• Arrange transport facilities for removal of causalities to dispensary / hospital.
• Take responsibility of law and order.
• Keep detailed records of the incident and progress of operations to fight the emergency.
9.14.9 FACTORY MANAGER:
He will rush to the Emergency Control Centre and collect the information from the Incident
Controller. Further he will,
• Announce the location of the Assembly Point after getting information from Incident
Controller / site controller.
• Take the list of persons to be communicated internally and externally.
• Maintain liaison with the press, government agencies i.e. Police, Fire Brigade etc.
and the neighborhood regarding the emergency under instructions from Incident
Controller.
• Courteously Receive officers from the State Government or neighbors to the
Administration Block only and inform to Incident Controller that they can be taken
care off.
• Take all the steps required for the welfare such as providing tea, snacks, emergency
temporary Medical Center in consultation with the incident controller/site controller.
• Disclose all the necessary information in the plant and media so as to avoid rumors
and confusion.
• Also be responsible for the head counts at the Assembly Points.
9.14.10 FIRE & SAFETY SUPERVISOR/ SHIFT INCHARGE& S ECURITY:
• Proceed to the scene; establish contact with firemen and incident controller to
supplement efforts in fire fighting.
• Assist in searching casualties and help to remove them to the medical center.
• Organize outside assistance in fire fighting and rescue operations if required.
• Mobilize personal protective equipment and safety appliances and assist personnel
handling emergency in using them.
REIA of Kusa Chemicals Pvt. Ltd. S. No. 126/1,2,3, Godhra-Halol Highway, Vi: Popatpura, Ta: Godhra, Di:
Panchmahal, Gujarat
Chapter 9 Additional Studies
Prepared By: ECO-CARE SOLUTIONS, Vadodara,
September - 2014
233
• Keep and check on any new development of unsafe situation and report the same to
Site Main Controller.
• Collect and preserve evidence to facilitate future inquiries.
• Effectively cordon off the emergency area and will prevent unauthorized people
entering the scene.
• Permit the Fire tenders or Ambulance requisitioned by Incident Controller to the
plant.
• Ensure that vehicles and trolleys are sent out of the plant premises.
• Ensure that all the employees are conducted out of plant and assembled at Assembly
Point.
• Control Traffic Movement.
• Remove tankers, tanker drivers outside.
• Entry of unauthorized public to be prevented.
• Arrange for vehicles for shifting casualties and essential workers to safe assembly
points.
9.14.11 ENGINEERING/ OPERATION & MAINTENANCE:
• Ensure the safety of the remaining part of the plant.
• Take necessary steps for plant shutdown in consultation with the site controller.
• Ensure that an Operator is immediately available at the Water Pump House for fire
fighting.
• Mobilize with necessary tools and tackles to handle any repair work on an
emergency basis.
REIA of Kusa Chemicals Pvt. Ltd. S. No. 126/1,2,3, Godhra-Halol Highway, Vi: Popatpura, Ta: Godhra, Di:
Panchmahal, Gujarat
Chapter 9 Additional Studies
Prepared By: ECO-CARE SOLUTIONS, Vadodara,
September - 2014
234
9.15 MSDS – MATERIAL SAFETY DATA SHEET
A material safety data sheet has information on using and storing hazardous substances safely.
It must state:
• a hazardous substances product name
• the chemical name of certain ingredients which also have a generic name
• the chemical and physical properties of the hazardous substance
• health hazard information
• precautions for safe use and handling
• manufacturer or importer’s name, address and telephone number
How to use MSDS
• identify the hazards associated with a hazardous substance
• check that all hazardous substances are being used in the manner intended
• decide whether any improvements should be made to control methods or procedures
• Identify necessary control measures before the introduction of a new hazardous substance.
• Decide whether workplace monitoring or health surveillance should be done.