Abstract of Speedy and Safe Development of Infrastructure Project at Sivakasi
Transcript of Abstract of Speedy and Safe Development of Infrastructure Project at Sivakasi
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Abstract of Speedy and Safe Development of Infrastructure Project at Sivakasi
The illiteracy of the fireworks employees, the hesitancy from the occupiers of fireworks industries and
the remoteness of the fireworks industries have all clubbed together to form a very big barrier in
between the infrastructure providers and the establishment of fireworks safety. The first move to
reinforce the infrastructure towards better Hazard Communication Programme1 in accordance with
United Nations Classification System, Material Safety Data Sheet and the National Fire Protection
Association (NFPA704) Hazard Diamond Information2. Only when an employee with a working
understanding of the chemical reactions involved would be able to serve as an informational resource in
the development of infrastructure towards Zero Harm.
The occupiers of the fireworks industries should be taught the provisions of the Factories Act, the Arms
Act and the Explosives Act as well as the social value of human life and the Societal Approach towards
Safety. At present Competence management to cope up with the requirements for establishment of
fireworks safety is limited to the bottom level and the middle level, whereas the initiative has to be
originated from the top level management.
Remoteness of the fireworks industries has played a pivotal role in preventing speedy approach by the
Emergency Teams like Fire Service, Medical Service, Police Personnel, Safety Experts and the Essential
Department Personnel. Moreover, considering the number of fireworks industries in and around
Sivakasi Area, the catastrophic nature of the major accidents taking place in those factories and the
quantum of manpower engaged in the manufacturing activities, anybody would be surprised to hear
that there is no Burn Ward in the Government Hospital, Sivakasi.
Hence, benchmarking with the compliance of all Statutory Regulations, worrying about the response
from the other industrial sectors to find a suitable place in the Safety League and above all ethically
considering the value of Human Life, every organization at whatever level it may be should come
forward at this juncture to identify and establish an Action Programme for speedy and safe development
of Infrastructure Project at Sivakasi in the form of either Industrial Corridor or Industrial Estate so as to
set the clock back correctly.
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Petroleum and Explosives Safety Organization (PESO) has established a Fireworks Research and
Development Centre (FRDC) at sivakasi. Though one of the objectives of the establishment of FRDC at
Sivakasi is Testing of Raw Materials, there are fire and explosions incessantly resulting in the multiple
deaths of precious manpower. Thus it is indicating that the efforts are not supportive for our objectives.PESO has developed infrastructure with dedicated Physical, Chemical, Pyro & Instrumentation
Laboratories and a library, Modern Thermo Analytical Equipments, various Spectrophotometers and
Sound Level Meters. But the main emphasis towards Reactive Chemistry and Controlling the Runaway
Reactions are yet to find place in the objectives of the PESO. Safety and Health are the eyes of the
fireworks industry and Dos and Donts of the Safe Fireworks Manufacture with correct understanding of
the reactive chemicals used in the process, the compatibility of the different chemicals, runaway
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reactions, spontaneous heating in certain instances of the chemical application and the control of the
reaction parameters are the prime components of fireworks safety. As such appropriate measures
should be oriented and incorporated in the infrastructure by the PESO.
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Infrastructure to combat Reactive Chemical Hazards
A Chemical Reactivity Hazard is a situation with the potential for an uncontrolled chemical reaction that
can result directly or indirectly in serious harm to people, property and environment. Reactivity involves
the tendency of substances to undergo chemical change; it encompasses several more specific types of
hazards, such as instability and water reactivity3. For example, intrusion of water into the Methyl
Isocyanate Storage Tank during the maintenance activities resulted in the catastrophic uncontrolled
chemical reaction on the night of 2nd and early hours of 3rd of December 1984 at Bhopal.
Reactive Chemistry is about studying materials which become chemically unstable for a variety of
reasons. Intended chemical reactions are not as per our expectations and they are getting out of controlall of a sudden. These spontaneous unintended chemical reactions take place due to accidental mixing
of the chemicals that are normally separate. Housing two reactive chemicals that would generate toxic
fumes or cause explosion when mixed within the same enclosure is an inherent safety blunder. As can
be seen from the Global Reactive Chemicals Standard4, all existing chemical processes will have a
Reactive Chemicals/Process Hazard Analysis Review on a predetermined periodic basis. In addition, any
new plant Production Leader should review their process with the Reactive Chemical Committee within
90 days of assuming responsibility for a pilot or production plant. Prior to the review, the Leader should
acquire training on the Process Chemistry as well as Reactive Chemistry and the processes that they are
working with. This should include an evaluation of raw materials, Processes, products and waste to
understand the potential reactive chemical hazards, if any.
The preliminary screening method is based on a series of following 12 questions that are intended to
help quickly decide whether chemical reactivity hazards are likely to be present at a given facility. If
chemical reactivity hazards are indicated, they examined either individually or by a group. A Team
Approach involving several people is typically preferred. Those involved need some basic knowledge of
process chemistry to properly understand the quantum of chemicals stored/used in the industrial
premises and their severity at the instances of catastrophic situation:
1. Is intentional chemistry performed?2. Is there any mixing or combining of different substances?3. Does any other physical processing of substances occur?4. Are there any hazardous substances stored or handled?5. Is combustion with air the only chemistry intended?6. Is any heat generated during mixing or physical processing of substances?7. Is any substance identified as spontaneously combustible?8. Is any substance identified as peroxide forming?9. Is any substance identified as water reactive?
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10. Is any substance identified as oxidizer?11. Is any substance identified as self-reactive? and12.Can incompatible chemicals coming into contact cause undesired consequence based on the
analysis?
The aforesaid Reactive Chemical Review as per the Global Reactive Chemicals Standard should be
conducted on the new processes, periodically on existing processes and facilities, on changes planned
for existing facilities and on changes in the supervision. The prime focus of Reactive Chemicals Review
should be on the Process Chemistry including the principal reaction and expected side reactions along
with their heat of reactions, exotherms, and shock sensitivity, other indication of instability and pressure
buildup potential. Differential Scanning Calorimetry (DSC) is a basic screening test and shall be applied to
all chemicals and mixtures unless the thermal stability has been clearly established. The evaluation of
thermal stability requires understanding the rate of such a reaction as a function f temperature and the
heat generated per unit of material by the reaction. In many cases, if not most, information on the
pressure increase during the reaction is also essential, particularly for vent sizing. Mixing Calorimetryscreens the results of intentional or unintentional mixing for immediate heat or gas release. Accelerating
Rate Calorimetry ((ARC) determines the self-heating rate of a chemical under near-adiabatic conditions
and will usually give a conservative estimate of the conditions for, and the consequence of, a Runaway
Reaction. Yet another Macro-DTA (Differential Thermal Analysis) is designed to yield information
between ARC and DSC. Reaction Calorimetry consists of a jacketed reactor, addition device, and
temperature transducer and calibration heaters. While each of these calorimetric devices has their
unique attributes, e.g. in-situ spectrometry, quick turn-around ability to reflux, etc. will produce a signal
of heat flow vs. time.
List of References:
1. U.S.: Occupational Safety and Health Administration: Hazard Communication Standard: 29 CFR:1910.120
2. Essential practices for Managing Reactive Chemical Hazards: CCPS Publication: G-81:20033. Screen your facilities for Chemical Reactive Hazards: CEP Aug. 2003: Pages 50-584. Process Safety Services: Reactive Chemicals Program Guidelines: Se.19975.
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