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Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra
SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES
Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 1
CHAPTER 7: ADDITIONAL STUDIES
7.1 Public Hearing
“Public Consultation” refers to the process by which the concerns of local affected persons and
others who have plausible stake in the environmental impacts of the project or activity are
ascertained with a view to taking into account all the material concerns in the project or activity
design as appropriate. M/s Galaxy Surfactants Ltd. will commence the project activity Tarapur
MIDC at plot no. G-59. As per the OM No. J-11013/36/2014-IA-I dated 10th December 2014
public hearing is not mandatory for the industries which are established in industrial estate or
parks notified prior to 14.06.2006 i.e. the EIA notification, 2006 coming into force.
7.2 Risk Assessment
7.2.1 Introduction
As indicated in the earlier chapter the proposed facility to manufacture Specialty
chemicals poses various types of hazards due to storage, handling and manipulation of
different chemicals, which are indicated in Chapter no. 2
In order to study the risks envisaged by the activities, the following methodology was
adopted.
7.2.1.1 Detailed study of all manufacturing activities
7.2.1.2 The factory would be manufacturing about 29 different products with total
production quantity of 3472 MT/A. The hazop studies have been carried out for
the products.
7.2.1.3 A detailed scrutiny of various chemicals which would be stored on the site was
done. Aloha is performed for the raw materials which are mentioned below,
Table No. 7.1: List of Tanks in CCOE Area
Sr.No Name of the RawMaterials Capacity Nature
Qty Area MOC
1 Cyclohexane 20 MT Underground 1 Tank CCOE SS316L
Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra
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2Toluene 15 MT Underground
1 Tank CCOE SS316L
3Methanol 15 MT Underground
1 Tank CCOE SS316L
4Ethyl Acetate 15 MT Underground
1 Tank CCOE SS316L
5IPA 15 MT Underground
1 Tank CCOE SS316L
Table No 7.2: Gas Storage Details
The Gas Storage Details are tabulated below -
Sr.No.
Gas Type Storagepressurebar
Diameter,m
Length /height, m
Capacity, Area
1 Hydrogen Cylinder(150 )
150 atm. 0.2 m 1.6m 45 lit CCOE
2 TrimethylamineGas
Tank 4 bar 2.2 m 3 m 10 MT CCOE
Table No. 7.1: List of Tanks in Non CCOE Area (Considered for Aloha)
Sr.NoRaw materials Proposed
consumptionMax.Storage State Storage type
TPM MT1. Thionyl Chloride 81.40 40.00 Liquid Above ground Storage tank
2. 2-Ethyl hexanol 169.25 50 LiquidAbove ground Storage tank
3. Benzyl Chloride 28.75 30.00 LiquidAbove ground Storage tank
4. Acetic Acid 50 30 Liquid Above ground Storage tank
5. HCl solution 15.21 50.00 Liquid Above ground Storage tank
7.2.1.4 M.S.D.S.s
Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra
SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES
Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 3
Brief M.S.D.S.s of all the above chemicals and other raw materials which would be used in the
manufacturing processes of products are used as reference for preparation of hazop & risk
assessment study.
7.2.1.5 A Quantitative Risk Assessment based on the software ALOHA – Areal Locations of
Hazardous Atmospheres was carried out. The criteria failure scenarios considered for ALOHA
depend on the type of storage whether above ground/ underground, physical state of the chemical
stored, chemical properties of the chemical.
The summary of the ALOHA footprints are attached as Annexure 7.1
Table No 7.3: Summary of Aloha Footprints
Substance Failure Scenario No. Effectsconsidered
LOC Distance,m
Tri methylAmine
Direct Source Tri methylAmine/01
Toxic area ofvapor cloud
AEGL-3 380 ppm 351 meters
AEGL-2 120 ppm 659 metersAEGL-1 8 ppm 2.7
kilometers
Tri methylAmine/02
Flammable Areaof Vapor Cloud
12000ppm =60% LEL =FlamePockets
42 meters
2000 ppm= 10% LEL
126 meters
Tri methylAmine/03
Overpressure(blast force)from vaporcloud explosion
8.0 psi LOC wasneverexceeded
3.5 psi 29 meters1.0 psi 54 meters
Flammablechemicalescaping fromtank (not
Tri methylAmine/04
Toxic Area ofVapor Cloud
AEGL-3 380 ppm 1.1kilometers
Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra
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burning)
AEGL-2 120 ppm 1.7kilometers
AEGL-1 8 ppm 4.4kilometers
Tri methylAmine/05
Flammable Areaof Vapor Cloud
12000ppm =60% LEL =FlamePockets
330 meters
2000 ppm= 10% LEL
624 meters
Tri methylAmine/06
Overpressure(blast force)from vaporcloud explosion
8.0 psi LOC wasneverexceeded
3.5 psi 288 meters1.0 psi 368 meters
Flammablechemical isburning as itescapes fromtank
Tri methylAmine/07
10.0kW/(sq m)
80 meters
5.0kW/(sq m)
124 meters
2.0kW/(sq m)
201 meters
BLEVE offlammable liquidin verticalcylindrical tank
Tri methylAmine/08
10.0kW/(sq m)
136 meters
5.0kW/(sq m)
193 meters
2.0kW/(sq m)
301 meters
Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra
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Hydrogen Catastrophicfailure of cylinder
Hydrogen/01 Toxic area ofvapor cloud
AEGL-3 400000ppm
11
AEGL -2
230000ppm
14
AEGL -1
65000ppm
28
Hydrogen / 02 Flammable areaof vapor cloud
24000ppm =60% LEL
64
4000 ppm= 10%LEL
157
Hydrogen / 03 Blast area ofvapour cloudexplosion
8.0 psi < 10
3.5 psi < 101.0 psi < 10
failure of outletpipeline, pig tail(Chemical notburning)
Hydrogen / 04 Toxic area ofvapor cloud
AEGL-3 400000ppm
20
AEGL -2
230000ppm
52
AEGL -1
65000 ppm 119
Hydrogen/ 05 Flammable areaof vapor cloud
24000ppm =60% LEL
< 10
4000 ppm= 10%LEL
22
Hydrogen / 06 Blast area ofvapour cloudexplosion
-- --
failure of outletpipeline, pig tail(Chemical
Hydrogen / 07 Thermalradiation fromjet fire
10 kw/sq m. < 10
Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra
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burning)5 kw/sq m. < 102 kw/sq m. < 10
Isopropanol
Direct Source –20% leakagethrough transferpump
Isoproponal /01 Toxic area ofvapor cloud
PAC-3 12000ppm
20
PAC-2 400 ppm 146PAC -1 400 ppm 146
Isoproponal /02
Flammable areaof vapor cloud
12000ppm =60% LEL
17
2000 ppm= 10%LEL
43
Isoproponal /03
Blast area ofvapour cloudexplosion
8.0 psi --
3.5 psi 141.0 psi 22
Road Tankerrupture
Isoproponal /04
Toxic area ofvapor cloud
PAC-3 12000ppm
--
PAC-2 400 ppm 112PAC -1 400 ppm 112
Isoproponal /05
Flammable areaof vapor cloud
12000ppm =60% LEL
< 10
2000 ppm= 10%LEL
42
Isoproponal /06
Blast area ofvapour cloudexplosion
--
EthylAcetate
Direct Source –20% leakage
Ethyl Acetate/01
Toxic area ofvapor cloud
PAC-3 10000ppm
20
Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra
SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES
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through transferpump
PAC-2 400 ppm 127PAC -1 400 ppm 127
Ethyl Acetate /02
Flammable areaof vapor cloud
13080ppm =60% LEL
17
2150 ppm= 10%LEL
46
Ethyl Acetate /03
Blast area ofvapour cloudexplosion
8.0 psi --
3.5 psi 131.0 psi 30
Road Tankerrupture
Ethyl Acetate /04
Toxic area ofvapor cloud
PAC-3 10000ppm
19
PAC-2 400 ppm 134PAC -1 400 ppm 134
Ethyl Acetate /05
Flammable areaof vapor cloud
13080ppm =60% LEL
15
2150 ppm= 10%LEL
47
Ethyl Acetate /06
Blast area ofvapour cloudexplosion
8.0 psi --
3.5 psi 101.0 psi 15
Methanol Road Tankerrupture
Methanol /01 Toxic area ofvapor cloud
AEGL-3 7200 ppm 624
AEGL-2 2100 ppm 1100AEGL-1 530 ppm 1800
Methanol / 02 Flammable areaof vapor cloud
43800ppm =
235
Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra
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60% LEL7180 ppm= 10%LEL
679
Methanol / 03 Blast area ofvapour cloudexplosion
8.0 psi --
3.5 psi --1.0 psi 192
Direct Source –20% leakagethrough transferpump
Methanol / 04 Toxic area ofvapor cloud
AEGL-3 7200 ppm 42
AEGL-2 2100 ppm 82AEGL-1 530 ppm 170
Methanol / 05 Flammable areaof vapor cloud
43800ppm =60% LEL
17
7180 ppm= 10%LEL
53
Methanol / 06 Blast area ofvapour cloudexplosion
8.0 psi --
3.5 psi --1.0 psi 14
Toluene Road tankerrupture
Toluene /01 Toxic area ofvapor cloud
AEGL-3 4500 ppm 520
AEGL-2 1200 ppm 869AEGL-1 200 ppm 1700
Toluene / 02 Flammable areaof vapor cloud
6600 ppm= 60%LEL
443
1100 ppm= 10%LEL
897
Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra
SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES
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Toluene / 03 Blast area ofvapour cloudexplosion
8.0 psi --
3.5 psi 3701.0 psi 455
Direct Source –20% leakagethrough transferpump
Toluene / 04 Toxic area ofvapor cloud
AEGL-3 4500 ppm 36
AEGL-2 1200 ppm 75AEGL-1 200 ppm 215
Toluene / 05 Flammable areaof vapor cloud
6600 ppm= 60%LEL
31
1100 ppm= 10%LEL
78
Toluene / 06 Blast area ofvapour cloudexplosion
8.0 psi --
3.5 psi --1.0 psi 13
Cyclohexane
Road tanker Cyclohexane/01
Toxic area ofvapor cloud
AEGL-3 8600 ppm 363
AEGL-2 2900 ppm 567AEGL-1 -- --
Cyclohexane /02
Flammable areaof vapor cloud
7200 ppm =60% LEL
392
1200 ppm =10% LEL
792
Cyclohexane /03
Blast area ofvapour cloudexplosion
8.0 psi --
3.5 psi 3291.0 psi 411
Direct Source – Cyclohexane / Toxic area of AEGL-3 8600 ppm 23
Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra
SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES
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20% leakagethrough transferpump
04 vapor cloud
AEGL-2 2900 ppm 43AEGL-1 -- --
Cyclohexane /05
Flammable areaof vapor cloud
7200 ppm =60% LEL
25
1200 ppm =10% LEL
67
Cyclohexane /06
Blast area ofvapour cloudexplosion
8.0 psi --
3.5 psi 171.0 psi 37
Aceticacid
Direct Source –20% leakagethrough transferpump
Acetic acid/01
Toxic area ofvapor cloud
AEGL-3 250 ppm 164
AEGL-2 35 ppm 459AEGL-1 5 ppm 1300
Acetic acid /02
Flammable areaof vapor cloud
24000 ppm= 60% LEL
29
4000 ppm= 10% LEL
72
Acetic acid /03
Blast area ofvapour cloudexplosion
8.0 psi --
3.5 psi 181.0 psi 34
The entire contentsof the storage tankgettingaccumulated in thedyke enclosurebecause of failureof the tank –
Acetic acid /04
Toxic area ofvapor cloud
AEGL-3 250 ppm 23
Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra
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Chemical notburning
AEGL-2 35 ppm 96AEGL-1 5 ppm 264
Acetic acid /05
Flammable areaof vapor cloud
24000 ppm= 60% LEL
--
4000 ppm= 10% LEL
< 10
Acetic acid /06
Blast area ofvapour cloudexplosion
--
The entirecontents of thestorage tankgettingaccumulated inthe dykeenclosurebecause offailure of thetank – Chemicalburning.
Acetic acid/07
Thermalradiation frompool fire.
10 kw/sq m. 12
5 kw/sq m. 182 kw/sq m. 29
Hydrochloric acid
The entire contentsof the storage tankgettingaccumulated in thedyke enclosurebecause of failureof the tank –Chemical notburning
HCl / 01 Toxic area ofvapor cloud
AEGL-3 100 ppm 54
AEGL-2 22ppm 129AEGL-1 1.8 ppm 467
BenzylChloride
Direct Source –20% leakagethrough transferpump
BenzylChloride/01
Toxic area ofvapor cloud
ERPG-3 50 ppm 175 meters
Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra
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ERPG-2 10 ppm 411 metersERPG-1 1 ppm 1.4
kilometers
BenzylChloride/02
FlammableArea of VaporCloud
6600 ppm= 60%LEL =FlamePockets
11
1100 ppm= 10%LEL
31
BenzylChloride/03
Overpressure(blast force)from vaporcloudexplosion
8.0 psi --
3.5 psi 131.0 psi 29
The entirecontents of thestorage tankgettingaccumulated inthe dykeenclosurebecause offailure of thetank – Chemicalnot burning
BenzylChloride/04
Toxic area ofvapor cloud
ERPG-3 50 ppm 10
ERPG-2 10 ppm 22ERPG-1 1 ppm 82
BenzylChloride/05
FlammableArea of VaporCloud
6600 ppm= 60%LEL =FlamePockets
10
1100 ppm= 10%
10
Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra
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LEL
BenzylChloride/06
Overpressure(blast force)from vaporcloudexplosion
-- --
The entirecontents of thestorage tankgettingaccumulated inthe dykeenclosurebecause offailure of thetank – Chemicalburning
BenzylChloride/07
Thermalradiation frompool fire
10.0kW/(sq m)
13
5.0kW/(sq m)
17
2.0kW/(sq m)
25
2-ETHYLHEXANOL
Direct Source –20% leakagethrough transferpump
2-ETHYLHEXANOL/01
Toxic area ofvapor cloud
ERPG-3 200 ppm 73 meters
ERPG-2 100 ppm 105 metersERPG-1 0.1 ppm 3.9
kilometers
2-ETHYLHEXANOL/02
FlammableArea of VaporCloud
5280 ppm= 60%LEL
11
880 ppm =10% LEL
31
2-ETHYLHEXANOL/03
Overpressure(blast force)from vapor
8.0 psi --
Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra
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cloudexplosion
3.5 psi 141.0 psi 32
The entirecontents of thestorage tankgettingaccumulated inthe dykeenclosurebecause offailure of thetank – Chemicalnot burning
2-ETHYLHEXANOL/04
Toxic area ofvapor cloud
ERPG-3 200 ppm <10
ERPG-2 100 ppm <10ERPG-1 0.1 ppm 125
2-ETHYLHEXANOL/05
FlammableArea of VaporCloud
5280 ppm= 60%LEL
<10
880 ppm =10% LEL
<10
2-ETHYLHEXANOL/06
Overpressure(blast force)from vaporcloudexplosion
-- --
The entirecontents of thestorage tankgettingaccumulated inthe dykeenclosurebecause offailure of thetank – Chemicalburning
2-ETHYLHEXANOL/07
Thermalradiation frompool fire
10.0kW/(sq m)
18
Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra
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5.0kW/(sq m)
24
2.0kW/(sq m)
35
THIONYLCHLORIDE
Direct Source –20% leakagethrough transferpump
THIONYLCHLORIDE/01
Toxic area ofvapor cloud
AEGL-3 14 439
AEGL-2 2.4 1.1 KmAEGL-1 - -
THIONYLCHLORIDE/02
Toxic area ofvapor cloud
AEGL-3 14 428
AEGL-2 2.4 1.1 KmAEGL-1 - -
Interpretation
The probability of failure of the entire tank etc, which is considered in the above scenario is veryless. However to further reduce the same, following precautions would be taken,
A) For Underground Solvent Storage Tanks & Above ground tanks
The tanks will be fabricated taking into account the corrosion resistance properties of the
material of construction.
The tank will be provided with water sprinkler arrangement so as to cool the same in
summer season
The tanks will be provided with breather valves and will have nitrogen blanketing
arrangement wherever required
Dyke wall of adequate volume (110%) capacity of the tank will be constructed around the
tanks.
The dyke enclosure will be lined with impervious coating
Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra
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Regular inspection of the tank, transfer pipelines and dyke will be done visually and
records maintained.
Wherever required, the tanks would be covered under a license under Petroleum Rules
from PESO.
It is recommended to establish foam monitor in the solvent tank yard farm.
B) For Hydrogen Cylinders
1. The licensed premises shall not be used for any purpose other than for keeping of compressed
gas filled in cylinders.
2. Compressed gas cylinders shall be stored only in the storage shed, which shall be constructed
of suitable non-flammable materials provided that, when only non-flammable gas filled in
cylinder is stored, the beams, rafters, columns, windows and doors may be of wood.
3. The storage shed shall be adequately ventilated near the ground level and near or in the roof.
4. As far as possible, different types of gases should not be stored in the same shed. Where
different types of gas cylinders are stored in the same shed, cylinders may be grouped together
depending on the nature of the gas contained therein e.g. flammable gas cylinders shall be
separated from cylinders containing oxidizing gases by an intervening space of one meter or by a
fire resisting partition wall in between them and cylinders containing toxic gases shall be
segregated from the cylinders containing non-toxic gases by a suitable partition wall.
5. The following distances shall be kept clear at all times, between any building, public place,
public road or any adjoining property which may be built upon and the storage shed used for the
storage of liquefied petroleum gas cylinder: Quantity of compressed gas in Minimum distance to
be Cylinder kept clear Kg. Metres 0 -- 101 – 101 -- 2000 3 2001 -- 3000 4 3001 -- 4000 5 4001 --
6000 6 6001 -- 8000 7 8001 -- 10000 8 10001 -- 12000 9 12001 -- 20000 12 over 20000 15
Provided that the distance specified above may be reduced by the Chief Controller (i) where
Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra
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screen walls are provided or other special precautions taken, or (ii) where there are special
circumstances which in the opinion of the Chief Controller would justify such reduction.
6. Notwithstanding anything contained in condition 5 above, cylinders containing liquefied
petroleum gas exceeding 100 Kg. but not exceeding 500 Kg. may be kept in a storage shed
forming part of, or attached to a building, provided that it is separated there from by a substantial
partition and the only means of access to it is from outside air, such a storage shed shall not be
situated under any staircase or near other entrances to, or exits from the rest of the building or
other buildings.
7. A shed used for storage of liquefied petroleum gas cylinders shall be surrounded by a suitable
brick masonry compound wall of 1.8 meters high with a 1.2 meter wide gate to prevent
unauthorized person from having access to the shed and its safety zone.
8. Thin wall cylinders shall not be stacked in a horizontal position, provided that in case of
liquefied petroleum gas cylinders, the following method of stacking may be permitted:- (i) filled
cylinders shall be stored vertically and not be stacked more than 2 high; (ii) empty cylinders if
stored vertically, shall not be stacked more than 3 high and; if stored horizontally, shall not be
stacked more than 5 high; (iii) the pile of the cylinders shall be kept stable by using chocks at the
ends; (iv) at least 60 centimeter wide gangway, to permit access and maneuvering of cylinders,
shall be left between stacks of single or double rows and between stacks and walls,
9. True chemical name(s) of the gases shall be prominently displayed in the storage shed.
10. The storage shed shall be in the charge of a competent person.
11. Any accident, fire, explosion or untoward incident occurred within the licensed premises shall
be immediately reported to the Chief Controller (Gram “EXPLOSIVES”, Nagpur, E-
[email protected]), Controller, District Magistrate and the Officer-in-Charge of
the nearest Police Station and by quickest mode of communication.
Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra
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13. No shed used for storage of flammable gases shall be opened and no handling of the gas
cylinders shall be permitted between the hours of sunset and sunrise, except where approved
electric lighting is exclusively used.
14. The storage shed and the area surrounding it shall at all times be kept clean and free from all
flammable materials, waste vegetation and, rubbish.
15. (a) No fire, furnace or other source of heat or light other than flameproof electric light and
fittings shall be allowed in the storage shed and within the safety zone required to be maintained
under condition 5. (b) No person shall smoke in the storage shed or carry matches, fuses, mobile
phones or other appliances producing ignition in the premises. Conspicuous ‘No smoking signs in
Hindi, English and the regional language shall be pasted or hung up at prominent places outside
the storage shed.
16. The licensee shall provide at the licensed premises a minimum of two potable foam
type/ordinary chemical type fire extinguishers of 10 kg. Each BIS marked or approved which
shall be kept ready at a convenient location for immediate use in the event of any fire in addition
to other fire fighting for other mitigating facilities required for flammable or toxic gases.
7.2.2 DOW INDEX
The Dow index has been calculated for chemicals stored in tank farm. Dow Index has beencalculated separately for F.O and HSD Tank area, CCOE U.G Tank area and Non CCOE TankArea.
Table No. 7.4 Storage details of Furnace Oil and LDO Tank.
Sr.No Raw MaterialTank/ Drum
CapacityKL.
Quantity atany
given time
No. ofTanks
Flash PointOC
1 Furnace Oil 40 KL 40 KL 1 662 LDO 20 KL 20 KL 1 66
Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra
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Since, the flash point of Furnace Oil & LDO is the same, the DOW Index is performed for FOconsidering total volume is 60 KL of FO.
Tank No. -- Equipment Name FO 60 KLBasic Material for Materialfactor
MS Drums Density, kg/l 0.97Properties of materialN h 0 N f 2 N r 0 M.F. 10Boil.pt.
-- 0F -- 0C Flash pt. 150 0F 66 0C
HC = Heat ofComb.
18700 BTU / lb
Quantity of thematerial
60000 l 58200 kg 128309.04 LbStorage conditions Temp 30 0C Pressure 1.0 bar
Penalty factorrange
Penalty factorused1.General Process
HazardBase Factor 1.00 1.00
Exothermic Chemical Reaction 0.30 to 1.25 0.00Endothermic Processes 0.20 to 0.40 0.00
Material handling and transfer 0.25 to 1.05 0.40Enclosed or Indoor Process Units 0.25 to 0.90 0.00
Access 0.20 to 0.35 0.00Drainage and Spill Control 0.25 to 0.50 0.00
General Process Hazard Factor ( F1 ) 1.4
2.Special ProcessHazard
Base Factor 1.00 1.00Toxic material(s) 0.20 to 0.80 0.00Sub atmospheric pressure (< 500 mmHg)
0.50 0.00Operation in or near flammable range
_____inerted ______noninerted
0.00 to 0.80
1. Tank farm storage flammableliquids
0.50 0.002. Process upset or purge failure 0.30 0.003. Always in contact of Flame
process
0.80 0.00
Dust Explosion 0.25 to 2.00 0.00Pressure Operating pressure psig
Relief setting ________psig
0.00
Low temperature 0.20 to 0.30 0.00Quantity of flammable / unstablematerial1. Liquids or gases in process 0.12. Liquids or gases in storage 0.6
Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra
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3. Combustible Solids in Storage, Dustin Process
0.00
Corrosion & Erosion 0.10 to 0.75 0.10Leakage - Joints & Packing 0.10 to 1.50 0.10Use of Fired Equipment 0.00Hot oil heat exchange system 0.15 to 1.15 0.00Rotating Equipment 0.50 0.00Special Process Hazard Factor ( F2 ) 1.9
Process Unit Hazard Factor ( F3 = F1 x F2) 2.66Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 26.6Degree of Hazard Light
The calculations for Dow Fire and Explosion Index is given and from the calculations it is seenthat the storage will have a Dow Index of 26.6 indicating Light hazard potential.
Table No. 7.5 Degree of Hazard for F & EI
Degree of Hazard for F & EIF & EI Index Range Degree of Hazard
1-60 Light61-96 Moderate
97-127 Intermediate128-158 Heavy159-up Severe
RECOMMENDED MINIMUM FEATURES ACCORDING TODOW FIRE AND EXPLOSION INDEX
Preventive & ProtectiveFeatures
Fire & Explosion Index Number Index for the present case
0-20
20-40 40-60
60-75
75-90
>90 26.6
Suggested Recommended Featurerequired
1) Fireproofing 1 2 2 3 4 4 √
2) Water spray
a) directional 1 2 3 3 4 4 √b) area 1 2 3 3 4 4 √c) curtain 1 1 2 2 2 4 √
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3) Special instrumentation
a) temperature 1 2 3 3 4 4 √b) pressure 1 2 3 3 3 4 √c) flow control 1 2 3 4 4 4 √
4) Dust, blowdown, spillcontrol
1 1 2 3 3 4 √
5) Internal examination 1 2 3 3 4 4 √
6) Combustible gasmonitors
a) signal alarm 1 1 2 3 3 4 √b) actuate equipment 1 1 2 2 3 4 √
7) Remote operation 1 1 2 3 3 4 √
8) Diking, (NotApplicable as barrelstorage)
1 4 4 4 4 4 √
9) Blast & barrier wallsseparation
1 1 2 3 4 4 √
1) Feature optional 2) Feature suggested 3) Feature recommended 4) Feature required
Dow index for chemicals stored in non CCOE storage tanks
Sr. No Raw MaterialTank/ Drum
CapacityMT.
No. ofTanks
Flash PointOC
1 Acetic acid 30 1 392 Epichlorohydrin 10 -- 31
1. Acetic acid
Tank No. -- Equipment Name Acetic acid 30 MTBasic Material for Materialfactor
MS Tank Sp. gravity 1.049Properties of materialN h 3 N f 2 N r 0 M.F. 14
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Boil.pt.
-- 0F -- 0C Flash pt. 103 0F 39 0C
HC = Heat ofComb.
5600 BTU / lb
Quantity of thematerial
-- l 30000 kg -- LbStorage conditions Temp 30 0C Pressure 1.0 bar
Penalty factorrange
Penalty factorused1.General Process
HazardBase Factor 1.00 1.00
Exothermic Chemical Reaction 0.30 to 1.25 0.00Endothermic Processes 0.20 to 0.40 0.00
Material handling and transfer 0.25 to 1.05 0.40Enclosed or Indoor Process Units 0.25 to 0.90 0.00
Access 0.20 to 0.35 0.00Drainage and Spill Control 0.25 to 0.50 0.00
General Process Hazard Factor ( F1 ) 1.4
2.Special ProcessHazard
Base Factor 1.00 1.00Toxic material(s) 0.20 to 0.80 0.6Sub atmospheric pressure (< 500 mmHg)
0.50 0.00Operation in or near flammable range
_____inerted ______noninerted
0.00 to 0.80
1. Tank farm storage flammableliquids
0.50 0.002. Process upset or purge failure 0.30 0.003. Always in contact of Flame
process
0.80 0.00
Dust Explosion 0.25 to 2.00 0.00Pressure Operating pressure psig
Relief setting ________psig
0.00
Low temperature 0.20 to 0.30 0.00Quantity of flammable / unstablematerial1. Liquids or gases in process 0.12. Liquids or gases in storage 0.63. Combustible Solids in Storage, Dustin Process
0.00
Corrosion & Erosion 0.10 to 0.75 0.10Leakage - Joints & Packing 0.10 to 1.50 0.10Use of Fired Equipment 0.00Hot oil heat exchange system 0.15 to 1.15 0.00Rotating Equipment 0.50 0.00Special Process Hazard Factor ( F2 ) 2.5
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Process Unit Hazard Factor ( F3 = F1 x F2) 3.5Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 49Degree of Hazard Light
The calculations for Dow Fire and Explosion Index is given and from the calculations it is seenthat the storage will have a Dow Index of 49 indicating light hazard potential.
2. Epichlorohydrin
Tank No. -- Equipment Name Epichlorohydrin drumsBasic Material for Material factor HDPE
DrumsDensity, g/cc 1.18
Properties of materialN h 3 N f 3 N r 2 M.F. 24Boil. pt. 241 0F 116 0C Flash pt. 88 0F 31 0CHC = Heat of Comb. 7200 BTU / lbQuantity of the material -- l 10000 kg -- LbStorage conditions Temp 32 0C Pressure 1.0 bar
Penalty factorrange
Penalty factor used
1.GeneralProcessHazard Base Factor 1.00 1.00
Exothermic Chemical Reaction 0.30 to 1.25 0.00Endothermic Processes 0.20 to 0.40 0.00Material handling and transfer 0.25 to 1.05 0.6Enclosed or Indoor Process Units 0.25 to 0.90 0.00Access 0.20 to 0.35 0.00Drainage and Spill Control 0.25 to 0.50 0.00General Process Hazard Factor ( F1 ) 1.6
2.SpecialProcessHazard
Base Factor 1.00
1.00Toxic material(s) 0.20 to 0.80 0.6Sub atmospheric pressure (< 500 mm Hg) 0.50 0.00Operation in or near flammable range
_____inerted ______noninerted0.00 to 0.80
0.00
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1. Tank farm storage flammable liquids 0.50 0.02. Process upset or purge failure 0.30 0.003. Always in contact of Flame process 0.80 0.00
Dust Explosion 0.25 to 2.00 0.00Pressure Operating pressure psigRelief setting ________ psig 0.0Low temperature 0.20 to 0.30 0.00Quantity of flammable / unstable material1. Liquids or gases in process 0.02. Liquids or gases in storage 0.103. Combustible Solids in Storage, Dust inProcess
0.00
Corrosion & Erosion 0.10 to 0.75 0.10Leakage - Joints & Packing 0.10 to 1.50 0.10Use of Fired Equipment 0.00Hot oil heat exchange system 0.15 to 1.15 0.00Rotating Equipment 0.50 0.00Special Process Hazard Factor ( F2 ) 1.9
Process Unit Hazard Factor ( F3 = F1 x F2) 3.04Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 72.96Degree of Hazard ModerateRadius of exposure 18.6 mArea of exposure 1086.83 sq. m.
The calculations for Dow Fire and Explosion Index is given and from the calculations it is seenthat the storage will have a Dow Index of 72.96 indicating moderate hazard potential.
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RECOMMENDED MINIMUM FEATURES ACCORDING TODOW FIRE AND EXPLOSION INDEX
Preventive & ProtectiveFeatures
Fire & Explosion Index Number Index for the present case
0-20 20-40 40-60 60-75 75-90 >90 72.96
Suggested Recommended Feature
required1) Fireproofing 1 2 2 3 4 4 √
2) Water spray
a) directional 1 2 3 3 4 4 √
b) area 1 2 3 3 4 4 √c) curtain 1 1 2 2 2 4 √
3) Special instrumentation
a) temperature 1 2 3 3 4 4 √
b) pressure 1 2 3 3 3 4 √
c) flow control 1 2 3 4 4 4 √
4) Dust, blowdown, spill
control
1 1 2 3 3 4 √
5) Internal examination 1 2 3 3 4 4 √
6) Combustible gas
monitors
a) signal alarm 1 1 2 3 3 4 √
b) actuate equipment 1 1 2 2 3 4 √
7) Remote operation 1 1 2 3 3 4 √
8) Diking, (Not Applicable as
barrel storage)
1 4 4 4 4 4 √
9) Blast & barrier walls
separation1 1 2 3 4 4 √
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1) Feature optional 2) Feature suggested 3) Feature recommended 4) Feature required
7.2.3 MONDS INDEX
Introduction
The principle and general approach used in the DOW method of hazard evaluation have beenfurther developed by ICI Mond Division, Their revised Mond fire, explosive and toxicity index isa series of papers by lewis (1979). The main development made to the DOW Index in the MondIndex are:
1. It covers a wider range of process and storage installation2. It covers the processing of chemicals with explosive properties3. A calculation procedure is included to allow for the off-setting effects of good design and
control and safety instrumentation4. The procedure has been extended to cover plant layout5. Separate indices are calculated to access the hazards of fire, internal explosion and aerial
explosion.
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Table No. 7.6: Monds Toxicity index of toxic chemicals
Sr.
Raw Materials Quantity
MT
FlashPoint,
0C
UNClassification
HealthHazard
Threshold
LimitValue
Flammability/
Reactivity
Mondindex
Degree
1 Phosphoruspentoxide
20 NA 8 3 2mg/m3
Corrosive/Toxic
7.37 Moderate
2 Cautic lyesolution
50 NA 8 3 2mg/m3
Corrosive 7.00 Moderate
3 epichlorohydrin 10 31 8 3 NA Corrosive 8.12 Moderate
4Con.
Hydrochloricacid
50NA 8 3 5
Corrosive 7.25 Moderate
5 Acetic acid 30 39 8 3 100 Corrosive/Toxic
4.63 Light
6 Acrylamide 25 138 8 3 2mg/m3
Toxic 7.7 Moderate
7 Thionylchloride
40 NF 8 4 5mg/m3
Corrosive/Toxic
8.7 Moderate
Monds Index CalculationToxicity Index : Th + Ts (1+GPH+SPH)
100
Where, SPH = Special Process Hazard
GPH = General Process Hazard
Th = Toxicity factor based on the NFPA hazard index (0 – 4)
Ts = Correction factor (additional penalty) for toxicity based on Maximum
Allowable Concentration (MAC) value in ppm
Th (Toxicity Factor): For TEA will be 250 from the table no. 6.6 as the Nh factor for TEA is 3
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Ts (Correction Factor): For TEA will be 125 from the table no. 6.7 as the MAC is 2 ppm
Table No. 7.7 Toxicity factor Index
NFPA Index Number Toxicity Factor (Th)
0 0
1 50
2 125
3 250
4 325
Table No. 7.8 Correction factor for Toxicity
MAC (in ppm) Ts
5 and below 125
Between 5 and 50 75
50 and more 50
Table No. 7.9 Toxicity Index
The resulting TI values are ranked into three categories:1-5 Light6-9 Moderate10-up High
1. Monds Index Calculation for Phosphorus pentoxide
Th (Toxicity Factor): For Phosphorus pentoxide will be 250 from the table as the Nh factor for
Phosphorus pentoxide is 3
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Ts (Correction Factor): For Phosphorus pentoxide will be 125 from the table as the MAC is 2
ppm.
General & Special Process Hazard
1.General Process
Hazard
Base Factor 1.00 1.0Exothermic Chemical Reaction 0.30 to 1.25 0.3Endothermic Processes 0.20 to 0.40 0.00Material handling and transfer 0.25 to 1.05 0.0Enclosed or Indoor Process Units 0.25 to 0.90 0.0Access 0.20 to 0.35 0.0Drainage and Spill Control 0.25 to 0.50 0.0General Process Hazard Factor ( F1 ) 1.3
2.Special Process
Hazard
Base Factor 1.00 1.0Toxic material(s) 0.20 to 0.80 0.6Sub atmospheric pressure (< 500 mm
Hg)
0.50 0.00Operation in or near flammable range
_____inerted ______noninerted
0.00 to 0.80 0.00
1. Tank farm storage flammable
liquids
0.50 0.002. Process upset or purge failure 0.30 0.003. Always in Flammable range
process
0.80 0.00
Dust Explosion 0.25 to 2.00 0.00Pressure Operating pressure psig
Relief setting ________
psig
0.00
Low temperature 0.20 to 0.30 0.00Quantity of flammable / unstable
material1. Liquids or gases in process 0.002. Liquids or gases in storage 0.0
3. Combustible Solids in Storage, Dust
in Process
0.00
Corrosion & Erosion 0.10 to 0.75 0.0Leakage - Joints & Packing 0.10 to 1.50 0.00Use of Fired Equipment 0.00Hot oil heat exchange system 0.15 to 1.15 0.0Rotating Equipment 0.50 0.00Special Process Hazard Factor ( F2 ) 1.6
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Therefore from the above table the GPH and SPH is coming to be around 1.3 and 1.6
respectively.
Calculation of Toxicity Index:
Toxicity Index : Th + Ts*(1+GPH+SPH)/ 100
Toxicity Index : [250 + 125* (1 + 1.3+1.6)]/100
Toxicity Index : 7.00
The Toxicity Index for phosphorus pentoxide is calculated to be around 7.00 which indicatethat the degree of hazard is moderate.
2. Monds Index Calculation for caustic lye solution
Th (Toxicity Factor): For caustic lye will be 250 from the table as the Nh factor for caustic lye is 3
Ts (Correction Factor): For caustic lye will be 125 from the table as the TLV is 2 mg/m3.
General & Special Process Hazard
1.General Process
Hazard
Base Factor 1.00 1.0Exothermic Chemical Reaction 0.30 to 1.25 0.0Endothermic Processes 0.20 to 0.40 0.00Material handling and transfer 0.25 to 1.05 0.0Enclosed or Indoor Process Units 0.25 to 0.90 0.0Access 0.20 to 0.35 0.0Drainage and Spill Control 0.25 to 0.50 0.0General Process Hazard Factor ( F1 ) 1.0
2.Special Process
Hazard
Base Factor 1.00 1.0Toxic material(s) 0.20 to 0.80 0.6Sub atmospheric pressure (< 500 mm
Hg)
0.50 0.00
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Operation in or near flammable range
_____inerted ______noninerted
0.00 to 0.80 0.00
1. Tank farm storage flammable
liquids
0.50 0.002. Process upset or purge failure 0.30 0.003. Always in Flammable range
process
0.80 0.00
Dust Explosion 0.25 to 2.00 0.00Pressure Operating pressure psig
Relief setting ________
psig
0.00
Low temperature 0.20 to 0.30 0.00Quantity of flammable / unstable
material1. Liquids or gases in process 0.002. Liquids or gases in storage 0.0
3. Combustible Solids in Storage, Dust
in Process
0.00
Corrosion & Erosion 0.10 to 0.75 0.0Leakage - Joints & Packing 0.10 to 1.50 0.30Use of Fired Equipment 0.00Hot oil heat exchange system 0.15 to 1.15 0.0Rotating Equipment 0.50 0.00Special Process Hazard Factor ( F2 ) 1.6
Therefore from the above table the GPH and SPH is coming to be around 1.0 and 1.6
respectively.
Calculation of Toxicity Index:
Toxicity Index : Th + Ts*(1+GPH+SPH)/ 100
Toxicity Index : [250 + 125* (1 + 1.0+1.6)]/100
Toxicity Index : 7.00
The Toxicity Index for caustic lye is calculated to be around 7.00 which indicate that thedegree of hazard is moderate.
3. Monds index for epichlorohydrin drums
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Th (Toxicity Factor): For TEA will be 250 from the table as the Nh factor is 3
Ts (Correction Factor): Ts will be 125 from the table as the MAC is 2 ppm
Tank No. -- Equipment Name Epichlorohydrin 10 MTBasic Material for Materialfactor
HDPE Drums Density, g/cc 1.18Properties of materialN h 3 N f 2 N r 3 M.F. 29Boil.pt.
-- 0F 116 0C Flash pt. 87 0F 31 0C
HC = Heat ofComb.
-8143 BTU / lb
Quantity of thematerial
l 10000 kg Lb
Storage conditions Temp 30 0C Pressure 1.0 barPenalty factor
rangePenalty factor
used1.General ProcessHazard
Base Factor 1.00 1.00
Exothermic Chemical Reaction 0.30 to 1.25 0.00Endothermic Processes 0.20 to 0.40 0.00
Material handling and transfer 0.25 to 1.05 0.6Enclosed or Indoor Process Units 0.25 to 0.90 0.00
Access 0.20 to 0.35 0.00Drainage and Spill Control 0.25 to 0.50 0.00
General Process Hazard Factor ( F1 ) 1.6
2.Special ProcessHazard
Base Factor 1.00 1.00Toxic material(s) 0.20 to 0.80 0.6Sub atmospheric pressure (< 500 mmHg)
0.50 0.00Operation in or near flammable range
_____inerted ______noninerted
0.00 to 0.800.00
1. Tank farm storage flammableliquids
0.50 0.02. Process upset or purge failure 0.30 0.003. Always in contact of Flame
process
0.80 0.00
Dust Explosion 0.25 to 2.00 0.00Pressure Operating pressure psig
Relief setting ________psig
0.0
Low temperature 0.20 to 0.30 0.00Quantity of flammable / unstablematerial1. Liquids or gases in process 0.0
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2. Liquids or gases in storage 0.13. Combustible Solids in Storage, Dustin Process
0.00
Corrosion & Erosion 0.10 to 0.75 0.10Leakage - Joints & Packing 0.10 to 1.50 0.10Use of Fired Equipment 0.00Hot oil heat exchange system 0.15 to 1.15 0.00Rotating Equipment 0.50 0.00Special Process Hazard Factor ( F2 ) 1.9
The Toxicity Index for epichlorohydrin is calculated to be around 8.125 which indicate that
the degree of hazard is Moderate from above table.
4. Monds Index Calculation for Acetic acid
Th (Toxicity Factor): For Acetic acid will be 250 from the table as the Nh factor for Acetic Acid is
3
Ts (Correction Factor): For Acetic acid will be 50 from the table as the MAC is 100 ppm
General & Special Process Hazard
1.General Process
Hazard
Base Factor 1.00 1.00Exothermic Chemical Reaction 0.30 to 1.25 0.3Endothermic Processes 0.20 to 0.40 0.00Material handling and transfer 0.25 to 1.05 0.85Enclosed or Indoor Process Units 0.25 to 0.90 0.3Access 0.20 to 0.35 0.35Drainage and Spill Control 0.25 to 0.50 0.5General Process Hazard Factor ( F1 ) 3.3
2.Special Process
Hazard
Base Factor 1.00 1.00Toxic material(s) 0.20 to 0.80 0.4Sub atmospheric pressure (< 500 mm
Hg)
0.50 0.00Operation in or near flammable range
_____inerted ______noninerted
0.00 to 0.80 0.00
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1. Tank farm storage flammable
liquids
0.50 0.502. Process upset or purge failure 0.30 0.003. Always in Flammable range
process
0.80 0.00
Dust Explosion 0.25 to 2.00 0.00Pressure Operating pressure psig
Relief setting ________
psig
0.00
Low temperature 0.20 to 0.30 0.00Quantity of flammable / unstable
material1. Liquids or gases in process 0.002. Liquids or gases in storage 0.16
3. Combustible Solids in Storage, Dust
in Process
0.00
Corrosion & Erosion 0.10 to 0.75 0.10Leakage - Joints & Packing 0.10 to 1.50 0.30Use of Fired Equipment 0.00Hot oil heat exchange system 0.15 to 1.15 0.0Rotating Equipment 0.50 0.00Special Process Hazard Factor ( F2 ) 2.46
Therefore from the above table the GPH and SPH is coming to be around 3.3 and 2.46
respectively.
Calculation of Toxicity Index:
Toxicity Index : Th + Ts*(1+GPH+SPH)/ 100
Toxicity Index : [250 + 50(1 + 3.3+2.46)]/100
Toxicity Index : 4.63
The Toxicity Index for Acetic Acid is calculated to be around 4.63 which indicate that thedegree of hazard is light.
5. Monds Index for Hydrochloric acid
Th (Toxicity Factor): For HCl will be 250 from the above table as the Nh factor for HCl is 3
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Ts (Correction Factor): For HCl will be 125 from the table as the MAC is 2 ppm.
General & Special Process Hazard
1.General ProcessHazard
Base Factor 1.00 1.00Exothermic Chemical Reaction 0.30 to 1.25 0.00Endothermic Processes 0.20 to 0.40 0.00Material handling and transfer 0.25 to 1.05 0.00Enclosed or Indoor Process Units 0.25 to 0.90 0.00Access 0.20 to 0.35 0.00Drainage and Spill Control 0.25 to 0.50 0.00General Process Hazard Factor ( F1 ) 1.00
2.Special ProcessHazard
Base Factor 1.00 1.00Toxic material(s) 0.20 to 0.80 0.6Sub atmospheric pressure (< 500 mmHg)
0.50 0.00Operation in or near flammable range
_____inerted ______noninerted
0.00 to 0.80
1. Tank farm storage flammableliquids
0.50 0.02. Process upset or purge failure 0.30 0.003. Always in Flammable range
process
0.80 0.00
Dust Explosion 0.25 to 2.00 0.00Pressure Operating pressure psig
Relief setting ________psig
0.00
Low temperature 0.20 to 0.30 0.00Quantity of flammable / unstablematerial1. Liquids or gases in process 0.00
2. Liquids or gases in storage 0.003. Combustible Solids in Storage, Dust
in Process0.00
Corrosion & Erosion 0.10 to 0.75 0.10Leakage - Joints & Packing 0.10 to 1.50 0.10Use of Fired Equipment 0.00Hot oil heat exchange system 0.15 to 1.15 0.00Rotating Equipment 0.50 0.00Special Process Hazard Factor ( F2 ) 1.8
Therefore from the above table the GPH and SPH is coming to be around 1.00 and 1.8 respectively.
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Calculation of Toxicity Index:
Toxicity Index : Th + Ts (1+GPH+SPH)
100
Toxicity Index : [250 + 125 (1 + 1.00 + 1.8)]/100
Toxicity Index : 725
The Toxicity Index for HCl is calculated to be around 7.25 which indicate that the degree ofhazard is moderate.
6. Monds Index for Acrylamide
Th (Toxicity Factor): For acrylamide will be 250 from the table as the Nh factor for
acrylamide is 3
Ts (Correction Factor): For acrylamide will be 125 from the table as the MAC is 2 mg/m3
General & Special Process Hazard
1.General Process
Hazard
Base Factor 1.00 1.00Exothermic Chemical Reaction 0.30 to 1.25 0.0Endothermic Processes 0.20 to 0.40 0.00Material handling and transfer 0.25 to 1.05 0.2Enclosed or Indoor Process Units 0.25 to 0.90 0.0Access 0.20 to 0.35 0.0Drainage and Spill Control 0.25 to 0.50 0.0General Process Hazard Factor ( F1 ) 1.2
2.Special Process
Hazard
Base Factor 1.00 1.00Toxic material(s) 0.20 to 0.80 0.6Sub atmospheric pressure (< 500 mm
Hg)
0.50 0.00Operation in or near flammable range
_____inerted ______noninerted
0.00 to 0.80 0.00
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1. Tank farm storage flammable
liquids
0.50 0.002. Process upset or purge failure 0.30 0.003. Always in Flammable range
process
0.80 0.00
Dust Explosion 0.25 to 2.00 0.00Pressure Operating pressure psig
Relief setting ________
psig
0.00
Low temperature 0.20 to 0.30 0.00Quantity of flammable / unstable
material1. Liquids or gases in process 0.002. Liquids or gases in storage 0.16
3. Combustible Solids in Storage, Dust
in Process
0.00
Corrosion & Erosion 0.10 to 0.75 0.10Leakage - Joints & Packing 0.10 to 1.50 0.10Use of Fired Equipment 0.00Hot oil heat exchange system 0.15 to 1.15 0.0Rotating Equipment 0.50 0.00Special Process Hazard Factor ( F2 ) 1.96
Therefore from the above table the GPH and SPH is coming to be around 1.2 and 1.96
respectively.
Calculation of Toxicity Index:
Toxicity Index : Th + Ts*(1+GPH+SPH)/ 100
Toxicity Index : [250 + 125 (1 + 1.2+1.96)]/100
Toxicity Index : 7.7
The Toxicity Index for acrylamide is calculated to be around 7.7 which indicate that thedegree of hazard is moderate.
7. Monds Index for Thionyl chloride
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Th (Toxicity Factor): For thionyl chloride will be 325 from the table as the Nh factor for
thionyl chloride is 4.
Ts (Correction Factor): For thionyl chloride will be 125 from the table as the MAC is 5 ppm
General & Special Process Hazard
1.General Process
Hazard
Base Factor 1.00 1.00Exothermic Chemical Reaction 0.30 to 1.25 0.0Endothermic Processes 0.20 to 0.40 0.00Material handling and transfer 0.25 to 1.05 0.2Enclosed or Indoor Process Units 0.25 to 0.90 0.0Access 0.20 to 0.35 0.0Drainage and Spill Control 0.25 to 0.50 0.0General Process Hazard Factor ( F1 ) 1.2
2.Special Process
Hazard
Base Factor 1.00 1.00Toxic material(s) 0.20 to 0.80 0.8Sub atmospheric pressure (< 500 mm
Hg)
0.50 0.00Operation in or near flammable range
_____inerted ______noninerted
0.00 to 0.80 0.00
1. Tank farm storage flammable
liquids
0.50 0.002. Process upset or purge failure 0.30 0.003. Always in Flammable range
process
0.80 0.00
Dust Explosion 0.25 to 2.00 0.00Pressure Operating pressure psig
Relief setting ________
psig
0.00
Low temperature 0.20 to 0.30 0.00Quantity of flammable / unstable
material1. Liquids or gases in process 0.002. Liquids or gases in storage 0.16
3. Combustible Solids in Storage, Dust
in Process
0.00
Corrosion & Erosion 0.10 to 0.75 0.10Leakage - Joints & Packing 0.10 to 1.50 0.10Use of Fired Equipment 0.00Hot oil heat exchange system 0.15 to 1.15 0.0
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Rotating Equipment 0.50 0.00Special Process Hazard Factor ( F2 ) 2.16
Therefore from the above table the GPH and SPH is coming to be around 1.2 and 2.16
respectively.
Calculation of Toxicity Index:
Toxicity Index : Th + Ts*(1+GPH+SPH)/ 100
Toxicity Index : [325 + 125 (1 + 1.2+2.16)]/100
Toxicity Index : 8.7
The Toxicity Index for thionyl chloride is calculated to be around 8.7 which indicate thatthe degree of hazard is moderate.
Recommendations for storage:
• MSDS of all the raw materials will be provided in the storage area.
• Raw material will be segregated and stored by compatibility.
• The material will be stacked in cabinets away from the source of ignition & heat.
• Spill kit will be provided.
• Training will be given to employees to handle hazardous and toxic chemicals.
• PPEs like full body suit, glove, goggles, mask will be provided to employees for handlingtoxic & hazardous raw materials.
• Storage area will be provided with sufficient ventilation.
Earthing will be provided to eliminate risk of fire.
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7.3 HAZOP Study
Hazop study has been carried out for all hazardous operations and process. It is attached asAnnexure 7.1.
7.4 DISASTER MANAGEMENT PLAN
Objectives of Disaster Management Plan [DMP]The Disaster Management Plan (DMP) is aimed to ensure safety of life, protection ofenvironment, protection of installation, restoration of production and salvage operations in thesame order of priorities. For effective implementation of the DMP, it should be widely circulatedand personnel training through rehearsals/drills should be organized. Further, the managementshould be able to demonstrate that its assessment of the consequences as good supportingevidence. To tackle the consequences of a major emergency inside the factory or immediatevicinity of the factory, a DMP has to be formulated and this planned emergency document iscalled "Disaster Management Plan". The objective of the Industrial Disaster Management Plan isto make use of the combined resources of the plant and the outside services to achieve thefollowing:
Effect the rescue and medical treatment of causalities Safeguard other people
Minimize damage to property and the environment Initially contain and ultimately bring the incident under control
Identify any dead Provide for the needs of relatives Provide authoritative information to the news media
Secure the safe rehabilitation of affected area Preserve relevant records and equipment for the subsequent inquiry into the cause and
circumstances of the emergency. In effect, it is to optimize operational efficiency to rescuerehabilitation and render medical help and to restore normalcy.
7.4.1 Onsite Emergency Plan
Salient Features of the Project
Name of Project M/s Glaxy surfactants Ltd.
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Address (Plant) Plot No: G-59, Tarapur MIDC, Boisar, Palghar,Dist : Palghar, Maharashtra, India
Nature of the Project Production of specialty chemicalsCapacity 4132 MT/monthMan Power 177Name of Site Head Mr. Milind PatilKey Persons in the Emergency Plan Site Manager
Corporate EHS HeadEHS ManagerSr. ExecutiveSafety OfficerFire OfficerChemist
OBJECTIVES OF THE PLAN
On-Site emergency preparedness plan has the following objectives:
1. Safeguard lives and property at site and in its vicinity area.2. Contain the incident and bring it under control;3. Minimize damage to lives, property and environment;4. Rescue and treat casualties;5. To train the people to act efficiently and with confidence in an emergency.6. Evacuate people to safe areas;7. To minimize its occurrence.
7.4.1.1 Pre – Emergency Plans -
Pre – Emergency means the preparatory stage of the plan. It should be ensured that the preparedplan contains all required provisions and details of facility to handle and to contain the emergencysituation successfully. The unit has to consider maximum and possible worst scenario foremergency purpose while planning. The unit has to develop and maintain the essential facilities,so that the emergency can be controlled and the damages are minimized in the shortest periodwith proper use of all available resources.
The unit should be duly prepared and ready all the time to encounter any possible emergency,while it may strike or not. Being a specialty chemicals Manufacturing unit various type of
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chemicals are used possessing varied types of hazards and knowing the hazards of the chemical,stored, handled or processed in the factory, the quick response action must be created within unit.
The structure of the plan may vary depending on the number of employees, materials, process,and availability of recourses, location of site, size and complexity of the unit. It should ensure towork out a plan with possibilities of various emergencies with likely to arise within unit. Furtherthe periodical rehearsal is also to be carried out to check and examine the effectiveness, awarenessand preparedness of the plan as well as services. The emergency planning is not a substitute forgood design, plant operating and maintenance practices. Therefore, the Onsite Emergency ActionPlan must be followed to avoid emergency
7.4.1.2 Periodic Checking Schedule-
To check availability, work ability and take necessary actions for replacement and maintenance, ifrequired. Check resources of water. Keep all emergency and essential Telephone Nos. withcontact persons, suppliers for the same handy. Contact details may be displayed on the boardsinstalled at prominent locations in the plant and offices. Maintain the co- ordination with otherfire – services. Also the Firefighting system and PPE should be checked if they are in workingcondition and proper maintenance should be done.
7.4.1.3 Preventive Maintenance (To Avoid Emergency)
A scheduled periodical preventative maintenance and inspection of the plants, Reactors,centrifuges, equipment’s, storage tanks, air compressors, D.G. Sets etc. are as per laid downprocedures and check that records are maintained properly. Check the test, examination andcertification have been carried out within reasonable period.
7.4.1.4 Training
By imparting an effective training to the plant supervisors, inspectors, and education and trainingof the workers from time to time, the awareness is to be kept alive all the time to ensure safetyawareness, preparedness for emergency situations, good housekeeping, discipline, etc. Display ofsafety slogans, operative instructions and motivation for safety should be made part of thecompany’s normal activities. All the persons earmarked for the emergency services are to betrained to respond to the emergency. The company conducts internal & external training forEnvironment Health & safety. The training is conducted at a documented frequency. The externaltraining is conducted six monthly and internal training is conducted every month.
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7.4.1.5 Monitoring the Environment
Continuous and periodic monitoring of environment is required for detection of a possibledamage or a risky situation arises.
7.4.1.6 Mock Drill
Organize the periodical mock drill / rehearsal as per suggested format by creating an emergencysituation so as to verify preparedness and awareness as well as shortcomings on the part of theperson to overcome the same. Provide sufficient time prior to mock drill to the emergencyservices and public for proper response to exercise and provide training also. Record thedeficiencies of the system during the trial and take appropriate actions to improve the efficiencyof the plan in terms of preparedness and response.
7.4.1.7 Maintenance of Records
Keep the records of the monitoring conditions, safety systems, storage levels, process condition,etc. and maintain the log- books, registers etc. Keep the M.S.D.S. and onsite emergency plan withrequired details. The solvent and trimethyl amine tanker unloading and handling sheet is prepared.It will be duly filled by the workers and SOP for unloading shall be followed strictly.
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Work Instructions for Unloading Of Solvents
(Ethyl Acetate / Toluene / 2-Ethyl hexanol/ LDO)
A. Precautions:
Check level of the tank in which you are planning to unload the tanker
Check vents line of storage tank. It must be open through flame arrestor.
Unloading hose must be metallic.
Check whether safety instruments e.g. fire extinguishers are in place.
Check for muffler (flame arrester to tanker flue gas exhaust)
B. Procedure:1. Before entering the tanker into the UG tank area ask the driver for his driving license,
cleaner, Spark arrestor, Trem card etc.
2. After receiving the tanker slowly in tank area park the vehicle at required position
with providing stopper & remove the key.
3. Wear the required the PPEs(safety Goggle, safety shoes, helmet & gloves.
4. Connect tanker to the earth.
5. Take a clean & dry bucket; Keep it below the outlet valve of the vehicle.
6. Start opening the blind flange fitted to tanker outlet valve.
7. While opening blind flange, first open ground side bolt about 2-3 threads.
8. Make loose any other adjacent bolt, so that the contents of the line will be drain into the
bucket.
9. Remove the blind flange, connect one end of the SS hose to the receiver line and other to the
tanker.
10. Check all the connections are properly fitted & provide the jumpers to all required places.
11. Start unloading into the UG tank by slowly opening unloading valve of the tanker.
12. If there are compartments, open all the valves slowly.
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13. Keep safe distance (around 3 meters) while unloading into UG tank & keep watch on level ofthe storage tank.
14. After complete unloading, remove the hose connected to the tanker first & then from thereceiver line by repeating procedure 5-8.
15. Remove the earth connection of the tanker.
16. Solvent which is collected in bucket is pour into Solvent tank.
17. Take care of no spillages of the solvent; If spillage occurs then spreading sand on it.
Ask driver to remove tanker slowly out of the UG tank area by removing stopper & Retuningvehicle key
Protocols of handling TMA gas
1. The storage tank will be stainless steel
2. The TMA gas in the storage tank will be kept under nitrogen pressure of about 3-4 kgf/cm2
3. The temperature of the TMA gas in the storage tank will be maintained between <20 ° C.
4. The handling area of TMA gas will be flameproof
5. The storage tank and pipelines will be properly earthed using jump-overs over flanges toprevent generation of static charges
6. The vent of the TMA gas will be connected to the scrubber system
7. 2- Level transmitter, 2- pressure transmitter and 2- temperature transmitter will be providedover storage tank of TMA gas to control and monitor the parameters through DCS system
8. Control valve will be provided on chilled water line to control the temperature of thestorage tank
9. The pipe line to transfer TMA gas to reactor will be insulated to avoid increase intemperature
10. The reaction will be controlled through DCs system with adequate interlocks to avoid humanerror. Reactor will be equipped with Pressure transmitter, level transmitter and temperaturetransmitter to control the process parameters through DCS system.
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11. Gas concentration monitors will be installed in the gas storage section as well as near reactorto monitor the concentration of TMA gas in the area
12. Emergency vent will be connected to the stack with diluents
13. The electrical equipments in the reactor area will also be of flameproof type
14. Showers and eye washers will be provided in the storage area as well as near to reactor area
7.4.1.8 Emergency Control Room
The equipped Emergency Control Room should be in working order. The plant layout maps,drawing, storage details, Material safety Data Sheets (MSDS), emergency operations, manualsetc. should be kept and should be updated continuously. List of essential telephone Nos. is alsomaintained up to date. The senior and expert person should be posted as in charge of the controlroom.
7.4.1.9 Command & Control
The organization chart, for the emergency plan has been given which explains the chart ofcommand, channel of information flow, and actions as required during the emergency. The singleorganizational structure has been created on striking emergency and the same shall be continuedtill the emergency over. The Shift Supervisor shall take the initial charge as incident controller; hewill be coordinating with various agencies effectively to combat the situation. The security officeroom will be used as emergency control Room. The security gate will be used as Assembly point.The Factory Manager will act as site main controller for the unit. On arrival, he will supervise allactivities with the help of asst. Plant in- charge. The duties & responsibilities have been definedas per below.
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7.4.1.10 Identification of Hazards
The type of hazards have been identified in the previous section accordingly and riskquantification is also been done for all the raw materials.
7.4.3 List of fire extinguishers & fire buckets provided
Type of extinguishers and location
Sr.no.
Type Units
1 ABC type Fire Extinguishers6 kg 129 kg 10
2 FOAM type Fire Extinguishers9 L 5
50 L 43 CO2 type Fire Extinguishers
2 kg 14.5 kg 56.5 kg 6
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Table – 7.10 Type of Fire Extinguishers
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7.4.4 Fire Hydrant details
SRNO
DESCRIPTION LOCATION
MATERIAL QTY REMARK
1.Fire Hydrant inplant
G-59plant Fire Hydrant hose box 21
Fire Hydrantsite
2. ' ' Fire Hydrant box keys 21 ''
3. ' 'Fire Hydrant hose boxhammer 21 ''
4. ' ' Fire Hydrant nozzels 21 ''5. ' ' Fire Hydrant TPB nozzel 0 ''
6. ' 'Fire Hydrant box ( F )Spanner 0 ''
7. ' 'Fire Hydrant hose pipe7.5M 12 ''
8. ' 'Fire Hydrant hose pipe15M 27 ''
9. ' ' Singal door hose box 10 ''10. ' ' Double door hose box 16 ''11. ' ' Fire Hydrant stand post 21 ''
12. ' 'Fire Hydrant site Hose reeldrums 7 ''
13. ' ' Fire Hydrant spinkler 71 ''14. ' ' Old MCP ( siten) 315. ' ' Old MCP pannel 116. ' ' New MCP 1117. ' ' Water release point 318. ' ' Hooter 7
19. ' 'New Fire hydrant detectionpannel 2
20. ' 'Fire Hydrant air releasevalve 3
21. ' ' Deluge valve 1Fire Hydrant
site
22. ' ' Heat Detector 20 ''
23. ' ' Smoke Detector 48 ''24. ' ' Emergency Safety Shower 2
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25. ' ' Fire sand bucket 16
26. ' 'Etp In line Inductor (Foam
generation) 1
27. ' 'Fire Hydrant etp site foamtroly 0
28. ' '(foam trolly foam ore-40 lit
)………
29. ' ' sv 2' 2' 0Fire Hydrant
site
30. ' ' sv 2' 4' 0 ''
31. ' ' sv 2' 6' 0 ''
32. ' ' P.G. 2' 9 ''
33. ' ' P.G. 2' 0 ''
34. ' ' P.G. 2' 0 ''
35. ' ' NRV 2' 0 ''
36. ' ' NRV 2' 0 ''
37. ' ' NRV 2' 0 ''
38. ' ' B .FLY all 0 ''39. ' ' pressure guage 040. ' ' '' 0
Table No. 7.11 : Location of fire hydrants points and quantity.
7.4.5 Fire Fighting Systems
Please fill the following informationFire Fighting Tank DetailsCapacity of Fire Fighting tanks 400 m3.Type of tank Overhead/ Below head overheadMaterial of Construction RCC
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Pump Capacity of fire fighting tank Jockey Pump-10.8 m3/hr.Main Pump-171 m3/hr.Diesel Pump-171 m3/hr.
No of assembly points 1No of exit points for emergencyevacuation
10
Fire Hydrant system Yes
7.4.6 Flow Diagram showing Key Persons involved in Emergency Situation and theirhierarchy.
PLANT HEAD
ASSISTANT MANAGER
(EHS)
EXECUTIVE EHS
EHS OFFICER
`ETP
CHEMISTETP
OPERATOR
FIREOFFICER
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7.4.7 Emergency Responsibilities
The responsibilities of the key personnel are appended below.
Sr. Executive
On knowing about emergency, rushes to ECC.
Helps the Incident Controller in containment of the emergency.
Ensures fire pumps in operating conditions and instructs pump house operator to be ready
for any emergency with standby arrangement.
Guides the fire fighting crew i.e. firemen, trained plant personnel and security staff.
Organizes shifting the fire fighting facilities to the emergency site, if required.
Takes guidance of the Incident Controller for firefighting as well as assesses the
requirements of outside help.
Arranges to control the traffic at the gate and the incident area.
Directs the security staff to the incident site to take part in the emergency operations under
his guidance and supervision.
Evacuates the people in the plant or in the nearby areas as advised by Site Controller.
Searches for casualties and arranges proper aid for them.
Assembles a search and evacuation team.
Arranges for safety equipment for the members of this team.
Decides which paths the evacuated workers should follow.
Maintains law and order in the area and, if necessary, seeks the help of police.
7.4.8 EHS Manager - Medical, Mutual Aid, Rehabilitation, Transport and Communication
In the event of failure of electric supply and thereby internal telephone, sets up
communication point and establishes contact with the Emergency Control Centre (ECC).
Organizes medical treatment to the injured and, if necessary, arrange to shift the injured to
nearby hospitals.
Mobilizes extra medical help from outside, if necessary.
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Keeps a list of qualified first aiders of the factory and seeks their assistance.
Maintains first aid and medical emergency requirements.
Makes sure that all safety equipment is made available to the emergency team.
Assists Site Controller with necessary data and to coordinate the emergency activities.
Assists Site Controller in updating the emergency plan, organizing mock drills,
verification of inventory of emergency facilities and furnishing report to Site Controller.
Maintains liaison with Civil Administration.
Ensures availability of canteen facilities and maintenance of rehabilitation centre.
He will liaise with Site Controller/Incident Controller.
Ensures transportation facility.
Ensures availability of necessary cash for rescue/rehabilitation and emergency
expenditure.
Controls rehabilitation of affected areas on discontinuation of emergency.
Makes available diesel/petrol for transport vehicles engaged in emergency operation.
7.4.9 EHS Manager - Essential Services
He would assist Site Controller and Incident Controller.
Maintains essential services like Diesel Generator, Water, Fire Water, compressed
Air/Instrument Air and power supply for lighting.
He would plan alternate facilities in the event of power failure, to maintain essential
services such as lighting, refrigeration plant etc.
He would organize separate electrical connections for all utilities and emergency services
so that in the event of emergency or fires, essential services and utilities are not affected.
Gives necessary instructions regarding emergency electrical supply, isolation of certain
sections etc. to shift in charge and electricians.
Ensures availability of adequate quantities of protective equipment and other emergency
materials, spares etc.
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7.4.10 General Responsibilities of Employees during an Emergency
During an emergency, it becomes more enhanced and pronounced when an emergency warning is
raised; the workers, if they are in charge of process equipment, should adopt safe and emergency
shut down and attend to any prescribed duty as essential employee. If no such responsibility is
assigned, he should adopt a safe course to assembly point and await instructions. He should not
resort to spread panic. On the other hand, he must assist emergency personnel towards objectives
of DMP.
7.4.11 Emergency Facilities
7.4.11.1 Emergency Control Centre (ECC)
M/s Galaxy surfactants Ltd has established an Emergency Control Centre. It has external
telephone, telefax and telex facility. All the Site Controller/ Incident Controller Officers, Senior
Personnel would be located here. The following information and equipment will be provided at
the Emergency Control Centre (ECC):
Intercom, telephone
P and T telephone
Safe contained breathing apparatus
Fire suit/gas tight goggles/gloves/helmets
Hand tools, wind direction/velocities indicators
Public address megaphone, hand bell, telephone directories
(Internal, P and T) factory layout, site plan
Emergency lamps/torch lights/batteries
Plan indicating locations of hazard inventories, plant control room, sources of safety
equipment, work road plan, assembly points, rescue location, vulnerable zones, and escape
routes
Hazard chart
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Emergency shut-down procedures
Nominal roll of employees
List of key personnel, list of essential employees, list of Emergency Co-ordinators
Duties of key personnel
Addresses with telephone numbers of key personnel, emergency coordinator, and essential
employees.
Important addresses and telephone numbers including Government agencies, neighboring
industries and sources of help, outside experts, chemical fact sheets, population details
around the factory.
7.4.11.2 Assembly Point
Number of assemblies depending upon the plant location would be identified wherein employees
who are not directly connected with the disaster management would be assembled for safety and
rescue. Emergency breathing apparatus, minimum facilities like water etc. would be organized. In
view of the size of plant, different locations are earmarked as assembly points. Depending upon
the location of hazard, the assembly points are to be used.
7.4.11.3 Emergency Power Supply
Plant facilities would be connected to Generator and would be placed in auto mode. Thus, water
pumps, plant’s lighting and emergency control centre, administrative building and other auxiliary
services are connected to emergency power supply. In all the blocks, flameproof type emergency
lamps would be provided.
7.4.11.4 Fire Fighting Facilities
First Aid and Firefighting equipment suitable for emergency are maintained well in each section
in the plant. This would be developed according to the statutory requirements. However, fire
hydrant line covering major areas has been laid. Fire alarms have been located in the bulk storage
areas.
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7.4.11.5 Location of Wind Sock
Windsocks exist in the plant
7.4.11.6 Emergency Medical Facilities
Stretchers, gas masks and general first aid materials for dealing with chemical burns, fire burns
etc. will be maintained in the medical centre as well as in the emergency control room. Private
medical practitioners’ help would be sought. Government hospital would be approached for
emergency help. Apart from plant first aid facilities, external facilities would be augmented.
Names of medical personnel and medical facilities in the area would be Prepared and updated.
Necessary specific medicines for emergency Treatment of burns patients and for those affected by
toxicity would be maintained. Breathing apparatus and other emergency medical equipment
would be provided and maintained. The help of nearby industrial managements in this regard
would be taken on mutual support basis.
7.4.12 Emergency Actions
7.4.12.1 Emergency Warning
Communication of emergency will be made familiar to the personnel inside the plant and people
outside. An emergency warning system has already been established in the plant.
7.4.12.2 Emergency Shutdown
There are a number of facilities which can be provided to help deal with hazardous conditions,
when a tank is on fire. The suggested arrangements are:
Stop feed
Dilute contents
Remove heat
Deluge with water
Transfer contents. Whether a given method is appropriate depends on the particular case.
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Cessation of agitation may be the best action in some instances but not in others. Stopping
of the feed may require the provision of bypass arrangements.
Methods of removing additional heat include removal through the normal cooling arrangements
or use of an emergency cooling system. Cooling facilities, which use vaporizing liquid, may be
particularly effective, since a large increase in vaporization can be obtained by dropping pressure.
7.4.12.3 Evacuation of Personnel
There could be more number of persons in the storage area and other areas in the vicinity. The
area would have adequate number of exits and staircases. In the event of an emergency,
unconnected personnel have to escape to assembly point. Operators have to take emergency
shutdown procedure and escape. Time Office maintains a copy of deployment of employees in
each shift. If necessary, persons can be evacuated by rescue teams.
7.4.12.4 All Clear Signal
Also, at the end of an emergency, after discussing with Incident Controllers and Emergency Co-
coordinators, the Site Controller orders an all clear signal. When it becomes essential, the Site
Controller communicates to the District Emergency Authority, Police, and Fire Service personnel
regarding help required or development of the situation into an Off-Site Emergency.
7.4.13 General
7.4.13.1 Employee Information
During an emergency, employees would be warned by raising siren in specific pattern. Employees
would be given training of escape routes, taking shelter, protecting from toxic effects. Employees
would be provided with information related to fire hazards, antidotes and first aid measures.
Those who would be designated as key personnel and essential employees should be given
training in emergency response.
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7.4.13.2 Public Information and Warning
The industrial disaster effects related to this plant may mostly be confined to the plant area. The
detailed risk analysis has indicated that the pool fire effects would not be felt outside. However,
as an abundant precaution, the information related to chemicals in use would be furnished to
District Emergency Authority (normally the Collector) for necessary dissemination to general
public and for any use during an offsite emergency.
7.4.13.3 Co-ordination with Local Authorities
Keeping in view the nature of the emergency, two levels of co-ordination are proposed. In the
case of an On Site Emergency, resources within the organization would be mobilized and in the
event of an extreme emergency, local authorities’ help should be sought.
In the event of an emergency developing into an offsite emergency, local authority And District
Emergency Authority (normally the Collector) would be apprised and Under his supervision, the
Off Site Disaster Management Plan would be exercised. For this purpose, the facilities that are
available locally, i.e. medical, transport, personnel, rescue accommodation, voluntary
organizations etc. would be mustered. Necessary rehearsals and training in the form of mock
drills should be organized.
7.5 Off-Site Emergency Preparedness PlanThe off-site plan will be prepared with the help of the local district authorities. The proposed plan
will be based on the following guidelines.
7.5.1 Introduction
Off-site emergency plan follows the on-site emergency plan. When the consequences of an
emergency situation go beyond the plant boundaries, it becomes an off-site emergency. Off-site
emergency is essentially the responsibility of the public administration. However, the factory
management will provide the public administration with the technical information relating to the
nature, quantum and probable consequences on the neighboring population. The off-site plan in
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detail will be based on those events, which are most likely to occur, but other less likely events,
which have severe consequence, will also be considered. Incidents, which have very severe
consequences yet have a small probability of occurrence, should also be considered during the
preparation of the plan. However, the key feature of a good off-site emergency plan is flexibility
in its application to emergencies other than those specifically included in the formation of the
plan.
The roles of the various parties who will be involved in the implementation of an off-site plan are
described below. Depending on local arrangements, the responsibility for the off-site plan should
either rest with the works management or, with the local authority. Either way, the plan should
identify an emergency coordinating officer, who would take the overall command of the off-site
activities. As with the on-site plan, an emergency control centre should be set up within which the
emergency coordinating officer can operate. An early decision will be required in many cases on
the advice to be given to people living "within range" of the accident; in particular, whether they
should be evacuated or told to go indoor. In the latter case, the decision can regularly be reviewed
in the event of an escalation of the incident.
Consideration of evacuation may include the following factors:
In the case of a major fire but without explosion risk (e.g. an oil storage tank), only houses
close to the fire are likely to need evacuation, although a severe smoke hazard may require
this to be reviewed periodically
If a fire is escalating and in turn threatening a store of hazardous material, it might be
necessary to evacuate people nearby, but only if there is time; if insufficient time exists,
people should be advised to stay indoors and shield themselves from the fire For release or
potential release of toxic materials, limited evacuation may be appropriate downwind if
there is time. The decision would depend partly on the type of housing "at risk".
Conventional housing of solid construction with windows closed offers substantial
protection from the effects of a toxic cloud, while shanty house, which can exist close to
factories, offers little or no protection
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7.5.2 Aspects Proposed to be considered in the Off-Site Emergency Plan
The main aspects, which should be included in the emergency plan, are:
7.5.2.1 Organization
Details of command structure, warning systems, implementation procedures, emergency control
centers. Names and appointments of incident controller, site main controller, their deputies and
other key personnel.
7.5.2.2 Communications
Identification of personnel involved, communication centre, call signs, network, lists of telephone
numbers.
7.5.2.3 Specialized knowledge
Details of specialist bodies, firms and people upon whom it may be necessary to call e.g. those
with specialized chemical knowledge, laboratories.
7.5.2.4 Voluntary organizations
Details of organizers, telephone numbers, resources etc.
7.5.2.5 Chemical information
Details of the hazardous substances stored or processed on each site and a summary of the risk
associated with them.
7.5.2.6 Meteorological information
Arrangements for obtaining details of weather conditions prevailing at the time and weather
forecasts.
7.5.2.7 Humanitarian arrangements
Transport, evacuation centers, emergency feeding treatment of injured, First aid, ambulances,
temporary mortuaries.
7.5.2.8 Public information
Arrangements for: (a) dealing with the media press office; (b) informing relatives, etc.
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7.5.2.9 Assessment
Arrangements for: (a) collecting information on the causes of the emergency; (b) reviewing the
efficiency and effectiveness of all aspects of the emergency plan.
7.5.2.10 Role of the Emergency Co-ordinating Officer
The various emergency services should be co-ordinated by an emergency co-ordinating officer
(ECO), who will be designated by the District Collector. The ECO should liaise closely with the
Site Controller. Again, depending on local arrangements, for very severe incidents with major or
prolonged off-site consequences, the external control should be passed on to a senior local
authority administrator or even an administrator appointed by the central or state government.
7.5.2.11 Role of the Local Authority
The duty to prepare the off-site plan lies with the local authorities. The emergency planning
officer (EPO) appointed should carry out his duty in preparing for a whole range of different
emergencies within the local authority area. The EPO should liase with the works, to obtain the
information to provide the basis for the plan. This liaison should ensure that the plan is
continually kept up to date.
It will be the responsibility of the EPO to ensure that all those organizations, which will be
involved off site in, handling the emergency, know of their role and are able to accept it by having
for example, sufficient staff and appropriate equipment to cover their particular responsibilities.
Rehearsals for off-site plans should be organized by the EPO.
7.5.2.12 Role of Police
Formal duties of the police during an emergency include protecting life and property and
controlling traffic movements. Their functions should include controlling bystanders, evacuating
the public, identifying the dead and dealing with casualties, and informing relatives of dead or
injured.
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7.5.2.13 Role of Fire Authorities
The control of a fire should normally be the responsibility of the senior fire brigade officer who
would take over the handling of the fire from the site incident controller on arrival at the site. The
senior fire brigade officer should also have a similar responsibility for other events, such as
explosions and toxic release. Fire authorities in the region should be apprised about the location
of all stores of flammable materials, water and foam supply points, and fire-fighting equipment.
They should be involved in on-site emergency rehearsals both as participants and, on occasion, as
observers of exercises involving on-site personnel.
7.5.2.14 Role of Health Authorities
Health authorities, including doctors, surgeons, hospitals, ambulances, and similar other
persons/institutions should have a vital part to play following a major accident, and they should
form an integral part of the emergency plan. For major fires, injuries should be the result of the
effects of thermal radiation to a varying degree, and the knowledge and experience to handle this
in all but extreme cases may be generally available in most hospitals. For major toxic releases, the
effects vary according to the chemical in question, and the health authorities should be apprised
about the likely toxic releases from the plant, which will enable them to deal with the aftermath of
a toxic release with treatment appropriate to such casualties. Major off-site incidents are likely to
require medical equipment and facilities in additional to those available locally, and a medical
"mutual aid" scheme should exist to enable the assistance of neighboring authorities to be
obtained in the event of an emergency.
7.5.2.15 Role of Government Safety Authority
This will be the factory inspectorate available in the region. Inspectors are likely to want to satisfy
themselves that the organization responsible for producing the off-site plan has made adequate
arrangements for handling emergencies of all types including major emergencies. They may wish
to see well documented procedures and evidence of exercise undertaken to test the plan. In the
event of an accident, local arrangements regarding the role of the factory inspector will apply.
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These may vary from keeping a watch to a close involvement in advising on operations. While the
industry will activate the DMP and take necessary alleviating measures and arrange to extend all
medical and security support, the factory inspectorate may be the only external agency with
equipment and resources to carry out appropriate tests to assess the impact.
7.5.3 External agencies contact details involved during emergency
Off site Emergency Plan
1. No. and names of nearest Hospitals from the industry, their address, telephone no and distancesfrom industry. ( Minimum 3 hospitals)
Sr.No.
NameofHospital
Address Telephone Distances
1 TIMAHospital
MIDC Tarapur, Near Khaira FateBoisar, Dist. Palghar
02525278444,02525278666
2.5km
TMRCTHospital
J-70,MIDC Tarapur, Boisar, Dist. Palghar 02525 27030802525 270309
2.0km
SaiLeelaHospital
Ground Floor, Satyam Building, Opp. BalajiSweets, Otaswal, Boisar, Dist. Palghar
0226167785 1.5km
2. No. and names of nearest Police Station from the industry, their address, telephone no anddistances from industry.
Sr No Name of Police Station Address Telephone Distances1 MIDC Police Station MIDC Police
Station, NavapurRd., Camlin Naka,MIDC Tarapur,Boisar, Dist.Palghar.
02525 272444 1.5km
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3. No. and names of nearest Fire Station from the industry, their address, telephone no anddistances from industry.
Sr No Name of FireStation
Address Telephone Distances
1 Boisar Fire Station Boisar Fire Station, NavapurRd, Camlin Naka, MIDCTarapur, Boisar, Dist. Palghar.
02525 27200002525 272262
1.5km
4. Names of nearest MIDC from the industry, their address, telephone no
Sr No Name of MIDC Address Telephone Distances1 Maharashtra Industrial
DevelopmentCorpn.Tarapue
MIDCTarapur,Takinaka,NavapurRd.,Dist.Palghar.
02525272389 1.5km
5. Names of nearest Municipality from the industry, their address, telephone no
Sr No Name of Municipality Address Telephone Distances1 Gram Panchyat
KolawadeGram PanchyatKolawade,PO.TAPP,Boisar,Tal.Palghar,Dist.Palghar.
02525 645340 1.5 km
6. Names of nearest Pollution Control Department from the industry, their address, telephoneno
Sr No Name of PCD Address Telephone Distances1 Maharashtra Pollution
Control Board, MIDCTarapur
MPCB Tarapur,Chitralaya, BoisarTarapur Rd. Boisar,Dist. Palghar
02525 273314 1.5km
7.6 Socio Economic status of the study area
Introduction
Social Impact Assessment (SIA) is an integral part of project planning and policy evaluation and
part of EIA report due the importance that social considerations must be included in the decision
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process. Social Impact Assessment (SIA) is understood as a process of assessing and managing
the impacts of a project, plan, program or policy on people. Social impacts include all social and
cultural consequences to human populations of any public or private actions that alter the ways in
which people live, work, play, relate to one another, organize to meet their needs, and generally
cope as members of society. Cultural impacts involve changes to the norms, values, and beliefs of
individuals that guide and rationalize their cognition of themselves and their society.
In general, the SIA process includes:
1. Understanding, managing, and controlling change.
2. Predicting probable impacts from change strategies or development projects that are to be
implemented.
3. Identifying, developing, and implementing mitigation strategies in order to minimize
potential social impacts
4. Developing and implementing monitoring programs to identify unanticipated social
impacts that may develop as a result of the social change.
5. Developing and implementing mitigation mechanisms to deal with unexpected impacts as
they develop.
6. Evaluating social impacts caused by earlier developments, projects, technological change,
specific technology, and government policy.
Aim of the study:
1. The present endeavour is to understand the socio-economic situation in the vicinity of the
proposed plant and assess the impact on the socio-economic factors of the proposed plant.
2. Secondary data were collected through various sources namely:-
3. Census of India, 2011
4. Economic Survey of Maharashtra 2013-14
5. District Social and Economic Survey of Palghar District
Table 7.12: Palghar Taluka, Palghar District, population figures for 2011
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2011 Male Female PersonUrban 86,842 69,608 1,56,480Rural 1,65,149 1,59,637 3,24,786Total 2,51,991 2,29,245 4,81,236
Source: Census of India, 2011& 2001
From the secondary data it is evident that male population was comparatively high in both the
rural & urban areas in Palghar Taluka
Table 7.13: Palghar Taluka, Palghar District child population in the age group 0 to 6 figures
for 2011
2011 Boys Girls TotalUrban 10,57 9,724 20,298Rural 20,736 20,381 41,117Total 31,310 30,105 61,415
Source: Census of India, 2011
Off the total 61,415 child population (in age group of 0 to 6) of Palghar Taluka, the population of
girl child was observed to be slightly lower than that of boys.
Table 7.14: Literacy rates by residence and sex - 2011
PalgharTehsil
Literacy rateRural
Person Male FemaleUrban 88.09 92.25 82.98Rural 75.56 83.15 67.69Total 80.69 87.05 73.63
Source: Census of India, 2011
As per the data published by Census of India, it is observed that literacy rate amongst the males
was comparatively higher in both the urban & rural areas.
Table 7.15: Basic Amenities
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Palghar TehsilFacilities/Amenities No. of villages
Total number of inhabited villages in the CD block 200No. of villages with electrification 200
No. of villages with S.T bus facility 179
No. of villages with commerce bank office 17
No. of villages with primary school 193
No. of villages with healthrelated facilities
Primary health entre 9
Primary health sub centre 61
Maternity & child welfarecentre
9
T.B centre 9
Hospital - allopathic 9
Dispensary 30
Veterinary hospital 9
Mobile health clinic 6
Family welfare centre 9
Medical practioner (withMBBS degree)
5
Medical practioner (withother degree)
116
Medicine shop 20
No. of villages with anganwadi 199
No. of villages with postoffice
Post office 20
Sub post office 35
Post & telegraph office 20
No. of villages with primary agricultural supply institutes 130
Source: Census of India 2011
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As per the Census of India 2011, 200 villages in Palghar, Tehsil are inhabited off which all
villages have electric supply, 179 villages have facilities of State Transport, 193 villages have pre
primary schools/aanganwadis. It is observed that medical/health related & post office facilities
are present only in selective villages.
Industrial profile of Palgahr District
Palghar Districts have one MIDC (Maharashtra Industrial Development Corporation) industrial
area, three Government Cooperative industrial colonies which host 5757 small registered
industries, 1883 small temporary registered industries & 427 large/medium scale industries. The
industries belong to textile, chemical, engineering & steel production categories.
Table 7.16: Taluka wise industrial profile
Sr. No. Taluka No. of industries Investment (Lakhs) Employment (No. of people)
1 Palghar 276 2,65,267 22,012
2 Vasai 45 29,130 2,197
3 Talasri 19 7,219 8,05
4 Vikramgad 0 0 0
5 Wada 80 4,00,897 9,195
6 Jawhar 0 0 0
7 Dahanu 7 1,597 7,69
8 Mokhada 0 0 0
Source: Official website of Collector Office Palghar :
http://collectorpalghar.in/industry.php?english=English
Social Commitments
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It is anticipated that the proposed project & related activities will generate further employment for
the local people which will help to increase income of the local people to some extent. The project
proponent is also actively involved in CSR activities & in continuation with same Project
Proponent will undertake locale specific CSR activities such as distribution of school stationery in
nearby schools at the project area.
R&R details in respect of land in line with state Government policy.
The project is located in the MIDC area hence R & R scheme is not applicable for this project.