M/s. Kutch Chemical Industries Limited. - Gujarat Pollution Control ...
M/s. Kutch Chemical Industries Limited. - Gujarat Pollution Control ...
M/s. Kutch Chemical Industries Limited. - Gujarat Pollution Control ...
Create successful ePaper yourself
Turn your PDF publications into a flip-book with our unique Google optimized e-Paper software.
M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong>.<br />
Survey No 166/1,2,3, 171/1, 172,167,168,<br />
Village : Padana<br />
Gandhidham, Dist. <strong>Kutch</strong><br />
RISK ASSESSMENT STUDY<br />
For Existing and Proposed Plan<br />
PREPARED BY<br />
VAIBHU SAFETY CONSULTANTS<br />
FF-11, Akshat Complex,<br />
Nr. Reliance Petrol Pump,<br />
High Tension Road, Subhanpura,<br />
Vadodara-390 023<br />
Phone: 9825756467/9427838021 (M)<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 1<br />
HSE Department Rev. : 00
CERTIFICATE<br />
We are pleased to certify that this Risk Assessment study of Company has been<br />
conducted by us.<br />
This is the first Risk Assessment report of this company for new project and it has<br />
been carried out during the month of March- 2010.<br />
Risk Assessment is a legal requirement u/r 12-c & 68-O of the <strong>Gujarat</strong> Factories<br />
Rules.<br />
The recommendations are based on information supplied to us by the company and<br />
our plant visits.<br />
The Executive Summary is given in the beginning to highlight the important<br />
summary of our report and methodology of the risk assessment carried out.<br />
We are thankful to the Mr. Shivlal Goyal (Occupier), Mr. D.S. Purohit (Factory<br />
Manager), Mr. R. K. Jha ( Dy. Manager HSE) and Officers of the Company for their<br />
all co-operation to prepared this report. In particular we acknowledge the continuous<br />
support given to us by Mr. R. K. Jha for completion of this report.<br />
FOR VAIBHU SAFETY CONSULTANT<br />
Authorized Signatory<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 2<br />
HSE Department Rev. : 00
SECTION<br />
NO.<br />
CONTENTS<br />
CONTENTS<br />
1 Executive Summary<br />
2 Objectives, Philosophy and methodology of<br />
Risk assessment<br />
3 Introduction of the unit<br />
3.1 Company Introduction<br />
3.2 Details of Unit<br />
3.3 Project setting<br />
3.4 Organisational setup<br />
3.5 List Of product<br />
3.6 List of Raw Material<br />
3.7 Details of storage of Hazardous Materials in<br />
Bulk and control measures provided<br />
3.8 Hazardous Properties Of The <strong>Chemical</strong>s,<br />
Compatibilities And Special Hazard<br />
3.9 Facilities / System for process safety,<br />
transportation, fire fighting system and<br />
emergency capabilities to be adopted<br />
3.10 Brief Description of process plant<br />
4 Hazard identification<br />
4.1 Introduction<br />
4.2 DOW’s Fire and Explosion Index<br />
4.3 Failure Frequencies<br />
4.4 Identification of Hazardous area<br />
5 Risk Assessment<br />
5.1 Effects of Release of Hazardous Substances<br />
5.2 Identification of High Risk Areas<br />
5.3 Modes of Failure<br />
5.4 Damage Criteria for heat radiation<br />
6 Consequence Analysis<br />
6.1 Consequence Analysis<br />
6.2 Table of Consequences analysis results<br />
6.3 Comments<br />
7 Risk Reduction Measures<br />
7.1 Design<br />
7.2 Safety Devices<br />
NO. OF<br />
PAGES<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 3<br />
HSE Department Rev. : 00
7.3 Operation and Maintenance<br />
7.4 Recommendations<br />
8 Disaster Management plan<br />
8.1 On site emergency Plan (OSEP)<br />
8.2 Scope of OSEP<br />
8.3 Elements of OSEP<br />
8.4 Methodology<br />
8.5 Emergencies Identified<br />
8.6 Others<br />
8.7 Emergency Organisation<br />
8.8 Emergency Facilities<br />
8.9 Emergency Escapes<br />
8.10 Assembly points<br />
8.11 Wind sock<br />
8.12 Emergency transportation<br />
8.13 Emergency communication<br />
8.14 Warning Alarm/ Communication of Emergency<br />
8.15 Emergency responsibilities<br />
8.16 Mutual Aids<br />
8.17 Mock Drill<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 4<br />
HSE Department Rev. : 00
SECTION I<br />
EXECUTIVE SUMMARY<br />
1.0 Executive Summary<br />
1.1 M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> Ltd. retained the services of Vaibhu Safety Consultants<br />
for carrying out Risk Assessment Studies for their Gandhidham plant.<br />
1.2 Experts from Vaibhu Safety Consultants visited the site on 23/05/2010 for inspection of<br />
facilities to be erected and commissioned at site as per site plan and the environs and for<br />
collection of relevant information about the installation and the operations will be carried<br />
out in the plant. They also held detailed discussions on various aspects including Chlorine<br />
tonner handling facilities, Solvent storage facilities, Oleum, Sulfur trioxide, Sulfuric Acid,<br />
Nitric Acid, Chloro sulphonic Acid storage area, Ethylene Oxide storage facilities, process<br />
safety, Finished product storage godown and tank farm area, HSE management system<br />
procedures( SOP) and it implementation, Emergency management plan, Emergency<br />
handling facilities, Emergency organization and action planet., with the officers of the<br />
company.<br />
1.3 In this plant Chlorine, Sulphur, Ethylene Oxide(EO), Caustic soda ( NaOH), Nitric Acid (<br />
HNO3), Benzene, Methanol, toluene, and Paraffin Oil will be majorly used as raw<br />
materials and received through road tanker and stored in designated tank farm area.<br />
1.4 Flammable solvents receive through road tanker and stored in underground storage tank<br />
farm area as per petroleum Act and Rules. Ethylene Oxide will be received from road<br />
tanker and transferred in to tank by Nitrogen pressure and stored under Nitrogen<br />
blanketing. EO and Anhydrous ammonia storage facilities generated as per Static and<br />
mobile pressure vessel Rule (SMPV), Separate Acid storage area is located at Sulfuric<br />
Acid, CSA & Thionyl Chloride (TC) plant.<br />
1.5 Most of products are used as a raw material in one or the more products. Material transfer<br />
from one plant to other only by pumping and required quantity for one day is being stored<br />
at process plant in Day tank.<br />
1.6 Separate utility plant is provided for chilling cooling in each plant. Oil, Steam, Nitrogen<br />
and Air utilities are common for all plants.<br />
1.7 Based on the data furnished and the study of the installation, certain hazards have been<br />
identified and their consequences are modeled mathematically using HAMSGAP software.<br />
1.8 The study indicates that possible hazards associated with the plant are confined to (a)<br />
Under ground storage tank area, road truck unloading area (b) Chlorine tonner storage<br />
area. (c) Ethylene Oxide storage tank area, (d) Oleum, Sulfuric Acid, Nitric Acid, Thionyl<br />
Chloride, Sulfur Trioxide and storage tank area. Various hazard scenarios have been<br />
identified for Risk Assessment and the consequences modeled. The results of the analysis<br />
have been summarized in the table appended.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 5<br />
HSE Department Rev. : 00
1.9 It will be observed from the summary that the consequences of hazards associated with any<br />
possible spills / leaks except for catastrophic failure of Chlorine tonner, Ethylene Oxide,<br />
Anhydrous Ammonia and Oleum release scenarios would be of a relatively small in nature<br />
and would be taken care of with the proposed emergency facilities and the manpower<br />
deployed at the plant.<br />
1.10 The possibility of occurrence of such hazards and their effects could be further reduced by<br />
implementing the suggestions made in this report.<br />
1.11 Catastrophic failure of tonner resulting in major toxic releases is very unlikely events<br />
barring gross neglect of time tested safety standards and procedures set up by the industry.<br />
1.12 The possibility of occurrence of major toxic release and mishaps is considered very<br />
remote, considering the past operating performance of plant in relation to fire and safety<br />
and the field management’s total commitment to implementation of safety systems and<br />
procedures.<br />
1.13 However considering the potential for major hazards, however remote they may be,<br />
associated with storage area, some suggestions are made in the subsequent chapters for<br />
further improvement in the areas of safety, environmental impact, Emergency facilities and<br />
emergency preparedness plan.<br />
1.14 Conclusion Based on the<br />
1) Risk Analysis study and information regarding the layout plan and safety systems.<br />
2) Discussions with company officials,<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 6<br />
HSE Department Rev. : 00
2.1 Objective :<br />
CHAPTER II<br />
OBJECTIVE, PHILOSOPHY AND METHODOLOGY OF RISK ASSESSMENT<br />
The main objectives of the Risk Assessment (RA) study is to determine damage due to<br />
major hazards having damage potential to life & property and provide a scientific basis to<br />
assess safety level of the facility.<br />
The principle objective of this study was to identify major risks in the manufacture of<br />
chemicals and storage of hazardous chemical at site and to evaluate on-site & off-site<br />
consequences of identified hazard scenarios. Pointers are then given for effective<br />
mitigation of hazards in terms of suggestions for effective disaster management,<br />
suggesting minimum preventive and protective measures & change of practices to ensure<br />
safety.<br />
2.2 PHILOSOPHY :<br />
This report is limited to the following:<br />
Identification of major risk areas.<br />
Hazard identification/Identification of failure cases<br />
Consequential analysis of probable risks / failure cases<br />
o Evaluation of heat radiation & pressure wave profiles for identified failure<br />
cases<br />
o Risk assessment on the basic of the above evaluation & risk acceptability<br />
o Minimum preventive & protective measures to be taken to minimize risks to<br />
maximum possible extent.<br />
Giving pointers for effective disaster management<br />
Suggesting other measures to further lower the probability of risk<br />
2.3 Methodology<br />
The procedure used for carrying out the Quantitative Risk Assessment Study is outlined<br />
bellow:<br />
Identify Credible Loss Scenarios for the facility under the study by discussion with KCIL.<br />
Simulate loss Scenarios to determine the vulnerable zones for toxic dispersion, pool fire or<br />
jet fire, ( Thermal Radiation ), Flash fire, Explosion over pressure ( Vapour cloud<br />
Explosion, Ball fire using software packages HAMSGAP.<br />
Suggest mitigating measures to reduce the damage, considering all aspects of the facilities.<br />
The flowchart of the methodology for the present study is shown in following page.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 7<br />
HSE Department Rev. : 00
RISK ASSESSMENT STUDY METHODOLOGY FLOWCHART<br />
START<br />
FACILITY, PROCESS AND METEOROLOGICAL DATA COLLECTION<br />
LISTING OUT OF HAZARDOUS OPERATIONS & STORAGE DETAILS<br />
IDENTIFICATION OF FAILURE SCENARIOS & QUANTIFICATION OF<br />
PROBABLE HAZARDS ASSOCIATED WITH THEM<br />
DEFINING OF PARAMETERS FOR EACH OF CHEMICALS & EACH OF<br />
HAZARDS<br />
DEFINING RELEASE TYPE (CONTINUOUS OR INSTANTANIOUS ) &<br />
DETERMINE RELEASE RATES<br />
SIMULATION OF SELECTED CASES FOR CONSEQUENCE MODELING<br />
PREPARATION OF SUMMERY OF CONSEQUENCE RESULTS<br />
EVALUATION OF POTENTIAL RISK TO THE SURROUNDING<br />
POPULATION<br />
DISCUSSION & RECOMMENDATION OF MITIGATIVE / REMEDIAL<br />
MEASURES<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 8<br />
HSE Department Rev. : 00<br />
END
3.1 COMPANY INTRODUCTION<br />
SECTION III<br />
INTRODUCTION OF THE UNIT<br />
M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> Ltd., is operating a manufacturing unit of various<br />
chemicals and dye intermediates at Survey No 166/1,2,3, 171/1, 172,167,168, Village :<br />
Padana, Gandhidham, Dist. <strong>Kutch</strong><br />
Produce unit is classified as Major Accident Hazards unit ( MAH Installation ) based on<br />
the storage of the listed hazardous chemicals more than specified threshold<br />
quantities.(Schedule 3 under Rule 68-J of the <strong>Gujarat</strong> Factories Rules-1963 (2004).<br />
<strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> Ltd, with spot light on export market potential was founded in<br />
2004 near the Global all weather ports of Kandla and Mundra. It consists of a well<br />
integrated chemical complex consisting of Chlorination, Nitration, Sulphonation and Dyes<br />
Intermediates products.<br />
In 2006, as a part of its backward integration plan M/s <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> Ltd,<br />
has set up a 400 TPD of Sulphuric Acid plant at Gandhidham.<br />
3.2 DETAILS OF UNITS<br />
Sr.<br />
No.<br />
Particulars<br />
1. Full Name & Address of : <strong>Kutch</strong> chemical <strong>Industries</strong> limited<br />
Unit<br />
Plot no- 165,166/1&3,168,171/1&172<br />
Village:Padana, Nr.Aquagel <strong>Chemical</strong>s,<br />
Gandhidham, Dist – <strong>Kutch</strong><br />
<strong>Gujarat</strong>.<br />
2. Telephone No. : 02836-28551-52, Fax-02836-285233<br />
3. Month & Year of : 10<br />
Establishment<br />
TH June 2002<br />
4. Full name & Address of : Sh. Shivlal Goyal ( Director)<br />
the occupier<br />
2, Sri Ram Society, Gotri Road Baroda<br />
5. Full name & Address of : Sh. D.S.Purohit<br />
the Factory manager Plot no – 23, Ward -9B(D)<br />
New Bharat Nagar, Gandhidham<br />
Pin- 370201<br />
6. Man Power<br />
: 172 including all shift<br />
G Shift- 31<br />
A Shift- 47<br />
B Shift- 47<br />
C Shift- 47<br />
7. No. Of shift & Shift timing : Total no of shift :- 04<br />
General shift :- 09AM To 06 PM<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 9<br />
HSE Department Rev. : 00
8. Environs (Nearest<br />
Facilities)<br />
9. Meteorogical Data<br />
Latitude 23º 10’N<br />
Longitude 70º 13’ E<br />
Temperature<br />
Maximum 48º C<br />
Minimum 7.2 º C<br />
Relative Humadity :<br />
Maximum 100 %<br />
Minimum 1 %<br />
Annual Rain Fall :<br />
Minimum 73.6 mm<br />
Maximum 1393 mm (1979)<br />
Seasonal wind directions :<br />
Jan- Feb N / NNW / ENE<br />
March – Sept SW / WSW<br />
Oct to Dec N / NNE<br />
First Shift “A”:- 07 AM To 03 PM<br />
Second Shift “B”:- 03 PM To 11PM<br />
Night Shift “C”:- 11PM To 07AM<br />
Wind Velocity :<br />
Maximum 100 km/hr NNW (26.10.1975)<br />
Minimum 132 km/hr NNW (26.10.1975)<br />
Avg. Wind Speed 14 Km/hr<br />
1. Railway Station : Gandhidham, Distance – 20 KM<br />
2. Police Station : Anjar, Distance – 20 KM<br />
3. Fire Station : Anjar , Distance- 20 KM<br />
4. Hospitals : Anjar , Distance- 20KM<br />
10. Total Land at Plant 50 ACRE<br />
11. Total Built-up area at the<br />
Factory<br />
30000 M2<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 10<br />
HSE Department Rev. : 00
12. Power connection Demand : 3000 KVA<br />
13. DG Set KVA: 250 KVA<br />
14. Power plant details : DG Set - 2.5 MW<br />
Turbine – 4.2 MW<br />
15. Water Storage and source Capacity in m3:20000 M3,<br />
Source – <strong>Gujarat</strong> water infrastructure limited<br />
(GWIL)<br />
16. Boiler<br />
Type Model no Capacity Licence<br />
from<br />
<strong>Gujarat</strong><br />
Govt.<br />
Combi pack CPB-80 8Ton/Hr GT 4879<br />
IB-1478- 10 Ton/Hr GT 5516<br />
Waste heat Maker no- 25 Ton/Hr GT-5207<br />
Recovery 21943<br />
AVU Make<br />
17. Chilled water plant Particulars Model No Capacity Location<br />
18. Cooling Tower<br />
VAM ------ 150 TR DMS<br />
Plant<br />
VAM SD30BHX/1 200TR OLD VS<br />
VAM SD30BHX/1 200 TR MCB &<br />
PNCB<br />
Ammonia<br />
compr 2 nos<br />
KC6-3 150 TR MCB<br />
Ammonia<br />
compr 2 nos<br />
KC6-3 150 TR PNCB<br />
Ammonia<br />
compr 2 nos<br />
KC6-3 150 TR PDCB<br />
Ammonia<br />
compr 5 nos<br />
KC6 300 TR New VS<br />
Ammonia<br />
compr 3 nos<br />
KC6 180 TR OLD VS<br />
Total 1480 TR<br />
Particulars<br />
Process<br />
cooling water<br />
Process<br />
cooling water<br />
Process<br />
cooling water<br />
Process<br />
cooling water<br />
Process<br />
cooling water<br />
Process<br />
cooling water<br />
Flow rate<br />
T R Plants<br />
4200M3/H 3260 Acid<br />
Division<br />
1300M3/H 1000 DMS<br />
Plant<br />
1200M3/H 1000 OLD VS<br />
1200M3/H 1000 MCB<br />
Plant<br />
1200M3/H 1000 Acetanili<br />
de plant<br />
600m3/H 500 PNCB<br />
Plant<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 11<br />
HSE Department Rev. : 00
Process 600M3/H 250 PDCBPla<br />
cooling water<br />
nt<br />
Process 500M3/H 300 New VS<br />
cooling water<br />
plant<br />
Process<br />
cooling water<br />
1350M3/H 1100 TC Plant<br />
Total 9410<br />
19. Effluent treatment<br />
Plant<br />
Capacity: 50 M3<br />
20. Fire water source Water reservoir (GWIL)<br />
14 Fire Water Reservoir<br />
capacity : M3<br />
200M3<br />
21. Department wise List Departments Total nos of<br />
of fire extinguishers<br />
F/Extinguisher<br />
with mapping if Benzene storage 04 nos<br />
available<br />
Power plant 12 nos<br />
PNCB Plant 16 nos<br />
MCB Plant 07 nos<br />
PDCB Plant 02nos<br />
Ice plant 01 no<br />
New VS Plant 09 nos<br />
ETP 01 no<br />
Acetanilide plant 06 nos<br />
EO Storage 05 nos Capacity-25 kg<br />
FO Storage 02 nos<br />
VS OLD 06 Nos<br />
CSA Plant 02nos<br />
DMS Plant 18 nos<br />
Methanol storage 04 nos<br />
SAP Plant 15 nos<br />
Boiler house 09 nos<br />
ECC Room 10 nos as spare<br />
Total 129 nos<br />
22. SCBA sets<br />
Total Nos of SCBA Sets – 08 Nos<br />
availability and Acid division C/R- 01No<br />
location mapping Chlorine Shed- 02 Nos<br />
DMS Plant- 01 Nos<br />
TC Plant- 02 Nos<br />
Emergency <strong>Control</strong> centre- 02 nos<br />
23. OHC facilities Occupational Health Centre is declared near main gate<br />
and factory medical officer visit schedule is once in a<br />
week.<br />
Well equipment Ambulance VAN.<br />
Stretcher-01<br />
Oxygen cylinder with mask-01<br />
First aid box- 10 nos in all departments<br />
24. EMP Prepared as Per ISO-14000<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 12<br />
HSE Department Rev. : 00
25. EMP plan ( Action<br />
Plan) one page<br />
Prepared and displayed in all department<br />
26. List of emergency facilities<br />
A.<br />
B.<br />
C.<br />
D.<br />
E.<br />
F.<br />
G.<br />
H.<br />
I.<br />
J.<br />
K.<br />
L.<br />
M.<br />
N.<br />
O.<br />
P.<br />
Q.<br />
R.<br />
Dry powder (50% of fire extinguishers ) 50 nos<br />
CO2 Cartridges ( 50% of fire extinguishers )<br />
200 gms (10 kg DCP<br />
50 nos<br />
As above 2 Kg ( 75 Kg DCP ) 06 nos<br />
Sand scoops 50 nos<br />
Safety helmets 500 nos<br />
Water curtain nozzles 20 nos<br />
Stretchers 01 nos<br />
First aid box with anti snake serum 10 nos<br />
Rubber hand gloves 200 nos<br />
Explosive meter 01 no<br />
Fire entry suit w/o breathing apparatus 01 no<br />
Resuscitator 05 no<br />
Electric siren with 3 km range 01 no<br />
Hand operated siren Nil<br />
Water gel blandest NA<br />
Red/green flags for fire drill Nil<br />
Pressure type self contained breathing apparatus<br />
with spare cylinder (30 minutes)<br />
08 nos<br />
Safety Shower 14 nos<br />
27. Fire Water Reservoir :- 200 M3<br />
28. Other Source of Water :<br />
29. Fire Pump Details<br />
<strong>Gujarat</strong> water infrastructure<br />
limited , Anjar<br />
Pump Detail Number of Head Capacity KW/HP<br />
Pump<br />
(Flow)<br />
Jockey Pump 01 70 mtr 10.8 m3/h 10<br />
Electrical Pump 01 70 mtr 270m3/h 120<br />
Diesel Pump Nil Nil Nil Nil<br />
Total 02 Nil Nil Nil<br />
30. Hydrant System Details<br />
Area / Plant Nos. Of Hydrant<br />
with Hose Box<br />
PNCB Plant Hydrant – 07 nos<br />
Hose box- 01 nos<br />
Nos. Of<br />
Monitors<br />
01 no<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 13<br />
HSE Department Rev. : 00
MCB Plant Hydrant – 01 nos<br />
Hose box- 01 nos<br />
Acid Division Hydrant – 11 nos<br />
Hose box- 03 nos<br />
Old VS plant Hydrant – 06 nos<br />
Hose box- 05 nos<br />
New VS Plant Hydrant – 011nos<br />
Hose box- 05 nos<br />
Acetanilide Plant Hydrant – 01no<br />
Hose box- 01 no<br />
PDCB Plant Hydrant – 02 nos<br />
Hose box- 01 nos<br />
Power Plant Hydrant – 05 nos<br />
Hose box- 02 nos<br />
Canteen Hydrant – 01 no<br />
Hose box- 01 no<br />
DMS Plant Hydrant – 02nos<br />
Hose box- 02 nos<br />
Total Hydrant – 47 nos<br />
Hose box- 30 nos<br />
31. License & Approval:<br />
A.<br />
B.<br />
C.<br />
D.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 14<br />
HSE Department Rev. : 00<br />
Nil<br />
01 no<br />
Factory Inspectorate<br />
Licence No : 018712<br />
Validity : 31/12/2010<br />
GPCB Consent No: 5991/3/5/2005<br />
Validity : 31/1/2010<br />
Note – Application inward ID-<br />
12531/Dated- 18/12/2009 for<br />
renewal of consent<br />
Solid waste Disposal<br />
Member ship : TSDF,<br />
Explosive Particulars<br />
Nandesari Baroda<br />
Licence no Validity<br />
licence No : Chlorine G/WC/GJ/06/109(G15607) 30/09/2011<br />
Ethylene oxide<br />
old VS Plant<br />
S/HO/GJ/03/718(SS5280) 31/03/2013<br />
Ethylene oxide<br />
New VS Plant<br />
S/HG/GJ/03/1066(S32386) 31/03/2011<br />
Furnace oil P/WC/GJ/15/2380(PII9928) 31/12/2010<br />
Methanol P/HQ/GJ/15/4682(P120542) 31/12/2010<br />
Benzene&<br />
Toluene<br />
P/HQ/GJ/15/4568(P20641) 31/12.2012<br />
3.3 PROJECT SETTING:<br />
The company is located at 70 0 11’ 40.17”East longitude & 23 0 10’ 14.44” North latitude<br />
in Village: Padana, Tal: Gandhidham, Dist. <strong>Kutch</strong> in <strong>Gujarat</strong> State.<br />
The site location is shown as figure 1.1. and plant layout is provided as figure 1.2.
Figure 1.1<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 15<br />
HSE Department Rev. : 00
Figure 1.2<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 16<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 17<br />
HSE Department Rev. : 00
3.4 HSE ORGANISATIONAL SET UP<br />
Advise Company of safety<br />
legislation & updates,<br />
safety awareness, carry<br />
out safety audits, update<br />
safety policy, provide<br />
training when required, to<br />
provide investigations and<br />
reports for any accidents.<br />
Safety setup organisation chart<br />
3.5 LIST OF EXISTING AND PROPOSED PRODUCTS<br />
Sr.<br />
No.<br />
Name of the Product<br />
Directors<br />
Unit Head<br />
VP Operation Dy. Mgr ((Fire & Safety)<br />
(General Shift only)<br />
GM Operation<br />
Fire & Safety Supervisor<br />
(One in every shift)<br />
Fireman<br />
Two in each shift<br />
Table-3.1<br />
Existing<br />
Capacity,<br />
MT/Month<br />
Additional<br />
Capacity,<br />
MT/Month<br />
Total<br />
Capacity,<br />
MT/Month<br />
Product Required Environmental Clearance<br />
1. Vinyl Sulphone 500 4000 4500<br />
2. Acetanilide 1000 Nil Nil<br />
3.<br />
Sulphonation of PNT,ONT,VS,<br />
Tobies & Other<br />
0 1500 1500<br />
4. Benzene Sulphonyl Chloride 0 1500 1500<br />
5. DASDA 0 1000 1000<br />
6. V.S Condense 0 1000 1000<br />
7. Dimethyl Sulfate (DMS) 100 3000 3100<br />
8. Dimethyl Aniline (DMA) 0 1500 1500<br />
9. Diethyl Sulfate (DES) 0 1500 1500<br />
10. Sulfamic Acid 0 1000 1000<br />
11. Power Plant (Coal) 2.5 MW 10 MW 12.5 MW<br />
Product do not required Environmental Clearance<br />
12. Sulphuric Acid (98%) 250 15000 15250<br />
13. Oleum (23% & 65%) 0 3000 3000<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 18<br />
HSE Department Rev. : 00
14. Liquid SO3 ( 70-90%) 0 7500 7500<br />
15. Chloro Sulphonic Acid 1200 5000 6200<br />
16. Thionyl Chloride 0 5000 5000<br />
17. Sodium Bisulphite (SBS) 0 3000 3000<br />
18. Calcium Chloride 0 4000 4000<br />
19. Dicalcium Phosphate (DCP) 0 1500 1500<br />
20. Sulphur Monochloride 0 200 200<br />
21. Sulphuryl Chloride 0 200 200<br />
22. Aluminium Sulphate (Alum) 0 1000 1000<br />
3.6 LIST OF PROPOSED RAW MATERIALS<br />
Sr<br />
No.<br />
Raw Materials Physical & chemical composition Rate of<br />
Consumption<br />
<strong>Chemical</strong> Formula<br />
State MT/Month<br />
1 Acetanilide C6H5NHCOCH3 Solid 2182<br />
2 Chloro Sulphonic Acid Cl.SO3H Liquid 10182<br />
3 Caustic Lye NaOH Liquid 2182<br />
4 Sodium bysulphite NaHSO3 Solid 3545<br />
5 Sulfuric Acid H2SO4 Liquid 3989<br />
6 Sluphur S Solid 1949<br />
7 Hydrochloric Acid HCl Liquid 6567<br />
8 o-Nitro Toluene C6H4CH3NO2 Liquid 215<br />
9 p-Nitro Toluene C6H4CH3NO2 Liquid 215<br />
10 Oluem H2S2O7 Liquid 19683<br />
11 Sodium Chloride NaCl Solid 117<br />
12 Benzene C6H6 Liquid 663<br />
13 Chlorine Cl2 Gas 2967<br />
14 Soda Ash Na2CO3 Solid 106<br />
15 Iron Fe Solid 29<br />
16 Sodium Hypochloride NaOCl Liquid 406<br />
17 Ammonium Chloride NH4Cl Liquid 88<br />
18 Sodium Carbonate Na2CO3 Solid 1986<br />
19 Methanol CH3OH Liquid 780<br />
20 Aniline C6H5NH2 Liquid 1134<br />
21 Ethanol C2H5OH Liquid 896<br />
22 Ammonia NH3 Liquid 166<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 19<br />
HSE Department Rev. : 00
3.7 Details of Storage of Hazardous Materials in Bulk<br />
NAME OF<br />
HAZARDOUS<br />
SUBSTANCE<br />
Vinyl Sulphone Plant<br />
Ethylene<br />
Oxide<br />
Chloro<br />
Sulfonic Acid<br />
Chloro<br />
Sulfonic Acid<br />
(Proposed)<br />
MAX. STORAGE<br />
CAP.[Qty.]<br />
25 KL X 1 bullet<br />
15 KL X 1 bullet<br />
45 KL X 6 Nos<br />
Tank<br />
PLACE<br />
OF IT’S<br />
STORAGE<br />
Licenced<br />
Premises<br />
A/G SS<br />
Tank farm<br />
area<br />
A/G MS<br />
OPERATING<br />
PRESSURE<br />
AND TEMP.<br />
10 Kg/ cm2<br />
Ambient<br />
ATP<br />
Ambient<br />
200 MT X 3 Nos. Do ATP<br />
Ambient<br />
Caustic Lye 25 KL X 2Nos<br />
Tank<br />
Caustic Lye 40 KL X6 Nos<br />
Tank<br />
Sulfuric Acid 20 KL X 1Nos<br />
Tank<br />
Hydrochloric 30 KL X 3Nos<br />
Acid<br />
Tank<br />
Acetanilide Plant<br />
Tank farm<br />
area<br />
A/G MS<br />
ATP<br />
Ambient<br />
Do ATP<br />
Ambient<br />
Do ATP<br />
Ambient<br />
Tank farm ATP<br />
area Ambient<br />
A/G HDPE<br />
Acetanilide 600 MT Godown ATP,<br />
Ambient<br />
Aniline 100 KL X 1 No Tank farm ATP,<br />
Tank<br />
area<br />
A/G MS<br />
Ambient<br />
Aniline 200 KL X 1 No Do ATP,<br />
Tank<br />
Ambient<br />
Acetic Acid 100 KL X 2 No Do ATP,<br />
Tank<br />
Ambient<br />
Dil. Acetic 25 KL X 2 No Do ATP,<br />
Acid<br />
Tank<br />
Ambient<br />
TYPE OF<br />
HAZARD<br />
Fire<br />
/Explosion/<br />
Toxic<br />
CONTROL<br />
MEASURE PROVIDED<br />
Double Safety Valve<br />
Nitrogen Blanketing<br />
Double Static earthing<br />
Dyke wall<br />
Scrubber provided<br />
Jumper clips on flanges<br />
Hydrant system<br />
Fire extinguishers<br />
Fencing and No Smoking<br />
and prohibited area.<br />
Tanker unloading<br />
procedure.<br />
Shed provided on bullets.<br />
Sprinkler provided on<br />
bullets.<br />
SCBA sets available.<br />
Safety shower.<br />
Corrosive Level gauge provided.<br />
Scrubber provided<br />
Required PPEs provided to<br />
Corrosive all employees<br />
Double drain valve will be<br />
provided to sulfuric Acid<br />
Corrosive storage tank<br />
Full body protection will<br />
be provided to operator.<br />
Corrosive Caution note and<br />
emergency first aid will be<br />
Corrosive displayed and train for the<br />
same to all employees.<br />
Corrosive Safety shower and eye<br />
wash will be provided in<br />
storage tank area and plant<br />
area.<br />
Total close process will be<br />
adopted for Sulfuric acid<br />
handling.<br />
Dyke wall will be provided<br />
to storage tank<br />
Combustible Flame proof plant,<br />
pumping transfer, close<br />
Flammable process, etc.<br />
Double Static earthing<br />
Dyke wall<br />
Flammable Tanker unloading<br />
procedure.<br />
Corrosive/ SCBA sets available .<br />
Flammable Flame proof plant,<br />
Corrosive<br />
pumping transfer, close<br />
process, etc.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 20<br />
HSE Department Rev. : 00
Ethyl Acetate 25 KL X 1 No<br />
Tank<br />
15 KL X 1No<br />
Tank<br />
MCB, ODCB, PDCB, DCB Plant<br />
Chlorine 209 Tonners Storage<br />
Chlorine 200 Tonners Storage<br />
Shed<br />
Benzene 40KLX4 Nos<br />
Tank<br />
Monochloro<br />
Benzene<br />
(MCB)<br />
Total : 160 KL<br />
200KLX2Nos<br />
Tank<br />
PNCB 90KLX<br />
Tank<br />
2 Nos<br />
ONCB 200KLX<br />
Tank<br />
1 No<br />
Dichloro 200KLX 1 No<br />
Benzene<br />
(DCB)<br />
Tank<br />
NB, PNT, ONT, Plant<br />
Toluene 40KLX4 Nos<br />
Tank<br />
Total : 160 KL<br />
Benzene 40KLX4 Nos<br />
Tank<br />
Total : 160 KL<br />
Nitric Acid 20KLX3 Nos<br />
Tank<br />
Do ATP,<br />
Ambient<br />
Flammable Jumper clips on flanges<br />
Fire extinguishers<br />
Fencing and No Smoking<br />
and prohibited area.<br />
Tanker unloading<br />
procedure.<br />
Flame arrestor provided on<br />
vent line of the tank<br />
10 Kg/cm2 Toxic Chlorine Kit, Caustic<br />
Shed Ambient<br />
Pit, SBA sets, Cl2 Shed,<br />
10 Kg/cm2<br />
Ambient<br />
Toxic Cl2 Hood, EOT, etc.<br />
Provided.<br />
U/G Tank ATP Fire Flame proof plant,<br />
MS<br />
pumping transfer, close<br />
process, etc.<br />
Tank farm ATP Fire Double Static earthing<br />
area<br />
Dyke wall<br />
A/G MS<br />
Tanker unloading<br />
DO ATP Fire<br />
procedure.<br />
SCBA sets available .<br />
DO ATP Fire Flame proof plant,<br />
pumping transfer, close<br />
Tank farm ATP<br />
area<br />
A/G MS<br />
Fire<br />
process, etc.<br />
Jumper clips on flanges<br />
Fire extinguishers<br />
Fencing and No Smoking<br />
and prohibited area.<br />
Tanker unloading<br />
procedure.<br />
Flame arrestor provided on<br />
vent line of the tank<br />
Hydrant system<br />
U/G Tank<br />
MS<br />
U/G Tank<br />
MS<br />
MS A/G<br />
Tank<br />
ATP Fire Flame proof plant,<br />
pumping transfer, close<br />
process, etc.<br />
ATP Fire Double Static earthing<br />
Dyke wall<br />
Tanker unloading<br />
procedure.<br />
SCBA sets available .<br />
Flame proof plant,<br />
pumping transfer, close<br />
process, etc.<br />
Jumper clips on flanges<br />
Fire extinguishers<br />
Fencing and No Smoking<br />
and prohibited area.<br />
Tanker unloading<br />
procedure.<br />
Flame arrestor provided on<br />
vent line of the tank<br />
Hydrant system<br />
ATP Corrosive Safety Showers provided<br />
Caution note provided<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 21<br />
HSE Department Rev. : 00
Sulphuric<br />
Acid<br />
PNT<br />
(P-<br />
NitroToluene)<br />
ONT<br />
O- Nitro<br />
Toluene<br />
MNT<br />
(Meta Nitro<br />
Toluene)<br />
NB<br />
(Nitro<br />
Benzene)<br />
20KLX 1 No<br />
Tank<br />
200KLX1No<br />
Tank<br />
200 KLX 1 No<br />
Tank<br />
90KL X1 No<br />
Tank<br />
200KLX 1 No<br />
Tank<br />
Total : 290 KL<br />
150KLX 1 No<br />
Tank<br />
MS A/G<br />
Tank<br />
MS A/G<br />
Tank<br />
MS<br />
A/G(V)<br />
Tank<br />
MS A/G<br />
(H) Tank<br />
MS<br />
A/G(V)<br />
Tank<br />
Sulphuric Acid Plant<br />
Sulfur powder 5000 MT Storage<br />
yard<br />
Oleum 65 % 250 MT X2 Nos<br />
Tank<br />
Oleum 23% 250 MT X 1No<br />
Tank<br />
MS A/G<br />
Tank<br />
MS A/G<br />
Tank<br />
Oleum 65 % 100 MT X 2 Nos. MS A/G<br />
Tank<br />
Liq Sulphur<br />
Trioxide<br />
Sulphuric<br />
Acid 98 %<br />
CSA Plant<br />
Chloro<br />
sulphonic<br />
Acid<br />
Chloro<br />
sulphonic<br />
Acid<br />
1000 MT X 2<br />
Nos. tank<br />
50 KLX 3 Nos<br />
Tank<br />
140 KL X 01<br />
Tank<br />
2000 MT X 2 Nos<br />
Tanks<br />
MS A/G<br />
Tank<br />
MS A/G<br />
Tank<br />
MS A/G<br />
Tank<br />
MS A/G<br />
Tank<br />
ATP Corrosive Dyke wall provided<br />
Level gauge provided.<br />
Double drain valve<br />
provided<br />
Scrubber provided<br />
Required PPEs provided to<br />
all employees<br />
ATP Fire Flame proof plant,<br />
pumping transfer, close<br />
process, etc.<br />
ATP Fire Double Static earthing<br />
Dyke wall<br />
Jumper clips on flanges<br />
ATP Fire Hydrant system<br />
Fire extinguishers<br />
Fencing and No Smoking<br />
and prohibited area.<br />
Tanker unloading<br />
procedure.<br />
ATP Fire Flame arrestor Provided.<br />
ATP Fire Separate storage area.<br />
Monitors provided<br />
surrounding the storage<br />
area.<br />
Automatic conveyer<br />
system for charging in<br />
Atmospheric<br />
Ambient<br />
Atmospheric<br />
Ambient<br />
Atmospheric<br />
Ambient<br />
Atmospheric<br />
Ambient<br />
Atmospheric<br />
Ambient<br />
Atmospheric<br />
Ambient<br />
Atmospheric<br />
Ambient<br />
melter.<br />
Corrosive Level gauge provided.<br />
Scrubber provided<br />
Required PPEs provided to<br />
Corrosive all employees<br />
Double drain valve will be<br />
provided to sulfuric Acid<br />
Corrosive storage tank<br />
Full body protection will<br />
be provided to operator.<br />
Corrosive Caution note and<br />
emergency first aid will be<br />
displayed and train for the<br />
Corrosive same to all employees.<br />
Safety shower and eye<br />
wash will be provided in<br />
storage tank area and plant<br />
area.<br />
Total close process will be<br />
adopted for Sulfuric acid<br />
handling.<br />
Dyke wall will be provided<br />
to storage tank<br />
Corrosive Level gauge provided.<br />
Scrubber provided<br />
Required PPEs provided to<br />
all employees<br />
Corrosive<br />
Double drain valve will be<br />
provided to sulfuric Acid<br />
storage tank<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 22<br />
HSE Department Rev. : 00
Dimethyl<br />
Sulfate (DMS)<br />
Dimethyl<br />
Aniline<br />
(DMA)<br />
Diethyl<br />
Sulfate (DES)<br />
Benzene<br />
Sulphonyl<br />
Chloride<br />
DASDA<br />
200 MTX 3 Nos.<br />
100 MTX 2 Nos.<br />
200 MTX 2 Nos.<br />
100 MTX 2 Nos.<br />
MS A/G<br />
Tank<br />
MS A/G<br />
Tank<br />
MS A/G<br />
Tank<br />
MS A/G<br />
Tank<br />
100 MTX 2 Nos. MS A/G<br />
Tank<br />
Methanol 60KLX 4 Nos<br />
Tank<br />
Ethanol 200 KL X 1 No.<br />
tank<br />
Ammonia<br />
Anhydrous<br />
( Liquefied )<br />
Hydrochloric<br />
Acid<br />
50 MT X 1 No.<br />
Bullet<br />
MS A/G<br />
Tank<br />
MS A/G<br />
Tank<br />
25 KL X 03 Nos A/G HDPE<br />
Tank<br />
Atmospheric<br />
Ambient<br />
Atmospheric<br />
Ambient<br />
Atmospheric<br />
Ambient<br />
Atmospheric<br />
Ambient<br />
Atmospheric<br />
Ambient<br />
Atmospheric<br />
Ambient<br />
Atmospheric<br />
Ambient<br />
MS bullet 35 0 C<br />
4 to 10<br />
kg/cm 2<br />
Atmospheric<br />
Ambient<br />
Fire Full body protection will<br />
be provided to operator.<br />
Caution note and<br />
Fire<br />
emergency first aid will be<br />
displayed and train for the<br />
same to all employees.<br />
Safety shower and eye<br />
Fire<br />
wash will be provided in<br />
storage tank area and plant<br />
area.<br />
Fire Total close process will be<br />
adopted for Sulfuric acid<br />
handling.<br />
Fire Dyke wall will be provided<br />
to storage tank<br />
Fire Flame proof plant,<br />
pumping transfer, close<br />
process, etc.<br />
Fire Double Static earthing<br />
Jumper clips on flanges<br />
Hydrant system<br />
Fire extinguishers<br />
Fencing and No Smoking<br />
and prohibited area.<br />
Tanker unloading<br />
procedure.<br />
Flame arrestor Provided.<br />
Toxic Flame proof equipment,<br />
pumping transfer, close<br />
process, etc.<br />
Double Static earthing<br />
Dyke wall<br />
Scrubber provided<br />
Jumper clips on flanges<br />
Hydrant system<br />
Fire extinguishers<br />
Fencing and No Smoking<br />
and prohibited area.<br />
Tanker unloading<br />
procedure.<br />
SCBA sets available .<br />
Safety Showers provided<br />
Caution note provided<br />
Dyke wall provided<br />
Level gauge provided.<br />
Double drain valve<br />
provided<br />
Scrubber provided<br />
Required PPEs provided to<br />
all employees<br />
Corrosive Safety Showers provided<br />
Caution note provided<br />
Dyke wall provided<br />
Level gauge provided.<br />
Double drain valve<br />
provided<br />
Scrubber provided<br />
Required PPEs provided to<br />
all employees<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 23<br />
HSE Department Rev. : 00
TC plant (PROPOSED)<br />
Thyonile<br />
chloride<br />
150KL X 03 Tank SS<br />
A/G Bullet<br />
Chlorine 140 Toner Storage<br />
Shed<br />
Sulpher<br />
trioxide<br />
100 MT X 02<br />
Tank<br />
Atmospheric<br />
Ambient<br />
10 Kg/cm2<br />
Ambient<br />
MS Tank Atmospheric<br />
Ambient<br />
Chlorinated Paraffin Wax CPW (PROPOSED)<br />
HNP 65KLX 04 TANK MS Tank Atmospheric<br />
Ambient<br />
HCL 75KLX 6 TANK HDPE<br />
TANK<br />
Atmospheric<br />
Ambient<br />
Corrosive Level gauge provided.<br />
Scrubber provided<br />
Required PPEs provided to<br />
all employees<br />
Double drain valve will be<br />
provided to sulfuric Acid<br />
storage tank<br />
Full body protection will<br />
be provided to operator.<br />
Caution note and<br />
emergency first aid will be<br />
displayed and train for the<br />
same to all employees.<br />
Safety shower and eye<br />
wash will be provided in<br />
storage tank area and plant<br />
area.<br />
Total close process will be<br />
adopted for Sulfuric acid<br />
handling.<br />
Dyke wall will be provided<br />
to storage tank<br />
Toxic Chlorine Kit, Caustic<br />
Pit, SBA sets, Cl2 Shed,<br />
Cl2 Hood, EOT, etc.<br />
Provided.<br />
Scrubber provided .<br />
Corrosive Safety Showers provided<br />
Caution note provided<br />
Dyke wall provided<br />
Level gauge provided.<br />
Double drain valve<br />
provided<br />
Scrubber provided<br />
Required PPEs provided to<br />
all employees<br />
Flammable Safety Showers provided<br />
Caution note provided<br />
Dyke wall provided<br />
Level gauge provided.<br />
Double drain valve<br />
provided<br />
Scrubber provided<br />
Required PPEs provided to<br />
all employees<br />
Corrosive Safety Showers provided<br />
Caution note provided<br />
Dyke wall provided<br />
Level gauge provided.<br />
Double drain valve<br />
provided<br />
Scrubber provided<br />
Required PPEs provided to<br />
all employees<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 24<br />
HSE Department Rev. : 00
Chlorinated<br />
Paraffin oil<br />
20 KLX 03 FRP Atmospheric<br />
Ambient<br />
Furnace Oil/ 27 KLX 2 Nos MS Tank Atmospheric<br />
LDO<br />
U/G tanks<br />
Ambient<br />
HSD 21 KL Tank MS Tank Atmospheric<br />
Ambient<br />
Corrosive Safety Showers provided<br />
Caution note provided<br />
Dyke wall provided<br />
Level gauge provided.<br />
Double drain valve<br />
provided<br />
Scrubber provided<br />
Required PPEs provided to<br />
all employees<br />
Fire Flame proof plant,<br />
pumping transfer, close<br />
Fire<br />
process, etc.<br />
Double Static earthing<br />
Jumper clips on flanges<br />
Hydrant system<br />
Fire extinguishers<br />
Fencing and No Smoking<br />
and prohibited area.<br />
Tanker unloading<br />
procedure.<br />
Flame arrestor Provided.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 25<br />
HSE Department Rev. : 00
3.8 HAZARDOUS PROPERTIES OF THE CHEMICALS, COMPATIBILITIES, SPECIAL HAZARD AND ANTIDOTES<br />
Table-3.3<br />
SR. NAME OF<br />
CHEMICAL<br />
1. Ethylene oxide<br />
CAS # 75-21-8<br />
2. Chlorine<br />
CAS #7782-50-5<br />
3. Benzene<br />
CAS # 71-43-2<br />
HAZARD FLASH<br />
POINT<br />
0 C<br />
BP<br />
0 C<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 26<br />
HSE Department Rev. : 00<br />
LEL<br />
%<br />
UEL<br />
%<br />
SP.GR.<br />
20 0 C<br />
VD SOLUBILI<br />
TY WITH<br />
WATER<br />
at 20 0 C<br />
T/F/E - 17.8 10.6 3.0 100 0.869 1.5 2.0 %<br />
SOLUBL<br />
E<br />
NFPA<br />
H F R<br />
HAZARDOUS<br />
COMBUSTIO<br />
N PRODUCT<br />
2 4 3 Irritating<br />
vapour<br />
T - -34.1 - - 1.424 - Boils 3 0 0 Toxic and<br />
irritating<br />
gases<br />
TLV<br />
PPM<br />
TWA<br />
IDLH<br />
PPM<br />
LC50<br />
mg/m3<br />
1.0 3.0 5748 ppm<br />
for 1 Hr.<br />
1 ppm 25<br />
ppm<br />
-11 81.1 1.3 7.9 0.879 2.8 Insoluble 2 3 0 - 0.5 ppm 500<br />
ppm<br />
4. Methanol F/T 10 54 5.4 44 0.792 1.1 Soluble 1 3 0 Irritating<br />
vapour<br />
5. Toluene<br />
CAS # 108-88-3<br />
6. Ethanol<br />
CAS # 64-17-5<br />
7. Acetanilide<br />
CAS # 103-84-4<br />
8. Ethyl Acetate<br />
CAS # 141-78-6<br />
9. Acetic Acid<br />
CAS # 64-19-7<br />
F 4.0 111 1.1 7.1 0.87 3.2 Insoluble 2 3 0 Irritating<br />
Vapour<br />
generated<br />
F 17.7 78.2 3.3 19 0.790 1.6 Soluble 0 3 0 - 1000<br />
ppm<br />
T 173.8 303.8 - - 1.219 4.65 Insoluble 1 1 0 NOX Not<br />
listed<br />
F -4.0 77.0 2.0 11.5 0.902 3.0 1 ml/10ml<br />
water<br />
T / F 44.4 117.9 5.4 16.0 1.015 -- SOLUBL<br />
E<br />
1 3 0 Irritating<br />
Vapour<br />
generated<br />
2 2 1 Irritating<br />
Vapour<br />
generated<br />
200 6000<br />
LEL<br />
Rat<br />
1017<br />
For human<br />
24 ml/kg<br />
for rat for<br />
2H<br />
64000<br />
ppm for<br />
4H rat<br />
50 2000 400 ppm<br />
for 24Hr<br />
Rat<br />
3300<br />
ppm<br />
Not<br />
listed<br />
39 gm/m3<br />
for 4H<br />
Rat<br />
100 mg/L;<br />
96 Hr Fish<br />
- 400 200<br />
gm/m3<br />
rat<br />
10 40 5620 ppm<br />
for 1 Hr<br />
Rat<br />
CARCIN ANTIDOT<br />
OGENIC<br />
CHARAC<br />
TERISTI<br />
C<br />
Yes Not available<br />
No milk, milk<br />
butter and<br />
milk of<br />
magnesia.<br />
Yes Not available<br />
No 10 mg<br />
diazepam<br />
through<br />
injection<br />
No Diazem – 1<br />
mg/Kg.(Intrav<br />
enous),<br />
Epinephina,<br />
Efidrine<br />
No Diazepam 10<br />
mg through<br />
injection<br />
No Milk,<br />
Activated<br />
Charcoal or<br />
water<br />
No Not available<br />
No Sodium<br />
Hydro-<br />
Carbonate<br />
(4% Conc.),<br />
Milk, Lime
10. Chloro Sulphonic<br />
Acid<br />
CAS # 7790-94-5<br />
11. Caustic Lye<br />
CAS # 1310-73-2<br />
12. Sulfuric Acid<br />
CAS # 7664-93-9<br />
13. Sulfur powder<br />
CAS # 7704-34-9<br />
14. Sulfur Trioxide<br />
CAS # 7446-11-9<br />
15. Aniline<br />
CAS # 62 – 53 - 3<br />
16. Hydrochloric Acid<br />
HCL<br />
17. Ammonia (Anhydrous)<br />
CAS # 7664-41-7<br />
T/C - 155 - - 1.375 - Water<br />
reactive<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 27<br />
HSE Department Rev. : 00<br />
3 0 2 Non<br />
combustible<br />
T - - - - 2.13 - Soluble 3 0 1 Non<br />
combustible<br />
C -- 340 -- -- 1.84 -- Water 3 0 2 Non<br />
reactive<br />
combustible<br />
T/F 207 115 MP 35<br />
g/m<br />
3<br />
140<br />
0<br />
g/m<br />
3<br />
- 8.9 None 2 1 0 Irritating<br />
fumes<br />
generated<br />
C - 45 - - 1.92 2.76 Water<br />
reactive<br />
- SO2 100<br />
ppm<br />
C 75.5 184.1 1.3 11 1.022 - Insoluble 3 2 0 Toxic Vapour 2 ppm 100<br />
ppm<br />
C/T NF 108 NF NF 1.12 -<br />
1.19<br />
0.2 - - No<br />
Juice, Milk of<br />
Megnesia<br />
Sodium<br />
mg/m3<br />
Hydro-<br />
Carbonate<br />
(4% Conc.),<br />
Milk, Lime<br />
Juice, Milk of<br />
Megnesia<br />
- 10<br />
mg/m3<br />
No Apply Water<br />
1<br />
mg/m3<br />
15<br />
mg/m 3<br />
510<br />
mg/m3 for<br />
2H Rat<br />
No Sodium Hydro-<br />
Carbonate (4%<br />
Conc.), Milk,<br />
Lime Juice,<br />
Milk of<br />
Megnesia<br />
- - 9200 mg<br />
m-3 4h<br />
No Not Available<br />
510<br />
mg/m3<br />
for 2H<br />
Rat<br />
175 ppm<br />
for 7H<br />
mouse<br />
1.267 Soluble 3 0 1 N A 5 ppm 50 ppm 3124 ppm<br />
for 1h rat<br />
C - - 33.3 15.50 27 0.682 0.6 Insoluble 3 1 0 N A 25 ppm 300<br />
ppm<br />
7040<br />
mg/m3<br />
for3 0 Mnt<br />
Rat-<br />
Yes<br />
Classifie<br />
d : 1<br />
Sodium Hydro-<br />
Carbonate (4%<br />
Conc.), Milk,<br />
Lime Juice,<br />
Milk of<br />
Magnesia<br />
Yes Mitholene Blu<br />
– 1%<br />
Excartric Acid<br />
– 5%<br />
No Sodium<br />
Hydro-<br />
Carbonate<br />
(4% Conc.),<br />
Milk, Lime<br />
Juice, Milk of<br />
Megnesia<br />
No Smelling<br />
Ethanol or<br />
Ether
18. O- Nitro Toluene<br />
CAS # 64-17-5<br />
19. P- Nitro Toluene<br />
CAS # 99-99-0<br />
20. Oleum<br />
CAS # 8014-95-7<br />
21. Nitric Acid<br />
CAS # 7697-37-2<br />
22. Chloro Benzene<br />
CAS # 108-90-7<br />
23. Ortho Dichloro<br />
Benzene (ODCB)<br />
CAS # 95-50-1<br />
24. Para Dichloro<br />
Benzene (PDCB)<br />
CAS # 106-46-7<br />
25. Nitro Benzene<br />
( NB)<br />
CAS # 98-95-3<br />
T/F 106 222 2.0 - 1.16 4.73 Insoluble 2 1 4 Irritating<br />
Vapour<br />
generated<br />
C 106.1 238.3 - - 1.286 4.72 Insoluble 3 1 0 Toxic Oxides<br />
of Nitrogen<br />
T/C - - - - 1.91-1.97 - Insoluble 3 0 2 Toxic and<br />
irritating<br />
vapors<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 28<br />
HSE Department Rev. : 00<br />
2 ppm 200<br />
ppm<br />
2 ppm 200<br />
ppm<br />
1 mg/m3 15<br />
mg/m3<br />
C -- 121 -- -- 1.408 2.5 Soluble 3 0 0 - 4 67<br />
ppm<br />
(NO2)<br />
/4H.<br />
T/F 28 132 1.3 9.6 1.11 3.9 Insoluble 2 3 0 Phosgene &<br />
Hydrochloric<br />
gases<br />
generated<br />
T/F 66 180-183 2.2 9.2 1.3 5.1 Insoluble 2 2 0 CO, CO2,<br />
HCL<br />
T/F 66 180 - - 1.25 5.1 Insoluble 2 2 0 CO, CO2,<br />
HCL<br />
T/F 88 211 1.8 40.0 1.2 4.3 0.2 3 2 1 Irritating<br />
Vapour<br />
generated<br />
10 ppm 10<br />
ppm<br />
- 25<br />
ppm<br />
10 ppm 10<br />
ppm<br />
790<br />
mg/m3<br />
Rat<br />
975<br />
mg/m3<br />
Rat<br />
510<br />
mg/m 3<br />
for<br />
2 hrs<br />
RAT<br />
260<br />
mg/m3/30<br />
M Rat<br />
22,000<br />
ppm<br />
Rat<br />
8150<br />
mg/m3<br />
for 4H<br />
Rat<br />
> 6.0 mg/<br />
m3 for 4hr<br />
Rat<br />
- 1 ppm 556 ppm<br />
for 4H<br />
Rat<br />
No Mitholene Blu<br />
– 1%,<br />
Excartric Acid<br />
– 5%<br />
No Mitholene Blu<br />
– 1%,<br />
Excartric Acid<br />
– 5%<br />
No Sodium<br />
Hydro-<br />
Carbonate<br />
(4% Conc.),<br />
Milk, Lime<br />
Juice, Milk of<br />
Magnesia<br />
Yes Sodium<br />
Hydro-<br />
Carbonate<br />
(4% Conc.),<br />
Milk, Lime<br />
Juice, Milk of<br />
Megnesia<br />
No Diazem – 1<br />
mg/Kg.(Intrav<br />
enous)<br />
Epinephina,<br />
Efidrine<br />
No Diazem – 1<br />
mg/Kg.(Intrav<br />
enous)<br />
Epinephina,<br />
Efidrine<br />
No Diazem – 1<br />
mg/Kg.(Intrav<br />
enous)<br />
Epinephina,<br />
Efidrine<br />
No Diazem – 1<br />
mg/Kg.(Intrav<br />
enous)<br />
Epinephina,<br />
Efidrine<br />
26. Thionyl Chloride T - 76 1.64 4.6 - - Water 4 0 2 sulfur dioxide, 1 ppm Not 500 ppm No natural oil and
CAS # 771909-7 reactive sulfur chloride determi<br />
ned<br />
27. Di methyl sulphate<br />
CAS #77-78-1<br />
28. Aluminum Chloride<br />
CAS #7446-70-0<br />
29. Sodium Hydroxide<br />
CAS #1310-73-2<br />
T/C 83 188.8 3.6 23.2 1.33 4.35 Soluble 3 2 0 CO , Toxic 0.1 ppm 10<br />
vapour<br />
ppm<br />
C/T - - - - 2.44 4.5 - 3 0 2 Toxic fumes 5 ppm 100<br />
ppm<br />
C - very<br />
high<br />
- - - - Miscible 3 0 1 Toxic fumes<br />
of sodium<br />
oxide.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 29<br />
HSE Department Rev. : 00<br />
2 mg/m 3 200<br />
mg/m 3<br />
F = FIRE T = TOXIC<br />
E = Explosive R = REACTIVE<br />
BP = BOILING POINT LEL = LOWER EXPLOSIVE LIMIT<br />
UEL = UPPER EXPLOSIVE LIMIT SP.GR = SPECIFIC GRAVITY<br />
VD = VAPOUR DENSITY ER = EVAPORATION RATE<br />
H = HEALTH HAZARD CLASS F = FIRE HAZARD CLASS<br />
R = REACTIVE HAZARD BR = BURNING RATE<br />
TLV = THRESHOLD LIMIT VALUE PPM = PARTS PER MILLION<br />
STEL = SHORT TERM EXPOSURE LIMIT NFPA = NATIONAL FIRE PROTECTION ASSOCIATION-usa<br />
for 1 Hr Rat one table<br />
spoon sodium<br />
or magnesium<br />
sulphate with<br />
one glass of<br />
water. one cup<br />
strong tea or<br />
coffee.<br />
45 mg/m3 No Cotirco steroid<br />
for 4H Rat<br />
injection.<br />
- No 2 to 5 gm<br />
sodium<br />
thiosulphate in<br />
5% sodium bi<br />
carbonate<br />
solution in 200<br />
2300<br />
mg/m3 for<br />
2H Rat<br />
ml<br />
No Sodium Hydro-<br />
Carbonate (4%<br />
Conc.), Milk,<br />
Lime Juice,<br />
Milk of<br />
Magnesia
3.9 Facilities / System for process safety, transportation, fire fighting system and<br />
emergency capabilities to be adopted<br />
Following facilities and system will be installed / implemented.<br />
1. Total enclosed process system.<br />
2. DCS operation plant.<br />
3. Instrument & Plant Air System for control all parameters.<br />
4. High level, low level, High pressure, low pressure, high temp, high<br />
flow, low flow indication and cut off interlocking provided on storage<br />
as well as process reactors.<br />
5. Safety valve, rupture disk provided on reactor and pressure storage<br />
tanks.<br />
6. Static earthing and electric earthing (Double) will be provided.<br />
7. Jumpers for static earthing on pipeline flanges of flammable chemical<br />
provided.<br />
8. Flame proof light fitting installed where ever it is required.<br />
9. Emergency handling equipments like SCBA sets, Fire extinguishers,<br />
Gas mask, PPEs, Chlorine emergency Kit, chlorine hood, caustic pit,<br />
Air line respirator, provided.<br />
10. Full fledge ETP plant made and it will take care of liquid effluent of<br />
the plant and final discharge parameter will be maintained as per<br />
GPCB norms.<br />
11. Scrubbers provided on all process vent and air monitoring carried out<br />
and parameters will be maintained as per GPCB norms. Fire Water<br />
reservoir for fire hydrant and sprinkler system.<br />
12. Storage tank area are away from the process plant and Separation<br />
Distance has been maintained.<br />
13. Dyke wall provided to all above ground storage tanks, collection pit<br />
with valve provided.<br />
14. Flame arrestor with breather valve is installed on flammable material<br />
storage tank vent.<br />
15. Lightening arrestor on all chimneys and building provided.<br />
16. Fencing and caution notes and hazard identification boards displayed.<br />
17. Only authorized person are permitted in storage tank farm area.<br />
18. Safety permit for hazardous material loading unloading is prepared<br />
and implemented.<br />
19. Static earthing provision is made at all loading unloading points of<br />
flammable chemical storage tank farm area.<br />
20. TREM CARD provided to all transporters and trained for<br />
transportation Emergency of Hazardous chemicals.<br />
21. Fire hydrant system and water sprinkler system installed at tank farm<br />
area.<br />
22. Caution note, safety posters, stickers and emergency preparedness<br />
plan will be displayed.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 30<br />
HSE Department Rev. : 00
23. Emergency facilities and medical emergency facilities are available at<br />
site. Occupational Health centre facility generated at factory premises<br />
and paramedical staff is available round the clock.<br />
24. Wind direction indicators are provided.<br />
25. Safety Shower and eye wash are installed at acid/ alkali handling area.<br />
26. Tele Communication system and mobile phone will be used in case of<br />
emergency situations for communication.<br />
27. Emergency siren installed at main gate as well as in all plant.<br />
28. Training programme are being conducted regularly and induction<br />
training are being provided to all employees on chemical safety and<br />
process safety.<br />
3.10 BRIEF DESCRIPTION OF PROCESS AND FLOW CHART<br />
3.10.1 Vinyl Sulphone & Vinyl Sulphone Condense:<br />
Chloro Sulphonation:<br />
Chloro Sulphonic Acid is charged into the sulphonation reactor. Acetanilide is then slowly<br />
added to maintain the temperature below 80° C. The temperature is then maintained<br />
between 50-60 °C. The batch thus prepared is transferred to the storage tank.<br />
Dumping:<br />
Sulphonated mass is charged into the Reactor cooled with brine. Ice water is then added<br />
slowly to remove all the HCl formed due to decomposition of excess Chloro Sulphonic<br />
Acid. The HCl is scrubbed and absorbed in water to make HCl. Further Ice water is added<br />
to dilute the concentrated Sulfuric Acid formed due to the decomposition of Chloro<br />
Sulphonic Acid. Here we get of Sulfuric Acid of strength 30-40%.<br />
The mass is then filtered out (ASC Cake).<br />
Reduction:<br />
Sodium Bi Sulphite slurry is added to the reactor. The pH is maintained neutral by adding<br />
Caustic Lye. The ASC wet cake is then charged under controlled temperature and pH.<br />
After addition is over the temperature is raised up to 50 °C. The mass is then filtered and<br />
transferred to condensation vessel.<br />
Condensation:<br />
The reduction mass in condensation vessel is maintained at 50°C. Ethylene Oxide is slowly<br />
added. The pH is maintained to 5-7 by adding dilute sulphuric acid. The material after<br />
condensation is transferred to the Nutsch Filter. The Mother liquor is stored in storage<br />
tank. The condensed product is then washed and dried.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 31<br />
HSE Department Rev. : 00
Esterification:<br />
The condensed product is charged in esterification reactor. Concentrated Sulphuric Acid is<br />
added. The temperature is then raised and maintained at 160°C for 4 hours. Vacumm is<br />
applied to take out acetic acid vapors and being condensed. The product is then collected a<br />
tank. The dried Vinyl Sulphone is pulverized and packed in PVC bags.<br />
Chlorosulphonation:<br />
NHCOCH 3<br />
ACETANILIDE<br />
Reduction:<br />
NHCOCH 3<br />
SO 2 Cl<br />
Ethoxylation:<br />
NHCOCH 3<br />
SO 2 Na<br />
+<br />
Esterification:<br />
+<br />
+ 2Cl.SO 3 H<br />
CHLORO SULPHONIC ACID<br />
NaOH + NaHSO 3<br />
H2C CH2<br />
H2SO4 + H2O +<br />
NHCOCH 3<br />
+ H 2 SO 4<br />
SO 2 CH 2 CH 2 OH<br />
O<br />
ETHYLENE OXIDE<br />
NHCOCH 3<br />
SO 2 Cl<br />
NHCOCH 3<br />
SO 2 Na<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 32<br />
HSE Department Rev. : 00<br />
NH 2<br />
+<br />
+<br />
HCl + H 2 SO 4<br />
Na 2 SO 4 + NaCl<br />
NHCOCH 3<br />
+ Na 2 SO 4<br />
SO 2 CH 2 CH 2 OH<br />
+ CH 3 COOH<br />
SO 2 CH 2 CH 2 OSO 3 H<br />
VINYL SULPHONE
Process Flow Chart:<br />
Acetanilide 2182<br />
CHLOROSULPHONIC<br />
10182<br />
ACID<br />
12364<br />
Ice 14545 DUMPING(ICE)<br />
SOD. BISULPHITE<br />
SLURRY(30%)<br />
6545<br />
CAUSTIC LYE 2182<br />
PRODUCT FROM FILT<br />
ETHYLENE OXIDE 1018<br />
H2SO4 2269.00<br />
PRODUCT FROM<br />
Dryer<br />
CHLOROSULPHONATION<br />
26909<br />
FILTERATION(Nutch) H2SO4 (35-40%)<br />
12364 14545<br />
21091<br />
24378.00<br />
6625.00<br />
FILTER 17753<br />
SODIUM SULPHITE<br />
SALT<br />
(BYPRODUCT)<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 33<br />
HSE Department Rev. : 00<br />
Salt<br />
8299<br />
CONDENSED PRODUCT 9454<br />
6625.00<br />
4363.00<br />
DRYER<br />
H2SO4 1455 ESTERIFICATION<br />
5818.00<br />
4000.0<br />
REDUCTION<br />
ETHOXYLATION<br />
VINYL SULPHONE<br />
2262 MOISTURE LOSS<br />
ACETIC ACID<br />
1818<br />
MASS BALANCE/FLOW CHART OF THE VINYL SULPHONE<br />
ETP
3.10.2 Sulphuric Acid<br />
The process for the manufacture of sulphuric acid comprise the following steps:<br />
1. Solid Sulphur after weighment is fed to sulphur melter which is provided with steam coils.<br />
The ash content of the molten sulphur settles in the melter cum settler and molten sulphur<br />
free of impurities is pumped to the sulphur burner where it is burnt with air. Sulphur is<br />
converted in to SO2 in the sulphur burner as per the following reaction<br />
S + O2 SO2<br />
2. SO2 is further converted to SO3 in presence of Vanadium Pentoxide catalyst in the<br />
converter as per the following reaction:<br />
3.<br />
SO2 + ½ O2 SO3<br />
The conversion of SO2 to SO3 is carried out in stages in all the five pass of the convertor.<br />
The conversion is optimized by intermediate cooling of gases between the different stages<br />
and also by interpass absorption of SO3 after 3 rd pass of the convertor.<br />
4. The gas from the 3 rd & 5 th pass of the convertor containing SO3 is cooled & then fed to the<br />
interpass & final absorption tower where SO3 is removed by circulating Sulphuric Acid in<br />
the absorption towers. The concentration of sulphuric acid is controlled by addition of<br />
water in the pump tank.<br />
5. Air for sulphur burner is routed through Air Filter to drying tower and further to suction<br />
side of Centrifugal Air Blower. 98.5% acid is circulated through drying tower at 70°C,<br />
thus heating to 125°C before entering sulfur burner. This system helps to increase<br />
generation of steam and hence power generation.<br />
6. SO2 emission during start up of the plant is controlled by a Venturi Scrubber using alkali<br />
as scrubbing medium. The plant therefore does not cause any pollution either during start<br />
up or during normal operation.<br />
The process as described above has been divided into five main sections described as<br />
follows:<br />
• Sulphur Circuit<br />
The weighed quantity of sulphur of about 99.5% purity is fed to the first compartment<br />
of sulphur melter. The heat for melting sulphur is provided through steam coils. The<br />
optimum pressure to be maintained for melting sulphur in the first compartment is upto<br />
7 kg/cm2 G.<br />
The molten sulphur flows from compartment no. 1 to pumping compartment through<br />
underflows/overflows. The sulphur pumps for feeding sulphur are fitted in pumping<br />
compartment. The total time of retention in the compartments corresponds to more<br />
than 72 hrs at normal rated production capacity of the plant. In order to achieve<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 34<br />
HSE Department Rev. : 00
optimum results, it is necessary that the feeding of sulphur to the melter should be<br />
maintained at specified temperature of 135 °C. All compartments are fitted with steam<br />
coil to provide the necessary heat for maintaining the temperature of molten sulphur at<br />
the desired level. Molten sulphur from the pumping compartment is pumped to the<br />
sulphur burner through one of the submersible type sulphur pumps through specially<br />
designed sulphur feeding gun. The rate of feed of sulphur to the sulphur burner is<br />
controlled by operation of sulphur feed control valve. Drain lines have been provided<br />
in the molten sulphur discharge line at two different points.<br />
The optimum steam pressure for coils located in 2 nd , 3 rd , 4 th through pumping<br />
compartments of the sulphur melter is around 4 kg/cm2 G. This regulated steam<br />
pressure is achieved through pressure reducing valve. Molten sulphur line starting from<br />
the discharge flange of the sulphur pump to the inlet of the sulphur burner is suitably<br />
steam jacketed to maintain correct temperature of molten sulphur fed to the sulphur<br />
burner.<br />
• SO2 Scrubber<br />
It is very important that SO2 emission during plant startup is controlled within<br />
persmissible limits. This is achieved by use of a alkali scrubber located after the final<br />
absorption tower where gas is scrubbed with circulating alkali solution.<br />
• DM and Water Softening Plants<br />
For generation of steam of high quality DM water is required for this purpose RO<br />
plant and DM plant will be installed.<br />
• The plant is provided with data logging system through DCS control circuits for<br />
control of parameters like Acid concentration control, pump tank level control, Boiler<br />
feed water level control, boiler feed water from deaerator temperature control. All the<br />
output signals are fed to a computer and output data is collected based on reports to be<br />
prepared including log sheets.<br />
<strong>Chemical</strong> Reaction:<br />
Overall<br />
S + O2 SO2<br />
SO2 + 1/2O2 SO3<br />
SO3 + H2O H2SO4<br />
S 3/2O2 + H2O H2SO4<br />
M.W 32 48 18 98<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 35<br />
HSE Department Rev. : 00
3.10.3 Oleum & SO3<br />
Oleum (23%)<br />
Oleum 23% is manufactured by absorbing SO3 gas with Sulphuric Acid.<br />
H2SO4 + SO3 H2S2O7<br />
Oleum 23% means free SO3 in the product is 23%, which is equivivalent to 105.17%<br />
Sulphuric Acid. This way 23% Oleum is equivalent to 1.07 of 98% Sulphuric Acid.<br />
The sulphur required for 1 ton of 23% oleum is 0.326 x 1.07 = 0.349 ton.<br />
Oleum (65%)<br />
Oleum 65% means, the free SO3 in this product is 65% which is equivalent to 114.626%<br />
sulphuric acid. This way the oleum 65% is equivalent to 1.17 times of 98% sulphuric acid.<br />
The sulphur required for 1 ton of 65% Oleum 0.326 x 1.17 = 0.381 ton<br />
Liquid SO3<br />
Liquid SO3 is = 1.25 times of 98% Sulphuric Acid. The Sulfur required for 1 ton of liquid<br />
SO3 = 0.326 x 1.25 = 0.41 ton.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 36<br />
HSE Department Rev. : 00
100 MT<br />
DM Water<br />
Sulphur<br />
163.25 MT<br />
904341 M 3 Air Drying Tower<br />
(Oxygen: 245 MT)<br />
Acid Pump Tank P<br />
Water<br />
Metler<br />
(135°C)<br />
Furnace<br />
(1100°)<br />
WHB Steam Steam Turbine to Generate<br />
Convertor<br />
(upto 3rd pass)<br />
IPAB(Inter Pass<br />
Absorption<br />
Tower<br />
Convertor<br />
(4th pass)<br />
99%<br />
H2SO4<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 37<br />
HSE Department Rev. : 00<br />
4 MW Power<br />
Oleum<br />
Tower<br />
Oleum<br />
Pump Tank<br />
(Oleum 23%<br />
or 65%)<br />
Oleum<br />
Storage<br />
(23% or 65%)<br />
99% H2SO4<br />
H2SO4<br />
(98.5%) Storage<br />
Final Absorption<br />
Tower<br />
Alkali<br />
Scrubbe<br />
r<br />
Vent to<br />
Atmosphere<br />
Wastewater<br />
500 MT/Day 0.8 KLD<br />
PROCESS FLOW CHART OF H2SO4(98.7%), Oleum (23% & 65%)<br />
H2SO4 (98.5%)
Oluem Pump<br />
Tank (23%)<br />
8070<br />
3.10.4 Chloro Sulphonic Acid<br />
SO3 + HCl ClSO3H<br />
(l) (g) (l)<br />
80 36.5 116.5<br />
1567 HCl Chilling<br />
H2SO4<br />
SO3<br />
Convertor<br />
(132 °C)<br />
Oleum<br />
Tower<br />
(23%)<br />
PROCESS FLOW CHART OF SO3 LIQUID<br />
1567<br />
Chilled HCl<br />
Gas<br />
Cleaning Bleed<br />
1567<br />
Dry HCl 99.90%<br />
3433 Liq SO3<br />
Reactor<br />
100.00% Gas to Stack<br />
Caustic<br />
Scrubber<br />
0.8 Castic Solution Wastewate To ETP<br />
10% 0.8 KL/Month<br />
5000<br />
Chlorosulphonic Acid<br />
MASS BALANCE OF CHLOROSULPHONIC ACID<br />
Condenser SO3 Liquid<br />
The HCl gas is refrigerated and cleaned in gas cleaning tower. The dry HCl is reacted with<br />
liq SO3 to get Chloro Sulphonic Acid. The unconverted gas is scrubbed in caustic<br />
scrubber.<br />
<strong>Chemical</strong> Reaction:<br />
Mass Balance:<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 38<br />
HSE Department Rev. : 00<br />
7500
3.10.5 Sulfonation (of ONT/PNT, Tobias, VS)<br />
Take ONT/PNT in as sulfonator and charge 98% Sulphuric Acid and 65% Oluem in it<br />
slowly. After completion of reaction blow sulfomass in another vessel containing water,<br />
charge common salt, mix it, cool it and filter in neutsch. Material is then centrifuge.<br />
Collect filterate as Spent Sulphuric Acid for sale. Sulphonated ONT/PNT from centrifuge<br />
is then packed in HDPE bags and sent for sale.<br />
For Tobias, Take Oleum (65%) in sulfonator, charge Tobias Acid slowly and after<br />
completion of charging raise temperature and maintain it. Now cool the sulphonated mass<br />
and blow it in Brine water. Allow for mixing, filter and give wash of brine water.<br />
Centrifuge the mass and collect the wet cake as product and packed in HDPE bags.<br />
<strong>Chemical</strong> Reaction (o-NT/p-NT):<br />
CH3 NO2<br />
98<br />
H2SO4<br />
H2S2O7<br />
178<br />
CH3 NO2<br />
o-Nitro Toluene Sulphonated Sulfuric Acid<br />
o-NT<br />
137 217 98<br />
<strong>Chemical</strong> Reaction: (Tobias)<br />
SO3H<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 39<br />
HSE Department Rev. : 00<br />
SO3H<br />
+ H2SO4<br />
NH2<br />
SO3H<br />
SO3H<br />
NH2<br />
+ H2S2O7 + H2SO4<br />
Tobias Acid (TA) STA (Sulfo Tobias Acid)<br />
223 178 303 98<br />
MASS BALANCE:<br />
ONT 137<br />
H2SO4 98<br />
H2S2O7 178<br />
Sulfonator<br />
Water 18<br />
Drawning<br />
Common Salt 117<br />
Vessel<br />
(NaCl) 548<br />
Filteration<br />
Spent Acid (25%)<br />
(Water+Salt+Sulfuric Acid)<br />
217 331<br />
413<br />
Centrifuge 2<br />
(Recycle to Drawning Vessel)<br />
Wet Cake<br />
215<br />
MASS BALANCE OF SULPHONATION ONT/PNT
3.10.6 BENZENE SULPHONYL CHLORIDE<br />
Benzene is reacted with Chloro Sulphonic Acid in a agitated vessel at low temperature at<br />
about 20 -25 °C. Chloro Sulphonic Acid is used in excess for the reaction. The reacted<br />
mass is then kept under agitation for some time. It is then transferred to another vessel<br />
containing chilled water. During the addition, the vessel is cooled up to desire temperature<br />
till the addition complete. The contents are kept under agitation for some time. The mass is<br />
then separated. The acid layer is transferred to the storage tank for sale. The organic layer<br />
is washed, dried & distilled under vacuum to get the product. The HCl gas evolved during<br />
the reaction & isolation is send to CAS plant for making Chloro Sulphonic Acid.<br />
<strong>Chemical</strong> Reaction:<br />
C6H6 + HOSO2Cl C6H5SO2Cl + HCl<br />
Benzene CSA BSC Hydrochloric Acid Gas<br />
(l) (l) (l) (g)<br />
M.W 78 116.5 176.5 36.5<br />
Mass Balance/Flow Chart:<br />
3.10.7 Thionyl Chloride<br />
663 Benzene HCl gas<br />
Reactor<br />
1980 CSA 310<br />
Isolation<br />
Distillation<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 40<br />
HSE Department Rev. : 00<br />
2333<br />
1500<br />
Benzyl Sulphonyl Chloride<br />
Dilute H2SO4<br />
833<br />
Crude<br />
Dimethyl<br />
Sulphone<br />
1485 15<br />
MASS BALANCE OF BENZYL SULPHONYL CHLORIDE<br />
Sulphur is charged in sulfur monochloride reactor along with chlorine in measured<br />
quantity and reacted over a period of 12 hours to Sulphur Monochloride (SMC), which is<br />
stored for further reaction. Thionyl Chloride reacted is fed with SMC, SO3 and Chlorine.<br />
Reactor is fitted with fractionating column. TC gas thus produced is passed through 3<br />
condenser, out of which first condenser used cooling water and other two condenser use<br />
chilled water. Crude TC is then sent to Distillation column as reflux. A part of crude TC is<br />
reacted with sulfur to get pure Thionyl Chloride.
Alkali Scrubber is provided to absorb SO2 when required; similarly chlorine scrubber<br />
removes traces of chlorine. Byproduct is recycled back to sulfuric acid plant, where it is<br />
converted to Sulphur Trioxide for reuse in TC Plant.<br />
<strong>Chemical</strong> Reaction:<br />
Mass Balance:<br />
3.10.8 DASDA<br />
818 Sulphur<br />
890 Chlorine<br />
2S + Cl 2 S 2Cl 2<br />
Sulphur Chlorine Sulphur Monochloride (SMC)<br />
64 70 134<br />
S 2Cl 2 + 2SO 3 + Cl 2 2SOCl 2 + 2SO 2<br />
134 160 70 236 128<br />
SMC Sulphur Trioxide Chlorine TC<br />
Overall <strong>Chemical</strong> Reaction:<br />
2S + 2Cl 2 + 2SO 3 2SOCl 2 + 2SO 2<br />
64 140 160 236 128<br />
SMC Reactor<br />
2044 SO3<br />
890 Chlorine<br />
1708<br />
TC Reactor<br />
3015<br />
To Sulfuric Acid & SBS plant (Recycle)<br />
1627<br />
Condenser<br />
Product<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 41<br />
HSE Department Rev. : 00<br />
2400<br />
Distillation<br />
600<br />
Column Product<br />
15<br />
Total Product 3000<br />
MASS BALANCE OF THIONYL CHLORIDE<br />
Sulfuric Acid & Oluem (65%) are taken in Sulfonator, Para Nitro Toluene (PNT) is then<br />
charged. The mass in then dumped in to the water, cooled and filtered in Neutsch filter.<br />
The acid is then separated, The mass (PNTOSA) is then oxidized with sodium<br />
hypochloride. After completion of the reaction common salt is charged at the room<br />
temperature the mass is then filtered in Neutsch Filter .<br />
Then reduction of PNTOSA is carried out with Fe, HCl and NH4Cl. Filter the reduction<br />
mass & isolate the filterate using dilute H2SO4 & filter it in Neutsch filter. Material thus<br />
prepared is DASDA. Which is then centrifuged and packed in the HDPE bags.
<strong>Chemical</strong> Reaction:<br />
PNT(137) 98 178 PNTSA (217)<br />
SO3H<br />
2 + 2NaOCl +H2O<br />
O2N<br />
O2N<br />
CH3<br />
NO 2<br />
+<br />
SO3H<br />
H2SO 4 + H2S2O7 + 2H2SO4<br />
PNT 63<br />
H2SO4 45<br />
Oleum 82<br />
Water 20<br />
Salt 15<br />
Common Salt 15<br />
Soda Ash 18<br />
NaOCl 69<br />
Water 25<br />
Fe 5<br />
HCl 8<br />
NH4Cl 15<br />
Sulfonator<br />
Drawning<br />
Vessel<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 42<br />
HSE Department Rev. : 00<br />
190<br />
225<br />
Neutsch Filter 58 To ETP<br />
167<br />
Centrifuge 30 ML(Recycle)<br />
137 Drawning<br />
Oxidation<br />
264<br />
Neutsch Filter 58 To ETP<br />
206<br />
Centrifuge 5 ML(Recycle)<br />
201 Drawning<br />
Reduction<br />
Vessel<br />
229<br />
Filter Press 27 To ETP<br />
202<br />
Isolation Vessel<br />
202<br />
Neutsch Filter 26 To ETP<br />
176<br />
Centrifuge 6 ML(Recycle)<br />
170 Isolation Vessel<br />
Product<br />
DASDA<br />
MASS BALANCE OF DASDA<br />
+ 2HCl + 3H2O<br />
NO2<br />
NO2 H H<br />
217 149 18 474 73 54<br />
SO3Na<br />
- C = C<br />
H H<br />
SO3N<br />
NO2<br />
Fe/HCl<br />
NH4Cl<br />
(DNSDA) Di-Sodium Salt (Nitro form) Di-Sodium Salt (Amino form)<br />
414<br />
H2N<br />
CH3<br />
SO3Na<br />
Mass Balance:<br />
- C = C<br />
H H<br />
SO3N<br />
NH2 + H2SO4<br />
H2N<br />
414 DASDA 370<br />
H2N<br />
CH3<br />
NO 2<br />
SO3Na<br />
- C = C<br />
SO3Na<br />
- C = C<br />
H H<br />
SO3H<br />
- C = C<br />
H H<br />
SO3N<br />
SO3N<br />
SO3H<br />
NH2<br />
NH
3.10.9 Power Generation of 10 MW (Coal)<br />
For power generation steam will be generated from the boiler, which is then sent to steam<br />
turbine to generated the power. At the outlet of the turbine steam goes to condenser to<br />
recover the water utilized and further sent back to the boiler. The fuel utilized for the boiler<br />
will be Coal.<br />
To generated 10 MW, a steam of 40 MTD required, which is generated from the coal<br />
based boiler. The coal consumption for the required steam would be approximately 10<br />
MTD.<br />
For Power plant, separate coal yard will be made in which coal will be stored, from coal<br />
yard the coal will be sent to crusher. The crushed coal is then sent to silo for ultimate feed<br />
in to the combustion chamber.<br />
Process Flow Chart:<br />
High Pressure Steam<br />
45 kg/cm 2<br />
410°C<br />
3.10.10 Sodium Bi Sulphite<br />
Turbine<br />
Generator<br />
Set<br />
Exhaust<br />
0.1 kg/cm 2<br />
100 °C<br />
Condenser Condensate back to<br />
Boiler feed water<br />
Sodium Carbonate and Water is charged in the reactor. Sulphur Dioxide is then passed<br />
slowly to the reactor. The mass is then allowed for continuous mixing. The material thus<br />
prepared is Sodium Bi Sulphite.<br />
<strong>Chemical</strong> Reaction:<br />
Na2CO3 + 2SO2 + H2O 2NaHCO3 + CO2<br />
106 64 18 208 28<br />
Sodium SBS<br />
Carbonate<br />
Mass Balance:<br />
Sodium Carbonate 106<br />
CO2<br />
28<br />
SO2 64<br />
Reactor<br />
Water 18<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 43<br />
HSE Department Rev. : 00<br />
160<br />
MASS BALANCE OF SODIUM BI SULPHITE
3.10.11 Dimethyl Sulphate<br />
Methanol from day tank in the plant is taken through metering pump passed through heat<br />
exchanger and condenser in gas cycle. The methanol gas is passed through the aluminum<br />
catalyst, further it is reacted with liquid SO3. The ration of consumption of methanol +<br />
SO3 for DMS produced is as follows:<br />
1524 Methanol Day Tank<br />
SO3 = 0.70 MT<br />
Methanol = 0.55 MT.<br />
The moisture shall be collected out of Methanol and sent to ETP. After reaction of SO3 +<br />
Methanol gas in a closed reaction , Which will have chilled water circulation in jacket. The<br />
crude DMS formed is having a high acidity. The distilled and acid thus produced is 98%<br />
Sulphuric Acid. This is a by product and will be sold.<br />
<strong>Chemical</strong> Reaction:<br />
Mass Balance :<br />
260°C<br />
2 CH3OH CH3-O-CH3 + H2O<br />
Catalyst(Al2O3)<br />
Methanol Dimethyl Ether<br />
2 x 32 46 18<br />
CH3-O-CH3 + SO3 (CH3)2SO4<br />
Dimethyl Sulphate<br />
46 126<br />
SO3 + H2O H2SO4<br />
80 18 98<br />
Heat<br />
Exchanger<br />
386 Water To ETP<br />
Reactor<br />
Containing<br />
Al2O3<br />
Catalyst(260°C)<br />
Condensation<br />
Tank<br />
DME Gas<br />
1138<br />
1979 Liq SO3<br />
Reactor<br />
Pure Dimethyl Sulphate 3000 Distillation<br />
MASS BALANCE OF DIMETHYL SULPHATE<br />
117<br />
98% Spent Sulfuric Acid<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 44<br />
HSE Department Rev. : 00
3.10.12 Dimethyl Aniline<br />
Methanol from day tank in the plant is taken through metering pump passed through heat<br />
exchanger and condenser in gas cycle. The methanol gas is passed through the aluminum<br />
catalyst, further it is reacted with Aniline. The product is then distilled to get Dimethyl<br />
Aniline<br />
The moisture shall be collected out of Methanol and sent to ETP.<br />
<strong>Chemical</strong> Reaction:<br />
Mass Balance:<br />
260°C<br />
2 CH3OH CH3-O-CH3 + H2O<br />
Catalyst(Al2O3)<br />
Methanol Dimethyl Ether<br />
2 x 32 46 18<br />
CH3-O-CH3 + C6H5NH2 (CH3)2C6H5NH2<br />
780 Methanol Day Tank<br />
3.10.13 Diethyl Sulfate<br />
Dimethly Aniline<br />
46 93 123<br />
Heat<br />
Exchanger<br />
220 Water To ETP<br />
560<br />
Reactor<br />
Containing<br />
Aluminium<br />
Catalyst<br />
Condensation<br />
Tank<br />
MASS BALANCE OF DIMETHYL ANILINE<br />
DME Gas<br />
Reactor<br />
1500 Pure Dimethyl Aniline Distillation<br />
Aniline<br />
1134<br />
194<br />
Wastewate to ETP<br />
Ethyl Alcohol and SO3 reacts in presence of catalyst Sodium Sulphate and Urea and<br />
formed Ethyl Hydrogen Sulfate (EHS). This EHS mass is ammoniated by ammonia and<br />
EHS gets converted into Diethyl Sulfate. Ammonia is passed in Ethyl Hydrogen Sulfate<br />
mass. The product thus formed is crude Diethyl Sulphate.<br />
Moisture content present in the Ethyl Alcohol reacts with SO3 and forms Sulphuric Acid.<br />
Distillation of crude EHS takes place under vacuum. The pure DES is produced and<br />
transported to the storage tanks.<br />
<strong>Chemical</strong> Reaction:<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 45<br />
HSE Department Rev. : 00<br />
1694
2C2H5OH + 2SO3 2C2H5OSO3H<br />
Catalyst<br />
Ethyl Alcohol Ethyl Hydrogen Sulfate<br />
92 160 228<br />
2C2H5OSO3H + NH3 (C2H5)2SO4 + NH4SO4<br />
EHS Ammonia Diethyl Sulfate Ammonium Sulfate<br />
228 17 154 114<br />
Mass Balance:<br />
896 Ethyl Alcohol<br />
1558 SO3<br />
NH3<br />
Cooler<br />
3.10.14 Calcium Chloride<br />
166<br />
354<br />
Reactor (Catalyst:<br />
Urea+Sod. Sulfate)<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 46<br />
HSE Department Rev. : 00<br />
2100<br />
Ammoniation Reactor<br />
Distillation<br />
2266<br />
1500<br />
Pure Diethyl Sulfate<br />
MASS BALANCE OF DIETHYL SULFATE<br />
Spent ST Tank<br />
766<br />
Calcium Carbonate is reacted with Hydrochloric Acid to get Calcium Chloride.<br />
<strong>Chemical</strong> Reaction:<br />
2CaCO3 +4 HCl 2CaCl2 + 2 HCO3
Mass Balance:<br />
0.2<br />
Water<br />
5 Lime Stone Ventury Scrubber (Alkali)<br />
Reactor<br />
ETP<br />
4 HCl 0.2<br />
9<br />
3.10.15 Di Calcium Phosphate<br />
Filter Press<br />
8 CaCl2<br />
Clear Liquid<br />
Evaporator<br />
5<br />
Dry CaCl2<br />
Product<br />
Sludge to ETP<br />
1<br />
Mosture Loss<br />
MASS BALANCE OF CALCIUM CHLROIDE<br />
Rock Phosphate is reacted with Hydrochloric Acid to generated Phosphoric Acid, which is<br />
further reacted with Lime stone to get DCP which separated and crystallized.<br />
<strong>Chemical</strong> Reaction:<br />
Ca F2 3 ( Ca3(PO4)2) + 14 HCl 7 CaCl2 + 3Ca H(PO4)2 + 2HF<br />
Mass Balance:<br />
Rock Phosphate 1800<br />
HCl (30%) 3600<br />
Lime 200<br />
Hydrated Lime 200<br />
Sodium Silicate 10<br />
Reactor<br />
3Ca (OH)2 6CaHPO4<br />
DCP<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 47<br />
HSE Department Rev. : 00<br />
5400<br />
Neutralisation<br />
5600<br />
Separation<br />
5810<br />
Filteration Process Sludge<br />
5310 500<br />
Recycle to Reactor<br />
to recover DCP 1500 Centriguge<br />
3810<br />
Dryer Mositure Loss<br />
3000 810<br />
Finished Product<br />
MASS BALANCE OF DI CALCIUM PHOSPHATE
3.10.16 Sulphur Mono Chloride<br />
Sulphur Monochloride is generated by reacting sulphur & Hydrochloric Acid in a reactor.<br />
<strong>Chemical</strong> Reaction:<br />
Mass Balance:<br />
3.10.17 Sulphuryl Chloride<br />
2S + Cl 2 S 2Cl 2<br />
Sulphur Chlorine Sulphur Monochloride (SMC)<br />
64 70 134<br />
95.5 Sulphur<br />
104.5 Chlorine<br />
SMC Reactor<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 48<br />
HSE Department Rev. : 00<br />
200<br />
MASS BALANCE OF SULPHUR MONOCHLORIDE<br />
Sulphur, Chlorine & Sulphur Trioxide is reacted to gether to get Sulphuryl Chloride.<br />
<strong>Chemical</strong> Reaction:<br />
S + 3Cl2 + 2SO3<br />
3SO2Cl2<br />
32 210 160 402<br />
Sulphuryl<br />
Chloride<br />
Mass Balance:<br />
16 Sulphur<br />
17.5 Chlorine<br />
80 SO3<br />
89.5 Chlorine<br />
Reactor<br />
Reactor<br />
Condenser<br />
33.5<br />
203<br />
Product<br />
190<br />
13<br />
Residue<br />
Distillation<br />
Column Product 10<br />
3<br />
MASS BALANCE OF SULPHURYL CHLORIDE
3.10.18 Aluminium Sulphate (Alum)<br />
Aluminium Sulphate is manufactured by the reaction of Aluminia Hydrate and Bauxite<br />
with Sulphuric Acid.<br />
Bauxite is ground in the pulveriser to 90% passing through 200 mesh and elevated to batch<br />
hopper through bucket elevator. Measure quantity of water is added in the lead bonded<br />
reactor and slowly sulphuric acid is to be added in the reactor.. After getting the required<br />
temperature in the reactor, slowly ground bauxite i.e added. After the addition of measure<br />
quantity of bauxite/alumina hydrate, the agitator is kept on for about 45 minutes, solution<br />
is then dumped in to the settling tank.<br />
The decanted solution of Aluminium Sulphate is then taken to the reactor and the required<br />
quantity of sulphuric acid is added after getting the required temperature Hydrated<br />
Alumina is added slowly. After addition, Aluminum Sulphate is moulded in the trays with<br />
the help of tray filling arrangements. The slabs after cooling are to be taken out from the<br />
trays and stacked in the store.<br />
<strong>Chemical</strong> Reaction:<br />
2Al(OH)3 + 3H2SO4 Al2(SO4)3 + 6H2O<br />
156 294 342 108<br />
Mass Balance:<br />
Water<br />
860 Alumina Hydrate/Bauxite<br />
456 Sulphuric Acid<br />
456 Sulphuric Acid<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 49<br />
HSE Department Rev. : 00<br />
1316<br />
1316<br />
Reactor<br />
Settling Tank<br />
Reactor<br />
Moulding<br />
in to Slab<br />
MASS BALANCE OF ALUM
3.10.19 Sulfamic Acid<br />
Urea & 23-25% Oleum are fed at controlled rates to reactor, which is cooled by chilled<br />
water/brine and cooling water. The reaction products are diluted by mixing with recycled<br />
mother liquor (available after separation of crystals of sulfamic acid). Temperature is<br />
controlled during mixing by chilled water/brine. Dilute acid streams (70% sulfuric acid) is<br />
separated after the mixing operation and is sold to SSP/Alum manufacturer.<br />
<strong>Chemical</strong> Reaction:<br />
NH2CONH2 + SO3 NH2CONHSO3H + CO2<br />
NH2CONHSO3H + H2SO4 2NH2SO3H + CO2<br />
Overall Reaction<br />
NH2CONH2 + SO3 + H2SO4 2NH2SO3H + CO2<br />
60 80 98 2 x 97 44<br />
Mass Balance:<br />
350 Urea Reactor<br />
3300 SO3/Oleum<br />
(23-25%) 3650<br />
5150<br />
Mixing<br />
100 Water Make -Up<br />
Figure are in Ton/Month<br />
R/C Mother Liquor<br />
Separation Spent Acid<br />
2400 2750<br />
2500<br />
Cyrstallisation<br />
1000<br />
Packing/Bagging<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 50<br />
HSE Department Rev. : 00<br />
1500<br />
MASS BALANCE OF SULFAMIC ACID
4.1 INTRODUCTION<br />
SECTION IV<br />
HAZARD IDENTIFICATION<br />
Risk assessment process rests on identification of specific hazards, hazardous areas and<br />
areas vulnerable to effects of hazardous situations in facilities involved in processing and<br />
storage of chemicals.<br />
In fact the very starting point of any such assessment is a detailed study of materials<br />
handled & their physical / chemical / thermodynamic properties within the complex at<br />
various stages of manufacturing activity. Such a detailed account of hazardous materials<br />
provides valuable database for identifying most hazardous materials, their behaviour<br />
under process conditions, their inventory in process as well as storage and hence helps in<br />
identifying vulnerable areas within the complex.<br />
Hazardous posed by particular installation or a particular activity can be broadly<br />
classified as fire and explosive hazards and toxicity hazards. Whether a particular<br />
activity is fire and explosive hazardous or toxicity hazardous primarily depends on the<br />
materials handled and their properties.<br />
It will be from the above discussion that study of various materials handled is a<br />
prerequisite from any hazard identification process to be accurate. Based on this study<br />
the hazard indices are calculated for subsequent categorization of units depending upon<br />
the degree of hazard they pose.<br />
In a Dyes Intermediates manufacturing plant main hazard handling of hazardous<br />
chemicals like Chlorine, Ethylene Oxie, Flammable solvents, corrosive and toxic<br />
chemicals, Natural Gas and HSD as a fuel in CPP, the primary concern has always been<br />
toxic release, fire and explosion prevention and control as these are the main hazard<br />
posed by such unit. This concern has grown through the lose of life, property and<br />
materials experienced after experienced after major disasters, which have occurred over<br />
the years.<br />
Identification of hazards is the most important step to improve the safety of any plant.<br />
The hazard study is designed to identify the hazards in terms of chemicals, inventories<br />
and vulnerable practices /operations.<br />
The hazard evaluation procedures use as a first step by chemical process industries and<br />
petroleum refineries are checklists and safety reviews. Dow and Mond fire and explosion<br />
indices, which make use of past experience to develop relative ranking of hazards, is also<br />
extensively used. For predictive hazard analysis, Hazard and Operability studies<br />
(HAZOP), Fault tree analysis, Event tree analysis, Maximum credible accident and<br />
consequence analysis etc are employed.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 51<br />
HSE Department Rev. : 00
Sr.<br />
No<br />
Material<br />
Stored<br />
4.2 Dow’s fire and Explosion Index (F & EI)<br />
4.2.1 Steps in fire and explosion index calculation are given below :<br />
4.2.2 Results of fire explosion and toxicity indices.<br />
Storage<br />
Qty.<br />
1. Chlorine 900 Kg. X<br />
209 Nos.<br />
2. Ethylene Oxide 15 MT<br />
Bullet<br />
Calculate GHP(F1),<br />
General Process Hazards<br />
Nh Nf Nr M<br />
F<br />
Select Pertinent Process<br />
Determine Material Factor<br />
Determine Hazard Factor<br />
F1 X F2 =F3<br />
F3XMaterial Factor<br />
=F & E Index<br />
Determine Exposure area<br />
TABLE- 4.1<br />
GPH SPH FEI Degree of<br />
hazard<br />
Radius<br />
of expo.<br />
(ft.)<br />
Th Ts TI Degree of<br />
Hazard<br />
4 0 0 1 2.05 2.82 5.8 Light 4.9 325 125 26.41 Severe<br />
2 4 3 29 3.0 3.2 278 Severe<br />
Calculate SPH(F2), special<br />
process Hazards<br />
200 125 125 18.0 Severe<br />
3. Sulfur Trioxide/ 100MTl x2 3 0 2 1 2.9 3.3 9.57 Low hazard 8 250 125 27.00 Severe<br />
Sulfuric<br />
Tanks<br />
for fire<br />
4. Benzene 40 KLx6<br />
U/G Tanks<br />
2 3 0 16 2.55 3 122.4 Intermediate 106 125 125 16.38 Heavy<br />
5. Toluene 40 KL X2<br />
U/G Tanks<br />
2 3 0 16 2.55 3 122.4 Intermediate 106 125 125 16.38 Heavy<br />
6. Methanol 60 KLX4<br />
Tanks<br />
1 3 0 16 2.55 2.35 95.88 Moderate 78 50 50 5.3 Light<br />
7. Oleum 150 MTx 2<br />
Tanks<br />
3 0 2 24 2.85 1.5 102.6 Intermediate 87 250 125 20.06 Severe<br />
8. Sulfuric acid 1000MTX2 3 0 2 1 2.9 3.3 9.57 Low hazard 8 250 125 27.00 Severe<br />
Tanks<br />
for fire<br />
9. Nitric Acid 20 KLX 3<br />
Tanks<br />
2 1 0 4 2.90 3.0 34.8 Intermediate 28 125 75 7.9 Moderate<br />
10. Thionyl Chloride<br />
11. Ammonia 50 MT 3 1 0 4 3.75 2.91 10.9 Light 8 250 75 24.89 Heavy<br />
12. FO 60 MT 0 0 0 10 2.2 2.4 52.8 Light 44 0 50 2.7 Light<br />
13. HSD 20 0 2 0 10 2.55 1.93 49.21 Light 41 0 50 2.4 Light<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 52<br />
HSE Department Rev. : 00
FEI= MF x GPH x SPH<br />
TI = Th + Ts x ( 1+ GPH tot + SPH tot )<br />
-------------<br />
100<br />
Nh = NFPA Health rating GPH = General Process Hazard<br />
Nf = NFPA Fire rating SPH = Special Process Hazard<br />
Nr = NFPA Reactive rating FEI = Fire Explosion Index<br />
MF = Material Factor Th = Penalty Factor<br />
Ts = Penalty for Toxicity TI = Toxicity Index<br />
4.3 Failure Frequencies<br />
4.3.1 Hazardous material release scenarios can be broadly divided into 2 categories<br />
I) catastrophic failures which are of low frequency and<br />
II) ruptures and leaks which are of relatively high frequency.<br />
Releases from failure of gaskets, seal, rupture in pipelines and vessels fall in the second<br />
category whereas catastrophic failure of vessels and full bore rupture of pipelines etc fall<br />
into the first category.<br />
4.3.2 Typical failure frequencies are given below:-<br />
TABLE-4.2<br />
Item Mode of failure Failure frequencies<br />
Atmospheric<br />
Catastrophic failure<br />
10-9 /yr<br />
storage<br />
Process Pipelines<br />
Significant leak<br />
10-5 /yr<br />
< = 50 mm dia Full bore rupture<br />
8.8 x 10-7 /m.yr<br />
Significant leak<br />
8.8 x 10-6 /m.yr<br />
> 50 mm
TABLE-4.3<br />
TABLE-4.4<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 54<br />
HSE Department Rev. : 00
4.4 Identification of Hazardous Areas:<br />
A study of process for manufacturing as given in chapter 2 of the report indicates the<br />
following:<br />
Various raw materials used in the manufacturing processes are listed in Table-3.2 in<br />
Section-3 along with mode / type of storage & storage conditions. It can be readily seen<br />
that raw materials even though hazardous in nature, are used in continuous process &<br />
inventory are low at process plant. However some chemicals such as Methanol, Chlorine<br />
are used / common in more than one process & therefore their inventory requirement is<br />
higher. Most of hazardous chemicals are stored in dedicated Explosive licence premises.<br />
List of chemicals stored in larger quantities is provided in Table-4.5<br />
Following areas considered as a Hazardous area of the plant.<br />
(a) CCOE approved Chlorine tonner Shed<br />
(b) Class A petroleum storage tank farm<br />
(c) Ethylene Oxide Storage bullet tank farm ( CCOE approved licenced premises).<br />
(d) Oleum, Sulfuric Acid, SO3, CSA, TC & DMS storage area.<br />
(e) Anhydrous Ammonia storage tank (CCOE approved licenced premises)<br />
4.4.1 Evaluation Of Hazards :<br />
4.4.1.1 Major inventory of Hazardous chemicals within the factory premises are-<br />
The materials were studied with respect to their flammability, reactivity and toxicity based<br />
on the criteria given by the NFPA (NFPA ratings). Material factor values were determined<br />
using these ratings. General process hazards and Special process hazards for all the<br />
materials stored were determined as per the guidelines given by DOW <strong>Chemical</strong>s<br />
Company in DOW Index. FEI values for all these materials were calculated form the<br />
above data.<br />
Value of material factor, General Process Hazard & Special Process Hazard as also FEI /<br />
TI values & degree of hazard are given in Table 4.1 It can be seen storage in tank farms is<br />
mostly in the Severe category due to pressure storage and highly flammable and toxic<br />
nature of chemicals. The radius of exposure for various tanks considering FEI Values is<br />
also calculated and presented in the Table.<br />
4.4.1.2 Evaluation of Process Areas :<br />
Existing and proposed Sulfuric Acid and Thyonil Chloride, VS, CSA & DMS plant are<br />
a state of the art Technology process fully automatic DCS operation and continuous<br />
process plant. Thus the inventory of hazardous chemicals is in the plant is very small.<br />
Existing and proposed plants are generally controlled by Distributed <strong>Control</strong> System<br />
(DCS) to provide an integrated plant control built in safety devices provided. Process<br />
parameters control and interlocking are provided and foolproof safety interlocking and<br />
logics applied at design level and maintained.<br />
Existing Captive Power Plant and proposed CPP plant gas base engine and NG will be<br />
used through pipe line.<br />
From heat recovery of sulfuric acid plant, steam will be utilized in steam turbine for<br />
power generation.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 55<br />
HSE Department Rev. : 00
Thus Produce units will do not warrant any detailed calculations as consequences due<br />
to any worst case scenario due to very quantity of material & damage is such a case is<br />
expected to be limited to within the factory premises.<br />
Considering this, the risk analysis and consequences studies are concentrated on<br />
storage in bulk as per Table -3.2.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 56<br />
HSE Department Rev. : 00
5.1 Effects Of Releases Of Hazardous Substances<br />
SECTION V<br />
RISK ASSESSMENT<br />
Hazardous substances may be released as a result of failures / catastrophes,<br />
causing possible damage to the surrounding area. In the following<br />
discussion, an account is taken of various effects of release of hazardous<br />
substances and the parameters to be determined for quantification of such<br />
damages.<br />
In case of release of hazardous substances the damages will depend largely<br />
on source strength. The strength of the source means the volume of the<br />
substance released. The release may be instantaneous or semi-continuous.<br />
In the case of instantaneous release, the strength of the source is given in<br />
kg and in semi-continuous release the strength of the source depends on the<br />
outflow time (kg/s.).<br />
In order to fire the source strength, it is first necessary to determine the<br />
state of a substance in a vessel. The physical properties, viz. Pressure and<br />
temperature of the substance determine the phase of release. This may be<br />
gas, gas condensed to liquid, liquid in equilibrium with its vapour or<br />
solids.<br />
Instantaneous release will occur, for example, if a storage tank fails.<br />
Depending on the storage conditions the following situations may occur.<br />
The source strength is equal to the contents of the capacity of the storage<br />
system.<br />
In the event of the instantaneous release of a liquid a pool of liquid will<br />
form. The evaporation can be calculated on the basis of this pool.<br />
Pool Fire<br />
In the event of the instantaneous release of a liquid a pool of liquid will<br />
form. The evaporation can be calculated on the basis of this pool.<br />
The heat load on object outside a burning pool of liquid can be calculated<br />
with the heat radiation model. This model uses average radiation intensity,<br />
which is dependent on the liquid. Account is also taken of the diameter-toheight<br />
ratio of the fire, which depends on the burning liquid. In addition,<br />
the heat load is also influenced by the following factors :<br />
Distance from the fire<br />
The relative humidity of the air (water vapour has a relatively high<br />
heat-absorbing capacity)<br />
the orientation i.e. horizontal/vertical of the objective irradiated with<br />
respect to the fire.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 57<br />
HSE Department Rev. : 00
Jet Fire<br />
The escaping jet of Hydrogen gas from a pipe line or a pipeline if ignited causes a jet<br />
flame. The direction and tilt of this jet flame will depend on the prevailing wind direction<br />
and velocity. The damage in case of such type of jet fire is restricted within the plant<br />
boundary limit. However, the ignited jet may impinge on other nearby vessel / equipment /<br />
pipeline causing a domino effect.<br />
Fire Ball<br />
This happens during the burning of Methanol vapour cloud, the bulk of which is initially<br />
over rich (i.e. above the upper flammable limit.). The whole cloud appears to be on fire as<br />
combustion is taking place at eddy boundaries where air is entrained (i.e. a propagating<br />
diffusion flame). The buoyancy of the hot combustion products may lift the cloud form the<br />
ground, subsequently forming a mushroom shaped cloud. Combustion rates are high and<br />
the hazard is primarily thermal.<br />
“UVCE”<br />
UVCE stands for unconfined vapor cloud explosion. The clouds of Hydrogen Gas mix<br />
with air (within flammability limit 3.0 % to 74 %) may cause propagating flames when<br />
ignited. In certain cases flame may take place within seconds. The thermal radiation<br />
intensity is severe depending on the total mass of Gas in cloud and may cause secondary<br />
fire. When the flame travels very fast, it explodes causing high over pressure or blast<br />
effect, resulting in heavy damage at considerable distance from the release point. Such<br />
explosion is called UVCE (Unconfined Vapor Cloud Explosion) and is most common<br />
cause of such industrial accident.<br />
BLEVE( Boiling Liquid Expanding Vapour Cloud Explosion )<br />
Is a physical explosion, which occurs when the vapour side of a storage tank is heated by<br />
fire e.g. a torch. As a result of the heat the vapour pressure will rise and the tank wall will<br />
weaken. At a given moment the weakened tank wall will no longer be able to withstand<br />
the increased internal pressure and will burst open. As a result of the expansion and flashoff,<br />
a pressure wave occurs. With flammable gases, a fireball will occur.<br />
DISPERSION CASES :<br />
PLUMES :<br />
Plumes are continuous release of hazardous gases and vapours. Smoke from<br />
a chimney is an example. Plumes can cause FIRES AND EXPLOSIONS as<br />
secondary scenarios.<br />
PUFFS :<br />
Puffs are instantaneous release of hazardous gases and vapours. Puffs can<br />
give rise to FIRE BALLS and vapour cloud explosions(VCE). A special<br />
case of vapour cloud explosion is the Boiling Liquid Evaporating Vapour<br />
Explosion (BLEVE).<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 58<br />
HSE Department Rev. : 00
SPILLS POOL:<br />
Spills are liquid pools created by leaking liquid chemicals. Spills cause<br />
evaporation and dispersal of toxic gases and if the spilled liquid is<br />
flammable, then it can catch fire creating a pool fire also the vapours can<br />
cause explosion.<br />
5.2 Identification of High Risk Areas :<br />
Following areas considered as a High Risk area of the plant.<br />
(a) Chlorine tonner Shed ( CCOE licenced premises )<br />
(b) Class A petroleum storage area ( CCOE licenced premises )<br />
(c) Ethylene Oxide Storage bullet tank farm ( CCOE approved licenced premises).<br />
(d) Oleum, Sulfuric Acid, SO3, CSA, TC storage area.<br />
(e) Anhydrous Ammonia storage tank (CCOE approved licenced premises)<br />
5.3 Modes of Failure:<br />
5.3.1 Following failure are considered for detailed analysis and safe distances computed:<br />
Liquid release due to catastrophic failure of storage vessel or road tanker.<br />
Liquid release through a hole/crack developed at welded joints/flanges / nozzles /<br />
valves etc.<br />
Vapour release due to exposure of liquid to atmosphere in the above scenarios.<br />
Gas release due to catastrophic failure of gas/ liquid outlet valve failure.<br />
Based on the above the following accident scenarios were conceived as most probable<br />
failure cases:<br />
TABLE-5.1<br />
Event Causes<br />
Tank on Fire/ - Catastrophic failure of tank + Ignition availability<br />
Pool fire - Failure of liquid outlet line + Ignition availability<br />
Fire Ball/ - Catastrophic failure of road tanker/ storage tank<br />
Flash Fire Vapour generation due to substrate and wind<br />
UVCE Vapour cloud generation and about 15 % of<br />
total vapour mass Above the UEL-LEL % Ignition availability<br />
Toxic gas dispersion - Toxic Gas release due to catastrophic failure of tonner/bullet/<br />
Tanks and ignition not available within LEL- UEL range.<br />
Considering the quantity of storages & nature of Toxic nature and Flammable storage,<br />
following scenarios were taken up for detailed analysis & safe distances computed :<br />
Catastrophic failure of road tanker of Methanol, Toluene, Benzene and presence of<br />
ignition source poses heat radiation hazards to nearby areas.<br />
Dispersion of vapour up to LC-50 ( Fatal ), Immediate Danger to Life and Health<br />
(IDLH ) and TLV ( Threshold Limit Value ) concentration Dispersion of vapour to<br />
toxic end points<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 59<br />
HSE Department Rev. : 00
Failure cases considered for consequence analysis are representative of worst-case<br />
scenarios. Probability of occurrence of such cases is negligible (less than 1 x 10 -6 per<br />
year) because of strict adherence to preventive maintenance procedures within the<br />
complex. General probabilities for various failure is provided in Table-4.2, 4.3 and<br />
4.4, but consequences of such cases can be grave & far reaching in case such systems<br />
fail during life history of the company. Hence such scenarios are considered for<br />
detailed analysis. It is to be noted however that such situations are not foreseeable or<br />
credible as long as sufficient measures are taken. Also, consequence analysis studies<br />
help us evaluate emergency planning measures of the Company.<br />
Scenario<br />
No.<br />
Failure Type<br />
Table-5.2<br />
Failure Mode Consequence<br />
1,2,3,4 Methanol, Benzene, Un loading Un confined Pool fire Ball<br />
Toluene, Ethanol road arm 100 % Fire, Flash Fire, UVCE<br />
tanker catastrophic<br />
failure.<br />
failure<br />
Random<br />
failure<br />
5,6,7,8,9,<br />
10<br />
Ethylene Oxide storage<br />
bullet catastrophic failure<br />
11 Puff Isopleth Simulation<br />
For Chlorine Tonner<br />
Catastrophic Failure<br />
12 Point source plume<br />
release for Chlorine<br />
14<br />
liquid/ gas phase valve<br />
failure.<br />
Oleum storage Tank<br />
catastrophic failure<br />
15 SO3 storage Tank<br />
catastrophic failure<br />
16 CSA storage Tank<br />
catastrophic failure<br />
17 TC storage Tank<br />
catastrophic failure<br />
18 HCL storage Tank<br />
catastrophic failure<br />
19 Sulfuric Acid storage<br />
tank catastrophic failure<br />
20 Sulpher powder storage<br />
area fire<br />
21 Anhydrous Ammonia<br />
storage bullet<br />
catastrophic failure<br />
Catastrophic<br />
failure<br />
Catastrophic<br />
failure<br />
Random<br />
failure<br />
Catastrophic<br />
failure<br />
Catastrophic<br />
failure<br />
Catastrophic<br />
failure<br />
Catastrophic<br />
failure<br />
Catastrophic<br />
failure<br />
Catastrophic<br />
failure<br />
Due to source<br />
of ignition and<br />
heat<br />
Catastrophic<br />
failure<br />
Pool fire, Ball Fire/ BLEVE,<br />
Flash Fire, UVCE, Puff<br />
dispersion, Spill pool<br />
Evaporation up to LC 50,<br />
IDLH and TLV level.<br />
Puff dispersion up to LC 50<br />
Human, IDLH and TLV level.<br />
Puff dispersion up to LC 50<br />
Human, IDLH and TLV level.<br />
Spill pool Evaporation up to<br />
LC 50, IDLH and TLV level.<br />
Spill pool Evaporation up to<br />
LC 50, IDLH and TLV level.<br />
Spill pool Evaporation up to<br />
LC 50, IDLH and TLV level.<br />
Spill pool Evaporation up to<br />
LC 50, IDLH and TLV level.<br />
Spill pool Evaporation up to<br />
LC 50, IDLH and TLV level.<br />
Spill pool Evaporation up to<br />
LC 50, IDLH and TLV level.<br />
Fire in storage area, Toxic<br />
release due to SO3 gas<br />
generated during fire<br />
Puff dispersion up to LC 50<br />
Human, IDLH and TLV level.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 60<br />
HSE Department Rev. : 00
5.4 Damage Criteria For Heat Radiation:<br />
Damage effects vary with different scenarios. Calculations for various<br />
scenarios are made for the above failure cases to quantify the resulting<br />
damages.<br />
The results are translated in term of injuries and damages to exposed<br />
personnel, equipment, building etc.<br />
Tank on fire /Pool fire due to direct ignition source on tank or road tanker<br />
or catastrophic failure or leakage or damage from pipeline of storage<br />
facilities or road tanker unloading arm, can result in heat radiation causing<br />
burns to people depending on thermal load and period of exposure.<br />
All such damages have to be specified criteria for each such resultant<br />
effect, to relate the quantifier damages in this manner, damage criteria are<br />
used for Heat Radiation.<br />
TABLE 5.3<br />
DAMAGE CRITERIA – HEAT RADIATION<br />
Heat Radiation<br />
Incident Flux KW/m2 Damage<br />
38 100% lethality, heavy damage to tanks<br />
37.5 100% lethality, heavy damage to equipment.<br />
25 50% lethality, nonpiloted ignition<br />
14 Damage to normal buildings<br />
12.5 1% lethality, piloted ignition<br />
12 Damage to vegetation<br />
6 Burns (escape routes)<br />
4.5 Not lethal, 1st degree burns<br />
3 1st degree burns possible<br />
(personnel only in emergency allowed)<br />
2 Feeling of discomfort<br />
1.5 No discomfort even after long exposure<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 61<br />
HSE Department Rev. : 00
6.1 Consequence analysis.<br />
CHAPTER VI<br />
CONSEQUENCE ANALYSIS<br />
In the risk analysis study, probable damages due to worst case scenarios<br />
were quantified and consequences were analyzed with object of emergency<br />
planning. Various measures taken by the company and findings of the study<br />
were considered for deciding acceptability of risks.<br />
6.1.1 Weather Data :<br />
Average wind speed : 5 m / sec.<br />
Average Ambient Temperature : 35 deg. c.<br />
Average Humidity : 70 %<br />
Atmospheric Stability : A<br />
6.1.2 Assumption :<br />
6.1.2.1 For Class A Petroleum Road tanker catastrophic failure( Unloading arm 100 %<br />
failure<br />
Catastrophic failure is considered for 20 MT Methanol, Toluene, &<br />
Benzene road tanker while unloading and due to vapour cloud of<br />
evaporated solvent vapour mass comes in the contact with ignition source<br />
pool fire, UVCE, Ball Fire and Flash Fire scenarios were considered for<br />
various situation.<br />
6.1.2.2 For Ethylene Oxide as follows.<br />
♦ Pool Fire in 15 MT, 18.8 MT and 11.3MT E.O. storage Bullet<br />
♦ Catastrophic failure is considered for E.O. Storage tanks and road<br />
tanker while unloading and due to vapour cloud of E.O. If release<br />
vapour mass come in the contact with ignition source it may give<br />
various scenarios like UVCE, Ball Fire, Flash fire and BLEVE were<br />
considered for various situation.<br />
♦ We have calculated following hazardous distance for the above<br />
mentioned scenarios.<br />
♦ Fatality ( LC-50 )<br />
♦ Immediate danger to life and health (IDLH) concentration area<br />
♦ TWA/TLV concentration distance( Meters)<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 62<br />
HSE Department Rev. : 00
6.1.2.3 For Chlorine supply system as follows.<br />
♦ Chlorine tonner catastrophic failure i.e. 900 kg gas puff dispersion<br />
♦ For Chlorine liquid/ gas phase valve failure release scenario, we have<br />
considered release rate 1000 grms/sec. Maximum contents of the<br />
tonners will be release within 900 seconds or 15 minutes.<br />
♦ We have calculated following hazardous distance for the above<br />
mentioned scenarios.<br />
♦ Fatality ( LC-50 )<br />
♦ Reverse Injury Concentration (RIC-50 )for human<br />
♦ Immediate danger to life and health (IDLH) concentration area<br />
♦ TWA/TLV concentration distance( Meters)<br />
6.1.2.4 For Oleum/ CSA/ DMS/ Sulfuric Acid / Thyonil Chloride storage tanks/ road<br />
tanker as follows.<br />
♦ Oleum Storage tank catastrophic failure i.e. So2 gas puff dispersion<br />
♦ For Oleum outlet line valve failure release scenario, we have<br />
considered release rate 1000 grms/sec. 900 kgs oleum release within<br />
15 minutes.<br />
♦ We have calculated following hazardous distance for the above<br />
mentioned scenarios.<br />
♦ Fatality ( LC-50 )<br />
♦ Immediate danger to life and health (IDLH) concentration area<br />
♦ TWA/TLV concentration distance( Meters)<br />
6.1.2.5 For Ammonia release scenarios<br />
♦ Ammonia tank catastrophic failure i.e. 50 MT gas puff dispersion<br />
♦ Due to pool evaporation maximum evaporation rate will be 1442<br />
g/sec.<br />
♦ We have calculated following hazardous distance for the above<br />
mentioned scenarios.<br />
♦ Fatality ( LC-50 )<br />
♦ Immediate danger to life and health (IDLH) concentration area<br />
♦ TWA/TLV concentration distance( Meters)<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 63<br />
HSE Department Rev. : 00
Scenario –1 Unconfined Pool Fire for Solvent road tanker catastrophic failure<br />
TABLE –1<br />
Unconfined Pool Fire for Solvent road tanker catastrophic failure<br />
Scenario : UNCONFINED POOL FIRE<br />
Input Data Results of Computations<br />
Stored quantity 20 KL Max. IHR at flame centre height 180 Kw/m 2<br />
Pool diameter 25(m) Flame centre height 9.6 meter<br />
Pool liquid depth 0.1 (m) Maximum Flame width 9.59 meter<br />
Wind speed 6 m/s Mass burning rate liquid 1.34 kg/ m 2 /min.<br />
Liquid Density 791 kg/m 3 Flame burnout time 58.82 Mims.<br />
Incident Intensity of<br />
Heat Radiation<br />
(IHR) at ground<br />
level KW /m 2<br />
Results<br />
IHR-<br />
Isopleth<br />
Distance<br />
( Meters )<br />
Effect if IHR at Height of Simulation<br />
37.5 13.5 Damage to process equipment. 100 % Fatal in 1 Min. 1 %<br />
fatal in 10 sec.<br />
25.0 15.6 Min. to ignite wood ( without flame contact ). 100 % fatal<br />
in 1 Min. Significant injury in 10 sec.<br />
12.5 22.1 Min. to ignite wood (with flame contact). 1 % fatal in 1<br />
min. 1 st deg. burn in 10 sec.<br />
4.0 39.0 Pain after 20 secs. Blistering unlikely.<br />
1.6 61.6 No discomfort even on long exposure.<br />
♦ In the 13.5 meter radius area is considered as 100% fatality in 1 min.<br />
♦ In the 22.1 meter radius first degree burn in 10 sec.<br />
♦ In the 39 meter radius area will give pain after 20 seconds. Blistering unlikely.<br />
♦ In the 61.6 meter radius area is considered as safe area and no discomfort even on long<br />
exposure.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 64<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 65<br />
HSE Department Rev. : 00
Scenario –2 Fire Ball simulation for Solvent road tanker unloading catastrophic failure<br />
TABLE –2<br />
Fire Ball simulation Solvent road tanker catastrophic failure<br />
In put Data<br />
Scenario : FIRE BALL<br />
Results of Computations<br />
Stored quantity 20 KL Fire Ball radius 14.66 meter<br />
Mass of vapour 184 Kgs. Fire ball Intensity of Heat 243 Kw /m<br />
Between LEL-UEL%<br />
radiation<br />
2<br />
Heat of combustion 28500 Kj/Kg Fire Ball rate of energy<br />
release<br />
658492 Kj/ sec.<br />
Wind speed 6 m/s Fire- Ball total energy<br />
release<br />
3.9e +006 Kj<br />
Liquid Density 791 kg/m 3 Fire ball duration 5.98 sec.<br />
Incident Intensity of<br />
Heat Radiation<br />
(IHR) at ground<br />
level KW /m 2<br />
IHR-<br />
Isopleth<br />
Distance<br />
( Meters )<br />
Damage effects<br />
37.5 30 100 % Fatal . Min. to ignite wood (without flame<br />
contact)<br />
25.0 38 Min. to ignite wood ( without flame contact ).<br />
Significant injury.<br />
12.5 54 Min. to ignite wood (with flame contact). 1 st deg. burn<br />
.<br />
4.0 94 Pain after 20 secs. Blistering unlikely.<br />
1.6 180 No discomfort even on long exposure.<br />
Results<br />
♦ In the 30 meter radius area is considered as 100 % fatality in 1 min. and first degree burn in 10<br />
sec.<br />
♦ In the 54 meter radius first degree burn in 10 sec.<br />
♦ In the 94 meter radius area will give pain after 20 seconds. Blistering unlikely.<br />
♦ In the 180 meter radius area is considered as safe area and no discomfort even on long<br />
exposure.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 66<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 67<br />
HSE Department Rev. : 00
Scenario –3 Flash Fire simulation Solvent road tanker catastrophic failure<br />
TABLE –AB<br />
Flash Fire simulation Solvent road tanker catastrophic failure<br />
In put Data<br />
Scenario : FLASH FIRE<br />
Results of Computations<br />
Stored quantity 20 KL Visible Flash Fire Height 34.38 meter<br />
Mass of Gas 184 Kgs. Visible Flash Fire Width 17.19meter<br />
Heat of combustion 42267 Kj/kg Duration of Flash-Fire in Sec. 5.99 sec.<br />
Fuel-Air volume ratio<br />
in Flash fire cloud<br />
0.600 Radius of fuel-air cloud mixture 14.67 meter<br />
Stochiometric<br />
Air Mixture<br />
Fuel- 0.133 Total energy release 2622000 Kj<br />
Wind speed 6.0 m/s Max. Heat Radiation from 1 m 162 Kw/ m<br />
from Flash Fire<br />
2<br />
Gas Density 1.29 kg/m 3 Combustion efficiency 0.5<br />
Incident Intensity of<br />
Heat Radiation<br />
(IHR) at ground<br />
level KW /m 2<br />
Results<br />
IHR- Isopleth<br />
Distance<br />
( Meters )<br />
Damage effects<br />
37.5 30 100 % Fatal . Min. to ignite wood (without flame<br />
contact)<br />
25.0 38 Significant injury. Min. to ignite wood ( without flame<br />
contact ).<br />
12.5 54 Min. to ignite wood (with flame contact). 1 st deg.<br />
burn .<br />
4.0 93 Pain after 20 secs. Blistering unlikely.<br />
1.6 148 No discomfort even on long exposure.<br />
♦ In the 30 meter radius area is considered as 100 % fatality in 1 min. and first degree burn in 10<br />
sec.<br />
♦ In the 54 meter radius first degree burn in 10 sec.<br />
♦ In the 93 meter radius area will give pain after 20 seconds. Blistering unlikely.<br />
♦ In the 148 meter radius area is considered as safe area and no discomfort even on long<br />
exposure.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 68<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 69<br />
HSE Department Rev. : 00
Scenario –4 Unconfined Vapour cloud Explosion ( UVCE ) for Solvent road tanker<br />
TABLE – 4<br />
Unconfined Vapour cloud Explosion ( UVCE ) for Solvent road tanker<br />
Scenario : UVCE<br />
In put Data<br />
Stored quantity 20 KL<br />
Mass of vapour between LEL – UEL % 405 lbm.<br />
TNT equivalent 7.8<br />
Explosion efficiency 0.04<br />
Wind speed 6.0 m/s<br />
Radial<br />
Distance<br />
in feet<br />
Results<br />
Over<br />
pressure<br />
( psi )<br />
% Fatality<br />
lung Rupture<br />
% Eardrum<br />
rupture<br />
%Structural<br />
damage<br />
% Glass<br />
rupture<br />
20 47.7 100 100 100 100<br />
25 28.0 98.8 100 100 100<br />
40 9.1 0.0 78.7 100 100<br />
105 2.3 0.0 2.6 10.9 100<br />
2005 0.3 0.0 0.0 0.0 4.3<br />
♦ In case of UVCE up to 20 feet distance is considered as 100 % fatality and 100 % ear drum<br />
rupture radius.<br />
♦ Up to 40 feet distance is considered as 100 % structural Damage and up to 105 feet distance<br />
for 100 % glass damage area.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 70<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 71<br />
HSE Department Rev. : 00
Scenario –5 Unconfined Pool Fire for Ethylene Oxide Road Tanker catastrophic failure<br />
TABLE – 5<br />
Unconfined Pool Fire for Ethylene Oxide Road Tanker catastrophic failure<br />
Scenario : UNCONFINED POOL FIRE<br />
In put Data Results of Computations<br />
Stored quantity 14 MT Max. IHR at flame centre<br />
height<br />
108.40 Kw/m 2<br />
Pool diameter 45 (m) Flame centre height 39.13 meter<br />
Pool liquid depth 0.3 (m) Maximum Flame width 38.83 meter<br />
Wind speed 6 m/s Mass burning rate liquid 6.96 kg/ m 2 /min.<br />
Liquid Density 869 kg/m 3 Flame burnout time 37.97 Mims.<br />
Incident Intensity<br />
of Heat Radiation<br />
(IHR) at ground<br />
level KW /m 2<br />
IHR- Isopleth<br />
Distance<br />
( Meters )<br />
Effect if IHR at Height of Simulation<br />
37.5 34.8 Damage to process equipment. 100 % Fatal in 1 Min.<br />
1 % fatal in 10 sec.<br />
25.0 42.6 Min. to ignite wood ( without flame contact ). 100 %<br />
fatal in 1 Min. Significant injury in 10 sec.<br />
12.5 60.2 Min. to ignite wood (with flame contact). 1 % fatal in<br />
1 min. 1 st deg. burn in 10 sec.<br />
4.0 106.3 Pain after 20 secs. Blistering unlikely.<br />
1.6 168.1 No discomfort even on long exposure.<br />
Results<br />
♦ In the 34.8 meter radius area is considered as 100% fatality in 1 min.<br />
♦ In the 60.2 meter radius first degree burn in 10 sec.<br />
♦ In the 106.3 meter radius area will give pain after 20 seconds. Blistering unlikely.<br />
♦ In the 168.1 meter radius area is considered as safe area and no discomfort even on long<br />
exposure.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 72<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 73<br />
HSE Department Rev. : 00
Scenario –6 Ball Fire for Ethylene Oxide Road Tanker catastrophic failure<br />
TABLE – 6<br />
Ball Fire for Ethylene Oxide Road Tanker catastrophic failure<br />
In put Data<br />
Scenario : FIRE BALL<br />
Results of Computations<br />
Stored quantity 14 MT Fire Ball radius 26.58 meter<br />
Mass of vapour 1135 Kgs. Fire ball Intensity of Heat 314.43 Kw /m<br />
Between LEL-UEL%<br />
radiation<br />
2<br />
Heat of combustion 26710 Kj/Kg Fire Ball rate of energy 2.79317e+006 Kj/<br />
release<br />
sec.<br />
Wind speed 5 m/s Fire- Ball total energy release 3.03159e+007 Kj<br />
Liquid Density 869 kg/m 3 Fire ball duration 10.85 sec.<br />
Incident Intensity<br />
of Heat Radiation<br />
( IHR) at ground<br />
level KW /m 2<br />
IHR-<br />
Isopleth<br />
Distance<br />
( Meters )<br />
Damage effects<br />
37.5 78 100 % Fatal . Min. to ignite wood (without flame contact)<br />
25.0 96 Min. to ignite wood ( without flame contact ). Significant<br />
injury.<br />
12.5 136 Min. to ignite wood (with flame contact). 1 st deg. burn .<br />
4.0 238 Pain after 20 secs. Blistering unlikely.<br />
1.6 368 No discomfort even on long exposure.<br />
Results<br />
♦ In the 78 meter radius area is considered as 1% fatality in 1 min.<br />
♦ In the 136 meter radius area is considered as first degree burn in 10 sec.<br />
♦ In the 238 meter radius area will give pain after 20 seconds. Blistering unlikely.<br />
♦ In the 368 meter radius area is considered as safe area and no discomfort even on long<br />
exposure.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 74<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 75<br />
HSE Department Rev. : 00
Scenario –7 Flash Fire simulation for Ethylene Oxide road tanker catastrophic failure<br />
TABLE – 7<br />
Flash Fire simulation for Ethylene Oxide road tanker catastrophic failure<br />
In put Data<br />
Scenario : FLASH FIRE<br />
Results of Computations<br />
Stored quantity 14 MT Visible Flash Fire Height 64.07 meter<br />
Mass of Gas 1135 Kgs. Visible Flash Fire Width 32.04 meter<br />
Heat of combustion 42267.5 Kj/kg Duration of Flash-Fire in Sec. 10.85 Sec.<br />
Fuel-Air volume ratio<br />
in Flash fire cloud<br />
0.600 Radius of fuel-air cloud mixture 16.62 meter<br />
Stochiometric<br />
Air Mixture<br />
Fuel- 0.128 Total energy release 1396584.22 Kj<br />
Wind speed 6.0 m/s Max. Heat Radiation from 1 m 157.22 Kw/ m<br />
from Flash Fire<br />
2<br />
Gas Density 869 kg/m 3 Combustion efficiency 0.5<br />
Incident Intensity of<br />
Heat Radiation<br />
(IHR) at ground<br />
level KW /m 2<br />
Results<br />
IHR-<br />
Isopleth<br />
Distance<br />
( Meters )<br />
Damage effects<br />
37.5 58 100 % Fatal . Min. to ignite wood (without flame<br />
contact)<br />
25.0 66 Significant injury. Min. to ignite wood ( without flame<br />
contact ).<br />
12.5 96 Min. to ignite wood (with flame contact). 1 st deg.<br />
burn .<br />
4.0 164 Pain after 20 secs. Blistering unlikely.<br />
1.6 264 No discomfort even on long exposure.<br />
♦ In the 58 meter radius area is considered as 100 % fatality in 1 min<br />
♦ In the 96 meter radius first degree burn in 10 sec.<br />
♦ In the 164 meter radius area will give pain after 20 seconds. Blistering unlikely.<br />
♦ In the 264 meter radius area is considered as safe area and no discomfort even on long<br />
exposure.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 76<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 77<br />
HSE Department Rev. : 00
Scenario –8 Unconfined Vapour cloud Explosion ( UVCE ) for Ethylene Oxide road tanker<br />
catastrophic failure<br />
TABLE – 8<br />
Unconfined Vapour cloud Explosion ( UVCE ) for Ethylene Oxide road tanker<br />
catastrophic failure<br />
Scenario : UVCE<br />
In put Data<br />
Stored quantity 14 MT<br />
Mass of vapour between LEL – UEL % 2504 lbm.<br />
TNT equivalent 0.16<br />
Explosion efficiency 0.1<br />
Wind speed 6.0 m/s<br />
Radial<br />
Distance<br />
in meter<br />
Results<br />
Over<br />
pressure<br />
( psi )<br />
% Fatality<br />
lung Rupture<br />
% Eardrum<br />
rupture<br />
%Structural<br />
damage<br />
% Glass<br />
rupture<br />
50 38.00 100 100 100 100<br />
51 32.6 98.8 100 100 100<br />
53 11.2 0.0 78.7 100 100<br />
73 1.9 0.0 2.6 10.9 100<br />
♦ In case of UVCE up to 50 meter distance is considered as 100 % fatality and 100 % ear drum<br />
rupture radius.<br />
♦ Up to 53 meter distance is considered as 100 % structural Damage and up to 73meter feet<br />
distance for 100 % glass damage area.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 78<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 79<br />
HSE Department Rev. : 00
Scenario –9 Puff release simulation for Ethylene Oxide road tanker catastrophic failure<br />
TABLE – 9<br />
Puff release simulation module for Ethylene Oxide road tanker catastrophic failure<br />
Scenario : PUFF RELEASE<br />
Input Data Results of Computations<br />
Stored quantity 14 MT End point<br />
Release Rate 1.4e + 007 gms/ Sec.<br />
(meter)<br />
LC50 Human 4443 ppm 397.34<br />
IDLH value 800 ppm 663.95<br />
TLV value 1 ppm 4186.56<br />
Results<br />
• LC50 Human (4443 ppm) area up to 397.34 meter, IDLH (Immediate danger to life and<br />
health-800 ppm) concentration area up to 663.95 meter and TLV (1 PPM ) area up to 4186.56<br />
meter. Therefore 663.95 meter area in wind direction is considered as evacuation zone.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 80<br />
HSE Department Rev. : 00
Scenario – 10 Spill Pool simulation for Ethylene Oxide road tanker catastrophic failure<br />
TABLE – 10<br />
Spill Pool simulation module for Ethylene Oxide road tanker catastrophic failure<br />
Scenario : SPILL POOL<br />
Input Data Results of Computations<br />
Stored quantity 14 MT End point<br />
Release Rate 8041 Gms/ Sec.<br />
(meter)<br />
LC50 Human 4443 ppm 79.78<br />
IDLH value 800 ppm 201.16<br />
TLV value 1 ppm 2841.01<br />
Results<br />
• LC50 HUMAN (4443 ppm) area up to 79.78 meter, IDLH (Immediate danger to life and<br />
health-800 ppm) concentration area up to 201.16 meter and TWA (1 PPM ) area up to 2841.01<br />
meter. Therefore 201.16 meter area in wind direction is considered as evacuation area.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 81<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 82<br />
HSE Department Rev. : 00
Scenario –11 Pool Fire for Ethylene Oxide 15MT Bullet catastrophic failure<br />
TABLE – 11<br />
Pool Fire for Ethylene Oxide 15MT Bullet catastrophic failure<br />
Scenario : UNCONFINED POOL FIRE<br />
In put Data Results of Computations<br />
Stored quantity 15 MT Max. IHR at flame centre height 46.55 Kw/m 2<br />
Pool diameter 10 (m) Flame centre height 14.43 meter<br />
Pool liquid depth 1 (m) Maximum Flame width 13.43 meter<br />
Wind speed 6 m/s Mass burning rate liquid 6.86 kg/ m 2 /min.<br />
Liquid Density 869 kg/m 3 Flame burnout time 2.10 Mims.<br />
Incident Intensity<br />
of Heat Radiation<br />
(IHR) at ground<br />
level KW /m 2<br />
IHR- Isopleth<br />
Distance<br />
( Meters )<br />
Effect if IHR at Height of Simulation<br />
37.5 8.6 Damage to process equipment. 100 % Fatal in 1 Min.<br />
1 % fatal in 10 sec.<br />
25.0 10.6 Min. to ignite wood ( without flame contact ). 100 %<br />
fatal in 1 Min. Significant injury in 10 sec.<br />
12.5 14.9 Min. to ignite wood (with flame contact). 1 % fatal in<br />
1 min. 1 st deg. burn in 10 sec.<br />
4.0 26.4 Pain after 20 secs. Blistering unlikely.<br />
1.6 41.7 No discomfort even on long exposure.<br />
Results<br />
♦ In the 8.6 meter radius area is considered as 100% fatality in 1 min.<br />
♦ In the 14.9 meter radius first degree burn in 10 sec.<br />
♦ In the 26.4 meter radius area will give pain after 20 seconds. Blistering unlikely.<br />
♦ In the 41.7 meter radius area is considered as safe area and no discomfort even on long<br />
exposure.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 83<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 84<br />
HSE Department Rev. : 00
Scenario –12 Ball Fire for Ethylene Oxide 15MT Bullet catastrophic failure<br />
TABLE – 12<br />
Ball Fire for Ethylene Oxide 15MT Bullet catastrophic failure<br />
Input Data<br />
Scenario : FIRE BALL<br />
Results of Computations<br />
Stored quantity 15 MT Fire Ball radius 16.06 meter<br />
Mass of vapour 243 Kgs. Fire ball Intensity of Heat 305.35 Kw /m<br />
Between LEL-UEL%<br />
radiation<br />
2<br />
Heat of combustion 26710 Kj/Kg Fire Ball rate of energy 989915 Kj/ sec.<br />
release<br />
Wind speed 6 m/s Fire- Ball total energy release 6.49053e+006 Kj<br />
Liquid Density 869 kg/m 3 Fire ball duration 6.55 sec.<br />
Incident Intensity<br />
of Heat Radiation<br />
( IHR) at ground<br />
level KW /m 2<br />
IHR-<br />
Isopleth<br />
Distance<br />
( Meters )<br />
Damage effects<br />
37.5 49.0 100 % Fatal . Min. to ignite wood (without flame contact)<br />
25.0 54.0 Min. to ignite wood ( without flame contact ). Significant<br />
injury.<br />
12.5 84.0 Min. to ignite wood (with flame contact). 1 st deg. burn .<br />
4.0 144.0 Pain after 20 secs. Blistering unlikely.<br />
1.6 217.0 No discomfort even on long exposure.<br />
Results<br />
♦ In the 49 meter radius area is considered as 1% fatality in 1 min.<br />
♦ In the 54 meter radius area is considered as first degree burn in 10 sec.<br />
♦ In the 144 meter radius area will give pain after 20 seconds. Blistering unlikely.<br />
♦ In the 217 meter radius area is considered as safe area and no discomfort even on long<br />
exposure.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 85<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 86<br />
HSE Department Rev. : 00
Scenario –13 Flash Fire simulation for Ethylene Oxide 15MT Bullet catastrophic failure<br />
TABLE – 13<br />
Flash Fire simulation for Ethylene Oxide 15MT Bullet catastrophic failure<br />
In put Data<br />
Scenario : FLASH FIRE<br />
Results of Computations<br />
Stored quantity 15 MT Visible Flash Fire Height 40.53 meter<br />
Mass of Gas 243 Kgs. Visible Flash Fire Width 20.26 meter<br />
Heat of combustion 42267.5 Kj/kg Duration of Flash-Fire in Sec. 6.56 Sec.<br />
Fuel-Air volume ratio<br />
in Flash fire cloud<br />
0.600 Radius of fuel-air cloud mixture 16.06 meter<br />
Stochiometric<br />
Air Mixture<br />
Fuel- 0.128 Total energy release 3245265 Kj<br />
Wind speed 6.0 m/s Max. Heat Radiation from 1 m 152.68 Kw/ m<br />
from Flash Fire<br />
2<br />
Gas Density 869 kg/m 3 Combustion efficiency 0.5<br />
Incident Intensity of<br />
Heat Radiation<br />
(IHR) at ground<br />
level KW /m 2<br />
Results<br />
IHR-<br />
Isopleth<br />
Distance<br />
( Meters )<br />
Damage effects<br />
37.5 32 100 % Fatal . Min. to ignite wood (without flame<br />
contact)<br />
25.0 40 Significant injury. Min. to ignite wood ( without flame<br />
contact ).<br />
12.5 58 Min. to ignite wood (with flame contact). 1 st deg.<br />
burn .<br />
4.0 100 Pain after 20 secs. Blistering unlikely.<br />
1.6 157 No discomfort even on long exposure.<br />
♦ In the 32 meter radius area is considered as 100 % fatality in 1 min<br />
♦ In the 40 meter radius first degree burn in 10 sec.<br />
♦ In the 100 meter radius area will give pain after 20 seconds. Blistering unlikely.<br />
♦ In the 157 meter radius area is considered as safe area and no discomfort even on long<br />
exposure.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 87<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 88<br />
HSE Department Rev. : 00
Scenario –14 Vapour cloud Explosion ( UVCE ) for Ethylene Oxide 15MT Bullet<br />
catastrophic failure<br />
TABLE – 14<br />
Vapour cloud Explosion ( UVCE ) for Ethylene Oxide 15MT Bullet catastrophic failure<br />
Scenario : UVCE<br />
In put Data<br />
Stored quantity 15 MT<br />
Mass of vapour between LEL – UEL % 535 lbm.<br />
TNT equivalent 0.16<br />
Explosion efficiency 0.1<br />
Wind speed 6.0 m/s<br />
Radial<br />
Distance<br />
in Meter<br />
Results<br />
Over<br />
pressure<br />
( psi )<br />
% Fatality<br />
lung Rupture<br />
% Eardrum<br />
rupture<br />
%Structural<br />
damage<br />
% Glass<br />
rupture<br />
13 49.9 100 100 100 100<br />
14 37.7 98.8 100 100 100<br />
27 8.2 0.0 78.7 100 100<br />
32 1.8 0.0 2.6 10.9 100<br />
♦ In case of UVCE up to 13 meter distance is considered as 100 % fatality and 100 % ear drum<br />
rupture radius.<br />
♦ Up to 27 meter distance is considered as 100 % structural Damage and up to 32 meter distance<br />
for 100 % glass damage area.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 89<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 90<br />
HSE Department Rev. : 00
Scenario – 15 Puff release simulation module for Ethylene Oxide Bullet catastrophic failure<br />
TABLE –15<br />
Puff release simulation module for Ethylene Oxide Bullet catastrophic failure<br />
Scenario : PUFF RELEASE<br />
In put Data Results of Computations<br />
Stored quantity 15 MT End point<br />
Release Rate 1.5e + 007 Gms/<br />
Sec.<br />
(meter)<br />
LC50 Human 4443 ppm 405.79<br />
IDLH value 800 ppm 677.54<br />
TLV value 1 ppm 4262.31<br />
Results<br />
• LC50 HUMAN (4443 ppm) area up to 405.79 meter, IDLH (Immediate danger to life and<br />
health) concentration area up to 677.54 meter and TWA (1 PPM ) area up to 4262.31 meter.<br />
Therefore 677.54 meter area in wind direction is considered as evacuation area.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 91<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 92<br />
HSE Department Rev. : 00
Scenario – 16 Spill Pool evaporation module for Ethylene Oxide Bullet catastrophic failure<br />
TABLE – 16<br />
Spill Pool evaporation module for Ethylene Oxide Bullet catastrophic failure<br />
In put Data<br />
Scenario : SPILL POOL<br />
Results of Computations<br />
Stored quantity 15 MT End point<br />
Release Rate 1800 Gms/ Sec.<br />
(meter)<br />
LC50 Human 4443 ppm 41.24<br />
IDLH value 800 ppm 89.79<br />
TLV value 1 ppm 1681.42<br />
Results<br />
• LC50 HUMAN (4443 ppm) area up to 41.24 meter, IDLH (Immediate danger to life and<br />
health) concentration area up to 89.79 meter and TWA (1 PPM ) area up to 1681.42 meter.<br />
Therefore 89.79 meter area in wind direction is considered as evacuation area.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 93<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 94<br />
HSE Department Rev. : 00
Scenario – 17 Spill Pool evaporation module for Oleum 250 MT Tank catastrophic failure<br />
TABLE – 17<br />
Spill Pool evaporation module for Oleum 250 MT Tank catastrophic failure<br />
Scenario : SPILL POOL<br />
In put Data Results of Computations<br />
Stored quantity 250 MT End point<br />
Release Rate 2405 Gms/ Sec.( As SO3)<br />
(meter)<br />
LC50 Human 460 ppm ( 1460 mg.m3) 96.26<br />
IDLH value 3.0 ppm ( 15 mg/m3) 872.05<br />
TLV value 0.30 ppm (1 mg/m3) 1967.21<br />
Results<br />
• LC50 HUMAN (460 ppm) area up to 96.26 meter, Immediate danger to life and health (3 ppm<br />
) concentration area up to 872.05 meter and TWA (0.30 PPM ) area up to 1967.21 meter.<br />
Therefore 267.76 meter area in wind direction is considered as evacuation area.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 95<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 96<br />
HSE Department Rev. : 00
Scenario – 18 Spill Pool evaporation module for Chloro Sulphonic Acid Tank catastrophic<br />
failure<br />
TABLE – 18<br />
Spill Pool evaporation module for Chloro Sulphonic Acid Tank catastrophic failure<br />
Scenario : SPILL POOL<br />
In put Data Results of Computations<br />
Stored quantity 2000 MT End point<br />
Release Rate 1000 Gms/ Sec.<br />
( As HCL gas)<br />
(meter)<br />
LC50 Human for 30 3940 ppm 29.73<br />
mints<br />
IDLH value 50 ppm 292.07<br />
TLV value 1 ppm 1238.93<br />
Results<br />
• LC50 HUMAN (3940 ppm) area up to 29.73 meter, IDLH (Immediate danger to life and<br />
health) concentration area up to 292.07 meter and TWA (1 PPM ) area up to 1238.93 meter.<br />
Therefore 292.07 meter area in wind direction is considered as evacuation area.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 97<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 98<br />
HSE Department Rev. : 00
Scenario – 19 Spill Pool evaporation module for Sulphuric Acid Storage Tank catastrophic<br />
failure<br />
TABLE – 19<br />
Spill Pool evaporation module for Sulphuric Acid Storage Tank catastrophic failure<br />
Scenario : SPILL POOL<br />
In put Data Results of Computations<br />
Stored quantity 1000 MT End point<br />
Release Rate 1000 Gms/ Sec. ( As SO3)<br />
(meter)<br />
LC50 Human 460 ppm (1460 mg/m3) 59.85<br />
IDLH value 3.0ppm (15mg/m3) 587.63<br />
TLV value 0.2 ppm (1mg/m3) 1349.6<br />
Results<br />
• LC50 HUMAN (460 ppm) area up to 59 meter, IDLH (Immediate danger to life and health)<br />
concentration area up to 587.63 meter and TWA (0.2 PPM ) area up to 1349.6 meter.<br />
Therefore 587.63 meter area in wind direction is considered as evacuation area.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 99<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 100<br />
HSE Department Rev. : 00
Scenario – 20 Puff release simulation module for Sulfur Trioxide 100 MT Tank catastrophic<br />
failure<br />
TABLE –20<br />
Puff release simulation module for Sulfur Trioxide 100 MT Tank catastrophic failure<br />
Scenario : PUFF RELEASE<br />
In put Data Results of Computations<br />
Stored quantity 100 MT End point<br />
Release Rate 1e + 008 Gms/ Sec.<br />
(meter)<br />
LC50 Human 460 ppm (1460 mg/m3) 1192.32<br />
IDLH value 3.0 ppm (15mg/m3) 4121.82<br />
TLV value 0.2 ppm (1mg/m3) 7486.05<br />
Results<br />
• LC50 HUMAN (460 ppm) area up to 1192.32 meter, IDLH (Immediate danger to life and<br />
health) concentration area up to 4121 meter and TWA (0.30 PPM ) area up to 7486.05 meter.<br />
Therefore 7486 meter area in wind direction is considered as evacuation area.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 101<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 102<br />
HSE Department Rev. : 00
Scenario – 21 Spill Pool evaporation module for Sulfur Trioxide 100 MT Tank catastrophic<br />
failure<br />
TABLE – 21<br />
Spill Pool evaporation module for Sulfur Trioxide 100 MT Tank catastrophic failure<br />
Scenario : SPILL POOL<br />
In put Data Results of Computations<br />
Stored quantity 100 MT End point<br />
Release Rate 999 Gms/ Sec.<br />
(meter)<br />
LC50 Human 460 ppm (1460 mg/m3) 66.22<br />
IDLH value 3.0 ppm (15mg/m3) 970.84<br />
TLV value 0.2 ppm (1mg/m3) 3958.42<br />
Results<br />
• LC50 HUMAN (460 ppm) area up to 66.22 meter, IDLH (Immediate danger to life and health)<br />
concentration area up to 970 meter and TWA (0.20 PPM ) area up to 3958 meter. Therefore<br />
970 meter area in wind direction is considered as evacuation area.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 103<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 104<br />
HSE Department Rev. : 00
Scenario – 22 Puff release simulation module for Ammonia 50 MT Bullet catastrophic<br />
failure<br />
TABLE –22<br />
Puff release simulation module for Ammonia 50 MT Bullet catastrophic failure<br />
Scenario : PUFF RELEASE<br />
In put Data Results of Computations<br />
Stored quantity 50 MT End point<br />
Release Rate 5e + 007 Gms/ Sec.<br />
(meter)<br />
LC50 Human 6164 ppm 649.68<br />
IDLH value 300 ppm 1509.17<br />
TLV value 25 ppm 2951.09<br />
Results<br />
• LC50 HUMAN (6164 ppm) area up to 649.68 meter, IDLH (Immediate danger to life and<br />
health) concentration area up to 1509.17 meter and TWA (25 PPM ) area up to 2951.09 meter.<br />
Therefore 1509.17 meter area in wind direction is considered as evacuation area.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 105<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 106<br />
HSE Department Rev. : 00
Scenario – 23 Spill Pool evaporation module for Ammonia 50 MT Bullet catastrophic failure<br />
TABLE – 23<br />
Spill Pool evaporation module for Ammonia 50 MT Bullet catastrophic failure<br />
In put Data<br />
Scenario : SPILL POOL<br />
Results of Computations<br />
Stored quantity 50 MT End point<br />
Release Rate 1442 Gms/ Sec.<br />
(meter)<br />
LC50 Human 4443ppm 102.31<br />
IDLH value 300 ppm 553.38<br />
TLV value 25 ppm 2709.05<br />
Results<br />
• LC50 HUMAN (4443 ppm) area up to 102.31 meter, IDLH (Immediate danger to life and<br />
health) concentration area up to 553.38 meter and TWA (25 PPM ) area up to 2709.05 meter.<br />
Therefore 553.38 meter area in wind direction is considered as evacuation area.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 107<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 108<br />
HSE Department Rev. : 00
Scenario – 24 Spill Pool evaporation module for Ammonia Road Tanker Unloading Arm<br />
failure<br />
TABLE – 24<br />
Spill Pool evaporation module for Ammonia Road Tanker Unloading Arm failure<br />
In put Data<br />
Scenario : SPILL POOL<br />
Results of Computations<br />
Stored quantity 50 MT End point<br />
Release Rate 856 Gms/ Sec.<br />
(meter)<br />
LC50 Human 4443ppm 38.39<br />
IDLH value 300 ppm 58.27<br />
TLV value 25 ppm 399.82<br />
Results<br />
• LC50 HUMAN (10000 ppm) area up to 38.38 meter, IDLH (Immediate danger to life and<br />
health) concentration area up to 58.27 meter and TWA (300 PPM ) area up to 399.82 meter.<br />
Therefore 58.27 meter area in wind direction is considered as evacuation area.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 109<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 110<br />
HSE Department Rev. : 00
Scenario-25 Puff Isopleth Simulation For Chlorine Tonner Catastrophic Failure<br />
In put Data<br />
TABLE –O FOR CHLORINE<br />
Scenario : PUFF DISPERSION<br />
Results of Computations<br />
Stored quantity 1 MT Tonner Max. ground level conc. 456393 ppm<br />
Instantaneous Puff 900 kgs Dist. of maxi. ground level 17 meter<br />
Release quantity<br />
Molecular weight 70.9<br />
Wind speed 3.0 m/s<br />
Density ( Air) 2.49kg/m 3<br />
conc.<br />
Hazard Level Concentration<br />
End point<br />
(PPM)<br />
(Meter)<br />
LC50 1017 210.30<br />
IDLH 10 856.39<br />
TWA/ TLV 1 1619.16<br />
• LC50 HUMAN (1017 ppm) area up to 210 meter, IDLH (Immediate danger to life and health)<br />
concentration area up to 856 meter and TWA (1 PPM ) area up to 1619 meter. Therefore 856<br />
meter area in wind direction is considered as evacuation area.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 111<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 112<br />
HSE Department Rev. : 00
Scenario-26 Point source plume release for Chlorine tonner liquid/ gas phase valve failure<br />
TABLE –P FOR CHLORINE<br />
Scenario : POINT SOURCE PLUME RELEASE<br />
In put Data Results of Computations<br />
Stored quantity 1 MT Max. ground level conc. 501046ppm<br />
Rate of release 1000 g/s Dist. of maxi. ground level 5 meter<br />
Molecular weight 70.9<br />
conc.<br />
Wind speed 6.0 m/s<br />
Density ( Air) 2.49kg/m 3<br />
Hazard Level Concentration<br />
End point<br />
(PPM)<br />
(Meter)<br />
LC50 HUMAN 1017 51.91<br />
IDLH 10 445.25<br />
TWA/ TLV 1 1035.91<br />
• LC50 HUMAN (1017 ppm) area up to 51 meter, IDLH (Immediate danger to life and health)<br />
concentration area up to 445 meter and TWA (1 PPM ) area up to 1038 meter. Therefore 445<br />
meter area in wind direction is considered as evacuation area.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 113<br />
HSE Department Rev. : 00
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 114<br />
HSE Department Rev. : 00
6.2 Assessment Of Consequence Modeling Results :<br />
Results of consequence analysis for the release of various flammable and toxic materials at<br />
the KCIL are depicted in Table 6.3.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 115<br />
HSE Department Rev. : 00
Scenario Type of failure<br />
considered<br />
1,2,3,4 Unconfined Pool<br />
Fire, Fire Ball,<br />
Flash fire &<br />
Unconfined<br />
Vapour Fire for<br />
Solvent road tanker<br />
catastrophic failure<br />
5,6,7,8 Unconfined Pool<br />
Fire, Fire Ball,<br />
Flash fire &<br />
Unconfined<br />
Vapour Fire for<br />
Ethylene Oxide<br />
road tanker<br />
11,12,13,<br />
14<br />
catastrophic failure<br />
Unconfined Pool<br />
Fire, Fire Ball,<br />
Flash fire &<br />
Unconfined<br />
Vapour Fire for<br />
Ethylene Oxide 15<br />
MT Bullet<br />
catastrophic failure<br />
Spill<br />
quantity<br />
considerat<br />
ion Max.<br />
Credible<br />
loss<br />
scenario<br />
in KL.<br />
TABLE - 6.3<br />
Details regarding Fire and Explosion Risk Assessment table :-<br />
Evaporati<br />
on vapor<br />
cloud<br />
mass Btn.<br />
LEL-UEL<br />
% for 15<br />
mints<br />
release<br />
from the<br />
source.<br />
Tank fire / pool fire<br />
damage radius at various<br />
KW/ M 2 in meter<br />
Fire Ball damage radius<br />
at various KW/ M 2 in<br />
meter<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 116<br />
HSE Department Rev. : 00<br />
Flash fire simulation<br />
radius at various KW/<br />
M 2 in meter<br />
Heat Intensity KW/ M 2<br />
37.5 12.5 1.6 37.5 12.5 1.6 37.5 12.5 1.6 100%<br />
Fatality<br />
Vapor cloud Explosion<br />
( Unconfined vapor cloud<br />
explosion) UVCE peak over<br />
pressure in feet.<br />
100%<br />
Eardrum<br />
rupture<br />
100%<br />
Structur<br />
al<br />
Damage<br />
20 184 13.5 22.1 61.6 30 54 148 30 54 148 20 25 40 105<br />
14 1135 34.8 60.2 168.1 78 136 368 58 96 264 15 16 25 85<br />
15 243 8.6 14.9 41.7 49 84 217 32 56 157 8 9 17 55<br />
100%<br />
Glass<br />
brk.
TABLE - 6.4<br />
Type of failure considered Spill quantity<br />
consideration<br />
Max. Credible<br />
loss scenario in<br />
Scenario –9 Puff release simulation<br />
module for Ethylene Oxide road<br />
tanker catastrophic failure<br />
Scenario – 10 Spill Pool simulation<br />
module for Ethylene Oxide road<br />
tanker catastrophic failure<br />
Scenario – 15 Puff release<br />
simulation module for Ethylene<br />
Oxide Bullet catastrophic failure<br />
Scenario – 16 Spill Pool simulation<br />
module for Ethylene Oxide Bullet<br />
catastrophic failure<br />
Scenario – 17 Spill Pool<br />
evaporation module for Oleum 250<br />
MT Tank catastrophic failure<br />
Scenario – 18 Spill Pool<br />
evaporation module for Chloro<br />
Sulphonic Acid Tank catastrophic<br />
failure<br />
Scenario – 19 Spill Pool<br />
evaporation module for Sulphuric<br />
Acid Storage Tank catastrophic<br />
failure<br />
Scenario – 20 Puff release<br />
simulation module for Sulfur<br />
Trioxide 100 MT Tank catastrophic<br />
failure<br />
Scenario – 21 Spill Pool<br />
evaporation module for Sulfur<br />
Trioxide 100 MT Tank catastrophic<br />
failure<br />
Scenario – 22 Puff release<br />
simulation module for Ammonia 50<br />
MT Bullet catastrophic failure<br />
Scenario – 23 Spill Pool<br />
evaporation module for Ammonia<br />
50 MT Bullet catastrophic failure<br />
Scenario – 24 Spill Pool<br />
evaporation module for Ammonia<br />
Road Tanker Unloading Arm<br />
failure<br />
Scenario-25 Puff Isopleth<br />
Simulation For Chlorine Tonner<br />
Catastrophic Failure<br />
Scenario-26 Point source plume<br />
release for Chlorine tonner liquid/<br />
gas phase valve failure<br />
MT.<br />
Evaporati<br />
on Rate<br />
Grm/ Sec.<br />
LC50<br />
Distance<br />
in meter<br />
IDLH<br />
Distance<br />
in meter<br />
TLV<br />
Distance in<br />
meter<br />
14 - 397.34 663.95 4186.56<br />
14 8041 79.78 201.16 2841.01<br />
15 - 405.79 677.54 4262.31<br />
15 1800 41.24 89.79 1681.42<br />
250 2405 79.18 267.76 1489.53<br />
2000 1000 29.73 292.07 1238.93<br />
1000 1000 71.03 230.91 1349.46<br />
100 - 1192.32 2234.82 7486.05<br />
100 999 178.26 748.04 15709.48<br />
50 - 649.68 1509.17 2951.09<br />
50 1442 102.31 553.38 2709.05<br />
50 856 38.39 58.27 399.82<br />
1 - 210 856 1619<br />
1 1000 51 445 1035<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 117<br />
HSE Department Rev. : 00
6.3 Comments<br />
The appended table 6.3 and 6.4 summarizes the consequences of the various hazards<br />
analyzed under this study.<br />
As can be seen from the results of the summary of the Risk Analysis study, the Fatality<br />
zone due to burn up to 78 meters in worst case scenario. First degree burn zone up to 136<br />
meter. Due to explosion fatal distance is maximum 20 feet, structural damage zone is up to<br />
40 feet for fire and explosion scenarios.<br />
In case of toxic gas release Fatal distance upto 1192 meters and evacuation zone maximum<br />
up to 2234 meter and company has to plan for evacuation accordingly. Company has to<br />
increase awareness programme in the surrounding vicinity and educate people for safe<br />
evacuation at the time of toxic release.<br />
On site emergency preparedness plan<br />
On site emergency preparedness plan is prepared but risk assessment study data needs to<br />
be studied and further prepared as per risk assessment findings. Emergency control<br />
facilities and resources to be plan and rehearsal / Mock- Drill needs to be conducted<br />
regularly to combat emergency in minimum time.<br />
Emergency handling facilities and training:<br />
All employees should be well aware about possible emergencies and its consequences,<br />
emergency control equipments and practices to control such hazardous condition within<br />
premises.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 118<br />
HSE Department Rev. : 00
SECTION VII<br />
RISK REDUCTION MEASURES<br />
Some of the safeties and risk reduction measures adopted and recommended for the safety of the<br />
plant are as follows:-<br />
7.1 Design<br />
7.1.1 During the design stage itself adequate care has been taken for design, selection,<br />
fabrication, erection and commissioning of Flammable and toxic liquid / gas handling<br />
facilities and other equipment, piping, pipe fittings, electrical equipment etc. relevant and<br />
prevalent international and Indian standards has been followed for design, fabrication,<br />
inspection of the storage tanks and other equipment.<br />
7.1.2 Civil foundations is suitably designed to take care of earthquakes, cyclones, landslides,<br />
flooding, collapse of structures etc.<br />
7.1.3 Plant operator and staffs are selected well experience and qualified for chemical plant<br />
operation.<br />
7.1.4 All key personals are trained for emergency handling procedures and regular Mock- Drills<br />
has been conducted on various scenarios.<br />
7.2 Safety Devices<br />
Following safety devices are provided to protect from any malfunctioning of plant<br />
equipments:<br />
7.2.1 Storage tanks.<br />
a) Nitrogen blanketing for flammable liquid/ gas storage tanks.<br />
b) Pressure ( Maximum and Minimum ) cutoff and gauge provided.<br />
c) DCS operational process plan with 100 % foolproof safety logics are provided for<br />
process as well as storage safety.<br />
d) Level gauges on storage tanks.<br />
e) Static bonding of pipeline flanges.<br />
f) Dyke wall provided surround above ground storage tanks.<br />
g) Safety valve and other venting system provided on pressure storage vessels.<br />
h) All pumps flameproof type and double mechanical seal type.<br />
i) All pipeline and tanks painted as per IS colour code.<br />
j) Jumpers and static earthing provision made on all flanges and tanks.<br />
k) Caution note and Material identification, capacity displayed on all storage tanks.<br />
l) Water sprinklers surrounding Ammonia storage tank and EO storage tank.<br />
m) Matur curtain sprinkler will be provided for Acid storage tanks leakage spillage.<br />
n) Mosture absorbent (Silica gel provision will be made on sulfuric, Oleum , SO3 storage<br />
tanks.<br />
7.2.2 Pumps<br />
a) Required out let valve and NRV provided on pump outlet.<br />
b) Modular fire extinguishers provided near of most of the pumps.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 119<br />
HSE Department Rev. : 00
c) FLP type and mechanical seal type pump installed for flammable chemicals.<br />
7.2.3 Pipelines<br />
a) Jumper connections on flanges to prevent build up of static electricity charge.<br />
b) Proper supports and clamping are provided<br />
c) Double earthing provided to all electrical motors.<br />
d) Colour code as Per IS maintained.<br />
7.3 Operation and Maintenance<br />
Operations and maintenance of the plant is being in accordance with the well-established<br />
safe practices. Some of the guidelines are as follows:-<br />
a) Periodic testing of hoses for leakages and continuity.<br />
b) Earthing of all plant equipment and earthing of vehicles under unloading operations.<br />
c) Annual testing of all safety relief valves.<br />
d) Planned preventive maintenance of different equipment for their safety and reliable<br />
operations.<br />
e) Inspection of the storage tanks as per prefixed inspection schedule for thickness<br />
measurement, joint and weld efficiency etc.<br />
f) Comprehensive color code scheme to identify different medium pipes.<br />
g) Strict compliance of safety work permit system.<br />
h) Proper maintenance of earth pits.<br />
i) Strict compliance of security procedures like issue of identify badges for outsides, gate<br />
pass system for vehicles, checking of spark arrestors fitted to the tank lorries etc.<br />
j) Strict enforcement of no smoking regime.<br />
k) Periodic training and refresher courses to train the staff in safety, fire fighting and first<br />
aid.<br />
7.4 Recommendations<br />
7.4.1 From the Risk Analysis studies conducted, it would be observed that by and large, the risks<br />
are confined within the factory boundary walls in case of fire & explosion, except in the<br />
event of a catastrophic failure of storage tanks of gas it will create OFF site emergency<br />
situations and required more attention and emergency preparedness for combat such<br />
situations.. To minimize the consequential effects of the risk scenarios, following steps are<br />
recommended.<br />
Plant should meet provisions of the Manufacture, storage & Import of Hazardous<br />
<strong>Chemical</strong>s Rules, 1986 & the factories Act, 1948.<br />
Sprinkler system to be installed in Ammonia storage area and EO storage area to be<br />
made more effective and pressure needs to be maintained.<br />
Sprinkler opening valve location needs to be relocate away from the EO storage tanks.<br />
Air line respirator provision to be made in Chlorine, EO, Oleum, Sulfur trioxide, DMS<br />
and CSA, Thionyl chloride storage tank farm area.<br />
Chlorine hood with blower and neutralizing pit arrangement needs to be made at<br />
Chlorine tonners storage area.<br />
React with water and generate toxic fumes while contact with water caution note to be<br />
displayed in Acid tank farm area.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 120<br />
HSE Department Rev. : 00
Fire hydrant system for proposed plant to be installed as per TAC/NFPA Norms in<br />
each plant and buildings.<br />
Dyke wall and collection pit with drain valve needs to be provided in acid storage area<br />
Tanker unloading procedure needs to be displayed at tanker unloading area.<br />
Periodic On Site Emergency Mock Drills and occasional Off Site Emergency Mock<br />
Drills to be conducted, so those staffs are trained and are in a state of preparedness to<br />
tackle any emergency.<br />
Emergency handling facilities to be maintained in tip top condition at all time.<br />
Safe operating procedure to be prepared for hazardous process and material handling<br />
process.<br />
Safety devices and control instruments to be calibrated once in a year.<br />
Proper colour work as per IS 2379 to plant pipeline and tank, equipments to be done<br />
once in a six month to protect from corrosion.<br />
Permit to work system to be implemented 100 % for hazardous work in the plant.<br />
Safety manual as per Rule-68 K & P and Public awareness manual as per 41 B & C be<br />
prepared and distributed to all employees and nearby public.<br />
As per puff release Scenario for Catastrophic Failure of storage tanks, it has been<br />
observed that IDLH distance cover surrounding 2234 meters distance. Hence,<br />
population evacuation plan up to 3.0 kms. needs to be prepared for near by factories in<br />
wind direction in case of extreme accident scenario.<br />
The details of emergency equipments are given in on site emergency Plan along with<br />
its quantity. As per our site visit, these was found in order & working condition and<br />
sufficient for existing production Activates.<br />
Manual call points for fire location identification to be installed in plant premises.<br />
Fog type Pressure sprinkler to be installed at EO storage tank farm.<br />
For proposed plant Fire & Safety organization setup to be replanted for batter plant<br />
process safety.<br />
On line gas detection system needs to be provided in Chlorine shed area and EO<br />
storage tank farm area.<br />
All Acid vents to be connected with scrubber system.<br />
A HAZOP study to be carried out for all product plant and storage facilities.<br />
Induction safety course to be prepared and trained all new employees before starting<br />
duties in plant.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 121<br />
HSE Department Rev. : 00
SECTION VIII<br />
DESASTER MANAGEMENT PLAN<br />
An onsite emergency in the industries involving hazardous processes or in hazardous installations<br />
is one situation that has potential to cause serious injury or loss of life. It may cause extensive<br />
damage to property and serious disruption in the work area and usually, the effects are confined to<br />
factory or in several departments of factory, premise. An emergency begins when operator at the<br />
plant or in charge of storage cannot cope up with a potentially hazardous incident, which may tum<br />
into an emergency.<br />
8.1 ONSITE EMERGENCY PLAN<br />
8.1.1 OBJECTIVES OF ONSITE EMERGENCY PLAN<br />
A quick and effective response at during an emergency can have tremendous significance<br />
on whether the situation is controlled with little loss or it turns into a major emergency.<br />
Therefore, purpose an emergency plan is to provide basic guidance to the personnel for<br />
effectively combating such situations to minimize loss of life, damage to property and loss<br />
of property.<br />
An objective of Emergency Planning is to maximize the resource utilisation and combined<br />
efforts towards emergency operations are as follows. :<br />
8.1.2 DURING AN EMERGENCY.<br />
To increase thinking accuracy and to reduce thinking time.<br />
To localize the emergency and if possible eliminates it.<br />
To minimize the effects of accident on people and property.<br />
To take correct remedial measures in the quickest time possible to contain the incident<br />
and control it with minimum damage.<br />
To prevent spreading of the damage in the other sections.<br />
To mobilize the internal resources and utilize them in the most effective way<br />
To arrange rescue and treatment of causalities.<br />
8.1.3 DURING NORMAL TIME.<br />
• To keep the required emergency equipment in stock at right places and ensure the<br />
working condition.<br />
• To keep the concerned personnel fully trained in the use of emergency equipment.<br />
• To give immediate warning tooth surrounding localities in case of an emergency<br />
situation arising.<br />
• To mobilize transport and medical treatment of the injured.<br />
• To get help from the local community and government officials to supplement<br />
manpower and resources.<br />
• To provide information to media & Government agencies, Preserving records, evidence<br />
of situation for subsequent emergency etc.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 122<br />
HSE Department Rev. : 00
8.2 SCOPE OF OSEP<br />
This OSEP is prepared for industrial emergencies like fires, explosions, toxic releases, and<br />
asphyxia and does not cover natural calamities and societal disturbances related<br />
emergencies (like strikes, bomb threats, civil commission’s etc.)<br />
8.3 ELEMENTS OF ONSITE EMERGENCY PLAN<br />
The important elements to be considered in plan are<br />
Emergency organization<br />
Emergency Facilities.<br />
Roles and Responsibilities of Key Personnel and Essential Employee.<br />
Communications during Emergency<br />
Emergency Shutdown of Plant & <strong>Control</strong> of situation.<br />
Rescue Transport & Rehabilitation.<br />
Developing Important Information.<br />
8.4 METHODOLOGY.<br />
The consideration in preparing Emergency Plan will be included the following steps:<br />
• Identification and assessment of hazards and risks.<br />
• Identifying, appointment of personnel & Assignment of Responsibilities.<br />
• Identification and equipping Emergency <strong>Control</strong> Centre.<br />
• Identifying Assembly, Rescue points Medical Facilities.<br />
• Formulation of plan and of emergency sources.<br />
• Training, Rehearsal & Evaluation.<br />
• Action on Site.<br />
Earlier, a detailed Hazard Analysis and Risk Assessment was carried out on hazards and<br />
their likely locations and consequences are estimated following the standard procedure.<br />
However the causing factors for above discussed end results may be different and causing<br />
factors are not discussed in this plan.<br />
8.5 EMERGENCIES IDENTIFIED<br />
Emergencies that may be likely at bulk fuel storage area, process plant, cylinder storage<br />
area, and drum storage shed, and autoclave reactor area. There are chances of fire and<br />
explosive only.<br />
8.6 OTHERS<br />
Other risks are earthquake, lightning, sabotage, bombing etc., which are usually, not in the<br />
purview of management control.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 123<br />
HSE Department Rev. : 00
8.7 EMERGENCY ORGANISATION.<br />
Plant organization is enclosed. Based on the plant organization, which includes shift<br />
organization, an Emergency Organization is constituted towards achieving objectives of<br />
this emergency plan.<br />
Plant Manager is designated as Overall in Charge and is the Site <strong>Control</strong>ler.<br />
The following are designated as Incident <strong>Control</strong>lers for respective areas under their<br />
control. Shift in charge Engineer (Plant Operations) is designated at Incident <strong>Control</strong>ler for<br />
all areas of plant.<br />
8.8 EMERGENCY FACILITIES<br />
8.8.1 EMERGENCY CONTROL CENTRE (ECC)<br />
It is a location, where all key personnel like Site <strong>Control</strong>ler, Incident <strong>Control</strong>ler etc. can<br />
assemble in the event of onset of emergency and carry on various duties assigned to them.<br />
Plant Manager’s Office is designated as Emergency <strong>Control</strong> Centre. It has P&T telephone<br />
as well as internal telephones, ECC is accessible from plant located considerably away<br />
from process plant, Storage’s and on evaluation of other locations, Plant Manager’s Room<br />
find merit from the distance point of view, communication etc.<br />
8.8.2 FACILITIES PROPOSED TO BE MAINTAINED AT EMERGENCY CONTROL<br />
CENTRE (ECC)<br />
The following facilities and information would be made available at the ECC<br />
• Latest copy of Onsite Emergency Plan and off sites Emergency Plan (as provided by<br />
District Emergency Authority).<br />
• Intercom Telephone.<br />
• P&T Telephone.<br />
• Telephone directories (Internal, P&T)<br />
• Factory Layout, Site Plan<br />
• Plans indicating locations of hazardous inventories, sources of safety equipment,<br />
hydrant layout, location of pump house, road plan, assembly points, vulnerable zones,<br />
escape routes.<br />
• Hazard chart.<br />
• Emergency shut-down procedures.<br />
• Nominal roll of employees.<br />
• List and address of key personnel<br />
• List and address of Emergency coordinators.<br />
• List and address of first aides,<br />
• List and address of first aid fire fighting employees,<br />
• List and address of qualified Trained persons.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 124<br />
HSE Department Rev. : 00
8.8.3 FIRE FIGHTING FACILITIES.<br />
• Internal hydrant system<br />
• Portable extinguishers<br />
8.8.4 FIRE PROTECTION SYSTEMS<br />
These systems are proposed to protect the plant by means of different fire protection<br />
facilities and consist of<br />
• Hydrant system for exterior as well as internal protection of various buildings/areas of<br />
the plant.<br />
• Portable extinguishers and hand appliances for extinguishing small fires in different<br />
areas of the plant.<br />
• Water cum foam monitor to be provided in bulk fuel storage area.<br />
• Fire water pumps.<br />
• Two (2) independent motor driven pumps each of sufficient capacity and head are<br />
proposed for the hydrant systems which is capable to extinguish Fire or cooling<br />
purpose.<br />
8.8.5 HYDRANT SYSTEM.<br />
Adequate number of fire hydrants and monitors will be provided at various locations in and<br />
around the buildings and other plant areas. The hydrants will be provided on a network of<br />
hydrant mains drawing water from the hydrant pump, which starts automatically due to<br />
drop of pressure in the event of operating the hydrant valves. We are suggesting you to go<br />
for TAC approved hydrant system for foolproof safety and benefit from fire policy<br />
premium.<br />
8.9 EMERGENCY ESCAPES<br />
The objective of the emergency escape is to escape from the hazardous locations, to the<br />
nearest assembly point or the other safe zone, for rescue and evacuation.<br />
8.10 ASSEMBLY POINT.<br />
Assembly point is location, where, persons unconnected with emergency operations would<br />
proceed and await for rescue operation.<br />
8.11 WIND SOCK.<br />
Wind socks for knowing wind direction indication would be provided at a suitable location<br />
to visible from many locations. It is proposed to install windsocks at E.O storage area and<br />
Administration Building so as to be visible from different locations in the plant.<br />
8.12 EMERGENCY TRANSPORT.<br />
Emergency Ambulance would be stationed at the Administration Office and round the<br />
clock-driver would be made available for emergency transportation of injured etc.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 125<br />
HSE Department Rev. : 00
However, the other vehicles of the company also would be available for emergency<br />
services.<br />
8.13 EMERGENCY COMMUNICATION.<br />
There are two kinds of communication system provided.<br />
(a) Regular P&T phones with intercom facility.<br />
(b) Mobile phone<br />
8.14 WARNING/ALARM/COMMUNICATION OF EMERGENCY<br />
The emergency would be communicated by operating electrical siren for continuously for<br />
five minutes with high and low pitch mode.<br />
8.15 EMERGENCY RESPONSIBILITIES:<br />
Priority of Emergency Protection.<br />
• Life safety<br />
• Preservation of property<br />
Restoration of the normalcy<br />
8.16 MUTUAL AID<br />
While necessary facilities are available and are updated from time to time, sometimes, it<br />
may be necessary to seek external assistance; it may be from the neighboring factories or<br />
from the State Government as the case may be.<br />
8.17 MOCK DRILL<br />
Inspite of detailed training, it may be necessary to try out whether, the OSEP works out<br />
and will there be any difficulties in execution of such plan. In order to evaluate the plan<br />
and see whether the plan meets the objectives of the OSEP, occasional mock drills are<br />
contemplated. Before undertaking the drill, it would be very much necessary to give<br />
adequate training to all staff members and also information about possible mock drill.<br />
After few pre-informed mock drills, few UN-informed mock drills would be taken. All<br />
this is to familiarize the employees with the concept and procedures and to see their<br />
response. These scheduled and unscheduled mock drills would be conducted during shift<br />
change, public holidays, in night shift etc. To improve preparedness once in 6 months and<br />
performance is evaluated and Site <strong>Control</strong>ler maintains the record. Incident <strong>Control</strong>ler (IC)<br />
coordinates this activity.<br />
Prepared By M/s. <strong>Kutch</strong> <strong>Chemical</strong> <strong>Industries</strong> <strong>Limited</strong> Page : 126<br />
HSE Department Rev. : 00