ANNEXURE – 22 RISK ASSESSMENT REPORT

ANNEXURE – 22

RISK ASSESSMENT REPORT

FOR

PROPOSED CHANGE IN PRODUCT MIX FOR BULK DRUGS ANDINTERMEDIATES MANUFACTURING UNIT

AT

KIADB Industrial Area,VILLAGE: JIGANITALUK: ANEKAL

DISTRICT: BENGALURU, URBANSTATE: KARNATAKA

BY

M/s. ACEBRIGHT (INDIA) PHARMA PVT LTD,

(Project termed under schedule 5(f), Category ‘B’ Synthetic organic chemicals as per EIA Notification

2006 and its Amendments)

REPORT PREPARED BY

HUBERT ENVIRO CARE SYSTEMS (P) LTDCHENNAI

November, 2016

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TABLE OF CONTENTS

ABBREVIATIONS ...................................................................................................................................... 3

1 INTRODUCTION ................................................................................................................................4

2 QUANTITATIVE RISK ANALYSIS .................................................................................................. 5

3 SUMMARY OF THE RISK ANALYSIS .........................................................................................32

4 SAFETY MEASURES .....................................................................................................................33

4.1 MDC Tanks ...............................................................................................................................33

4.2 Basic Preventive & Protective Measures..............................................................................33

4.3 Storage tanks............................................................................................................................33

4.4 Reactors.....................................................................................................................................37

4.5 Pipelines ....................................................................................................................................37

5 EMERGENCY PLAN .......................................................................................................................38

5.1 Objectives ..................................................................................................................................38

5.2 Basic forms of Emergency ......................................................................................................38

5.3 Types of Emergency ................................................................................................................38

5.4 Causes of Emergency .............................................................................................................39

5.5 Safety, Health & Environment Policy ....................................................................................39

5.6 Identification of Emergency in Each Hazard Activity through Risk Analysis ...................40

5.7 Severity / Severity Mapping (Zoning Diagram)....................................................................44

5.8 Mitigation Measures Required................................................................................................48

5.9 Mitigation Measures Possessed / Proposed by the Industries .........................................49

5.10 Emergency Shutting Down Procedure..................................................................................53

5.11 Identification of Mutual Aid Partners......................................................................................53

5.12 Identification of Resource Suppliers (Both Public & Private).............................................53

5.13 Emergency Transport Facility.................................................................................................54

5.14 Control Room ............................................................................................................................54

5.15 Alert Action Plan during Working & Nonworking Hours .....................................................56

5.16 On Site Emergency Planning .................................................................................................59

5.17 Offsite Emergency Plan...........................................................................................................67

5.17.1 Preamble ...............................................................................................................................67

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5.17.2 Objective ................................................................................................................................68

5.17.3 Offsite Emergency Control..................................................................................................68

5.17.4 Emergency Instruction to the General Public...................................................................68

5.17.5 Category of Alarm Systems ................................................................................................69

5.17.6 Fire Fighting System ............................................................................................................69

5.17.7 General Instruction to the Public........................................................................................70

5.17.8 Security & Police ..................................................................................................................72

5.17.9 Medical facilities in case of emergency.............................................................................74

5.17.10 Mutual Aid..........................................................................................................................75

LIST OF TABLES

Table 2-1 Chemical properties & rating .................................................................................................. 7Table 2-2 - Damages to Human Life Due to Heat Radiation...............................................................9Table 2-3 Effects Due To Incident Radiation Intensity ......................................................................... 9Table 2-4 Damage due to Overpressures ............................................................................................10Table 2-5 Pasquill – Giffard Atmospheric Stability..............................................................................14Table 2-6 Distribution of stability Class.................................................................................................15Table 2-7 Atmospheric data (Manual Input).........................................................................................15Table 2-8 Details of tanks .......................................................................................................................16Table 2-9 Details of pipelines .................................................................................................................17Table 2-10 Summary of pipeline results ...............................................................................................18Table 5-1 Activity / area wise hazards, affected workers, precautions and preparedness...........41Table 5-2 Fire and Explosion Index for Cyclization Reaction............................................................44Table 5-3 Fire and Explosion Index for Condensation Reaction ......................................................45Table 5-4 Fire and Explosion Index for Hydrolysis Reaction.............................................................47Table 5-5 Details of Fire Extinguishers.................................................................................................50Table 5-6 Telephone numbers of all the stake holders ......................................................................55Table 5-7 Line of Control – Responsibility & Alternative Line of Control.........................................59Table 5-8 Emergency Telephone Numbers .........................................................................................71Table 5-9 Hospitals list in case of emergency .....................................................................................74Table 5-10 List of industries nearby with phone numbers .................................................................75

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LIST OF FIGURES

Figure 2-1 Dispersion of vapor cloud from Ethanol line .....................................................................21Figure 2-2 Jet Fire from Rupture of Ethanol Line................................................................................21Figure 2-3 Late Pool fire from Rupture of Ethanol Line......................................................................22Figure 2-4 Flash Fire from Rupture of Ethanol Line ...........................................................................23Figure 2-5 Dispersion of vapor cloud from Methanol line ..................................................................23Figure 2-6 Jet Fire from Rupture of methanol line ..............................................................................23Figure 2-7 Late Pool fire from Rupture of methanol line ....................................................................24Figure 2-8 Flash Fire from Rupture of methanol line..........................................................................25Figure 2-9 Dispersion of vapor cloud from rupture of Isopropyl Alcohol line ..................................25Figure 2-10 Jet Fire from Rupture of isopropyl alcohol line...............................................................25Figure 2-11 Late Pool fire from Rupture of isopropyl alcohol line.....................................................26Figure 2-12 Flash Fire from Rupture of isopropyl alcohol line ..........................................................27Figure 2-13 Dispersion of vapor cloud from the rupture of Toulene Pipeline .................................27Figure 2-14 Jet Fire from Rupture of Toluene line ..............................................................................27Figure 2-15 Late Pool fire from Rupture of Toluene line....................................................................28Figure 2-16 Flash Fire from Rupture of Toluene line..........................................................................29Figure 2-17 Dispersion of vapor cloud from rupture of acetone line ................................................29Figure 2-18 Jet Fire from Rupture of acetone line ..............................................................................30Figure 2-19 Late Pool fire from Rupture of acetone line ....................................................................30Figure 2-20 Flash Fire from Rupture of acetone line..........................................................................31Figure 4-1 Site Layout .............................................................................................................................34Figure 4-2 Product Storage Facility at Production Block – 01 (Warehouse Layout) .....................35Figure 4-3 Product Storage Facility at Production Block – 01 (Warehouse Layout) .....................36Figure 5-1 Emergency Alert Action Plan for Working hours..............................................................58Figure 5-2Emergency Organization Chart............................................................................................59

ABBREV IATIONS

MDC Methylene Di Chloride

API Active Pharmaceutical Ingredients

KIADB Karnataka Industrial Areas Development Board

ALARP As Low As Reasonably Practical

BLEVE Boiling Liquid Expanding Vapor Explosion

TNO Thai National Observatory

VCE Vapor Cloud ExplosionNFPA National Fire Protection AgencyLFL Lower Flammability LimitAAQ Ambient Air Quality

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1 INTRODUCTION

1.1 INTRODUCTION

M/s. Acebright (India) Pharma Pvt. Ltd. is positioned to become one of leading Pharmaceuticals

Manufacturing and Exporting Company in India.

In line with the Market Demand M/s. Acebright (India) Pharma Pvt. Ltd. Proposes for a change

of product mix, presently manufacturing 6 Nos. products in which 4 existing products will be

stopped and 2 Nos. existing products are continued and 25 new products will be included within

the existing premises with no overall change in production quantity of Active Pharmaceutical

Ingredients (APIs).

The Consequence Risk Analysis is been carried out for the Proposed change in product mix of

Acebright which is located in KIADB Industrial Area, Jigani village, Anekal Taluk, Bangalore

District and Karnataka State. Based on the available studies & plant layout the potential

scenarios which can cause significant consequences like fire and explosion scenarios were

identified. The consequences of the scenarios were assessed using the software PHAST 7.01

and analysis is carried by Hubert Enviro Care Systems Pvt Ltd, Chennai consultant.

The purpose of the study includes the following:

To identify and assess those hazards and risks with NFPA rating.

To eliminate or reduce to As Low As Reasonably Practical (ALARP) in terms of risk to

human health, risk of injury, risk of damage to plant, equipment and environment,

business interruption or loss etc.,

To Suggest On-site and Off-site mitigative Measures.

1.2 SCOPE OF STUDY

The main scope of the study is to carry out Quantitative Risk Analysis study as per The Indian

Standard IS 15656: Code of practice - Hazard Identification and Risk Analysis

- Identification of hazards

- Consequence Modelling

- Contour Mapping on Site Google Earth image

- Damage Distance identification & Quantification of risk

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2 QUANTITATIVE RISK ANALYS IS

2.1 HAZARD IDENTIFICATION

Hazards will be identified based upon consideration of factors such as the physical & chemical

properties of the fluids being handled, the arrangement of equipment & maintenance

procedures and processing conditions.

2.1.1 Selection

The goal of selection is to limit the total number of incident outcome cases to be studied to a

manageable size. The purpose of incident outcome selection is to develop a set of incident

outcomes that must be studied for each incident included in the finalized incident study list.

Each incident needs to be considered separately. Using the list of incident outcomes the risk

analyst needs to determine which may result from each incident. While the analyst can decide

whether an incident involving the loss of a process chemical to the atmosphere needs to be

examined using dispersion analysis because of potential toxic gas effects, what happens if the

same material is immediately ignited on release. Based on the NFPA rating the chemicals

ranked 3 and 4 in the scale of 0-4 are selected for the consequence analysis.

2.1.2 Characterising t he Failures

Accidental release of flammable or toxic vapors can result in severe consequences. Delayed

ignition of flammable vapors can result in blast overpressures covering large areas. This may

lead to extensive loss of life and property. Toxic clouds may cover yet larger distances due to

the lower threshold values in relation to those in case of explosive clouds (the lower explosive

limits). In contrast, fires have localized consequences. Fires can be put out or contained in most

cases; there are few mitigating actions one can take once a vapor cloud gets released. Major

accident hazards arise, therefore, consequent upon the release of flammable or toxic vapors or

BLEVE in case of pressurized liquefied gases. In an industry, main hazard arises due to storage

and handling of hazardous chemicals. To formulate a structured approach to identification of

hazards and understanding of contributory factors is essential.

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2.1.3 Blast Overpressures

Blast Overpressures depend upon the reactivity class of material and the amount of gas

between two explosive limits. The hydrocarbon that is expected to give rise to a vapor cloud on

release is pressurized gases.

2.1.4 Inventory

Inventory Analysis is commonly used in understanding the relative hazards and shortlisting of

release scenarios. Inventory plays an important role in regard to the potential hazard. Larger the

inventory of a vessel or a system, larger the quantity of potential release. A practice commonly

used to generate an incident list is to consider potential leaks and major releases from fractures

of pipelines and vessels containing sizable inventories. The potential vapor release (source

strength) depends upon the quantity of liquid release, the properties of the materials and the

operating conditions (pressure, temperature). If all these influencing parameters are combined

into a matrix and vapor source strength computed for each release case, a ranking should

become a credible exercise.

Loss of Containment

Liquid Release may be instantaneous. Failure of a vessel leading to an instantaneous outflow

assumes the sudden appearance of such a major crack that practically all of the contents above

the crack shall be released in a very short time.

The more likely event is the case of liquid release from a hole in a pipe connected to the vessel.

The flow rate will depend on the size of the hole as well as on the pressure in front of the hole,

prior to the accident. Such pressure is basically dependent on the pressure in the vessel.

The vaporization of released liquid depends on the vapor pressure and weather conditions.

Such consideration and others have been kept in mind both during the initial listing as well as

during the short listing procedure. Initial listing of all significant inventories in the process plants

was carried out. This ensured no omission through in advertence.

2.2 FACTORS CONSIDERED FOR IDENTIFICATION OF HAZARDS

The National Fire Protection Agency (NFPA) is responsible for 380 codes and standards that

are designed to minimize the risk and effects of fire by establishing criteria for building,

7

processing, design, service and installation. NFPA provides standard for the chemicals to

reduce the risk of fire and other hazards which are mentioned in Table 2-1.

Table 2-1 Chemical properties & rating

S.No. Materials Boiling Point(oC) NFPA- Health NFPA- Fire NFPA-Stability

1. High Speed Diesel 110to 375 1 2 0

2. Ethanol 78.2- 78.5 2 3 0

3. Methanol 64.5 2 3 0

4. Isopropyl Alcohol 82.5 2 3 0

5. Isopropyl Acetate 89 1 3 0

6. Ethyl Acetate 77 2 3 0

7. Toluene 110.6 2 3 08. Acetone 56.2 2 3 0

9. Furnace Oil 185-500 2 2 0

10. Methylene dichloride(MDC) 39.75 2 1 0

As per the NFPA Rating on the scale from 0-4 the chemicals having 3 & 4 are considered are

highly hazardous and considered for analysis. From the above list it is observed that all the

chemicals are having fire hazard except MDC, HSD and FO exhibit a minor fire hazard. No

chemical causes a toxic health hazard.

2.3 RISK ANALYSIS CALCULATIONS

2.3.1 Damage Criteria

In consequence analysis, use is made of a number of calculation models to estimate the

physical effects of an accident (spill of hazardous material) and to predict the damage (lethality,

injury, material destruction) of the effects. The calculations can roughly be divided in three major

groups:

Determination of the source strength parameters;

Determination of the consequential effects;

Determination of the damage or damage distances.

The basic physical effect models consist of the following.

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2.3.2 Source Strength Parameters

Calculation of the outflow of liquid out of a tank or pipe, in case of rupture.

Calculation, in case of liquid outflow, of the instantaneous flash evaporation and of the

dimensions of the remaining liquid pool.

Calculation of the evaporation rate, as a function of volatility of the material, pool

dimensions and wind velocity.

Source strength equals pump capacities, etc. in some cases of pump discharge line

ruptures for catastrophic cases.

2.3.3 Consequential effects

Dispersion of gaseous material in the atmosphere as a function of source strength, relative

density of the gas, weather conditions and topographical situation of the surrounding area.

Intensity of heat radiation [in kW/ m2] due to a fire, as a function of the distance to the

source.

Concentration of gaseous material in the atmosphere, due to the dispersion of evaporated

chemical. The latter can be either explosive or toxic.

The type of models depend on type of materials i.e.,

Physical state

Flammability & Toxicity

Depends on Storage conditions

Type of Failure

2.3.4 Selection of Damage Criteria

The damage criteria give the relation between extent of the physical effects (exposure) and

the percentage of the people that will be killed or injured due to those effects. For instance,

much more is known about the damage caused by heat radiation, than about the damage

due to toxic exposure, and for these toxic effects, the knowledge differs strongly between

different materials. In Consequence Analysis studies, in principle three types of exposure to

hazardous effects are distinguished:

1. Heat radiation, from a jet, pool fire or flash fire.

2. Explosion

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3. Toxic effects, from toxic materials or toxic combustion products.

Heat Radiation

The consequence caused by exposure to heat radiation is a function of:

• The radiation energy onto the human body [kW/m2];

• The exposure duration [sec];

• The protection of the skin tissue (clothed or naked body).

The limits for 1% of the exposed people to be killed due to heat radiation, and for second-

degree burns are given in Table 2-2.

Table 2-2 - Damages to Human Lif e Due to Heat Radiation

Exposure

Duration

Radiation energy(1%

lethality,kW/m2

Radiationenergyor 2nddegree

burns, kW/m2Radiation energyfor first

degreeburns, kW/m2

10 sec 21.2 16 12.5

30 sec 9.3 7 4

Since in practical situations, only the people outside will be exposed to heat radiation in case of

a fire, it is reasonable to assume the protection by clothing. It can be assumed that people

would be able to find a cover or a shield against thermal radiation in 10-sec. time. Furthermore,

100% lethality may be assumed for all people suffering from direct contact with flames, such as

the pool fire, a flash fire or a jet flame. The effects due to relatively lesser incident radiation

intensity are given Table 2-3.

Table 2-3 Effects Due To Incident Radiation Intensity

Incident Radiation–Kw/m2 Type of Damage

0.7 Equivalent to Solar Radiation

1.6 No discomfort for long exposure

4.0 Sufficient to cause pain within20 sec. Blistering of skin (first degree burnsare likely)

9.5 Pain threshold reached after 8 sec. second degree burns after 20 sec.

12.5 Minimum energy required for piloted ignition of wood, melting plastic tubing’s etc.,

18.47 Sufficient to cause damage

37.5 Heavy Damage to process equipment

*Source - Purple book from TNO, Netherlands.

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Explosion

In case of vapour cloud explosion, two physical effects may occur:

Flash fire over the whole length of the explosive gas cloud;

A blast wave, with typical peak overpressures circular around ignition source.

As explained above, 100% lethality is assumed for all people who are present withinthe

cloud proper.

For the blast wave, the lethality criterion is based on:

Peak overpressure of 0.1 bar will cause serious damage to 10% of the

housing/structures.

Falling fragments will kill one of each eight persons in the destroyed buildings.

The damage criteria may be distinguished with respect to the peakoverpressures resulting from

a blast wave: the detailed damage list is mentioned in Table 2-4.

Table 2-4 Damage due to Overpressures

Peak Overpressure Damage Type Description

0.83 bar Total Destruction TotalDestruction of plantequipmentstructure

0.20 bar Heavy Damage Major damage to plant equipmentstructure

0.10 bar Moderate Damage Repairable damage to plant equipment

&structure

0.03 bar Significant Damage Shattering of glass

0.01 bar Minor Damage Crack in glass

*Source: Green book from TNO, Netherlands.

2.3.5 Fire And Explosion Modelling

Jet Fire

Jet fires are burning jets of gas or atomized liquid whose shape is dominated by the momentum

of the release. The consequence of the jet fire is directional depending on the release

orientation. Jet fires typically have flame temperature of 2200 degree can produce high intensity

thermal radiation. The jet flame stabilizes on or close to the point of release and continues until

the release is stopped. Jet fires could occur during unloading or transfer operations when

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pressures are increased by compressors. Such fires could cause severe damage but will

generally affect only the local area.

If compressed or liquefied gases are related from storage tanks or pipelines, the materials

discharging through the hole will form a gas jet that entrains and mixes with the ambient air. If

the material encounters an ignition sources while it is in the flammable range, a jet fire may

occur. Jet fires could occur during unloading operations when pressures are increased by

pumping. Such fires could cause severe damage but will generally affect only the local area.

The effect of jet flame impingement is severe as it may cut through equipment, pipeline or

structure. The damage effect of thermal radiation is depended on both the level of thermal

radiation and duration of exposure.

Flash Fire

When a volatile, flammable material is released to the atmosphere, a vapor cloud forms and

disperses (mixes with air). If the resultant vapor cloud is ignited before the cloud is diluted below

its LFL, a flash fire may occur. The combustion normally occurs within only portions of the vapor

cloud (where mixed with air in flammable concentrations), rather than the entire cloud. A flash

fire may burn back to therelease point, resulting in a pool or jet fire but is unlikely to generate

damaging over pressures (explode) when unconfined.

A flash fire occurs when a cloud of vapor/gas burns without generating any significant

overpressure. The cloud is typically ignited on its edge, remote from the leak source. The

combustion zone moves through the cloud away from the ignition point. The duration of the

flash fire is relatively short but it may stabilize as a continuous jet fire from the leak source. For

flash fires, an approximate estimate for the extent of the total effect zone is the area over which

the cloud is above the LFL. It is assumed that this area is not increased by cloud expansion

during burning.

Fire Ball (BLEVE)

BLEVE stands for Boiling Liquid Expanding Vapor Explosion. Sometimes referred to as a

fireball, a BLEVE is a combination of fire and explosion with an intense radiant heat emission

within a relatively short time interval. As implied by the term, the phenomenon can occur within

a vessel or tank in which a liquefied gas is kept above its atmospheric boiling point.

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It is the result of a liquid within a container reaching a temperature well above its boiling point at

atmospheric temperature, causing the vessel to rupture into two or more pieces. BLEVE can be

defined as a rapid failure of a container of flammable material under pressure during fire

engulfment. Failure is followed by a fireball or major fire which produces a powerful radiant-heat

flux.

BLEVE can occur when fire impinges on the tank shell at a point or points above the liquid level

of the contents of the tank. This impingement causes the metal to weaken and fail from the

internal pressure. A fireball is an intense spherical fire resulting from a sudden release of

pressurized gas which is immediately ignited, burning as it expand forming a ball of fire, rising in

the air. When this cloud is ignited, a fireball occurs, causing enormous heat-radiation intensity

within a few seconds. This heat intensity is sufficient to cause severe skin burns and deaths at

several hundred meters from the vessel, depending on the quantity of the gas involved. When a

BLEVE occurs, debris may travel hundreds of feet, with tremendous force, and the escaping

fuel can ignite causing an expanding fireball.

Explosions

Explosions are characterized by a shock-wave which can be heard as a bang and which can

cause damage to buildings, breaking windows and ejecting missiles over distances of several

hundred meters. The injuries and damage are in the first place caused by the shock-wave of the

explosion itself. People are blown over or knocked down and buried under collapsed buildings

or injured by flying glass. Although the effects of over-pressure can directly result in deaths, this

would be likely to involve only those working in the direct vicinity of the explosion. The history of

industrial explosions shows that the indirect effects of collapsing buildings, flying glass and

debris cause far more loss of life and severe injuries.

Vapor Cloud Explosion

Generally catastrophic gas explosions happen when considerable quantities of flammable

material are released and dispersed with air to form an explosive vapor cloud before ignition

takes place.

A Vapor Cloud Explosion (VCE) occurs if a cloud of flammable gas burns sufficiently quickly to

generate high overpressures (i.e., pressures in excess of ambient).

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The following main types of explosion can be distinguished.

Confined explosions where the burning gas is largely confined, typically inside a largely

empty enclosed tank or building.

Semi-confined explosions where the gas is partly confined, typically in an offshore

process module therefore not considered for this study.

Unconfined explosions where the gas cloud is largely unconfined, typically on an

onshore installation, but there are sufficient obstacles to generate turbulence and start

the build-up of pressure.

Toxic gas release

In case of release of toxic gas, when a gas that is heavier than air is released, it initially behaves

very differently from a neutrally buoyant gas. The heavy gas will first "slump," or sink, because it

is heavier than the surrounding air. As the gas cloud moves downwind, gravity makes it spread;

this can cause some of the vapor to travel upwind of its release point. Farther downwind, as the

cloud becomes more diluted and its density approaches that of air, it begins behaving like a

neutrally buoyant gas.

This takes place when the concentration of heavy gas in the surrounding air drops below about

1 percent (10,000 parts per million). For many small releases, this will occur in the first few

yards (meters). For large releases, this may happen much further downwind.

2.3.6 Weather Data

For this study weather conditions pertaining to Acebright are considered as per the (IMD

Climatological for Bangalore Region 1971 – 2000), Predominant wind direction is West to East.

Wind Speed

The mean wind Speed is taken as around 1.4 to 4.6 m/s. (IMD Climatological for Bangalore

Region 1971 – 2000).

Temperature

The annual mean of maximum and minimum temperature are 34°C and 14.2°C respectively.

The annual average temperature is min 18.2 – max 29.4 °C (IMD Climatological for Bangalore

Region 1971 – 2000).

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Stability class

Dispersion of gases or vapor largely depends upon the Stability Class. Various stability classes

that are defined by Pasquill – Giffard are mentioned in Table 2-5.

Table 2-5 Pasquill – Giffard Atmospheric Stability

S.No. Stability Class Weather Conditions

1 A Very Unstable- sunny, light wind

2 A/B Unstable- as with A only less sunny or more windy

3 B Unstable- as with A/B only less sunny or more windy

4 B/C Moderately unstable–Moderate sunny and moderate wind

5 C Moderately unstable–very windy / sunny or overcast / light wind

6 C/D Moderate unstable–Moderate sun and high wind

7 D Neutral– little sun and high wind or overcast / windy night

8 E Moderately stable– less overcast and less windy nightthan D

9 F Stable–night with moderate clouds and light/ moderate wind

10 G Very stable–possibly fog

Low wind speed corresponds with 1 – 2 m/s

Medium wind speed corresponds with 3 – 5 m/s

High wind speed corresponds with 8 - 9 m/s

The stability class for a particular location is generally dependent upon:

Time of the Day (Day or Night)

Cloud Cover

Season

Wind Speed

Wind speed does not influence consequences as much as stability class and for a given stability

class, the influence of wind speed is relatively less. On the other hand consequences vary

considerably with stability class for the same speed. Except during the monsoon months little or

no cloud cover along with the prevailing low wind velocities results in unstable conditions during

the day (C or D) and highly stable conditions (E or F) at night. During the four months of

monsoon the wind velocities are generally higher and cloud cover generally present. This

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results instability class of D during the day and E or F during the night. The stability class

distribution over the year roughly works out as mentioned in Table 2-6:

Table 2-6 Distribution of stability Class

Stability Class Distribution (%)

A - B – C 17%

D 50%

E or F 33%

The atmospheric data in the site as mentioned in Table 2-7 are used for Quantified Risk

Analysis:

Table 2-7 Atmospheric data (Manual Input)

*Source- Annual IMD climatology data (1971 -2000)

2.3.7 Accident Scenarios For t his Project

2.3.7.1 Tank Scenarios

The storage tank details with properties are mentioned in Table 2-8.

S.No Parameters Case

1. Wind Speed (Km/hr) Min : 5.1

Avrge : 9.2

Max : 16.9

2. Wind Direction W to E

3. Average Temperature (0c) Min 18.2 – Max 29.4

4. Relative Humidity 28 to 88%

Considered: 62%

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Table 2-8 Details of tanks

S.No Chemical No. of

Tanks

Dia

(m)

Height

(m)

Volume

(m3)

Internal

Pressure

(kg/cm2)

Type of

storage

Internal

Temp

(0c)

Physical State

1. MDC 1 2.2 2.75 10.44 1 Above

Ground

in

drums

30 Liquid

2. Furnace

oil

1 2.7 3.78 21.63 1 Above

Ground

30 Flammable liquid

3. High

Speed

Diesel

1 2.5 5 24.53 1 Under

Ground

30 Liquid/Flammable

solvent

4. Ethanol 1 2.5 5 24.53 1 Under

Ground

30 Liquid/Flammable

solvent

5. Methanol 2 2.5 5 24.53 1 Under

Ground

30 Liquid/Flammable

solvent

6. Isopropyl

Alcohol

2 2.5 5 24.53 1 Under

Ground

30 Liquid/Flammable

solvent

7. Isopropyl

Acetate

1 2.5 5 24.53 1 Under

Ground

30 Liquid/Flammable

solvent

8. Ethyl

Acetate

1 2.5 5 24.53 1 Under

Ground

30 Liquid

/Flammable

solvent

9. Toluene 1 2.5 5 24.53 1 Under

Ground

30 Liquid/Flammable

solvent

10. Acetone 2 2.5 5 24.53 1 Under

Ground

30 Liquid/Flammable

solvent

From the Table 2-8 list only the MDC and furnace oil is stored above ground. Both the

chemicals exhibit very minor fire hazard. Remaining all the chemicals are flammable solvents

but are stored underground where the impacts become negligible. None of the above list of

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chemicals exhibits toxic health hazard. Due to this reason none of the storage tanks are

considered for risk analysis.

2.3.7.2 Consequence analysis of pipelines

The storage tanks area connected through pipelines from the storage area to further process

area. The pipeline details are mentioned in Table 2-9.

Table 2-9 Details of pipeline s


pipelines

Dia (m) Length

(m)

Internal

Pressure

(kg/cm2g)

Internal

Temp (0c)

Source

1. MDC 1 0.0254 8 1 30 Drum storage area to

production block

through Air-operated

double diaphragm

(AODD) pump

2. Furnace oil* 1 0.0254 80 1 30 FO storage areato

Utility block

3. High Speed

Diesel

1 0.0254 30 1 30 Underground solvent

tank yard to

dispensing area

4. Ethanol 1 0.0254 30 1 30 Underground solvent

tank yard to

dispensing area

5. Methanol 2 0.0254 30 1 30 Underground solvent

tank yard to

dispensing area

6. Isopropyl

Alcohol


tank yard to

dispensing area

7. Isopropyl

Acetate


tank yard to

dispensing area

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pipelines

Dia (m) Length

(m)

Internal

Pressure

(kg/cm2g)

Internal

Temp (0c)

Source

8. Ethyl Acetate 1 0.0254 30 1 30 Underground solvent

tank yard to

dispensing area

9. Toluene 1 0.0254 30 1 30 Underground solvent

tank yard to

dispensing area

10. Acetone 2 0.0254 30 1 30 Underground solvent

tank yard to

dispensing area

From FO lorry platform to FO storage tank only 2m hose connected with pump to unload the FOfrom lorry to tank.

MDC and FO exhibits very minor fire hazard so the chemicals are not considered for analysis.

Note: All the other UG stored chemicals are unloaded with underground suction pipelines fromlorry platform.

The consequence analysis is performed for pipelines and the results are mentioned in Table

2-10.

Table 2-10 Summary of pipeline results

S.No Description Event Impact criteria

Consequence Distance (m)

Category

1.5/F

Category

1.5/D

Category

5/D

1. Rupture of

Ethanol

Pipeline

Dispersion ofvapor

cloud

UFL (190000) ppm2.81903 2.1846 2.71371

LFL (43000) ppm 3.059 3.92212 3.34716

LFL Frac(21500)

ppm

3.12 4.01841 3.48314

Jet fire 4 kW/m2 NR NR NR

12.5 kW/m2 NR NR NR

37.5 kW/m2 NR NR NR

Late Pool fire 4 kW/m2 7.59717 9.46462 7.70752

19



Category

1.5/F

Category

1.5/D

Category

5/D

12.5 kW/m2 5.02637 7.16629 5.35747

37.5 kW/m2 NR NR NR

Flash Fire 21500 ppm 3.12819 4.01841 3.48314

43000 ppm 3.05922 3.92212 3.34716

2. Rupture of

methanol

Pipeline

Dispersion of vapour

cloud

UFL (360000)ppm2.54219 1.76355 2.31166

LFL (73000) ppm 3.03409 3.86389 3.2996

LFL Frac (36500)

ppm

3.11134 4.00395 3.44961


12.5 kW/m2 NR NR NR

37.5 kW/m2 NR NR NR


12.5 kW/m2 4.57277 6.01647 4.76603

37.5 kW/m2 NR NR NR

Flash Fire 36500 ppm 3.11134 4.00395 3.44961

73000 ppm 3.03409 3.86389 3.2996

3. Rupture of

Isopropyl

Alcohol

Pipeline

Dispersion ofvapor

cloud

UFL (120000)ppm2.88432 2.49218 2.94748

LFL (20000) ppm 3.1171 4.00592 3.45713

LFL Frac (10000)

ppm

3.1768 4.043 3.5755


12.5 kW/m2 NR NR NR

37.5 kW/m2 NR NR NR


12.5 kW/m2 5.8164 8.39655 6.14723

37.5 kW/m2 4.5909 6.02559 4.77875

Flash Fire 10000 ppm 3.1768 4.043 3.5755

20000 ppm 3.1171 4.00592 3.45713

4. Rupture of

Toulene

Dispersion ofvapor

cloud

UFL (71000)ppm 2.83739 2.62469 2.98067

LFL (12000) ppm 3.03947 3.96454 3.42077

20



Category

1.5/F

Category

1.5/D

Category

5/D

Pipeline LFL Frac (6000)

ppm

3.09479 4.03167 3.53419

Jet fire 4 kW/m2 NR 3.0648 3.662

12.5 kW/m2 NR NR NR

37.5 kW/m2 NR NR NR


12.5 kW/m2 9.473 12.16 9.595

37.5 kW/m2 5.1908 7.491 5.494

Flash Fire 6000 ppm 3.09479 4.031 3.53419

12000 ppm 3.03947 3.96454 3.42077

5. Rupture of

acetone

Pipeline

Dispersion ofvapor

cloud

UFL (128000)ppm2.87774 2.39828 2.90755

LFL (26000) ppm 3.11234 3.98103 3.43336

LFL Frac (13000)

ppm

3.17917 4.03342 3.56367

Jet fire 4 kW/m2 12.635 10.7801 12.9043

12.5 kW/m2 NR 7.04655 NR

37.5 kW/m2 NR NR NR


12.5 kW/m2 6.07897 8.91171 6.46701

37.5 kW/m2 4.551 5.99576 4.74722

Flash Fire 13000ppm 3.17917 4.03342 3.56367

26000 ppm 3.11234 3.98103 3.43336

The contour maps for the consequence analysis of pipelines are mentioned below for each case

of hazard separately.

21

Scenario -1 Rupture of Ethanol line from UG Tank to Dispensing area

Case-1 Dispersion of vapor cloud from Ethanol line

Ethanol pipeline is connected from Underground solvent tank yard to dispensing area where the dispersion of vapor cloud is analyzed for

different wind directions. The image for 1.5m/s wind speed / F stability class is shown in

Figure 2-1.

Figure 2-1 Dispersion of vapor cloud from Ethanol line

Case-2 Jet Fire from Rupture of Ethanol Line

Ethanol pipeline is connected from Underground solvent tank yard to dispensing area where the jet Fire is analyzed for different wind

directions. The image for 1.5m/s wind speed / F stability class is shown in

Figure 2-2where the impact is very minimum and not reached the risk zone.

Figure 2-2 Jet Fire from Rupture of Ethanol Line

Case-3 Late Pool fire from Rupture of Ethanol Line

Ethanol pipeline is connected from Underground solvent tank yard to dispensing area where the Late pool Fire is analyzed for different wind

directions. The Graph and GIS image for 1.5m/s wind speed / F stability class is shown in

Figure 2-3 where the ethanol travels to a distance of 7.59m.

22

Figure 2-3 Late Pool fire from Rupture of Ethanol Line

Case-4 Flash Fire from Rupture of Ethanol Line

Ethanol pipeline is connected from Underground solvent tank yard to dispensing area where the Flash fire is analyzed for different wind


Figure 2-4 where the ethanol travels to a distance of 3.12 m.

Source: PHAST Software

23

Figure 2-4 Flash Fire from Rupture of Ethanol Line

Scenario -2 Rupture of Methanol line from UG Tank to Dispensing area

Case-1 Dispersion of vapor cloud from Methanol line

Methanol pipeline is connected from Underground solvent tank yard to dispensing area where the dispersion of vapor cloud is analyzed for

different wind directions. The Graph image for 1.5m/s wind speed / F stability class is shown in Figure 2-5.


Figure 2-5 Dispersion of vapor cloud from Methanol line

Case-2 Jet Fire from Rupture of methanol line

Methanol pipeline is connected from Underground solvent tank yard to dispensing area where the jet Fire is analyzed for different wind

directions. The image for 1.5m/s wind speed / F stability class is shown in

Figure 2-2where the impact is very minimum and not reached the risk zone.


24

Figure 2-6 Jet Fire from Rupture of methanol line

Case-3 Late Pool fire from Rupture of methanol line

Methanol pipeline is connected from Underground solvent tank yard to dispensing area where the Late pool Fire is analyzed for different wind

directions. The Graph and GIS image for 1.5m/s wind speed / F stability class is shown in Figure 2-7 where the ethanol travels to a distance of

6.06 m.


Source: PHAST Result superimposed on Satellite image

Figure 2-7 Late Pool fire from Rupture of methanol line

Case-4 Flash Fire from Rupture of methanol line

Methanol pipeline is connected from Underground solvent tank yard to dispensing area where the Flash fire is analyzed for different wind

directions. The Graph and GIS image for 1.5m/s wind speed / F stability class is shown in Figure 2-8 where the ethanol travels to a distance of

3.11 m.

25

Figure 2-8 Flash Fire from Rupture of methanol line

Scenario -3 Rupture of Isopropyl Alcohol line from UG Tank to Dispensing area

Case-1 Dispersion of vapor cloud from rupture of Isopropyl Alcohol line

Isopropyl Alcohol pipeline is connected from Underground solvent tank yard to dispensing area where the dispersion of vapor cloud is analyzed

for different wind directions. The Graph image for 1.5m/s wind speed / F stability class is shown in Figure 2-9.

Figure 2-9 Dispersion of vapor cloud from rupture of Isopropyl Alcohol line

Case-2 Jet Fire fr om Rupture of isopropyl alcohol line

Isopropyl Alcohol pipeline is connected from Underground solvent tank yard to dispensing area where the jet Fire is analyzed for different wind

directions. The image for 1.5m/s wind speed / F stability class is shown in Figure 2-10 where the impact is very minimum and not reached the

risk zone.

Figure 2-10 Jet Fire from Rupture of isopropyl alcohol line

26

Case-3 Late Pool fire fro m Rupture of isopropyl alcohol line

Isopropyl Alcohol pipeline is connected from Underground solvent tank yard to dispensing area where the Late pool Fire is analyzed for

different wind directions. The Graph and GIS image for 1.5m/s wind speed / F stability class is shown in Figure 2-11 where Isopropyl alcohol

travels to a distance of 8.64 m.

Figure 2-11 Late Pool fire from Rupture of isopropyl alcohol line

Case-4 Flash Fire from Rupture of isopropyl alcohol line

Isopropyl Alcohol pipeline is connected from Underground solvent tank yard to dispensing area where the Flash fire is analyzed for different

wind directions. The Graph and GIS image for 1.5m/s wind speed / F stability class is shown in Figure 2-12 where the isopropyl alcohol travels

to a distance of 3.17 m.

27

Figure 2-12 Flash Fire from Rupture of isopropyl alcohol line

Scenario -4 Rupture of Toluene line from UG Tank to Dispensing area

Case-1 Dispersion of vapor cloud from the rupture of Toulene Pipeline

Toulene pipeline is connected from Underground solvent tank yard to dispensing area where the dispersion of vapor cloud is analyzed for


Figure 2-13 Dispersion of va por cloud from the rupture of Toulene Pipeline

Case-2 Jet Fire from Rupture of Toluene line

Toluene pipeline is connected from Underground solvent tank yard to dispensing area where the jet Fire is analyzed for different wind

directions. The image for 1.5 m/s wind speed / F stability class is shown in Figure 2-14 where the impact is very minimum and not reached the

risk zone.

Figure 2-14 Jet Fire from Rupture of T oluene line

28

Case-3 Late Pool fire from Rupture of Toluene line

Toluene pipeline is connected from Underground solvent tank yard to dispensing area where the Late pool Fire is analyzed for different wind

directions. The Graph and GIS image for 1.5m/s wind speed / F stability class is shown in Figure 2-15 where Toluene travels to a distance of

13.94 m.

Figure 2-15 Late Pool fire from Rupture of Toluene line

Case-4 Flash Fire from Rupture of To luene line

Toluene pipeline is connected from Underground solvent tank yard to dispensing area where the Flash fire is analyzed for different wind

directions. The Graph and GIS image for 1.5m/s wind speed / F stability class is shown in Figure 2-16 where the toluene travels to a distance

of 3.09 m.

29

Figure 2-16 Flash Fire from Rupture of Toluene line

Scenario -5 Rupture of acetone line f rom UG Tank to Dispensing area

Case-1 Dispersion of vapor cloud from rupture of acetone line

Acetone pipeline is connected from Underground solvent tank yard to dispensing area where the dispersion of vapor cloud is analyzed for


Figure 2-17 Dispersion of vapor cloud from rupture of acetone line

Case-2 Jet F ire from Rupture of acetone line

Acetone pipeline is connected from Underground solvent tank yard to dispensing area where the jet Fire is analyzed for different wind

directions. The image for 1.5 m/s wind speed / F stability class is shown in

Figure 2-18 where the Acetone travels to a distance of 12.63 m.

.

30

Figure 2-18 Jet Fire from Rupture of acetone line

Case-3 Late Pool fire from Rupture of acetone line

Acetone pipeline is connected from Underground solvent tank yard to dispensing area where the Late pool Fire is analyzed for different wind


Figure 2-19 where Acetone travels to a distance of 9.46 m.

Figure 2-19 Late Pool fire from Rupture of acetone line

31

Case-4 Flash Fire from Rupture of acetone line

Acetone pipeline is connected from Underground solvent tank yard to dispensing area where the Flash fire is analyzed for different wind

directions. The Graph and GIS image for 1.5m/s wind speed / F stability class is shown in Error! Reference source not found. where the acetone

travels to a distance of 3.17 m.

Figure 2-20 Flash Fire from Rupture of acetone line

32

3 SUMMARY OF THE RISK ANALYSIS

1. Some of the solvents like diesel, ethanol, methanol, acetone, isopropyl alcohol, Ethyl

acetate, Isopropyl acetate and Toluene are stored Underground Storage Yard where the

impact is negligible.

2. As per the NFPA rating the solvents such as FO, MDC which are stored in above ground

exhibit very minimum fire hazard hence Risk Assessment study is not carried out.

3. As per NFPA rating none of the solvents exhibit health hazards.

4. The consequence analysis is performed for pipelines which are connected from

underground tanks to dispensary area.

5. It is observed for acetone pipeline jet fire at Minimum conc. of 4 kW/m2 radiation heat &

weather condition of 5 m/s wind speed and D stability class, the impact travels to a

distance of 12.90 m.

6. All the hazards are observed in East direction due to the wind blowing from West.

7. Safety measures for tanks and pipelines are proposed to avoid hazards.

8. In case of emergency, onsite and offsite emergency plan will be implemented as given in

5.16 & 5.17.

33

4 SAFETY MEASURES

4.1 MDC Tanks

1. If the leak in a tank, immediately transfer the content to another non leak tank.

2. Transferred tank should be compatible with the material.

3. After the material transferred, empty tank to be neutralized, washed and then taken for

service complying to work permit system.

4.2 Basic Preventive & Protective Measures

1. Adequate water supplies for fire protection. The amount/quantity of the water

requirement is based on rate of firewater required for the worst possible fire and the time

duration for which the fire will last

2. Structural design of vessels, piping, structural steel, etc.

3. Overpressure relief devices

4. Corrosion resistance and / or allowances

5. Segregation of reactive materials in process lines and equipment

6. Work permit system with strict compliance.

4.3 Storage tanks

1. Dedicated underground solvent storage area with flame proof electrical connections,

breather valve, enough jumpers and earthing & bonding facility to unload the solvent

from road tankers.

2. No ignitable zones are declared and marked so.

3. Dedicated chemical storage area with good ventilation and exhaust system and all

chemical are stored as per compatibility.

4. Dyke walls provided for the day storage chemical tanks.

5. Calibration is ensured for the gauges of pressure, temperature and vacuum.

6. Body earthing provided to all equipments involved in the process, electrical earthing,

static earthing and instrument earthing provided wherever required.

34

We are having two production blocks each consist of two line of production facility. At a time we can produce maximum of 4 products. We will produce APIs as per market demand in campaign basis

Dedicated Product storage facility is provided at PB-01 & PB-02 warehouse with good ventilation and exhaust system.

Figu re 4-1 Site Layout

35

Figure 4-2 Product Storage Facility at Production Block – 01 (Warehouse Layout)

36

Figure 4-3 Product Storage Facility at Production Block – 01 (Warehouse Layout)

37

4.4 Reactors

1. All reactors will be hydro tested and certified by the competent person once in a year.

2. All reactors provided with safety valves followed by rupture discs and relief valve outlets

are extended.

3. Nitrogen provision provided to all reactors in view of providing nitrogen blanketing during

handling of flammables.

4. Process block zones are classified as per flameproof area zonal classification and

accordingly used the flameproof electrical fittings.

5. Scrubber system with lye circulation is installed to create vapor free work environment

and to release neutralized / nontoxic fumes to the environment.

6. Touch pads are provided in all prominent places to discharge our body static electricity.

7. Wrist bands are provided to use during charging of chemicals in to reactors to avoid

static electricity.

8. Zero interlock, proximity switch and nitrogen line provision provided to all centrifuge

system to avoid personal injury and fire hazard.

9. Safety relief valve and gate limit switch provided to all RCVDs to avoid explosion and

personal injury.

10. Air handling units (AHUs) with BIBO (Bag In Bag Out) are provided to keep the work

environment in controlled manner (air flow pattern, temperature and humidity) to reduce

the exposure to chemicals.

11. Ventilation air units (VAUs) and Exhaust air units (EAUs) and are provided to ensure

good ventilation in the work environment.

12. Isolators are provided to handle potent chemicals.

13. HAZOP studies will be carried for all chemicals.

4.5 Pipelines

1. If the leak in a pipe line, immediately stop the supply to corresponding pipe line.

38

5 EMERGENCY PLAN

5.1 Objectives

a. To establish a method of systematic, safe and orderly evacuation in the least

possible time, to a safe area or by the nearest safe means of way out.

b. Control the accidents.

c. Rapid control and containment of hazardous situation.

d. Rescue and treatment of casualties.

e. Safeguard people (both at site and neighbourhood).

f. Minimize damage to property and environment.

g. Identify casualties, notify their relatives and render necessary help to them.

h. Proper training of the concerned person.

i. Prevent recurrence.

j. Be capable of dealing with largest incident that can reasonably be foreseen.

k. Have sufficient flexibility with a view to handling the emergency efficiently and

avoiding unnecessary calling outside agencies like external fire brigade.

l. HAZOP study will carried out for all new product start up, change in process and

new equipment installation, SOP has been enclosed as Part A

5.2 Basic forms of Emergency

a. Fire

b. Explosion

c. Toxic release

d. Natural disaster (earth quake, flooding, tsunami etc.)

e. A combination of more than one

5.3 Types of Emergency

5.3.1 On-site Emergency

If an accident/ incident takes place in a factory, its effects are confined to the factory premises,

involving only the persons working in the factory and the property inside the factory it is called

as On-site Emergency.

39

It can be again classified as minor and major emergency based on severity of the incident.

Minor Emergency (Evacuation is not required)

In the case of minor emergency there will be no evacuation siren and the respective department

personnel will handle the same with assistance of Safety Squad.

Major Emergency (Evac uation is required)

In case of major emergency there will be emergency siren and situation is tackled as per the

plan.

5.3.2 Off -site Emergency

If the accident is such that it affects inside the factory are uncontrollable and it may spread

outside the factory premises, it is called as Off-site Emergency.

Assessment reveals that an Off-site emergency is a very remote possibility in our factory. If

there is a situation, first we shall avail the service of local police to warn and advice the local

public about things to do to save them from the effect of emergency situation. Moreover, the

factory is located in industrial area. Hence, there are no residential houses in factory

surrounding area.

The detailed offsite emergency plan is given 5.17.

5.4 Causes of Emergency

The emergency may caused by factors like failure of system, human error, sabotage and natural

calamities like earth quake, flooding etc. Irrespective of cause, the emergency will generally

manifest itself in one of the three basic forms i.e. fire, explosion and release of toxic substance.

5.5 Safety, Health & Environment Policy

Acebright Management firmly commits and obliges as below:

1. We, at Acebright (India) Pharma Pvt. Ltd. commit ourselves to provide and

maintain Safe & Healthy Environment to all our employees, contractors, and our

neighborhood.

2. Our endeavour is to ensure that all the applicable statutory Rules, Acts &

Regulations are complied.

40

3. Assurance of Safety, Protection of Health & Environment is prime function and

responsibility of the Management and the Management will inculcate the safety

behaviour down the line through exemplary behaviour.

4. All the employees are periodically trained & informed about the hazards to which

they are exposed & Safety measures to be taken including personal protective

equipment.

5. To provide the resources required for Safety, Health and Environment protection.

6. We affirm to reduce the wastages, recycle the resources and disposal of

wastages will be as per statutory norms.

7. All our facilities will be operated & maintained by the prescribed Standard

Operating Procedures covering routine & non-routine activities.

8. All the accidents / near-miss accidents will be investigated thoroughly for their

root cause to avoid recurrence. Corrective and preventive actions applicable for

the same will be enforced.

9. Health, Safety & Environmental performance is constantly measured through

periodic audits of facility for continuous improvements.

5.6 Identification of Emergency in Each Hazard Activity t hrough Risk Analysis

5.6.1 Method used for identification of Hazards

a. HAZOP Study

The detailed HAZOP study is mentioned in Table 5-1.

b. Internal Safety Audit

c. External Safety Audit

41

Table 5-1 Activity / area wise hazards, affected workers, precautions and preparedness

S.

No.:

Activity / Area Area affected

workers

Hazards Anticipated Precautions Preparedness

1 Solvent

Storage,

Receipt &

Issuing

Warehouse

(Approx. 8

Nos.)

Fire and Explosion

Chemical Spillage

/ Toxic release

Designed the

yard with fire

proof materials.

All electrical

connections are

of flameproof.

Eliminated

welded joints as

much as possible.

Ignition sources

are not allowed in

storage area.

Breather valve

Work Permit

system

Effective Earthing

Dyke wall

Fire Extinguisher

Fire Hydrant

System

Emergency

Equipments /

PPE’s

Eye Wash

Fountain and

Safety Shower

OHC

First Aid Boxes

2 Chemical

Storage

Warehouse

(Approx. 8

Nos.)

Fire and Explosion

Toxic Chemical

Release

Storing as per

Compatibility

Flame proof area

Good ventilation

Dyke wall

Fire Extinguisher

Fire Hydrant

System

Emergency

Equipments /

PPEs

Eye Wash

Fountain and

Safety Shower

OHC

First Aid Boxes

3 Process in Production Runaway reactions Safety Relief Fire Extinguisher

42

S.

No.:


workers


reactor /

reaction

(Approx. 20

Nos.)

leads to explosion

Fire

Chemical Spillage

/ Toxic release

Valves

Rupture Discs

Calibrated

Gauges

Proper Earthing&

Jumper

connections

Earthing and

Bonding

Procedure

N2Blanketing

Flameproof

Electrical

connections

Scrubber System

& Exhaust unit

Touch Pads

Wrist band

Fire Hydrant

System

Emergency

Equipments /

PPEs

Eye Wash

Fountain and

Safety Shower

Work Zone

Monitoring

Equipments

Wind Sack

OHC

First Aid Boxes

4 Centrifuging Production

(Approx. 5

Nos.)

Fire

Chemical Spillage

/ Toxic release

Proper Earthing&

Jumper

connections

N2 Blanketing

Flameproof

Electrical

connections

Scrubber System

& Exhaust unit

Proximity Switch

Zero interlock

system

Fire Extinguisher

Fire Hydrant

System

Emergency

Equipments /

PPEs

Eye Wash

Fountain and

Safety Shower

Work Zone

Monitoring

Equipments

Wind Sack

OHC

43

S.

No.:


workers


First Aid Boxes

5 Milling Production

(Approx. 5

Nos.)

Fire due to dust

explosion

Spillage

Proper Earthing&

Jumper

connections

Flameproof

Electrical

connections

TouchPads

Wrist band

Fire Extinguisher

Fire Hydrant

System

Emergency

Equipments /

PPEs

Eye Wash

Fountain and

Safety Shower

OHC

First Aid Boxes

6 Drying Production

(Approx. 5

Nos.)

Fire

Spillage

Proper Earthing&

Jumper

connections

Flameproof

Electrical

connections

Touch Pads

Wrist band

Fire Extinguisher

Fire Hydrant

System

Emergency

Equipments /

PPEs

Eye Wash

Fountain and

Safety Shower

OHC

First Aid Boxes

7 Boilers /

Transformers/

Receivers for

the Air

compressors.

Engineering

(Approx. 5

Nos.)

Explosion Safety Relief

Valve

Proper Earthing

Fire Extinguisher

Fire Hydrant

System

Emergency

Equipments /

PPEs

OHC

First Aid Boxes

44

5.7 Severity / Severity Mapping (Zoning Diagram)

a. Fire and Explosion Index for Cyclization Reaction

Location: Production Block – 1

Process Unit: GLR Reactor

Material in Process Unit: EV-06, Potassium bicarbonate, Toluene,

Methanol, Charcoal, Hyflo, Sodium Chloride

Basic Material for Material Factor: Toluene

Material Factor: 16

The Fire & Explosion and penality factor is given in Table 5-2, Table 5-3 & Table 5-4

respectively.

Table 5-2 Fire and Explosion In dex for Cyclization Reaction

S.

No.:

Description Penalty Factor

Range

Penalty Factor

Used (1)

1 General Process hazards

A. Exothermic Chemical Reactions 0.30 to 1.25 0.30

B. Endothermic Process 0.20 to 0.40 0.00

C. Material handling and Transfer 0.25 to 1.05 0.40

D. Enclosed or Indoor Process units 0.25 to 0.90 0.25

E. Access 0.25 to 0.35 0.25

F. Drainage and Spill Control _ gal or cu.m. 0.25 to 0.50 0.30

G. Base Factor 1.00 1.00

General Process Hazards Factor (F1) 2.50

2 Special Process Hazards

Base Factor 1.00 1.00

A. Toxic Material(s) 0.20 to 0.80 0.60

B. Sub-Atmospheric Pressure(< 500 mmHg) 0.50 0.00

C. Operation in or near Flammable Range - -

1. Tank Farms Storage Flammable Liquids 0.50 0.00

2.Process Upset or Purge Failure 0.30 0.00

3.Always in Flammable Range 0.80 0.00

45

D. Dust Explosion 0.25 to 2.00 0.00

E. Pressure Operating - 0.00

F. Low Temperature 0.20 to 0.30 0.00

G. Quantity of Flammable/ Un stable Solvents - -

1. Liquids or Gases in Process - 0.30

2. Liquids or Gases in Storage - 0.30

3. Combustible Solids in Storage - 0.00

H. Corrosion and Erosion 0.10 to 0.75 0.25

I. Leakage and Joint Package 0.10 to 1.50 0.60

J. Use of Fired Equipment - 0.00

K. Hot oil Heat Exchange System 0.15 to 1.15 0.00

L. Rotating equipment 0.50 0.00

Special Process Hazards Factor (F2) 3.05

Process Units Hazards Factor (F1 x F2) = F3 7.63

Fire and Explosion Index (F3 x MF) = F & EI 122.08

Radiousof Exposure(25.6m X F&EI)/100 31.25mts

b. Fire an d Explosion Index for Condensation Reaction


Process Unit: SS Reactor

Material in Process Unit: PMPA, TBAB, Sodium Chloride

Fumaric Acid, CMIC, Triethylamine, NMPO,

Sodium Sulphate, Hyflow, IPA, IP Acetate,

MDC, Methanol

Basic Material for Material Factor: Triethylamine

Material Factor: 16

Table 5-3 Fire and Explosion Index for Condensation Reaction

S.

No.:


Range

Penalty Factor

Used (1)



46

B. Endothermic Process 0.20 to 0.40 0.00



E. Access 0.25 to 0.35 0.25

F. Drainage and Spill Control_gal or cu.m. 0.25 to 0.50 0.25




Base Factor 1.0 1.0








E. Pressure Operating - -








J. Use of Fired Equipment 0.00





Fire and Explosion Index (F3 x MF) = F & EI 110.04

RADIOUS OF EXPOSURE (25.6m X F&EI)/100 28.26mts

47

c. Fire and Explosion Index for Hydrolysis Reaction


Process Unit: SS Reactor

Material in Process Unit: CPT-I, Methanol, n-PentylChloro

Formate, C.P HCl, MDC, Pyridine, Sodium

hydroxide, Ethyl acetate, N-Heptane,

Sodium Sulphate, Hyflo

Basic Material for Material Factor: Pyridine

Material Factor: 16

Table 5-4 Fire and Explosion Index for Hydrolysis Reaction

S.

No.:


Range

Penalty Factor

Used (1)



B. EndothermicProcess 0.20 to 0.40 0.00



E. Access 0.25 to 0.35 0.25

F. Drainage and Spill Control_ gal or cu.m. 0.25 to 0.50 0.25




Base Factor 1.0 1.0








E. Pressure Operating - -

48








J. Use of Fired Equipment - 0.00





Fire and Explosion Index (F3 x MF) = F &EI 114.72

RADIOUS OF EXPOSURE (25.6m X F&EI)/100 29.36mts

Note: For no penalty used 0.00 and Zoning diagrams are shown in the Site Plan attached as

Annexure – 8.

References:

1. Dow’s Fire & Explosion

2. Fire Protection Manual

5.8 Mitigation Measures Required

a. Fire Hydrant System

b. Fire Extinguisher

c. Emergency Equipments / PPEs

d. Eye Wash Fountain and Safety Shower

e. Work Zone Monitoring Equipments

f. Wind Sack / Wind Direction Indicator

g. OHC

h. First Aid Boxes

49

5.9 Mitigation Measures Possessed / Proposed by the Industries

5.9.1 Fire Hydrant System

Fire monitoring system at solvent storage facility

A pressurized (7 kg/cm2); automatically operated Fire Hydrant System has been installed in the

plant with rings and wet risers around all blocks to achieve maximum coverage. Water reservoir

of 600 m3 (Hydrant Tank) capacity is provided for approximately 4 hrfire fighting. Following are

the details of the system.

a. Jockey pump of 10.8 m3/hrs@70m head capacity with pressure switches

b. Main electrical pump of 136.8 m3/hrs@70m head capacity pressure switches and

delivers water at 7 kg/cm2

c. Standby arrangement-Diesel Generator of capacity same as Main electrical

pump with auto control panel.

d. Yard Hydrant points - 35 Nos.

e. Hose Boxes – 35 Nos. (Each Hose Box contains 2 Nos. of hoses and 1 No. of

Nozzle)

f. Hose Reel Drums – 20 Nos.

g. Foam Concentrate tank of capacity 1000 Lts – 1 No.

h. Water / foam Monitor – 1 No.

i. Mobile Foam Unit with 200 liters capacity – 1 No.

j. Two way fire brigade inlet – 1 No.

k. Four way fire brigade inlet – 1 No.

l. Automatic sprinkler system in chemical storage tank area.

5.9.2 Fire Extinguisher

The company has trained personnel for firefighting and intends to improve the firefighting skills

of employee by conducting frequent training on firefighting.

We have 218 Nos. of different types (CO2, ABC, Water Jet, Mechanical Foam and DCP) of

portable fire extinguishers placed in all prominent places of the factory. Extinguisher break-up

based on area is given in Table 5-5.

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Table 5-5 Details of Fire Extinguishers

S. No.: Area No. of Extinguishers

1 Production Block- 1 51

2 Production Block- 2 48

3 Admin Block 19

4 Engineering Block & Utility Area 33

5 Other Areas including Solvent Storage Yard, Drum Sheds 39

6 Emergency Stock 28

Total 218

Sand buckets also kept in transformer yard, R&D area etc.

5.9.3 Emergency Equipments and PPEs

We have total 7 number of Emergency cupboards in that Production Block -1 consist 3 Nos. and

Production Block – 2 consist 3 Nos. and remaining 1 No. placed in Safety Department. Each

Emergency Cupboard consist the following items

1. Self-Contained Breathing Apparatus (SCBA)

2. Air suits / Air Line Respirators

3. Respirator / Full Face Mask (Air purifying)

4. PVC / Acid Suit

5. Helmet

6. Ear Muff

7. Safety Glass & Face Shield

8. Gum boot

9. Safety Belt

10. Manila Rope / Life Safety Rope

11. Fire Axe

12. Fire Proximity Suit

13. Fire Gel Blankets / Water Gel Blanket

14. Resuscitator

15. Spill Kit

16. Safety Ladder

17. Emergency Flameproof Torches

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5.9.4 Eye Wash Fountain and Safety Shower

We have total 18 Nos. of Eye wash fountain / Safety showers in that Production Block -1 consist

6 Nos. and Production Block – 2 consist 9 Nos. and remaining 3 Nos. are existed at Solvent

Yard and Chemical Storage area.

5.9.5 Work Zone Monitoring Equipments

We have multi gas / toxic gas and oxygen detectors in that multi gas detector can be used to

check oxygen, LEL, VOC, CO and H2S concentration in atmosphere and also in confined

spaces like inside the reactor, overhead tanks, underground tanks, sump etc and oxygen

detector can be used for checking oxygen concentration in atmosphere and also in confined

spaces like inside the reactor, overhead tanks, underground tanks, sump etc.

Both the detectors are available in the Safety Department.

5.9.6 Wind Sack / Wind Direction Indic ator

It is a conical textile tube. It is used where there is a risk of gaseous leakage or fire. It shows the

direction of wind to fight fire. The employees should run perpendicular to the wind direction and

not against / along the wind direction during toxic leakage. Wind sacks are placed above the

Engineering Office and Administration Block buildings.

5.9.7 OHC

We have well equipped Occupational Health Centre and also have an agreement with Suhas

General & Charitable Hospital, Jigani for their valuable service during emergency along with

24/7 ambulance facility.

OHC consist the following items;

a. Single bed

b. Stretchers

c. BP Apparatus

d. Stethoscope

e. Pair of scissor

f. Sterilized cotton wool

g. Hot and Cold Pack

h. Resuscitator

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i. Eye Wash Bottle

j. Triangular Bandage

k. Tourniquet

l. Splints

m. Safety Pins

n. Kidney Tray

5.9.8 First Aid Boxes

A first aid kit is a collection of supplies and equipment for use in giving first aid. First Aid boxes

are available in Security Room (ECC), Admin Block and at OHC. First Aid items will issue to

injure only by authorized persons. Following are the contents of First Aid Box,

a. Dettol – Antiseptic solution

b. Ciplox – Eye Drops

c. Soframycin – Skin ointment

d. Silverex – Burn ointment

e. Betadine – Microbicidal solution

f. Iodex – Pain reliever

g. Sterilized Cotton Wool

h. Adhesive Plaster

i. Surgical Paper Tape

j. Small Sterilized Dressings

k. Medium Sterilized Dressings

l. Large Sterilized Dressings

m. Sterilized Burn Dressings

n. Roller Bandage – 5 cm wide

o. Roller Bandage – 10cm wide

p. Band Aid

q. Crocin / Paracetamol Tablet

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5.10 Emergency Shutting Down P rocedure

1. Critical operations will be shut down by the respective technician / operator upon

getting the necessary instruction from the shift in charge. An emergency shutdown

can be done after getting approval from Incident Controller / Site Controller.

2. Utility Controls will be shut off by maintenance personnel who will know the location

and operation of main controls for gas, solvent and electrical supply leading into the

building.

3. An emergency shutdown of computers should be accomplished in the event of a

severe electrical storm. If time permits, exit the program and shut off the computer

power supply.

5.11 Identification of Mutual Aid Partners

1. M/s. HIKAL Limited

#82/A, KIADB Industrial Area

Jigani, Bangalore – 560 105

Ph: 080 – 2782 6800

2. M/s. Kumar Organic Products Limited

#36, KIADB Industrial Area


Ph: 080 – 2782 5439, 080 – 2782 5376

5.12 Identification of Resource Suppliers (Both Public & Private)

1. M/s. HIKAL Limited

#82/A, KIADB Industrial Area


Ph: 080 – 2782 6800

2. M/s. Kumar Organic Products Limited

#36, KIADB Industrial Area


Ph: 080 – 2782 5439, 080 – 2782 5376

3. Suhas General & Charitable Hospital

Plot No. CA 3, Anekal Main Road

54

Jigani Industrial Area, AneklTaluk

Bangalore – 560 105

Ph: 080 - 27826145 / 144

4. Police Station – Jigani

Opposite to Santhe Market


Ph: 080 – 27825108

5. Fire Station – Electronic City

No. 101, Hosur Road

Behind KEB Office

1st Phase, Electronic City

Bangalore 560 100

Ph: 080 – 22971576

5.13 Emergency Transport Facility

a. We have memorandum of understanding with Suhas General & Charitable

Hospital for ambulance and emergency services.

b. We ensure a four wheeler presence inside the premises round the clock.

5.14 Control Room

Control Room also termed as Emergency Control Centre (ECC) is a place from which all the

decisions with regard to actions for control of emergency, rescue and medical treatment are

made. Security office is considered as emergency control centre. It contains the following

facilities.

a. Communication equipment

b. Copies of emergency management plan

c. Emergency escape route map

d. List of emergency contact numbers

e. Emergency light

f. Location of emergency supplies like PPEs / emergency equipments, layout

of fire fighting system, assembly point etc.

g. Emergency organization team details

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5.14.1 Communication facilities (internal and external agencies)

Different modes of communication are available depend on requirement. The major

communication systems used are as follows;

5.14.1.1 Telephone / Intercoms

Facility covered almost all section of the plant for better communication and provided

emergency contact number i.e., 528. This is emergency control center number.

5.14.1.2 Walky – Talky

For easy and reliable communication particularly while taking actions like plant start-up, shut-

down, search & rescue, firefighting and transport of injured.

Table 5-6 Telephone numbers of all the stake holders

Name Phone Number

The Deputy Commissioner

Bangalore Urban District

4th Floor, DC Office Building, Revenue Complex

KG Road, Bangalore–560 009

080–2221 1292

080–2221 4553

Superintendent of / Local Police

No. 108, Palace Road

Bangalore- 560001

080–2294 2215

080–2226 0707

Police Police Emergency Line 100

Traffic Police Emergency Line 103

Jigani Police Station 080–27825108

Bannerghatta Police Station 080–27828595

Fire Service Fire Emergency Line 101

Fire Brigade Number, Electronic City 080–22971576

Fire Brigade Number, Bannerghatta Road 080–22971538

Hospitals Hospital Emergency Line 102

Suhas General & Charitable Hospital, Jigani080–27826145 / 144

St. John’s Ambulance Association 080–22223384

Factory OHC 08110–415531

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Name Phone Number

All India Emergency Number 108

Occupier Mrs. ManoramaAvinash

Executive Director

Acebright (India) Pharma Private Limited

08110–415502

9343720118

Mrs. Ying Kan

Executive Director

Acebright (India) Pharma Private Limited

08110–415502

Directorate of Factories and Boilers

KarmikaBhavana

Dairy Circle, Bannerghatta Road

Bangalore–560 029

080–2653 1201

9845 666 691

Karnataka State Pollution Control Board

NisargaBhavan, Thimmaiah Road

Opposite to Pushpanjali Theatre

Basaveshwara Nagar, Bangalore–560 010

080–2322 1575

9945 276 544

Key

Personnel of

the Industry

Head–Operation 08110–415 547

Head–SHE 08110–415 531 / 526

Head–Production 08110–415 578 / 564

Head–Maintenance 08110–415 541 / 521

Head–HR & Admin 08110–415 511 / 514

Factory Gate 08110–415 529

Factory Emergency Contact Number 528

Mutual aid

partners

M/s. HIKAL Limited, #82/A, KIADB Industrial Area,

Jigani

080–2782 6800

M/s. Kumar Organic Products Limited, #36,

KIADB Industrial Area, Jigani

080–2782 5439

080–2782 5376

5.15 Alert Action Plan during Working & Nonworking Hour s

5.15.1 Alert Action Plan during Working Hours

It can be divided as follows

a. Detection

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b. Decision

c. Annunciation

d. Reaction

e. Recovery and Return to normal activities

a) Detection

The detection of any mishap like fire, explosion or toxic release is identified by either sensors or

by any person working in the plant. If detection by sensors, alarm system will get activated or if

it by a person, he will shout and / or break MCP to activate alarm system.

b) Decision

The Department Head / Shift in-charge (Incident Controller) has to assess the size and nature of

emergency and to decide whether it is a minor or major emergency and then to inform Site

Controller immediately.

c) Annunciation

Site Controller will get complete information of the incident, assess the incident and if require

pass an order to security to wail Emergency Siren through which every Department will come to

know about the emergency, then accordingly they will plan to evacuate from their respective

Departments.

Emergency Siren pattern,

This alarm will blow in the high pitch and low pitch level with interval of 15 sec between two

blows. The mechanism will be in the form of waves of high and low frequency for 3 minutes.

d) Reaction

After hearing the emergency siren, all should stop their activities in a safe manner. Except

Emergency Organization Team members, all should come to safe assemble area and stay there

for head count and for further instruction of Site Controller.

Emergency Organization Team members should act as per their pre- determined responsibility

to;

i. To localize the emergency and if possible to eliminate it

ii. Minimize the effects of accident on people and property

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e) Recovery and return to normal activities

Once Emergency is mitigated, normalcy is restored; head count is matched, then Site Controller

will pass an order to Security to wail All Clear Signal.

All Clear Signal Siren pattern. It is a continuous alarm for one minute .

After hearing the All Clear Signal, all can move to their respective work places to start their

normal activities.

Emergency aler t action plan for working hours is shown diagrammaticall y as below

Figure 5-1 Emergency Alert Action Plan for Working hours

5.15.2 Alert Action Plan during Non -Working Hours

During non-working hours, i.e., in holidays, there will be no production activities. As we are

carrying only batch processes, all the equipments (both process and utility) will be shut down

and no chemical storage inside the production areas during holidays and also ensure the

cleaning and good housekeeping.

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All the 365 days Fire Hydrant System and Fire alarm systems are kept in active mode, to

monitor this technical person and security persons will present round the clock throughout the

year to tackle the worst case scenario in case of emergency.

5.15.3 Emergency Organization Chart

Figure 5-2Emergency Organization Chart

5.16 On Site Emergency Planning

A. Establish Line Of Control – Responsibility & Alternative Line Of Control

Table 5-7 Line of Control – Responsibility & Alternative Line of Control

Responsible During General Shift (09:00 Hrs to 17:30

Hrs)

During Shift(17:30 Hrs to 09:00 Hrs)

Site Controller Head- Operation SafetyOfficer

Alternate Head- HSE Shift in-charge

Site Controller

IncidentController

Emergency Coordinator– HR & Admin (for

Hospital, Law, Order &Head Count)

EmergencyCoordinator -Safety Squad

EmergencyCoordinator -Maintenance

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Incident ControllerHOD of the concerned Department when

emergency occurs

In-charge of the concerned Department

when emergency occurs.

Alternate In charge of the Department when

emergency occurs.

----

Hospital, Law &

Order

Head- HR & Admin Security

Alternate Staff- HR & Admin ----

Head Count Executive- HR & Admin Security

Alternate Staff- HR & Admin ----

Maintenance Head- Maintenance Shift Engineer

Alternate Executive- Maintenance ----

List of Safety Squads (Fire Fighters / Rescuers and First Aiders) covered from all Departments and

planned to avail round the Clock.

B. Constitution o f Teams

a. Fire Fighters / Rescuers

b. First Aiders

c. Maintenance Team

a. Fire Fighters / Rescuers

The fire fighters / rescuers shall attempt to extinguish or control the fire / prevent

further toxic leakage without taking personal risk before the arrival of the fire

brigade / other external agency.

The fire fighters / rescuers shall also attempt to save the lives of people who are

unable to ensure their own survival without assistance.

b. First Aiders

The First Aiders shall get ready the first aid equipment, proceed to designated

area and set up First Aid Point in coordination with Site Controller.

c. Maintenance Team

The Maintenance Team shall;

The maintenance team shall go to important controlling areas like Fire Hydrant

Pump House, DG area, MCC area etc.

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C. Define Roles And Responsibilities In Brief

In the event of emergency, nominated individuals / teams are given specific

responsibilities; separate from their day to day activities.

The Emergency Organization Team consist,

a. Site Controller (SC)

b. Incident Controller (IC)

c. Emergency Co-ordinator – HR & Admin

i. Hospital, Law & Order

ii. Head Count

d. Emergency Co-ordinator Maintenance

e. Emergency Co-ordinator Safety Squad

i. Fire Fighters / Rescuer

ii. First Aider

C.1. Roles and responsibilities of Emergency Organization Team members

a. Site Controller (SC)

Site Controller is a person who has ultimate control over the affairs of the company

during emergencies inside the plant.His responsibilities include;

He should go to the Emergency Control Centre as soon as he is aware of

the emergency and take over the situation.

Get complete information of the incident.

Assess the incident and if require pass an order to security to wail

Emergency Siren.

Remain in ECC and establish the contact with Incident Controller and

guide him about the actions to be taken.

Arrange for additional help as requested by Incident Controller with the

help of Emergency Coordinators.

If required call outside services like fire brigade, medical facility, water

tankers, police etc with the help of Emergency Coordinators.

Guide and control the traffic movements in evacuation.

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Establish communication and liaise with agencies like Department of

Factories and Boilers, Pollution Control Board, Police and other

Government Officials.

Inform Incident Controller about missed people if any, after head count

has been done.

To issue authorized statements to the news media.

Once situation is controlled, head count matched then instructs security

to wail ‘All Clear Signal’.

Rehabilitation of affected areas after the emergency.

b. Incident Controller (IC)

Incident Controller is a person who is responsible for incident control measures, rescue

operations and mitigation of emergency situation on Coordination with Site Controller.

His responsibilities include;

Proceed to the incident spot as information is received.

Assess the size and nature of emergency and communicate the same to

Site Controller and keep in touch with Site Controller till the emergency is

mitigated / controlled.

Start and direct all emergency control operations with the help of

Emergency Coordinator - Safety Squads.

Request Site Controller for additional help like Safety Squads from other

Departments, fire brigades etc.

Direct shut down of the processes / plants and also nearby plants.

Ensure evacuation of all personnel in coordination with Site Controller.

Once emergency is mitigated, normalcy is observed, instruct Site

Controller for the same.

c. Emergency Co -ordinator – HR & Admin

HR & Admin team consist two persons, one person will be stationed at the Emergency

Control Centre during the emergency to handle hospital, fire, police and other inquiries

under instruction of Site Controller and other person will carry out headcount at

assembly point and pass on the absentee information to the Site Controller.

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i. Emergency Co -ordinator Hospital, Law & Order

His responsibilities shall include -

Proceed to the Emergency Control Centre and report to Site

Controller.

Ensure the gates are closed.

With the help of security, control crowd at gate as per instruction

from Site Controller.

Deploy one guard at main gate with instructions not to allow / send

any personnel, vehicles inside except fire tender and ambulance.

Keep ready the list of important telephone numbers and contact

numbers of police and other law and other agencies.

Inform other statutory departments, corporate office as per

instruction from Site Controller.

Inform relatives / contact persons of the injured accordingly.

Get hold of medical management procedure / list, hospital /

telephone numbers, accordingly.

Call the respective medical institute as per the instruction from Site

Controller.

Prepare a sequential report of the incident.

ii. Emergency Co -ordinator Head Count

His responsibilities shall include -

Proceed to the Emergency Control Centre and report to Site

Controller

Ensure carrying Master Attendance Copy.

Proceed to assembly point and collect attendance sheet from

respective department.

Compare the list and look for missing personnel if any.

Inform Site Controller about the same.

d. Emergency Co -ordinator Maintenance

Emergency Co-ordinator Maintenance will take care of emergency control systems like

Fire Hydrant System, DG units etc and also mobilize the tool and other emergency

equipments as per the instruction of Site Controller.

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One of the co-ordinator will move to Fire Hydrant pump house and switch

on /off the pump as per the instruction of Site Controller.

One of the co-ordinator will move to Generator room and switch on / off

as per the instruction of Site Controller.

One of the co-ordinator will move to respective MCC of incident spot and

keep in touch with Site Controller.

One of the co-ordinator will be available on phone and act as per the

instruction of Site Controller.

e. Emergency Co -ordinator Safety Squad

Emergency Co-ordinator Safety Squads will fight the emergency to mitigate it and to

protect life, property.

i. Emergency Co -ordinator Fire Fighters / Rescuer

Proceed to the incident spot along with emergency equipments and

report to Incident Controller.

Set up emergency equipment.

Act as per the instruction of Incident Controller.

Make quick assessment of the injured and arrange to shift with the

help of Incident Controller to safer place for first aid.

Send one co-ordinator of the team along with injured.

Search for missed ones and do rescue operation for the needy.

ii. Emergency Co -ordinator First aider

Proceed to Emergency Control Centre along with team and report

to Site Controller.

Set up emergency equipments.

Be ready to receive and to provide first aid to victim and to help the

ambulance staff.

Make quick assessment of the injured and arrange to send victim to

hospital with the coordination of Site Controller.

Send one co-ordinator of the team to hospital along with injured with

medical management procedures.

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C.2. Roles and responsibilities of persons other than Emergency Organization

Team members

Do not venture out for help.

Be available in the Department till evacuation is called.

After hearing the Emergency siren, all should stop their work in a safe manner

immediately.

All work permits will be cancelled automatically.

All should come to Safe Assembly Area (In front of Safety Office).

While coming to Safe Assemble Area,

Do not run, walk brisk.

Do not use lift, use only staircase.

Do not block staircase, use hand rail. Come in a line.

Do not obstruct / block the path to Emergency Organization Team

members.

Do not go back for your belongings.

Do not use telephone except for emergency purpose.

Follow instructions of Site Controller in Safe Assemble Area.

After All Clear Signal all can go back to their respective places / Departments.

D. Notification o f Emergency

The notification of any mishap like fire, explosion or toxic release is identified by either

sensors or by any person working in the plant. If detection by sensors, alarm system will get

activated or if it by a person, he will shout and / or break MCP to activate alarm system. As

soon as Incident Controller aware of the emergency, he will rush to incident spot and assess

the size and nature of emergency and communicate the same to Site Controller.

E. Declaration o f Emergency

Site Controller will be the person to decide whether the situation warrants evacuation of the

premises or is a localized incident. This individual will be termed as the declarer of

emergency. Immediately the declarer will make arrangements to give information to the

Executive Director.

Once an emergency requiring evacuation has been decided upon by the declarer, the

Emergency will be declared by putting on the Emergency Siren.

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F. Evacuation o f Personnel

All Safety Squad co-ordinators from the Department where the incident has occurred and

from other Department will reach earliest to the point of incident. All other people working in

the factory will assemble at designated assembly point i.e., in front of Safety Department

after hearing the Emergency Siren.

The Emergency co-ordinators will assist in directing the individuals to the assembly point.

G. Acc ounting o f Personnel

The Emergency Co-ordinator HR & Admin, Head Count Person will conduct head count as

per particular days attendance record at the assembly point to account for persons working

inside the factory and also for visitors / vendors present inside the premises. Information on

missing persons will immediately convey to Site Controller.

H. Controlling o f Emergency

The Safety Squad member from the affected area and Safety Squad members from other

Departments will attempt to control / mitigate the emergency situation under the supervision

of Incident Controller and instruction of Site Controller.

I. Arrangements f or Medical Treatment

Any person injured in the incident and subsequently, will be treated by Emergency Co-

coordinator, First Aider. The designated vehicle will be kept ready to move the injured to

hospital, all the injured will be sent to Suhas General & Charitable Hospital, Jigani. First Aid

team member will accompany the injured to hospital. In the event of additional medical help,

the injured will be shift to recommended Hospital.

J. Information to t he Relatives of t he Injured

The relatives of injured will be informed by Emergency Coordinator HR & Admin for Hospital,

Law & Order. The communications to the relatives of injured will be through telecom or by a

messenger. The clear address of availability of the injured person (if hospitalized) will be

communicated to his relatives.

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K. Information to t he Government Authorities

The Emergency Coordinator HR & Admin for Hospital, Law and Order is the person to

inform and get help from Fire Station, Police and other Government Hospitals in

coordinating with Site Controller.

L. Law & Order

Site Controller will take over and control emergency in coordination with Incident Controller

and other Emergency Coordinators.

The Executive Director will arrange to send information regarding the incident to the Director

of Factories, Government of Karnataka.

M. All Clear Signal

Once Emergency is mitigated, normalcy is restored; head count is matched, then Site

Controller will pass an order to Security to wail All Clear Signal.

After hearing the All Clear Signal, all can move to their respective work places to start their

normal activities.

5.17 Offsite Emergency Plan

5.17.1 Preamble

An offsite emergency arising out of chemical hazards in one, which has potential to cause

serious damage or loss of life beyond the plant boundary. In addition, Accidents during

transportation of hazardous chemicals by road, rail, pipeline etc. can cause offsite emergencies.

Emergency services such as Police, Fire, Medical etc., need to be prepared to handle such

situations promptly and effectively.

It is mandatory under Rule 16 of the Hazardous Chemical Rules for District authorities to

prepare an off-site emergency plan in respect of clusters of hazardous chemical industries or at

locations where accidents are likely to have an off-site adverse effect.

In order to be in a state of preparedness to respond to the accidents and minimize their adverse

impacts on the offsite population, requires an offsite emergency plan to be prepared by the

District Controller for every District or Industrial Areas as applicable.

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5.17.2 Objective

The objective of the present assignment is to prepare an area specific Offsite Emergency Action

Plan for Jigani, Bangalore, Karnataka which can be practically implemented / activated at a

short notice to ensure minimal impact on life and property due to emergencies arising out of

Chemical Accidents or during Transportation of Hazardous Chemicals in the district.

The plan should be regularly updated when there are changes occurring in the Industrial set up,

Transportation Aspects, Key Manpower and Administrative Changes etc., Regular drills,

Training of key persons, increasing safety awareness etc is extremely important areas that must

be looked into for sound preparedness.

5.17.3 Offsite Emergency Control

As we all know that jigani is an industrial area having many industries of large, medium & small

scale. After the “Bhopal Gas Tragedy” (Methyl Isocyanides- MIC Poisonous and toxic gas

release Accident at Union Carbide, 1984) the Government felt an immediate need to be more

conscious about handling of Hazardous Chemicals.

Central control room Centre or Offsite Industrial Emergency Control Room “OIECR” should be

established by company. It should work under the Governing Council. The Governing Council

should be headed under the chairmanship by District Collector & Magistrate of jigani. The

Governing Council Members are the permanent Ex. Officio Members to manage the affairs of

the Emergency Control Room.

5.17.4 Emergency Instruction to the General Public

The Notification o f Emergency

The emergency can be declared by following media to alert or alarm the public ;

1. Public address system

2. Blow horns/Bells

3. Sirens / Hooters

4. Telephone message / Fax Messages / Hot lines/ Pager / E-mail / Mobile Phone /

Satellite system

5. Sending messages through a messenger

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6. Rushing personally to the Central Control Room or to the nearest Police Department or

Fire Department for declaration of emergency.

7. Raising of Flag for denoting the level of natural calamities

8. Ham Radio

9. By any other source by which information can reach to the public in time.

5.17.5 Category of Alarm Systems

The following alarm system may be considered which will identify the various level of

emergency.

5.17.5.1 First Level Warning ( Fire Alarm)

For an accident / incident within the unit

Hooter / Siren – Short, intermittent

5.17.5.2 Second Level Warning

When the District Authority receives information that a toxic or flammable gas has

leaked then the siren has to be sounded in order to facilitate early evacuations

from the unit.

Siren – A wailing short and long intermittent siren notification of emergency.

5.17.5.3 Third Level Warning (All Clear)

When the District Authority considers that the accident / incident is under control,

emergency is withdrawing and it is safe for re-entry.

Siren – A wailing, long and continues, intermittent siren.

5.17.6 Fire Fighting System

In order to tackle great risk of fire explosion, spillage of hazardous liquid or release of toxic

gases, firefighting system should be mobilized under chief fire officer. The operational response

will be coordinated from the Central Control Room.

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5.17.7 General Instruction to the Public

A major emergency may affect areas outside the works. The surrounding public will be alerted

with public address system by Police or Government Authorities or nearby industrial concerns.

The siren / hooter will blow to indicate arising the emergency situation.

It will be indicated which kind of emergency arised, Start the Radio / TV for further instruction &

act accordingly. So that public will take prompt action to protect them-selves or rush to the safe

shelter as instructed by the authority.

First of all to ascertain which type of emergency arised.

1. Fire

2. Explosion

3. Gas Leakage / Release

4. Collapse of Building, Brusting of Vessel etc.

5. Natural Calamities.

If gas leakage emergency arised, ascertain probability of gas whether flammable, toxic or

poisonous. The following actions are suggested as per prevailing situation: Otherwise follow

the instruction as issued by the authority

5.17.7.1 Flammable Gas :

a. Be calm, don’t get panicky

b. Do not light Bidi / Cigarette / Lighter etc

c. Shut down open flame, gas and electrical instruments or any source of ignition

d. Do not move any vehicle in the area

e. Do not go near the incident & don’t allow any others

f. Shut down the windows, doors etc. & seat open ground or terrace.

g. Follow the instruction as directed by the authority

5.17.7.2 Toxic Poisonous Gas

a. Cover your nose with wet hand kerchief / cloth and breath through it.

b. Come out in open, check the wind direction and move away quickly in perpendicular

direction of wind. (cross wind direction )

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c. Immediately go & try to get to a higher elevation, if gas is heavier than air (like chlorine, as

it settles in low lying area)

Follow the instruction and reach safe shelter as instructed notified by Government Authority or

Public authority.

5.17.7.3 General Instruction :

(A) DON’T

1. Do not get panicky, be calm

2. Do not approach the site of incident as a spectator

3. Do not approach unnecessarily for information or more enquires

4. Do not allow unnecessarily crowd nearby incident place

5. Do not believe in rumors unnecessarily

(B) DO’S

1. Listen radio, TV or Public Addressing System.

2. Emergency will be communicated by public addressing system / TV / Radio or siren (Siren-

code wailing sound for one minute)

3. Follow the instruction & convey to others accordingly

4. On announcement of withdrawal of emergency or clearance Siren, start your routine work

5. On enquiry, deposit your statement as required by authority at the time of investigating the

incident

6. Co-operate, help and assist the person(s) / authority handling the emergency and rescue

operation.

Table 5-8 Emergen cy Telephone Numbers

Sr.

No.

Designation / Post STD

Code

TelephoneNumber

Office Resident Mobile

A. Control Rooms

1 NDMA, Karnataka 080 22032416/

1070

- -

2 Fire Service Station, Bangalore 080 29442999/

2251780

- -

3 Police Control Room, Bangalore 080 2294222 - -

72

4 Civil Defence Control Room, Karnataka 080 25570733/

22971501

- -

5 Railway Control Room 080 22942666 - 9480802140

6 Airport Authority, Bangalore 080 25223344 - -

7 Home Guard, Bangalore 080 23142542 - -

8 Coastal Guard, New Mangalore,

Karnataka

0824 2405269/7

0

- -

9 Emergency Centre-Nearby Hospital - 102 - -

B .Collectoralay-Jigani

1 The Deputy Commissioner, Bangalore

Urban District

080 22211292/

22214553

- -

2 Special Deputy Commissioner 080 22214370 - -

3 Dist. Supply Officer 080 22215594 - -

4 Dist. Planning Officer (D.P.O.) 080 22253651 - -

5.17.8 Security & Police

Security, protection of life & property and traffic control & maintenance of law and order should

be taken care by police. During an emergency duties and responsibilities of the police may be:

a) Cordoning of the incident area

b) Warning public about the hazards

c) Traffic Control

d) Assist fire fighting services

e) Assist first-aid medical teams

f) Assist evacuation and ensure protection of property in evacuated areas.

Different phases of emergency management practices would be as under:

a) Before the Cri sis

Proper planning of manpower, transport and communication network to

coordinate possible incident areas and regulation of traffic should be made for

each industry in the area.

b) During the Crisis

The Security Commander of the area will set in motion the relevant contingency

plan to control the operation.

73

c) After the Crisis

Protect property in the evacuated area.

d) Media

The Control Room should release an up-to-date information to the media to the

people.

Sr.

No.


Code

Telephone Number


Police

1 Police Emergency Line - 100 - -

2 Police Commissioner, Bangalore 080 22260222/2

2942215

- 9480801001

3 Police Station–Jigani 080 27825108 - -

4 Superintendent of / Local Police

Bangalore

080 22942215/2

2260707

- -

5 Traffic Police Emergency Line - 103 - -

6 Jigani Police Station 080 27825108 - -

7 Bannerghatta Police Station 080 27828595 - -

Fire

1 Fire Emergency Line - 101 - -

2 Fire Station–Electronic City 080 22971576 - -

3 Fire Brigade Number, Electronic City 080 22971576 - -

4 Fire Brigade Number, Bannerghatta Road080 22971538 - -

5 KIADB Industrial. Estate 080 22265383 - -

6 Karnataka State Natural Disaster

Monitoring Centre

080 67355000 - -

74

5.17.9 Medical facilities in case of emergency

A large number of ambulances would be necessary to transport casualties to the casualty

response centre and base hospital. For this purpose, jeeps/ matadors/ special wagons which

can be converted as ambulance at short notice should be kept at the unit and the Control Room

or should have the mutual aid agreement with nearby hospitals as mentioned in Error! Not a valid

bookmark self-reference..

Table 5-9 Hospitals list in case of emergency

Sr.

No.

Designation/ Post STD

Code

Telephone Number


1 Suhas General & Charitable Hospital 080 27826145/1

44

- -

2 Hospital Emergency Line - 102 - -

3 Suhas General & Charitable Hospital,

Jigani

080 27826145/1

44

- -

4 St. John’s Ambulance Association 080 22223384 - -

5 Factory OHC 080110 415531 - -

6 All India Emergency Number - 108 - -

Sr.

No.


Code

Telephone Number


STATE GOVERNMENT OFFICERS

1 Karnataka State Pollution Control Board,

Bangalore

080 23221575 - 9945276544

2 Directorate of Factories and Boilers,

Karnataka

080 26531200 - 9448100590

3 Jt. Director, Industrial Safety & Health,

Bangalore

080 26531207 - 9880128763

4 Dy. Director, Industrial Safety & Health,080 26531206 - 9448353099

75

Bangalore

5 Regional Officer(ESI), Bangalore 080 26742485 - -

6 ChiefEngineer(PWD), Bangalore 080 22212830 - 9483008987

7 Transport Commissioner, Bangalore 080 22254900 - 9880726761

8 Commissioner of Agriculture, Karnataka080 22212804 - 8277929803

Sr.

No.

Designation / Post STDCod

e

Telephone Number


Central Government

1 Chief Engineer CPWD, Karnataka 080 25534968 - -

2 Dy.Chief Controller of Explosive,

Mangalore, Karnataka

0824 2420167 - -

3 Labour Enforcement Officer, Karnataka 080 22032313 - -

News Paper

1 Indian Express 080 22866893 - 9448689473

2 Times of India 080 42200000/20

2

- -

5.17.10 Mutual Aid

All the nearby industrial units which are mentioned in Table 5-10 should have mutual aid

arrangement for getting/extending help in firefighting facilities, special firefighting agents, trained

manpower, etc. The Control Room will allocate additional resources to fire zone including

protective equipments kept centrally as a pool.

Table 5-10 List of industries nearby with phone numbers

Sr,No. Name of Industry Address Phone No.1 Mallik Engineering No 126, Road No 3, KIADB

Indl Estate, II Phase,Jigani,AnekalTaluk,Bangalore560 105

080- 27825436,

2 Shashi Bio-energy Products No.104, KIADB Industrial Area,080-23202370,

76

Jigani, Bangalore- 560105,Near APC

9620166777

3 J’Pan Tubular Components FLAT NO 115, Industrial EstateJigani, Bommasandra, FortRoad, Bengaluru- 562106,Karnataka

+917829916937

4 Aron Universal Ltd. # 25/1,2nd Phase, JiganiIndustrial Area, Jigani,Bangalore (South)– 560105,Karnataka

91 80 27825331/+91 80 27825315

5 Hikal Ltd. #82/A, KIADB Industrial AreaJigani, Bangalore–560 105

080–2782 6800

6 OTIS No.92, KIADB Indl.Estate,Phase II, JiganiIndl.Area,AnekalTaluk,Bangalore -562106.

080- 40314500

7 Kirloskar Toyota textile machineryPvt. Ltd.

Plot 10 ~ 13, Phase IIJigani Industrial Area, Jigani,Bangalore 560 105.Karanatka

08110-419555

8 Bill Forge Pvt Ltd No.98-L, Kiadb Industrial Area,2nd Phase, Jigani IndustrialArea, Bangalore- 562106

080-27826993

9 Kumar Organics Pvt. Ltd. #36, KIADB Industrial AreaJigani, Bangalore–560 105

080– 2782 5439,080–2782 5376

10 Cipla Limited No.285, 286, 287, Jigini LinkRoad, Kiadb 4th Phase,Bommasandra Industrial Area,Bangalore- 560099, Near HCL

080- 22059200

11 Micropack Plot No.16, AnekalTaluk, JiganiIndustrial Area, Bangalore -562106, Near APC Circle(Map)

080-27825223

12 HCL Technologies No. 129, JiganiBommasandra,Link Road, Jigani IndustrialArea, Bengaluru, Karnataka562106

080-678 10000

13 Microbabs #121,KIADD, AnekalTaluk,Jigin Link Road,BommasandraIndustrial Area, Bangalore-560099

080-27839036

14 RichcoreLifesciencesPvt Ltd Plot No. 204 and 237,Bommasandra- Jigani LinkRoad, K.I.A.D.B Industrial

081104 19777

77

Area, Bengaluru, Karnataka560105

15 BIOCON BIOCON SEZ, Biocon ParkPlot# 2&3 Bommsandra IvPhase, Jigani Link Road,BommasandraIndl AreaBangalore, KarnatakaPin :560099

080-28083912

16 Strides Shasun Limited Strides House, Opposite IIM-B,Bannerghatta Main Road,Bilekahalli, Bengaluru,Karnataka 560076

080-678 40000

17 ApotexPharmachem Site No. 1A, 4th Phase,BommasandraJigani LinkRoad, Bommasandra IndustrialArea, Bengaluru, Karnataka560099

080 2289 1000

18 Sigma Aldrich Plot No. 12, Bommasandhara,Jigani Link Road, Bengaluru-560100, Karnataka, India

91-80-66219443/66219400/66219000

19 Anthem Bioscience Pvt Ltd No 49, Canara Bank Road,Bommasandra IndustrialArea,Phase 1,Hosur Road,Bengaluru, Karnataka 560099

080 4044 4000

20 Ansell No- 74 - 91, KIADBIndustrialArea, Jigani 2nd Phase,Anekal, Bangalore-562106

080-27826223

21 Sansera Engineering Pvt Ltd Bommasandra Industrial Area,Bommasandra, Karnataka560099

080 2783 3056

HUBERT ENVIRO CARE SYSTEMS (P) LTDCHENNAI

A-21, III Phase, Behind Lions Club School, Thiru Vi Ka IndustrialEstate, Guindy , Chennai – 600 032, Tamil Nadu, India

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