Transcript Introduction : The State of Karnataka has 10730 factories

Presentation on
CONTROL AND MANAGEMENT
OF INDUSTRIAL DISASTERS
IN
THE STATE OF KARNATAKA
ACHIEVEMENTS AND NEW INITIATIVES
By
H. SRINIVASAIAH
Director of Factories & Boilers
Government of Karnataka
Introduction
The State of Karnataka has 11553 factories and
2799 boilers registered with the department. It
employs around 11 lakh workmen. Amongst 11553
registered factories, about 1019 units have been
identified as industries involving hazardous processes
of which 78 industries are classified as Major Accident
Hazardous installations.
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
Hazardous Units
• 78 industries has been classified as major accident
hazard installations in the State of Karnataka, as per
schedule - 2 of Chemical Accident (Emergency
Planning, Preparedness, Response) Rules, 1996.
• All the MAH industries have got their On-site
emergency plan approved the department of
Factories and Boilers.
• All the onsite emergency plans are revised on any
change in the capacities, process, organization
setups.
• All these MAH installations have furnished the
technical informations, details of off site effects by
conducting risk analysis, identifying the affecting
area, population, flora-fauna, available resources,
mutual aid partners, etc.
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
DISTRICT WISE LOCATIONS OF MAH
INSTALLATIONS
Sl.No.
Name of the District
No. of MAH
units
1
Bangalore Rural
18
2
Bangalore Urban
13
3
Belgaum
05
4
Bellary
04
5
Dakshina Kannada
12
6
Dharwad
06
7
Haveri
02
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
DISTRICT WISE LOCATIONS OF MAH INSTALLATIONS
contd…..
Sl.No.
Name of the District
NO. of MAH
units
01
8
Hassan
9
Kolar
01
10
Koppal
01
11
Mysore
07
12
Raichur
01
13
Shimoga
03
14
15
Tumkur
Uttar Kannada
02
02
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
THE INVENTORY OF HAZARDOUS MATERIAL
STORED, USED AND HANDLED IN THE STATE.
Sl.
No.
Particulars
Quantity
Main Hazard
1
LPG
72580 MT
Fire / Explosion
2
Petroleum Products
295396 KL
Fire
3
Chlorine
1705 MT
Toxic and Corrosive
4
Liquid Oxygen
4591 MT
Cold burns, oxidizing
5
Carbon Di sulphide
200 MT
Toxic
6
Ammonia
7
Liquid Nitrogen
10053 MT
720 MT
Toxic and Corrosive
Cold burns
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
THE INVENTORY OF HAZARDOUS MATERIAL
STORED, USED AND HANDLED IN THE STATE.
Sl.
No.
Particulars
Quantity
100000nm3
Main Hazard
8
Corex Gas
9
Hydrochloric acid
1185 MT
Corrosive
10
Sulphuric acid
3039 MT
Corrosive
11
Phosphoric acid
21000 MT
Corrosive
12
Blast furnace gas
27000 nm3
Toxic, Fire and
Explosion
13
Other chemicals like
Naptha, Solvent, Ethyl
Mercaptan, Sulphur
dioxide, Sodium
Hydroxide, etc.
5402 Mt
Toxic, Fire & Explosion
-
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
Glance on District wise distribution of Hazardous materials
• Large storage of capacity of petroleum product is at
Dakshina Kannada followed by Bangalore Districts.
• Large quantity of chlorine is handled at Uttara Kannada
followed by Shimoga and Haveri Districts.
• Large quantity of Ammonia is being handled at
Dakshina Kannada.
• Large quantity of liquid oxygen is being handled at
Bellary Districts.
• Large quantity of (5.6 million metric tones per annum)
petroleum products is being pumped in the Mangalore –
Bangalore oil pipeline.
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
MAJOR CHEMICAL ACCIDENT INDUSTRIES – DISTRICT WISE WITH HAZARD MATRIX.
No. of MAH
units
Sl.
No.
Name of
the
District
1
Bangalore
Rural
19
-
2
Bangalore
Urban
09
-
3
Ramanaga
ram
04
-
4
Belgaum
04
01
5
Bellary
-
03
6
Dakshina
Kannada
11
01
Petrole chem
um
ical
Hazards
Fire
Toxi
Explo
c
Poison
sion rele
ing
ase
spilla
ge
combin
ation



7
Dharwar
06
-
8
Haveri
-
02
9
Kolar
01
-
10
Koppal
-
01
11
Mysore
07
-
12
Raichur
-
01
13
Shimoga
01
02
14
Tumkur
02
-
15
Uttar
Kannad
a
-
02
16
Hassan
01
-
17
Udupi
01
-
67
12
Total





M/S. INDIAN OIL CORPORATION LIMITED, LPG BOTTLING PLANT,
DEVANAGONTHI, HOSKOTE TALUK, BANGALORE
Worst case scenario
: Rupturing of in 1400 MT LPG Horton sphere due to Boiling liquid vapour explosion
Zone A
– 37.5 Kw/M2 – 524 M rad – 100% lethality
Zone A – 37.5 Kw/M2 – 524
(Plant personnel)
M rad – 100% lethality
(Plant personnel)
Zone- A
Affecting areas
Plant personnel
Public and vehicles passing nearby
Total
Population
100
50
150
12.5 Kw/M2 – 908 M rad – 1% lethal
(Kanekkal, Devalapura)
Zone B
Zone - B
Affecting areas
Plant personnel
Public and vehicles passing nearby
Kannanehalli village
Population
100
50
450
Zone C
Zone C
- 4.0 Kw/M2
- 1830 M
- First Degree burns
Affecting areas
Plant personnel
Public and vehicles passing nearby
Kannanehalli village
Kacharnahalli village
Dasaraha
Doddasandra
Total
Population
100
50
450
300
400
500
1950
M/S. MCF LIMTIED, PANAMBUR, MANGALORE
Worst case scenario :
Steady state released of 300 MT/hr liquid Ammonia which is considered
equivalent to instantaneous release of 700 tonnes.
Likely affecting areas
1 KM radius circle
Panambur, Baikampady, Padukodi and a small portion of
Padukodi.
2 KMs radius
Bangra Kulur, Kunjathbail, Padukodi, Kulai and portion of
Kavoor, Markada, Kenjar, Thokur.
3 KMs radius
Hosabettu, Kenjar, Markada, Derebail, Boloor and major portion of
Thannirbavi, Kavoor, Kulai, Bala, Kalavar, Malavoor.
4 KMs Radius
Kodialbail, Kasba Bazar, Pachanady, Padushedde, Katipalla, Iddya and
smaller portion of Kadri, Padav, Mudushedde, Adyapady, Malavoor, Bajpe,
Kavoor and Bala.
HAZARDOUS MATERIALS TRANSPORTED THROUGH
UNDERGROUND PIPE LINES WITH ROUTES AND HANDLING
STATIONS.
Sl.
No.
1
2
Name of the
pipeline
Mangalore Hassan
Bangalore Pipe Line
project ( MHB
Petronet
Devanagonthi
Devanahalli Pipe
line project
Products
transferred
Length in
distance
Routes
Petroleum
Products like,
HSD, MS,
SKO,
Mangalore to
Hassan
156kms and
Mangalore Chikkamagalure –
Hassan with POL
depot & pipelines
station.
Diesel
206 kms up to
Devanagonthi.
Hassan - Tumkur –
Bangalore Rural
District,
36kms
Bangalore Rural
District
Devanagonthi –
Devanahalli
ATF
3
Reliance Pipe line
project
Natural Gas
68 kms
Bidar with
pumping station of
Humunabad Tq
4
Pipe lines between
NMPT to MCF,
Ammonia
Phosphoric
acid naphtha
1 km
NMPT, Panambur
5
Pipe lines between
NMPT to MRPL &
Vice Versa
Crude oil
Petroleum
products
LPG
10.8 kms
NMPT Panambur,
Kunthethur, Bala
6
Pipe lines between
NMPT to HPCL,
MLIF
LPG
11.2 kms
NMPT Panambur,
Kunthethur, Bala
7
NMPT to BPCL
Petroleum
products
3 kms
NMPT, Panambur,
Baikampady.
PORTS HANDLING HAZARDOUS MATERIALS IN THE
STATE – DISTRICT WISE
Type of port
Hazardous Material
handled
Dakshina Kannada
District
New
Mangalore
Port Trust,
Panambur
Major port
Crude oil
Petroleum products
Ammonia
Phosphoric acid
Edible oil
LPG
Methyl metha crylate
Sodiuk metha bisulphate
Uttara Kannada
District
Karwara
port,
Karwara
Minor port
Petroleum products
Edible oil
Udupi District
Maple Port,
Maple
Minor port
Soda ash
District
Location
Compliance by the State
•
The State Crisis Group has been constituted in
the year 1998.
•
The District Crisis Groups
have been
constituted in all the 15 Districts which are
having MAH units and reconstituted wherever
necessary.
•
The Local Crisis Groups have been constituted
in respect of six talukas ( wherever MAH
industries are located away from the District
Head Quarters).
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
The Constitution of different Crisis Groups under the
Chemical Accident (Emergency Planning, Preparedness
and Response) Rules, 1996 speaks on four tier system of
Control and Mitigation procedures. They are :I.
Central Crisis Group.
Secretary, Government of India,
Ministry of Environment and Forest.
II.
III.
State Crisis Group.
Chief Secretary to Government.
District Crisis Group.
Deputy Commissioner / District Collector.
IV. Local Crisis Group.
Sub-Divisional Magistrate.
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
Functioning of SCG
• Monitoring the
– safety status of MAH installations in the state.
– preparation and updating of Off-site emergency plans.
– siting of major and potentially hazard installations.
• Identifying the shortfalls in resources required to
handle the emergencies recommending the concerned
for compliance.
• Reviewing of chemical accidents.
• Assisting the district in fulfilling the shortfalls and
augmentation of emergency facilities.
• Conducting of National / State level symposiums,
seminars, workshops for sensitization of top and
middle level managements and public authorities.
• Reviewing of off-site emergency plans and mock drills.
• Updating the Central Crisis Group by furnishing the
necessary informations.
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
Functioning of DCG
• All the Districts are conducting DCG meetings at an
intervals of 3 – 6 months.
• Reviewing the
–
–
–
–
Health and safety status of the industries,
On site emergency plans
Mock drills conducted by the industries.
Infrastructure facilities available in industries, emergency
authorities and other organizations.
– Inspections and Compliance by the industry.
• Conducting the on site emergency mock drills in
presence of district administration, experts and local
authorities to analyse the strength and weakness in
the system.
• Assist the district administration in handling of
disasters and emergencies.
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
• Preparation and publication of off-site
emergency plan and reviewing on need
basis.
• Investigation of chemical accidents.
• Conducting public awareness programmes
• Conducting
training
programmes,
workshops, seminars and symposiums.
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
Details of DCG constituted
Sl.N
o.
Name of the District
NO. of
Whether DCG
MAH units constituted or not?
1
Bangalore Rural
18
Constituted
2
Bangalore Urban
13
Constituted
3
Belgaum
05
Constituted
4
Bellary
03
Constituted
5
12
Constituted
6
Dakshina
Kannada
Dharwar
06
Constituted
7
Haveri
02
Constituted
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
Details of DCG constituted
Sl.N
o.
Name of the District
NO. of
Whether DCG
MAH units constituted or not?
8
Hassan
01
Constituted
9
Kolar
01
Constituted
10 Koppal
01
Constituted
11 Mysore
07
Constituted
12 Raichur
01
Constituted
13 Shimoga
03
Constituted
14 Tumkur
15 Uttara Kannada
02
02
Constituted
Constituted
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
Functioning of LCG.
• Assisting the DCG in preparation of off-site
emergency plan.
• Conducting on site emergency mock drills.
• Coordinating
with
the
industries
augmenting the mutual aid system
industrial pockets.
in
in
• Preparation of resource directories.
• Conducting
programmes.
local
public
awareness
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
Constitution of Local Crisis Groups
Sl.
No.
Name of the District
NO. of
Whether DCG
MAH units constituted or not?
1
2
3
4
5
Haliyal
Puttur
Ramanagaram
Nelamangala
Hoskote
01
01
03
07
06
Constituted
Constituted
Constituted
Constituted
Constituted
6
Kunigal
02
Constituted
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
Initiatives of the State Government
• Constitution
of
Monitoring Cell.
Central
Safety
• Site Appraisal Committee has been
constituted
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
THE CENTRAL SAFETY MONITORING CELL(1989).
 Identify hazardous Industries.
 Creation of data-bank
 Approval of On-site Emergency Plans.
 Assisting the Districts in preparation of Off site emergency
plan.
 Organize awareness programmes / Seminars/ Symposiums/
Workshop, in Prevention of Chemical Disasters.
 Monitoring the inspections of MAH installations,
 organizing the expert committees visits.
 Monitoring of work environment using scientific
instruments.
 Coordinating with NDMA and DMI in conducting of off site
exercise and other awareness programmes.
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
Technical Assistance
 State/ District/ Local Crisis Groups
 Periodical Mock-rehearsals / Public awareness .
 Investigation into all Chemical Accidents.
 Information to Central Crisis Group.
 Coordination with Governmental and
Non- Governmental agencies.
CHEMICAL INDUSTRIES STATISTICS
Sl
No
Particulars
Total
1
No. of chemical units
1019
2
No. of MAH Units
3
No. of employees involved in hazardous industries
4
No. of On-site Emergency Plans approved in respect of
MAH units
77
5
No. of Safety Audit & Safety reports prepared.
25
6
No. of rehearsals (mock drill) of Major Accident Hazard
Industries.
212
77
1,41,857
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
STATISTICS OF CSMC
Subject
2006
2007
2008
No. of On site emergency plans
approved
104
111
97
No. of on site emergency mock drills
conducted
124
192
206
No. of public awareness programmes
conducted
02
02
08
No. of special training programmes
conducted
01
03
03
No. of state level seminars
02
01
01
No. of off site emergency moke drills
conducted
02
02
02
No. of state level off site emergency
moke drills conducted
--
01
01
Special achievements
• The full scale Off site emergency mock
exercise was conducted under the aegis of
NDMA, New Delhi and DMI, Bhopal.
• State level seminars conducted
– Plant and Process Safety, Emergency Preparedness in
Hazardous Industries – 2005.
– Disaster Prevention, Planning and Emergency Response
in Hazardous Industries
– 2006.
– New Trends and Challenges in SHE Management in
Hazardous Industries
– 2007.
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
State level Site Appraisal Committee constituted
w.e.f. 11.12.2007

Director of Factories and Boilers
-
Chairman

KSPCB ,Member Secretary
-
Member

ROC, Officer In-charge
(Occupational Health Specialist)
-
Member

IISc-Professor and HOD
(Chemical Engineering Dept)
-
Member

State Oil Coordinator
(Oil Industry Expert)

Joint Director of Factories
-
Member
Member Convener
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
State level Site Appraisal Committee
Main Functions
 Clearance for siting and expansion of MAH
and potentially hazardous industries
 Review of On-Site and Off-Site Emergency
plans
 Visiting the factories to review the safety and
health status.
 Investigation of chemical accidents/ disasters
and give its report and recommendations.
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
Statistics of SAC-
2008
Subject
No’s
No. of site clearances issued for
initial location / expansion
101
No. of on site emergency plans
reviewed and revised
05
No. of hazardous installations visited
08
No. of accidents / dangerous
occurrences investigated
04
No. of meetings conducted
10
No. of accidents / dangerous
occurrences investigated
04
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA
THANK YOU
H.Srinivasaiah
Director of Factories & Boilers in
Karnataka
DEPARTMENT OF FACTORIES AND BOILERS, KARNATAKA