Mock Exercise on Chemical (Industrial Disaster)

Indian Oil Corporation Ltd.

LPG Bottling Plant, Devanagunthi Vijay Kumar C.

Sr. Plant Manager

Profile of Devanagunthi LPG Bottling Plant Plant is situated at Devanagunthi.

45 Km from Banglore Dist HQ. Neighbouring Industries 1. IOCL (Terminal) – 2. BPCL (Terminal) – 1.0 Km away 1.25 Km away 3. HPCL (Installation) 1.5 Km away 4. Petronet MHB Limited-1.25 Km away

Indane bottling plant Layout

Major Activities



LPG receipt by rail and road, Storage, bottling & Despatch



Loading of LPG bullet trucks for Auto LPG Dispensing stations and other bottling plants

Bulk LPG Receipt



Source of Receipt : Rail Wagons from Mangalore and Hazira and road tankers from CPCL



Supply Area : Bangalore city, Peripheral markets of Bangalore city

LPG BOTTLING PLANT, DEVANAGUNTHI – MAH INDUSTRY

•

Bottling Capacity Existing : 138 TMTPA Proposed: 232 TMTPA

•

Total Land Area : 93.35 ACRES

•

Green belt Area : 25 ACRES

Bulk LPG Storage Facilities

Existing Additional Existing 3150 MT Sphere 2 x 1400 MT Bullets 2 x 100 MT Bullet 1 x 150 MT Mounded 3 x 1200 MT Bullets After Augumentation 6750MT

Bulk Receipt Facilities

•

By Road 12 nos. Tank lorry unloading bays with unloading arms.

•

By Rail Two spur full rake gantry unloading facility. Equipped to unload both conventional and BTPGLN wagons.

Population in nearby Villages

Sl. No.

1 2 6 7 5 3 4 Name of the village Kacharakanahalli Dasarahalli Geddlapura Dodda Donnasandra Kannekal Makkanahalli Devalapura Population 437 458 163 1677 410 1465 446

Material Safety Data

Product Name Trade name Formula Physical State Appearance Odor Solubility in Water Calorific Value (Kcal / Kg.) Explosivity

Flammability Extinguishing Media Special Procedures LPG. Bottle gas, Liquefied hydrocarbon gas.

LPG Mixture of propane and butane Gas Colourless Odorless/stanche d Insoluble 11400 Highly explosive Dangerous

UN No.

IDENTITY OF MATERIAL :

1075

HAZCHEM Code PHYSICAL AND CHEMICAL PROPERTIES Boiling Point / Range , deg. C Melting / Freezing Point , deg. C Vapor Density (Air =1)

1

138

1.5 to 2.0

Vapor Pressure at 65 deg. C, Specific Gravity , 20 deg. C

0.53 to 0.57

Dyn. Viscosity (PA.S 30 deg. C) Molecular Weight.

FIRE AND EXPLOSIVE DATA

Auto Ignition Temp. deg. C 405-450 Explosive Limits , % 2WE 1.8 – 9.6

Label / Class

Red: Flammable Liquid / 2.1

16.9 kg/cm2 CO 2 , DCP. Water spray may be used to control and confine LPG fires.

Do not attempt o extinguish fire until leak has been shut off. For small fire use dry chemicals. Let large fires burn if not heating the container. When exposed to heat and flame, containers may rupture due to BLEVE

Risk Analysis

•

Based on three steps

• • •

What can go wrong? (Hazard identification) How often it can go wrong? (Failure frequency) What are the effects of consequences? (Effect and damage calculations)

MODES OF FAILURE OF PRODUCT STORAGE VESSELS

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Material and construction failures

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Corrosion

•

Gasket failures

PRINCIPAL HAZARDS - LPG Flammability & Explosion



Jet Fire

 

Pool Fire BLEVE

 

Flash Fire UVCE

  

Asphyxia Cold Burns Metal brittleness due to Low temperature

Consequences Analysis

Damages are caused due to • Heat radiation • Overpressure effect from explosions • Toxic effect

Exposure time, heat radiation and damage levels Intensity of radiation (Kw/ m2 Exposure time in Seconds 37.5

12.5

4 28 28 28 % Lethality 100% Lethality 1% Lethality /100 % first deg.burns

1% first degree burns

Damage distance for BLEVE

Storage Vessel LPG in MT BLEVE Radious (m) Radiation distance in meters to 37.5 KW/m2 12.5 Kw/m2 4.0 KW/m2 HORTON SPHERE 1400 273 524 908 1830

Damage contour for catastrophic failure of 1400 MT sphere

Zone A

Zone A – 37.5 Kw/M2 – 524 M rad – 100% lethality (Plant personnel)

Zone B

Zone - B

12.5 Kw/M2 – 908 M rad – 1% lethal (Kanekkal Village)

Zone C

Zone C

- 4.0 Kw/M2 - 1830 M - First Degree burns (Kacharakanahalli, Dasarahalli, Giddapura,Doddasandra)

Risk intensity

Zone Zone A Radiation (KW/M2) Distance in meter 37.5

524 Affected population Plant Personnel 80 Zone B 12.5

908 Zone C 4 1830 Kanekal village 443 Kacharaknahalli Dasarahalli Gidlapura Donnasandra Makanahalli Devalapura Vagatta Neighboring industries 472 495 176 1811 1582 482 1103 400

Mitigation measures

      Gas Monitoring System Air/Vapor Extraction System Remote control Valve Emergency Trip Button Manual Call point Quartzoid bulb detector.

Fire Fighting Facilities

• FIRE WATER STORAGE TANKS 3 Nos. of 4000 KL capacity each FIRE PUMPS • 8 Nos. diesel driven water pumps of 410 / Hr. capacity each. • JOCKY PUMPS 2 Nos. of 24 Cum /Hr .

CUM

Fire Fighting Facilities

• Ring main hydrant system • 57 double hydrant points • 46 water monitors • 4 long range monitors covering truck Parking Area.

• Auto sprinkler system for Sheds , TLD , Storage Vessels and Tank Wagon Gantry.

Additional Safety Features

• Carousel Inter locked with Vapour extraction system • Remote operated valves for LPG pipe line inter locked with sprinkler system • LPG and Air compressors inter locked with cooling water pumps.

• Emergency trip buttons and Manual call stations at strategic points.

• ROV closure of Storage Vessel interlocked with HLAs.

On-site Emergency Plan

• Detailed on-site emergency management plan prepared and approval obtained from Dept. of Factories.

• Emergency Response Drills (ERDs) are conducted twice in a year.

• Mock drills are conducted every month & shortcomings are addressed.

• Mutual aid arrangement with neighbouring industries.

Mutual Aid

To Assist its neighbouring industries in responding to emergencies that may occur either on-site or off-sites.

Member

IOCL, Terminal BPC Terminal HPCL Installation PETRONET Mutual Aid agreemnt

Roles and responsibilities

Traffic control and smooth evacuation of trucks Assist the Rescue Team members Assist Auxilliary team members Assist Auxilliary team members

Fire Fighting Organisation Chart

FIRE IN CHIEF: Sr. Plant Manager Alternate FIRE IN CHIEF: Manager (P) FIRE COMBAT TEAM

Team In Charge: Floor Officer Alternate team Incharge: Officer (Bulk Operations) Assisted by: 1.

Tally operator 1 2.

Tally operator 2 3.

Segregation 1 4.

Segregation 2 5.

Pump House 1 6.

TLD 7.

Carousel Tare wt. 1 8.

Carousel Tare wt. 2 9.

Evacuation 10.

ICU 11.

Gantry operator 1 12.

Gantry operator 2 13.

Security guard 1 (Main gate) 14.

Security guard 2 (Main gate) 15.

Security guard 3 (Patrolling)

AUXILIARY TEAM RESCUE TEAM

Team In Charge: Manager (P) Assisted by: Team In Charge: Asst. Manager (F) Alternate team Incharge: S&D officer Alternate team Incharge Accounts officer-II : Assisted by: 1.

Dy. Manager (P) 2.

Safety Officer 3.

Maintenance Officer 4.

Maintenanc e operator 1 5.

Maintenanc e operator 2 6.

Employees on Relief 7.

Security guard 3 (Stores) 8. Security guard 4 (Gate –2) 1.

A O - II 2.

Sr. Assistant

Emergency Transport facility

 Dedicated Vehicle for emergency transportation is available round the clock.

 Between 08.00 hr to 17.15 hr one more vehicle also will be available.

Shutting down procedure

Shutting down is done through the following means:  Emergency trip Buttons & Manual Call Point  Remote Control Valves  Quartzoid Bulb detector.

On site Emergency Structure

The basic concept of this plan is to provide a comprehensive approach for managing emergencies. Four elements of this plan are 

Prevention

- incorporates all those activities that eleminate the probabilityof disaster occuring on-site.



Preparedness

- includes all activities necessary to ensure a high degree of readiness 

Response

- measures taken during an incident which minimise damage to life and property.



Recovery

– includes those short and long-term activities that return all systems to normal operations.

Declaration of Emergency

Upon declaration of Emergency Sr.Plant Manager  makes initial assessment of incident and determine the need for evacuation.

  ensure that all personnel are accounted for.

ensure that outside agencies are communicated as per DMP as follows:          Dy. Commisioner Regional, State & Head Offices Fire Dept Law & Order Revenue Dept Local Panchayat Railways KPTCL Medical Dept.

Public Awareness Programs

Various programs being conducted For creating public awareness to the Neighboring villages.