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The Primary Emphasis in Safety Engineering Is to Reduce Risk to Human Life, Property and Environment. Some of the More Important Methods Used to Achieve This Are

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The Primary Emphasis in Safety Engineering Is to Reduce Risk to Human Life, Property and Environment. Some of the More Important Methods Used to Achieve This Are Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL) CHAPTER 7. ADDITIONAL STUDIES This Chapter provides the details about the Quantitative Risk Assessment and emergency plan as proposed for the proposed project. 7.1. Introduction Industrial plants deal with materials, which are generally hazardous in nature by virtue of their intrinsic chemical properties or their operating temperatures or pressures or a combination of these. Fire, explosion, toxic release or combinations of these are the hazards associated with industrial plants using hazardous chemicals. More comprehensive, systematic and sophisticated methods of Safety Engineering, such as, Hazard Analysis and Quantitative Risk Assessment have now been developed to improve upon the integrity, reliability and safety of industrial plants. The primary emphasis in safety engineering is to reduce risk to human life, property and environment. Some of the more important methods used to achieve this are • Quantitative Risk Analysis: Provides a relative measure of the likelihood and severity of various possible hazardous events by critically examining the plant process and design. • Work Safety Analysis: The technique discerns whether the plant layout and operating procedures in practice have any inherent infirmities. • Safety Audit: Takes a careful look at plant operating conditions, work practices and work environments to detect unsafe conditions Together, these three broad tools attempt to minimize the chances of accidents occurring. Yet, there always exists, no matter how remote, probability of occurrence of a major accident. If the accident involves highly hazardous chemicals in sufficiently large quantities, the consequences may be serious to the plant, to surrounding areas and the populations residing therein. 7.2. Scope of Work The scope of the study is to model and appraise the risks associated with all toxic , flammable and explosive hazards resulting from potential loss of containment accident scenarios from M/s Smartchem Technologies Limited (henceforth STL) Operations of Technical Ammonium Nitrate Plant [which comprises of 900 MTPD (100% basis) Nitric Acid (NA) plant to manufacture Ammonium Nitrate solution 1143 MTPD (100% basis] at the Industrial Park being developed by Tata Steel SEZ Limited (TSSEZL) at Gopalpur, Odisha and developing a Disaster Management Plan. 7.3. Objectives The specific objectives of the study are to identify: • Hazardous materials associated with the project EQMS INDIA PVT. LTD. 231 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL) • Potential consequences of identified threats • Recommend risk prevention and reduction measures to ensure that all risks are within ALARP. • Defines the actions to be taken in case of emergencies. 7.4. Methodology of HIRA Hazard Identification and Risk Assessment: Hazard is defined as a chemical or physical condition those have the potential for causing damage to people, property or the environment. In this chapter the hazards associated with only the proposed expansion project have been discussed. The primary step of the Hazard identification is the risk analysis and entails the process of collecting information on: • the types and quantities of hazardous substances stored and handled at the plant, • the location of storage tanks & other facilities, and • potential hazards associated with the spillage and release of hazardous chemicals. 7.4.1. Identification of Hazards The main hazard potentials in the proposed Plant, Plant are categorized as below: • Material hazards; Associated with Hazardous Materials Storage Facilities. • Process hazards due to loss of containment during handling of hazardous materials or processes resulting in fire, explosion, etc • Mechanical hazards due to "mechanical" operations such as welding, maintenance, falling objects etc. - basically those NOT connected to hazardous materials. • Electrical hazards: electrocution, high voltage levels, short circuit, etc. Out of these, the material and process hazards are the one with a much wider damage potential as compared to the mechanical and electrical hazards, which are by and large limited to very small local pockets. 7.5. Hazardous Materials Bulk Storages at STL Plant The major hazardous chemical to be stored at the STL site will be Ammonia, Ammonium Nitrate, Chlorine, fuel and other hazardous chemicals etc. as given below in the Table 7.1: Table 7.1 : Bulk Storages at STL Plant Sr No. Hazardous Chemical Type of storage Capacity in MT Ammonia Atmospheric 1. Ammonia 10,000 X2 Storage Tanks Overall TAN storage 2. Ammonium Nitrate (TAN) 4400 capacity Weak Nitric acid 3. Tank 1500 X 4 (100 % Basis) EQMS INDIA PVT. LTD. 232 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL) Ammonium nitrate 4. solution storage (100 % Tank 3 x 30 Basis) 5. Sulphuric Acid (98%) Tank 25 X 1 6. Caustic (48-50%) Tank 35 X 1 7. Coal for Boiler Bulk 2000 8. Chlorine 100 kg cylinders 5 cylinders 9. Diesel Tank 990 litres 10. LPG 19.5 kg cylinders 5 cylinders 7.5.1. Hazardous Analysis of Bulk Storage Materials STL will be using several raw materials but only few are stored in bulk and few chemicals are listed under “List of hazardous and Toxic Chemicals” category under MSIHC Rules, 1989. The raw materials coming under hazardous category as specified by MSIHC Rules, 1989 (including subsequent amendments) is given in Table 7.2 below: EQMS INDIA PVT. LTD. 233 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL) Table 7.2 : Hazard Analysis of Bulk Storage Materials S No Material S. No & Threshold Quantity (TQ in Chemicals Hazards Potential Remarks Kg) as per MSHIC Rules Schedul Schedule- Schedule-3, Hazards Toxic e-1, 2, Part-I DT->---mg/Kg; Part-II OT----mg/Kg; IT----mg/l; (Rats) 1. 31 2 105 Fire Hazards: (Gas); Mixing ERPG-1: 25 ppm Contact with liquid may cause Ammonia TQ-1: 60 TQ-1: 50 MT of ammonia with several ERPG-2: 150 ppm froast bite. MT TQ-2: 500 chemicals can cause fire IDLH: 300 ppm TQ-2: 600 MT hazards, / or explosions; MT vapours are toxic- irritation to eyes and respiratory tract. 2. 423 -- -- Yellow to brown liquid with Inhalation LC-50 (rat Eye: Causes severe eye burns. Nitric Acid suffocating strong odour 4-h): 0.13 mg/L May cause irreversible eye HNO3 – 60-62%; 2 ppm TWA; 4 ppm injury. NO2->6%’ STEL Skin: Exposure of the skin to the liquid or concentrated CAS No.: 7697- vapor produces severe and 37-2 penetrating burns. Ingestion: Causes gastrointestinal tract burns Inhalation respiratory tract. 3. 33 --- 126 Ammonium nitrate is ; d steel Ammonium TQ-1: 350 moderately toxic if large Nitrate MT amounts are swallowed; CAS No: 6484- TQ-2: 2500 Highly Reactive 52-2 MT EQMS INDIA PVT. LTD. 234 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL) S No Material S. No & Threshold Quantity (TQ in Chemicals Hazards Potential Remarks Kg) as per MSHIC Rules Schedul Schedule- Schedule-3, Hazards Toxic e-1, 2, Part-I DT->---mg/Kg; Part-II OT----mg/Kg; IT----mg/l; (Rats) White odourless When heated to prills, with decomposition (unconfined) strong ammonium nitrate produces disagreeable nitrous oxides, white acrid taste. ammonium Ammonium nitrate fumes. nitrate is not Ammonium nitrate is flammable. incompatible with copper, zinc, or their alloys (i.e., Gr. 3-Highly bronze, brass, galvanised Reactive metals, Substance etc.), aluminium powder Decomposes and mil from 170 °C before boiling water 4. 119 5 108 ERPG-1: 1.0 ppm Hazards: Poisonous; may be Chlorine TQ-1: 10MT TQ-1: 10MT Non Combustible; May ERPG-2: 3.0 ppm fatal if inhaled. Contact may CAS No:7782- TQ-2: 25 TQ-2: 25 MT ignite other combustible ERPG-3: 20 ppm cause burns to skin and eyes. 50-5 MT materials (wood, paper, oil, IDLH: 10 ppm Bronchitis or chronic lung UN No:1017 etc.). Mixture with fuels may conditions cause explosion. Container Poisonous; may be fatal if may explode in heat of fire. inhaled. Contact may cause EQMS INDIA PVT. LTD. 235 Final EIA report for Proposed Technical Ammonium Nitrate Manufacturing Plant at DLCT- 1, Domestic Tariff Area, Gopalpur Industrial Park, Chamakhandi, Tehsil- Chatrapur, District- Ganjam, Odisha-761020 by M/s Smartchem Technologies Ltd. (STL) S No Material S. No & Threshold Quantity (TQ in Chemicals Hazards Potential Remarks Kg) as per MSHIC Rules Schedul Schedule- Schedule-3, Hazards Toxic e-1, 2, Part-I DT->---mg/Kg; Part-II OT----mg/Kg; IT----mg/l; (Rats) A greenish Chlorine reacts explosively burns to skin and eyes. yellow gas with with or supports the burning Bronchitis or chroniclung a pungent of numerous common conditions suffocating odor. Toxic by inhalation. 5. 591 Flammability: Will not burn ERPG-1: 2.0 mg/m3 Sulphuric Acid Health Hazard: Extremely CAS No: 7664- ERPG-2: 10 mg/m3 hazardous - use full 93-9 UN No: protection; Reactivity: ERPG-3: 30 mg/m3 1830 Violent chemical change IDLH: 15 mg/m3 possible 6. 571 --- --- Not flammable; Corrosive to ERPG-1: 0.5 ppm Caustic Soda metals and tissue. (Sodium ERPG-2: 5.0 ppm Hazardous. Hydroxide) ERPG-3: 50 ppm CAS No: 1310- 730-2 IDLH: ---- ppm UN No: 1823 7. LPG 347 6 1 Inhalation: --- Colourless / TQ-1: 50 TQ-1: 15MT • Irritation of eyes & Odourless (but MT TQ-2: 200 respiratory tract MT • Burning action on skins EQMS INDIA PVT.
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