Trisha Speciality Chemical Pvt. Ltd., Plot no.1015 & 1016, GIDC Estate, Kerala, near Bavla, Taluka-Dholka, District-Ahmedabad, State Gujarat CHAPTER 6 RISK ASSESSMENTS AND SAFETY MEASURES 6.1 PREAMBLE Increasing use of hazardous chemicals as raw materials, intermediates and finished products has attracted attention of the Government and the public at large in view of the chemical disasters. The serious nature of the accidents, which cause damage to the plant, personnel and public, has compelled industries to pay maximum attention to the safety issues and also to effectively manage the hazardous material and operations. It is mandatory for the industries handling hazardous chemicals to maintain specific safety standards and generate an on-site emergency plan and keep it linked with offsite emergency plan. The Risk Assessment Study and Safety Management for the proposed expansion of M/s. Trisha Speciality Chemicals Pvt. Ltd. have been carried out and the details are elaborated in this chapter. Based on the findings & recommendations of RA report risk management plan for the proposed project has also been prepared and included. Risk Assessment is defined as a continuous and integrated process of identification, evaluation and measurement of risks, along with their potential impact on the organization. The benefits of risk assessment include the following: Prevention or reduction in occurrence of accidents. Mitigation of the severity and/or consequences by way of improved process techniques, fire protection systems, arrangements of storage, inventory monitoring to fit production requirements. Development of confidences in employees by improving competency. Preparedness and prompt response to deal with any accident. The safety management includes the implementation of preventive methods or accident prevention methods to avoid incident or accident and handling of emergency in case of accident. 6.2 Objectives & methodology of risk assessment study A three ‘LEVEL’ risk assessment approach has been adopted. The brief outline of the three tier approach is given below: Level 1 Risk Screening This is top down review of worst case potential hazards/risks, aimed primarily at storage of chemicals, which pose the highest risk. The Material Safety Data Sheets (MSDS) of the chemicals were reviewed to identify the potential hazards posed by the chemicals. Various screening factors considered include: o Inventory of hazardous materials; o Hazardous properties; RAONEP Report Prepared by Ahmedabad 1 Trisha Speciality Chemical Pvt. Ltd., Plot no.1015 & 1016, GIDC Estate, Kerala, near Bavla, Taluka-Dholka, District-Ahmedabad, State Gujarat o Storage capacity Level 2 Risk Scenario Identification After identification of potential hazards, different risk scenarios were delineated for each of the chemicals based on the nature of hazard. Level 3 Quantitative Risk Assessment ALOHA 5.4.7 version software was used for the risk assessment of the raw materials and products, which will be stored at the premises. Risk assessment was carried out for each of the risk scenarios identified for the chemicals in case of leakages from the storage tanks. Worst possible scenarios were taken into account for the risk analysis. 6.3 Hazards Classification 6.3.1 Details of Hazardous Chemicals RAONEP Report Prepared by Ahmedabad 2 Trisha Speciality Chemical Pvt. Ltd., Plot no.1015 & 1016, GIDC Estate, Kerala, near Bavla, Taluka-Dholka, District-Ahmedabad, State Gujarat Table 6.1: Hazardous chemical Identification as per MSIHCR with storage details Day Tank Storage Tank details, MT Total Hazardous Falling under category of Threshold Storage Storage No. Hazard Chemical name MSIHC Rules Quantity in MT Capacity, MT Existing Proposed Total capacity, MT 1 Caustic lye 1. As per Schedule 1 Part I (a) - 3 37 - 37 40 Corrosive sr. no. 3 as Toxic chemical as LD50 as 90 mg/kg falling between 50 to 200 mg/kg 2. Sr. no. 571 of schedule 1 part II 2 Formaldehyde 1. As per Schedule 1 Part I(b) 5 T for rule 5,7- 1.62 27.00 - 27.00 28.62 Flammable , (v) as flammable liquid 9,13-15 toxic under rule 2e (i), 4 (1)(a), 4(2), 17 and 18 50 T for 10-12 2. As per Schedule 1 Part I (a) sr. no. 3 as Toxic chemical as LD50 as 100 mg/kg falling between 50 to 200 mg/kg 3. Sr. no. 285 of schedule 1 part II 4. Sr. No. 112 of Group-2 Toxic Substance in Schedule 3 Part I 3 Octanol 1. As per Schedule 1 Part I(b) - 3 - 25 25 28 Flammable (iii) as very highly flammable liquids under rule 2e (i), 4 (1)(a), 4(2), 17 and 18 4 Oleum (23 %) 1. Sr. No. 121 of Schedule 3 15 t (as Sulfur 5.67 - 38.00 38.00 43.67 Corrosive Part I Group 2 Toxic Tiroxide-SO3) for &toxic substance rule 5, 7-9 and 2. Sr. no. 444 of schedule 1 75 t for 10 to 12 part I as Oelum RAONEP Report Prepared by Ahmedabad 3 Trisha Speciality Chemical Pvt. Ltd., Plot no.1015 & 1016, GIDC Estate, Kerala, near Bavla, Taluka-Dholka, District-Ahmedabad, State Gujarat Day Tank Storage Tank details, MT Total Hazardous Falling under category of Threshold Storage Storage No. Hazard Chemical name MSIHC Rules Quantity in MT Capacity, MT Existing Proposed Total capacity, MT 3. Sr. No. 590 of schedule 1 part I as Sulfur Trioxide 4. Sr. no. 11 of Schedule 2 Sulfur Trioxide storage as Isolated storage 5 Sulphuric Acid 1. Group -2 – Toxic Substances - 2.76 37.00 - 37.00 39.76 Corrosive – sr.no.121- RAONEP Report Prepared by Ahmedabad 4 Trisha Speciality Chemical Pvt. Ltd., Plot no.1015 & 1016, GIDC Estate, Kerala, near Bavla, Taluka-Dholka, District-Ahmedabad, State Gujarat Table 6.2: Characteristics of hazardous chemicals to be used as per the MSIHC Rules Main properties (refer MSDS, Sch‐9 of MSIHC Rules) Full name of State : Solid, LD Sr. No. LEL 50 product Liquid or Gas LC mg/kg -oral B.P. F.P. 50 Specific Gravity Vapor Density mg/kg °C °C UEL (Water = 1) (Air = 1) LD % 50 mg/L -dermal 1 2 3 6 7 8 9 10 11 12 1. Caustic Lye Aqueous 1388 N.A. N.A. N.A. N.A. 2.300 -- 6 100 2. Formaldehyde Liquid 96 50 203 1.080 0.62 to 1.04 36 270 2047 3. Octanol Liquid 184 77 -- 1400 0.827 4.5 >2600 - 4. Oleum (23%) Liquid 100-140 -9 to 30 -- -- 1.892 --- 500 Sulphuric Acid -- 5. Liquid 270 – 340 -- 510 2140 1.840 3.4 (98%) -- RAONEP Report Prepared by Ahmedabad 5 Trisha Speciality Chemical Pvt. Ltd., Plot no.1015 & 1016, GIDC Estate, Kerala, near Bavla, Taluka-Dholka, District-Ahmedabad, State Gujarat 6.3.2 Potential Hazard Classification The hazard classification has been carried out based on the data provided in MSDS data sheets and as per the classification MSHIC Rules, 1986 and its amendments thereof. The hazard classification is given in Tab Table 6.3: Potential Hazard Classification and Analysis of Chemicals to be handled in the Proposed Expansion Unit No. Hazardous Chemical Hazard Rating System Type of Hazard/Risk Involved name 1 Oleum (Toxic and TLV – 5 ppm, STEL – 10 ppm, Toxic when contact with skin Corrosive Liquid) NFPA ratings: Health – 4 , Flammability -2 , Cause Burns Instability – 0 , Flash Point – NA Toxic , if swallowed Irritating to skin , eye and respiratory system 2 Octanol (Flammable TLV: - STEL: - Highly flammable and Corrosive liquid) NFPA ratings:Health: 2; Flammability: 2; Toxic when contact with skin Instability:0 Toxic by inhalation o Flash Point: 81 C Toxic , if swallowed Danger of very serious irreversible effects 3 Formaldehyde TLV – 0.3 ppm (1 ppm ), Flammable (Corrosive Liquid) NFPA ratings: Health – 3 , Flammability -2 , Toxic when contact with skin Reactivity – 0 , Toxic by inhalation Flash Point – 50°C Toxic , if swallowed Causes burn Limited evidence of carcinogenic effect Risk of serious danger to eyes. 4 Sulphuric Acid TLV – 1mg/m3, Toxic when contact with skin (Corrosive& Reactive) NFPA ratings: Health – 3 , Fire – 0 Physical-2 , Toxic by inhalation Personal Protection – C Toxic , if swallowed Causes burn Limited evidence of carcinogenic effect Highly reactive. Reacts violently with: many chemicals, including, water RAONEP Report Prepared by Ahmedabad 6 Trisha Speciality Chemical Pvt. Ltd., Plot no.1015 & 1016, GIDC Estate, Kerala, near Bavla, Taluka-Dholka, District-Ahmedabad, State Gujarat No. Hazardous Chemical Hazard Rating System Type of Hazard/Risk Involved name Corrosive to: aluminum alloys, carbon steel, and other metals. Risk of serious danger to eyes. 5 Caustic Lye (Corrosive STEL – 2mg/m3, Flammable & Reactive) NFPA ratings: Health – 3 , Flammability– 0 Toxic when contact with skin Instability-1 Toxic by inhalation Toxic , if swallowed Causes burn Limited evidence of carcinogenic effect Risk of serious danger to eyes. Incompatible Materials: Highly reactive. Reacts violently with: many chemicals, including, water, organic acids (e.g. acetic acid), inorganic acids (e.g. hydrofluoric acid), oxidizing agents (e.g. peroxides), metals (e.g. aluminum) Corrosive to: aluminum alloys, carbon steel, and other metals RAONEP Report Prepared by Ahmedabad 7 Trisha Speciality Chemical Pvt. Ltd., Plot no.1015 & 1016, GIDC Estate, Kerala, near Bavla, Taluka-Dholka, District-Ahmedabad, State Gujarat 6.4 Risk Scenarios: 6.4.1 Worst Case Scenario: In worst case scenario conditions, For projection of maximum effects due to release of chemicals is considered by considering maximum amount of chemical leakage or at sudden release of all the chemicals within a minute time, in the atmosphere, with considering meteorological data for projection of probable loss of chemicals, release of fumes, vapor and area covered, number of persons affected. It is projection at project stage, to take preventive measures to avoid such type of incidents, at actual level. It is also useful for training and awareness for company employee and surrounding village or nearby people by giving proper information in prior, to take care of emergency in real condition.