Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products 7.0 ADDITIONAL STUDIES 7.1 RISK ASSESSMENT 7.1.1 Risk Analysis Accidental risk involves the occurrence or potential occurrence of some accident consisting of an event or sequence of events resulting into fire, explosion or toxic hazards to human health and environment risk assessment (RA) provides a numerical measure of the risk that a particular facility poses to the public. It begins with the identification of probable potential hazardous events at an industry and categorization as per the predetermined criteria. The consequences of major credible events are calculated for different combinations of weather conditions to simulate worst possible scenario. These consequence predictions are combined to provide numerical measures of the risk for the entire facility. MCA stands for maximum credible accident or in other words, an accident with maximum damage distance, which is believed to be probable. MCA analysis does not include quantification of the probability of occurrence of an accident. In practice the selection of accident scenarios for MCA analysis is carried out on the basis of engineering judgement and expertise in the field of risk analysis especially in accident analysis. Detailed study helps in plotting the damage contours on the detailed plot plan in order to assess the magnitude of a particular event. A disastrous situation is the outcome of fire, explosion or toxic hazards in addition to other natural causes that eventually lead to loss of life, property and ecological imbalances. 7.1.1.1 Methodology of MCA Analysis The MCA analysis involves ordering and ranking of various sections in terms of potential vulnerability. The data requirements for MCA analysis are: Operating manual Flow diagram and P& I diagrams Detailed design parameters Physical and chemical properties of all the chemicals Detailed plant layout Detailed area layout Following steps are involved in the MCA analysis: Identification of potential hazardous sections and representative failure cases Visualization of release scenarios considering type and the quantity of the hazardous material Damage distance computations for the released cases at different wind velocities and atmospheric stability classes for heat radiations and pressure waves. Drawing of damage contours on plot plan to show the effect due to the accidental release of chemicals 7.1.2 Identification of Hazards Identification of hazards is an important step in risk assessment as it leads to the generation of accidental scenarios. The merits of including the hazard for further investigation are subsequently determined by its significance, normally using a cut-off or threshold quantity. Once a hazard has been identified, it is necessary to evaluate it in terms of the risk it presents to the employees and the neighbouring community. In principle, both probability and consequences should be considered, but there are occasions where it either the probability or the consequence can shown to be sufficiently low or sufficiently high, decisions can be made on just one factor. Chapter 7- Additional Studies 7-1 Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products During the hazard identification component, the following considerations are taken into account. Chemical identities Location of process unit facilities for hazardous materials. The types and design of process units The quantity of material that could be involved in an airborne release and The nature of the hazard (e.g. airborne toxic vapours or mists, fire, explosion, large quantities stored or processed handling conditions) most likely to accompany hazardous materials spills or releases The type and location of likely hazards are summarized below: A. CATEGORY – FIRE PROCESS / STORAGE 1. Plant Surroundings : Jungle Fire 2. Raw Material Storage : Fire in storage area 2.1 Chemicals: Ammonium Nitrate Aluminum powder Acetone Fuse head Storage Sulfur Wax & oil Storage 2.2 Packing Materials: Corrugated boxes store PVC compound Briquette & Coal storage yard B. CATEGORY – EXPLOSION 1] Magazines 2] Slurry manufacturing plant 3] Emulsion Manufacturing plants 4] Detonating Fuse plant 5] Lead Azide /Lead Styphnate plant 6] ASA Stores 7] ASA Drying 8] Detonators filling & pressing 9] Detonator Crimping House 10] Cast Booster Plant 11] PETN manufacturing 12] PETN Drying 13] Pilot Plant 14] Accessories Testing 15] HMX & Compounded products C. CATEGORY – TOXIC RELEASE: a. Nitric Acid Storage (CNA & WNA) in PP-8 & PP-10 b. Acetic Acid, Acetic Anhydride & Gama Butyro Lactone in PP-6 7.1.2.1 Hazard Survey This is a formal systematized approach using a rotary form the final rating number provides a relative ranking of the hazard. Inventory analysis and Fire and Explosive Toxicity Index (FEI) are the two techniques employed for hazards identification process. Chapter 7- Additional Studies 7-2 Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products i. Inventory Analysis Inventory analysis requires the holdup quantities in process vessels associated, intermediate and main storages. All process materials which are capable of producing major accident hazards owing to their physical and chemical properties are identified. Hold up of materials are calculated on the basis of material balance. Quantities in pipelines are also taken into account. Large or substantial inventories in storage or process streams are indicative of the potential hazards to the plant and its surrounding. Flammability and toxicity factors of these inventories can lead to unpredictable incident. The list of all the holdups is tabulated and the major inventory of chemicals is marked on the plot plan to show the relative significance and interactive effect. Each inventory is evaluated based on its hazards nature, temperature and pressure in relation to the flash point, auto ignition characteristics, MAC value, LD 50 value and its location in the complex. In case of pipeline, the flow rates and the total material handled are also considered since these dynamic inventories may or may not be isolated effectively during accident. The hold up in the system (including pipeline) is quite small as compare to inventories in storage and as such the process holdups are not being considered for hazard analysis. ii. Material Inventory and Storage M/s SIIL maintains adequate inventory of raw material and others utility items (fuels, chemical, solvent etc.) to ensure uninterrupted production of explosives. iii. Inventory and Mode of Storage of Raw Materials The raw material and packaging material details with capacity are given in Table 7.1 and Storage tank details are presented in Table 7.3. TABLE 7.1 RAW & PACKING MATERIALS Maximum Sr.No Item Description Store location Block UOM Capacity 1 HDPE FILMS S.POWER-80/90 (Domestic) Store-1 KGS 18800 2 HDPE FILMS SUPERCOAL-5 Store-1 KGS 6000 3 SEALING COMPOUND Store-1 KGS 4500 4 HDPE FILMS SOLAR PRIME Store-1 KGS 7500 5 SALT Sodium Chloride STORE-3 Block-1 KGS 58000 6 GUAR GUM (LLVG) STORE-3 Block-2 KGS 20000 7 SODIUM NITRITE. STORE-3 Block-3 KGS 42000 8 PARAFFIN WAX (S.R.)/(F.R) STORE-3 Block 5 KGS 48000 9 SUPER - 1 (MAP) STORE-3 Block-6 KGS 16000 10 SUPER - 2 (DAP) STORE-3 Block-6 KGS 16000 11 EMDILITE DM-45 (For Export) STORE-3 Block 6 KGS 1000 12 MALEIC ANHYDRIDE STORE-3 Block 7 KGS 10000 13 CUPROUS CHLORIDE (C1) STORE-3 Block 7 KGS 250 14 PARA TOLUENE SULFONIC ACID (C2) STORE-3 Block 7 KGS 250 15 S.P.L.-1 (Lauric Acid) STORE-3 Block 7 KGS 3000 16 ALUMINIUM WIRE 1.70 mm (SD) STORE-3 Block 8 KGS 9000 17 G.I.WIRE 1.50 mm (For KP) STORE-3 Block 8 KGS 11000 GLASS BUBBLES (Q-CEL)(PQ 7014) for 18 STORE-3 Block 8 KGS 1860 Domestic Seismic only 19 STRAPPING ROLLS 12 mm (Normal) STORE-3 Block 8 EA 120 20 HOT MELT GLUE (ADHESIVE) STORE-3 Block 8 KGS 1200 21 HDPE FILM SUP.POWER-90, EXPORT STORE-3 Block 9 KGS 9700 22 GLASS BUBBLES (Q-CEL)(PQ 7019)) STORE-3 Block 9 KGS 3000 23 LAYFLATS SOLAR PRIME /GEL STORE-3 Block 10 KGS 8400 Chapter 7- Additional Studies 7-3 Expansion & Modernization of Existing Project For Manufacturing of Explosives & Defence Products Maximum Sr.No Item Description Store location Block UOM Capacity 24 MAIZE STARCH POWDER STORE-6 Block-4 KGS 36000 25 SEISMIC TUBES STORE-6 B-5-8 NOS 45000 26 COTTON YARN Accessories Stores KGS 24400 27 PAPER BOOSTER SHELLS DO EA 540000 28 PVC REEL EA 14400 29 PVC COMPOUND KGS 50000 30 PENTA ERYTHRITOL ACC STORE KG 48000 31 SODIUM NITRATE (SN) ACC STORE KG 63000 32 DEXTRINE WHITE ACC STORE KG 250 33 DEXTRINE YELLOW ACC STORE KG 250 34 DI PENTA ERYTHRITOL ACC STORE KG 2000 35 SODA ASH KG 60000 36 G.I.WIRE (24.5 Gage) (0.52 mm) C.Box Store KG 20000 37 G.I.WIRE (25.5 Gage) (0.48 mm) C.Box Store KG 40000 38 Sodium Perchlorate STORE-4 KG 178000 39 Sodium Azide DCU-AREA KG 1200 40 Magnesium Oxide DCU-AREA KG 125 41 IPA DCU-AREA KG 2400 42 Lead Sterate DCU-AREA KG 50 43 Lead Nitrate DCU-AREA KG 600 44 MONO ETHYLINE GLYCOL (MEG) PLATFORM KG 11000 45 DEA (DS-302) KG 11000 46 OLEIC ACID (SM-101) KG 9500 47 FURNACE OIL KL 35 TABLE 7.2 STORAGE TANK INSTALLATIONS MATERIAL TANK -1 TANK-2 TANK-3 TANK-4 TANK-5 TANK-6 UNIT LOCATION: MELT ROOM AMMONIUM NITRATE MELT 84 84 - - - - KL CALCIUM NITRATE MELT - 76 57 13.6 13.6 23.5 KL LOCATION: COB/CFB AREA AMMONIUM NITRATE MELT 85 85 85 70 175 - MT CALCIUM NITRATE MELT 15.8 - - - - - FURNACE OIL 40 - - - - - KL SLACK WAX 75 75 - - - - KL LOCATION PETN PLANT ( PP-8/PP-10) CONC.