Mock Drill

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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) – 1.0 Km away
2. BPCL (Terminal) – 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
ACRES

: 93.35

•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
3
4
5
6
7

Name of the village
Kacharakanahalli
Dasarahalli
Geddlapura
Dodda Donnasandra
Kannekal
Makkanahalli
Devalapura

Population
437
458
163
1677
410
1465
446

Material Safety Data
IDENTITY OF MATERIAL :
Product Name

Trade name
Formula

LPG. Bottle gas,
Liquefied
hydrocarbon gas.
LPG

UN No.

Mixture of
propane and
butane

HAZCHEM Code

Physical State

Gas

Appearance

Colourless

Odor

Odorless/stanche
d
Insoluble

Solubility in Water
Calorific Value
(Kcal / Kg.)

11400

1075
Label / Class

Red: Flammable
Liquid / 2.1

2WE

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

1

Specific Gravity , 20 deg. C

0.53 to 0.57

Vapor Pressure
at 65 deg. C,

16.9 kg/cm2

138
1.5 to 2.0

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

FIRE AND EXPLOSIVE DATA
Explosivity

Highly explosive

Auto Ignition Temp. deg. C

405-450

Flammability

Dangerous

Explosive Limits , %

1.8 – 9.6

Extinguishing Media

CO2, DCP. Water spray may be used to control and confine LPG fires.

Special Procedures

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
• Material and construction failures
• 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 Exposure
radiation (Kw/ time in
m2
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 LPG in BLEVE Radiation distance in meters to
Vessel MT Radious
(m) 37.5 KW/m2 12.5 Kw/m2 4.0 KW/m2
HORTON
1400
SPHERE

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

Radiation
(KW/M2)

Distance in
meter

Zone A

37.5

524

Plant Personnel

80

Zone B

12.5

908

Kanekal village

443

Kacharaknahalli

472

Zone C

4

1830

Affected population

Dasarahalli
Gidlapura
Donnasandra
Makanahalli
Devalapura
Vagatta
Neighboring
industries

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
CUM / Hr. capacity each.
JOCKY PUMPS


2 Nos. of 24 Cum /Hr.

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.

Mutual Aid agreemnt
Member

Roles and responsibilities

IOCL, Terminal

Traffic control and smooth evacuation of trucks

BPC Terminal

Assist the Rescue Team members

HPCL Installation

Assist Auxilliary team members

PETRONET

Assist Auxilliary team members

Fire Fighting Organisation Chart
FIRE IN CHIEF: Sr. Plant Manager
Alternate FIRE IN CHIEF: Manager (P)
FIRE COMBAT TEAM

AUXILIARY TEAM

RESCUE TEAM

Team In Charge:

Team In Charge:
Manager (P)

Team In Charge: Asst.
Manager (F)

Floor Officer

Alternate team Incharge: Officer
(Bulk Operations)

Alternate team Incharge: S&D Alte rnate te am Incharge :
officer
Accounts officer-II

Assisted by:

Assisted by:

Assisted by:

1.     Tally operator 1

1.     Dy. Manager (P)

1.     A O - II

2.     Tally operator 2

2.     Safety Officer

2.     Sr. Assistant

3.     Segregation 1

3.     Maintenance Officer

4.     Segregation 2

4.     Maint enanc e operator 1

5. Pump House 1

5.     Maint enanc e operator 2

6.     TLD

6.     Employees on Relief

    

7.     Carousel Tare wt. 1

7.     Security guard 3
(Stores)
8. Security guard 4

8.     Carousel Tare wt. 2
9.     Evacuation

(Gate –2)

10.            ICU
11.            Gantry operator 1
12.            Gantry operator 2
13.            Security guard 1
(Main gate)
14.            Security guard 2
gate)
15.            Security guard 3
(Patrolling)

(Main

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.

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