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
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)
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
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.