7.1.2.3 Data References for Risk Assessment 7.1.2.4 Meteorological Dataenvironmentclearance.nic.in/writereaddata/FormB/EC/Ris… · · 2015-10-14Failure frequency data as given

7.1.2.3 Data References for Risk Assessment

7.1.2.4 Meteorological Data

• Wind: 6 meters/second from ESE at 3 meters

• Ground Roughness: open country

• Cloud Cover: 5 tenth

• Air Temperature: 24.2° C

• Stability Class: D

• No Inversion Height

• Relative Humidity: 50%

7.1.2.5 The Levels of Concern

1. For Toxicity - IDLH / TLV / AEGL-1 / AEGL -2 / AEGL -3, whichever is applicable

2. For Calculation Of Distance For Flammable Cloud - 60% LEL = Flame Pockets, 10% LEL

3. For Radiative Fluxes – 10 kw / m2 (100% lethality), 5 kw/m2 (1% lethality), 2 kw /m2 (no

discomfort)

4. For Overpressures - 8.0 psi (destruction of buildings); 3.5 psi (serious injury likely); and 1.0 psi

(shatters glass).

7.1.2.6 Failure Frequency Data

Failure frequency data as given in Loss Prevention in Process Industries by Frank P Lees is presented

below:

200

Table 7.1 Failure Frequency Data

SR.

NO.

ITEM FAILURE FREQUENCY

(No. per 106 years)

1 Shell

2 Process / Pressure Vessel 1.0

3 Atmospheric Pressure Storage 0.1

4 Full Bore Vessel Connection

25 30.0

40 10.0

50 7.5

100 4.0

150 3.0

5 Full Bore Process Pipeline (Diameter in mm)

Less Than 50 0.30*

>50, <150 0.09*

More than 150 0.03*

(*Failure frequency expressed in No. per met length per 106 years)

7.1.3 Aloha Analysis for Isophorone Storage Tank – 1

Scenario 1/01- Isophorone failure of Isophorone tank and contents getting accumulated in the dyke enclosure

– Toxic area of vapour cloud

SITE DATA:

Location: LOTE PARSHURAM MIDC, TAL KHE, INDIA

Building Air Exchanges Per Hour: 0.33 (sheltered single storied)

Time: August 25, 2015 1414 hours ST (using computer's clock)

CHEMICAL DATA:

Chemical Name: ISOPHORONE Molecular Weight: 138.21 g/mol

PAC-1: 4 ppm PAC-2: 5 ppm PAC-3: 800 ppm

IDLH: 200 ppm LEL: 8400 ppm UEL: 38000 ppm

Ambient Boiling Point: 417.2° F

Vapor Pressure at Ambient Temperature: 6.58e-004 atm

Ambient Saturation Concentration: 677 ppm or 0.068%

ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)

201

Wind: 2 meters/second from 270° true at 10 meters

Ground Roughness: urban or forest Cloud Cover: 3 tenths

Air Temperature: 27° C Stability Class: B

Inversion Height: 20 meters Relative Humidity: 53%

SOURCE STRENGTH:

Evaporating Puddle (Note: chemical is flammable)

Puddle Area: 20 square meters Puddle Volume: 25 cubic meters

Ground Type: Concrete Ground Temperature: 27° C

Initial Puddle Temperature: Ground temperature

Release Duration: ALOHA limited the duration to 1 hour

Max Average Sustained Release Rate: 0.0363 pounds/min

(averaged over a minute or more)

Total Amount Released: 2.12 pounds

THREAT ZONE:

Model Run: Gaussian

Red : less than 10 meters(10.9 yards) --- (800 ppm = PAC-3)

Note: Threat zone was not drawn because effects of near-field patchiness

make dispersion predictions less reliable for short distances.

Orange: less than 10 meters(10.9 yards) --- (5 ppm = PAC-2)



Yellow: less than 10 meters(10.9 yards) --- (4 ppm = PAC-1)



202

Scenario 1/02- Isophorone failure of isophorone tank and contents getting accumulated in the dyke enclosure

– Flammable area of vapour cloud

SITE DATA:

Model Run: Gaussian







Yellow: less than 10 meters(10.9 yards) --- (4 ppm = PAC-1)






CHEMICAL DATA:












SOURCE STRENGTH:









THREAT ZONE:

Threat Modeled: Flammable Area of Vapor Cloud

Model Run: Gaussian

Red : less than 10 meters(10.9 yards) --- (5040 ppm = 60% LEL = Flame Pockets)



Yellow: less than 10 meters(10.9 yards) --- (840 ppm = 10% LEL)



203

Scenario 1/03- Isophorone failure of isophorone tank and contents getting accumulated in the dyke enclosure –

Overpressure from vapor cloud explosion

SITE DATA:




CHEMICAL DATA:












SOURCE STRENGTH:









204

THREAT ZONE:


Model Run: Gaussian







Threat Modeled: Overpressure (blast force) from vapor cloud explosion

Type of Ignition: ignited by spark or flame

Level of Congestion: congested

Model Run: Gaussian

No explosion: no part of the cloud is above the LEL at any time

Scenario 2/01- Isophorone failure of isophorone tank and contents getting accumulated in the dyke enclosure

– Thermal radiation from pool fire.

SITE DATA:




CHEMICAL DATA:












SOURCE STRENGTH:

Burning Puddle / Pool Fire


Initial Puddle Temperature: Air temperature

Flame Length: 11 yards

Burn Duration: ALOHA limited the duration to 1 hour

Burn Rate: 144 pounds/min

205

Total Amount Burned: 8,640 pounds




Model Run: Gaussian


THREAT ZONE:

Threat Modeled: Thermal radiation from pool fire

Red : less than 10 meters(10.9 yards) --- (10.0 kW/(sq m) = potentially lethal within 60 sec)

Orange: 13 yards --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)

Yellow: 22 yards --- (2.0 kW/(sq m) = pain within 60 sec)

Scenario 3/01 catastrophic failure of the pump discharge line from road tanker to storage tank. Toxic area of

vapor cloud

SITE DATA:




CHEMICAL DATA:





206








SOURCE STRENGTH:

Direct Source: 10 cubic meters/hr Source Height: 0

Source State: Liquid

Source Temperature: equal to ambient

Release Duration: 5 minutes

Release Rate: 337 pounds/min

Total Amount Released: 1,687 pounds

THREAT ZONE:

Model Run: Heavy Gas

Red : 111 yards --- (800 ppm = PAC-3)

Orange: 1.1 miles --- (5 ppm = PAC-2)

Yellow: 1.2 miles --- (4 ppm = PAC-1)

207

Scenario 3/02 catastrophic failure of the pump discharge line from road tanker to storage tank. Flammable

area of vapor cloud

SITE DATA:




CHEMICAL DATA:












SOURCE STRENGTH:







THREAT ZONE:



Red : 42 yards --- (5040 ppm = 60% LEL = Flame Pockets)



Yellow: 108 yards --- (840 ppm = 10% LEL)

208

Scenario 3/03 catastrophic failure of the pump discharge line from road tanker to storage tank. Explosion of

vapor cloud

SITE DATA:




CHEMICAL DATA:












209

SOURCE STRENGTH:







THREAT ZONE:





Red : LOC was never exceeded --- (8.0 psi = destruction of buildings)

Orange: 35 yards --- (3.5 psi = serious injury likely)

Yellow: 70 yards --- (1.0 psi = shatters glass)

Scenario 4/01 catastrophic failure of the pump discharge line from storage tank to day tank. Toxic area of

vapor cloud

SITE DATA:




210

CHEMICAL DATA:












SOURCE STRENGTH:







THREAT ZONE:


Red : 84 yards --- (800 ppm = PAC-3)

Orange: 1558 yards --- (5 ppm = PAC-2)

Yellow: 1727 yards --- (4 ppm = PAC-1)

211

Scenario 4/02 catastrophic failure of the pump discharge line from storage tank to day tank. Flammable area of vapor

cloud

SITE DATA:




CHEMICAL DATA:











212


SOURCE STRENGTH:







THREAT ZONE:







213

Scenario 4/03 catastrophic failure of the pump discharge line from storage tank to day tank. Overpressure of

vapor cloud

SITE DATA:




CHEMICAL DATA:












SOURCE STRENGTH:







THREAT ZONE:








214

215

Table 7.2 Summary of aloha & mitigation for isophorone

Substance Failure Scenario

No.

Effects

considered

LOC Distance,

yards

Mitigation plan

Isophorone Catastrophic

failure of the

isophorone tank &

contents getting

accumulated in

the dyke enclosure

IPH 1/01 Toxic area

of vapor

cloud

PAC-3 800 ppm <10 PPE are provided.

EarthLink to tank

provided.

Dyke wall provided.

Area is barricaded.

Half yearly medical

checkup for employees.

PAC-2 5 ppm

PAC-1 4 ppm

IPH 1/02 Flammable

area of

vapor cloud

60%

LEL

5040 ppm <10 Fire extinguisher are

provided.

10%

LEL

840ppm

IPH 1/03 Overpressu

re effects of

vapor cloud

8.0 psi - Breather & vent

provided. 3.5 psi

1.0 psi

IPH 2/01 Radiation

effects of

pool fire

10 kW/sq m 11 Fire extinguisher are

provided.

Fire hydrant system is in

place.

Dyke wall provided.

5 kW/ sq m 13

2 kW/ sq m 22

Catastrophic

failure of the

pump discharge

line from road

tanker to storage

tank

IPH 3/01 Toxic area

of vapor

cloud

PAC-3 800 ppm 111 PPE are provided.

EarthLink to tank

provided.

Dyke wall provided.

Area is barricaded.

Half yearly medical


PAC-2 5 ppm 1.1 miles

PAC-1 4 ppm 1.2 miles

IPH 3/02 Flammable

area of

vapor cloud

60%

LEL

5040 ppm 42 Fire extinguisher are

provided.

10%

LEL

840 ppm 108

IPH 3/03 Overpressu

re effects of

vapor cloud

8 psi - Breather & vent

provided. 3.5 psi 35

1 psi 70

Catastrophic

failure of the

pump discharge

line from storage

tank to day tank

IPH 4/01 Toxic area

of vapor

cloud

PAC-3 800 ppm 84 PPE are provided.

Dyke wall provided.

Half yearly medical


PAC-2 5 ppm 1558

PAC-1 4 ppm 1727

IPH 4/02 Flammable

area of

vapor cloud

60%

LEL

5040 ppm 31 Fire extinguisher are

provided.

10%

LEL

840 ppm 82

IPH 4/03 Overpressu

re effects of

vapor cloud

8 psi - Breather & vent


1 psi 54

216

7.1.4 Aloha Analysis for Toluene Storage Tank – 2

Scenario 5/01 Toluene

SITE DATA:



Time: August 25, 2015 1717 hours ST (user specified)

CHEMICAL DATA:

Chemical Name: TOLUENE Molecular Weight: 92.14 g/mol

AEGL-1 (60 min): 200 ppm AEGL-2 (60 min): 1200 ppm AEGL-3 (60 min): 4500 ppm



Vapor Pressure at Ambient Temperature: 0.042 atm

Ambient Saturation Concentration: 42,779 ppm or 4.28%






SOURCE STRENGTH:


Puddle Area: 12.5 square meters Puddle Volume: 18 cubic meters







217

THREAT ZONE:

Model Run: Gaussian

Red : less than 10 meters(10.9 yards) --- (4500 ppm = AEGL-3 (60 min))



Orange: less than 10 meters(10.9 yards) --- (1200 ppm = AEGL-2 (60 min))



Yellow: less than 10 meters(10.9 yards) --- (200 ppm = AEGL-1 (60 min))




SITE DATA:




CHEMICAL DATA:











218


SOURCE STRENGTH:



Model Run: Gaussian

Red : less than 10 meters(10.9 yards) --- (4500 ppm = AEGL-3 (60 min))



Orange: less than 10 meters(10.9 yards) --- (1200 ppm = AEGL-2 (60 min))



Yellow: less than 10 meters(10.9 yards) --- (200 ppm = AEGL-1 (60 min))









THREAT ZONE:


Model Run: Gaussian








SITE DATA:




CHEMICAL DATA:




219






Model Run: Gaussian











SOURCE STRENGTH:









THREAT ZONE:




Model Run: Gaussian


Scenario 6/01

SITE DATA:




CHEMICAL DATA:


220










Model Run: Gaussian






SOURCE STRENGTH:








THREAT ZONE:


Red : less than 10 meters(10.9 yards) --- (10.0 kW/(sq m) = potentially lethal within 60 sec)



221

Scenario 7/01 toluene

SITE DATA:




CHEMICAL DATA:












222

SOURCE STRENGTH:

Direct Source: 10 liters/min Source Height: 0





Total Amount Released: 570 pounds

THREAT ZONE:


Red : 13 yards --- (4500 ppm = AEGL-3 [60 min])



Orange: 25 yards --- (1200 ppm = AEGL-2 [60 min])



Yellow: 79 yards --- (200 ppm = AEGL-1 [60 min])

223


SITE DATA:




CHEMICAL DATA:












SOURCE STRENGTH:







THREAT ZONE:









224


SITE DATA:




CHEMICAL DATA:




















SOURCE STRENGTH:







THREAT ZONE:



225






Table 7.3 Summary of aloha & mitigation for toluene

Substance Failure Scenario

No.

Effects

considered

LOC Distance,

yards

Mitigation plan

Toluene Catastrophic

failure of the

toluene tank &

forming

evaporating

puddle

Tol 5/01 Toxic area of

vapor cloud

AEGL-3 4500 ppm <10 PPE are provided.

EarthLink to tank

provided.

Dyke wall provided.

AEGL-2 1200 ppm

AEGL-1 200 ppm

Tol 5/02 Flammable

area of vapor

cloud

60%

LEL

6600 ppm <10 Fire extinguisher are

provided.

Water sprinkler system

provided. 10%

LEL

1100 ppm

Tol 5/03 Overpressure

effects of

vapor cloud

8.0 psi -

Breather & vent

provided. 3.5 psi

1.0 psi

Tol 6/01 Radiation

effects of

pool fire

10 kW/sq m <10 Fire extinguisher are

provided.


provided.

Fire hydrant system is in

place.

Dyke wall provided.

5 kW/ sq m 13

2 kW/ sq m 22

Catastrophic

failure of the

pump discharge

line from tank

Tol 7/01 Toxic area of

vapor cloud

AEGL-3 4500 ppm 13 PPE are provided.

EarthLink to tank

provided.

Dyke wall provided

AEGL-2 1200 ppm 25

AEGL-1 200 ppm 79

Tol 7/02 Flammable 60% 6600 ppm 12 Fire extinguisher are

area of vapor

cloud

LEL provided.


provided. 10%

LEL

1100 ppm 26

Tol 7/03 Overpressure

effects of

vapor cloud



1.0 psi 40

7.1.5 Aloha Analysis for Furnace Oil Storage Tank – 3

Scenario 8.01

SITE DATA:




CHEMICAL DATA:

Chemical Name: N-DECANE Molecular Weight: 142.28 g/mol

PAC-1: 1.9 ppm PAC-2: 20 ppm PAC-3: 440 ppm

LEL: 7500 ppm UEL: 54000 ppm









SOURCE STRENGTH:





Release Rate: 53.4 pounds/min


227

THREAT ZONE:


Red : 60 yards --- (440 ppm = PAC-3)

Orange: 367 yards --- (20 ppm = PAC-2)

Yellow: 1296 yards --- (1.9 ppm = PAC-1)

Scenario 8.02

SITE DATA:




CHEMICAL DATA:







228






SOURCE STRENGTH:







THREAT ZONE:









Scenario 8.03

SITE DATA:




229

CHEMICAL DATA:




















SOURCE STRENGTH:







THREAT ZONE:








230

Scenario 9.01

SITE DATA:




CHEMICAL DATA:







231






SOURCE STRENGTH:









THREAT ZONE:

Model Run: Gaussian










232

Scenario 9.02

SITE DATA:



Model Run: Gaussian











CHEMICAL DATA:












SOURCE STRENGTH:









THREAT ZONE:


Model Run: Gaussian







233


Model Run: Gaussian







Scenario 9.03

SITE DATA:




CHEMICAL DATA:












SOURCE STRENGTH:









234

THREAT ZONE:




Model Run: Gaussian


10.01

SITE DATA:




CHEMICAL DATA:












SOURCE STRENGTH:







235


THREAT ZONE:


Red : 11 yards --- (10.0 kW/(sq m) = potentially lethal within 60 sec)






Model Run: Gaussian


Table 7.4 Summary of aloha & mitigation for Furnace oil Substance Failure Scenario No. Effects

considered

LOC Distance,

yards

Mitigation plan

FO Catastrophic

failure of the

toluene tank &

forming

evaporating

puddle

FO 9/01 Toxic area of

vapor cloud

PAC-3 440 <10 PPE are provided.

EarthLink to tank

provided.

Dyke wall

provided.

PAC-2 20 <10

PAC-1 1.9 22

FO 9/02 Flammable

area of vapor

cloud

60% LEL 4500 ppm <10 Fire extinguisher

are provided.

10% LEL 750 ppm

FO 9/03 Overpressure

effects of

vapor cloud

8.0 psi -

Breather & vent

provided. 3.5 psi

1.0 psi

FO 10/01 Radiation

effects of

pool fire

10 kW/sq m 11 Fire extinguisher

are provided.

Fire hydrant

system is in place.

Dyke wall

provided.

5 kW/ sq m 17

2 kW/ sq m 28

Catastrophic FO 8/01 Toxic area of PAC-3 440 60 PPE are provided.

failure of the

pump discharge

line from tank

vapor cloud PAC-2 20 367 EarthLink to tank

provided.

Dyke wall

provided

PAC-1 1.9 1296

FO 8/02 Flammable

area of vapor

cloud

60% LEL 4500 ppm 16 Fire extinguisher

are provided. 10% LEL 750 ppm 44

FO 8/03 Overpressure

effects of

vapor cloud



1.0 psi 46

7.4 Adequate water balance calculation

The water required for firefighting purpose can be estimated by the below formula:

Water required in liters per minutes = ( A + B + C + D )/20

A) The total area in sq. mtr. of all floors & galleries in all building of the factory.

B) The total area in sq. mtr of all floors and galleries including open spaces in which combustible materials.

C) The total area in sq. mtr of all floors over 15 mtr above ground level.

D) The total area in sq. mtr of all floors of building other than those of fire resisting construction of various

floors is so certified by any fire association or fire insurance company.

Therefore water required in liters per minutes = (192.3 + 192.3 +7162.43)/20

= 377.35 liters/min

The quantity of fire fighting tank is 1.72 lakh liters. ( Actual capacity = 3.45 lakh liters )

237

Therefore the back-up water supply time = Total water in fire fighting tank / water required

= 172000/377.35

= 455.81 min = 7.6 hrs.

The pump capacity in plant is 2033 liters/min. The back-up time by which the tank will be empty is calculated below,

Time, min = total water in fire fighting tank / discharge capacity

= 172000/2033

= 84.60 min = 1.41 hrs

7.5 Fire Load Calculation

Defination of fIre load

The weight of combustiable material per square foot of floor space.

The cumbustiable contents or interior finish of a building per unit floor area, often expressed as pounds per

square foot or as Btu per square foot.

The amount of fuel with in a building which has the potential of burning and releasing heat to feed the

growth of fire.

FIRE LOAD CAN BE CALCULATED AS FOLLOWS:

Weight of material per Kg (Mass) X Calorific value of material.

Calculating the fire loading of a compartment The fire loading of the compartment is a way of establishing the severity of a fire and the

measurement is related to the heat outout as stated by Drysdale (1985) the formula for calculating the

fire loading is noted as:

(Calorific Value X Mass (or Volume) ) / Floor Area = Area Fire loading Kj/m2

Fire load calculation

Sample calculation

Toluene ( Tank T106)

Specific heat of toluene = 43033.326 kJ/Kg.

Diameter of tank T106 = 1500 mm.

Area= 1.76625 m2

Quantity at any time in T106 = 1000 lit.

238

Specific gravity of toluene = 0.87

Quantity at any time = 870 Kg.

Area fire loading =

= 21196.88 kJ/m2

Table 7.5 Fire load calculation

Material Tank Diameter

, m

C/s area,

m2

Qty at

any time

in lit

Specific

gravity

Qty in

kg

Specific

heat, kJ/kg

Area fire

loading

Toluene T106 1.5 1.76625 1000 0.87 870 43033.326 21196.88

Toluene T106A 1 0.785 400 0.87 348 43033.326 19077.19

Isophorone T127 14.26 10000 0.92 9200 314.01 202.587

Isophorone T104 2.1 3.46185 2000 0.92 1840 314.01 166.898

Furnace oil T101 2.6 5.3066 5000 0.965 4825 41030 37306.326

7.6 Accident Statistics Table 7.6 Accident / Incident Records for the Year - 2010-15

Sr.No. Name of the person Date Time Area Accident / Incident Mitigation Plan

1 Subhash Kadam 17.06.2010 12:00 Catalyst - De-dusting Drum falled on right toe Training on drum movement

Height of dedusting machine increased

2 Sandip palkar 29.11.2010 1.15 Reactor section Leg injured in hole of platform Substitute plate kept

Emergency work in day shift

3 Mr. Pandurang Gothal( Compony) 21.09.2011 11:30

3,5 Plant : QC Lab

Material in eyes from hot plate Training on chemicals handling

Training on awareness

4 Mr.S.V.Abmre( Compony) 23.11.2011 17:30

3,5 Plant : Near D-102 reboiler

Material on face, sholder Dechocking by steam

Permanent drum draining line provided

5 Mr. Atit Baikar( Pragati Ent.) 06.04.2012 12:00

3,5 Plant : Pusher Centrifuge Material splashed on hand. Training given

6 Mr.Prashant raghunath gujar (Pragati)

22.08.2012

18:30 Catalyst:Extruder belt Tip of finger got pressed Fixed guard modified

Work permit must to open guard

7 Mr.Sumit C Sawant 16.07.2013 2:30 Drainage Area

Fall in gutter while cleaning wall Training given

8 Mr.Bare 04.08.2013 12:00 Extractor Right ear scratch while moving packing Training given

9 Mr.Dattaram Gunadekar 18.08.2013 10:30 MM-04

Right hand finger injury by scrapper Modification proposed

10 Mr. Mukund Kadam( Co.) 24.11.2014 18:00 D-106 bottom

Material on sholder while steaming Hose clip to use now

Male female connection provided

11 Mr. Ramashri Jaiswal(Shiwam) 10.12.2014 12:00 ETP sand BED

Hammer on thumb in sandbed work Communicatin training required

12 Mr. Prakash Bhekare 12.02.2015 5:30 V-105 area

Steam hose pressuried & steam burn to ankle. Training given

13 Mr. Hemant survanshi 10.06.2015 11:00

Transformer yard

Ac sheet cracking person using belt no injury Training for person

Documents

7.1.2.3 Data References for Risk Assessment 7.1.2.4 Meteorological Dataenvironmentclearance.nic.in/writereaddata/FormB/EC/Ris… · · 2015-10-14Failure frequency data as given