Transcript
Annexure 27A
RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. PLOT NO 675, GIDC JHAGADIA MEGA INDUSTRIAL ESTATE DIST. BHARUCH, GUJARAT
JHAGADIA, APRIL 2016
RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. ACRYLAMIDE PLANT, JHAGADIA
CONTENTS CHAPTERS
TITLE
PAGE NO.
1
INTRODUCTION
2
2
PROCESS AND MATERIALS
4
3
STORAGE AND HANDLING
6
4
RISK ASSESSMENT
8
5
PREVENTION AND RISK MITIGATION
13
6
CONCLUSIONS
23
ANNEXURES 1
PROCESS FLOW DIAGRAM
2
MSDS OF ACRYLONITRILE
3
ACRYLONITRILE TANK FARM
4
ALOHA SIMULATIONS
5
FIREFIGHTING SYSTEM DIAGRAM
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RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. ACRYLAMIDE PLANT, JHAGADIA
CHAPTER 1 - Introduction 1.1 The Company Black Rose Industries Ltd. is a public limited company listed on the Mumbai Stock Exchange. The company was established in 1990 and has its registered office at 145A, Mittal Towers, Nariman Point, Mumbai. The chemical division of the company is engaged in the imports, distribution, and exports of a wide range of specialty, performance, and pharmaceutical chemicals into India. The textile division of the company manufactures and exports textiles at their plant in Kolhapur, Maharashtra. The company is governed by a Board of Directors and run by technocrats with a strong understanding of chemical processes. The Executive Director, Mr. Anup Jatia, is a chemical engineer from the California Institue of Technology, Pasadena, USA. The business turnover of the group is approaching Rs.200 crores and has been growing at a fast pace.
1.2 The Project The company proposes to expand its manufacturing facility for the production of liquid acrylamide solution from 10,000MTPA to 20,000MTPA under technical license from M/s. Mitsui Chemicals, Inc., of Japan. The product, acrylamide, is a key ingredient in the manufacture of water and effluent treatment chemicals. The technology licensed to the company is an ENVIRONMENTALLY FRIENDLY PROCESS based on the bio-catalytic conversion of acrylonitrile. The technology has been used safely since development for several years in locations in Japan and in South Korea, and at the company’s plant in Jhagadia. The project has been categorized as B2 by the State Level Expert Appraisal Committee, Gujarat. The plant site is located on Plot 675, Jhagadia Mega Industrial Estate, Distrist Bharuch, Gujarat.
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RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. ACRYLAMIDE PLANT, JHAGADIA
1.3 The Report This report has been prepared as per the requirements of the State Level Expert Appraisal Committee. Accordingly, this report analyses the various risks associated with the project and suggests methods for mitigation of the same. It includes predictions of the WORST CASE SCENARIO (catastrophic failure) and MAXIMUM CREDIBLE ACCIDENT SCENARIO along with damage distances and preparedness plan for effectively combating such situations. The report also discusses and demarcates the vulnerable zones. A detailed fire control plan for flammable substances and processes is also included. No plan is perfect and there is always a scope of improvement, which is a continuous process. Hence, the RISK ASSESSMENT REPORT is to be reviewed and updated as and when: • • •
any expansion, alteration, or extension of the plant is planned / implemented an accident has occurred and been dealt with, based on feedback gathered on any shortcomings in the handling of the situation any feedback is received from the users of the report
RISK ASSESSMENT is therefore 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: • • • •
Mitigation or reduction of the risk of an accident Mitigation of the severity and/or consequences by way of improved process techniques Confidence building in employees Preparedness and prompt response to deal with an accident
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RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. ACRYLAMIDE PLANT, JHAGADIA
CHAPTER 2 – Process and Materials 2.1 The Process The company proposes to expand its manufacture of acrylamide using an ENVIRONMENTALLY FRIENDLY TECHNOLOGY licensed by Mitsui Chemicals, Inc. , of Japan. The process flow diagram is given in Annexure 1. The technology is based on the total biocatalytic conversion of acrylonitrile into acrylamide and is a continuous process. The process system is heavily instrumented and controlled by DCS systems. Some brief information is provided below. 1. Acrylonitrile and water are dosed into a continuous reactor containing a catalyst at controlled rates. 2. The heat of the reaction is continuously removed by heat exchangers. 3. The reaction is monitored through outlet sampling. 4. The reaction mass then flows to agitated reactors wherein post treatment purification is carried out. 5. The product is pumped into the finished product storage tank. The plant is operated continuously and hence has been suitably instrumented for optimum plant operations. The plant is installed with a stand-by D.G. Generator set of 380 KVA for uninterrupted power supply.
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RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. ACRYLAMIDE PLANT, JHAGADIA
2.2 Materials TABLE-1 LIST OF RAW MATERIAL AND PRODUCTS PARAMETERS
RAW MATERIALS
PRODUCT
Acrylonitrile
Acrylic Acid
Caustic Soda
Activated Carbon
Acrylamide (aqueous)
Consumption (kg/mth)
629,160
166
50
2660
N/A
Physical State
Liquid
Liquid
Solid
Solid
Liquid
Storage
CS Zinc Coated Tank
Carbuoys
Bags
Bags
Tanks
Atmospheric
Atmospheric
N/A
N/A
N/A
Storage Temp. (°C)
Ambient
Ambient
Ambient
Ambient
20
Boiling Point (°C)
77
141
145
N/A
125
Flash Point (°C)
-1
46
N/A
N/A
N/A
LEL %
3
2
N/A
N/A
N/A
UEL %
17
8
--
N/A
N/A
TLV (8 hours)
2 ppm
2 ppm
N/A
0.03 mg/m³*
LD50 (mg/kg)
78
294
N/A
>10,000
124 (oral)* 400 (dermal)*
LC50
2600 µg/l
5300 mg/m³
N/A
N/A
N/A
Sp. Gravity (Water = 1)
0.8
1.05
1.511.54
2.3
1.122*
Vpr. density (Air = 10)
1.8
2.5
N/A
N/A
2.45*
Storage Press. (Kg/cm²)
pH Vpr. Press. (mm Hg at 106 4.5 N/A N/A 25°C) MSDS of key raw material, acrylonitrile, has been provided in Annexure 2. * Data provided for acrylamide 100%
6.0 - 8.0 19 (Water)
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RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. ACRYLAMIDE PLANT, JHAGADIA
CHAPTER 3 – Storage and Handling 3.1 Acrylonitrile Acrylonitrile is a colourless, slightly pungent liquid at NTP. Acrylonitrile is a hazardous chemical and must be handled and stored according to appropriate safety procedures. It is flammable and explosive under certain conditions. Acrylonitrile is stored and handled in a closed system with nitrogen capping to prevent contact with air for the prevention of polymerization. Acrylonitrile is toxic when it comes in contact with the skin or is inhaled in certain quantities and relevant PPE must be used during manual handling of the chemical. The maximum quantity of acrylonitrile stored at the unit is 190MT, with a storage capacity of 190MT in one tank. The material is transported to the location by special dedicated tankers, unloaded using specially selected glandless pumps, and stored in the raw material storage tanks located 20 meters from the utility building, in an area designed specifically for the storage of acrylonitrile. As per established safe strorage methods, the material contains a polymerisation inhibitor and is stored in zinc coated carbon steel tanks as per approved design codes. The tanks are marked and labeled as “ACRYLONITRILE” with tag number and tank volume. The material is stored at NTP with nitrogen capping. Tank vents are provided with recovery vent condensers using refrigerated water and exhausts will be taken to vent scrubbers. One tank is always kept empty for emergency transfer from other tanks. As per internationally accepted safety norms, the tank yard is equipped with a dyke wall with the floor of the dyked area sloping away from the tanks and made of materials impervious to liquid. The dykes are constructed with intermediate dyke walls and with sufficient capacity to contain unwanted spills. Material spilled into the dyke flows into an isolation tank located on one side of the tank farm to control exposure of any spilled material to the atmosphere. Detailed design of tank farm is provided in Annexure 3. The acrylonitrile storage location including tanks and pumps is provided with gas detection monitors and fire protection systems (to be explained in detail in Chapter 5). Foam-based fire extinguishers and sand buckets will also be used to take care of local minor incidents.
3.2 Acrylamide Acrylamide solution is non-flammable, and any vaporisation will release only water to the atmosphere since the vapour pressure at 30°C is only 0.01 Torr. At higher solution concentrations and / or low temperatures, acrylamide may partially precipitate. Acrylamide is toxic when in contact with the skin or inhaled and needs to be handled with the appropriate PPE. Adequate number of eye wash stations and shower booths will be located at strategic spots. The maximum quantity of acrylamide proposed to be stored at the unit is 500 MT. The material is directly pumped from the manufacturing process to the storage tanks. Page 6
RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. ACRYLAMIDE PLANT, JHAGADIA
As per established safe storage methods, the material contains a polymersisation inhibitor and is stored at 20°C in SS304 tanks in order to avoid polymerisation. The tanks are marked and labeled as “Acrylamide Solution” with tag number. Multiple storage tanks enable transfer and storage of different production lots. As per internationally accepted safety norms, the tank yard is equipped with a dyke wall with the floor of the dyke area being made of materials impervious to liquid. The dikes are constructed with intermediate dike walls and with sufficient capacity to contain unwanted spills. The acrylamide storage location is isolated, well-ventilated and provided with fire hydrant loops and sprinkler system.
3.3 Caustic Soda Caustic soda easily reacts with organic materials to cause violent reactions. It behaves exothermically when mixed with water. Caustic soda is toxic and inhalation of the dust or vapour of caustic soda may damage the upper respiratory track and sometimes even lungs. The maximum quantity of caustic soda proposed to be stored at the unit is 0.5MT in solid / pellet form. It is stored in bags in the process building with adequate wall barriers in a closed, exhaust-ventilated room containing other compatible chemical raw materials. The process plant building is provided with fire hydrant protection, eye wash stations, and shower booths at strategic locations.
3.4 Acrylic Acid Acrylic acid is a toxic and inflammable chemical. The maximum quantity of acrylic acid proposed to be stored at the unit is 0.4MT. It is stored in HDPE drums in the process plant building, in a closed, exhaust-ventilated room containing other compatible chemical raw materials. The process plant building is provided with fire hydrant protection, eye wash stations, and shower booths at strategic locations on every floor.
3.5 Activated Carbon Activated carbon is non-flammable and non-toxic. However, appropriate PPE should be used when handling the same. The maximum quantity of activated carbon proposed to be store at the unit is 10MT. It is stored in small bags in the process plant building in a closed, exhaust-ventilated room containing other compatible chemical raw materials. The process plant building is provided with fire hydrant protection, eye wash stations, and shower booths at strategic locations on every floor. Page 7
RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. ACRYLAMIDE PLANT, JHAGADIA
CHAPTER 4 – Risk Assessment 4.1 Risk Identification and Analysis Identification of risk is done qualitatively and quantitatively through the identification of hazardous substances and by studying the manufacturing process to arrive at possible failures and their inherent causes. Probability of risk occurrence is also ascertained in order to determine the MAXIMUM CREDIBLE ACCIDENT SCENARIO and the WORST CASE SCENARIO. Hazardous substances have been identified as follows considering the applicable criteria laid down under the Chemical Accident (Emergency Planning, Preparedness and Response) Rules, 1996, as well as other relevant guidelines:
TABLE 2 – LIST OF HAZARDOUS CHEMICALS HAZARDOUS CHEMICAL
Quantity on Site
Nature of Hazard
Acrylonitrile
190MT (max)
Flammable, Toxic, Corrosive, Reactive
The flammability limits as well as the toxicity limits for acrylonitrile have been provided in Table 1. The use, processing, and storage of acrylonitrile was analysed and the risks as shown in Table 3 have been identified. The risks are then analysed quantitatively in terms of probability, and severity. The risks have also been rated according to the matrix R = Probability x Severity. Based on generally accepted definitions, the MAXIMUM CREDIBLE ACCIDENT (MCA) SCENARIO indicates most likely or possible accident scenario, taking into account the effect of existing control measures also. Accordingly, the risk marked “B1” was selected from Table 3. MAXIMUM CREDIBLE ACCIDENT SCENARIO: RISK B1 – Leaking of acrylonitrile during unloading of road tanker due to improper coupling fit with the tank loading pipe inlet, causing puddle formation of mass 50kg in the tank unloading dyke. Flammability is a concern due to the properties of the material. Toxicity is a concern due to the proximity of unloading personnel in such a situation. Similarly, the WORST CASE SCENARIO is defined as the release of the largest quantity of a regulated substance from a single vessel, such as catastrophic failure. It considers the failure of all control systems and release of the whole mass resulting in maximum damage. It is a highly unlikely occurrence but has the highest severity. Accordingly, the risk marked “D” was selected from Table 3.
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RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. ACRYLAMIDE PLANT, JHAGADIA
TABLE 3 – RISK ANALYSIS S. No
Mechanism
Consequence
A1
Acrylonitrile storage tank
Leakage due to corrosion
A2
Acrylonitrile storage tank
Leakage at welding joint
B1
Unloading pipe coupling
Leakage due to faulty coupling fit
C1 C2 D 1
Source
Pipe carrying acrylonitrile in process plant Pipe carrying acrylonitrile in process plant Acrylonitrile storage tank
PROBABILITY: 1 – HIGHLY UNLIKELY 2 – UNLIKELY 3 – SOMEWHAT LIKELY 4 – LIKELY 5 – VERY LIKELY
2
Leakage due to corrosion Leakage at pipe gasket Catastrophic failure
SEVERITY: 1 – EXTREMELY MILD 2 – MILD 3 – MODERATE 4 – SEVERE 5 – MOST SEVERE
Puddle formation in tank dyke Puddle formation in tank dyke Puddle formation in unloading dyke Puddle formation on floor below pipe Puddle formation on floor below pipe Filling of isolation tank with acrylonitrile
Probability1
Severity2
Risk Rating3 (max = 25)
2
2
4
2
2
4
3
2
6
2
2
4
2
2
4
1
5
5
3
RISK RATING: PROBABILITY x SEVERITY
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RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. ACRYLAMIDE PLANT, JHAGADIA
WORST CASE SCENARIO: RISK D – Catastrophic failure of acrylonitrile storage tank, causing closed isolation tank to fill with acrylonitrile. Flammability and toxicity are concerns due to the properties of the material.
4.2 Vulnerability Analysis A vulnerability analysis is carried out on the MAXIMUM CREDIBLE ACCIDENT SCENARIO and the WORST CASE SCENARIO. The analysis is carried out using the help of sophisticated computer software that provides the zone of influence as well as the geographical risk contours. The calculations are complex in nature, and various parameters are defined to assist the software in simulating the risk contours. The parameters include details such as the size of the leakages / holes, quantity of materials released, duration of the release, and weather and geographic conditions. The simulations are generated under standard operating conditions. Data given in the reports and manuals are taken as correct information. The weather conditions were taken as per Table 4 for all simulations.
TABLE 4 – WEATHER CONDITIONS PARAMETERS
CONDITION A
CONDITION B
Wind Speed
1.5 m/s
3.0 m/s
Wind Direction
225° true at 3 m
225° true at 3 m
Pasquill Stability
B
D
Ground Roughness
Urban (Industrial)
Urban (Industrial)
30
30
30
30
Relative Humidity
60%
60%
Cloud Cover
50%
50%
Air Temperature (°C) Surface temperature
MAXIMUM CREDIBLE ACCIDENT SCENARIO: The MAXIMUM CREDIBLE ACCIDENT SCENARIO was analysed based on flammable vapour and toxic vapour risks. The ALOHA simulation software was used to obtain the risk contours and the zone of influence, as well as levels of risk associated with each zone. The calculations performed are based on Unified Dispersion Modeling and provide the footprints of hazardous chemical dispersion and the distances of critical concentrations for flammability and toxicity. The model consider a three stage method as given in the following illustration:
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RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. ACRYLAMIDE PLANT, JHAGADIA
POOL SPREADING AND VAPORIZATION The release containing liquid droplets forms a pool. Any evaporation from this pool will contribute to the dispersing pool. Evaporation ↓ DISPERSION The vapour cloud disperses in the atmosphere until it has reached harmless concentration. Calculation of the concentration profile of the cloud ↓ FLAMMABILITY AND TOXICITY
The results of the ALOHA simulation as well as the parameters used for carrying out the simulations is given in Annexure 4 and summarised below in Table 5.
TABLE 5 - MAXIMUM CREDIBLE ACCIDENT SCENARIO SIMULATIONS Parameters
Risk
Threat Zones
Red –100% of LEL Leakage of 50 kg of acryonitrile from unloading joint into pit, 60 minutes evaporation from pit into atmosphere, Weather Condition A
Flammable Vapour Cloud
Orange – 60% of LEL Yellow – 10% of LEL ERPG 3: 75 ppm
Toxic Vapour Cloud
ERPG 2: 35 ppm ERPG 1: 4 ppm
Vulnerability Zone* <10 m (unascertainable) <10 m (unascertainable) <10 m (unascertainable) <10 m (unascertainable) <10 m (unascertainable) <10 m (unascertainable)
Threat at Point: DW 5 m, OC 5 m No significant concentration
.0686 ppm (No significant concentration)
The flammable vapour cloud (100% of LEL) and the toxic vapour cloud that may be formed in this scenario would be smaller than can be accurately calculated by the software. Besides, as the areas around the unloading area are open and wellventilated, the chances of a flammable or toxic “cloud” forming are negligible. The Emergency Response Planning Guidelines (ERPG) set by the American Industrial Hygiene Association (AIHA) is used, and the ERPG2 zone is considered as the zone within which a 1 hour response time is available without experiencing or developing irreversible or other serious health effects or symptoms that could impair an individual’s ability to take protective action. As per the simulation, we can see that the ERPG2 zone is less than 10 meters and the threat at point 10 meters away and 5 meters off center is insignificant, signifying that the threat zone is probably limited to a very narrow area directly in the downwind direction. There is sufficient time and
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RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. ACRYLAMIDE PLANT, JHAGADIA
space available for plant personnel to deal with such situations without need for evacuation. WORST CASE SCENARIO: We have assumed a catastrophic failure of a single acrylonitrile storage tank as the WORST CASE SCENARIO. In such a scenario, we have assumed that all control systems have failed. The 190MT of acrylonitrile released from the tank would pour into the tank dykes and then would flow to the covered isolation tank located several meters away. The isolation tank is fitted with vents, and toxic vapour of acrylonitrile may leak into the atmosphere from these vents.
TABLE 6 – WORST CASE SCENARIO SIMULATION Parameters
Risk
Threat Zones
Red –100% of LEL 190MT of acrlyonitrile discharged into isolation tank, Weather Condition B
Flammable Vapour Cloud
Toxic Vapour Cloud
Orange – 60% of LEL Yellow – 10% of LEL ERPG 3: 75 ppm ERPG 2: 35 ppm ERPG 1: 4 ppm
Vulnerability Zone* <10 m (unascertainable) <10 m (unascertainable) <10 m (unascertainable) <10 m (unascertainable) <10 m (unascertainable)
Threat at Point: DW 5 m, OC 5 m No significant concentration
No significant concentration
17 m
The flammable vapour cloud (100% of LEL) and the toxic vapour cloud that may be formed in this scenario would be smaller than can be accurately calculated by the software. Besides, as the areas around the isolation tank are open and wellventilated, the chances of a flammable or toxic “cloud” forming are negligible. The Emergency Response Planning Guidelines (ERPG) set by the American Industrial Hygiene Association (AIHA) is used, and the ERPG-2 zone is considered as the zone within which a 1 hour response time is available without experiencing or developing irreversible or other serious health effects or symptoms that could impair an individual’s ability to take protective action. As per the simulation, we can see that the ERPG2 zone is less than 10 meters and the threat at point 10 meters away and 5 meters off center is insignificant, signifying that the threat zone is probably limited to a very narrow area directly in the downwind direction. The ERPG-1 zone is the zone within nearly all individuals could be exposed for up to 1 hr without experiencing other than mild transient adverse health effects or perceiving a clearly defined, objectionable odor. All the zones are within non-working areas where people are normally not present.
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RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. ACRYLAMIDE PLANT, JHAGADIA
CHAPTER 5 – Prevention and Risk Mitigation Accident prevention is the primary safety goal of any organisation. There are risks that can be eliminated through preventive measures and those which can be reduced through mitigation measures.
5.1 Preventive Measures The 4 E’s for elimination of hazards and prevent accidents are as follows: • • • •
Engineering and technological innovation to improve reliability Experience in the study of hazards and operations Enforcement of decisions on study results Education, awareness, and practice in prevention of accidents
Various measures have been / will be adopted at each stage of the project for ensuring safety of people, environment, and property. These measures include the following: • • • • • • • •
Site selection Choice of technology Equipment design incorporating domestic and international safety codes Plant layout with utmost consideration given to operational safety aspects Incorporation of interlocks and protection systems in plant design Safety awareness for key management persons Safety training for all operational staff Regular safety audits and inspections
A. Site Selection The plant is located in an industrial estate managed by the Gujarat Industrial Development Corporation, more than 15 km away from the closest city of Ankleshwar. The site soil conditions are rigid and safe, complying with the requirements of the load bearing capacity of various installations. The size of the plot is large enough to ensure proper layout of plant buildings with adequate interconnecting roads and distance from administrative areas. GIDC also provides adequate support for firefighting in case required and continuous water and power supply.
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B. Choice of Technology The Japanese technology chosen is the latest development using biocatalysts and negligible environmental hazards and high concern for safety. The process generates no by-products or wastes, reducing the risk to humans and the environment. It is a green chemistry process as acknowledged internationally. C. Equipment Design Acrylonitrile Storage Tank Farm 1. Tanks are fabricated out of carbon steel sheeting material of IS2062 grade steel. 2. Inside of tanks will be buffed with 180 grit and subsequently zinc coated to reduce risk of corrosion from acrylonitrile. 3. Tank exterior is painted with white epoxy for protection against atmospheric corrosion and for reflection of solar heat. 4. Tanks are nitrogen-blanketed with positive pressure maintained through pressure regulating valves. 5. Venting is done through conservation vent and flame arrestor with connection to nitrogen supply. 6. Pumps are located outside the dyke wall and are connected to tanks through flexible hose section. 7. Flexible hose section is located in a separate dyke area / unloading pit so as to limit the spread of any acrylonitrile leaked during tanker unloading. 8. Tanks are provided with instrumentation, such as level and temperature transmitters, which will send signals to the DCS system with alarms and interlocks. 9. Provision has been made for interlocking tanker earthing with pump start. 10. External tank circulation is carried out continuously to ensure uniform temperature within tanks. 11. Tanks are filled using a dip pipe to prevent splashing inside the tanks 12. Tank farm is surrounded by a fire hydrant system getting water supplies from multiple loops. 13. A foam tank is provided close to the tank farm so that foam can be injected into the water during spills or leaks. 14. A foam line shall be provided inside the storage tank for blanketing the surface in case of enhanced fire risk. 15. All tanks and pumps are double-earthed through independent earth pits so as to ensure resistance of not more than 10Ω. 16. Sprinkler system connected to the fire hydrant system is provided around the tank farm for cooling tanks in case of higher temperature. 17. All pumps are canned pumps which are without glands and seals for reducing the possibility of leakage during transport. 18. PTFE (Teflon) envelope gaskets are used in all flange connections.
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RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. ACRYLAMIDE PLANT, JHAGADIA
19. Lightning arrestors are provided on storage tanks. Other Equipment Mechanical 1. All process equipments operating under pressure are designed as per ASME Section VIII pressure vessel code for un-fired pressure vessels. The material of construction selected is compatible with the chemicals handled to ensure minimum corrosion effects. 2. Heat exchangers are designed as per TEMA Class B and Class C standards as applicable 3. Process tankages and vessels are sized taking into account minimum storage of intermediates and are provided with adequate instrumentation to measure temperature, pressure, level etc. 4. All process pumps are either glandless canned pumps or provided with double mechanical seals to ensure no leakage during operation. Piping 1. All pipes, fittings, and valves carrying acrylonitrile are made of SS304 grade stainless steel, with PTFE (Teflon) gaskets. 2. All pipes carrying acrylonitrile are designed to ensure non-restrictive flow from one equipment to another with minimum hold up of acrylonitrile in the lines. 3. All pipes are color coded / labeled for easy identification of materials. 4. Line sizes will be chosen such that pressure drops due to flow will be within permitted limits. 5. Wherever required, design incorporates suitable by-pass system to carry out maintenance work during plant operations and also to enable sectional closedown during machinery break down, etc. 6. Safety valves, relief valves, breather valves and rupture discs are mounted on hook-up piping to all critical equipments. 7. All normally operated manual valves will be located within easy reach of operator and at operable height. 8. Adequate number of flange joints shall be provided in long lines for easy dismantling and maintenance. Electrical 1. Plant areas are segregated into flame-proof and non-flameproof areas with adequate distances to separate the two zones. 2. Areas designated as flame proof areas will have all electrical fixtures including lighting fixtures, switches, junction boxes, cable glands, etc. of approved make. 3. A stand-by diesel generator of 380 KVA is installed in case of power trip/failure. This DG is located far away from the processing area.
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4. All tanks, pumps, tankers, and pipelines are properly earthed and bonded for dissipation of electrical leaks and static electric charges. Double earthing will be provided to drain electrical charge to two independent earth pits. 5. All incomers to the electrical panels including MCCs and PCC have air circuit breakers of adequate capacity for electrical protection of equipments connected to the outgoing feeders. 6. All feeders in MCCs and PCC have user point identification at both termination ends for easy tracking of faults and rectification. 7. Adequate ventilation with fans are provided in electrical panels for effective heat removal. 8. Earthing pits locations and requirements with looping grids shall be provided as per the legal and regulatory requirements. 9. Overhead cable routing will take into account safe distances from buildings and facilities. Underground cabling shall be marked with metal markers as per the regulatory requirements. 10. All panels will have incomer earth fault relay. 11. Lightning arrestors are provided on top of all structures. 12. All cables running on trays at elevation are properly dressed up and tied with clamps for rigidity. 13. All areas of plant and machinery and roads including all open operating areas are illuminated sufficiently to carry out operations round the clock. Instrumentation 1. This is a continuous chemical process plant and is therefore adequately instrumented. 2. All process operations are controlled by a centralized DCS system. DCS unit with its paraphernalia such as control modules, power supply unit, etc. are located in an isolated room away from process hazards and the room is airconditioned. This room has restricted entry. 3. DCS is provided with a UPS system which is adequate for ½ hour power break down. Since there is a stand-by DG set installed, this battery back up of ½ hour is adequate. 4. A Public Address system controlled from DCS room will warn of abnormal situations throughout the plant for taking quick corrective action. 5. All instrumentation hardware including measuring/control instruments are of standard make from reputed manufacturers. 6. Adequate redundancies are incorporated in measurements to take care of instrument failures. D. Plant Layout Acrylonitrile Storage Area 1. Acrylonitrile storage tanks are surrounded by a dyke wall capable of holding 110% of the largest tank’s capacity.
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2. The dyke walls and floors are made of concrete, which is impervious to liquid seepage. 3. The dyke area is subdivided into smaller compartments to restrict spreading of acrylonitrile pool. 4. The floor of the dyke area is sloped away from the tanks to prevent collection of material near the tanks. 5. The valves for drainage of the dyke area are located outside the dyke wall. 6. In case of catastrophic failure of a tank, the spilled acrylonitrile will drain to a further covered isolation tank located several meters away from all storage tanks to restrict the effects of toxicity and flammability. 7. The tank farm is located in an open, well-ventilated area. General / Other Areas 1. The plant is laid out in such a way that hazards are either eliminated or isolated so as to manage it effectively. 2. The location of the disaster prone areas of the plant is such that, they cause less impact to the nearby factories or habitations. 3. Buildings housing heat generating equipment or containing chemicals are well-ventilated with adequate air circulation. 4. Process Plant 1 which handles acrylonitrile conversion is designed as an open structure with all sides open for adequate ventilation 5. Administrative office provided away from process plants and storage tanks. 6. Security office provided close to gate and away from process plants and storage tanks. 7. Workers’ rest area, shower, and dispensary provided close to security area away from process plants. 8. Adequate number of safety showers and eye wash fountains are provided in areas close to storage facilities and process plants and on floors wherever necessary. 9. A large area has been provided on site in the upwind direction for emergency evacuation. 10. Interconnecting roads within the plot are made circular so that more than one get-away is available at any point. 11. A second “truckable” gate is provided for use in case of emergency. 12. Proper drainage and enclosures are provided to drain away storm water from unforeseen flooding. 13. Flame proof areas have been isolated from the non-flameproof areas. 14. DG room and electrical transformer located away from administrative office, process plant and storage tanks. 15. The storage tanks of acrylonitrile are located in an isolated area, protected by dykes with adequate facilities for handling spills and leakages. 16. Fire hydrant system covers the entire operating area of the plant. 17. Separate installation for fire water storing and pump house, with alternate and independent power source.
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RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. ACRYLAMIDE PLANT, JHAGADIA
18. Separate power distribution and isolation boards have been installed in each building. 19. Hazardous waste bin is located away from processing and administrative areas in an area clearly demarcated for the same. 20. Warning boards will be put up in areas where entry is restricted. 21. No Smoking boards are put up at the entrance and at other locations throughout the plant. 22. Boards showing the numbers and contact details of government / district officials as well as fire department, police department, district commissioner, etc. are installed at security gate as well as in the operational area. 23. Battery-cum-electrically operated emergency alarms will be located in every building. 24. Speed breakers and speed limit signs will be displayed as required. 25. Hazardous chemicals are stored as per compatibility and based on corrosive and reactive capabilities as per the guidelines in the MSDS. 26. MSDS of all hazardous chemicals are kept in the areas where such materials are stored. 27. Waste containers shall be located at appropriate locations throughout the plant, and will be coded according to the type of waste. E. Interlocks and Protection Systems 1. All process equipments including reactors, pumps, tanks, and vessels, etc. are provided with temperature, pressure and level measuring with control instruments. These controls are interlocked for auto-corrective action through system design. 2. Interlocks ensure that the parameters measured do not go out of range setting and enormously improve process efficiencies. 3. Recording, control and interlocks eliminate human factor in operation considerably and ensure smooth functioning of equipments. 4. Flow interlocks in reactor systems ensure optimum conversions and consistent product quality. F. Safety Awareness for Key Management 1. Key management personnel have been made aware of the key issues regarding the safety in design and operation of the plant. 2. Project management personnel have visited industrial plants where acrylonitrile is used in bulk as a raw material for the production of acrylamide as well as for the production of ABS rubber and acrylic fibers. Discussions with operational staff of the plants during these visits has given them valuable insight into the safety aspects of handling acrylonitrile. 3. Discussions on safe handling of acrylonitrile have been carried out with various safety experts, technical collaborators, and with overseas suppliers. G. Safety Training for All Operational Staff
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RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. ACRYLAMIDE PLANT, JHAGADIA
1. All operational staff are given safety training as a compulsory part of their induction program. 2. Safety training includes, among other things, the following important aspects: a. awareness of hazards of individual chemicals through study of MSDS b. correct usage of Personal Protective Equipment (PPE) c. explanation of the hazards and risks present in the premises, as well as their analysis d. impact on safety, health, and environment due to improper handling of hazardous chemicals e. guidelines for safety in operations f. Do’s and Don'ts H. Safety Audits and Inspections 1. Regular safety audit will be conducted to ascertain the safety levels followed in the plant and suggestions for improvement. 2. Special safety audits will be conducted whenever there are process-related equipment / operational changes made in the plant. 3. Safety audits will be carried out jointly by HSE personnel and external agencies, and corrective actions will be recorded and presented to management for review. 4. Daily safety inspections are carried out throughout the plant by HSE personnel. 5. Testing and inspection of high pressure equipment with periodical hydrotesting and thickness testing will be carried out once in a year during maintenance shutdown. 6. Testing of pressure safety valves and setting will be carried out once in a year during maintenance shutdown. 7. Calibration of control valves, instruments as and when required, but at least once in a year during maintenance shutdown. 8. Testing of thickness of all equipments with thickness meter will be carried out at least once in three years during maintenance shutdown. 9. Testing of electrical measurements, such as earthing resistance, will be carried out every month. 10. Testing of all fire hydrant installations, fire extinguishers, fire pumps, fire water level monitors will be carried out on a daily basis by HSE personnel.
5.2 Mitigation Measures Risk mitigation involves the reduction of the likelihood of a loss occurring due to an accident and the reduction of the severity of such a loss. Several risk mitigation measures have been taken into consideration in the planning of this project: •
Personal Protective Equipment Page 19
RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. ACRYLAMIDE PLANT, JHAGADIA
• • • • •
Medical facilities Handling of leakages and spills Firefighting system Emergency Control Centre On Site Emergency Plan
A. Personal Protective Equipment Personal protective equipment (PPE) is needed to protect individuals from injury. Several types of PPE are necessary for providing the optimum protection to individuals from the various risks. In addition to the PPE that will be used for regular plant operation, the following PPE has been selected for preservation at the plant’s Emergency Control Centre room for use in case of emergency: 1. 2. 3. 4. 5. 6.
Self contained Breathing Apparatus (SCBA) 04 sets Chemical face masks 50 sets Full body chemical suits with goggles 10 sets Firefighting suits 02 sets Helmets 50 pieces Chemical resistant gloves 50 pairs
B. Medical Facilities Medical facililites are needed to provide immediate medical attention to people who may been exposed to certain health risks during an accident. As there will be no resident doctor on site at all times, the focus will be on providing first aid before moving the concerned person(s) to an off-site medical facility. 1. 2. 3. 4. 5. 6. 7. 8. 9.
First Aid Centre is located in the security building at the main gate. Five personnel trained in First Aid shall be available during different shifts. A doctor visits the First Aid Centre periodically. Emergency vehcile is made available round the clock. First Aid Centre will be equipped with a safety shower, eye wash centre, and oxygen-administering facility. Medicines and antidotes for relevant hazardous chemicals will be stored at site. There will be two beds and stretchers in the First Aid Centre. The contact numbers of all nearby hospitals and medical facilities are kept and put up on a board in the First Aid Centre. A general agreement for immediate treatment will be made between the nearest hospital and the plant.
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RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. ACRYLAMIDE PLANT, JHAGADIA
C. Handling of Leakages and Spills Quick and safe handling of leakages and spills is the most effective method of risk mitigation in the plant. The company will take the following steps to ensure that leakages and spills can be effectively handled: 1. Ensuring availability and provisioning of suitable PPE for handling spills and leakages 2. Preparation of handling manuals and placement of the same at important locations 3. Placement of sand buckets, AFFF (aqueous film forming foam) fire extinguishers, and dry chemical fire extinguishers at high risk areas 4. Provisioning of specially marked containers for disposal of spillages 5. Decontamination area shall be earmarked for clothing contaminated by spills 6. Gas detectors are installed in the storage, unloading, and process areas where acrylonitrile is handled. 7. Provision of dykes in the areas where likelihood of spillages and leakage is greatest 8. Round-the-clock availability of foam through installation of a foam (AFFF) tank 9. Eye-wash stations and showers 10. Training of operating personnel in foam (AFFF) handling In case the leakage or spill can be handled by on-site trained personnel using proper protective clothing and equipment, the incident is not considered an emergency situation. Such non-emergency situations can include malfunctioning pumps, defective pipelines or leaking valves or seals. Also small spills may occur but can generally be handled without alarm. The MAXIMUM CREDIBLE ACCIDENT SCENARIO can be suitably handled without creating an emergency situation. In the WORST CASE ACCIDENT SCENARIO, the designated incident controller will be alerted and he will ensure that the emergency is properly dealt with and mitigated with all resources available at his disposal, as per the guidelines laid out in the On Site Emergency Plan. D. Firefighting Systems Due to the handling of flammable chemicals in the plant, it is necessary to provide an effective and efficient firefighting system. A map of the firefighting installations is given in Annexure 5. Some of the salient features are described as follows: 1. Fire water tank capacity of 305m3 and pump capacity of 137m3/hour are based on the number of monitors, risers, and outlets provided. 2. A total of 18 firefighting points have been provided. 3. Firewater pump is provided with two sources of power – DGVCL and diesel 4. All firewater piping is located adequately underground to prevent accidental damage Page 21
RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. ACRYLAMIDE PLANT, JHAGADIA
5. Pressure in firewater system piping will be maintained at 7.0kg/cm2g, with the help of jockey pumps. 6. Foam tank is provided for effective firefighting and hazardous chemical spill handling using foam. 7. All risers have two independent ring mains for adequate water flow and safety. 8. Firefighting points are located at an appropriate safe distance from tank dykes so as to allow effective firefighting operations. 9. A foam / water sprinkler system is located in the dyke area of the acrylonitrile storage tank farm for quick and effective handling of spills and firefighting. 10. All acrylonitrile tanks in the tank farm shall have provision for introduction of foam inside the tank through emergency glass seals to cover liquid surface. E. Emergency Control Centre The Emergency Control Centre is a designated room that shall be occupied by the Incident Controller, the final authority to give directives, coordinate with various teams, communicate with district government agencies, and to deal with an emergency inside the plant. The following documents and equipment shall be kept here for the use of the Incident Controller during an emergency: 1. Updated drawings of all plants 2. Site layout plan showing raw materials and finished products storage locations, security gates, assembly points, process plants, utility building, raw water storage, and other areas of the plant 3. Map of GIDC Jhagadia 4. On Site Emergency Plan 5. List of key plant operating personnel 6. Telephone numbers and contact details of key plant operating personnel 7. Telephone numbers and contact details of district government officials and emergency offices 8. Battery-cum-electricity operated Public Address system 9. Siren with a 500 m range 10. Essential tools including spades and crowbars 11. Personal Protective Equipment for emergency use 12. Fire extinguishers F. On Site Emergency Plan A separate On Site Emergency Plan has been prepared. The same will be kept in all the buildings of the plant.
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RISK ASSESSMENT REPORT OF BLACK ROSE INDUSTRIES LTD. ACRYLAMIDE PLANT, JHAGADIA
CHAPTER 6 – Conclusions As can be seen from this report, the primary risk associated with the plant is the risk of handling acrylonitrile. Acrylonitrile, being a hazardous chemical, must be handled in a plant designed to accommodate such handling. With the proper and safe handling of acrylonitrile, the risks associated with it are mitigated to an extent that the probability and severity of loss become negligible.
Page 23
Annexure 1
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3
Annexure 4 – ALOHA SIMULATIONS
1.MAXIMUM CREDIBLE SCENARIO – B1 LEAKAGE DUE TO FAULTY COUPLING FIT AT TIME OF UNLOADING FLAMMABLE AREA OF VAPOUR CLOUD SCENARIO SITE DATA: Location: JHAGADIA, ANKLESHWAR, GUJARAT, INDIA Building Air Exchanges Per Hour: 12 (user specified) Time: April 19, 2016 & 1344 hours ST (user specified) CHEMICAL DATA: Chemical Name: ACRYLONITRILE CAS Number: 107-13-1 Molecular Weight: 53.06 g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 1.7 ppm AEGL-3 (60 min): 28 ppm IDLH: 85 ppm LEL: 30500 ppm UEL: 170000 ppm Carcinogenic risk - see CAMEO Chemicals Ambient Boiling Point: 77.2˚ C Vapor Pressure at Ambient Temperature: 0.16 atm Ambient Saturation Concentration: 165,065 ppm or 16.5% ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) Wind: 1.5 meters/second from 225˚ true at 3 meters Ground Roughness: urban or forest Cloud Cover: 5 tenths Air Temperature: 30˚ C Stability Class: B No Inversion Height Relative Humidity: 60% SOURCE STRENGTH: Evaporating Puddle (Note: chemical is flammable) Puddle Area: .16 square meters Puddle Mass: 50 kilograms Ground Type: Concrete Ground Temperature: 30˚ C Initial Puddle Temperature: Ground temperature Release Duration: ALOHA limited the duration to 1 hour Max Average Sustained Release Rate: 20.3 grams/min (averaged over a minute or more) Total Amount Released: 1.16 kilograms THREAT ZONE: (GAUSSIAN SELECTED) Threat Modeled: Flammable Area of Vapor Cloud Model Run: Gaussian Red : less than 10 meters(10.9 yards) --- (30500 ppm = LEL) 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) --- (18300 ppm = 60% LEL = Flame Pockets) Note: Threat zone was not drawn because effects of near-field patchiness make dispersion predictions less reliable for short distances. Yellow: less than 10 meters(10.9 yards) --- (3050 ppm = 10% LEL) Note: Threat zone was not drawn because effects of near-field patchiness make dispersion predictions less reliable for short distances. THREAT AT POINT: Concentration Estimates at the point: Downwind: 10 meters Off Centerline: 5 meters Note: Concentration not drawn because there is no significant concentration at the point selected.
2.MAXIMUM CREDIBLE SCENARIO – B1 LEAKAGE DUE TO FAULTY COUPLING FIT AT TIME OF UNLOADING TOXIC VAPOUR DISPERSION SCENARIO SITE DATA: Location: JHAGADIA, ANKLESHWAR, GUJARAT, INDIA Building Air Exchanges Per Hour: 12 (user specified) Time: April 19, 2016 & 1344 hours ST (user specified) CHEMICAL DATA: Chemical Name: ACRYLONITRILE CAS Number: 107-13-1 Molecular Weight: 53.06 g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 1.7 ppm AEGL-3 (60 min): 28 ppm IDLH: 85 ppm LEL: 30500 ppm UEL: 170000 ppm Carcinogenic risk - see CAMEO Chemicals Ambient Boiling Point: 77.2˚ C Vapor Pressure at Ambient Temperature: 0.16 atm Ambient Saturation Concentration: 165,065 ppm or 16.5% ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) Wind: 1.5 meters/second from 225˚ true at 3 meters Ground Roughness: urban or forest Cloud Cover: 5 tenths Air Temperature: 30˚ C Stability Class: B No Inversion Height Relative Humidity: 60% SOURCE STRENGTH: Evaporating Puddle (Note: chemical is flammable) Puddle Area: .16 square meters Puddle Mass: 50 kilograms Ground Type: Concrete Ground Temperature: 30˚ C Initial Puddle Temperature: Ground temperature Release Duration: ALOHA limited the duration to 1 hour Max Average Sustained Release Rate: 20.3 grams/min (averaged over a minute or more) Total Amount Released: 1.16 kilograms THREAT ZONE: (GAUSSIAN SELECTED) Model Run: Gaussian Red : less than 10 meters(10.9 yards) --- (75 ppm = ERPG-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) --- (35 ppm = ERPG-2) Note: Threat zone was not drawn because effects of near-field patchiness make dispersion predictions less reliable for short distances. Yellow: less than 10 meters(10.9 yards) --- (10 ppm = ERPG-1) Note: Threat zone was not drawn because effects of near-field patchiness make dispersion predictions less reliable for short distances. THREAT AT POINT: Concentration Estimates at the point: Downwind: 10 meters Off Centerline: 5 meters Max Concentration: Outdoor: 0.0686 ppm
3.WORST CASE SCENARIO – D CATASTROPHIC FAILURE OF ACRYLONITRILE STORAGE TANK LEADING TO FLOW OF MATERIAL INTO ISOLATION TANK FLAMMABLE AREA OF VAPOUR CLOUD SCENARIO SITE DATA: Location: JHAGADIA, ANKLESHWAR, GUJARAT, INDIA Building Air Exchanges Per Hour: 12 (user specified) Time: April 19, 2016 & 1340 hours ST (user specified) CHEMICAL DATA: Chemical Name: ACRYLONITRILE CAS Number: 107-13-1 Molecular Weight: 53.06 g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 1.7 ppm AEGL-3 (60 min): 28 ppm IDLH: 85 ppm LEL: 30500 ppm UEL: 170000 ppm Carcinogenic risk - see CAMEO Chemicals Ambient Boiling Point: 77.2˚ C Vapor Pressure at Ambient Temperature: 0.16 atm Ambient Saturation Concentration: 165,065 ppm or 16.5% ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) Wind: 3 meters/second from 225˚ true at 3 meters Ground Roughness: urban or forest Cloud Cover: 5 tenths Air Temperature: 30˚ C Stability Class: D No Inversion Height Relative Humidity: 60% SOURCE STRENGTH: Leak from hole in vertical cylindrical tank Flammable chemical escaping from tank (not burning) Tank Diameter: 16.61 meters Tank Length: 1 meters Tank Volume: 217 cubic meters Tank contains liquid Internal Temperature: 30˚ C Chemical Mass in Tank: 190 tons Tank is 100% full Circular Opening Diameter: .5 meters Opening is 1 meters from tank bottom Ground Type: Concrete Ground Temperature: 30˚ C Max Puddle Diameter: .5 meters Release Duration: ALOHA limited the duration to 1 hour Max Average Sustained Release Rate: 41.2 grams/min (averaged over a minute or more) Total Amount Released: 2.47 kilograms Note: The chemical escaped as a liquid and formed an evaporating puddle. The puddle spread to a diameter of 0.5 meters. THREAT ZONE: Threat Modeled: Flammable Area of Vapor Cloud Model Run: Gaussian Red : less than 10 meters(10.9 yards) --- (30500 ppm = LEL) 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) --- (18300 ppm = 60% LEL = Flame Pockets) Note: Threat zone was not drawn because effects of near-field patchiness make dispersion predictions less reliable for short distances. Yellow: less than 10 meters(10.9 yards) --- (3050 ppm = 10% LEL) Note: Threat zone was not drawn because effects of near-field patchiness make dispersion predictions less reliable for short distances.
THREAT AT POINT: Concentration Estimates at the point: Downwind: 10 meters Off Centerline: 5 meters Note: Concentration not drawn because there is no significant concentration at the point selected.
4.WORST CASE SCENARIO – D CATASTROPHIC FAILURE OF ACRYLONITRILE STORAGE TANK LEADING TO FLOW OF MATERIAL INTO ISOLATION TANK TOXIC VAPOUR DISPERSION SCENARIO SITE DATA: Location: JHAGADIA, ANKLESHWAR, GUJARAT, INDIA Building Air Exchanges Per Hour: 12 (user specified) Time: April 19, 2016 & 1340 hours ST (user specified) CHEMICAL DATA: Chemical Name: ACRYLONITRILE CAS Number: 107-13-1 Molecular Weight: 53.06 g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 1.7 ppm AEGL-3 (60 min): 28 ppm IDLH: 85 ppm LEL: 30500 ppm UEL: 170000 ppm Carcinogenic risk - see CAMEO Chemicals Ambient Boiling Point: 77.2˚ C Vapor Pressure at Ambient Temperature: 0.16 atm Ambient Saturation Concentration: 165,065 ppm or 16.5% ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) Wind: 3 meters/second from 225˚ true at 3 meters Ground Roughness: urban or forest Cloud Cover: 5 tenths Air Temperature: 30˚ C Stability Class: D No Inversion Height Relative Humidity: 60% SOURCE STRENGTH: Leak from hole in vertical cylindrical tank Flammable chemical escaping from tank (not burning) Tank Diameter: 16.61 meters Tank Length: 1 meters Tank Volume: 217 cubic meters Tank contains liquid Internal Temperature: 30˚ C Chemical Mass in Tank: 190 tons Tank is 100% full Circular Opening Diameter: .5 meters Opening is 1 meters from tank bottom Ground Type: Concrete Ground Temperature: 30˚ C Max Puddle Diameter: .5 meters Release Duration: ALOHA limited the duration to 1 hour Max Average Sustained Release Rate: 41.2 grams/min (averaged over a minute or more) Total Amount Released: 2.47 kilograms Note: The chemical escaped as a liquid and formed an evaporating puddle. The puddle spread to a diameter of 0.5 meters. THREAT ZONE: Model Run: Gaussian Red : less than 10 meters(10.9 yards) --- (75 ppm = ERPG-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) --- (35 ppm = ERPG-2) Note: Threat zone was not drawn because effects of near-field patchiness make dispersion predictions less reliable for short distances. Yellow: 17 meters --- (10 ppm = ERPG-1) Note: Threat zone was not drawn because effects of near-field patchiness make dispersion predictions less reliable for short distances.
THREAT AT POINT: Concentration Estimates at the point: Downwind: 10 meters Off Centerline: 5 meters Note: Concentration not drawn because there is no significant concentration at the point selected.
ANNEXURE 5
