Mock Drill

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.