RISK ANALYSIS & DISASTER MANAGEMENT PLAN –

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RISK ANALYSIS & DISASTER MANAGEMENT PLAN – (UNIT-IV)1.0 Definition of RiskRisk (R) is thus defined as function of possibility of occurrence of hazard (f) and magnitude of itsconsequence (D).Risk (R) f (Hazard, Probability, Consequence)In most of the applications, however, risk may be defined asRisk (R) Probability (f) * Consequence (D)2.0 METHODOLOGY1. All the Raw Materials are listed to identify Hazardous chemicals as per MSIHC Rule –1989 andPLI Act/ rule.2. All the Hazardous Chemicals are categorized in two category a) Hazardous chemicals from RMlist of existing facility and b) from RM list of proposed facility.3. Hazardous chemicals from both the list are further classified as per their potential hazardousproperty and physical property.4. All the hazardous chemicals are assessed for their potential risk, using 3 x 3 Risk AssessmentMatrix. Procedure for risk assessment by 3 x 3 Risk Assessment Matrix is explains at Para 5(B).5.a. Significant hazard/ risk is identified as “Heavy spillage of liquid chemical with evolution oftoxic gas” or “ Toxic gas release” with Emergency status, in risk assessmentby3 x 3 RiskAssessment Matrix, n then such hazard/risk are further assessed for Gas Dispersion, usingALOHA software, approved by EPA-USA. Result of Risk Assessment and Gas dispersion P)andEMERGENCYRESPONSEPLAN(ERP).5. b. If the potential hazard is identified as “fire” or “explosion”, with Emergency status, in riskassessment using 3x3 Risk Assessment Matrix, then such situation/hazards are compared withthe risk assessment done by District Crisis group-Bharuch and Local Crisis group-Jhagadia,Ankleshwar area. Findings of the District Crisis group and Local Crisis group are also taken in toaccount for RISK MANAGEMENT PLAN ( RMP)and EMERGENCYRESPONSEPLAN.( ERP).R-1

Quantitative risk assessment(QRA) is ameansofmakingasystematic analysis of the risks fromhazardousactivities, and forminga rational evaluationoftheirsignificance,in order to dbelow,& illustrated in Figure1.System DefinitionHazard IdentificationAnalysis of AccidentScenariosEstimation of AccidentfrequenciesConsequence analysisand modelingRisk EstimationR-2

3.0 STORAGE AND HANDLING OF HAZARDOUS CHEMICALSThe properties of the important raw materials and the safety precautions to be taken to prevent anaccident are detailed in ‘Material Safety Data Sheets’( MSDS)The details of storage of Hazardous chemicals along with measures taken are given in Table 1.TABLE :1STORAGE DETAILS OF HAZARDOUS CHEMICALSSr.No.Name of Hazardous ChemicalTypeMOCSize KLNoDimension1DEG/PEGliquidMS6025.0 m x 4.0m2Sulphuric AcidliquidMS5034.5 m x 3.8 m3Hydrochloric AcidliquidFFFRP / HDPE2025.3 m x 2.5 m4Nitric AcidliquidAluminum coated tank1014.0 m x 2.0 m5BenzeneliquidMS5024.5 m x 3.8 m6Iso Propyl AlcoholliquidMS2015.3 m x 2.5 m7Chloro BenzeneliquidMS2025.3 m x 2.5 m8MethanolliquidMS2015.3 m x 2.5 m9EDCliquidSS 3042025.3 m x 2.5 m10 Ortho Di Chloro Benzene( ODCB)liquidMS2015.3 m x 2.5 m11 AmmoniaLiquidMS2015.3 m x 2.5 m12 Sodium Hydroxide LyeliquidMS2515.5 m x 2.5 m13 m-DichlorobenzeneLiquidMS7515.5 m x 4.25 m14 Meta Di Nitro Benzene ( MDNB)LiquidMS25 KL35.5 m x 2.5 mTonner/Pipeline from the900 Kgnearby manufacturer5----15 ChlorineGas16 3- Nitro -4- Methyl Benzoic AcidLiquidDrum200 Liter10----17 2- Methyl -5- Nitro PhenolLiquidDrum200 Liter10----18 Iso Butyl AlcoholLiquidDrum200 Liter10----19 Benzene Sulphonyl ChlorideLiquidDrum200 Liter10----LiquidDrum200 Liter10----21 2,4 – Dichloro PhenolLiquidDrum200 Liter10----22 Para Chloro Phenol ( PCP)LiquidDrum200 Liter10----23 Dimethyl SulfateLiquidDrum200 Liter10------24 PhenolLiquidDrum200 Liter10----25 Nitro BenzeneLiquidDrum200 Liter10----202- Chloro Ethanol (O - ChloroEthanol)R-3

Chemical Properties of the Hazardous Chemical1MethanolFlammable, Toxic1264.70.7911.11SOLUBILITYWITH WATERat 20 deg CMiscible23Benzene CAS # 71-43-2Sulphuric AcidFlammable, luble-2.3 kPa1.3-7.9-4280 .110 ppm2300 ppm5Chloro BenzeneCAS # 108-90-7Ethylene Dichloride83.2 Rat 4hour24 ml/kg for rat for2H-Flammable/Toxic1381-851.253.48.7 g/l65mmHg6.215.9625 Rat2800 Rabbit22,000 ppm 0.623.24SolubleSoluble17.53--1.78.6Ortho Dichloro Benzene(ODCB)CAS # 95-50-1Flammable, Toxic661801831.35.1Insoluble-2.29.2630 mg/kg[Rabbit]--28.79 Rat 1h1017 ppm8317mmg/kg [Rat]--m- Di chloro BenzeneToxic--2971.37--InsolublenegligibleNANA1900 mg/ Kg1011Nitric AcidSodium 4081.48SolubleMiscible6 KPa 2 KPa--------12Meta Di Nitro BenzeneToxic---3011.3682.52.3(hydrate)5.859.5 mg/Kg----Slightly Soluble----------13Chloro BenzeneFlammable/ Toxic29.41321.103.88Soluble8.8 KPa1.37.114Nitro BenzeneFlammable/ Toxic87.78201.81.234.25Slightly Soluble0.15 KPa1.8---151630 % Hydrochloric AcidIso Propyl 3 mm Hg2.012.0SR.NO.9NAME OF THE RAWMATERIALSHAZARDFP degCBPdeg CSP.GR.20 deg CVDvs airVPmm Hg20C128 kPa31LD50ORALmg/kgs5658 RatLD50DARMALmg/kgs15800 RabbitLEL%UEL%6LC 50 mg/L---------8150 mg/m3 for 4HRat-------------2300 ppm-----590 mg/Kg---22000 ppm Rat4396 mg.Kg Rat12800 mg/ KgRat74.4 mg/kg10 ppm----R-8

TABLE 2STORAGE HAZARDOUS AND CONTROLS -- ProposedDetails of all (A) Products (B) Raw materials (C) Intermediates & (D) Bi-productsSr.No.Name of thematerial(MentionConcentrationif any)TotalstorageCap. MT1.Meta Di NitroBenzene25 X 3 tankActuallystored(total)MT75ActuallyStored in thebiggestcontainerMT25Place of itsStorageState,pressure(Kg/cm2)& Temp.( C)Types ofhazardsPossible (Fire,Explosion,Toxic Release,Spill etc.)UNIT - 4AnupamRasayanIndia Ltd.AmbientToxic.R-9Control Measures Provided1) Tank, valve, pipeline are checkedand maintain, in good condition.2) All Gaskets are checkedperiodically & if found defective arereplaced by new one.3) Joints are checked regularly tofound any Leakage.4) PPE is kept to handle the Hazard.5) Sufficient amount of sand/soil arekept to control any spillage.6) Vent line & level indicatorprovided.7) Eye washer cum shower isprovided near tank-farm area.8) Dyke wall provided.9) Fire Hydrant system installed.10) Portable fire extinguisher provided.11) DCS / PLC control Systeminstalled.12) Vent line deep in water.EmergencyAction

Sr.No.Name of the material(MentionConcentration if any)Totalstorage Cap.MTActuallystored(total) MT2.Benzene50 X 2 tank10050UNIT - 4AnupamRasayanIndia Ltd.AmbientToxic / Flammable3.Caustic Soda Lye 48%25 X 1 tank2525-DO-AmbientCorrosive & Spill,if leak from tank4.Sulphuric Acid 98%50 X 3 tank15050-DO-Ambient5.Hydrochloric Acid20 X 1 tank2020-DO-AmbientCorrosive & Spill,if leak from tankCorrosive & Spill,if leak from tank6.Nitric Acid10 X 1 tank-DO-AmbientOxidizer, corrosive7.Di ethelene glycol(DEG)60 X 2 tank-DO.AmbientFire, if spill fromtank & comes incontact withspark.8.Meta Di ChloroBenzene75 X 1 Tank-DO-AmbientFire, if spill fromTank& comes incontact with spark10ActuallyStored in thebiggestcontainer MT10120756075Place of itsStorageState,pressure(Kg/cm2) &Temp. ( C)Types of hazardsPossible (Fire,Explosion, ToxicRelease, Spill etc.)ControlProvided(1) to (11)12) Proper ear-thing &bonding provided.13) No Smoking boarddisplay.14) Flame arrester withbreather valve provided.(1) to (11)R-10Measures EmergencyAction-DO-DO(1) To (11)(1)to (11)12) Proper ear-thing &bonding provided.13) No Smoking boarddisplay.14) Flame arrester withbreather valve provided.-DO-

Sr.Totalstorage Cap.MTActuallystored(total) MTActuallyStored in thebiggestcontainer MTPlace of itsStorageNo.Name of the material(MentionConcentration if any)State,pressure(Kg/cm2) &Temp. ( C)9.Iso Propyl Alcohol20 X 1 Tank2020-DO-Ambient10.Chloro Benzene20 X 2 Tank4020-DO-Ambient11.Methanol20 X 1 Tank2020-DO-Ambient12.EDC20 X 2 Tank4020-DO-Ambient13.Ortho Di ChloroBenzene (ODCB)20 X 1 Tank2020-DO-Ambient14.Ammonia20 X 1 Tank2020-DO-AmbientFire, if spill fromTank& comes incontact with sparkFire, if spill fromTank& comes incontact with sparkFire, if spill fromTank& comes incontact with sparkFire, if spill fromTank& comes incontact with sparkFire, if spill fromTank& comes incontact with sparkToxic15.Chlorine0.9 X 5Tonners4.50.9-DO-AmbientToxicR-11Types of hazardsPossible (Fire,Explosion, ToxicRelease, Spill etc.)ControlProvidedMeasures EmergencyAction-DO--DO--DO--DO--DO-(1)to (11)(1) to (11)12) Chlorine Kit & FRPhood with scrubbingsystem provided

Sr.No.Name of the material(MentionConcentration if any)Totalstorage Cap.MTActuallystored(total) MTActuallyStored in thebiggestcontainer MTPlace of itsStorageState,pressure(Kg/cm2) &Temp. ( C)Types of hazardsPossible (Fire,Explosion, ToxicRelease, Spilletc.)Control Measures Provided16.3- Nitro -4- MethylBenzoic Acid0.200 X 50Drums100.200-DO-AmbientCorrosive(1) to (11)17.2- Methyl -5- NitroPhenol2,4 – Dichloro Phenol0.200 X 50Drums0.200 X 50Drums0.200 X 50Drums100.200-DO-AmbientToxic(1) to oxic-DO-0.200 X 50Drums0.200 X ntFire, if spill fromTank & comes incontact withsparkFire, if spill fromTank & comes incontact withspark(1) to (11)(12) Separate storage-DO-18.19.Para Chloro Phenol (PCP)20.Phenol21.Iso Butyl Alcohol22.2- Chloro Ethanol (O Chloro Ethanol)0.200 X 50Drums100.200-DO-Ambient23.Nitro Benzene0.200 X 50Drums100.200-DO-AmbientFire, if spill fromTank & comes incontact withspark24.Benzene SulphonylChlorideDimethyl Sulfate0.200 X 50Drums0.200 X 50Drums100.200-DO-AmbientToxic(1) to yAction

Sr.No.Name of the material(MentionConcentration if any)Totalstorage Cap.MTActuallystored(total) MTActuallyStored in thebiggestcontainer MT26.NSA (By Product)150 X 1 tank15015027.Dilute Sulphuric Acid65- 70 % ( By Product)50 X 1 tank5028.1-4 Dioxane50 X 1 Tank30 X 1 tank80Place of itsStorageState,pressure(Kg/cm2) &Temp. ( C)Types of hazardsPossible (Fire,Explosion, ToxicRelease, Spilletc.)-DO-AmbientToxic, Oxidizer50-DO-AmbientCorrosive & Spill,if leak from tank-DO-50-DO-NitrogenBlanketingFire, if spill fromDrum & comes incontact withspark(1) to (11)12) Proper ear-thing &bonding provided.13) No Smoking boarddisplay.14) Flame arrester withbreather valve provided.R-13Control Measures Provided(1) To (12)EmergencyAction

PROCESS HAZARDS & CONTROL-- ExistingPROCESS AND VESSEL HAZARDS AND ITS CONTROLSr. Name of the Plant orNo. Place1121,4 Dioxane PlantName ofhazardousprocess.Materials inthe process /operationwith theirquantity.34DehydrationAs per raw&materialdistillation details givenon Page-13Name ofthe vessel& itslocation.5-OperatingType .67Atmospheric Fire,Temperature & ChemicalPressureSpillageControl measures /provided. 2 Drum filling roomPacking &FillingAs per rawmaterialdetails givenon Page-13-Atmospheric Fire, Temperature & Explosion,PressureToxic Release R-148Adequate quantity offire extinguishersprovided.Adequate number ofsafety shower providedPPE has been selectedas per materials andpackaging processShock proof electricalequipment provided toavoid electrical hazardTransfer of material byclosed circuit only andby pump using PPE’sEarthing bondingprovided to avoid staticcharge hazardThe production areasprovided flame prooffittingsIn charge Person /Telephone number.9Mr. Jitendra Pawaday. Manager – Works(O)8238035675

PROCESS AND VESSEL HAZARD AND CONTROLS --- ProposedDetails of the manufacturing process - plant and/or product wise.Sr. No.Name ofPlant,Departmentor PlaceName of theHazardousProcess andOperationMaterials in theprocess/ operationwith their quantityand concentrationName of theVessel and itsLocationChlorinationMDNB / ChlorineGLMS VesselWashingAcidic MDCB/ NitricAcidSS VesselDistillationCrude MDCBSS Vessel1.2.3.UNIT :- 4AnupamRasayan IndiaLtd.OperatingTypes of hazardsControl Measures Provided & EmergencyParameters Possible (Fire,actionpressure, temp., Explosion, ToxicRelease, Spillflow etc.etc.) 170 - 180 CFire(1) All Vessels are well designed to withstandVacuum 500 Spillthe pressure, temperature and the reactionToxic Gas release carried out inside it.mmHg(2) All Vessels are provided with pressuregauges and temperature indicator.(3) Jacket cooling system through Brine waterAtmosphericFire/ Plant water / Tower water circulationSpillprovided on all vessels.(4) All vessels are hydraulically pressure testedand record is maintained in Foam No. 11.(5) All the plants, departments are provided 125-135 CFirewith fire extinguishers as per requirement.Vacuum 750Spill(6) Process area provided with flameproofmmHgelectrical fittings and pumps. Plant declared"Fire Zone". No smoking board displayed inplants. Fire extinguishers are provided. All thepipelines are bounded and ear-thing provided.R-15

1,4 DioxineDEGGL MS Vessel 106 CAtmospheric4.R-16FireSpill(7) Workers/Supervisors/Officers working onprocess are well trained in safe operatingprocedures.(8) All plants are provided with eye washercum safety shower.(9) Fire Hydrant System Installed.(10) DCS / PLC control System installed.

PROCESS AND VESSEL HAZARD AND CONTROLS --- ProposedDetails of the manufacturing process - plant and/or product wise.Sr.No.5.Name ofPlant,Departmentor PlaceName of the Materials in theHazardousprocess/Process and operation withOperation their quantityandconcentrationNitrationBenzene/ NitricAcidName of the OperatingTypes ofVessel and Parameters hazardsits Locationpressure,Possible (Fire,temp., flowExplosion,etc.Toxic Release,Spill etc.)0SS Vessel 50 CFireAtmospheric Spill,Toxic GasreleaseUNIT :- 4AnupamRasayan IndiaLtd.R-17Control Measures Provided & Emergency action(1) All Vessels are well designed to withstand the pressure,temperature and the reaction carried out inside it.(2) All Vessels are provided with pressure gauges andtemperature indicator.(3) Jacket cooling system through Plant water / Tower watercirculation provided on all vessels.(4) All vessels are hydraulically pressure tested and record ismaintained in Foam No. 11.(5) All the plants, departments are provided with fireextinguishers as per requirement(6) Process area provided with flameproof electrical fittings andpumps. Plant declared "Fire Zone". No smoking board displayedin plants.Fire extinguishers are provided. All the pipelines are bounded andear-thing provided.(7) Workers/Supervisors/Officers working on process are welltrained in safe operating procedures.(8) All plants are provided with eye washer cum safety shower.(9) Fire Hydrant System Installed.(10) DCS / PLC control System installed.(11) Provision of Safety Valve, Rupture Disc & Blow Down TankSystem.

TABLE 3OTHER HAZARDS & CONTROLNameofthe Its source & reasonspossible hazard or (Activity)emergencyItseffecton Place of effectspersons, property& environmentBoiler1. Burning2. PhysicalInjury3. ExplosionBoiler-likely to causedue to temperature/pressure build upPerson andproperty02Spillage from pipelines1. Toxic gas release2. FirePersonPipe line & vessels-By not adhering safetynorms and bynegligence- Do -Regular inspection of pipelinesand vessels. The damagedpipes, flanges to be replacedregular painting of pipe lines03Electricity1.Burning2. Shock3. FireLoose contact of wires, Person Propertyweak earthing ShortCircuit, ImproperInsulation.- Do -Regular inspection of electricalfitting, flameproof fittingsprovided in flammable areas,proper earthing.04Bad House Keeping Bad House1. InjuryKeeping2. Burning3. Fire4. Chemical hazards05Structural Collapse1. InjurySr.No.01Due to over loading ofmachinery, badworkman ship ofconstructionEarthquakePerson & Property- Do -Factory PremisesFactory Premises- Do -Control MeasureStandard and necessaryfittings to be provided regularinspection to be carried out.Regular inspection of plant onday-to-day basis, Properplacement of materials.Structural stability to beobtained from Charteredengineer, load bearingcapacity to be checked, regularinspection of plant.R-19

Figure -2Layout of the PlantR-20

Risk Assessment by 3 x 3 Risk Assessment Matrix(1) Corrosive LiquidActivity: Sulfuric acid: Storage Tank And Transfer By Pump To Receiver OfSulphuric Acid / Nitrosyl Sulfuric Acid/NitricAcidRisk Assessment with considerationof control measuresNo.HazardSub hazard StatusControl Measures will be provided.Severity ProbabilityRisk1 Leakage & spillage Eye contactA SeriousHighlyModerate Dyke wall will be provided. Periodicfrom tank cell orunlikelytesting of tanks- once in two years,valve andSkin contactA Moderate UnlikelyModerate regular painting per year. Apron, Handsplashing ofSlip & fallA SeriousHighlyModerate gloves, gumboot, goggles and helmetmaterialwill be provided. Good house keepingunlikelyis maintained. SBA set, Canister maskand airline mask is provided. Eyewasher & shower will be provided.2 Heavy spillage due PropertyE SeriousHighlyModerate Dyke wall having sufficient size willto collapse of loss andunlikelybe provided. Tank’s thicknessstorage tank from injury.measured on regular interval.foundationPainting on tanks is done on regularbasis.3 Broken RailingFallfrom A SeriousHighlyModerate Railing will be provided, Apron, Handand broken steps height.unlikelygloves, gumboot, goggles and helmetof ladder.will be provided.4 Leakage fromToxic gasEModerateUnlikelyModerate Sound guard will be provided onglass level tubereleaselevel indicator and dyke wall will beprovided.5 Spillage due toInjury and A SeriousHighlyModerate Dyke wall having sufficient size isoverflow frommaterialunlikelyprovided. ADEQUATE PPE as above isStorage tank orloss.kept and warned. Dry sand is kept inreceiver.sufficient quantity. Level gauge andlevel indicator with guard isprovided. Overflow and return linewill be provided on receiver.6 Moving rotating InjuryN Moderate UnlikelyModerate U- Guards and fan guard will bepart of transferprovided.pump.7 Electrical shock. InjuryA SeriousHighlyModerate Proper enclosure of Electricalunlikelyequipments with earthing andADEQUATE PPE will be provided.R-21

(2) Flammable liquidActivity: 1-4 DioxineLoading From Store inStorage Tank to And Transfer By Pump toRoad Tanker.NoHazardSub Hazard Status Risk Assessment with considerationExistingof control measuresControl MeasureSeverity Probability Risk1 Leakage from tank Eye contactA SeriousHighlyModerate Dyke wall provided. Periodic testing ofcell or valve andunlikelytanks- once in two years, regularsplashing ofpainting per year. Apron, Hand gloves,InhalationA Moderate HighlyTolerablematerial.gumboot, goggles & helmet provided.of gasunlikelyGood house keeping is maintained. EyeSkin contactA Moderate HighlyTolerablewasher & shower provided. CCEunlikelyapproved premises with door havingSlip & fallA SeriousHighlyModerate locking arrangement provided. Flameunlikelyproof electrical connection provided.2 Heavy spillage due PropertyE SeriousHighlyModerate Dyke wall having sufficient size isto collapse ofdamage andunlikelyprovided. Tank’s thickness measured onstorage tank from injury.regular interval. RCC foundationfoundation.provided. Paintings of tanks are doneon regular basis.3 Leakage in present FireE SeriousHighlyModerate Earthing& bonding on tanks andof ignition source.unlikelytransfer line, flame proof electricalinstallation, flame arrester provided.FFE in sufficient quantity is provided.Well-trained fire staff with Fire hydrantsystem as per TAC guideline installed.Portable water monitor provided. Foamsolution sufficient quantity provided.4 Spillage due to Injury and A Moderate UnlikelyModerate Dyke wall having sufficient size isoverflowfrom materialprovided. Material can be recoveredStorage tank or loss.from dyke wall. Dry sand is kept inRoad Tanker.sufficient quantity. Level gauge isprovided. Overflow with return linefrom Receiver to st. tank is provided.Apron, Hand gloves, gumboot, gogglesand helmet provided.5 Escape of vapour InhalationN MinorLikelyModerate Good ventilation in the area. Vent linefrom vent lineof vapourprovided at sufficient height.during Un loading.6 Injury due toInjuryN Moderate UnlikelyModerate U- Guards and fan guard is provided.moving rotatingpart of transferpump.7 Injury due toInjuryA SeriousHighlyModerate ProperenclosureofElectricalElectrical shock.unlikelyequipmentswithearthingandADEQUATE PPE provided.R-22

(3) Combustible MaterialActivity: DEG&PEG:,UNLOADING FROM ROAD TANKER BY PUMP, STORE IN STORAGE TANK AND TRANSFER BY PUMP TORECEIVER TANK.NoHazardSub Hazard StatusRisk Assessment withExistingconsideration of controlControl MeasuremeasuresSeverity ProbabilityRisk1 Leakage fromEye contactASerious HighlyModerate Dyke wall provided. Periodic testing oftank cell or valveunlikelytanks- once in two years, regular paintingand splashing of InhalationAModerat HighlyTolerable per year. Apron, Hand gloves, gumboot,material.goggles and helmet provided. Good houseof gaseunlikelykeeping is maintained. SBA set, CanisterSkin contactAModerat HighlyTolerablemask and airline mask is provided. Eyeeunlikelywasher & shower provided.Slip & fallASerious HighlyModerateunlikely2 Heavy spillagePropertyESerious HighlyModerate Dyke wall having sufficient size is provided.due to collapse of damage andunlikelyTank’s thickness measured on regularstorage tank from injury.interval. RCC foundation provided.foundation.3 Leakage inFireEModerat HighlyTolerable Earthing& bonding on tanks and transferpresent ofeunlikelyline, flame proof electrical installation,ignition source.flame arrester provided. Fire Extinguisherin sufficient quantity is provided. Welltrained fire staff with Fire hydrant systemas per TAC guideline installed.4 Spillage due to Injury andAModerat UnlikelyModerate Dyke wall having sufficient size is provided.overflowfrom materialeMaterial can be recovered from dyke wall.Storage tank or loss.Dry sand is kept in sufficient quantity. Levelreceiver.gauge is provided. Overflow with returnline from Receiver to st. tank is provided.Apron, Hand gloves, gumboot, goggles andhelmet provided.5 Escape of vapour InhalationNMinorLikelyModerate Good ventilation in the area. Vent linefrom vent lineof vapourprovided at sufficient height.during Unloading.6 Injury due toInjuryNModerat UnlikelyModerate U- Guard and fan guards provided.moving rotatingepart of transferpump.7 Injury due toInjuryASerious HighlyModerate Proper enclosure of Electrical equipmentsElectrical shock.unlikelywith earthing and adequate PPE provided.R-23

(4) Flammable liquidActivity: Petroleum Class 'B' (Diesel - HSD) Unloading From Road Tanker, Store In Storage Tank And Transfer By Pump ToReceiver Tank.NoHazardSub Hazard Status Risk Assessment with considerationExistingof control measuresControl MeasureSeverity Probability Risk1 Leakage from tank Eye contactA SeriousHighlyModerate Dyke wall provided. Periodic testing ofcell or valve andunlikelytanks- once in two years, regularsplashing ofpainting per year. Apron, Hand gloves,InhalationA Moderate HighlyTolerablematerial.gumboot, goggles & helmet provided.of gasunlikelyGood house keeping is maintained. EyeSkin contactA Moderate HighlyTolerablewasher & shower provided. CCEunlikelyapproved premises with door havingSlip & fallA SeriousHighlyModerate locking arrangement provided. Flameunlikelyproof electrical connection provided.2 Heavy spillage due PropertyE SeriousHighlyModerate Dyke wall having sufficient size isto collapse ofdamage andunlikelyprovided. Tank’s thickness measured onstorage tank from injury.regular interval. RCC foundationfoundation.provided. Paintings of tanks are doneon regular basis.3 Leakage in present FireE SeriousHighlyModerate Earthing& bonding on tanks andof ignition source.unlikelytransfer line, flame proof electricalinstallation, flame arrester provided.FFE in sufficient quantity is provided.Well-trained fire staff with Fire hydrantsystem as per TAC guideline installed.Portable water monitor provided. Foamsolution sufficient quantity provided.4 Spillage due to Injury and A Moderate UnlikelyModerate Dyke wall having sufficient size isoverflowfrom materialprovided. Material can be recoveredStorage tank or loss.from dyke wall. Dry sand is kept inreceiver.sufficient quantity. Level gauge isprovided. Overflow with return linefrom Receiver to st. tank is provided.Apron, Hand gloves, gumboot, gogglesand helmet provided.5 Escape of vapour InhalationN MinorLikelyModerate Good ventilation in the area. Vent linefrom vent lineof vapourprovided at sufficient height.during Un loading.6 Injury due toInjuryN Moderate UnlikelyModerate U- Guards and fan guard is provided.moving rotatingpart of transferpump.7 Injury due toInjuryA SeriousHighlyModerate ProperenclosureofElectricalElectrical shock.unlikelyequipmentswithearthingandADEQUATE PPE provided.R-24

Risk assessment by 3 x 3 Risk Assessment Matrix for proposed facility:(1) TOXIC RELEASE & CORROSIVE:Activity: CHLORINE (CL2): Storage Of Chlorine Tonner At Storage Facility And Handling Of Chlorine:Risk Assessment withNoHazardSub HazardStatus consideration of control measures Control Measures will be provided.Severity ProbabilityRisk1 Fall of TonnerBody injury andA Serious HighlyModerate FLT will be maintained in goodfrom FLT.property damageunlikelycondition. Train driver will beToxic gas releaseE Serious HighlyModerate employed. Good road condition willbe maintained. Tonner will beif Tonner valveunlikelytransferred only when Tonner withbreakage.Valve protecting cap. SBA sets, Cl2Emergency Kit, Air line Respirator, AllADEQUATE PPE etc. Will be providedas required. FRP hood with alkalinescrubberwillbeprovided.Continuous monitoring system forchlorine will be installed andmaintained. On site Off siteEmergency plan will be revised,amended and rehearsed on regularbasis.2 Bursting ofToxic gas releaseE Serious HighlyModerate Same as above and chlorine will beTonner / Valveunlikelystored and used under Shed todue to storage inprotect from direct sun light. Testedopen area.Tonner will only be utilized & CCEapproval will be taken. Hot work willbe performed under safety workpermit only.3 Leakage fromEye contactA Serious HighlyModerate Chlorine transfer line will betransfer line.unlikelymaintained in good condition. Will beSkin contactA Moderate UnlikelyModerate checked periodically. Good andsound material will be used forInhalation of gasA Serious UnlikelySignificanttransfer line. Apron, Hand gloves,gumboot, goggles, helmet andcanister mask will be providedAmmonia torch will be provided.(2) Corrosive LiquidActivity: Sulfuric acid: Storage Tank and Transfer by Pump to Receiver of Sulphuric Acid / Nitrosyl Sulfuric Acid/NitricAcid /HCLRisk Assessment with considerationof control measuresNo.HazardSub hazard StatusControl Measures will be provided.Severity ProbabilityRisk1 Leakage & spillage Eye contactA SeriousHighlyModerate Dyke wall will be provided. Periodicfrom tank cell orunlikelytesting of tanks- once in two years,valve andSkin contactA Moderate UnlikelyModerate regular painting per year. Apron, Handsplashing ofgloves, gumboot, goggles and helmetSlip & fallA SeriousHighlyModeratematerialwill be provided. Good house keepingunlikelyis maintained. SBA set, Canister maskand airline mask is provided. Eyewasher & shower will be provided.R-25

Risk Assessment with considerationof control measuresNo.HazardSub hazard StatusControl Measures will be provided.Severity ProbabilityRisk2 Heavy spillage due PropertyE SeriousHighlyModerate Dyke wall having sufficient size willto collapse of loss andunlikelybe provided. Tank’s thicknessstorage tank from injury.measured on regular interval.foundationPainting on tanks is done on regularbasis.3 Broken RailingFallfrom A SeriousHighlyModerate Railing will be provided, Apron, Handand broken steps height.unlikelygloves, gumboot, goggles and helmetof ladder.will be provided.4 Leakage fromToxic gasEModerateUnlikelyModerate Sound guard will be provided onglass level tubereleaselevel indicator and dyke wall will beprovided.5 Spillage due toInjury and A SeriousHighlyModerate Dyke wall having sufficient size isoverflow frommaterialunlikelyprovided. ADEQUATE PPE as above isStorage tank orloss.kept and warned. Dry sand is kept inreceiver.sufficient quantity. Level gauge andlevel indicator with guard isprovided. Overflow and return linewill be provided on receiver.6 Moving rotating InjuryN Moderate UnlikelyModerate U- Guards and fan guard will bepart of transferprovided.pump.7 Electrical shock. InjuryA SeriousHighlyModerate Proper enclosure of Electricalunlikelyequipments with earthing andADEQUATE PPE will be provided.(3) Flammable & Corrosive MaterialActivity: EDC: UNLOADING FROM ROAD TANKER BY PUMP, STORE IN STORAGE TANK AND TRANSFER BY PUMP TORECEIVER TANK.NoHazardSub Hazard StatusRisk Assessment withExistingconsideration of controlControl MeasuremeasuresSeverity Probability Risk1 Leakage fromEye contactA SeriousHighlyModerate Dyke wall provided. Periodic testing oftank cell or valveunlikelytanks- once in two years, regular paintingand splashing of InhalationA Moderate HighlyTolerable per year. Apron, Hand gloves, gumboot,material.goggles and helmet provided. Good houseof gasunlikelySkin contactA Moderate HighlyTolerable keeping is maintained. SBA set, Canistermask and airline mask is provided. Eyeunlikelywasher & shower provided.Slip & fallA SeriousHighlyModerateunlikely2 Heavy spillagePropertyE SeriousHighlyModerate Dyke wall having sufficient size is provided.due to collapse of damage andunlikelyTank’s thickness measured on regularstorage tank from injury.interval. Tanks kept on sound foundation.foundation.3 Leakage inFireE SeriousHighlyModerate Earthing& bonding on tanks and transferprese

5. b. If the potential hazard is identified as “fire” or “explosion”, with Emergency status, in risk assessment using 3x3 Risk Assessment Matrix, then such situation/hazards are compared with the risk assess

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