1

CHAPTER 1

INTRODUCTION

COMPANY PROFILE

Supreme Petrochem Ltd (SPL) commenced the production of polystyrene in their grass root
complex at village Amdoshi / Wangani near Nagothane in Raigad District of Maharashtra,
India since October 1995. The present installed capacity of polystyrene at SPL’s complex is 2,
72,000 MT per annum in 3 – lines. Line – 10 and line – 12 are swing lines, capable of
producing both GPPS / HIPS and line – 11 is dedicated to GPPS production only.

Out of above, 15000 MT / annum can be processed for manufacture of Specialty Polystyrene,
Co-polymers, and coloured polystyrene and master batches in separate SPS Plant facility.
 2

SPL has state of the art, modern and totally computerized manufacturing processes for
manufacture of polystyrene which is basically a continuous bulk polymerization process of
styrene monomer in controlled conditions of temperature and pressure with aid of specified
additives and agents. In HIPS, polymerization of poly butadiene rubber dissolved styrene is
carried out.

Manufacture of specialty polystyrene involves basically blending of required dyes / pigment /

additives with virgin GPPS or HIPS and extrusion with twin screw extruder to obtain desired
finished product.

SPL has a dedicated team of employees at various levels to give required direction, vision and
to manage day to day function / operations.

SPL is committed to environmental protection, health and safety of employees / plants, right
from the inception stage.

Company has developed 50 meters wide green belt around the plant covering total area of 53
acres. It has also undertaken a social forestry project in 100 acre land which has created an
employment opportunities for the project affected people of the nearby locality. The entire
treated effluent from the plant is used in the horticulture activities during the non-monsoon
period. During monsoon period company has authorized to discharge the treated effluent to
saline zone of Amba river, downstream of KT Bandhara.
 3

CHAPTER 2

PROCESS SAFETY MANAGEMENT

2.1 Styrene Receipt and Storage:-

Styrene which is imported from various sources is received at the plant by road tankers. The
road tankers are unloaded at site into the styrene storage tanks. There are two storage tanks of
3000 MT capacity each and one Day tank of 1000 MT capacity. The styrene is inhibited by
using suitable inhibitor and stored less than ambient temperature by using refrigeration
system. The tanks are provided with nitrogen blanketing system with slight positive pressure
to provide inert atmosphere inside the tanks. All the styrene tanks are provided with a dyke
wall for containment of major spillage, oily water sewer pit is provided for avoiding any
hydrocarbon going into storm water drain due to minor leaks or floor washings. For
emergency management all the tanks are provided with foam pouring system and medium
velocity water sprinkler system. The layout of the storage facility is approved by the Chief
Controller of explosives India.

Styrene Polymerization:-

There are totally three lines (Plants) for manufacturing of Polystyrene. Two types of
Polystyrene namely General Purpose Polystyrene (GPPS) and High Impact Polystyrene
(HIPS) are manufactured in these plants.

2.2 General Purpose Polystyrene (GPPS):-

Styrene pumped from tank farm is preheated up to 70 to 80 degrees and then fed to first stage
pre-polymerization reactor which operates under vacuum and 120 to 150 degrees temperature.
Peroxide based initiator is added in this reactor with the help of metering pumps, polymer
 4

solution containing 35 to 40 % polymer is then pumped to the second pre polymerization

reactor with the help of gear pumps for further polymerization.

The second reactor is also operates under vacuum and at a temperature of 125 to 150 degrees.
After achieving 65 to 70 % conversion, the material is pumped to the third reactor. The third
reactor is horizontal, plug flow jacketed reactor where polymerization is completed up to 80 to
85 % at 150 to 220 degrees temperature and 0.5 to 2.0 bar pressure.

In order to remove the un reacted styrene from the polymer solution, it is heated in two steps
up to about 240 to 250 degrees and then flashed under vacuum in devolatilizer. The flashed
styrene and other impurities are condensed and recycled back to process.

The pallets are cooled, dried, classified and conveyed to silos from where it is packed in 25 Kg
PP bags or Jumbo bags.
 5

2.3 HIGH IMPACT POLYSTYRENE (HIPS)

HIPS is produced in line 10 or line 12. The feed preparation section is a batch process where
poly butadiene rubber is chopped into pieces, dissolved in styrene, recycled ethyl benzene
(REB) and mineral oil (mo) after rubber dissolution the batch is pumped to pre poly feed tanks
from where it is continuously fed to plant.

The feed solution is preheated to 100 to 110 degrees before entering first pre polymerization
reactor which operates under vacuum and at a temperature of about 110 to 125 degrees. A
peroxide based initiator is added in a metered quantity. The polymer solution containing about
15 % of polymer is then pumped to second stage pre polymerization reactor with the help of
gear pumps.

The second polymerization reactor also operates under vacuum and at a temperature of about
130 to 150 degrees from where the polymer is pumped to next reactors where the polymer is
pumped to next reactors where the reaction is continues at higher temperatures. The final
reactor temperature is about 175 to 220 degrees where final conversion of about 82 to 85 % is
achieved.

After achieving the final conversation, the material is preheated up to 230 to 250 degrees and
flashed under vacuum in the devolatilizer to remove the unreacted styrene and other inert. The
flashed vapors are condensed and recycled back to precess.

The polymer melt is then pumped to pelletize and finishing section. The pellets are cooled,
dried, classified and conveyed to silos from where it is packed in 25 Kg PP bags or Jumbo
Bags.
 6

GPPS Line 11:

Continuous mass polymerization process:

Styrene

EB Recycler

Mineral Oil

Feed Heater

Condenser

Pre Heater

1st Pre 2nd Pre

1st Polymerization
poly poly
reactor

Devolatizer

Reactor Reactor

Pelletization Die Head

SILO
 7

GPPS / HIPS SWING LINE:- LINE 12

Continuous mass polymerization process:

Styrene

EB Recycler
Feed Feed
Storage Storage Mineral Oil

---

Dissolver
Feed Heater
Condenser

- - - - - - - For GPPS Operation - - - - - - - - - - - - - - - - - -

Pre Heater

1st Stage
1st 2nd 3rd
Reactor
Pre Pre Pre
poly poly poly

2nd Stage Devoltizer

Reactor

Reactor Reactor

Pelletization Die Head

SILO
 8

2.4 EXTRUDED POLYSTYRENE (XPS):

The basic process involved is extrusion of Polystyrene into a melt mixing of the melt with a
blowing agent and there after cooling the admixture prior to the exist from the die.
At the die lips the material expands because of the de pressurization and the expansion of the
blowing agent with the cooling provided both externally and by the expansion of gas the melt
freezes to the desired shape and geometry.

A. Tandem Extruder System:-

Two extruders are connected in Tandem as the process task of the extruders is different in the
primary extruder all the raw material like polystyrene resin nucleating agent, flame and fed
through the extruder hopper. Two materials are conveyed, heated and plasticized into a melt at
this stage blowing agent is directly injected into the extruder and all the ingredients are mixed
into a homogeneous.
The melt from the first extruder is fed to the secondary extruder through an inter connecting
tube. The secondary extruder function more as a mixing and a cooling extruder.
When the melt is mixed with the blowing agent there is a reduction in the viscosity and
therefore it can be easily conveyed and cooled before it exits from the die. At this point the
 9

blowing agent in the melt expands into gas and making polymeric foam with gas entrapped
with in polymer cell walls.

B. Haul Off:-

The haul off unit continuously provides a pull and feeds the material out from the calibrating
plates. It is then continuously conveyed for further atmospheric cooling over a long conveying
table when the material is cool enough it is finished into the right size and length.

C. Finishing and Sizing.

The extruded foam section is continuously conveyed and once it is cool its edges have to be
trimmed and sized to the shape of the finished panel the trimming of the edge, length, shape of
the groove, etc has to be formed by milling cutters.
The panels once finished to its desired shape and size are stacked and packed for storage.
 10

2.5 EXPANDABLE POLYSTYRENE (EPS) :

Polystyrene beads are produced by the exothermic free radical initiated polymerization of
styrene monomer in water suspension.

Polymerization is carried out batch wise in a closed agitated reactor with a circulating water
jacket system for temp. control of batch purified water is added to the reactor first , water is
continuous phase in the suspension polymerization water not only suspended the styrene
droplets but also helps to transfer heat generated by the polymerization reaction to the
circulating reactor jacket system.

Reactor agitator is turned on after the water added. The agitator helps in uniform mixing of
other ingredients and keeps the styrene droplets suspended in the water phase ingredients are
then added to the phase ingredients are then added to the water phase, according to the
formulation for the specific products type and finally styrene is added.
Reactor jacket system is heated with steam to raise the reactor content to certain temperature
to start polymerization. After a specific time and temperature cycle complete polymerization
of the styrene monomer into rigid polystyrene spheres of specific particle size takes place.

In the later stage of production cycle, blowing agent is added to the reactor and the reactor
temperature is increased under these conditions the blowing agent is impregnated into the
beads. After the impregnation is completed the reactor contents are cooled and removed to the
slurry tank.

The suspension agents are washed out and the washed beads are dried by drying system. The
dried beads are sent to screening to separate various sizes of beads. The beads are then coated
with coating agent and are packed in 25 Kg bags or Jumbo bags.
For certain grade of EPS polymerization of styrene monomer in water suspension and
impregnation of pentane into the Polystyrene beads is done in two stage , in 1st stage PS beads
are produced , dried, recycled back to reactor for pentane impregnation in 2 nd stage pentane is
impregnated into PS beads in water suspension.
 11

EXPANDABLE POLYSTYRENE (EPS) CUP GRADE:-

1. Formation of polystyrene beads:-

Polystyrene beads are produced by the exothermic free radical initiated polymerization of
styrene monomer in water suspension.
Polymerization is carried out batch wise in a closed agitated reactor with a circulating water
jacket system for temp. control of batch purified water is added to the reactor first , water is
continuous phase in the suspension polymerization water not only suspended the styrene
droplets but also helps to transfer heat generated by the polymerization reaction to the
circulating reactor jacket system.
Reactor agitator is turned on after the water added. The agitator helps in uniform mixing of
other ingredients and keeps the styrene droplets suspended in the water phase ingredients are
then added to the phase ingredients are then added to the water phase, according to the
formulation for the specific products type and finally styrene is added.
Reactor jacket system is heated with steam to raise the reactor content to certain temperature
to start polymerization. After a specific time and temperature cycle complete polymerization
of the styrene monomer into rigid polystyrene spheres of specific particle size takes place.
Polystyrene bead slurry is dewatered and the wet material is dried in the dryer system the dry
beads are mixed with some additives for free flow and are mixed with some additives for free
flow and are screened over vibratory screeners to remove any oversize and undersize beads
the prime material is stored In a silo for use as feed stock for the second step of the cup EPS
Process.
 12

2. Impregnation of polystyrene beads:-

Purified water is added to the reactor first and then agitator is turned on ingredient as are then
added to the water phase according to the formulation for the specific product type. Pre-
weighed charge of polystyrene beads is added to the reactor. Reactor contents are heated with
steam through out reactor jacket system. Blowing agent is then added to the reactor which
diffuses into the polystyrene beads at the impregnation is completed, reactor contents are
cooled and transferred to slurry tank.
Cup EPS slurry is dewatered and the wet material is dried in the dryer system. The EPS beads
are screened over vibratory screeners to remove any oversize and undersize beads. The prime
cup EPS material is coated with coating agent and packed in 25 Kg bags or Jumbo Bags.

2.6 PROCESS DESCRIPTION OF CAPTIVE POWER PLANT

Two number of gas engines of CUMMINS make with 2 MW capacity each suitable for base
load operation are used for generation of totally 4 MW of electrical power Natural gas
 13

received from GAIL is used as a fuel for the gas engines and electrical power generated will
be used for the plant operations. Available heat from the exhaust gases will be used for steam
generation by installing a waste heat recovery, boiler of capacity 2.8 T/hr. Heat recovered
from Jacket cooling water is used for generation of chilled water +7 deg cel. By installing
vapor absorption machine. The generated steam and the chilled water will be used for process.

Flue gas
Silencer
Stack

C Exhaust Gas
Boiler capacity : Condenser
Recovery Steam to
2.8 T/hr
process

4 MW
electrical Blown down
power to sub
station

4Reactor
MW Gas Engine Genset Vapors absorption
machine
Capacity: 350 TR

Natural gas

+7 Degrees water to process

 14

2.7 PROCESS SAFETY MANAGEMENT

Supreme Petrochem Ltd. Basically deals with Styrene monomer as a raw material to make
different products such as

Polystyrene (PS).
General purpose polystyrene (GPPS).
High impact polystyrene (HIPS).
Extruded polystyrene (XPS)
Expandable polystyrene (EPS)

The above listed product are formed by different process system by adding several chemicals
and raw material to get desired product, however the main raw material will remain the same
as styrene monomer. The production of general purpose polystyrene (GPPS) is done by adding
styrene monomer to grind rubber for a period of time then it is fed to the reactor along with
Ethyl Benzene (act as a inert), mineral oil, blue dye.

The Line no. 11 is there in plant is specially for production of GPPS, it consisting three
reactors two vertical followed by one horizontal. After feeding material to reactor one it will
flow in sequence to all reactors. Each reactor will have there different operating temperature
and pressure, so by changing temperature and pressure chemical structure, composition and
property of product is maintained.

The above process shows how Polystyrene is prepared but there are several factors which are
required to be taken into consideration as Safety Measure while generation of Polystyrene.
 15

2.8 SAFETY PROCEDURE

The following safety precautions are to be taken while processing of Polystyrene.

 As self polymerization reaction gets starts in Styrene monomer above room

temperature so the storage area is always maintained under 20 degree C.

 In addition to above TBC (Tertiary butyl cathcole) is added is inhibitor in quantity of

50 to 100 ppm.

 The storage tanks are provided with all arrangement of fire fighting.

 From storage tank styrene monomer is transferred through pipeline to reactors. These
pipelines are leak proof and well insulated.

 The flash point of styrene monomer is 32 degree C, so while handling at any place it
will not come directly in contact with atmosphere.

 All the equipment of plant are flame proof.

 Sample points are given at different points on every process pipeline.

 When monomer reached to the reactor special care is taken with respect to temperature
and pressure. Every reactor will have its different working temperature and pressure.

 When the rate of change in reaction inside the reactor is 2 degree/minute it goes in cool
mode.

 Evaporative cooling is there in the process ie. If the temperature of the reactor
increases greater than the standard (150 degree C) full cooling interlock will activate,
 16

It will cerate vacuum inside the reactor and material get cooled in the condenser and
again fed to reactor.

 Provision of emergency DG set to run all the reaction drives without any abnormal
condition.

 Reactors are provided with radiation level indicators.

 The maximum capacity of polymer fed tank is 70 MT but for safety purpose it is fed
up to 60 MT only.

 If the pressure of reactor increase beyond limit the rapture disk will operate and
material will collect in polymer relief drum.

 The vent of polymer relief drum is provided with fire arrestor.

 Before the rapture disk operate a manual vent valve is also provided to release
pressure.

 The capacity of polymer relief drum is equal to the over all capacity of all rectors, so if
at a time accidentally all the reactors get failed the material can be collected in polymer
relief drum.

 An additional arrangement is given if rapture disk is fail to operate at given pressure,

after a certain pressure side glass in reactor have gasket it will break and pressure will
release.

 When the temperature of reactor rises cold oil is circulated in outer jacket of reactor to
decrease the temperature.
 17

 Every reactor is provided with a spare suction pump for safety.

 All the pumps (Gear pump) will give constant discharge pressure so whenever pressure
in pipeline increases (chock up) pump will trip on high current.

 At Palletized cutting strands is having automatic and manual lever for safety.

 The cutter of palletizes is closed and provided with interlock arrangement ie when the
guard is closed then only cutter will work.

 Water hydrants are placed at different locations and are connected with water pipeline
having pressure of 10 kg/cm2 to tackle any fire emergency.

 Arrangement of foam tank of 10000 lt capacity is also there with network of pipeline
through out the plant.

 DCP and CO2 cylinders are provided at several points separating 30 m apart.

 A Fire Tender with fire squad along with an Ambulance is available 24x7 in the plant
for dealing emergency.

 Auxiliary fire squad and medical team is available at occupational health centre of the
plant every time.

Process Hazards of Runaway Reaction:

Polymerization of styrene is exothermic in nature and an uncontrolled rise in reactor

temperature can lead to occurrence of a runaway reaction resulting in hazardous situation
which could cause an explosion due to overpressure and fire.
 18

However, various measures have been incorporated in the reaction system to minimize the
probability of occurrences of runaway reaction and these have been further enhanced by
provision of adequate safety devices and pressure relief system for protection in case of
inadvertent happening due to loss of control system or other failures. The measures include
provision to kill the reaction, reluctant temperature control for the reactors, emergency power
supply to cooling water and vacuum pumps, provision of rupture discs on all reactors,
discharging relieved overpressure into well designed water filled pressure relief drum for
collection, condensation and cooling of released materials etc. with these provisions,
probability of a hazardous condition developing due to runway reaction is considered very
low.

Pneumatic Conveying of Polystyrene product:

In pelletizing and finishing section of the plant polymer strands are cuts into pellets, are dried,
classified, cooled and finally pneumatically conveyed to silos. Presence of polymer fines and
dust during pneumatic conveying could result in a dust explosion.

However since pelletizing is carried out under water and fines generated, if any, are using dust
classifiers a hazard of dust explosion is considered unlikely.

Location Boiler / Heater block :

A block consisting of 3 nos hot oil heaters (direct fired) and a steam boiler including a
common stack and fuel oil dry tanks is located approx 20 meters north east of GPPS plant area
and about same distance northwest of intermediate storage tank area.

Considering the possibilities of spillage of styrene / ethyl benzene in the process plant and
intermediate storage areas as well as that of heater coil ruptures resulting in hot oil showering
the surrounding the location of boiler / heater block is considered a possible hazard and certain
measure, to minimize the risk
 19

2.9 DETAILS OF EFFLUENT TREATMENT PLANT

Industrial Effluent:-

The process of PS/SPS/XPS plants do not produce any organic process effluent, During
normal operating conditions, the effluent generated from the plant and tank form is floor
washing which may contain traces of hydrocarbon. However in Expendable Polystyrene
(EPS) process organic effluent is generated.

The other effluent generated is non organic streams from raw water treatment system cooling
tower blow down, boiler blow down etc. For the final disposal of these effluents separate
collection and treatment scheme is implemented.

Collection/Treatment of organic effluent:-

All floors washing in the process plants tank form are collected in local oily waste sewer
(OWS) pits; from these pits the collected washing effluents etc are pumped to the ETP area
are in equalization tanks. The treatment scheme in ETP consists of tilted plates interceptor
(TPI). Dissolved Air Floatation (DAF) followed by aeration. Clarification and filtration by
pressure sand filter and activated carbon filter.
The TPI comprises of packed plates designed to separate the free oil and non- soluble
hydrocarbon from water. The free oil (if any) is skimmed and collected in 200 lt drum.
The separated water is sent to DAF unit where coagulate agents like poly electrolyte and Alum
are added, if required in the circulation loop air is introduced to create buoyancy to the
flocculating oil resulting in these globules to rise and finally get separated.
The residual water having traces of soluble hydrocarbon if any, which has a potential to exert
BOD is sent to biological treatment unit (Aeration Tank). In this tank sewage from this plant is
also mixed. The effluent from primary facility in EPS plant is also pump to the aeration tank.
The tank is provided with a agitator. The effluent overflowing from this tank is sent to
secondary clarifier to remove biomass and suspended solids. The overflow of secondary
 20

clarifier goes to filter feed tank from where it is pumped to multi grade filter to remove
suspended solids. As part of tertiary treatment for removal of dissolved organic (if any) an
activated carbon filter has been installed. The filtrate from multi grade filter is passed through
activated carbon filter, and then stored in guard ponds. Sludge generated in the process is
pumped to the sludge drying beds.

COLLECTION/TREATMENT OF NON-ORGANIC EFFLUENTS:

The effluent generated in the area such as boiler blow down, water softening unit and DM
water unit regeneration, cooling tower blow down, filter back wash etc. is collected in a
common pit where it is treated for correction of Ph if necessary. The non-organic effluent is
then pumped to non-organic pond in the ETP.

DOMESTIC WASTE WATER (SEWAGE) GENERATION AND TREATMENT

Domestic effluent (sewage) from plant premises is pumped to the lift station and directly feed
to the aeration tank. For remote area in the plant i.e. Warehouse and XPS plant separated
septic tanks/soak pits are provided.

CHARACTERSTICS OF TREATED EFFLUENTS

The treated effluents meet the standards as prescribed under consent conditions

Sr. Contents Prescribed limits

No.
1. PH Between 5.5 to 9.0
2. Suspended solids Not exceeding 100 mg/lt
3. BOD 3days Not exceeding 100 mg/lt
4. COD Not exceeding 250 mg/lt
5. Oil and Grease Not exceeding 10 mg/lt
6. TDS Not exceeding 2100 mg/lt
7. Chlorides Not exceeding 600 mg/lt
 21

8. Sulphates Not exceeding 1000 mg/lt

9. Sulphide Not exceeding 2 mg/lt
10. D.O Not less than 5 mg/lt

DISPOSAL OF TREATED EFFLUENTS (INDUSTRIAL AND DOMESTIC)

The treated effluent stored in treated storage tank (Guard pond I and II) s used for gardening,
afforestation/green belt during 16 September to 14 June every year. During monsoon period
i.e. 15 June to 15 September every year if required. The treated effluent is discharged into the
saline zone of Amba river estuary, 225 meter down-stream to KT Bandhara.

ADDITIONAL CONTAINMENT SYSTEM

For containment of floor washing during first rain, fire water run off during fire fighting
operation and or generation of excess effluent due to emergency situation two lagoons of 3000
m3 and 4000 m3 capacities are provided. Run off water collected in the lagoons can be
pumped to ETP for treatment.

CHAPTER 3
 22

OCCUPATIONAL HEALTH AND SAFETY

3.1 Clauses of OHSMS as per BS OHSAS 18001:2007

Sr .No Clause No Title

1 4.1 General Requirement
2 4.2 OH & S Policy
3 4.3 Planning
4 4.3.1 Hazard Identification, risk assessment and determining
control
5 4.3.2 Legal and other requirement
6 4.3.3 Objectives and program
7 4.4 Implementation and operation
8 4.4.1 Resources, roles, responsibility, accountability and
authority.
9 4.4.2 Competence, training and awareness
10 4.4.3 Communication, participation and consultation.
11 4.4.3.1 Communication
12 4.4.3.2 Participation and consultation
13 4.4.4 Documentation
14 4.4.5 Control of documents
15 4.4.6 Operational control
16 4.4.7 Emergency Preparedness and response
17 4.5 Checking
18 4.5.1 Performance measurement and monitoring
19 4.5.2 Evaluation of compliance
20 4.5.3 Incident investigation, nonconformity, corrective action
and preventive action
21 4.5.3.1 Incident investigation
22 4.5.3.2 Nonconformity, corrective and preventive action
 23

23 4.5.4 Control of records

24 4.5.5 Internal audit
25 4.6 Management review

OCCUPATION HEALTH AND SAFETY MANAGEMENT

 24

COMPANY
POLICY PLAN

ORGANIZATION
NECESSARY AND PERSONALS
IMPROVEMENT
ACT

COMMUNICATION IDENTIFICATIO IDENTIFICAT

N OF IMPACTS ION OF
MANAGEMENT
AND HAZARD
REVIEWS
EVALUATION AND
OF ASSESMENT
SIGNIFICANCE OF RISK

CHECK

MONITORING AND SETTING COMPANY

AUTOTING OBJECTIVES

DO

INTERNAL CONTROL
PERFORMANCE
IMPROVEMENT
MEASUREMENT
MEASURES

3.2 OCCUPATIONAL HEALTH AND SAFETY POLICY

 25

Supreme Petrochem Ltd will endeavor its utmost and commits necessary resources to,

 Comply with all applicable occupational, health and safety legislations & Regulation.

 Comply with all applicable codes of practices as a signatory to responsible care

initiative.

 Prevent injuries and ill health to employees and other interested parties arising out of
the risk associated with their work related to activities, products and services of the
company.

 Encourage involvement of employees and other interested parties in occupational

health and safety management system by arranging various health and safety
participation, promotional and consultation activities.

 Encourage excellence in occupational health and safety performance by making it an

integral part of individual performance appraisal system.

 Integrate health and safety inn all decisions including those dealing with purchase of
plant, equipment, machinery and material as well as selection and placement of
personnel.

 Inform, educate, train and retrain all employees and other interested parties in the field
of occupational health and safety.

 Provide a resume of occupational health and safety performance of the company in its
annual report.

 Seek continual improvement in the occupational health and safety management system

 Review and revise this policy as necessary at periodic intervals.

 Communicate/make available this policy to employees and other interested parties.

Date:-01/01/2009 Executive Director- Styrenics

3.3 HAZARD IDENTIFICATION TECHNIQUES

Hazard:-
 26

A source or situation, which has potential to create harm or damage to human being, property,
environment or combination of these.

TYPES OF HAZARDS:-

 Chemical hazards
 Physical hazards
 Biological hazards
 Psychological hazards
 Ergonomically hazards
 Lifestyle hazards

Hazard identification techniques mainly classified in two groups

1) Qualitative Techniques
 Preliminary hazard analysis
 Job safety analysis
 Hazard and operability studies
 What If analysis

2) Quantitative Techniques
 Process risk analysis
 Fire and Explosion Index (DOW fire and Toxicity Index )
 Chemical exposure index
 Fault tree analysis
 Event tree analysis
3.4 HAZOP (HAZARD OPERABILITY) STUDIES

HAZOP:-
 27

An importation addition to the method of identification is the family of techniques known as

hazardous and operability studies.

A multi disciplinary term, who reviews process to discover potential hazard and operability
problems using a checklist approach, carries out these studies. The basis of the study is a word
model, A process flow sheet, A plant layout or a flow diagram. There are different types of
studies which have different objectives and which are done at different stages of projects.

The basic concept of HAZOP takes a full description of the process and to discover what
deviation, intention can occur and what may be their consequences.

The important features of study are

 Design intention
 Deviation
 Causes
 Consequences (hazard/operability difficulties )

The study continuous uses seven guide words. The guide words and their meaning are as
under

1. No/Not - Complete negation

2. More - Quantitative increase
3. Less - Quantitative decrease
4. As well as - Qualitative increase
5. Part of - Qualitative decrease
6. Reverse - Logical opposite of intention
7. Other than - Complete substitution
 28

The guide words may be applied to process condition, activities, substances, time, place, etc.
This technique is widely used to identify hazard to develop / modify operating procedures, to
develop / introduce additional operational controls.

HAZOP STUDY ON BATCH MANUFACTURING PROCESS

DEVIATION TYPICAL PROBLEMS

NO FLOW Isolation in error - wrong routine – blockage - non returnable valve

(NRV) - large leak - equipment failure (control valve, isolation
valve, pump, vessel etc) - Incorrect pressure differential – delivery
side over pressure – vapor lock service failure.

REVERSE Defective NRV – siphon effect – incorrect differential pressure, two

FLOW way flow – emergency venting – incorrect operation pump reversed
– service failure.

MORE FLOW Increased pumping capacity – increased suction pressure, reduced

delivery head – greater fluid density – exchange tubes leaks –
restriction orifice plates deleted – cross connection of systems –
control faults – control set wrong – open bypass – more quantity –
service failure – abnormal opening.

MORE Ambient condition – fouled or failed exchanger tube – less cooling –

TEMPERATURE cooling water failure – defective control – fire situation – reaction
control failure – connected high temperature source – energy from
machines

MORE Surge problem – leakage from interconnected high pressure system –

PRESSURE gas break through – inadequate venting – thermal over pressure –
failed open controls valves – explosion – fire imbalance of input and
output – extra pressure – water hammers – positive displacement
 29

pumps.

LESS FLOW Line restriction – partial blockage – defective pumps – cavitations

fouling of vessels – valves – restrictor or orifice plates – density or
viscosity problem – incorrect specification of process fluid – process
turn down – less quantity – small leak – service failure – abnormal
opening.

LESS Ambient condition – reducing pressure – fouled or failed exchanger

TEMPERATURE tubes – loss of heating – rain connected source – auto refrigeration.

LESS Vacuum condition – condensation – gas dissolving in liquid –

PRESSURE restricted pump/compressor – suction line – undetected – leakage
vessel damage – imbalance of input and output.

PART OF In correct feed stock – Incorrect separation failure – change in

reaction – emergency discharge – leaking isolation valves – leaking
exchanger tubes – Inadequate process control – settling – lack of
mixing – missing component

MORE THAN In correct routing – Interconnected system – effect of corrosion –

wrong additives – ingress of air – water – lube oils – shut down and
start up conditions – carry over of solid or liquid – accumulations –
Inert gas failure – Internal leaks – Extra phases.

OTHER THAN Shut up and shut down – testing and inspection – relief sampling –
service failure – planned abnormal operation – such as purging –
blow down – catalyst activation etc. – maintenance – unusual
emission and effluents – static generation – external events – domain
effect.

COMPOSITION Leaking Isolation valves – leaking exchanges tubes – phase change –

CHANGE Incorrect feed stock/specification – Inadequate quality control –
Process control.
 30

LESS VISOSITY Incorrect material – Specification temperature

MORE Incorrect material – Specification temperature

VISOSITY

CHANGE IN Valve open too much – too long – too short – wrong duration or
TIME OR Sequence.
OPERATION

3.5 RISK ANALYSIS:

WHAZAN:
 31

A) DISCHARGE MODEL
B) DISPERSION MODEL
C) CONSEQUENCE MODEL

STYRENE STORAGE:

In order to evaluate a worst scenario of styrene spillage, a catastrophic, double ended line
rupture of 6” size (pump suction line) has been considered such that spilled styrene could
spread all over the dyke and result in pool fire. Though the probability of such an occurrence
would be very low. Its consequences must be made known.
The WHAZAN model simulation indicates that the following distances would be affected by
thermal radiation.

Heavy Damage : 48 M radius

Secondary Fire Zone : 82 M radius
Burn Injuries : 146 M radius

Heavy thermal damage will be limited to tank farm area while a portion of the ware house
towards tank farm will be subjected to high heat flux. Any combustible material within a
radius of 32 M can catch fire. People within a radius of 146 M could be subjected to some
burn injuries. This distance falls more or less within the plant boundary, indicating no risk of
any kind to outside population.

However, main entrance road to the plant will be rendered unusable for traffic as well as
emergency escape. Since plant area as well as rest of north side will be unaffected it can be
used as a safe refuge. Even then SPL must consider an alternate exit safe for incoming and out
going traffic.
3.6 ROLES AND RESPONSIBILITY

Following responsibility with accountability and authority for -

 32

IN CHARGE / SAFETY REPRESENTATIVE

1. Understanding the requirements & maintaining compliance to QEOHS Management

system as per ISO 9001:2008, ISO-14001:2004 & BS OHSAS-18001:2007 Std.
2. Ensure safety practices are followed as per defined procedures within department.
3. Carrying out through analysis of departmental activities Aspects & their Impacts,
HIRA & other QEOHS documents and updating the same periodically and as and
when there is in change in technology.
4. Coordinating with MR in identifying significant aspects and significant risk for their
departmental activity centers.
5. Identifying, Organizing & executing QEOHS program to meet department objective.
6. Organizing and providing necessary resources and infrastructure as may be needed for
maintaining QEOHS System and for executing QEOHS Program.
7. Ensure compliance to applicable statutory requirement.
8. Ensure correction & corrective action & preventive action for QEOHS non
conformances.
9. Identifying the training needs of all associates with specific reference to requirements
of QEOHS related issues.
10. Consult associates for any change that affect QEOHS System.
11. Carry out departmental safety committee meeting periodically.
12. Investigation the major accidents. Identify root cause; decide corrective action, co
ordinate with HOD to complete corrective action.
13. Analysis Near Miss & First aid accidents. Identify trend decide preventive measure.
Implement preventive action in the plant.
14. Spread the awareness of PPE usage in employee thought consultation and discussion
with department.

Safety Committee:

Functions and duties as per the Maharashtra Factories Rules 1963

 33

1. Assisting and co-operating with the management in achieving the aims and objectives
outlined in the “Health and Safety Policy” of the occupier.
2. Dealing with all matters concerning health, safety and environment and to arrive at
practicable solutions to problems encountered.
3. Creating safety awareness amongst all workers.
4. Undertaking educational, training and promotional activities.
5. Deliberating on reports of safety, environmental and occupational health surveys,
emergency plans safety audits, risk assessment and implementation of the
recommendations made in the reports.
6. Carrying out health and safety surveys and identify causes of accidents.
7. Looking into any complaint made on the likelihood of an imminent danger to the
safety and health of the workers and suggest corrective measures, and
8. Reviewing the implementation of the recommendations made by it.

3.7 SAFETY RULES FOR ALL EMPLOYEES

GENERAL:-
 34

 Smoking consumption of tobacco and tobacco products are strictly prohibited within
entire complex.
 Carrying of any arms, ammunitions, and cellular phones without permission inside
complex is strictly prohibited. Photography inside the campus without permission is
strictly prohibited.
 Exercise care in walking and in moving around your work area. Horse play is strictly
prohibited.
 Make shifts arrangements of any kind is strictly prohibited
 Don’t wear polyester on nylon or any other synthetic fiber clothing while on duty to
avoid built-up of static charge.
 Good house keeping should become a matter of habit. Keep the plant, machine and
surroundings clean and keep every thing in its place
 Use of flash type camera or any other non flame proof instruments or machine in plant
premises is not permitted without proper authorization/permits. Use of cell phones is
not allowed inside the premises. Only few officials are permitted to use the cell phones
in the official areas.
 It is apart of every employee duty to actively participate in all safety promotional
activities and follow safety rules.
 All employees should report to occupational health centre for periodic medical
examination under statutory requirements, and in the interest of personal health of
individuals.
 All employees must wear safety shoes and helmet while working in plant. In addition
suitable respiratory and non respiratory PPE must be used appropriate to the job or as
indicated in work permit.
 Washing of clothes with any of the solvent or chemical or air is strictly prohibited.
 Traffic safety rules must be followed by vehicles as well as by the pedestrians.
 HSE refreshers training, fire and safety drills are conducted on regular basis. All
employees must undergo such training and achieve required competency.

During Normal Operation:-

 35

 Perform the job/activity as per the instruction prescribed in the respective operational
manuals / instructions. Implement risk controls as described under your departmental
register of hazard identification & risk assessment.
 Shift employees should not leave there jobs until persons to relieve them are properly
advised of all operating conditions.
 Only authorized plant personnel should operate or stop the equipment and can change
the status of valve, operating any of the equipment except during emergency that too
under the instruction of authorized personnel.
 Drums full of empty should not be used as work benches as supporting platforms.
 Approved safety torches are to be used in operating areas.
 Avoid running on roads during normal operation.
 The sample bottles, drums/containers should be cleaned labeled specifying nature of
contents etc.

During Maintenance and Repair:-

 Before starting any or repair work obtain a necessary work permit, carry out risk
assessment if the activity is non routine and implement risk controls accordingly
 Defective tools, ladders, safety gadgets should not be used. Opening created if any
during the cause of activity , the same should be either securely fenced or securely
covered.
 When working around moving machinery the working of loose clothes (lungies,
dhotis) is strictly prohibited.
 All belt coupling and moving part of machinery must be securely guarded at all the
times. Before removal of such guards the machinery should be electrically and
mechanically isolated.
 Compressed gas cylinder should not be taken inside any closed vessel under any
circumstances.
 Do not level the tools, materials around the machines.
 36

 The engines of vehicles, mobile and stationary equipment such as welding machine, air
compressor, gases etc. must be stopped when being filled with diesel / petrol.
 Never go or walk on a false ceiling except for any job to be carried out under access to
fragile roof permit.
 Protruding hails / bolts or any such part should be pulled outer bent over.

During abnormal condition / emergency

 In case of any unsafe condition, unsafe act, dangerous occurrence / near miss, deficient
HSE performance of equipment or personnel, shall be immediately to be brought to the
notice of concerned HOD and HSE department or by initiation of closed called report.
 In case of an abnormal incident, pull the MCP and inform to SIC by phone using PA
system. If it is not possible send messenger to inform the CCR.
 Try to contain, isolate, extinguish etc if without risk, and otherwise wait for
instruction.
 Suspension of job in shall be done in safe condition only.
 If you are AFS member, perform the duties of AFS member as described in On – site
emergency plan.
 Any injury no matter how minor it is , must be reported to your SIC / HOD and HSE
department immediately and necessary treatment is obtained.
 During emergency avoid panic, obey the instruction from incident controller get
familiar wit your role during emergency as described under On-site emergency plan.

Obligation of employees:-

(Provision made under section 111 of the factories act 1948)

All employees:-
 37

 Should not willfully interfere with or misuse any appliance or other thing provided in
the factory for the purpose of securing the safety, health and welfare of the workers.
 Should not willfully and without reasonable cause do anything, which may likely to
endanger him or others.
 Should not willfully neglect to make use of any appliance or other thing provide in the
factory for the securing safety and health of the worker.
 If any worker employed in the factory contrivances any of the above provisions , he is
punishable with imprisonment for a term which may extend to three month or with fine
which may extended to 100 Rs or both.

Right of workers:-
(Provision made under section 111 of the factories act 1948)

All employees have right to,

 Obtain from your HOD , information relating to workers health and safety at work
 Get trained within the factory wherever possible or in relation with health and safety at
work
 Represent in the matter of inadequate provision for protection of his health and safety
in the factory.

3.8 SPECIFIC ROLES OF ALL EMPLOYEES IN OHSMS AND EMS

(OHSAS 18001:2007, ISO 14001:2004)

HSE POLICIES:-
 38

 Awareness of contents of health and safety policy.

 Awareness of contents of environmental policy.
 Implementation of policy guidelines in your work area.

HAZARD IDENTIFICATION AND RISK ASSESMENT:-

 Identification of hazard from routine and non routine activities.

 Implementation of risk controls as per HIRA register.
 Investigation of hazard and risk control.
 Work as per OSHMPs and EMPs.

ENVIROMENT ASPECT MANAGEMENT:-

 Identification of environment aspect from all activities product and services.

 Management of significant environment aspects.
 Determination of new aspects, If any.
 Work as per EMPs.

TRAINING AND AWARENESS:-

 Compiles with all HSE rules and regulations.

 Achieved required competency in HSE training.
 Comply with training assessment given.
 Ask for any additional information on HSE to enhance your competency.

Operational Controls:-

 Work as per QI/QP and HODs instructions.

 Ensure documentation and record keeping in and around your workplace.
 39

 Storage and handle chemicals, materials as per the instruction of MSDS.

 Ensure fire and safety equipments in your area are in good working condition.
 Use all required PPE at work place. Ensure contract employees in your area also
comply with safety rules and regulations.
 Inform imminent danger, potential unsafe condition etc ie. SIC/HSE department
immediately.
 Participate in HSE promotional activities and campaigns and encourage participation
from fellow employees in such activities.
 Follow procedures for collections and disposal of various wastes.
 Conserve resources such as raw materials electricity, water etc. Avoid spillage of
materials on floor. Collect the spills into closed container and send it for disposal.

EMMERGENCY PREPARDNESS AND RESPONSE:-

 Know your role as incident information.

 Know your specific role during emergency.
 Perform mitigation activities as per onsite emergency management plan.
 Preserve evidence of any accident, incident or emergency.
 Assist investigation officer/team in correct investigation of any accident or incident.

CHECKING AND CORRECTIVE ACTION:-

 Take disposition, corrective and preventive action if any abnormality non conformity
as per the instructions from HOD.
 Suggest corrective and preventive action to avoid reoccurrence.
 Monitor your work area, work environment, work equipment for safe condition, In
case abnormality report to SIC/HOD immediately.
 Assist the co operate with safety committee member for effective implementation of
shop floor safety related points.
 40

 Conduct joint safety inspection along with HSE department representatives.

 Fill up safety checklists applicable in your areas.
 Undergo periodic medical examinations and follow the recommendations of medical
officer to improve your health.

3.9 BEHAVIOUR OBESARVATION CHECKLIST

(TO BE DEVOLPED TASK BASED BY ALL DEPARTMENT)
Name of the observer:- …………………..
Department where observation is conducted:-…………………
Sr.No. Behaviors categories Safe At Risk Comments
 41

1. PPE. Using PPE (eg:-eye glass, hearing protection,

gloves, hard hat etc.)
2. Housekeeping, work area maintained appropriately
(eg:- Trash and scrap picked up, no spills, walk way
unobstructed material and tools organized)

3. Using tools and equipment (eg:- Using correct tools

for job, using tools properly, tools in good condition)

4. Positioning/protecting body parts

(eg:- Avoiding line of fire, avoiding pinch points)

5. Material handling (eg:- body mechanics while lifting,

pushing, pulling, use of assist devices)

6. Communication (Verbal and Non-verbal) that

interacts safety.
7. Following procedures (eg:- Obtaining, complying
with permits, following SOP’s, lock out tag out
procedures)
8. Visual Focusing Attentiveness

Signature: Dated:

Name and Destination:

CHAPTER 4

Operational Controls / Work Practices in SPL

4.1 WORK PERMIT SYSTEM

SCOPE:-
 42

To establish and maintain a document procedures for work permit system. To provide written
communication of job to the person (s) performing activity to prevent the incident, accident
and to ensure safe working within the complex in systematic manner.

To provide a predetermined checklist to the issuing authorities

To allot the responsibility as per designated areas
To enhance the confidence level among the person/agency carrying out the job

The procedure is applicable to operational and constructional activities carried out within SPL
complex. Refer the table indicating type of work permit and its scope.
However above (For eg. Green belt, township etc) should be reviewed in detail for safety and
suitable permission must be obtained from CE(O) or any officer designated by him. He may
impose requirement of additional permits as the case based on risk assessment.

Sr. Work Permit Type of work permit and scope

No.
 43

1. Work Permit  For carrying out job associated with other activities
(Other than such as hot work, evacuation, work at height,
Bagging radiography blasting, hydro testing, civil/
Area) fabrication jobs.
 For job such as dismantling/connecting of pipes/
maintenance of equipment, inspection and testing of
equipment, working on instruments, civil jobs,
cleaning of equipments, electrical maintenance.
 Drilling/hacksaw cutting work/ floor chipping/
repair work in water block, ETP, Palletizer (floor,
wall, ceiling ), Ware house I, II, III, SPS, engg.
stores, scrap yard, boiler/heater blocks, factory
fencing, Storage yard, jack wall, repairing of roads.

2. Work Permit  Starting point of all other permits is bagging area.

(Bagging  For job such as dismantling/connecting of pipes,
Area) maintenance of machinery, inspection and testing of
equipment, working on instruments, electric jobs,
clearing of machinery equipment, Drilling/hacksaw,
cutting works, floor chipping, repairing works etc.
3. Hot Work  Welding cutting operation.
Permit  Drilling/hacksaw cutting works, floor chipping work
in PS plant, tank farm, TBC bed, pipe racks, cables
rack, palletize, pump foundation and processing
piping equipments, boiler/heater block and utility
blocks.
 Diesel piping at fire pump house and sub station.
 Opening burning of bitumen/tar.
4. Confined  Entry into confined space such as tanks, hoppers,
space work tank trucks, ship holds, compressor, sewers,
 44

permit (Entry) receivers, bins, sumps, pits, ventilation or exhaust

dusts, underground pipeline and earth evacuations in
excess of 300 cm depth and 100 cm wide.
5. Evacuation  Digging on floor/ trenches below one feet (all
work permit areas).

6. Fragile Roof  Working at height (more then 3 meters)

 Working on AC sheets/roofs.
7. Electrical  Isolation of electrical equipment or machinery.
Permit
(Lock out)
8. Inter lock  Isolation/ By pass of interlock.
bypass
(request)
9. Alarm/Trip  For changing alarm/trip setting (temporary or
setting change permanent)
request
10. Temporary  Temporary electrical connection of equipment or
electrical machinery.
connection
permit
11. Temporary  Temporary electrical lock out removal of electrical
electrical lock equipment or machinery for trial purpose.
out removal
permit
12. Blast work  Activities involving blast works.
Permit
4.2 INFORMATION OF MAJOR CHEMICALS HANDLED

STYRENE MONOMER:-
 45

Properties:-
 Colorless to yellow liquid with sweet pleasant odour.
 Immiscible with water and lighter than water.
 In air 0.1 ppm of styrene is detectable by smell
 Material is biodegradable.

Hazard:-
 Irritant to eyes and skin.
 Harmful to inhalation and ingestion.
 Threshold limit value (TLV/TWA)- 50ppm, STEL- 100ppm.
 Lethal dose LD50> 2000 mg/kg and LC50> 5mg/lt.
 Class B petroleum product having Flash point 32.2 degree C, Auto ignition
temperature 490 degree C.
 Vapors are heavier than air.
 Forms explosive mixture with air in range of 1.1% V/v to 6.1% V/v.
 Reacts violently with strong oxidizing agents. Oxidized on contact with air.
 If product enters soils, it will be mobile and may contaminate ground water.

Handling Precautions:-
 Avoid contact with skin, eyes and clothing. Don’t breathe vapors.
 Avoid exposure of heat, flame, spark, air, oxidizing agents and sunlight.
 Take precautionary measures against static charges
 Don’t empty into drains.

Personals Protective Equipments:-

 Non Respiratory Type:- Safety helmet, eye/face protection (spectacles/splash type/face
shield), Nitrile rubber/PVC gloves, PVC apron or suit, safety shoes/gum boots.
 46

 Respiratory Type:- Wear face mask with organic/hydrocarbon cartridge, where air
filtering respirators are unsuitable, wear BA set or supplied Air mask.

First Aid:-
 In case of skin and eyes contact wash effected area with water remove contaminated
clothing.
 If swallowed don’t induce vomiting.
 In case of breathing difficulty, remove victim to fresh air, start artificial respiration.
 In all cases, seek medical attention immediately.

Fire Protection:-
 Use foam, DCP, co2, sand for fire fighting.
 Keep containers cool by spraying water. Don’t use water jet.

Spillage:-
 Shut off leaks if without risks.
 Prevent liquid entering soil, sewers or vegetation.
 Absorb in sand or contain by making bonding with absorbent booms.
 Transfer the spilled material in the labeled container for safe disposal.

ETHYLE BENZENE:-

Properties:-
 Colorless liquid with aromatic odour having boiling point 136.2 degree C.
 Immiscible with water lighter than water.
 Material is biodegradable

Hazard:-
 Harmful if inhaled and ingested or come in contact with eyes and skin.
 47

 Irritant to eyes, nose, throat.

 Threshold limit value (TLV/TWA)- 100ppm, STEL- 125ppm.
 Lethal dose LD50> 3500 mg/kg.
 Class B petroleum product having Flash point 18 degree C, Auto ignition temperature
432 degree C.
 Vapors are heavier than air.
 Forms explosive mixture with air in range of 1.2% V/v to 6.8% V/v.
 Reacts violently with strong oxidizing agents. Oxidized on contact with air.
 If product enters soils, it will be mobile and may contaminate ground water.

Handling Precautions:-
 Avoid contact with skin, eyes and clothing. Don’t breathe vapors.
 Avoid exposure of heat, flame, spark, air, oxidizing agents and sunlight.
 Take precautionary measures against static charges
 Don’t empty into drains.
 PPE to be used during handling- face shields/ safety goggles, safety shoes/ gum boots,
PVC hand gloves, aprons.

Personals Protective Equipments:-

 Non Respiratory Type:- Safety helmet, eye/face protection (spectacles/splash type/face
shield), Nitrile rubber/PVC gloves, PVC apron or suit, safety shoes/gum boots.
 Respiratory Type:- Wear face mask with organic/hydrocarbon cartridge, where air
filtering respirators are unsuitable, wear BA set or supplied Air mask.

First Aid:-
 In case of skin and eyes contact wash affected area with water remove contaminated
clothing.
 In case of eye contact, flush with plenty of water for 15 minutes.
 If swallowed don’t induce vomiting.
 48

 In case of breathing difficulty, remove victim to fresh air, start artificial respiration.
 In all cases, seek medical attention immediately.

Fire Protection:-
 Use foam, DCP, co2, sand for fire fighting.
 Keep containers cool by spraying water. Don’t use water jet.

Spillage:-
 Shut off leaks if without risks.
 Prevent liquid entering soil, sewers or vegetation.
 Absorb in sand or contain by making bonding with absorbent booms.
 Transfer the spilled material in the labeled container for safe disposal.

AMMONIA (NH3):-

Properties:-
 Colorless gas with strong pungent odour stored in compressed liquefied state
 Soluble in water, gas, lighter than air.

Hazards:-
 Toxic gas harmful if inhaled or come in contact with eyes or skin.
 Irritant to eyes, mucus membrane acts as anesthetic.
 Threshold limit value (TLV/TWA)- 25ppm, STEL- 35ppm.
 Lethal dose LD50> 350 mg/kg
 Auto ignition temperature 651degree C
 Forms explosive mixture with air in range of 16% V/v to 25% V/v.

Storage and Handling Procedure:-

 49

 At the time of receipt of cylinder, ensure proper color coding (Body black, neck red,
with yellow band between body and neck).
 Ensure that no leaks to any parts of cylinder.
 Avoid liquid contact with skin, eyes, and clothing. Don’t breathe gas.
 Avoid storage of cylinders with oxidizing materials and all possible source of ignition.
 Keep cylinders in upright position secure from accident fall.

Personals Protective Equipments:-

 Non Respiratory Type:- Safety helmet, eye/face protection (spectacles/splash type/face
shield), cotton hand gloves, apron or suit.

 Respiratory Type:- Wear face mask with ammonia cartridge, where air filtering
respirators are unsuitable, wear BA set or supplied Air mask.

First Aid:-
 In case of skin and eyes contact wash affected area with water remove contaminated
clothing.
 In case of eye contact, flush with plenty of water for 15 minutes.
 In case of breathing difficulty, remove victim to fresh air, start artificial respiration.
 In all cases, seek medical attention immediately

Fire Protection:-
 Stop flow of gas, dilute the vapor with water spray or fog.
 Keep container cool by spraying water if container are under fire/ exposed to heat.

Spillage/ Leakage:-
 Shut off source of leaks if without risks.
 Contain the liquid and allow vaporize and dilute the vapors with water spray/fog.
CHLORINE ( Cl2 ):-
 50

Properties:-
 Greenish yellow gas with irritating chocking odour stored in compressed liquefied
state in cylinders.
 Insoluble in water, gas is heavier than air.

Hazard:-
 Toxic gas harmful if inhaled or come in contact with eyes or skin.
 Irritant to eyes, mucus membrane.
 Threshold limit value (TLV/TWA)- 0.01ppm, STEL- .03ppm.

Storage:-
 Stored in well ventilated cool area.
 At the time of receipt of cylinder, ensure proper color coding ie. Yellow color.
 Ensure that no leaks to any parts of cylinder.
 Avoid liquid contact with skin, eyes, and clothing. Don’t breathe gas.
 Avoid storage of cylinders with oxidizing materials and all possible source of ignition.
 Keep cylinders in upright position secure from accident fall.

Personal Protective Equipment:-

 Non Respiratory Type:- Safety helmet, eye/face protection (spectacles/splash type/face

shield), cotton hand gloves, apron or suit.
 Respiratory Type:- Wear face mask with ammonia cartridge, where air filtering
respirators are unsuitable, wear BA set or supplied Air mask.

First Aid:-
 In case of skin and eyes contact wash affected area with water.
 In case of eye contact, flush with plenty of water for 15 minutes.
 In case of breathing difficulty, remove victim to fresh air, start artificial respiration.
 51

 In all cases, seek medical attention immediately.

Fire Protection:-
 Stop flow of gas, dilute the vapor with water spray or fog.
 Keep container cool by spraying water if container are under fire/ exposed to heat.

Spillage/Leakage:-
 Shut off source of leaks if without risks.
 Neutralize small liquid spill with soda ash and drain with abundant water.
 Don’t apply water directly on cylinder in case of leak from cylinder body.
 Use chlorine kit to arrest the leak.

LIQUID CO2:-
Properties:-
 It is colorless, odorless liquid that transform to white crystalline particles when
discharged from its container. The gas is slightly acidic and may be felt to have a slight
pungent odour and biting taste.

Emergency overview:- Cold liquid gas under pressure:-

 Cold liquid and gas under pressure.

 Can cause rapid suffocation.
 Can increase respiration and heat rate.
 Can cause nervous system damage.
 May cause frost bite.
 May cause dizziness and drowsiness.
 Self contained breathing apparatus and protective clothing may be required by rescue
workers.

Effect of single (Acute) exposure:-

 52

Inhalation:-
CO2 is asphyxiate with effects due to lack of O2. It is also physiologically active, affecting
circulation and breathing, moderate concentration may cause headache, drowsiness, dizziness,
stinging vomiting and unconsciousness. Lack of O2 may be fatal.

Skin Contact:-
No harm expected from vapors, prolonged contact with CO 2 crystals could cause frost bite,
cold gas, or liquid or solid CO2 may cause savior frost byte.

Swallowing:-
An unlikely route of exposure. This product is gas at normal temperature and pressure but
severe frostbite of lips and mouth may result from contact with liquid or solid.

Eye Contact:-
No harm expected from vapor. Cold gas or liquid or solid carbon dioxide may cause severe
frost bite.

Effect of repeated (chronic) over exposure:-

No harm expected to health individuals where component medical authority deems that such
illness would be aggravated by exposure to CO 2, persons in ill health should restricted from
working with or handling product.

Other effect of over exposure:-

Damage to retinal or ganglions cell and the physical and system may occur.

First Aid Measures:-

 53

Inhalation:- Immediately remove to fresh air if not breathing is difficult, qualified personnel
may give oxygen, call a physician.

Skin contact:- For exposure to cold liquid vapor, immediately warm frost bite area with warm
water not exceeding 41 degree C. In case of massive exposure, remove contaminated clothing
while showering with warm water. Call a physician.
Swallowing:-
An unlikely route of exposure. The product is gas at normal temperature and pressure.

Eye contact:-
For exposure to cold liquid, vapor or solid, immediately flush eyes thoroughly with water at
least 15 minutes. Hold the eye shield open and away from the eye balls to ensure that all
surfaces are flushed thoroughly. See a physician preferably an ophthalmologist immediately.

Handling and Storage:-

Never allow any unprotected part of a body to touch un insulated pipes or vessels contained
refrigerated liquids. Flesh will stick to extremely cold metal and will tear when you try to pull
free.
Storage area should be clean and dry, free from oil and dust. Temperature should not be
exceeding 51 degree C.

Personal protective equipment:-

Wear insulated neoprene gloves (cryogenic) and metatarsal shoes for cylinder handling,
regardless of protective equipments, never touch live electrical parts.
Use face shield, hand gloves, apron, safety goggles etc.

FREYON GAS (R142b + R22):-

 54

Properties:-
 It is liquefied gas, it is heavier than air.

Potential Health Effect:-

Skin Contact:- Skin contact with liquid may include frost bite prolonged over exposure may
cause defatting or dryness of skin.

Eye contact:-
Eye contact with liquid may include eye irritation with discomfort, tearing or burning of
vision.

Inhalation:-
May include temporary nervous system depression with anesthetic effects such as dizziness,
headache, confusion, in coordination and loose of consciousness.

Other effects of higher exposure:-

May lead to temporary lungs irritation with cough, discomfort difficulty breathing or shortness
of breath or temperature alteration of the heart activity with irregular pulse, or inadequate
circulation fatality may occur from gross over exposure.

Individual and pre existing disease:-

Of the central nervous or cardiovascular system may have increased susceptibility to the
toxicity of excessive exposures.

First Aid:-
 55

Inhalation:- If inhaled, immediately remove to fresh air, keep person calm, if not breathing
give artificial breathing, qualified personnel may give oxygen, call a physician.

Skin Contact:- In case of contact, flush area with luke warm water. Don’t use hot water , if
frost bite has occurred. Call a doctor.

Eye Contact:- In case of eye contact flush eyes with plenty of water for 15 min.

Fire fighting Instruments:- Use water spray or fog to cool container. Self contained breathing
apparatus (SCBA) is required if cylinders rupture or contents are released under fire
conditions. Water run off should be contained and neutralized prior release.

Handling and Storage:- Use with sufficient ventilation to keep employee exposure below
recommended limit. Blend A should not be mixed with air for leak testing. In generation, it
should not be used to be present with high concentration of air above atmospheric pressure.
Contact with chlorine or other strong oxidizing agents should all be avoided.
Storage area should be clean and dry, free from oil and dust. Temperature should not be
exceeding 51 degree C.

Personal Protective Equipment:- Impervious gloves and chemical splash goggles should be
used when handling liquid, under normal manufacturing conditions, no respiratory protection
is required when using this product. Self contained breathing apparatus is required of large
release occur.

4.3 SAFE HANDLING OF HAZARDOUS CHEMICALS

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Definition:-

Manufacture storage and import of hazardous chemical rules 1989. Under the environmental
protection (EP) act 1986 defines hazardous chemical based on toxicity, flammability and
explosivity.

Legal Requirements:-

The Factory’s Act and The Environmental Protection Act and rules made under this acts
requires identification and labeling, Obtaining MSDS and discloser of the workers training
and supervision scale storage, handling and disposal exposure planning and preparedness.
Monitoring of work environment and health of workers.

Obligations workers under Factory’s Act, No worker shall will fully misuse any application,
do anything likely endangers him or others, neglect to make use of any applications provide
for security, safety and health of exposure, refuse to under go medical examination.

Identification and labeling:-

Label the container clearly with contents. Name and address manufacturer/import, physical
and health hazard and recommended personal protective equipments.

 Know how to use information provided on the labels

 Don’t handle any unlabeled container. Check with your supervision.
 57

Storage:-

 Store chemical in cool, dry and well ventilated place.

 Away from heat and ignition sources. Avoid storage in open sun.
 Store reactive chemicals separately.
 Don’t refill empty container with any chemical other than the one originally
contained.
 Use containers on First In, First Out basis.
 Store poisonous substances, such as cyanides, in locked.
 Cabinets away from acids.

Handling:-

 Ensure electrical bonding or grounding while transferring flammable chemicals from

one container to another.
 Follow strictly the approval procedure for loading/unloading
 Use PPE as necessary.
 Handle containers with care using appropriate trolleys.
 Keep cylinders in upright position with cap and chain them.
 Watch for the posted sign indicating area requiring particular protections and adhere
to them strictly.

Disposal:-

 Don’t pour Acid/Alkali in the drainage without proper naturalization.

 Don’t drain out toxic and flammable chemical spillage with water. Collect it by using
absorbent material for its safe disposal.
 Decontaminate the used containers not indented for reuse and make up usable by
puncturing before disposal.
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Handling Emergency:-

 Know and understand precautions and procedures in case of spillage/leakage and fire.
 Keep safety and emergency kits in working order and assessable.
 Keep antidotes ready and handy while handling toxic chemicals.
 Get trained in first aid procedures.
 Driver of vehicles transporting hazardous chemicals should know emergency
procedures and carry TREM cards.

General:-

Use non sparking tools and flame proof electrical equipments in the area where flammable
chemicals are stored and used.
 Follow established work permits.
 Periodically vent all drums containing volatile liquids.
 Don’t keep any food stuff or take meal in the area where hazardous chemicals are
stored or handled. Wash hand before eating.
 Don’t use any solvent for cleaning hands. Use soap.
 Maintain high house keeping standards and avoid spillage.
 Clean the floor immediately in case of any spillage.
 Never take chemicals away from the job for personal use.
 Identify hazardous chemicals at your workplace and know properties.
 59

4.4 OCCUPATIONAL HEALTH HAZARDS AND THEIR CONTROL

Introduction:

Health may be defined as an adjustment of disease. In mans working environment the

interrelationship of three important factors namely, the worker, the raw and processed material
and the machines and the major factors that affect man at work is the presence of various
chemical substances in the working environment.

Chemical agents:

The chemical hazards fall into two group fire and explosion and industrial poison or toxic
substances. What is an industrial poison ? . The late Sir Thomas Legge – ‘ An industrial
poison is one that is employed, produced or somehow occasioned in an industrial occupation,
the effect of which is brought about inadvertently against the will of the person poisoned, and
too often in the absence of sufficient precautions.

Classification of Air Bourne Contaminant

The chemicals used or produced generally disseminate into the work environment depending
on the process and can be classified as

1) Gases and vapors:

Sulphur dioxide, carbon monoxide and hydrogen cyanide gases, vapors of tri
chloroethylene, benzene, xylene etc.
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2) Particulate

 Dust:
These are solid particles produced by grinding, crushing, drilling and blasting
operations and are suspended in the air the sizes of the particles are predominantly
higher than 0.2 micron.

 Fumes :
These are solid particles generated by condensation, generally after volatilization
from melted substances and often accompanied by oxidation. The particles size is
usually less than 0.2 micron. Common examples are lead, zinc fumes.

 Mists:
Dispersion of liquid particulates in air these are generally formed by the
condensation of water vapors on submicroscopic particles or by the atomization of
liquids. Mist of sulphuric acid is an example of this dispersion.

If the air inhaled contains other gases or vapors they ordinarily reach the blood in a
similar fashion due to exquisite degree of intimacy between the lung tissue and the
soluble much of it may be deposited on the mist walls of the throat, and other
passages of the upper respiratory system and very little may enter alveoli.
Nonetheless, it finds its way into the blood stream although less rapidly than via
the alveoli. The action of the water soluble gases or vapors is primarily irritation.

In an industry, the worker has to undergo physical exertion depending upon the
nature of work. Physical exertion creates an intermediate demand for oxygen
resulting in stimulation of breathing. Also the rate of inhalation of any toxic
impurities in the air increases with increase in exertion.
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Harmful Effect:

Industrial poisoning is of two types, acute and chronic, first is induced by large doses of
poisonous substance and the later result of repeated and continuous small doses in an
industrial environment. The conditions causing chronic poisoning are more significant than
those causing acute poisoning.

There are three types of acute effect which may result from inhalation, particularly of gases
vapors. These are asphyxiation, irritation of respiratory organs, and narcosis. Other responses
which are more typically chronic in nature include damage to lungs, to blood nervous system,
lever, kidneys, bones, skin etc.

Permissible Limits:

In an industrial environment the optimum w and goal to be sought is zero concentration of the
air borne contaminants. However it is not always feasible to eliminate all the contaminants
may have to be tolerated. The question is to what is the percentage of toxic substance which
may be allowed without any adverse effect. In this respect the threshold limit value laid down
by American Conference of Governmental Industrial Hygienist provide the guidelines.

Appraisal of health hazards:

In evaluation of environmental conditions to get an overall picture in determining occupation

health hazards, information is to be sought on the following

1) Nature of substance or exposure.

2) Intensity or severity of exposure
3) Length of exposure.
4) Personal susceptibility.
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The toxic nature of the substance and the factors relating to workers potential exposure at
various periods are to be noted in environmental surveys and studies. A sufficient number of
samples should be collected so that the calculation of workers weighted exposure to dusts,
fumes, mists and vapors can be made.

Expression of results:

The units in which the concentrations are expressed are usually PPM (parts per million parts
of air) mg / m3 (milligram per cubic foot of air) or particles per C.C (MPPCF X 35.3 is equal
to particles per C.C). All the results are based on concentration of contaminants in normal
atmospheric pressure at 25 degrees.

Sampling of air borne contaminants for continuous sampling for a considerable time the
sampling instruments usually employed

1) Standard impinge
2) Midget impinge
3) Filter cone
4) Thermal precipitator
5) Konometer
6) Electrostatic sampler

Sampling for Biochemical tests:

The concentration of toxic agent in body blood, tissues or excretions often gives more accurate
measures of the workers exposure than can be obtained by any test on the environment.
Examination of blood for carboxyl hemoglobin is a common method of determining recent
carbon monoxide exposure. Analysis of urine for toxic elements such as lead, mercury,
fluorides, etc is the most widely applicable biochemical tests for the evaluation of exposure to
these substances
 63

Control of Environment:

The objective is to eliminate or reduce the Hazardous substances. This can be accomplish by
means of one or a combination of more than one of the following methods.

1) Substitution of less toxic material:

In the process where potentially hazardous material is used, the possibility of substituting non
toxic materials or change in process should always be considered. Less toxic solvents, such as
methyl chloroform, as substitute for highly toxic carbon tetra chloride.

2) Isolation and Enclosure:

In the manufacturing processing of highly toxic substances the entire operation should be
isolated in carefully sealed off area. All the personnel involved should be equipped with PPE
and trained thoroughly in safe practices. In the chemical industry the isolation of hazardous
processes is sometimes necessary.

3) General ventilation:

General ventilation rates are expressed as “ Air changed per hour”. This is the ratio of the
volume of air supplied or exhausted to the volume of the room. Air changes per hour are
dependent on the rate of release of the pollutants. Hence dilution ventilation rate should be
expressed by cubic feet per minutes or any other absolute unit of quantity flow.
Personal protective devices should be used as a last resort (option) because these devices do
not reduce or eliminate hazards.

They merely provide a guard or defense between the contaminants and the exposed individual.
These devices may be divided into four groups
1) Goggles and face shield
2) Protective clothing
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3) Respirators
4) Preventive creams and lotions.

Housekeeping is also an important control measures. If the toxic dust accumulating on the
floors, machines and ceilings are not periodically cleaned, many workers may be exposed to
hazardous concentrations.
Education and training of the workers, likewise is also essential, if all the control measures for
the protection of health and safety of the workers are to be effectively implemented.

“WORKS SHOULD ALWAYS BE ENCOURAGED IN THE PRACTICE OF GOOD

PERSONAL HYGIENE BY THE PROVISION OF ADEQUATE WASHING FACILITIES
AND CHANGE ROOMS.”
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4.5 BULK STORAGE AND HANDLING OF CHEMICALS:

There are thousand of chemical compound and mixture present some form of hazard. With the
increasing use of chemicals in industries, number of accidents increases year by year. Many of
these accidents are due to ignorance of the properties of the chemicals involved in the process.
Most of the chemicals being flammable, fire and explosive hazard prevail in the shop floor. By
evaluation of all known hazardous properties of chemicals and handling those by proper
methods may reduce the hazard potential. Initial standard safety assessment should made
about each chemical irrespective of the amounts of chemical involved following safety initial
assessment pro forma may be used for each chemical.

- Name of the chemical

- Physical state under known conditions of temperature and pressure
- Toxic properties
- Physical and chemical properties
- Flammability characteristics
- Fire fighting media
- Personal protective equipment
- Other special safe guards

The largest quantities of chemicals are available in storage facilities, which may be at factory
site or in other isolated storage places. Therefore It is very important to prevent the loss of
contaminant from storage of hazardous chemicals. The loss of toxic chemicals could give rise
to the worst kind of chemical industry disaster like Bhopal losses through fires in storage
results in financial loss rather than loss of life and make relatively less public impact.
There are numerous standards and codes of practices which are applicable to storage.
General Consideration:

The objective of storage in a factory is to smooth fluctuations in the day to day requirement
and availability. If there are no fluctuations, there is no need for storage.
 66

There are basically two basic principles in the design of a storage facility, which are kept in
mind
1) Economical consideration.
2) Safety aspect.
The types of storage, which economic in these alternative designs may be different and may
have different safety implication also. A hazardous chemical stored under pressurized
condition may pose comparatively more hazard than the same chemicals stored under
atmospheric conditions. The chemical will need more space when store under atmospheric
storage conditions and hence will cost more.

Layout of storage:

The storage, process and terminals should be suitably arranged. The storage should be built on
ground able to support the heavy load and located between the process and the terminals. The
wind characteristics should be taken into consideration, which reduce the hazard of flammable
liquids or vapors.

Segregation:

The segregation and separation of hazardous chemicals within the storage area is mainly
based on
1) Classification of hazardous chemicals
2) Electrical areas
3) Fire protection measures

The classification of hazardous chemicals is based on their physical, chemical and hazardous
properties like the flash point classification, toxicity rating, UN classification into zone 0,1
and 2 is based on fire hazard potential.

Bunds:
 67

In general bunds are provided for atmospheric storage tanks and for fully refrigerated storage
tanks of liquefied gas. Bunds are generally not recommended for pressure and semi
refrigerated storage of liquefied gas. The purpose of bund is to retain liquid so that it can be
dealt with a controlled manner. Atmospheric storage tanks are generally provided with full
bunds. If there are more than one talk inside the bund the capacity should be that of the largest
tank after allowing for the displacement due to other tanks.
The bund wall should be far enough from the side of the tank to prevent a jet of liquid
jumping over. The corners of the bund should be rounded. The bund should be provided with
drainage connection, with a valve on the inlet end but outside the bund wall. Walls of the
bund should not be so high to hinder fire fighting.

For pressure storage vessels containing LPG a full bund wall is not recommended, because
after spillage a large amount of liquid will remain after the initial flash off.

Separation Distances:

In Indian safety distances for pressurized (toxic, flammable and corrosive chemicals) storage
is given in the Static and Mobile Pressure Vessel (SMPV) Rule 1981.
The minimum recommended separation distance for storage tanks for class A and B
flammable liquids are as per Institute of Petroleum 1965, Refining Safety Codes.

Other aspects:

Diversion walls can be used to divert large vapors flows to areas where they can be dealt with
more safety. Steam curtains are considered as a means of maintaining separation from an
ignition source. Firewalls are utilized to give protection against flame or heat radiated from a
fire.

Storage tanks and vessels:

The main types of storage tanks and vessels for liquids and liquefied gasses are
 68

1) Atmospheric storage tanks

Atmospheric storage tanks are of two types namely

 Fixed roof tanks
 Floating roof tanks
Atmospheric storage tanks are designed to withstand an internal pressure / vacuum of not
more than 1 psig.

2) Low pressure storage tanks

Low pressure tanks are designed to withstand internal pressure in the range of 0.5 – 1.5 psig.
Use is also made up of low pressure tanks refrigerated storage as described below.

3) Pressure or refrigerated pressure storage tanks.

Pressure storage vessels are regular pressure vessels and can be designed to high pressure as
required. The lower end of the scale for pressure storage is 15 psig. Horizontal cylindrical
vessels have relatively limited capacity and for larger quantities spheres are used.

4) Refrigerated storage tanks.

This is a domed roof, flat – bottomed tank. It is essentially an atmospheric storage tank with a
design pressure below 1 psig.

Safety features (atmospheric storage vessel)

Atmospheric venting:
 69

A fixed roof atmospheric storage tank is connected to atmosphere by a vent to prevent the tank
from over pressure or under pressure at the time of filling and emptying, respectively. The
vent should always be kept free from blockage.

Pressure / vacuum valve :

A fixed roof tank containing volatile liquid breathes heavily. To prevent vapor loss a PV valve
is effective. The blockage of the valve should be avoided.
Flame arrester:
If vapor space above the liquid in a fixed roof atmospheric storage tank contains a flammable
mixture, there is a possibility that it will be ignited via the vent. A flame arrester may be used
to prevent this.

Fire relief:
A fixed roof tank should also be provided with certain arrangement to prevent it from getting
damaged / pressurized due to heat in case of a fire. In practice it is done by making the seam
between the shell and the roof weak so that it is the first to rupture. This is known as rupture
seam arrangement.

Safety features (pressure storage vessel)

A pressure storage vessel should be protected against overpressure. Protection is required

against overpressure due to
1) Abnormal operating conditions
2) Fire exposure
It may be provided by a single relief valve or by separate relief valve for each category.

Operational relief:
 70

Over pressurization of storage vessel may take place due to abnormal operational condition
like over filling, high rundown liquid temperature, high tank liquid temperature due to solar
radiation etc. A proper sized relief valve should be provided to protect the storage vessel
against over pressurization.

Combined relief:
If a single relief valve is used to provide both operational and relief it should be set to open at
100% of design pressure and the relieving capacity should be at least equal to the greater of
the individual capacities required for operational and fire relief.

Relief Discharge:
An operational relief valve and a fire relief valve should be discharged into a closed system
with proper treatment facilities. The idea is to prevent the environment from getting polluted.

Pipe work and fittings:

The pipe work valves and other fittings for storage systems should be designed in according
with approved practice for such equipment. The following aspects should be considered

1) Minimum temperatures, which may be attained

2) Materials of construction
3) Allowances in pipe work for stresses due to movement expansion / contraction and
vibration.
4) Joints / flanged joints should be kept to minimum
5) Size of pipelines, depending on filling / discharge and drainage.
6) Number of pipeline below the liquid level. If possible only one pipeline in a storage
vessel.
7) Liquid expansion valves between shut off valves.
8) Access to valves
9) Protection against mechanical damage
 71

4.5 ELECTRICAL SAFETY

Introduction:-

Electricity is most versatile form of energy. Electricity is a boon to mankind but it can cause
dangerous accidents if handled carelessly.

Hazards of Electricity:-

There are two major hazards associated with electricity in petrochemical industries and they
are
 Electrical shocks and burns
 Fire and explosion

Electrical Shocks and Burns:-

For prevention of electrical shocks, it is necessary to understand how it can be hazardous.

When electrical current passes through body, the body become the part of electrical path and
shock is experienced. The electrocution occurs unless the current is switched off or man is
separated from contact of live electrical system.
The following important factors are responsible for causing of electrical
shocks
 Magnitude of electrical current.
 Path of electrical current through body.
 Duration of electrical current.
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 Body resistance.

The following table shows the current values affecting the human body and human resistance
to electrical current.

Current strength Effect on human body

 1 mA : No sensation.
 1 to 8 mA : Sensation of shock but not painful.
 8 to 15 mA : Painful shock.
 15 to 20 mA : Painful shock, muscular control lost.
 20 to 50 mA : Painful, Sevier muscular contraction.
 50 to more mA : May be fatal, due to ventricular fibrillation

Human Resistance to Electric Current:-

Type of Resistance Resistance value

 Dry skin : 10000 to 60000 Ohms.

Effect of current on dry and wet skin:-

 Maximum current passing through dry skin : 22 mA

 Maximum current passing through wet skin : 220 mA

Do’s and Don’ts with respect to Electrical Safety:-

Do’s:-

 Only qualified person should undertake electrical repairs.

 73

 Treat all circuits as live unless after testing to be dead.

 Ensure extension chords are free from cuts, damage, insulation, joints etc.
 Check that pins of the sockets are not loose.
 Ensure easy excess to put off the supply.
 Use switches which clearly indicates ON and OFF and are of appropriate amperes.
 Frequency check of the values of electrical parameters like voltage and amperage and
ensure that they are appropriate.
 Get the equipment circuit breaker etc. check periodically with competent person.
 Use portable electrical equipments which are provided with double insulation and are
properly earthed.
 Identify electrical hazards and report them immediately.
 In case of short circuits or fire pull off the main switches immediately.
 Know First Aid procedure.

DONT’S:-

 Don’t have any unsafe temporary connection, naked joints/wiring.

 Don’t work at wet electrical equipment.
 Don’t use trial and error method with electrical circuits.
 Fuses are savior, don’t tamper with them.
 Don’t replace the blow off fuse unless the fault is detected and rectified.
 Don’t just operate the switch unless you know the consequences.
 Don’t use water type extinguisher form to extinguish electrical fire.
 Use dry sand, Foam, DCP type extinguisher.
 In case of lighting, don’t stand besides or rest against tall structure.
 Don’t take short cuts.
 The detailed protective measures (namely – design/engineering. Controls, operational
controls, monitoring controls and competency) taken to avoid/minimize the risk
 74

potential from each activity is documented under departmental hazard identification

and risk assessment register.

4.6 GOOD HOUSKEEPING

Purpose: To ensure safety by maintaining housekeeping.

Scope: All areas of Supreme Petrochem Ltd

Responsibility: Head of Department

Shift In charge
Maintenance In charge
In charge (House Keeping)
Details:
1. Housekeeping shall be maintained round the clock.
2. Ensure following things to maintain good housekeeping.

A. BUILDING
1. Walls, racks, roofs free from dust and cobwebs
2. Windows, bulbs should be clean and free from dust-deposition
3. Ensure adequate and clean urinals and toilets.

B. FLOORS / WORKING SURFACES

1. Floors / working surfaces should be even and free from dust wastes, spillages,
loose objects, cables / lying around.
2. Floor openings should keep covered or guarded with rails.
3. Trenches / pits should be free from accumulation of rubbish.
4. Floor should be clean at the end of the shift.
 75

5. Collect the spilled material immediately. if possible use the same in the appropriate
batch.
6. Gangways should be marked with painted stripes.
7. Ensure clear and safe access to switches, fire extinguishers and emergency exits.

C. MACHINERY AND EQUIPMENT

1. Ensure adequate space in between machinery, moving objects & fixed objects or
structures.
2. Always kept tools / fixtures on racks instead of on machines
3. All platforms, work benches, seats in good condition.
4. Ensure work area/surroundings free from chips, scrap, spillage..
5. Ensure cables/pipelines properly supported.
6. Fresh air / exhaust systems are provided and it should be maintain in good
condition.
D. MATERIAL
1. Ensure material should be properly piled/stacked in identified area.
2. Do not put material into gangways.
3. Material should not stack beyond the mark.

E. WASTE DISPOSAL

1. Collect each type of scrap separately as per procedure.

2. Provide sufficient containers of right size, conveniently located.
3. Combustible material should be store properly.
4. Ensure drainage channels free from choking.
5. Ensure scrap segregated properly and periodically removed & send to scrap yard.
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4.7 SAFE USE OF LIFTING MACHINES, CHAINS, ROPES AND LIFTING

TANCKLE, FORKLIFT

Chain pulley block:

1. A chain pulley block should not be overloaded than rated capacity (while
raising, lowering or suspending a load)
2. The hand chain and load chain should be hang freely without any knot or twist.
3. The load chain should not be used as a sling, e.g. for tying a load.
4. Abrupt loading which results in jerks / shocks should be avoided. Loading
should be smooth.
5. A suspended load must not be left unattended. If even this is necessary, the area
underneath must be cordoned off.
6. No one should pass below a suspended load.
7. A chain pulley block which is used for lifting loads must not be used for
dragging / pulling loads.
8. While lifting a near capacity load, it must be ensured that it does not slip by
lifting the load a few inches. If it slips, the block should not be used unless it is
repaired.
9. Chain pulley block should not be used for hoisting a person.

Forklift:
1. Only trained operators should operate a forklift.
2. Quick and jerky starts, halts, load raising /lowering should be avoided.
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3. The front view should be kept reasonably clear. In case a bulky load blocks the
front view completely, the truck should be operated in reverse and the operator
should carefully look out for people and other objects.
4. While driving the fork lift, if front side view is not clearly visible such situation
take the another associate help.
5. While traveling with a load the mast should be tilted backwards and the fork
should be kept low (preferably 6 inches above the ground).
6. Overloading must not be attempted. The operator should be aware of the safe
working load (SWL) and also the load centre of the truck.
7. While driving the forklift truck on ramps and inclines, the load must face uphill
and the path should be straight.
8. Shut off the ignition while re-fuelling the truck.
9. Traffic rules should be followed by the forklift operator.
10. Forks should be adjusted to match the width of the load or pallet.
11. The mass should be partially tilted backward while raising or lowering the load.
12. Extra care should be taken to maintain the stability of the stack while stacking
or de-stacking.
78
 79

4.8 FIRE SAFETY IN WARE HOUSES

Numerous fire occurred in ware houses of flammable, explosive or reactive chemicals causing
seviour harm to people, property and environment.

Following safety measures should be used:-

 Choose location based on risk assessment and analysis considering all risk including
those for external fire/explosion (proximity to LPG, diesel tanks, gas pipelines, over
head H.V lines etc ). General storage and ware housing; national building (NBC)
recommends fire zone 3 for hazardous chemicals.
 Easy access to public fire brigade or private fire station under mutual agreement is a
favorable consideration.
 Avoid basement location for chemical ware house.
 Building of more than 15 M high is not permitted near by.
 Separate from other manufacturing facilities by 15 M.
 Building to be non combustible construction (Type I or II per NBC).
 As far as possible install electrical wires externally excepting for the fittings. All
switching and control equipment should be located outside.
 80

 Arrange main electrical switch outside the ware house to facilitate rendering the entire
electrical circuit dead during silent hours.
 Install overload and earth leakage protection.

Ware House Operation:-

 Prohibit smoking at sites.

 Prohibits loading and unloading of vehicles inside the ware house
 Road tankers entering the compound for unloading of inflammable chemicals be
properly earthen to ground the static charge.
 Segregate incompatible chemicals.
 Allow NO naked flame. Use spark proof lamps.
 Good housekeeping is essential to prevent fire.
 Provide security against arson. Consider intruder alarm.
 Limit the stack height inside the ware house 4.5 M.
 Allow 1 M clearance from over head light and fire fighting equipments.
 Display instructions to deal with fire emergency.
 Train the work force to safe handling of chemicals, identification of hazards and fire
fighting.
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CHAPTER 5

FIRE PREVENTION AND FIRE PROTECTION

5.1 FIRE: -
Fire may be defined as a rapid oxidation of substance accompanied by the evolution of energy
in the form of heat and light. It is an exothermic chemical reaction. The heat evolved help in
continuing and further enhancing this reaction this phenomenon is commonly called
combustion or burning.

Four basic things necessary for a fire are [fire tetrahedron]

1. Fuel :- (any combustible / flammable material) Solid, Liquid or Gas

2. Air or Oxygen :- Oxygen reacts with fuel and evolves energy.
 82

3. Heat or source of ignition :- Chemical heat energy , mechanical heat energy, electrical
heat energy, nuclear heat energy, spontaneous ignition, open flame etc. act as source of
ignition.
4. Chain Reaction :- For fire to occur un inhibited chain reaction as required.

Fire is a chemical combustion reaction between fuel and oxygen (air) in presence of heat. In
other words four things are required for fire which represents four sides of tetrahedron viz fuel
,air , energy in the form of heat (ignition source ) & chain reaction , when these four sides
come together at sufficient proportion then only this tetrahedron is completed. Fire can not
takes place in absence of any of the side of tetrahedron.
Thus to extinguish any fire we have to remove any one of the four constituents of the fire. So
any fire can be extinguished by stopping fuel supply (starvation) or by excluding fuel from air
or oxygen (smothering) which can be accomplished by creating a barrier between the burning
fuel and the external air or oxygen / diluting oxygen or by removing heat (cooling) or
inhibiting chain reaction.

Fire load:-

Fire load is the heat generated by the combustible material within the building.
“ It is the product of mass of materials and its heat of combustion or calorific value “
Fire load density : it is the heat per unit area of floor which can be generated.

Type of fire load Fire load density Types of Occupancies

Low 12.5 Dwelling & offices
Medium 12.5 – 25 Factories
High above 25 Ware house

POTENTIAL IGNITION SOURCES:-

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1) Flames, heater, furnace.

2) Hot – surface – welding, cutting, grinding.
3) Hot – surface – hot process equipment distressed machinery.
4) Hot particles.
5) Friction and impacts.
6) Chemical energy.
7) Hot materials and gases.
8) Reactive, unstable and pyrophoric materials.
9) Engines.
10) Vehicles
11) Lightning.
12) Radio frequency emissions.
13) Smoking.
14) Arson and sabotage.
15) Self heating.
16) Static electricity.
17) Electrical equipment.
18) Auto ignition.
19) Compression ratio.

5.2 METHODS OF FIRE EXTINGUISHMENT:-

(FIRE EXTINGUISHING TRIANGLE)

1) Eliminating the combustible fuel (Starvation).

2) Cutting off the oxygen supply (Smothering).
3) Cooling to point below ignition temp (Cooling).
4) Inhibition (breaking) of chain reaction.

STARVATION METHOD:-
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If unburned fuel is removed from the fire by physical or mechanical means the combustion
will cease.
e.g.1. The best method of handling of gas fire is to stop the flow of a gas by closing of the
main valve for shutting of the supply.

SMOOTHERING METHOD:-
If the oxygen is removed or prevented from reaching the combustible material by blanketing
or diluted by an inert gas or dispersion in it of a non combustible power the combustion will
cease.

COOLING METHOD:-
It is removed by cooling with water then combustion will cease. Cooling of the burning
material reduces the temperature of the material to below it’s ignition temperature and thus the
fire is completely extinguished.

SPREADING OF FIRE:-

Conduction:- It is important particularly in allowing heat to pass through a solid barrier and
ignite material on the other side.

Convection:- The hot products of combustion rising from a fire typically have a temp range
800-1200 degrees and a density quarter that of air. On open plant much of the heat is
dissipated into the atmosphere but in buildings it is transferred to the ceiling.

Radiation:- It is the main mode of heat transfer although it is usually accounts for a smaller
proportion of the heat issuing from the fire radiated heat is transferred directly to nearby
objects.

PHASES OF BURNING:
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Before attacking fire remember following

- How much time the material is under fire.
- In case of a building, consider ventilation.
- Amount of combustible material (fire load).

PHASES OF BURNING:-

1. Incipient stage phase

-First stage burning.
-Emission of heat and combustible gases.

2. Free burning phase

-Second stage of burning
- Temperature goes up to 700 degrees
-and fire spread all over the area.

3. Smoldering phase
-complete combustion stage
-Flames normally disappeared
-Entire area / building found occupied with combustion products

4. Flash Over:
-Temperature in the surroundings obtains extremely.
-Possibility of re-ignition due to auto-ignition.

5.3 CLASSES OF FIRE

Class of fire Description Suitable fire

Extinguisher

Fire involving solid combustible materials of

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A organic nature such as wood, rubber, plastic etc. Water

where the cooling effect of water is essential for
extinguish of fire.

Fires involving flammable liquids or liquefiable Dry chemical powder,

B solids or the like where a blanketing effect is CO2, Mechanical
essential Foam

C Fires involving flammable gases, compressed Dry chemical powder,

gases, liquefied gases of flammable nature CO2

Fires involving combustible metal such as Special Dry chemical

Magnesium, aluminum, zinc, sodium, potassium powders/ like turnery
etc. when the burning metals are reactive to eutectic chloride, Na-
D
water and water containing agents and in certain X, Metal-X
cases carbon dioxide and ordinary dry powder.
These fires require special media and techniques
to extinguish.

5.4 FIRE EXTINGUISHING MEDIA:

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a) Water: - Water is called as best extinguisher media.

 It is the universal solvent –hence water dissolves ash etc and reach seat of fire.
 Specific heat -418.2 KJ/kg and latest heat vaporization is 2260 KJ/kg – highest
cooling capacity.
 Expansion ratio :1650 disperse oxygen on vaporization.
 Relatively stable liquid under atmospheric condition.
 High molecular stability up to 1650 degrees (does not dissociates on when
applied on normal fires)
 High surface tension = 72 dynes / cm (formation of jet)
 Less change in viscosity with atmospheric conditions make it easy to flow.
 High density ensures sufficient mass goes on fire.

Limitation of water:-

 Water freezes at 0 degrees

 Restricts penetrations and wetting various combustible materials because of
high surface tension.
 Water turns off readily because low viscosity
 High friction loss
 Unsuitable for extinguishing electrical fires
 Due to high surface tension does not penetrate in porous substances.

b) Foam:-

Water can not be used on hydrocarbon fires due to its high density. To overcome this
problem foam is used to extinguish hydrocarbon fires (class B fires)

 Water + foam concentrate + air = foam

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 It is a homogeneous mass of tiny air / gas filled in water bubbles of low

specific gravity
 It extinguishes the fire by
1) Cooling effect
2) Smothering effect
3) Starvation effect
 Used for extinguishment of bulk and spill fire of flammable liquids(Class B)

c) Dry Chemical Powder :-

Sod bi carbonate Alkali DCP

2NaHCO3 + Heat -------- Co2 + Na2CO3+H2O
Na2CO3 + Heat -------- Co2 + Na2O
Na2O + H2O (from combustion) -------- 2NaOH
NaOH + H- --------- Na + H2O
NaOH + OH- --------- Na + H2O

Chemical way absorption of radical

Limitations:-
- Short throw
- Ineffectiveness against deep seated fires
- Fire of oxygen generating chemicals

d) Carbon Dioxide (Co2)

 Its vapor density is 1.5 (heavier than air)

 It expands 450 times
 It is non-combustible gas and clean media
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 It is non – conducting media

 Extinguishes fire by
1) Smothering effect
2) Cooling
 It is suitable for Class B, Class C fires
 It is suitable for electrical fire.

Limitations

 Short term
 Unsuitable for fires involving chemicals containing oxygen like cellulose nitrile
and reactive metals.

e) Halon Alternatives:-

 FM 200 (Hepta fluoro propane)

 Inergen (Nitrogen – 52%, Argon – 40% & Co2 – 8%)
 Aragonite (fluoro iodo carbon)
 FE13 (Tri fluoro methane)
 FE 36 (Hexa fluoro propane)
 CEA 410 (Per fluoro Propane)
 Water mist system

ACTIVE PROTECTION

Fire Protection & Fire Fighting Facilities

Following facilities have been provided for the Fire Protection.

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 Fire water supply.

 Hydrants and Monitors.
 Sprinklers and Water spray.
 Foam Injection for storage tanks (Static foam system)
 Portable fire extinguishers.
 Fire alarm system.
 Hydrocarbon Detectors.
 Smoke detectors.
 Trailer mounted foam monitor.
 Foam / Water mobile tender.

Passive Fire Protection:-

Constructional requirement:-

Stability:- Means load bearing capacity of an element of compartment without fall during fire
condition.

Integrity:- Means ability of an element of a compartment to withstand the fire conditions

without cracking which may otherwise allow the smoke or flame to pass through the cracks
spread beyond the compartment.

Insulation:- Means ability of an element of compartment to prevent the transfer of heat from
one side to the other.

5.5 SOME FIRE PREVENTION TECHNIQUES

1. Compartmental Construction
2. Fire resistance (by construction material or by paints)
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3. Partitions and linings

4. Roofs
5. Vents
6. Escape route
7. Fire proof doors
8. Wired glass windows and damper

What to do in case of a Fire:-

 Familiarize your self with emergency plan by organization.

 Your role and responsibility during an emergency.
 Emergency communication system
 Location of fire alarm points nearest to your workplace
 Location of emergency kits , store well its key and items available in it.
 Location of first aid box and items available in it
 First aid procedures
 Emergency telephone nos of Fire station, Medical Center and Security (Main Gate)
 Assembly point
 Location of Fire Extinguishers and its use in case of Fire.
 Location of Fire Hydrants
 Electrical Switches.
 Emergency Exit.

Planning for Prevention and Handling of Fire:-

 Keep fire doors / shutters, passages and exists, doors unobstructed.

 Don’t obstruct access to fire extinguisher
 Maintain good house keeping
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 Don’t smoke in No Smoking Areas

 Use proper containers for flammable liquids.
 Maintain safe distance of flammable liquids from source of ignition.
 Welding and cutting equipment should be checked before and after use
 Soldering irons gas rings and crucibles must be kept in non combustible stands.
 Main electrical equipment should be switch off when not in use.
 You must be familiar with the fire fighting system and with the operations fire
extinguishers.
 Ensure that you know all escape routes.

If at all fire occurs:-

 Be concerned about your own safety as well as that of others.

 Communicated to HOD/SIC by breaking MCP followed by PA system , telephone or
in person.
 If without risk try to contain/extinguish/rescue/isolate or wait for instructions.
 Make certain you know your escape route and assembly point

5.6 FIRE PROTECTION AND FIRE FIGHTING FACILITIES AT SPL:-

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Fire water reservoir.

Capacity:- 7654 m3

Fire water supply (underground network).

Consist of following water pumps

a) Electric motor driven pump : 1 no

410 m3/hrs capacity, 105 MLC head

b) Diesel motor driven pump : 2 no

410 m3/hrs capacity, 105 MLC head

c) Electric motor driven jockey pump : 1 no

40 m3/hrs capacity, 105 MLC head

d) Electric motor driven jockey pump : 1 no

10.8 m3/hrs capacity, 105 MLC head

Medium velocity water spray system.

Medium velocity water spray systems have been provided for all bulk storage tanks, also for
tanker loading station. The design of spray system has been based on water demand rate of
10.2 LPM/m2 of tank surface.

A typical spray system for the styrene storage tanks in the tank farm consists of a taping form
the main fire hydrant line with a sluice valve, y type strainer, a deluge valve followed by
another sluice valves.

GI piping downstream of the valve branched off at required height into a ring and a branch
extending to top of tank.
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Adequate number of spray nozzles mounted on the GI piping and located to give the desired
spray pattern and wetting the protected surface area of the tank with the required flow rate of
10.2 LPM/m2 of tank surface.

Rings of quartzite bulb type temperature sensors have been provided which when fused will
automatically actuate the spray additional water curtain is also provided to protect the
intermediate storage tanks and pipe rack from the fired heaters.

Hydrants and Monitors

Fire water header is always maintained under pressure with the help of pilot jockey pump
through out the large network of underground hydrant line, feeding a number of hydrants,
monitors, MVWSS, water curtain and foam pouring system at different locations in the plant.

A total number of 88 single hydrants (external) are located above ground at critical locations
of the plant each on stand post.
In addition to this 25 single hydrants (internal) have been provided at higher elevations of the
main plant.
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14 monitors are installed around the main plant and another 4 monitors are installed around
the styrene storage area, each of these monitors has 38 mm dia outlet.
A total 10 hose stations (containing five hoses, two carboys – 40 liters each, two foam
branches and three water type branches) and 60 hose boxes (containing two hoses and one TP
branch) have been installed at SPL.

Foam pouring (Injection) for storage tanks (Static

foam system)
A 3% AFFF type foam system is provided for
protection of the insulated styrene storage tanks and
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HSD tanks (total 6 tanks) A FRP line MS foam tank of 2000 liters capacity is provided near
the storage tank area.
In addition a mobile fire tender and two portable foam monitor trolleys are also provided.

Portable fire extinguishers:-

Several portable fire extinguishers are provided at strategic location of the plant as required
under NFPA – 10 guidelines. They are mainly Dry chemical powder type (231), water (3),
foam type (7), modular type DCP (O2), Co2 (105), etc.

Fire alarm system:-

Manual call point and smoke detectors are provided in
the complex, which on actuation gives audio – visual
alarm in the Fire Station and repeated in the Control
room, indicating exact location of smoke detector
actuated

Hydrocarbon Detectors:-
Ten number of Hydrocarbon detectors are provided with alarms. Set at 20% of LEL (Lower
Explosive Limit) in the styrene storage area, intermediate storage area and GPPS and HIPS
process plants for arising timely warning to the operating personnel.

Smoke detectors:-
56 numbers of smoke detectors are provided in Control Room, Electrical substation and SPS
Control Room. On actuation it gives audio visual alarm in the Fire Station and repeated in
Control Room

Trailer mounted foam monitor:

Foam tank capacity : 1000 Liters

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Monitor installed : Water and Foam

Monitor range : Vertical – 50 meters

Horizontal – 60 meters

Multipurpose Industrial fire tender (water/foam/DCP/Co2):

The fire tender is fabricated on diesel chassis TATA LPT 1612.

Water tank capacity : 3000 liters

Foam tank capacity : 500 liters
DCP extinguisher capacity : 160 Kg
Co2 extinguisher capacity : 54 Kg
PUMP : Single stage centrifugal pump
capacity : – 2250 liters / min at 7 Kgf/cm2.

Fire tender is provided with various small gears, tools and specialized equipment, which are
useful for fire fighting, rescue and casualty mobilization operations.

Detection System:-

Following detection system has been provided for timely warning / information to the
operating personnel.

- One styrene LEL detector each in GPPS, HIPS and 3 rd line plant area with alarm in
Control Room.

- One styrene LEL detector in Pump area of the tank farm and intermediate storage tank.

- Smoke detector are installed in control room , pelletizer substation and SPS control
room plant.
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- High level alarms on all tanks.

- Periodic sampling and analysis of air in the downwind direction of styrene shall be
taken up.

- Portable Oxygen, LEL detectors and with dragger pump with detector tubes (styrene,
chlorine, ammonia, general hydrocarbon, etc) for PPM detection are also available.

Auxiliary Fire Squad: -

AFS members comprising of minimum 8 employees trained in fire and safety from different
department are available around the clock apart from Fire Operators. All AFS members are
trained in Fire Fighting, risqué and first aid and perform drill on 3 rd week of every month like
hydrant drill, extinguisher drill, pump drill, ladder drill, B.A. Set drill, Chlorine kit drill,
rescue drill, first aid drill, etc

CHAPTER 6

6.1 PIPELINE SAFETY MANAGEMENT

In a plant pipelines plays major roles in manufacturing process of material, Different size and
diameter of pipes are used to transfer material to different location in the plant. According to
characteristics of chemical right type of material of construction (MOC) is chosen for leak free
and safer operation over a period of long time.

SPL has also adopted international standard of piping safety from the design stage itself.

The following precautions are to be taken while making network of pipeline in the plant and
while in operating condition.
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 Material used for the pipelines is according to the chemical to be carried.

For Styrene monomer it is of Alloy steel.
For FO it is of Carbon steel.

 While building network of pipelines through out the plant special precautions are taken
during welding and joints.

 After the network is built radioactive material is used to identify cracks if they exist
there.

 Proper and appropriate support is given to pipelines with proper spacing for
maintenance

 The pipeline carrying styrene monomer, steam, hot oil, are well insulated and leak
proof to maintain temperature and safety.

 All pipelines are differentiated by proper and specific color coding.

 The maximum operating pressure of water hydrant is 10 kg/cm2.

 The gear pumps which are used to carry polymer will trip automatically on high
current if there is any pressure built up in pipeline due to chock up.

 Pipelines are provided with manual valves to avoid excessive pressure built up.

 According to the quantity of material to be carried out the standard specific dimensions
pipeline is used to maintain required pressure.

 The pipelines which carrying polystyrene are provided with sensors to detect pressure
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due to blockage.

6.2 SAFE OPERATION OF PRESSURE VESSELS AND PRESSURE PIPING

The various pressure vessels and pressure piping safety procedure are governed by

 The Factory’s Act/ Rules of factory inspectorate.

 Static and mobile pressure vessel rules of department of explosive.

Based on the above Act/ Rules government has formulated following rules on pressure vessels
in Maharashtra factories rules 1963.

Rule no – 65 Pressure Plant

Definition:-

Pressure plant means a pressure vessel along with its piping and other fittings, operated at a
pressure greater then atmospheric pressure.

Periodic Inspection:-

All pressure plant should be properly maintained and thoroughly examined by a competent
person as follows:-

 Externally - Every 6 month.

 Internally - Every 12 month
 Hydraulically - Every 4 years
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In case it is not possible to offer for inspection as prescribed at (b) ie. (internally every 12
month ) then it should be replaced by hydraulic test which shall be carried out by once in a
two year.
The report of all hydraulic test and other periodic examination mentioned above shall be
maintained in form no. 13 regarding the procedure for filling and record keeping on form no
13 following guide lines to be followed:-

Procedure as per Static and Mobile Pressure Vessels Rules:-

These are governed by department of explosives and government of India and they are
formulated specific rules regarding periodicity and procedure for examination of pressure
vessels – mobile – static – following under their preview.

As per the department of explosive, a pressure vessel means any closed metal container of
whatever shape, intended for storage and transportation of any compressed gas which is
subjected to internal pressure and whose water capacity exceeds 1000 liters and includes in
correcting parts and components there of up to the first point of connection as connected
pippins and fittings, but does not includes container where in steam or vapor is intended to be
heated by application of combustion or by electrical means, heat exchanger, evaporators, air
receiver, steam type digesters, steam type sterilizers, auto claves, reactors, clarifiers, and
pressure piping components such as separators and strainers.
Periodic examination as per following schedule will have to be conducted and recorded for the
storage and installation of tankers for which licenses have been obtained.

Periodic Testing of Pressure Vessels in Services:-

As vessels shall be hydraulically tested by the competent person art a pressure marked on the
vessel at interval of not more than five years after the date of first test, provided that in case of
first vessel, containing corrosive or toxic gases. The periodic test shall be done at interval of
two years.
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Precautions should be observed in carrying hydraulic test:-

In carrying out the hydraulic test referred to in rule 19 the following precautions shall be
observed namely

 Before the test is carried, each pressure vessel shall be thoroughly cleaned and
examined externally as far as practicable, internally also for surface defects corrosion
and foreign matter. During the process of cleaning and removal of sludge, if any all
due precautions shall be taken against fire or explosion, if such sludge is of
phosphoric nature or contain spontaneous combustible chemicals.
 As soon as the test is completed the vessel should be thoroughly dried internally and
shall be clearly stamped with the marks and figure indicating the person by whom the
test has been carried out and date of test and a record shall be kept for all such tests.
 Any vessel which fail to pass the hydraulic test or which for any other reason is found
to be unsafe for use shall be destroyed or rendered unsuitable under intimation of
chief controller of explosive.

Mobile Pressure Vessels:-

Other than the test mentioned for the static vessels following additional tests are also be
carried on road tankers

 A check should be make quarterly on the vehicle to ensure that it is all time road
worthy and that it is in a fit condition to fill, transport and discharge its load safely.
 Routine examination and maintenance of vehicle shall be carried out by a competent
person at regular interval of not more than three months.
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6.3 COLOR COADING OF PIPELINES:-

The purpose of marking/displaying safety color and safety signs is to draw attention rapidly to
the object and situation effecting safety and health. The use of safety sign should not replace
the need for the proper accident prevention measure, safety sign shall be used for the
instruction which are related to safety.

Under various legislations it is mandatory to display safety signs which are given below

Safety Colors for pipelines:-

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Pipe line color code at Supreme Petrochemical Ltd. :-

Sr. Name of Pipe line Color Code

No.
1. Hot Oil (Supply or Return Line) Oxford Blue

2. Slop/ REB/Fresh EB/ PS purge Wild Lilac

3. -15 degree C/ + 7 degree C brine (supply and return Phiroza Blue

line)
4. Low/Medium pressure steam Silver
(Supply and return lines)
5. Plant Air Sky Blue
6. Nitrogen Black

7. Drinking Water Bus Green

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8. Process Water Deep orange

9. Cooling Water ( S and R lines ) Phipoza Blue

10. New Mineral Oil Sea Green
11. Influent Pipe line to ETP Black

12. HSD Leaf Brown

13. Furnace Oil Oxford Blue

14. Styrene Monomer to Plant/RD Wild Lilac

15. Instrument Air Sky Blue

16. Old SM to plant (not use) Wild Lilac

17. Old Mineral Oil Sea Green

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6.4 SAFETY COLORS AND SAFETY SIGNS:-

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There are four safety colors of specified shade to which a safety meaning is attributed as
follows:-

Sr. Safety color Meaning or Objectives Example of Use Corresponding

No. Contrast

1. Red (shade no.- STOP sign, STOP Sign, White

537 Signal Red) Prohibition, Emergency Stop,
This color is fire Prohibition Sign,
fighting. Also used for prevention of fire
Equipments and indicates its
location.

2. Blue (shade no.- Mandatory Action Obligation to wear PPE White

166), French Blue Information equipments,
Location of telephone.

3. Yellow (Shade no.- Caution Risk, Indication of hazard/danger. Black

309), Canary Danger (fire, explosion, radiation,
Yellow chemical etc)
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4. Green (Shade no.- Safe Condition Escape routes,

221), Brilliant Emergency exits,
Green Emergency showers,
First Aid and Rescue Station.

6.5 SAFETY SIGNS:-

A sign which gives a particular safety message obtained from the combination of geometric
form, a color and symbol. The safety sign may also incompatible a text (word, letter or
number) it also supplementary sign with a text only for use where necessary, in conjunction
with a safety sign.
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CHAPTER 7

7.1 EMERGENCY PREPAREDNESS AND RESPONSE

“ON-SITE” EMMERGENCY PLAN:

1. This plan is prepared as per the requirements stipulated under manufacture, storage and
impact of hazardous chemical rules 1989 and The Maharashtra Factories (Control of
industrial major accident hazards ) rules 2003.
2. It covers the potential energy scenarios at line 10, line 11, line 12, Tank Form,
unloading areas, SPS building, Warehouse 1/2/3, Engineering stores, Initiator storage,
water block utility block ½, main sub station, XPS and main gate area including front
officers etc.
3. The emergency scenarios are taken from the revised risk analysis carried out for
existing as well as for the expansion activities. In addition emergency scenarios are
also taken from the register of environment aspects during emergency condition.
4. The observation and recommendation from various mock drills and table top exercise
are taken into consideration while releasing this revision.
5. The plan will only undergo revision incase of change in mitigation plans,
addition/alteration expansion of existing facilities which has a potential to result on
ON-SITE Emergency situation, addition and deletion of risk, change in statutory
requirement etc. Separate revision will not be issued under circumstances such as
change in designation, phone number, man power, reshuffled etc.
6. This plan shall be mailed to all user at SPL works and all HODs/HOSs shall keep the
plan as electronic version on their computer work station. However hardcopy shall be
maintained shall be maintained at security, control room, fire station, occupational
health centre, site controller, Incident controller.
7. All HOSs and HODs are required to go through the plan and communicate role of
incident informer and responsibilities during the emergency to SPL and contract
employees working with respective departments.
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CONTENTS OF “ON-SITE” EMMERGENCY PLAN:-

1. Important telephone numbers.

2. Name and address of person furnishing information.
3. Key personals and their responsibilities.
4. Guidelines and gathering at assembly points.
5. Details of out side organization.
6. Details of liaison arrangements between the organizations.
7. Information about preliminary hazard analysis.
8. Details about site.
9. Description of hazardous chemical.
10. Likely danger to plant.
11. Effect of fire and explosion.
12. Risk summary.
13. Details on:-
 Safety and security system.
 Hazard control plans- Prevention and Mitigations of potential scenarios.
 Instrumentation system.
 Design features of the buildings.
 Operational surveillance.
 Maintenance system.

14. Communication facilities.

15. Fire fighting facilities.
16. First Aid Facilities and installations.
17. DO’s and DON’T’s in natural calamit

7.2 OVER VIEW OF ONSITE EMMERGENCY MANAGEMENT PLAN:-

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Incident Communication:- Incident occurring in any part of complex area shall be

communicated by pulling MCP followed by PA system, telephone or in person.

Role during emergency:- As described in on-site emergency plan

Prevention and mitigation plans:-

 Chlorine cylinder outlet tubing rupture leading to dispersion of chlorine gas.

 Ammonia compressors outline line rapture leading to dispersion of ammonia gas.
 Styrene tank pump discharge nozzle failure leading pool fire in styrene storage area.
 Styrene storage tank outlet nozzle failure leading pool fire in styrene storage area.
 Absorption bed inlet line rapture leading to pool fire in TBC bed area.
 Spillage of SM from transfer line on pipe rack at battery limit leading to pool fire.
 Styrene tanker (10/20 MT) hose fire leading to pool fire in FO storage area.
 FO pump discharge failure leading pool fire in FO pump area.
 HSD tank overflow leading pool fire in HSD storage area.
 Thermia pump discharge nozzle failure leading pool fire in hot oil storage area.
 FO tanker hose failure leading pool fire FO tanker.
 GPPS/HIPS/Third line Reactor inlet line rapture leading to pool fire.
 Pre Poly/ Third line REB tank outlet nozzle failure leading to pool fire in intermediate
storage area.
 HIPS/ Third line recycle styrene pump discharge nozzle failure leading to pool fire in
intermediate storage area.
 Spillage/Fire to peroxide Storage due to thermal decomposition.

Testing and Rehearsal of Emergency Plans:-

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 By table top/exercise/mock drills (six month) - site level.

 By conducting department level mock drills.
 Mock drills of operational control.

Need for Review/revision of Plan:-

 Learning after the occurrence of accidents, incidents, emergency situations and drills,
if required than plan is revised.

7.3 OVER VIEW OF OFF SITE EMMERGENCY PLAN:-

 115

As per the regulations responsibilities of preparation of off site emergency management plan
lies with district collector, and health. However the regulation stipulates responsibility of
industry that the industry should assist these authorities in preparation of off site emergency
management plan.
Under these regulations, various groups are formed namely - Local
crisis group, District crisis group and Mutual aid response group. Under the auspices of these
groups, SPL is conducting training programs of neighboring villages, community,
dissemination of information for development off site disaster control plan etc.
In case of off site disaster, assistance such as trained man power, fire and safety equipments,
heavy equipments etc can be obtained from the member industry of these groups.

7.4 ROLES AND RESPONSIBILITY DURING EMERGENCY

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By consideration various scenarios it is seen that the emergency need to be considered in

stages. There are specific roles and responsibility for every person during emergency.

Incident informer (First emergency responder):-

 Incident occurring in any part of complex shall be communicated to CCR/SIC by

pulling MCP followed by PA system , telephone or in a person.
 If without risk, try to contain/extinguish/rescue/isolate or wait for instruction till arrival
of SIC/HOD/HOS.
 Be available at spot and wait for instruction.

Plant Coordinator (first emergency responder):-

 Communicate message received from incident informer to shift in charge. In case of

SIC is not communicated within 2 min (after receiving message from incident
informer) than perform the duties of SIC till his arrival.
 Communicate except location of emergency to fire department and security
department.
 Operate siren to declare emergency as per instruction of SIC inform the name of SIC to
security to enable him to instruct the guard accordingly.
 Communicate about emergency also to HOD Prd_PS or HSE or CEO.
 Announce on PA system
 Location of emergency
 Cancellation of work permits
 Assembling of AFS members to CCR
 Instruct employees who are not connected with incident to assemble at nearest
Assembly point.
 Repeat the announcement in English, Marathi, and Hindi.
 Maintain coordination between plant and CCR.
 Raise all clear siren followed by announcement on PA system about
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 “All CLEAR” of emergency in English, Marathi, Hindi on receiving

instruction in person from incident controller

HOD/HSE:-

 On receiving information from CCR, ensure information to HOD (Engg.), incident

controller and site controller.
 After hearing the siren, rush to the incident spot and work as per the instruction from
incident controller.
 Take the charge of all safety and fire requirement
 Coordinate with site and incident controllers and work as per their instruction.
 Liaise with statutory body/ other external agencies, under instructions from site or
incident controller.

Safety officer/Fire officer:-

 Mobile the Fire Tender and fire fighting equipments.

 Coordinate all fire fighting and rescue operations
 At as per the directives of incident controller
 Supervise fire fighting and rescue operation.
 Assist in search of casualties and rescue.
 Diagnose the casualties give first aid and mobilize casualties to medical centre under
the instruction of incident controller.
 Organize outside assistance in fire fighting and rescue operation if required under the
instruction of site controller.

Fire/Rescue coordinator:-
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 Rush to the incident spot immediately within fire tender followed by ambulance after
giving information to CCR. Consider wind direction and road condition while turning
out vehicles.
 Turn out fire tender ambulance and fire fighting appliances near the incident spot to
inform SIC about readiness.
 Search for casualties and arrange for rescue first aid/ shifting of OHC. As per the
instruction of SIC/Incident controller.
 Utilize auxiliary fire squad for fire fighting and rescue operation.
 Assist in search of casualties and rescue. Diagnose the casualties give first aid and
mobilize casualties to medical centre under the instruction of incident controller.

Medical Coordinator (Medical Officer):-

 Take charge of entire medical treatment operation.

 Ensure casualty mobilization in neighboring hospital in consultant with incident
controller/ site controller and give constant feedback to them about the status of
casualties.
 Liaise with local hospital for additional help if required.
 Coordinate with security department for causalities mobilization
 Contact designated hospital/nursing homes inform them about emergency.
 Work as per the instruction from incident/ site controller.

Medical Coordinator (Male nurse):-

 Organize first aid to the affected.

 Call trained first aider to OHC if requried.
 Give information to the medical officer about the first aid given and follow the
instruction
 Assist medical officer in treatment and shifting the casualties to hospital.
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 In absence of medical officer perform his/her duties.

 Assist the medical officer in providing medical aid to injured personnel’s.
 Work as per the instructions from medical officer/ Incident controller.

HOD (Security Office):-

 After hearing the siren and after receiving communication from central control room
ensure control of men and vehicles at gates.
 All gates will be closed unless or otherwise instructed by site controller.
 Communicate to key personnel as per the emergency plan.
 During working hours (1000 to 1800 hrs), the emergency need to communicated to
o All employees staying at SPL Township (HODs of all departments).
o CEO at township residence or at Mumbai residence.
o Employees staying at Roha (HODs).
o Send vehicles as per the need to key personnel.
o Depute two security guards to report to CCR.

 During Silent hours (1800 to 1000 hrs).

o Arrange for assembly point one coordinate.
o Give head count to SPL employees, Contractors, visitors, drivers, cleaners of
o Vehicles to CCR within 1.5 hours of occurrence of incident.
o Allow only responsible personnel to enter the operational areas. Other
employee
o or contract employee to be permitted only on permission of site controller.
o Ensure no vehicle movement on road to plant.

7.5 IMPORTANT INSTRUCTION DURING EMMERGENCY

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 The HOD/HOS as listed under key personnel’s and designation column should
perform all the duties as described their under. In absence of HOD/HOS the officer in
charge of concerned department shall follow the above instructions.
 After the communication about emergency employees (including visitors and
contractors) working at administration building, XPS SPS department MHD (ware
house I/II, bagging, Engineering. Stores, scrap yard, steel yard, EB storage, project
stores, office etc) QCA Technical centers, contractors sheds, and switch yard should
not leave their place unless they are instructed by their HOD or their work place is a
incident spot.
 All the normal operation and activities in the above mentioned areas should be
continued unless or otherwise instructed by incident controller.
 The incident collector shall arrange to inform any one available HOD/HOS each of
the above area about evacuation or stopping of operation if necessary, however it is
responsibility of the concerned HOD/HOS to inform all the personnel’s in their
respective areas about the instruction communicated by the incident controller.
 If the work place is an incident spot ie. XPS SPS department MHD (ware house I/II,
bagging, Engineering. Stores, scrap yard, steel yard, EB storage, project stores, office
etc). security Admin block, work shop QCA, switch yard, substation etc) workers as
co-incident controller and perform/coordinate, the duties of incident controller in
consultation and incident controller/site controller.
 Don’t engage telephone lines of your department, CCR, fire station and security.
 Don’t enquire about status of emergency.
 Avoid panic behavior and over enthusiasm.
 Keep communication Clear, Concise and Complete.
 Considered wind direction while fire fighting, rescue, choosing assembly point and
evacuation.
 Within one hour of given all clear siren, All HOD/HOS shall inform site controller or
incident controller at CCR about the head count for missing persons if any (SPL
employee, visitors, contractor employee) associated with their department.
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 Work permits are suspended after declaration of emergency. Restart all work after “
All Clear” siren. Work shall be done after fresh renewal of work permit from SIC.
 Employee handling emergency must wear all PPE like safety helmet , safety
goggle/face shield, full face/half face respirator, apron, hand gloves, safety shoes,/gum
boots. Special PPE such as Air line respirator, BA set, fire suit, PVC suit etc. shall be
used as per the instruction from SIC/Incident controller.

CHAPTER 8
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MONITORING AND MEASUREMENT OF HSE PERFORMANCE

8.1 Safety Performance Index

Safety performance index reveals the safety level in the organization.

Sr no Key Parameters Weightage factor Statistics Rating

A Number of reportable lost accidents / injuries 10
B Near miss / unusual occurrences 7
C Lost time injuries 7
D Minor / first aid cases 3
E Injury opportunity per audit hour 1
F Compliance with safety committee 1
recommendations
Total points
G Compliance with inspection / audit
recommendations
Total points
Complied points
H Man hours worked by staff / Employees at
works

SAFETY INDEX= ((10 A+7B+7C+3D+E+F+G)/H)*1000

= 0.21

TARGET SAFETY PERFORMANCE INDEX RANGE = 0.3 TO 0.5

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8.2 DEPARTMENT = PRODUCTION PS (POLY STYRENE) DEPARTMENT

Sr No Attribute Numbers Weight Points

age factor
1 No of accidents
1) Reportable -500
-50
2) Non reportable
2 No of accidents -50
3 Non compliance to safety meeting point
Non compliance by target date -5
4 Non compliance to inspection / audit points by target -5
date
5 No of deviations from stipulated condition / procedures
Permit audit
Surprise audit -10
Observation during normal area round -10
-10
6 Statutory compliance
No of default – direct -100
No of default – indirect -10
7 Deficiencies during mock drill / emergencies
No of deficiencies
-10
8 Participation in HSE activities % participation 10
(No of activities * no of participants / total no of
employees * no of activities) 10
9 House keeping -10
No of observations during audits / inspections
10 Generation and existence of unsafe conditions
No of unsafe conditions existed
-20
11 Employee competence in HSE % competence based on
training feedback / evaluations / drills / tests +10
12 Failure to attend training / periodical health check
% failure to attend training
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% failure to attend medical check -10

-10
13 No of suggestion given / implemented participation in +10
suggestion scheme
No of suggestions accepted 20
14 Improvement schemes to reduce hazard levels
No of activities where in risk rating is reduced

20
15 No of findings during internal / external audits
No of NCS
No of audit findings -25
-5
16 Accident/ incident reporting, non reporting within 48 -10
hrs
17 Investigation time delay
Accident / incident investigation time more than 7 days -25
18 Implementation of CAPA from accident / incident
analysis 2
% compliance with target date

8.3 SAFETY TERMINOLOGIES AND MONITORING INDICES

Accident:

The term accident means an unintended occurrence out of and in the course of employment of
a person resulting injury.

Death:

Fatality resulting from an accident disabling injury ( lost time injury ) an injury causing
disablement extending beyond the day of shift on which the accident occurred.

Non – disabling Injury:

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An injury which requires medical / first aid treatment only without causing any disablement
whether temporary or permanent nature

Reportable disabling injury (Reportable lost time injury)

An injury causing death or disablement to an extent as prescribed by relevant statute

As stipulated in rules 115 of Maharashtra Factories Rules 1963 as amended, reportable
accident means.
Accident which cause death to any person or are of serious nature
Accidents which such bodily injury as will prevent or will probably prevent the person injured
from working for a period of 48 hrs immediately following the accident.

Man hours worked:

The total number of employees hours worked by all employees working in the industrial
premises. It includes managerial, supervisory, professional, technical, clerical and other
workers including contractor’s labors.
Severity Rate:

SA = (Man days lost due to lost time injury *1000000) / man hours worked

SB = (Man days lost due to reportable lost time injury *1000000) / man hours worked

Frequency Rate:

FA = (Numbers of lost time injuries *1000000) / man hours worked

FB = (Numbers of reportable lost time injury *1000000) / man hours worked

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Incident Rate:

It is the ratio of the number of injuries due to the number of persons during the period under
review. It expressed as the number of injuries per 1000 persons employed.
The incidence rate may be calculated both for lost time injuries and reportable lost time
injuries as follows.

Lost time injury incident rate =

(Number of lost time injuries *1000) / Average number of persons employed

Reportable Lost time injury incident rate =

(Number of reportable lost time injuries *1000) / Average number of persons employed

8.4 Accident reporting system

For reporting purpose accidents may be classified as follows.

1. Accident which cause

a) Death of any person – to be reported within 4 hrs by telephone or special message to;

i) Local Police Station

ii) Jt.Director (Industrial Safety and Health) Konkan Bhavan, Navi Mumbai.
iii) District Magistrate
iv) Nearest relative of dead person.
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b) Bodily injury that prevents or will probably prevent the person injured from working for a
period of 48 hrs or more, following the accident which can be defined as reportable accident /
lost time. These injuries are reported to Jt.Director (Industrial Safety and health) Mumbai,
CBD with 72 hrs (use form no 24 for reporting)

c) First aid injury marked as FIT case permitting the employee for resuming duties on the
employees for resuming duties on the same day or the following day.

2.Dangerous Occurrence (whether with personal injury or without personnel injury)

A. Bursting of pressure vessel or boilers

B. Fire or explosion
C. Collapse or failure of crane, buildings, pipelines, floor, bridge etc. within the
compound of factory.

Reported to the Jt.Director (Industrial Safety and Health), Mumbai / CBD within 12 hrs in
form 24 A and to Chief Controller of Explosive, Nagpur.
If they happened in their licensed premises

3. Road accident of any nature occurring in any part outside the factory premises. Such
accidents should be dealt as per the directions of HSE department.

4. Poisoning or disease: Such cases should be informed within 4 hrs to the Jt.Director
(Industrial Safety and Health) , Mumbai / CBD , Asst. Commissioner and certifying
Surgeon in form no.25.

5. Electrical Accident: Electrical accidents should be reported by electrical department as per

Indian Electricity Act to the proper authorities.

6. Boiler Accident: It should be reported by operation / maintenance department as per Boiler

Act to the proper authorities.
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7. The reporting of accidents / dangerous occurrence to statutory authorities is the

responsibility of HSE department in consultation with Senior Management.

CHAPTER 9

DISCUSSION AND CONCLUSION

OBSERVATIONS AND RECOMMENDATIONS

During Project Work Period it is observed that in Supreme Petrochem Ltd all the safety
measures are taken. Some of the following points are observed

1) There are eight well trained fire fighters (auxiliary fire squad) are present round the
clock inside the Plant Premises.
2) Done HAZOP studies before adoption or implementation of any new activity.
3) Conducting motivational program regarding safety inside the organization and outside
also like,
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a) HSE Slogans, HSE Posters, HSE Suggestions – On risk reduction , Quality

Improvement, Elimination of Manual Handling Hazards, Improved Productivity
b) Independent HSE field inspection
c) Reporting in Max Behavioral Based Safety observations
d) Maximum near miss reporting
e) Safety Posters Competition in school at Amdoshi Village near the Plant Premises.
4) Conducting Fire and Safety Drill Competitions.
5) Regular basis training programs on Safety and Health issues are provided before going
to work for new employees, contractors, labors.
6) Giving a safety precautions training for visitors before Visiting Plant.
7) Total 4018 days have been worked without reportable accident.
8) Total Lost time accidents free Man – Hours Worked till 31.01.11 – 10.42 Million.
9) All the safety measures are taken during the manufacturing process, loading and
unloading of the Raw Material and finished goods follow all the safety guidelines in
sampling activity of incoming material and final product.
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CHAPTER 10

REFRENCES

1) ISO 9001:2007
2) ISO 14001: 2004
3) BS OHSAS 18001:2007
4) Induction Training Safety Manual of Supreme Petrochem Ltd.
5) Records of SPL
6) Images from google search
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