Download - Mock Drill Oil Bottling Plant Ban Gal Ores
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Mock Exercise on Chemical(Industrial Disaster)
Indian Oil Corporation Ltd.
LPG Bottling Plant, Devanagunthi
Vijay Kumar C.
Sr. Plant Manager
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Profile of Devanagunthi LPG Bottling Plant
Plant is situated at Devanagunthi.
45 Km from Banglore Dist HQ.
Neighbouring Industries
1. IOCL (Terminal) 1.0 Km away2. BPCL (Terminal) 1.25 Km away
3. HPCL (Installation)- 1.5 Km away
4. Petronet MHB Limited-1.25 Km away
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Indane bottling plantLayout
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Major Activities
LPG receipt by rail and road,Storage, bottling & Despatch
Loading of LPG bullet trucks forAuto LPG Dispensing stations andother bottling plants
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Bulk LPG Receipt
Source of Receipt : Rail Wagons fromMangalore and
Hazira and road tankersfrom CPCL
Supply Area : Bangalore city,Peripheral marketsof Bangalore city
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LPG BOTTLING PLANT, DEVANAGUNTHI MAH INDUSTRY
Bottling Capacity
Existing : 138 TMTPA
Proposed: 232 TMTPA
Total Land Area : 93.35 ACRES
Green belt Area : 25 ACRES
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Bulk LPG Storage Facilities
Sphere 2 x 1400 MT
Bullets 2 x 100 MT
Bullet 1 x 150 MT
Additional Mounded 3 x 1200 MT
Bullets
Existing 3150 MT After Augumentation
6750MT
Existing
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By Road
12 nos. Tank lorry unloading bayswith unloading arms.
By Rail
Two spur full rake gantry unloadingfacility. Equipped to unload both
conventional and BTPGLN wagons.
Bulk Receipt Facilities
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Population in nearby VillagesSl. No. Name of the village Population
1 Kacharakanahalli 437
2 Dasarahalli 4583 Geddlapura 163
4 Dodda Donnasandra 1677
5 Kannekal 410
6 Makkanahalli 1465
7 Devalapura 446
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Material Safety DataIDENTITY OF MATERIAL :
Product Name LPG. Bottle gas,Liquefied
hydrocarbon gas.
UN No. 1075
Label / Class Red: Flammable
Liquid / 2.1Trade name LPG
Formula Mixture of
propane and
butane
HAZCHEM Code 2WE
PHYSICAL AND CHEMICAL PROPERTIES
Physical State Gas Boiling Point / Range , deg.
C
1 Vapor Pressure
at 65 deg. C,
16.9 kg/cm2
Appearance Colourless Melting / Freezing Point ,
deg. C
138
Odor Odorless/stanche
d
Vapor Density (Air =1) 1.5 to 2.0
Solubility in Water Insoluble Specific Gravity , 20 deg. C 0.53 to 0.57
Calorific Value
(Kcal / Kg.)11400 Dyn. Viscosity (PA.S 30
deg. C)
Molecular Weight.
FIRE AND EXPLOSIVE DATA
Explosivity Highly explosive Auto Ignition Temp. deg. C 405-450
Flammability Dangerous Explosive Limits , % 1.8 9.6
Extinguishing Media CO2, DCP. Water spray may be used to control and confine LPG fires.
Special Procedures Do not attempt o extinguish fire until leak has been shut off. For small fire use dry chemicals. Let large fires burn if not heating
the container. When exposed to heat and flame, containers may rupture due to BLEVE
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Risk Analysis
Based on three steps
What can go wrong?
(Hazard identification)
How often it can go wrong?
(Failure frequency)
What are the effects of consequences?
(Effect and damage calculations)
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MODES OF FAILURE OF
PRODUCT STORAGE VESSELS
Material and construction failures
Corrosion
Gasket failures
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PRINCIPAL HAZARDS - LPG
Flammability & Explosion
Jet Fire
Pool Fire
BLEVE
Flash Fire
UVCE
Asphyxia
Cold Burns
Metal brittleness due to Low temperature
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Consequences Analysis
Damages are caused due to
Heat radiation
Overpressure effect from explosions
Toxic effect
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Exposure time, heat radiation anddamage levels
Intensity of
radiation (Kw/
m2
Exposure
time in
Seconds
% Lethality
37.5 28 100% Lethality
12.5 28 1% Lethality /100 % first deg.burns4 28 1% first degree burns
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Damage distance for BLEVE
37.5 KW/m2 12.5 Kw/m2 4.0 KW/m2
HORTONSPHERE
1400 273 524 908 1830
Storage
Vessel
LPG in
MT
BLEVE
Radious(m)
Radiation distance in meters to
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Damage contour for catastrophic failure of 1400 MT sphere
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Zone AZone A 37.5 Kw/M2 524
M rad 100% lethality
(Plant personnel)
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Zone B
12.5 Kw/M2 908 M rad 1% lethal
(Kanekkal Village)
Zone - B
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Zone C
- 4.0 Kw/M2
- 1830 M
- First Degree burns(Kacharakanahalli, Dasarahalli,
Giddapura,Doddasandra)
Zone C
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Risk intensity
ZoneRadiation
(KW/M2)
Distance in
meter
Zone A 37.5 524 Plant Personnel 80
Zone B 12.5 908 Kanekal village 443
Kacharaknahalli 472
Dasarahalli 495
Gidlapura 176
Donnasandra 1811
Makanahalli 1582
Devalapura 482
Vagatta 1103
Neighboring
industries400
Affected population
Zone C 4 1830
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Gas Monitoring System
Air/Vapor Extraction System
Remote control Valve
Emergency Trip Button
Manual Call point
Quartzoid bulb detector.
Mitigation measures
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FIRE WATERSTORAGE TANKS
3 Nos. of 4000 KL capacity each
FIRE PUMPS
8 Nos. diesel driven waterpumps of 410 CUM/ Hr. capacity each.
JOCKY PUMPS
2 Nos. of 24 Cum /Hr.
Fire Fighting Facilities
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Ring main hydrant system
57 double hydrant points
46 water monitors 4 long range monitors coveringtruck Parking Area.
Auto sprinkler system forSheds
, TLD , Storage Vessels andTank Wagon Gantry.
Fire Fighting Facilities
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Carousel Inter locked with Vapour extractionsystem
Remote operated valves for LPG pipe lineinter locked with sprinkler system
LPG and Air compressors inter locked withcooling waterpumps.
Emergency trip buttons and Manual callstations at strategic points.
ROV closure ofStorage Vessel interlockedwith HLAs.
Additional Safety Features
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Detailed on-site emergencymanagementplanprepared andapproval obtained from Dept. ofFactories.
Emergency Response Drills(ERDs) are conducted twice in ayear.
Mock drills are conducted
every month & shortcomings areaddressed.
Mutual aid arrangement withneighbouring industries.
On-site Emergency Plan
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Mutual Aid
To Assist its neighbouring industries in responding to
emergencies that may occur either on-site or off-sites.
Member Roles and responsibilities
IOCL, Terminal Traffic control and smooth evacuation of trucks
BPC Terminal Assist the Rescue Team membersHPCL Installation Assist Auxilliary team members
PETRONET Assist Auxilliary team members
Mutual Aid agreemnt
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Fire Fighting Organisation Chart
FIRE COMBAT TEAM AUXILIARY TEAM RESCUE TEAM
Team In Charge: Floor Officer Team In Charge:
Manager (P)
Team In Charge: Asst.
Manager (F)
Alternate team Incharge: Officer
(Bulk Operations)
Alternate team Incharge: S&D
officer
Alternate team Incharge:
Accounts officer-II
Assisted by: Assisted by: Assisted by:
1. Tally operator 1 1. Dy. Manager (P) 1. A O - II2. Tally operator 2 2. Safety Officer 2. Sr. Assistant3. Segregation 1 3. Maintenance Officer4. Segregation 2 4. Maintenance operator 15. Pump House 1 5. Maintenance operator 26. TLD 6. Employees on Relief
7. Carousel Tare wt. 1 7. Security guard 3(Stores)
8.Carousel Tare wt. 2 8. Security guard 4
9. Evacuation (Gate 2)10. ICU11. Gantry operator 112. Gantry operator 213. Security guard 1(Main gate)
14. Security guard 2 (Maingate)
15. Security guard 3(Patrolling)
FIRE IN CHIEF: Sr. Plant ManagerAlternate FIRE IN CHIEF: Manager (P)
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Emergency Transport facility
Dedicated Vehicle for emergency
transportation is available round the clock.
Between 08.00 hr to 17.15 hr one more
vehicle also will be available.
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Shutting down procedure
Shutting down is done through the following
means:
Emergency trip Buttons & Manual Call
Point
Remote Control Valves
Quartzoid Bulb detector.
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On site Emergency Structure
The basic concep
t of thisp
lan is top
rovide a comp
rehensiveapproach for managing emergencies. Four elements of this
plan are
Prevention - incorporates all those activities that eleminate
theprobabilityof disaster occuring on-site.
Preparedness - includes all activities necessary to ensure
a high degree of readiness
Response- measures taken during an incident which
minimise damage to life and property.
Recovery includes those short and long-term activitiesthat return all systems to normal operations.
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Declaration of Emergency
Upon declaration of Emergency Sr.Plant Manager
makes initial assessment of incident and determine the need for
evacuation.
ensure that all personnel are accounted for.
ensure that outside agencies are communicated as per DMP asfollows:
Dy. Commisioner
Regional, State & Head Offices
Fire Dept
Law & Order
Revenue Dept
Local Panchayat
Railways
KPTCL
Medical Dept.
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Public Awareness Programs
Various programs being conductedFor creating public awareness to the
Neighboring villages.
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