Mock Exercise on Chemical

(Industrial Disaster)
Indian Oil Corporation Ltd.
LPG Bottling Plant, Devanagunthi

Vijay Kumar C.
Sr. Plant Manager
 Profile of Devanagunthi LPG Bottling Plant

Plant is situated at Devanagunthi.

45 Km from Banglore Dist HQ.

Neighbouring Industries
1. IOCL (Terminal) – 1.0 Km away
2. BPCL (Terminal) – 1.25 Km away
3. HPCL (Installation)- 1.5 Km away
4. Petronet MHB Limited-1.25 Km away
Indane bottling plant
Layout
 Major Activities
LPG receipt by rail and road,
Storage, bottling & Despatch

Loading of LPG bullet trucks for

Auto LPG Dispensing stations and
other bottling plants
 Bulk LPG Receipt

 Source of Receipt : Rail Wagons from

Mangalore and
Hazira and road tankers
from CPCL
 Supply Area : Bangalore city,
Peripheral markets
of Bangalore city
 LPG BOTTLING PLANT, DEVANAGUNTHI –
MAH INDUSTRY

•Bottling Capacity
Existing : 138 TMTPA
Proposed: 232 TMTPA

•Total Land Area : 93.35 ACRES

•Green belt Area : 25 ACRES

 Bulk LPG Storage Facilities

Sphere 2 x 1400 MT

Existing Bullets 2 x 100 MT

Bullet 1 x 150 MT

Additional Mounded 3 x 1200 MT

Bullets
Existing 3150 MT After Augumentation
6750MT
 Bulk Receipt Facilities

By Road
• 12 nos. Tank lorry unloading bays
with unloading arms.

By Rail
• Two spur full rake gantry unloading
facility. Equipped to unload both
conventional and BTPGLN wagons.
 Population in nearby Villages
Sl. No. Name of the village Population
1 Kacharakanahalli 437
2 Dasarahalli 458
3 Geddlapura 163
4 Dodda Donnasandra 1677
5 Kannekal 410
6 Makkanahalli 1465
7 Devalapura 446
 Material Safety Data
IDENTITY OF MATERIAL :
Product Name LPG. Bottle gas, UN No. 1075
Liquefied
hydrocarbon gas. Label / Class Red: Flammable
Trade name LPG Liquid / 2.1

Formula Mixture of HAZCHEM Code 2WE

propane and
butane
PHYSICAL AND CHEMICAL PROPERTIES

Physical State Gas Boiling Point / Range , deg. 1 Vapor Pressure 16.9 kg/cm2
C at 65 deg. C,
Appearance Colourless Melting / Freezing Point , 138
deg. C
Odor Odorless/stanche Vapor Density (Air =1) 1.5 to 2.0
d
Solubility in Water Insoluble Specific Gravity , 20 deg. C 0.53 to 0.57

Calorific Value 11400 Dyn. Viscosity (PA.S 30

(Kcal / Kg.) deg. C)
Molecular Weight.

FIRE AND EXPLOSIVE DATA

Explosivity Highly explosive Auto Ignition Temp. deg. C 405-450

Flammability Dangerous Explosive Limits , % 1.8 – 9.6

Extinguishing Media CO2, DCP. Water spray may be used to control and confine LPG fires.

Special Procedures Do not attempt o extinguish fire until leak has been shut off. For small fire use dry chemicals. Let large fires burn if not heating
the container. When exposed to heat and flame, containers may rupture due to BLEVE
 Risk Analysis

• Based on three steps

• What can go wrong?

(Hazard identification)
• How often it can go wrong?
(Failure frequency)
• What are the effects of consequences?
(Effect and damage calculations)
 MODES OF FAILURE OF
PRODUCT STORAGE VESSELS

• Material and construction failures

• Corrosion

• Gasket failures
 PRINCIPAL HAZARDS - LPG

Flammability & Explosion

 Jet Fire
 Pool Fire
 BLEVE
 Flash Fire
 UVCE
 Asphyxia
 Cold Burns
 Metal brittleness due to Low temperature
 Consequences Analysis

Damages are caused due to

• Heat radiation
• Overpressure effect from explosions
• Toxic effect
 Exposure time, heat radiation and
damage levels

Intensity of Exposure
radiation (Kw/ time in % Lethality
m2 Seconds
37.5 28 100% Lethality
12.5 28 1% Lethality /100 % first deg.burns
4 28 1% first degree burns
 Damage distance for BLEVE

Storage LPG in BLEVE Radiation distance in meters to

Vessel MT Radious
(m) 37.5 KW/m2 12.5 Kw/m2 4.0 KW/m2
HORTON
1400 273 524 908 1830
SPHERE
Damage contour for catastrophic failure of 1400 MT sphere
 Zone
Zone A – 37.5 Kw/M2 – 524
A
M rad – 100% lethality
(Plant personnel)
 Zone B
Zone - B

12.5 Kw/M2 – 908 M rad – 1% lethal

(Kanekkal Village)
 Zone C

Zone C

- 4.0 Kw/M2
- 1830 M
- First Degree burns
(Kacharakanahalli, Dasarahalli,
Giddapura,Doddasandra)
 Risk intensity
Radiation Distance in
Affected population
Zone (KW/M2) 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
Zone C 4 1830
Makanahalli 1582
Devalapura 482
Vagatta 1103
Neighboring
400
industries
 Mitigation measures

 Gas Monitoring System

 Air/Vapor Extraction System
 Remote control Valve
 Emergency Trip Button
 Manual Call point
 Quartzoid bulb detector.
 Fire Fighting Facilities
FIRE WATER STORAGE TANKS
• 3 Nos. of 4000 KL capacity each
FIRE PUMPS
• 8 Nos. diesel driven water pumps of 410
CUM / Hr. capacity each.
JOCKY PUMPS
• 2 Nos. of 24 Cum /Hr.
 Fire Fighting Facilities

•Ring main hydrant system

• 57 double hydrant points
• 46 water monitors
• 4 long range monitors covering
truck Parking Area.
•Auto sprinkler system for
Sheds , TLD , Storage Vessels
and Tank Wagon Gantry.
Additional Safety Features

•Carousel Inter locked with Vapour extraction

system
•Remote operated valves for LPG pipe line
inter locked with sprinkler system
•LPG and Air compressors inter locked with
cooling water pumps.
•Emergency trip buttons and Manual call
stations at strategic points.
•ROV closure of Storage Vessel interlocked
with HLAs.
 On-site Emergency Plan

•Detailed on-site emergency

management plan prepared and
approval obtained from Dept. of
Factories.
•Emergency Response Drills
(ERDs) are conducted twice in a
year.
•Mock drills are conducted
every month & shortcomings are
addressed.
•Mutual aid arrangement with
neighbouring industries.
 Mutual Aid
To Assist its neighbouring industries in responding to
emergencies that may occur either on-site or off-sites.

Mutual Aid agreemnt

Member Roles and responsibilities
IOCL, Terminal Traffic control and smooth evacuation of trucks
BPC Terminal Assist the Rescue Team members
HPCL Installation Assist Auxilliary team members
PETRONET Assist Auxilliary team members
 Fire Fighting Organisation Chart
FIRE IN CHIEF: Sr. Plant Manager
Alternate FIRE IN CHIEF: Manager (P)

FIRE COMBAT TEAM AUXILIARY TEAM RESCUE TEAM

Team In Charge: Floor Officer Team In Charge: Team In Charge: Asst.

Manager (P) Manager (F)
Alternate team Incharge: Officer Alternate team Incharge: S&D Alte rnate te am Incharge :
(Bulk Operations) officer Accounts officer-II
Assisted by: Assisted by: Assisted by:

1.     Tally operator 1 1.     Dy. Manager (P) 1.     A O - II

2.     Tally operator 2 2.     Safety Officer 2.     Sr. Assistant

3.     Segregation 1 3.     Maintenance Officer

4.     Segregation 2 4.     Maint enanc e operator 1

5. Pump House 1
     5.     Maint enanc e operator 2
6.     TLD 6.     Employees on Relief

7.     Carousel Tare wt. 1 7.     Security guard 3

(Stores)
8.     Carousel Tare wt. 2 8. Security guard 4
9.     Evacuation (Gate –2)
10.            ICU
11.            Gantry operator 1
12.            Gantry operator 2
13.            Security guard 1
(Main gate)
14.            Security guard 2 (Main
gate)
15.            Security guard 3
(Patrolling)
 Emergency Transport facility

 Dedicated Vehicle for emergency

transportation is available round the clock.

 Between 08.00 hr to 17.15 hr one more

vehicle also will be available.
 Shutting down procedure

Shutting down is done through the following

means:
 Emergency trip Buttons & Manual Call
Point
 Remote Control Valves

 Quartzoid Bulb detector.

 On site Emergency Structure
The basic concept of this plan is to provide a comprehensive
approach for managing emergencies. Four elements of this
plan are
 Prevention - incorporates all those activities that
eleminate the probabilityof disaster occuring on-site.
 Preparedness - includes all activities necessary to ensure
a high degree of readiness
 Response- measures taken during an incident which
minimise damage to life and property.
 Recovery – includes those short and long-term activities
that return all systems to normal operations.
 Declaration of Emergency
Upon declaration of Emergency Sr.Plant Manager

 makes initial assessment of incident and determine the need for

evacuation.
 ensure that all personnel are accounted for.
 ensure that outside agencies are communicated as per DMP as
follows:
 Dy. Commisioner
 Regional, State & Head Offices
 Fire Dept
 Law & Order
 Revenue Dept
 Local Panchayat
 Railways
 KPTCL
 Medical Dept.
 Public Awareness Programs
Various programs being conducted
For creating public awareness to the
Neighboring villages.