7.0 Risk Assessment & DMP

Transcription

1 7.0 Risk Assessment & DMP 7.1 Risk Assessment Risk analysis deals with the identification and quantification of risks resulting from the hazards present in the factory which will lead to accidents. Hazard analysis involves the identification and quantification of the various hazards that are likely to occur in the industry. Both hazard and risk analysis require a very detailed design and engineering information. The various hazard analysis techniques that may be applied are Hazard and Operability (HAZOP) studies, Fault - Tree Analysis (FTA), Event Tree Analysis and Failure and Effects Mode Analysis. The scope of study includes the study of proposed operations, storage and handling of raw materials with respect to Hazard Identification, Risk Assessment and preparation of Emergency Preparedness and Response Plan and Disaster Management Plan for natural calamities. Hazard Identification using PHA Techniques : Hazard is present in any system, plant or process that handles flammable materials. The mere existence of hazards, however, does not automatically imply the existence of risk. Screening and ranking methodologies based on Preliminary Hazard Analysis (PHA) techniques have to be adopted at different stages of the project before risk can be evaluated. Plant Configuration : The Cement Grinding Unit is proposed for 2.0 MTPA Slag/OPC/PPC/PSC. Raw Material/Fuel & Transportation : Clinker will be sourced from RCL Cement Plants in AP &TN States and will be transported by covered trucks the Plant. Additives like Gypsum and Slag will be transported through covered trucks and Fly ash will be transported through bowsers/bulkers. High Speed Diesel (HSD) of 500 Lits. in about 3 barrels for standby DGs operations will be there within the premises. Hazard Classification based on Inherent Hazards of HSD : An inventory of the chemical stored was made and the chemical properties, including flammability and explosion characteristics, have been considered for hazard classification. The hazardous properties of HSD are : Specific Gravity 0.85 Specific Heat, kj/kg. K 0.48 Boiling point ( C) Flash point ( C) 51 Heat of Evaporation, kj/kg 244 Heat of Combustion, kj/kg NH 0 NFPA rating* NF 2 NR 0 MF 10 Fire Explosion Index (Medium) Toxicity Index 2.52 (Low) Threshold Quantity as per GOI 1000 Tons for Application of Rules (Rules 5, 7-15) Tons (Rules 10-12) *NFPA classification for Health, Flammability & Reactivity of a chemical on a scale of 0-4 least to worst. Thus, the HSD storage will be less than the Threshold capacity.

2 Based on Fire & Explosion Index : The next stage of hazard identification involves the estimation of Fire & Explosion Indices for the unit in the facility to give the relative severity of the unit from the fire angle. These are evaluated from the knowledge of the Material Factor, General Process Hazard (GPH) and Special Process Hazard (SPH) factors. Material Factor (MF) is the measure of the energy potential of a particular chemical or its mixture with other chemicals. GPH and SPH are evaluated by taking into account the exotherm or endotherm of a reaction, material handling and transfer hazards, accessibility, severity of process conditions and possibilities, dust and other explosions, inventory level of flammable material, etc. The F&EI value is then calculated as the product of MF, GPH and SPH. Detailed fire and explosion indexing were carried out for the major sections of the proposed plant. Fire & Explosion Indices (F&EI) for all the storage unit in the Plant have been estimated to give the relative degree of severity of the units using the criteria given below : Index Range Degree of Hazard 1-60 Light Moderate Intermediate Heavy >159 Severe Analysis of F&EI Results : A summary of the results including the material factors for each of the chemicals stored on site is given in the following Table. F& EI Calculations Material Fire & Explosion Units Max. Qty. Degree of Hazard Factor MF Index (F&EI) HSD Barrels 0.5 KL Low From the results of the F&EI studies, it can be observed that the storage unit have F&EI values less than 100 and fall under the low degree of fire and explosion hazard. HAZOP Studies : Hazard and Operability Study (HAZOP) is a powerful tool for identifying hidden design inadequacies and understanding operational mistakes that may lead to incidents or accidents. This will, in turn, help in taking suitable remedial measures. Cause - Consequence Analysis : Credible accident scenarios (CAS) were initially constructed followed by quantification using Cause-Consequence Analysis (CCA) for the identified scenarios. No explosion is possible as Quantity below explosive limits. Consequence output for Pool Fire due to outflow of HSD Service HSD Quantity 0.5 KL Probability 4.10 x 10-7 Circular Pool Rectangular Pool Out flow quantity, m Diameter/width of Pool, m

3 Intensity of Radiation at the centre of cloud Damage Distances for the Heat Radiation, m: i. Severe damage to life & property (within cloud) - - ii. 100% Lethality (37.5 kw/m 2 ) iii. 50% Lethality (25 kw/m 2 ) iv. 1% Lethality or severe burns (12.5 kw/m 2 ) v. First degree burns (4.5 kw/m 2 ) vi. No discomfort (1.6 kw/m 2 ) Nearest/Minimum Distance The damage contour cannot be given as the impact is confined at the Storage Area area itself. Probability of Occurrence : The overall probability of occurrence was found to be extremely low (10-7 ). 7.2 Disaster Management Plan Disasters are of natural as well as man-made nature. Natural Disasters include Earthquakes, Floods, Cyclones, Tsunami, River Erosion, Landslides/, Forest Fires, etc. and the Man Made Disasters include Nuclear, Chemical, Mines, Biological, Cyber Terrorism, Environmental Disasters, etc. The disasters will be handled in a proper manner with the help of local administration immediately on occurrence. Further support required, depending upon the severity, will be provided by District/State/National level Authorities. The resources available in the Plant will be extended to the maximum possible extent by the project proponent in the event of occurrence of any such natural disasters to provide rescue, first aid, ambulance service, medicines, shelter & food, to the affected people. DMP Cell : Disaster Management Plan for an industrial Unit is necessarily a combination of various actions which are to be taken in a very short time but in a present sequence to deal effectively and efficiently with any disaster, emergency or major accident with an aim to keep the loss of men, material, Plant / Machinery etc. to the minimum. A cell has to be formed for an effective implementation of disaster management plan. The main functions of the DMP Cell includes : Identification of various types of expected disasters depending upon the type of the industrial unit. Identification of various groups, agencies departments etc, necessary for dealing with a specific disaster effectively. Preparation by intensive training of relevant teams/groups within the organization to deal with a specific disaster and kept them in-readiness. Established of an early detection system for the disasters. Developed of a reliable instant information / communication system. Organization and mobilization of all the concerned departments/ organizations/ groups and agencies instantly when needed

4 Emergency Planning for Disaster Due to Fire : A major disaster that can be expected in any plant might be due to fire. Oil storgage, all conveyor lines, etc, are the likely areas for which plan is outlined to deal with any eventuality of fire. Stores, workshop, canteen and Administration Building have also been included. Fire Protection System : The following Fire Protection system are provided in the existing Grinding Unit : Hydrant system consisting of piping, valves instrumentation, hoses, nozzles and hydrants, valves etc to cover the entire plant including all important auxiliaries and buildings Portable extinguishers such as pressurized water type, carbon dioxide type and foam type at strategic locations throughout the plant. Automatic Medium Velocity water Sprinkler system for coal conveyors and transfer points. Fire water reservoir will be part of the water storage tank Fire water pumps (Fire water reservoir is part of the main water reservoir) : AC motor driven fire water pumps for hydrant, medium velocity water spray system Diesel engine driven pump as stand by for the above. Jackey pump 1 no. (AC motor driven) for maintaining pressure Fire Alarm System : Cable areas, control room will be provided with Ionization and photo electric smoke detectors. The system will be designed as per the requirements of Tariff Advisory Committee (TAC) of Insurance companies of India. Inspection : Fire alarm panel (electrical) would cover the entire plant. Fire Extinguishers in Fire Stations and machines and other places are periodically inspected by the inspection group. LOCATION AND QUANTITY OF FIRE EXTINGUISHER = DCP - 5 KG 1 DCP 5 kg CCR 1 st Flr.PCC Room 2 DCP 5 kg CCR 1 st Flr.PCC Room 3 DCP 5 kg CCR 1 st Flr.PCC Room 4 DCP 5 kg CCR 1 st Flr.PCC Room 5 DCP 5 kg CCR 1 st Flr.PCC Room 6 DCP 5 kg Store Building (New) 7 DCP 5 kg Work Shop 8 DCP 5 kg 132 kv Panel Room 1 st Floor 9 DCP 5 kg 132 kv S.S. Trf. Yard 10 DCP 5 kg LRS ROOM 11 DCP 5 kg Bag Go-down Ground Floor 12 DCP 5 kg MCC 5 Gr. Floor Packing Plant 13 DCP 5 kg Weight Bridge New 14 DCP 5 kg Weight Bridge Old 15 DCP 5 kg Security Office

5 LOCATION AND QUANTITY OF FIRE EXTINGUISHER = DCP - 9 KG 1 DCP 9 kg CCR GR.FLR (ENTRY) Corridor 2 DCP 9 kg D.G. Set 3 DCP 9 kg D.G. Set 4 DCP 9 kg Lighting Trf. 5 DCP 9 kg Store Building (New) 6 DCP 9 kg Store Building (New) 7 DCP 9 kg Admin Building / First aid Centre 8 DCP 9 kg 132 kv sub station 9 DCP 9 kg 132 kv sub station 10 DCP 9 kg 132 kv sub station 11 DCP 9 kg 132 kv sub station 12 DCP 9 kg Compressor Room 13 DCP 9 kg Compressor Room 14 DCP 9 kg Cement Mill Gr. Floor 15 DCP 9 kg Cement Mill Gr. Floor 16 DCP 9 kg Cement Mill 10 Mtr. Floor 17 DCP 9 kg Cement Mill 10 Mtr. Floor 18 DCP 9 kg Cement Mill 13 Mtr. Floor 19 DCP 9 kg Cement Mill Gr. Floor 20 DCP 9 kg Cement Mill Gr. Floor 21 DCP 9 kg Cement Silo 1 22 DCP 9 kg Cement Silo 2 23 DCP 9 kg Bag Godown Ground Floor 24 DCP 9 kg Bag Godown Ground Floor 25 DCP 9 kg Packing Plant 2 nd Floor (Mech. Maint.) 26 DCP 9 kg Packing Plant 2 nd Floor Control Room (I/S) 27 DCP 9 kg Packing Plant 2 nd Floor (Near Packer) 28 DCP 9 kg Packing Plant 2 nd Floor (Near Packer) 29 DCP 9 kg Packing Plant 3 rd Floor Near Stair 30 DCP 9 kg Packing Plant 3 rd Floor Near Stair 31 DCP 9 kg Packing Plant 4 th Floor Near Stair 32 DCP 9 kg Loading Point (Bag) 33 DCP 9 kg Loading Point (Bag) 34 DCP 9 kg Admin Building /First aid Centre 35 DCP 9 kg Lubrication Shed 36 DCP 9 kg Clinker Silo 2 37 DCP 9 kg Old Store 38 DCP 9 kg Fly ash silo 39 DCP 9 kg Work Shop 40 DCP 9 kg Work Shop 41 DCP 9 kg Security Office 42 DCP 9 kg Security Office 43 DCP 9 kg Security Office 44 DCP 9 kg Security Office 45 DCP 9 kg Security Office LOCATION AND QUANTITY OF FIRE EXTINGUISHER = DCP - 10 KG 1 DCP 10 kg CCR GR.FLR (ENTRY) Corridor 2 DCP 10 kg Packing Plant 2 nd Floor Control Room 3 DCP 10 kg Loading Point (Bag) 4 DCP 10 kg Security Office

6 LOCATION OF FIRE EXTINGUISHER = DCP - 50 KG 1 DCP 50 kg Cement Mill 2 DCP 50 kg Packing Plant 3 DCP 50 kg Bag Godown LOCATION AND QUANTITY OF FIRE EXTINGUISHER = FOAM - 9 Lt. 1 Foam 9 lt. Store 2 Foam 9 lt. Cement Mill Inlet Side 3 Foam 9 lt. Cement Mill Outlet Side 4 Foam 9 lt. Security Office LOCATION AND QUANTITY OF FIRE EXTINGUISHER = CO2-4.5 KG 1 CO2 4.5 kg CCR 2 nd Floor Corridor 2 CO2 4.5 kg CCR 2 nd Floor Corridor 3 CO2 4.5 kg CCR 2 nd Floor Corridor 4 CO2 4.5 kg CCR 2 nd Floor Corridor 5 CO2 4.5 kg CCR ROOM 2 nd Floor 6 CO2 4.5 kg CCR ROOM 2 nd Floor 7 CO2 4.5 kg Conference Room (CCR) 8 CO2 4.5 kg CCR 1 st Floor Shift Room Corridor (PCC) 9 CO2 4.5 kg CCR 1 st Floor Shift Room Corridor (PCC) 10 CO2 4.5 kg CCR 1 st Floor MCC Room 11 CO2 4.5 kg CCR 1 st Floor MCC Room 12 CO2 4.5 kg CCR Entry Gr. Floor Corridor 13 CO2 4.5 kg CCR Entry Gr. Floor Corridor 14 CO2 4.5 kg P & QC Lab Lobby(CHEM) 15 CO2 4.5 kg P & QC Lab Lobby(PHY) 16 CO2 4.5 kg Store (Office Area) 17 CO2 4.5 kg Store (Inside Material Store) 18 CO2 4.5 kg CDS 19 CO2 4.5 kg 132 KV SUB STAN. (1 st Floor Panel Room) 20 CO2 4.5 kg 132 KV SUB STAN. (1 st Floor Panel Room) 21 CO2 4.5 kg 132 KV SUB STATION (TRF. YARD) 22 CO2 4.5 kg 132 KV SUB STATION (TRF. YARD) 23 CO2 4.5 kg Cement Mill Ground Floor 24 CO2 4.5 kg Cement Mill Ground Floor 25 CO2 4.5 kg Cement Mill Outlet Side (H.T. Motor) 26 CO2 4.5 kg Cement Mill Outlet Side (H.T. Motor) 27 CO2 4.5 kg LRS Room 28 CO2 4.5 kg MCC 5 Gr. Floor Packing Plant 29 CO2 4.5 kg MCC 5 Gr. Floor Packing Plant 30 CO2 4.5 kg Packing Plant 2 nd Floor Control Room 31 CO2 4.5 kg Cement Mill Inlet Side 32 CO2 4.5 kg Security Office 33 CO2 4.5 kg Security Office 34 CO2 4.5 kg Security Office

7 The temperature of the bagfilters will be regularly measured and recorded. If the temperature exceeds 80 0 C, inert gas quenching would be carried out. 7.3 Onsite Emergency Plan To meet any major emergency, the following on site plan are laid down. Emergency personnel s responsibility during normal working hours are as follows: Emergency telephone number boards are displayed at vital points of the Plant. Emergency Contact Numbers of the District Disaster Mangment Authority is also being maintained to handle any Distaer with the Coordination of the District Authorities. ***