DISASTER MANAGEMENT PLAN of Bellary District Deputy Director of Factories Bellary

DISASTER MANAGEMENT PLANof

Bellary District

Deputy Director of Factories Bellary

Disaster Management Plan of Bellary 2

Bellary District Map

Bellary Industrial Map


BELLARY DISTRICT

Bellary District came into existence in 1800 A.D.

It has 7 Taluks

Bellary, Hospet, Sandur, Siraguppa, Kudligi,

Hadagli & Hagaribommanahalli.

Population of Bellary District – About 20 lakhs

Total geographical area – 8,13,196 Hectares

Forest area – 97107 Hectares


Rice and Oil Mills 154

Cotton Ginning 44

Sponge Iron/ Rolling Mills 47

Integrated steel plants 1

Power plant 5

Coke oven plant 2

Industrial Gases 3

Sugar Plant 2

Others 96

Total 354

IndustriesRegistered under Factories Act.

FACTORIES

Major Accident Hazard Factories – 04

Potentially Hazard Factories – 05

Hazardous Factories – 57


Major Accident Hazard Industries

1. M/s. J S W Steels Ltd. Toranagallu

2. M/s. Jindal Prax Air Oxygen Co. Ltd. Toranagallu.

3. M/s. Bellary Oxygen Co. Ltd, Toranagallu.

4. M/s. B O C India (P) Ltd, Toranagallu

All are located in the JSW complex, Toranagallu.


Potentially Hazard Industries.

1. M/s. J S W Energy Ltd, Toranagallu.

2. M/s. Bellary Thermal Power Station,Kudathini.

3. M/s. Monsanto India Ltd, Bellary.

4. M/s. United Galva (P) Ltd. Bellary

5. M/s. JAMIPOL, Toranagallu.


Hazardous Industries

Total industries – 57

Mainly Sponge Iron, Hydel power, Coke oven

plants, Oxygen Re-filling plants, etc,.

On-Site Emergency Plan of all the hazardous

industries have been approved by Director of

Factories & Boilers, Bangalore


Inventory of hazardous materials in the district

1. M/s. J.S.W. Steels ltd., Toranagallu.

LPG – 2 x 18 MT.

Gas Holders containing Carbon Monoxide i) Corex Gas Holder : 1,00,000 M3

ii) Blast furnace –Gas Holder : 50,000 M3

iii) LD Gas Holder : 30,000 M3

iv) Blast furnace - Gas Holder : 50,000 M3

v) Coke oven -Gas Holder : 50,000 M3

vi) LD Gas Holder : 50,000 M3

Total = 3,30,000 M3

• Chlorine – 6 x 1 MT

• Hydrogen Gas Holder – 3 x 81 M3


2.M/s. Jindal Prax Air Oxygen Co. Ltd, Toranagallu

Liquid oxygen – 1000 MT

3. Bellary Oxygen Company Ltd,. Toranagallu

Liquid Oxygen – 1000 MT

4. BOC India Ltd,. Thoranagallu

Liquid Oxygen – 1000 MT


Potentially Hazard Industries

1. JSW Energy Ltd,. Thoranagallu

Chlorine – 6 x 1 MT

2. Bellary Thermal Power Station

Chlorine – 8 x 1 MT

3. Monsanto India Ltd,. Bellary

LPG – 2 x 7 MT


4. United Galva Pvt. Ltd,. Bellary

LPG – 2 x 7.46 MT

5. United Spirits Ltd,. Hospet

Spirit – 2.0 Million liters

6. JAMIPOL Thoranagallu

Calcium Carbide – 500 MT


Worst Case Scenarios In The District

Release of toxic and flammable gas

• Failure of 1,00,000 M3 Corex/Blast Furnace Gas holder

containing carbon monoxide (CO). (Threshold Limit

Value(TLV) 50 ppm)

Release of toxic gas

Rupture of chlorine tonner and release of 900 kgs of

chlorine Leakage. (Threshold Limit Value 3ppm)


Vapour cloud explosion

Boiling Liquid expanding Vapor Explosion (BLEVE) -

Rupture of 18 MT LPG Bullet- explosion and fire.

Hydrogen Gas explosion

Explosion of 81 cum hydrogen bullet

Explosion of cryogenic liquid tank

Rupture of liquid Oxygen tank causing Cold Burns


Hazard Index Matrix of Bellary Dist

Name of the industry

Toxic release

Explosion Fire Cold burn

JSW Steels Ltd √ √ √

JPOCL √

Bellary Oxygen Co.Ltd

√

BOC India Ltd √

District Administration

Bellary District Crisis Group constituted &

meetings conducted Periodically.

Prepared Off-Site Emergency Plan for Bellary

district in the year 2006.

Updated as on May 2009

Off-site Emergency Plan is Available in The

Bellary District Website www.bellary.nic.in


Periodical Mock drills are being conducted at MAH &

Potentially Hazard industries involving District Authorities

On-Site Emergency plans have been re-viewed & have

been approved by the Director of Factories & Boilers,

Bangalore.

Mutual aid amongst MAH & Hazard Industries is being

practiced.

The safety and health status of 2 MAH Industries have been

reviewed by the site appraisal committee.


Mock Drill conducted in presence of Mock Drill conducted in presence of District District AdministrationAdministration


Involvement of Local Elected representativesInvolvement of Local Elected representatives in the Mock Drill in the Mock Drill


Major Accidents in Bellary

NO Major Chemical Accidents/Disasters has

occurred in the Bellary District


Creating awareness amongst the Workers & Neighboring Public by

• Circulating pamphlets

• Distributing

• Safety Hand Books in Kannada & English

• Handbook on Hazardous Chemicals

• Safety quiz Booklet for workers

• Involvement of workers & Public in the mock drill


• Conducting safety quiz Competition for workers

• Inter Industry competition to create awareness

on safety

• Conducting training programme for Engineers,

Supervisors & Middle Management On safety



Bellary District Crisis Group Meetings/Mock Drills

15.03.1999

27.07.1999

23.06.2000

22.12.2000

28.11.2002

04.12.2003

04.12.2004

15.09.2005

06.12.2006

By Deputy Commissioner, Bellary Disaster Management Plan of Bellary 25

•04.12.2007

•08.12.2008

•17.12.2008

•07.03.2009


•Corex gas contains Carbon Monoxide 43%.

•Blast Furnace gas contains 24 % CO and

•Colorless, Odorless, and Poisonous gas

•Highly In-flammable

•Density : 0.97 ( Air=1) it is lighter than Air

•Lower explosive Limit : 12.5 %

•Upper Explosive Limit : 74.5 %

•The threshold value of CO gas in atmosphere

is 50 ppm for 8 hours gas exposure

COREX GAS


CO Concentration In Air

Effects

00 to 50 ppm Can work safely for 8 hours exposure

50 to 100 ppm Can work safely for 4 hours exposure

100 – 200 ppm Mild headache after 2-3 hours exposure

200 – 400 ppm Nausea and mild headache after 1-2 hours of exposure, occipital headache after 2-3 hours of exposure

400 -800 ppm Headache, dizziness and nausea after 3-4 hours of exposure

800 – 1600 ppm All the above symptoms in 20 minutes exposure collapse, unconsciousness and probability of death after 2 hours of exposure

1600 – 3200 ppm All the above symptoms in 5-12 minutes exposure and death in 30 minutes

3200 – 6400 ppm All the above symptoms in 1-2 minutes and death in 15 minutes exposure

12800 ppm Effect instantaneous death in 1-4 minutes


S.No Industry Persons Likely to be affected Safety distance in

Metres > 800 M

Zone A100 M

Zone B250 M

Zone C400 M

1 JSW Steel Limited 10 15 25 discomfort for long exposure

2 JSW Energy Company Limited

5 5 10 discomfort for long exposure

3 Jindal Praxair Oxygen Company Ltd


4. Bellary Oxygen Co.Pvt.Ltd


5. BOC India Ltd 5 5 10 discomfort for long exposure

Severity Analysis for Carbon monoxide in Corex / Blast Furnace gas – Industry Wise


LIQUID CHLORINE


Sl.No

Industry Persons Likely to be affected

Safety distance in Metres > 500 M

Zone A100 M

Zone B250 M

Zone C400 M

1 JSW Steel Limited

50 250 500 Discomfort for long exposure needs immediate first aid 2 JSW Energy

Company Limited50 300 500

3. BTPS 50 300 500

Severity Analysis for Chlorine - Industry wise


Liquid Petroleum Gas (LPG)Properties Colorless Gas with

Pungent Smell

Vapor density

Heavier than air

LowerExplosiveLimit

1.8 %

UpperExplosiveLimit

9.6 %


Hydrogen GasHydrogen Gas


Properties of Hydrogen GasProperties of Hydrogen Gas

1.1. Odorless , Colorless Compressed Liquefied Gas Odorless , Colorless Compressed Liquefied Gas

2.2. The gas mixes well with air, explosive mixtures are The gas mixes well with air, explosive mixtures are easily formed. easily formed.

3.3. The gas is lighter than air. The gas is lighter than air.

4.4. Extremely flammable. Many reactions may cause fire Extremely flammable. Many reactions may cause fire

or explosion.or explosion.


Sl.No

Industry Persons Likely to be affected Safety distance in Metres > 500 M

Zone A100 M

Zone B250 M

Zone C400 M

1 Jindal Praxair Oxygen Company Ltd

10 10 10 Immediate evacuation as it supports Combustion

2. Bellary Oxygen Co.Pvt.Ltd

10 10 10 Immediate evacuation as it supports Combustion

3. BOC India Ltd 10 10 10 Immediate evacuation as it supports Combustion

Severity Analysis for Liquid Oxygen


Sl.No

Industry Persons Likely to be affected Safety distance in Metres > 500 M

Zone A100 M

Zone B250 M

Zone C400 M

1 United Spirits ltd

25 30 50 Immediate evacuation as it is high fire potential hazard

Severity Analysis for Rectified Spirit



The main focus of the Chemical Accident (Emergency Planning, Preparedness & Response)

Rules 1996.Provide scope to deal with major chemical accidents

in MAH Units and to provide expert guidance for handling major chemical accidents.

•Constitution of Crisis Groups for management of chemical accidents - Central, State, District

• Identification of Major Accident Hazard Installations;

•Defines - Major Accident Hazard Units,

- Major Chemical Accident

- Hazardous chemicals.


•Hazardous chemicals - Chemical Substances having hazardous properties viz., toxic, flammable, reactive and explosive - 431 Chemicals have been defined as Hazardous Chemicals.

•Major Chemical Accident means - an occurrence including any particular emission, fire or explosion involving one or more hazardous chemicals and resulting from uncontrolled development in the course of industrial activity leading to serious effects both immediate or delayed, inside or outside the installations likely to cause substantial loss of life and property including adverse effects on the environment.


Major Accident Hazard Installations means - isolated storage and industrial activity at a site- handling of hazardous chemicals equal to or, in excess of the threshold quantities specified.

For example

• LPG 15MT

•Chlorine 10MT

•Ammonia 50MT

•Liquid Oxygen 200MT

•Highly flammable liquids 10000MT


Central Crisis Group - apex body at the Centre(G.O.I) to deal with major chemical accidents and provide expert guidance in handling MCA

Secretary Govt., of India (MOF) -Chair person

Jt. Secretary(Env.and Forest) – Member Secretary

19 Government & non Govt. officers

State Crisis Group

Chief Secretary to Govt., - Chair Person

Pr.Secretary to Govt., Labour - Member Secretary

9 Government Officers and 2 Non Govt. agencies


District Crisis Group - apex body in the district to deal with major chemical accidents and to provide expert guidance for handling chemical accidents.

Deputy Commissioner - Chair Person

Deputy Director of Factories - Member Secretary

In the state of Karnataka - about 70 MAH factories have been identified in 16 districts

Bellary - 3 MAH Factories.


IN PURSUANT TO THE RULE 8 OF THE CHEMICAL ACCIDENT RULES, 1996,

Government of Karnataka

Vide GO No. KAE 68 KABANI 2006 dated 13.2.2007

has constituted District Crisis Group for the Bellary District.


Main Functions of the DCG - Rule 9 of CA Rules, 1996,

• Assist in the preparation of district off site emergency plan;

• Review all the on site emergency plan of MAH units;

•Assist the district administration in the management of chemical accident at a site lying within the district;

•Continuously monitor every chemical accident;

• Ensure continuous information flow from the district to the state regarding chemical accident and mitigation efforts.

•Forward a report of chemical accident if any to SCG

• Conduct one full scale mock rehearsal of chemical accident - off site emergency plan and submit report to DCG


MAH Units in the Bellary District

1. JSW Steel Ltd

Steel Manufacturing, Around 5000 workmen

LPG-36 MT ( 2 bullets ),Chlorine- 3MT and Corex Gas – 1.3 Lakh cubic meter

2. Jindal Praxair Oxygen Company Limited,

Oxygen, Nitrogen & Argon manufacturing, Around 100 workmen;

Liquid Oxygen - 1000 MT and Corex Gas as Fuel online.

3. Bellary Oxygen Co. Ltd.

Liquid Oxygen-1000 MT


POTENTIAL HAZARDOUS INDUSTRIES

1. JSW Energy Limited,

Chlorine- 1x6 MT.and Corex Gas as Fuel online.

2. Monsanto India Limited,

LPG- 14MT

3. United Galva Ltd.,

LPG- 14.92MT

4. Pampasara Distilleries Limited,

Spirit- 2.0 Million Gallons.


STATUS OF THE MAH AND POTENTIAL HAZARDOUS INDUSTRIES

• All factories are functioning;

• All factories have revised their on site emergency plans recently;

•The Hazardous Chemical stored (Total Qty.)

•LPG – 64.92MT

•Corex Gas – 1.3 Lakh cubic meter

•Chlorine - 9 tonners

•Liquid Oxygen- 2000 MT

•Spirit –2.0 Million Litres


Previous meetings of the DCG - Bellary

1. 15/03/1999

2. 27/07/1999

3.23/06/2000

4. 22/12/2000

5. 28/11/2002

2003 & 2004 witnessing of On Site Emergency Plan Mock Drill on 4th

December.

6.15-09-2005

7. 06-12-2006


TASKS BEFORE THE DCG

• Review the strength and weaknesses of the onsite emergency plans prepared by the MAH Units.

• Review of Off site emergency plan and suggests changes.

•Create Public Awareness among the workers and the neighboring public.

• Provide expert guidance/advise to the management to carryout out audits to ensure integrity of the system.


THANK YOU

Documents

DISASTER MANAGEMENT PLAN of Bellary District Deputy Director of Factories Bellary