RISK ASSESSMENT RISK ASSESSMENT HAZOP STUDY

RISK ASSESSMENT

(QRA)

RISK ASSESSMENT HAZOP

STUDY

ON SITE DISASTER CONTROL PLAN OFF SITE

DISASTER CONTROL PLAN

For

Proposed API Manufacturing Unit

At

LIVIA LIFE SCIENCES PVT. LTD.

PLOT NO. f-17, MIDC CHINCHOLI, SOLAPUR, MAHARASHTRA,

Prepared By

Enviro Resources

(NABET Certificate No: NABET/EIA/1821/IA0038)

E-604, Crystal Plaza, Opp. Infiniti Mall, New Link Road, Andheri West, Mumbai – 400 053. E-mail: [email protected]

MAY 2020

mailto:[email protected]

TABLE NO. 2.1: THE PROPOSED PRODUCTION CAPACITY OF PRODUCTS

Sr. No Name of Product CAS NO Qty in MTPA 1 Azacyclonol 115-46-8 384.00 2 Ethyl Iso Nipecotate 5006-62-2 102.00 3 Nicotinic Acid Methyl Ester 93-60-7 50.40 4 1-Benzylpiperidine-4-

Carboxaldehyde 22065-85-6 7.20

5 By-product Ammonium Sulfate

7783-20-2 120.96

Total 55.38 664.56

Figure no 1: Site Layout

SN. Name Of The Building Configuration Sn. Name Of The Building Configuration 1 Solvent Tank Farm PESO area. UG Laboratory Above office

2 Acid Tank Farm. UG Hazardous Waste Storage

3 Work Shed 1 -Utility Block. Ground + 1 Fire Water Storage

4 Work Shed 2 - Ware House. Ground + 1 RWH area. 5 Work Shed 3- Production Block. Ground + 1 Guard House & Entrance. 6 Work Shed 4- Production Block. Ground + 1 Parking. 7 Work Shed 5 - Ware House. Ground + 1 Future Expansion Blocks. 8 API Block Two Lines. ETP. 9 Boiler Area And Stack. Office. Ground + 1

10 Pollution Control Equipments. Coal Storage. Open yard /shed?

SECTION 3: IDENTIFICATION OF HAZARDS

TABLE NO. 3.1: FLAMMABILITY HAZARD MATERIAL

SN.

Name

CAS NO.

LEL

UEL

Flash Point

Boiling Point

NFPA Hazard

Index % % oC oC Nf

1 Mono Chloro Benzene 108-90-7 1.3 7.1 23.8 132.2 3 2 Triethyl Amine 121-44-8 1.2 8 -6.6 89.2 3 3 Vitride 22722-98-1 NA NA 4 110 3 4 Hydrogen

1333-74-0 4 75 gas gas 4

5 Ethyl Alcohol. 64-17-5 3.3 19 13 79 3 6 Tetra Hydro Furan. 109-99-9 2 11.8 -14.5 66 3 7 Toluene. 108-88-3 1.27 7.1 12.7 110.4 3 8 Methanol 67-56-1 6 36.5 11 64.7 3

TABLE NO. 3.1A: TOP FIVE - LOWEST BOILING POINT LIQUIDS

SN NAME CAS NUMBER BOILING POINT (oC) 1 Oxalyl Chloride 79-37-8 63

2 Tetra Hydro Furan. 109-99-9 66 3 Methanol. 67-56-1 64.7 4 Ethyl Alcohol. 64-17-5 79 5 Triethyl Amine 121-44-8 89.2

TABLE NO. 3.1B: TOP FIVE - WIDEST FLAMMABILITY RANGE MATERIALS

SN. NAME CAS NUMBER

LEL (%)

UEL (%)

RANGE 1 Hydrogen 1333-74-0 4 75 71

2 Methanol. 67-56-1 6 36.5 30.5 3 Ethyl Alcohol 64-17-5 3.3 19 15.7 4 Tetra Hydro Furan. 109-99-9 2 11.8 9.8 5 Triethyl Amine 121-44-8 1.2 8 6.8

TABLE NO. 3.2: TOXICITY HAZARD MATERIALS

S. No.

Name of RM CAS NO.

Oral LD50

Dermal LD50

Inhal. LC50

NFPA Hazard Index

mg/kg mg/kg ppm Nh

1 4-

Cyanopyridine

100-48-1 710 >20 Not listed 2

2 Ammonia

Gas 7664-41-

7 >90 112000 4230 3

3 Benzyl

Chloride 100-44-7 625 Not listed 0.74 3

4 Caustic Soda 1310-73-

2 Not listed 1350 Not listed 3

5 D.S. / Ethyl

Alcohol 64-17-5 3450 Not Listed 20000 2

6 Dimethyl sulfoxide

67-68-5 14500 40 5.33 2

7 Ethyl

Isonipecotate 1126-09-

6 Not listed Not listed Not listed 2

8 HCL 7647-01-

0 3124 900 NA 3

9 Methylene dichloride

75-09-2 2000 2000 53 2

10 Mono Chloro

Benzene 180-90-7 4000 7940 13.5 2

11 nicotinic acid 59-67-6 7000 2000 Not Listed 2

12 Oxalyl

Chloride 79-37-8 Not Listed Not Listed 1840 3

12 Sulfuric Acid 7664-93-

9 2140 250 g 510 mg/m3 3

14 Triethyl Amine

121-44-8 460 415 1250 3

15 Vitride 22722-

98-1 5000 12000 26700 3

TABLE NO. 3.3: REACTIVITY HAZARD MATERIALS

S. No. Name of RM

NFPA Hazard Index Material Factor Nh Nf Nr

1 4-Cyano Pyridine 2 1 0 4 2 Ammonia Gas 3 1 0 4 3 Benzyl Chloride 3 2 1 14 4 Caustic Soda 3 0 1 14 5 D.S. / Ethyl Alcohol 2 3 0 16 6 Dimethyl Sulforide 2 2 0 10 7 Ethyl Isonipecotate 2 2 1 14 8 HCL 3 0 1 1 9 Magnesium 0 1 1 4 10 MDC 2 1 0 4 11 Mono Chloro Benzene 2 3 0 16 12 Oxalyl Chloride 3 1 1 4 13 Sodium Sulfate 1 0 1 0 14 Sulfuric Acid 3 0 2 24 15 Tetrahydrofuran 2 3 1 16 16 Toluene 2 3 0 16 17 Triethyl Amine 3 3 0 16 18 Vitride 3 3 2 24 19 Methanol 1 3 0 16

TABLE NO. 3.4B: INVENTORY: NON BULK STORAGE

SN.

Name Mode of Storage

Consumption

Max. Qty. Stored

Kg/M Kg

1 4-Cyano Pyridine Bags 4000 1920

2 Ammonia Gas

Cylinder 5840 200

3 Benzyl Chloride Drum 750 360

4 Caustic Soda Bags 26176 12564.5

5 D.S. / Ethyl Alcohol Drums 19080 9158.4

6 Dimethyl Sulforide Drums 810 388.8

7 Ethyl Isonipecotate Drums 750 360

8 Isonicotinic Acid Drums 19200 9216

9 Magnesium Bags 18432 8847.4

10 MDC Drum 6000 2880

11 Nicotininc Acid Drum 4550 2184

12 Oxalyl Chloride Drum 420 201.6

13 Palladium catalyst Bags 1536 737.28

14 Palladium on Carbon Bags 192 92.16

15 Sodium Sulfate Bags 600 288

16 Triethyl Amine Drum 2295 1101.6

17 Vitride Drum 1125 540

18 Methanol Drum 1600 500

TABLE NO: 3.4C: INVENTORY: ACID STORAGE TANK

SN.

Name

CAS

Number

Mode of

Storage

Max. Qty.

St d

Consumption

Mt. Mt./M

1 Sulfuric Acid. 7664-93-9 Tank 10 13.82 2 Hydrochloric Acid. 7647-01-0 Tank 25 55.308

TABLE NO: 3.4D: INVENTORY: SOLVENT STORAGE TANK

SN.

Name

CAS

Number

Mode of

Storage

Max. Qty.

Stored

Consumption

Mt. Mt./M

1 Toluene 108-88-3 Tank 20X 2 78.95 2 Tetrahydrofuran 109-99-9 Tank 20X 2 69.12 3 Mono Chloro

180-90-7 Tank 20X 2 94.72

TABLE NO: 3.4E: INVENTORY: FUEL STORAGE

SN.

Name

CAS

Number

Mode of

Storage

Max. Qty.

Stored

Consumption

Mt. Mt./D

1 HSD 8052-41-3 Dum 0.2 0.107

2 Coal NA Open 60 18.8

TABLE NO: 3.4F: INVENTORY: GAS STORAGE

Sr.

No.

Gas Type Storage

pressure bar

Diameter

(mm)

Length /

height

(mm)

Capacity

1 Hydrogen 4 cylinder 151.2 B 200 mm 1600 mm 7 m3

2 Ammonia 4 cylinder 8.2 B 340 mm 1120 mm 50 kg

The DOW index is performed for all flammable chemicals which is to be stored in raw

material storage building (non bulk storage in drum) for proposed activity. The DOW index

has been performed for chemicals having Nf factor 3 or more than 3. Details of DOW index

is given in table below

Recommendation/Suggestions for non-PESO area

1. The storage in godown should be in a systematic way proper roads should be marked

by “Yellow” colour & should be kept free of obstruction all the time.

Chemical Ethyl Alcohol Triethyl Amine Vitride Methanol

Storage Considered Drum Drum Drum Drum N

h 2 3 3 1

N f 3 3 3 3

N r 0 0 2 0

Material Factor, MF 16 16 24 16 F1 (General Process

Hazard) 2.80 2.80 2.80 2.80

F2 (Special Process Hazard)

1.73 1.80 1.80 1.40

F3 (Hazard Factor) 4.844 5.04 5.04 3.92 Fire & Explosion Index 77.50 80.64 120.96 62.72

Degree of Hazard Moderate Moderate Intermediate Moderate Radius of Exposure in ft 65.1 67.73 101.6 52.68

Area of Exposure in sq.ft.

13307.3 14404.2 32412.8 8714

Damage Factor 0.5 0.52 0.80 0.45

2. The maximum stacking height should be marked on the walls in RED colour. The

stacking height should not be more than the red line. Red line should be marked on

1.5 mtrs. From lowest roof level.

3. All electrical fitting, fixtures should be flameproof & confirming to relevant IS. All

electrical wiring, fitting & fixture should be above the red line (stacking limit line)

4. The indication mark like Exits, Fire Escape, etc. should be prominently marked with

florescent paint so that it can be seen in darkness.

5. 3 Nos. of Alcohol Resistance Foam Extinguishers having capacity of 50 Ltrs. to be

installed in the Plant area.

6. Vitride is highly shall be kept away from Strong oxidizing agents, Acids, Acid

anhydrides, Acid chlorides, Alcohols.

7. Provide Safety Shower & Eye Wash Fountains and Portable Fire Extinguishers.

8. Personnel Protective Equipment (PPE) especially SCBA sets and training.

9. Provide Fire hydrant system.

10. Provide suitable arrangement at storm drain to avoid any organic contaminated water

/spill / fire water going out of the site

Monds Index

The principle and general approach used in the DOW method of hazard evaluation have been further developed by ICI Mond Division, the revised Mond Fire, Explosive and Toxicity index is a series of papers by Lewis (1979).

The main developments made to the DOW Index in the Mond Index are:

1. It covers a wider range of process and storage installation

2. It covers the processing of chemicals with explosive properties

3. A calculation procedure is included to allow for the off-setting effects of good design and

control and safety instrumentation

4. The procedure has been extended to cover plant layout

5. Separate indices are calculated to access the hazards of fire, internal explosion and aerial

explosion.

To estimate the Monds Index for raw materials in storage area following, All the raw materials stored in the industry premises are tabulated and data for their N (H) levels and TLV levels are obtained. Based on their highest toxicity factor and lowest TLV level Mond’s Index was calculated for chemicals with Nh =3 or more.

Table : Monds Toxicity index of toxic chemicals

Sr. No Raw Materials

Qty. at any given time in MT or

KL

Flash Point in 0C

UN Classification Health Hazard

(Nh)

TLV in ppm

1 Benzyl chloride 0.36 67.2

Class 8: Corrosive material

Class 6.1: Poisonous Material

3 10

2 Caustic Soda 12.56 NA Class 8: Corrosive

material 3 2

3 Triethylamine 1.10 -6.66

Class 3: Flammable material

Class 8: Corrosive material

3 5

4 Ammonia gas 2.80 132 Class 8: Corrosive

material 3 35

5 Oxalyl Chloride 0.201 NA

Class 4.3: Flammable material Class 8: Corrosive

material

3 50

6 Vitride 0.540 4

Class 4.3: Flammable material Class 8: Corrosive

material

3 20

Table 7.6: Calculated Mond’s Index and degree of Hazard for Hazardous chemicals.

Sr. No.

Raw Materials Th (Toxicity factor)

Ts ( Correction

factor)

Mond’s Index

Degree of hazard

1 Benzyl chloride 250 75 6.1 Moderate 2 Caustic Soda 250 125 8.0 Moderate 3 Triethylamine 250 125 9.01 High 4 Ammonia gas 250 75 5.80 Moderate 5 Oxalyl Chloride 250 75 5.80 Moderate 6 Vitride 250 75 5.51 Moderate

Toxicity (Mond) Index recommendations:

1. The raw materials are stored according to their compatibility.

2. Toxic materials are stored in cool place and kept away from heat.

3. Toxic material can cause breathing difficulty therefore storage area is well ventilated.

4. Good housekeeping practice is implemented in storage area.

5. Appropriate drainage with the slope of 2 % is provided to remove small and large

spillage of the chemicals.

6. The provision of fire water supply is provided through the hydrant line passing from the

raw material storage area

7. PPE’s are used wherever necessary.

8. MSDS recommendations are strictly followed while chemical storage and handling.

Recommendations for ‘High’ Mond Index chemical storage:

1. The chemicals are isolated from another chemical in well ventilated area and hazard

warning information is shown.

2. SOP is prepared for handling such chemicals and it should be strictly followed.

3. Spill kit is provided for storage to limit the spill of materials. Suitable Absorbent like

sodium bi carbonate is used to absorb the spill.

4. Proper training is provided to workers prior to handling and transporting chemicals.

5. PPE’s like face shield, goggles, apron, gloves, gumboots are used while handling the

chemicals to avoid exposure to chemicals.

Aerial Location of Hazardous Atmosphere (ALOHA):

A Quantitative Risk Assessment based on the software ALOHA – Aerial Locations of

Hazardous Atmospheres was carried out. The criteria failure scenarios considered for

ALOHA depend on the type of storage whether above ground tank, tank in storage area or

pressurized cylinders as well as physical state of the chemical stored and chemical properties

of the chemical.

ALOHA (Arial Locations of Hazards Atmosphere) is an atmospheric dispersion model used

for evaluating releases of hazardous chemical vapors. ALOHA is a part of software called

CAMEO (Computer Aided Management of Emergency Operation). CAMEO is one of the

tools developed by EPA’s Chemical Emergency Preparedness and Prevention Office

(CEPPO) and the National Oceanic and Atmospheric Administration Office of Response and

Restoration (NOAA), to assist front-line chemical emergency planners and responders. For

the present calculation version 5.4.4 is used.

CAMEO suite consists of three parts viz.

1. CAMEO: It is basically a chemical data base provided for calculations.

2. ALOHA: ALOHA allows the user to estimate the downwind dispersion of a chemical

cloud based on the toxicological/physical characteristics of the released chemical,

atmospheric conditions, and specific circumstances of the release.

3. MARPLOT (Mapping Applications for Response, Planning, and Local Operational

Tasks): Graphical outputs include a "cloud footprint" that can be plotted on maps with

MARPLOT to display the location of other facilities storing hazardous materials and

vulnerable locations, such as hospitals and schools. Specific information about these

locations can be extracted from CAMEO information modules to help make decisions

about the degree of hazard posed.

Acute Exposure Guideline Levels (AEGL):

Figure : Description of AEGL levels

THERMAL RADITION EFFECTS:

A Thermal Radiation Level of Concern (LOC) is a threshold level of thermal radiation,

usually the level above which a hazard may exist.

10 kW/(sq m) -- potentially lethal within 60 sec;

5 kW/(sq m) -- second-degree burns within 60 sec; and

2 kW/(sq m) -- pain within 60 sec.

Below are some effects at specific thermal radiation levels for which software was run.

37.5 kw / m2 (100% lethality),

12.5 kw/m2 (1% lethality),

1.6 kw/m2 (no discomfort)

The thermal radiation effects that people experience depend upon the length of time they are

exposed to a specific thermal radiation level. Longer exposure durations, even at a lower

thermal radiation level, can produce serious physiological effects.

OVERPRESSURE EFFECTS:

A major hazard associated with any explosion is overpressure. Overpressure, also called a

blast wave, refers to the sudden onset of a pressure wave after an explosion. This pressure

wave is caused by the energy released in the initial explosion—the bigger the initial

explosion, the more damaging the pressure wave. Blast waves can damage buildings or even

knock them flat—often injuring or killing the people inside them. The sudden change in

pressure can also affect pressure-sensitive organs like the ears and lungs. The damaging

effects of the overpressure will be greatest near the source of the explosion and lessen as you

move farther from the source.

An Overpressure Level of Concern (LOC) is a threshold level of pressure from a blast wave,

usually the pressure above which a hazard may exist. In vapor cloud explosion scenario,

ALOHA will suggest three default LOC values. ALOHA uses three threshold values to create

the default threat zones:

• Red: 8.0 psi (destruction of buildings);

• Orange: 3.5 psi (serious injury likely); and

• Yellow: 1.0 psi (shatters glass).

ALOHA software is used to estimate the risk associated with release of pressurized gases.

Following table represent the list of chemicals tank with their storage quantity for which

aloha is performed.

SN.

Name

CAS

Number

Mode of

Storage

Max. Qty.

Stored

Consumption

Dyke Area

Mt. Mt./M

1 Toluene 108-88-3 Tank 20X 2 78.95 Common dyke of 132

sq.m 2 Tetrahydrofuran 109-99-9 Tank 20X 2 69.12 3 Mono Chloro

Benzene 180-90-7 Tank 20X 2 94.72

Sr.

No.

Gas Type Storage

pressure bar

Diameter

(mm)

Length /

height

(mm)

Capacity

1 Hydrogen 4 cylinder 151.2 B 200 mm 1600 mm 7 m3

2 Ammonia 4 cylinder 8.2 B 340 mm 1120 mm 50 kg

ALOHA Footprint:

Table : ALOHA Footprints

Substance Scenario. Effects considered

LOC Distance, m

Toulene Spill of entire chemical

contained in tank-

evaporating puddle

Toxic area of vapor cloud

AEGL-3 3700 ppm 29 AEGL-2 560 ppm 80 AEGL-1 67 ppm 278

Flammable area of vapor cloud

60% LEL 6600 ppm 20

10% LEL 1100 ppm 54

Overpressure (blast force) from vapor

cloud explosion

8.0 psi destruction of

buildings

LOC was never exceeded

3.5 psi serious injury likely

14

1.0 psi shatters glass

20

Burning Puddle/

Pool Fire Thermal

radiation from pool fire

10.0 kW/(sq m)

potentially lethal

within 60 sec

35

5.0 kW/(sq m)

2nd degree burns

within 60 sec

51

2.0 kW/(sq m)

pain within 60

sec

81

Tank Failure (Leak from hole

Toxic area of vapor cloud

AEGL-3 3700 ppm 11 AEGL-2 560 ppm 39

in Horizontal cylindrical

tank)- Flammable chemical

escaping from tank (not burning)

AEGL-1 67 ppm 133

Flammable area of vapor cloud

60% LEL 6600 ppm Less than 10 meters

10% LEL 1100 ppm 26


cloud explosion


buildings

LOC never exceeded


Less than 10 meters


11 meters

Tank Failure

(Leak from hole in horizontal

cylindrical tank) - Flammable chemical is burning as it escapes from

tank

Thermal radiation from

pool fire

10.0 kW/(sq m)

potentially lethal

within 60 sec

Less than 10 meters

5.0 kW/(sq m)

2nd degree burns

within 60 sec

Less than 10 meters

2.0 kW/(sq m)

pain within 60

sec

Less than 10 meters

Tank Failure

(Leak from hole in Horizontal

cylindrical tank)- BLEVE of flammable

liquid in Horizontal

cylindrical tank


fireball

10.0 kW/(sq m)

potentially lethal

within 60 sec

312

5.0 kW/(sq m)

2nd degree burns

within 60 sec

441

2.0 kW/(sq m)

pain within 60

sec

688

Tetrahydrof

uran Spill of entire

chemical contained in

Tank- evaporating

puddle

Toxic area of vapour cloud

ERPG-3 5000 ppm 70 ERPG-2 500 ppm 228 ERPG-1 100 ppm 560

Flammable area of vapour cloud

60% LEL 12000 ppm

47

10% LEL 2000 ppm 111


cloud explosion


buildings

LOC never exceeded


37


51

Burning Puddle

/ Pool Fire Thermal

radiation from pool fire

10.0 kW/(sq m)

potentially lethal

within 60 sec

28

5.0 kW/(sq m)

2nd degree burns

within 60 sec

42

2.0 kW/(sq m)

pain within 60

sec

66

Leak from hole in Horizontal

cylindrical tank- Flammable chemical

escaping from tank (not burning)

Toxic Area of Vapor Cloud

ERPG-3 5000 ppm 21 ERPG-2 500 ppm 67 ERPG-1 100 ppm 176

Flammable Area of Vapor Cloud

60% LEL 12000 ppm

12

10% LEL 2000 ppm 33


cloud explosion


buildings



Less than 10 meters


20


cylindrical tank- Flammable chemical is burning as it


pool fire

10.0 kW/(sq m)

potentially lethal

within 60 sec

less than 10 meters

5.0 kW/(sq 2nd degree burns

less than 10

escapes from tank

m) within 60 sec

meters

2.0 kW/(sq m)

pain within 60

sec

less than 10 meters


cylindrical tank- BLEVE of flammable liquid in

Horizontal cylindrical tank


fireball

10.0 kW/(sq m)

potentially lethal

within 60 sec

279

5.0 kW/(sq m)

2nd degree burns

within 60 sec

396

2.0 kW/(sq m)

pain within 60

sec

620

Monochloro

bezene

Spill of entire chemical

contained in Tank-

evaporating puddle




60% LEL 43080 ppm


10% LEL 7180 ppm 29 meters


cloud explosion

-- -- No explosion: no part of the cloud is above the LEL at any

time

Burning Puddle / Pool Fire


pool fire

10.0 kW/(sq m)

potentially lethal

within 60 sec

23

5.0 kW/(sq m)

2nd degree burns

within 60 sec

35

2.0 kW/(sq m)

pain within 60

sec

56


cylindrical tank- Flammable



chemical escaping from

tank (not burning)


60% LEL 7800 ppm less than 10 meters

10% LEL 1300 ppm 13


cloud explosion

-- -- No explosion: no part of the cloud is above the LEL at any

time


cylindrical tank- Flammable chemical is burning as it escapes from

tank


pool fire

10.0 kW/(sq m)

potentially lethal

within 60 sec

less than 10 meters

5.0 kW/(sq m)

2nd degree burns

within 60 sec

less than 10 meters

2.0 kW/(sq m)

pain within 60

sec

less than 10 meters


cylindrical tank- BLEVE of flammable liquid in

Horizontal cylindrical tank


fireball

10.0 kW/(sq m)

potentially lethal

within 60 sec

269

5.0 kW/(sq m)

2nd degree burns

within 60 sec

385

2.0 kW/(sq m)

pain within 60

sec

605

Hydrogen Leak from

vertical cylindrical tank-

not burning


PAC-3 400000 ppm

13

PAC-2 230000 ppm

17

PAC-1 65000 ppm

32


60% LEL 24000 ppm

74

10% LEL 4000 ppm 162

Overpressure 8.0 psi destruction 55

(blast force) from vapor

cloud explosion

of buildings


56


67

Leak from


burning


pool fire

10.0 kW/(sq m)

potentially lethal

within 60 sec

Less than 10 meters

5.0 kW/(sq m)

2nd degree burns

within 60 sec

Less than 10 meters

2.0 kW/(sq m)

pain within 60

sec

Less than 10 meters

Catastrophic

failure of cylinder (Direct

Source)


PAC-3 400000 ppm

142

PAC-2 230000 ppm

177

PAC-1 65000 ppm

284


60% LEL 24000 ppm

520

10% LEL 4000 ppm 1000


cloud explosion


buildings

441


446


495

Ammonia Leak from


not burning




60% LEL 90000 ppm

12

10% LEL 15000 ppm

30


cloud explosion


buildings

LOC never exceeded


LOC never exceeded


Less than 10 meters

Leak from


burning


jet fire

10.0 kW/(sq m)

potentially lethal

within 60 sec

Less than 10 meters

5.0 kW/(sq m)

2nd degree burns

within 60 sec

Less than 10 meters

2.0 kW/(sq m)

pain within 60

sec

Less than 10 meters

Catastrophic

failure of cylinder (Direct

Source)




60% LEL 90000 ppm

116

10% LEL 15000 ppm

234


cloud explosion


buildings





91

HCL (30%) Spill of entire chemical

contained in Tank-

evaporating puddle

Gaussian- Toxic area of vapour

cloud

AEGL-3 100 ppm 161 AEGL-2 22 ppm 370 AEGL-1 1.8 ppm 1500

Interpretation

Based on the unsafe distances identified by the ALOHA software output file, the MCLS

(maximum credible loss scenario) for the factory works out to about 1800 meter for

Ammonia with 30 ppm concentration impact in the environment.

The scenario considered for assessing the impact by quantitative risk assessment was taken

from standard guideline.

The probability of occurrence of the scenario is very less. The Disaster management plan

highlights the suggestive measures to be taken during the occurrence of such an accident.

Recommendations – For storage tanks

The periodic inspection and maintenance program on the tank would be ensured.

The periodic maintenance of the pumps and piping would be ensured.

Least number of flanged joints will be provided in the pipelines.

The pipelines will be supported adequately so as to avoid sagging of the same during

operation.

Visual inspection of the pipelines will be done periodically to ascertain external

pitting and corrosion.

Protective painting on the tank and pipeline shall be provided.

Protective equipment such as gloves, lab coat, vapor respirator, splash goggles shall

be ensured while handling the substance.

Prominent signage of hazards (such as “Danger”, No smoking”) of the substances

shall be provided on the tank and surroundings

The tank installation will be protected against lightening.

All Electric Equipment & Fittings (e.g. Pump-motors, lamps, junction boxes, switches

etc.) shall be of Flame-proof Type, conforming to IS/IEC 60079 i.e. old IS 2148:1981,

suitable for GR. II A/II B and shall be of type approved by the CCoE.

Recommendations:

A) Hydrogen Cylinders

1. The area shall not be used for any purpose other than for keeping of compressed gas filled

in cylinders.

2. Compressed gas cylinders shall be stored only in the storage shed, which shall be

constructed of suitable non-flammable materials provided that, when only non-flammable gas

filled in cylinder is stored, the beams, rafters, columns, windows and doors may be of wood.

3. The storage shed shall be adequately ventilated near the ground level and near or in the

roof.

4. Store only where temperature will not exceed 52°C.

5. Hydrogen can form explosive mixture with oxidizing agent therefore storage should be

away from sodium hypochlorite storage.

6. The storage shed and the area surrounding it shall at all times be kept clean and free from

all flammable materials, waste vegetation and, rubbish.

7. No fire, furnace or other source of heat or light other than flameproof electric light and

fittings shall be allowed in the storage shed and within the safety zone required to be

maintained under condition

8. No person shall smoke in the storage shed or carry matches, fuses, mobile phones or other

appliances producing ignition in the premises. Conspicuous ‘No smoking signs in Hindi,

English and the regional language shall be pasted or hung up at prominent places outside the

storage shed.

B) For Ammonia Cylinder

1. Store in cool and well ventilated area.

2. Excess ammonia should be scrubbed.

3. Leakage Emergency Tool Kit for Ammonia should be provided and Self Contained

Breathing Apparatus (SCBA) should be provided in storage shed if needed.

DOW INDEX

1. Methanol

Tank No. NA Equipment Name Methanol ( Drum Storage-631 Liters)

Basic Material for Material factor Methanol Density, kg/l 0.792

Properties of material N h 1 N f 3 N r 0 M.F. 16 Boil. pt. 148.3 0F 64.6 0C Flash pt. 52 0F 11.11 0C

∆HC = Heat of Comb. 8600 BTU / lb Quantity of the material 631 l 500 kg 1102.3 Lb Storage conditions Temp 30 0C Pressure 1.0 Bar Penalty

factor range Penalty factor used

1.General Process

Base Factor 1.00 1.00 Exothermic Chemical Reaction 0.30 to 1.25 0.00 Endothermic Processes 0.20 to 0.40 0.00 Material handling and transfer 0.25 to 1.05 0.85 Enclosed or Indoor Process Units 0.25 to 0.90 0.25 Access 0.20 to 0.35 0.20 Drainage and Spill Control 0.25 to 0.50 0.50 General Process Hazard Factor ( F1 ) 2.80 2.Special Process

Base Factor 1.00 1.00

Toxic material(s) 0.20 to 0.80 0.20 Sub atmospheric pressure (< 500 mm Hg) 0.50 0.00 Operation in or near flammable range

_____inerted ______noninerted 0.00 to 0.80

1. Tank farm storage flammable liquids 0.50 0.00 2. Process upset or purge failure 0.30 0.00 3. Always in contact of Flame

0.80 0.00

Dust Explosion 0.25 to 2.00 0.00 Pressure Operating pressure psig

0.00

Low temperature 0.20 to 0.30 0.00 Quantity of flammable / unstable material 1. Liquids or gases in process 0.00 2. Liquids or gases in storage 0.10 3. Combustible Solids in Storage, Dust in

Process 0.00

Corrosion & Erosion 0.10 to 0.75 0.10 Leakage - Joints & Packing 0.10 to 1.50 0.00 Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to 1.15 0.00 Rotating Equipment 0.50 0.00 Special Process Hazard Factor ( F2 ) 1.40

Process Unit Hazard Factor ( F3 = F1 x F2) 3.92 Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 62.72 Degree of Hazard Moderate Radius of Exposure 52.68 ft Area of Exposure 8714 ft2

Degree of Hazard for F & EI Degree of Hazard for F & EI F & EI Index Range Degree of Hazard 1-60 Light 61-96 Moderate 97-127 Intermediate 128-158 Heavy 159-up Severe RECOMMENDED MINIMUM FEATURES ACCORDING TO DOW FIRE AND EXPLOSION INDEX

Preventive & Protective Features

Fire & Explosion Index Number Index for the present case

0-20 20-40 40-60 60-75 75-90 >90 62.72 Feature

optional Suggested Recommen

ded Feature required

1) Fireproofing 1 2 2 3 4 4 √ 2) Water spray a) directional 1 2 3 3 4 4 √ b) area 1 2 3 3 4 4 √ c) curtain 1 1 2 2 2 4 √ 3) Special instrumentation

a) temperature 1 2 3 3 4 4 √ b) pressure 1 2 3 3 3 4 √ c) flow control 1 2 3 4 4 4 √

4) Dust, blowdown, spill

control 1 1 2 3 3 4 √

5) Internal examination 1 2 3 3 4 4 √ 6) Combustible gas monitors

a) signal alarm 1 1 2 3 3 4 √ b) actuate equipment 1 1 2 2 3 4 √ 7) Remote operation 1 1 2 3 3 4 √

8) Diking, (Not Applicable as barrel storage)

1 4 4 4 4 4 √

9) Blast & barrier walls separation

1 1 2 3 4 4 √

1) Feature optional 2) Feature suggested 3) Feature recommended 4) Feature required

2. Ethanol

Tank No. -- Equipment Name Ethanol Drum Storage (9.16 MT)

Basic Material for Material factor Ethanol Density, kg/l 0.789

Properties of material N h 2 N f 3 N r 0 M.F. 16 Boil. pt. 173.3 0F 78.5 0C Flash pt. 55 0F 12.7 0C

∆HC = Heat of Comb. 11500 BTU / lb Quantity of the material 11609 l 9160 kg 20194.3 Lb Storage conditions Temp 30 0C Pressure 1.0 Bar Penalty


1.General Process






0.80 0.00


0.00

Low temperature 0.20 to 0.30 0.00 Quantity of flammable / unstable material 1. Liquids or gases in process 0.00 2. Liquids or gases in storage 0.23

3. Combustible Solids in Storage, Dust in Process

0.00

Corrosion & Erosion 0.10 to 0.75 0.10 Leakage - Joints & Packing 0.10 to 1.50 0.00 Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to 1.15 0.00 Rotating Equipment 0.50 0.00 Special Process Hazard Factor ( F2 ) 1.73 Process Unit Hazard Factor ( F3 = F1 x F2) 4.844 Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 77.50 Degree of Hazard Moderate Radius of Exposure 65.1 ft Area of Exposure 13307.3 ft2




0-20 20-40 40-60 60-75 75-90 >90 77.50 Feature






control 1 1 2 3 3 4 √


a) signal alarm 1 1 2 3 3 4 √ b) actuate equipment 1 1 2 2 3 4 √ 7) Remote operation 1 1 2 3 3 4 √ 8) Diking, (Not Applicable as barrel storage)

1 4 4 4 4 4 √


1 1 2 3 4 4 √


3. Triethylamine

Tank No. -- Equipment Name Triethylamine (1.10 MT)

Basic Material for Material factor Triethylamine Density, kg/l 0.726

Properties of material N h 3 N f 3 N r 0 M.F. 16 Boil. pt. 192.7 0F 89.3 0C Flash pt. 20 0F -6.66 0C

∆HC = Heat of Comb. 17800

BTU / lb Quantity of the material 1515 l 1100 kg 2425 Lb Storage conditions Temp 30 0C Pressure 1.0 Bar Penalty


1.General Process






0.80 0.00


0.00


Process 0.00


Process Unit Hazard Factor ( F3 = F1 x F2) 5.04 Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 80.64 Degree of Hazard Moderate Radius of Exposure 67.73 ft Area of Exposure 14404.2 ft2




0-20 20-40 40-60 60-75 75-90 >90 80.64 Feature






control 1 1 2 3 3 4 √




1 4 4 4 4 4 √


1 1 2 3 4 4 √


3. Vitride

Tank No. -- Equipment Name Vitride (0.54 MT)

Basic Material for Material factor Vitride Density, kg/l 1.036

Properties of material N h 3 N f 3 N r 2 M.F. 24 Boil. pt. 230 0F 110 0C Flash pt. 39.2 0F 4 0C

∆HC = Heat of Comb. -

BTU / lb Quantity of the material 521.23 l 540 kg 1190.5 Lb Storage conditions Temp 30 0C Pressure 1.0 Bar Penalty


1.General Process






0.80 0.00


0.00


Process 0.00


Process Unit Hazard Factor ( F3 = F1 x F2) 5.04 Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 120.96 Degree of Hazard Intermediate Radius of Exposure 101.6 ft Area of Exposure 32412.8 ft2




0-20 20-40 40-60 60-75 75-90 >90 120.96 Feature






control 1 1 2 3 3 4 √




1 4 4 4 4 4 √


1 1 2 3 4 4 √


Monds Index

The principle and general approach used in the DOW method of hazard evaluation have been further developed by ICI Mond Division, Their revised Mond fire, explosive and toxicity index is a series of papers by lewis (1979). The main development made to the DOW Index in the Mond Index are:

1. It covers a wider range of process and storage installation 2. It covers the processing of chemicals with explosive properties 3. A calculation procedure is included to allow for the off-setting effects of good

design and control and safety instrumentation 4. The procedure has been extended to cover plant layout 5. Separate indices are calculated to access the hazards of fire, internal explosion and

aerial explosion.

Table No. : Toxicity factor Index

NFPA Index Number Toxicity Factor (Th)

0 0

1 50

2 125

3 250

4 325

Table No. : Correction factor for Toxicity

MAC (in ppm) Ts

5 and below 125

Between 5 and 50 75

50 and more 50

Table No. : Toxicity Index

The resulting TI values are ranked into three categories:

1-5 Light

6-9 Moderate

10-up High

1) Mond’s Index of Benzyl chloride General & Special Process Hazard 1.General

Base Factor 1.00 1.00 Exothermic Chemical Reaction 0.30 to 1.25 0.00 Endothermic Processes 0.20 to 0.40 0.00 Material handling and transfer 0.25 to 1.05 0.40 Enclosed or Indoor Process Units 0.25 to 0.90 0.00 Access 0.20 to 0.35 0.20 Drainage and Spill Control 0.25 to 0.50 0.50 General Process Hazard Factor ( F1 ) 2.10 2.Special

Base Factor 1.00 1.00 Toxic material(s) 0.20 to 0.80 0.60 Sub atmospheric pressure (< 500 mm

0.50 0.00

Operation in or near flammable range

0.00 to 0.80

1. Tank farm storage flammable

0.50 0.00 2. Process upset or purge failure 0.30 0.00 3. Always in contact of Flame

0.80 0.00


0.00

Low temperature 0.20 to 0.30 0.00 Quantity of flammable / unstable

1. Liquids or gases in process 0.00 2. Liquids or gases in storage 0.00 3. Combustible Solids in Storage,

Dust in Process 0.00

Corrosion & Erosion 0.10 to 0.75 0.00 Leakage - Joints & Packing 0.10 to 1.50 0.10 Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to 1.15 0.00 Rotating Equipment 0.50 0.00 Special Process Hazard Factor ( F2 ) 1.70 Therefore, from the above table the GPH and SPH is coming to be around 2.10 and 1.70 respectively. Calculation of Toxicity Index:

Toxicity Index : Th + Ts (1+GPH+SPH) 100 Toxicity Index : [250 + 75 (1 + 2.10 + 1.70)]/100 Toxicity Index : 6.1

The Toxicity Index for Benzyl chloride is calculated to be around 6.1 which indicate that the degree of hazard is moderate.

2) Mond’s Index of Caustic Soda General & Special Process Hazard 1.General



0.50 0.00


0.00 to 0.80



0.80 0.00


0.00





Toxicity Index : Th + Ts (1+GPH+SPH) 100 Toxicity Index : [250 + 125 (1 + 1.70 + 1.70)]/100 Toxicity Index : 8.0 The Toxicity Index for Caustic Soda is calculated to be around 8.0 which indicate that the degree of hazard is moderate.

3) Mond’s Index of Triethylamine General & Special Process Hazard 1.General



0.50 0.00


0.00 to 0.80



0.80 0.00


0.00





Toxicity Index : Th + Ts (1+GPH+SPH) 100 Toxicity Index : [250 + 125 (1 + 2.55 + 1.70)]/100 Toxicity Index : 9.06 The Toxicity Index for Triethylamine is calculated to be around 9.06 which indicate that the degree of hazard is high.

4) Mond’s Index of Ammonia General & Special Process Hazard 1.General



0.50 0.00


0.00 to 0.80



0.80 0.00


0.00





Toxicity Index : Th + Ts (1+GPH+SPH) 100 Toxicity Index : [250 + 75 (1 + 1.70 + 1.70)]/100 Toxicity Index : 5.80 The Toxicity Index for ammonia is calculated to be around 5.80 which indicate that the degree of hazard is moderate.

5) Mond’s Index of Oxalyl Chloride General & Special Process Hazard 1.General



0.50 0.00


0.00 to 0.80



0.80 0.00


0.00




Corrosion & Erosion 0.10 to 0.75 0.00 Leakage - Joints & Packing 0.10 to 1.50 0.10 Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to 1.15 0.00 Rotating Equipment 0.50 0.00 Special Process Hazard Factor ( F2 ) 1.70 Therefore, from the above table the GPH and SPH is coming to be around 1.70 and 1.70 respectively.

Calculation of Toxicity Index: Toxicity Index : Th + Ts (1+GPH+SPH) 100 Toxicity Index : [250 + 75 (1 + 1.70 + 1.70)]/100 Toxicity Index : 5.80 The Toxicity Index for Oxalyl Chloride is calculated to be around 5.80 which indicate that the degree of hazard is moderate.

6) Mond’s Index of Vitride General & Special Process Hazard 1.General



0.50 0.00


0.00 to 0.80



0.80 0.00


0.00





Toxicity Index : Th + Ts (1+GPH+SPH) 100 Toxicity Index : [250 + 75 (1 + 2.55 + 1.80)]/100 Toxicity Index : 6.51 The Toxicity Index for Vitride is calculated to be around 6.51 which indicate that the degree of hazard is moderate.

The summary of ALOHA

The basic data used for running ALOHA

SITE DATA:

Location: GOGA INDUSTRIES, AVADHAN MID, INDIA Building Air Exchanges Per Hour: 0.37 (unsheltered single storied) Time: May 8, 2020 2022 hours ST (using computer's clock)

ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)

Wind: 1.5 meters/second from N at 10 meters Ground Roughness: open country Cloud Cover: 5 tenths Air Temperature: 30° C Stability Class: F (user override) No Inversion Height Relative Humidity: 50%

1) CHEMICAL DATA FOR TOLUENE:

CAS Number: 108-88-3 Molecular Weight: 92.14 g/mol AEGL-1 (60 min): 67 ppm AEGL-2 (60 min): 560 ppm AEGL-3 (60 min): 3700 ppm IDLH: 500 ppm LEL: 11000 ppm UEL: 71000 ppm Ambient Boiling Point: 228.7° F Vapor Pressure at Ambient Temperature: 0.048 atm Ambient Saturation Concentration: 50,246 ppm or 5.02%

The ALOHA Footprints (Toluene)

I) Source :-Puddle

i) Scenario :- Evaporating Puddle of Flammable Chemical

1. Toxic area of vapour cloud SOURCE STRENGTH:

Evaporating Puddle (Note: chemical is flammable)

Puddle Area: 216 square meters Puddle Volume: 132 cubic meters

Ground Type: Concrete Ground Temperature: 30° C

Initial Puddle Temperature: 30° C

Release Duration: ALOHA limited the duration to 1 hour

Max Average Sustained Release Rate: 6.46 kilograms/min

(averaged over a minute or more)

Total Amount Released: 377 kilograms

THREAT ZONE:

Model Run: Heavy Gas

Red : 29 meters --- (3700 ppm = AEGL-3 [60 min])

Note: Threat zone was not drawn because effects of near-field patchiness

make dispersion predictions less reliable for short distances.

Orange: 80 meters --- (560 ppm = AEGL-2 [60 min])

Yellow: 278 meters --- (67 ppm = AEGL-1 [60 min])

2. Flammable area of vapour cloud

SOURCE STRENGTH:









THREAT ZONE:

Threat Modeled: Flammable Area of Vapor Cloud


Red : 20 meters --- (6600 ppm = 60% LEL = Flame Pockets)



Yellow: 54 meters --- (1100 ppm = 10% LEL)

3. Blast Area of Vapor Cloud Explosion

SOURCE STRENGTH:









THREAT ZONE:

Threat Modeled: Overpressure (blast force) from vapor cloud explosion

Type of Ignition: ignited by spark or flame

Level of Congestion: congested


Red : LOC was never exceeded --- (8.0 psi = destruction of buildings)

Orange: 14 meters --- (3.5 psi = serious injury likely)

Yellow: 20 meters --- (1.0 psi = shatters glass)


I) Source :-Puddle

ii) Scenario :- Burning Puddle/ Pool Fire

1. Thermal radiation from pool fire

SOURCE STRENGTH:




Flame Length: 29 meters

Burn Duration: ALOHA limited the duration to 1 hour

Burn Rate: 1,050 kilograms/min

Total Amount Burned: 63,295 kilograms

THREAT ZONE:

Threat Modeled: Thermal radiation from pool fire

Red : 35 meters --- (10.0 kW/(sq m) = potentially lethal within 60 sec)

Orange: 51 meters --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)

Yellow: 81 meters --- (2.0 kW/(sq m) = pain within 60 sec)

The ALOHA Footprints (Toulene)

II) Source :-Tank Failure (Leak from hole in horizontal cylindrical tank)

i) Scenario :- Flammable chemical escaping from tank (not burning)

1. Toxic Area of Vapor Cloud

SOURCE STRENGTH:

Leak from hole in horizontal cylindrical tank

Flammable chemical escaping from tank (not burning)

Tank Diameter: 1.905 meters Tank Length: 7 meters

Tank Volume: 20.0 cubic meters

Tank contains liquid Internal Temperature: 30° C

Chemical Mass in Tank: 17,145 kilograms

Tank is 100% full

Circular Opening Diameter: 1 centimeters

Opening is 0.67 meters from tank bottom


Max Puddle Area: 216 square meters




Total Amount Released: 49.3 kilograms

Note: The chemical escaped as a liquid and formed an evaporating puddle.

The puddle spread to a diameter of 7.3 meters.

THREAT ZONE:









2. Flammable Area of Vapor Cloud

SOURCE STRENGTH:







Tank is 100% full











THREAT ZONE:



Red : less than 10 meters(10.9 yards) --- (6600 ppm = 60% LEL = Flame Pockets)






Th re a t Mo d e le d : F la m m a b le Are a o f Va p o r Clo u d

Mo d e l R u n : He a v y Ga s

R e d : le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (6 6 0 0 p p m = 6 0 % LE L = Fla m e P o c ke ts )

No te : Th re a t z o n e wa s n o t d ra wn b e c a u s e e ffe c ts o f n e a r-fie ld p a tc h in e s s

m a ke d is p e rs io n p re d ic tio n s le s s re lia b le fo r s h o rt d is ta n c e s .

Ye llo w: 2 6 m e te rs --- (1 1 0 0 p p m = 1 0 % LE L)



3. Overpressure (blast force) from vapor cloud explosion

SOURCE STRENGTH:







Tank is 100% full











THREAT ZONE:






Orange: less than 10 meters(10.9 yards) --- (3.5 psi = serious injury likely)


II) Source :-Tank Failure (Leak from hole in horizontal cylindrical tank)

ii) Scenario :- Flammable chemical is burning as it escapes from tank


SOURCE STRENGTH:


Flammable chemical is burning as it escapes from tank





Tank is 100% full




Max Flame Length: 4 meters


Max Burn Rate: 3.79 kilograms/min

Total Amount Burned: 225 kilograms

Note: The chemical escaped as a liquid and formed a burning puddle.


THREAT ZONE:


Red : less than 10 meters(10.9 yards) --- (10.0 kW/(sq m) = potentially lethal within 60 sec)

Orange: less than 10 meters(10.9 yards) --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)

Yellow: less than 10 meters(10.9 yards) --- (2.0 kW/(sq m) = pain within 60 sec)

) Source :-Tank Failure (Leak from hole in horizontal cylindrical tank)

iii) Scenario :- BLEVE of flammable liquid in horizontal cylindrical tank

1. Thermal radiation from fireball

SOURCE STRENGTH:

BLEVE of flammable liquid in horizontal cylindrical tank



Th re a t Mo d e le d : Th e rm a l ra d ia tio n fro m p o o l fire

R e d : le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (1 0 .0 kW /(s q m ) = p o te n tia lly le th a l with in 6 0 s e c )

Ora n g e : le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (5 .0 kW /(s q m ) = 2 n d d e g re e b u rn s with in 6 0 s e c )

Ye llo w: le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (2 .0 kW /(s q m ) = p a in with in 6 0 s e c )

Tank contains liquid

Internal Storage Temperature: 30° C


Tank is 100% full

Percentage of Tank Mass in Fireball: 100%

Fireball Diameter: 150 meters Burn Duration: 10 seconds

THREAT ZONE:

Threat Modeled: Thermal radiation from fireball




2) CHEMICAL DATA FOR TETRAHYDROFURAN:

CAS Number: 109-99-9 Molecular Weight: 72.11 g/mol

ERPG-1: 100 ppm ERPG-2: 500 ppm ERPG-3: 5000 ppm

IDLH: 2000 ppm LEL: 20000 ppm UEL: 118000 ppm

Ambient Boiling Point: 64.8° C

Vapor Pressure at Ambient Temperature: 0.26 atm

Ambient Saturation Concentration: 274,231 ppm or 27.4%

The ALOHA Footprints (Tetrahydrifuran)

III) Source :-Puddle

iii) Scenario :- Evaporating Puddle of Flammable Chemical

1. Toxic area of vapour cloud

SOURCE STRENGTH:








Total Amount Released: 1,796 kilograms

THREAT ZONE:


Red : 70 meters --- (5000 ppm = ERPG-3)

Orange: 228 meters --- (500 ppm = ERPG-2)

Yellow: 560 meters --- (100 ppm = ERPG-1)


SOURCE STRENGTH:









THREAT ZONE:








SOURCE STRENGTH:









THREAT ZONE:








The ALOHA Footprints (Tetrahydrofuran)

III) Source :-Puddle

iv) Scenario :- Burning Puddle/ Pool Fire


SOURCE STRENGTH:






Burn Rate: 879 kilograms/min


THREAT ZONE:





The ALOHA Footprints (Tetrahydrofuran)

IV) Source :-Tank Failure (Leak from hole in horizontal cylindrical tank)

iv) Scenario :- Flammable chemical escaping from tank (not burning)


SOURCE STRENGTH:







Tank is 100% full











THREAT ZONE:


Red : 21 meters --- (5000 ppm = ERPG-3)



Orange: 67 meters --- (500 ppm = ERPG-2)

Yellow: 176 meters --- (100 ppm = ERPG-1)


SOURCE STRENGTH:







Tank is 100% full











THREAT ZONE:











R e d : 1 2 m e te rs --- (1 2 0 0 0 p p m = 6 0 % LE L = Fla m e P o c ke ts )







SOURCE STRENGTH:







Tank is 100% full











THREAT ZONE:






Orange: less than 10 meters(10.9 yards) --- (3.5 psi = serious injury likely)


IV) Source :-Tank Failure (Leak from hole in horizontal cylindrical tank)

v) Scenario :- Flammable chemical is burning as it escapes from tank


SOURCE STRENGTH:







Tank is 100% full










THREAT ZONE:





vi) Source :-Tank Failure (Leak from hole in horizontal cylindrical tank)

Scenario :- BLEVE of flammable liquid in horizontal cylindrical tank

Thermal radiation from fireball

SOURCE STRENGTH:











Tank is 100% full



THREAT ZONE:





3) CHEMICAL DATA FOR MONO CHLORO BENZENE:


AEGL-1 (60 min): 10 ppm AEGL-2 (60 min): 150 ppm AEGL-3 (60 min): 400 ppm



Vapor Pressure at Ambient Temperature: 0.021 atm


The ALOHA Footprints (MCB)

V) Source :-Puddle

v) Scenario :- Evaporating Puddle of Flammable Chemical

1. Toxic area of vapour cloud SOURCE STRENGTH:









THREAT ZONE:






SOURCE STRENGTH:









THREAT ZONE:



Red : LOC was never exceeded --- (7800 ppm = 60% LEL = Flame Pockets)





SOURCE STRENGTH:









THREAT ZONE:





R e d : LOC wa s n e v e r e x c e e d e d --- (7 8 0 0 p p m = 6 0 % LE L = Fla m e P o c ke ts )






No explosion: no part of the cloud is above the LEL at any time

Th re a t Mo d e le d : Ov e rp re s s u re (b la s t fo rc e ) fro m v a p o r c lo u d e x p lo s io n

Ty p e o f Ig n itio n : ig n ite d b y s p a rk o r fla m e

Le v e l o f Co n g e s tio n : c o n g e s te d


No e x p lo s io n : n o p a rt o f th e c lo u d is a b o v e th e LE L a t a n y tim e


V) Source :-Puddle

vi) Scenario :- Burning Puddle/ Pool Fire


SOURCE STRENGTH:






Burn Rate: 760 kilograms/min


THREAT ZONE:






VI) Source :-Tank Failure (Leak from hole in horizontal cylindrical tank)

vii) Scenario :- Flammable chemical escaping from tank (not burning)


SOURCE STRENGTH:







Tank is 100% full






Max Average Sustained Release Rate: 739 grams/min





THREAT ZONE:








SOURCE STRENGTH:







Tank is 100% full











THREAT ZONE:



Red : less than 10 meters(10.9 yards) --- (7800 ppm = 60% LEL = Flame Pockets)






.



R e d : le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (7 8 0 0 p p m = 6 0 % LE L = Fla m e P o c ke ts )







SOURCE STRENGTH:







Tank is 100% full











THREAT ZONE:





No explosion: no part of the cloud is above the LEL at any time

VI) Source :-Tank Failure (Leak from hole in horizontal cylindrical tank)

viii) Scenario :- Flammable chemical is burning as it escapes from tank


SOURCE STRENGTH:







Tank is 100% full










THREAT ZONE:





No e x p lo s io n : n o p a rt o f th e c lo u d is a b o v e th e LE L a t a n y tim e





Source :-Tank Failure (Leak from hole in horizontal cylindrical tank)

ix) Scenario :- BLEVE of flammable liquid in horizontal cylindrical tank

2. Thermal radiation from fireball

SOURCE STRENGTH:

SOURCE STRENGTH:







Tank is 100% full



THREAT ZONE:









ALOHA (Hydrogen)

CHEMICAL DATA:

Chemical Name: HYDROGEN


PAC-1: 65000 ppm PAC-2: 230000 ppm PAC-3: 400000 ppm

LEL: 40000 ppm UEL: 750000 ppm

Ambient Boiling Point: -252.9° C

Vapor Pressure at Ambient Temperature: greater than 1 atm

Ambient Saturation Concentration: 1,000,000 ppm or 100.0%

1) Scenario - Hydrogen 1 - Leak from hole in vertical cylindrical tank,

SOURCE STRENGTH:

Leak from hole in vertical cylindrical tank


Tank Diameter: 0.2 meters Tank Length: 1.6 meters


Tank contains gas only Internal Temperature: 30° C

Chemical Mass in Tank: 0.61 kilograms

Internal Press: 150 atmospheres

Circular Opening Diameter: 0.6 centimeters

Release Duration: 1 minute

Max Average Sustained Release Rate: 9.98 grams/sec


Total Amount Released: 599 grams

THREAT ZONE:

Model Run: Gaussian

Red : 13 meters --- (400000 ppm = PAC-3)



Orange: 17 meters --- (230000 ppm = PAC-2)



Yellow: 32 meters --- (65000 ppm = PAC-1)



Mo d e l R u n : Ga u s s ia n

R e d : 1 3 m e te rs --- (4 0 0 0 0 0 p p m = P AC-3 )



Ora n g e : 1 7 m e te rs --- (2 3 0 0 0 0 p p m = P AC-2 )



Ye llo w: 3 2 m e te rs --- (6 5 0 0 0 p p m = P AC-1 )



2) Scenario - Hydrogen 2 - Leak from hole in vertical cylindrical tank, Flammable chemical escaping from tank (not burning), Flammable Area of Vapor Cloud

SOURCE STRENGTH: Leak from hole in vertical cylindrical tank Flammable chemical escaping from tank (not burning) Tank Diameter: 0.2 meters Tank Length: 1.6 meters Tank Volume: 0.050 cubic meters Tank contains gas only Internal Temperature: 30° C Chemical Mass in Tank: 0.61 kilograms Internal Press: 150 atmospheres Circular Opening Diameter: 0.6 centimeters Release Duration: 1 minute Max Average Sustained Release Rate: 9.98 grams/sec (averaged over a minute or more) Total Amount Released: 599 grams THREAT ZONE: Threat Modeled: Flammable Area of Vapor Cloud Model Run: Gaussian Red : 74 meters --- (24000 ppm = 60% LEL = Flame Pockets) Yellow: 162 meters --- (4000 ppm = 10% LEL)

3) Scenario - Hydrogen 3 - Leak from hole in vertical cylindrical tank, Flammable chemical escaping from tank (not burning),Overpressure (blast force) from vapor cloud explosion

SOURCE STRENGTH: Leak from hole in vertical cylindrical tank Flammable chemical escaping from tank (not burning) Tank Diameter: 0.2 meters Tank Length: 1.6 meters Tank Volume: 0.050 cubic meters Tank contains gas only Internal Temperature: 30° C Chemical Mass in Tank: 0.61 kilograms Internal Press: 150 atmospheres Circular Opening Diameter: 0.6 centimeters Release Duration: 1 minute Max Average Sustained Release Rate: 9.98 grams/sec (averaged over a minute or more) Total Amount Released: 599 grams THREAT ZONE: Threat Modeled: Overpressure (blast force) from vapor cloud explosion Type of Ignition: ignited by spark or flame Level of Congestion: congested Model Run: Gaussian Red : 55 meters --- (8.0 psi = destruction of buildings) Orange: 56 meters --- (3.5 psi = serious injury likely) Yellow: 67 meters --- (1.0 psi = shatters glass)

4) Scenario - Hydrogen 4 - Leak from hole in vertical cylindrical tank, Flammable chemical is burning as it escapes from tank

SOURCE STRENGTH:








Circular Opening Diameter: 0.6 centimeters

Flame Length: 0 meters Burn Duration: 20 seconds

Burn Rate: 161 grams/sec

Total Amount Burned: 599 grams

THREAT ZONE:

Threat Modeled: Thermal radiation from jet fire




5) Scenario - Hydrogen 5 - Catastrophic failure of cylinder (Direct Source), Toxic area of vapor cloud

SOURCE STRENGTH:

Direct Source: 7 cubic meters Source Height: 0

Source State: Gas

Source Temperature: 30° C

Source Pressure: 150 atmospheres


Release Rate: 1.42 kilograms/sec


THREAT ZONE:

Model Run: Gaussian

Red : 142 meters --- (400000 ppm = PAC-3)

Orange: 177 meters --- (230000 ppm = PAC-2)

Yellow: 284 meters --- (65000 ppm = PAC-1)

Th re a t Mo d e le d : Th e rm a l ra d ia tio n fro m je t fire




6) Scenario - Hydrogen 6 - Catastrophic failure of cylinder (Direct Source) , Flammable area of vapor cloud

SOURCE STRENGTH:


Source State: Gas






THREAT ZONE:


Model Run: Gaussian


Yellow: 1.0 kilometers --- (4000 ppm = 10% LEL)

7) Scenario - Hydrogen7 - Catastrophic failure of cylinder (Direct Source), Overpressure (blast force) from vapor cloud explosion

SOURCE STRENGTH:


Source State: Gas






THREAT ZONE:




Model Run: Gaussian

Red : 441 meters --- (8.0 psi = destruction of buildings)



Ammonia Cylinder - Gas

Chemical Name: AMMONIA


AEGL-1 (60 min): 30 ppm AEGL-2 (60 min): 160 ppm AEGL-3 (60 min): 1100 ppm


Ambient Boiling Point: -28.2° F

Vapor Pressure at Ambient Temperature: greater than 1 atm

Ambient Saturation Concentration: 1,000,000 ppm or 100.0%

1) Scenario - Ammonia 1 - Leak from hole in vertical cylindrical tank, Flammable chemical escaping from tank (not burning), Gaussian SOURCE STRENGTH: Leak from hole in vertical cylindrical tank Flammable chemical escaping from tank (not burning) Tank Diameter: 0.34 meters Tank Length: 1.12 meters Tank Volume: 0.10 cubic meters Tank contains gas only Internal Temperature: 30° C Chemical Mass in Tank: 0.59 kilograms Internal Press: 8 atmospheres Circular Opening Diameter: 1 centimeters Release Duration: 1 minute Max Average Sustained Release Rate: 8.47 grams/sec (averaged over a minute or more) Total Amount Released: 508 grams THREAT ZONE: Model Run: Gaussian Red : 78 meters --- (1100 ppm = AEGL-3 [60 min]) Orange: 178 meters --- (160 ppm = AEGL-2 [60 min]) Yellow: 331 meters --- (30 ppm = AEGL-1 [60 min])

2) Scenario - Ammonia 2 - Leak from hole in vertical cylindrical tank Flammable chemical escaping from tank (not burning), Flammable Area of Vapor Cloud

SOURCE STRENGTH:













THREAT ZONE:


Model Run: Gaussian







3) Scenario - Ammonia 3 - Leak from hole in vertical cylindrical tank Flammable chemical escaping from tank (not burning), Overpressure (blast force) from vapor cloud explosion

SOURCE STRENGTH:













THREAT ZONE:




Model Run: Gaussian


Orange: LOC was never exceeded --- (3.5 psi = serious injury likely)

Yellow: less than 10 meters(10.9 yards) --- (1.0 psi = shatters glass)

4) Scenario - Ammonia 4 - Leak from hole in vertical cylindrical tank, Leaking tank chemical is burning as a jet fire, Thermal radiation from jet fire

SOURCE STRENGTH:












Mo d e l R u n : Ga u s s ia n

R e d : LOC wa s n e v e r e x c e e d e d --- (8 .0 p s i = d e s tru c tio n o f b u ild in g s )

Ora n g e : LOC wa s n e v e r e x c e e d e d --- (3 .5 p s i = s e rio u s in ju ry like ly )

Ye llo w: le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (1 .0 p s i = s h a tte rs g la s s )

Flame Length: 1 meter Burn Duration: 20 seconds

Burn Rate: 69 grams/sec

Total Amount Burned: 508 grams

THREAT ZONE:

Threat Modeled: Thermal radiation from jet fire




5) Scenario - Ammonia 5 - Catastrophic failure of cylinder (Direct Source), Toxic area of vapor cloud

SOURCE STRENGTH: Direct Source: 50 kilograms Source Height: 0 Release Duration: 1 minute Release Rate: 833 grams/sec Total Amount Released: 50.0 kilograms Note: This chemical may flash boil and/or result in two phase flow. Use both dispersion modules to investigate its potential behavior. THREAT ZONE: Model Run: Gaussian Red : 473 meters --- (1100 ppm = AEGL-3 [60 min]) Orange: 957 meters --- (160 ppm = AEGL-2 [60 min]) Yellow: 1.8 kilometers --- (30 ppm = AEGL-1 [60 min])

Th re a t Mo d e le d : Th e rm a l ra d ia tio n fro m je t fire




6) Scenario - Ammonia 7 - Catastrophic failure of cylinder, Direct Source,

Flammable Area of vapor cloud

SOURCE STRENGTH: Direct Source: 50 kilograms Source Height: 0 Release Duration: 1 minute Release Rate: 833 grams/sec Total Amount Released: 50.0 kilograms Note: This chemical may flash boil and/or result in two phase flow. Use both dispersion modules to investigate its potential behavior. THREAT ZONE: Threat Modeled: Flammable Area of Vapor Cloud Model Run: Gaussian Red : 116 meters --- (90000 ppm = 60% LEL = Flame Pockets) Yellow: 234 meters --- (15000 ppm = 10% LEL)

1) Scenario - Ammonia 7 - Catastrophic failure of cylinder, Direct Source, Overpressure (blast force) from vapor cloud explosion

SOURCE STRENGTH:

Direct Source: 50 kilograms Source Height: 0


Release Rate: 833 grams/sec


Note: This chemical may flash boil and/or result in two phase flow.

Use both dispersion modules to investigate its potential behavior.

THREAT ZONE:




Model Run: Gaussian


Orange: LOC was never exceeded --- (3.5 psi = serious injury likely)


4) CHEMICAL DATA FOR HCL:

Chemical Name: HYDROCHLORIC ACID

Solution Strength: 30% (by weight)


Partial Pressure at Ambient Temperature: 0.028 atm


Hazardous Component: HYDROGEN CHLORIDE


AEGL-1 (60 min): 1.8 ppm AEGL-2 (60 min): 22 ppm AEGL-3 (60 min): 100 ppm

IDLH: 50 ppm


VII) Source :-Puddle

vii) Scenario :- Evaporating Puddle of Toxic Chemical

1. Toxic area of vapour cloud

SOURCE STRENGTH:

Evaporating Puddle

Puddle Area: 52.5 square meters Puddle Volume: 38.5 cubic meters






Total Amount Hazardous Component Released: 26.2 kilograms

THREAT ZONE:

Model Run: Gaussian



Yellow: 1.5 kilometers --- (1.8 ppm = AEGL-1 [60 min])

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