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

ACRES

: 93.35

Green belt Area

: 25 ACRES

Bulk LPG Storage Facilities

Existing

Additional
Existing 3150

MT

Sphere

2 x 1400 MT

Bullets

2 x 100

MT

Bullet

1 x 150

MT

Mounded 3 x 1200 MT
Bullets
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.
1
2
3
4
5
6
7

Name of the village

Kacharakanahalli
Dasarahalli
Geddlapura
Dodda Donnasandra
Kannekal
Makkanahalli
Devalapura

Population
437
458
163
1677
410
1465
446

Material Safety Data

IDENTITY OF MATERIAL :
Product Name

Trade name
Formula

LPG. Bottle gas,

Liquefied
hydrocarbon gas.
LPG

UN No.

Mixture of
propane and
butane

HAZCHEM Code

Physical State

Gas

Appearance

Colourless

Odor

Odorless/stanche
d
Insoluble

Solubility in Water
Calorific Value
(Kcal / Kg.)

11400

1075
Label / Class

Red: Flammable
Liquid / 2.1

2WE

PHYSICAL AND CHEMICAL PROPERTIES

Boiling Point / Range , deg.
C
Melting / Freezing Point ,
deg. C
Vapor Density (Air =1)

Specific Gravity , 20 deg. C

0.53 to 0.57

Vapor Pressure
at 65 deg. C,

16.9 kg/cm2

138
1.5 to 2.0

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

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
m2
Seconds
37.5
12.5
4

28
28
28

% Lethality
100% Lethality
1% Lethality /100 % first deg.burns
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
SPHERE

273

524

908

1830

Damage contour for catastrophic failure of 1400 MT sphere

Zone
A
Zone A 37.5 Kw/M2 524
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
Zone

Radiation
(KW/M2)

Distance in
meter

Zone A

37.5

524

Plant Personnel

80

Zone B

12.5

908

Kanekal village

443

Kacharaknahalli

472

Zone C

1830

Affected population

Dasarahalli
Gidlapura
Donnasandra
Makanahalli
Devalapura
Vagatta
Neighboring
industries

495
176
1811
1582
482
1103
400

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:

Team In Charge:
Manager (P)

Team In Charge: Asst.

Manager (F)

Floor Officer

Alternate team Incharge: Officer

(Bulk Operations)

Alternate team Incharge: S&D Alte rnate te am Incharge :

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. Security guard 4

8. Carousel Tare wt. 2

9. Evacuation

(Gate 2)

10. ICU
11. Gantry operator 1
12. Gantry operator 2
13. Security guard 1
(Main gate)
14. Security guard 2
gate)
15. Security guard 3
(Patrolling)

(Main

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.