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CHAPTER 1

INTRODUCTION, SCOPE AND OBJECTIVES

OF THE STUDY

1.1 INTRODUCTION

The major challenges to be met by the world population of the 21st

century are safety, health and environmental (SHE) risks. The concern for
managing them continues to prevail and tends to increase year after year due
to the exponential growth of industries. International agencies viz., United
Nations Environment Program (UNEP), United Nations Industrial
Development Organization (UNIDO) and International Labor Organization
(ILO) periodically review the ongoing regional development in
industrialization, urbanization, environment, health of the community and
risks in industrial operations. India being a signatory of the above agencies is
obliged to comply with the guidelines, regulations and planning process as
suggested by those agencies from time to time. Besides, the national agencies
such as Directorate of Industrial Safety and Health, Director General Factory
Advice Service and Labour Institutes (DGFASLI), Ministry of Labour and
Employment, Government of India, Petroleum and Explosives Safety
Organization, Manufacture Storage Import of Hazardous Chemical Rules
(MSIHC Rules 1989 & amended 2000) etc., provide guidelines and stipulate
standards for storage and handling of hazardous materials etc. to be complied
with by industries.
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Environmental Impact Assessment is considered to be one of the

tools in the management of safety, health and environment risks. The
Planning Commission of India conceived the concept of Environmental
Impact Assessment (EIA) in India during 1976-1977. The commission was
designated the task of examining cursorily river-valley projects from the
environmental standpoint and addressed the Department of Science and
Technology (DST), Government of India. This was subsequently extended to
cover other projects in need of approval by the Public Investment Board
(Ministry of Finance, Government of India). These were administrative
decisions without any legislative support. The Government of India, therefore,
enacted the Environment (Protection) Act, 1986 (in the Ministry of
Environment and Forest-MOEF). The Act enunciates set of legal instruments.
The decisions taken by the Government was to make environment impact
assessment as a statutory requirement before setting up of any production
activity in any part of the country. Risk Assessment, which is an integral part
of EIA, provides operable scientific frameworks for protecting the
environment and for decision-making. The scientific approach for conducting
the risk assessment study is essential to sustain long term benefits not only for
the industry but also for the overall general environmental resources including
air, water, land and noise affecting the public in the vicinity of the Industrial
site.

Energy is a basic need for operations. Liquefied Petroleum Gas -

LPG / Propane is commonly and continuously used in industries as an energy
source (e.g. heat treatment, power generation and drying etc). Consequently,
there is a substantial release of end products (Green house gases) after
combustion of LPG causing death, injury to persons and damage to the
properties. Energy, environment, safety, etc. exclusively with the use of LPG
have not been given due consideration by the planners as well as scientists.
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The study on risk assessment in LPG / Propane using industry

demands first-hand knowledge of the accident scenario. Also, a number of
institutions in India have studied possibilities and probabilities of the hazards
occurring within the industrial premises due to LPG storage. There are well-
defined parameters for quantification of flue gas release. These include flash
point, degree of flammability, explosion, toxicity to humans etc. Besides the
location of industry, the engineering design and systems implementation
during operation (production and maintenance) are important. Consequence
Analysis of an emergency situation at the industrial site and risk management
is the most important factors of risk analysis concerning hazardous
installations.

1.2 ROLE OF ENVIRONMENT RISK ASSESSMENT (ERA) IN

EIA PROCESS

One of the key components of EIA process is Environment Risk

Assessment (ERA). ERA is the development of EIA and Risk Assessment.
ERA provides theoretical and scientific frameworks for environmental
protection, decision making and for setting up of any Industry. With the rapid
economic growth and globalization movement, development of new
industries with sophisticated technologies is on the rise at an alarming rate all
over the world. However, it is imperative that a systematic approach be
adopted before setting up of a new industry, taking into consideration various
safety issues, health and environmental aspects of the inhabitants living in the
surrounding areas to safeguard them from possible accidents / incidents
arising out of the industrial activity. The scientific approach of conducting an
Environment Risk Assessment study before setting up of an industry is
essential to sustain long term benefit not only for the industry but also for the
general environment and the inhabitants living in the area24, 46,49.
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The use of LPG / Propane is continuously on the increase in

industries as a standard energy source for various purposes including heat
treatment processes. Consequently, there is a substantial release of LPG and
other hazardous materials into the ambient environment causing personal
injury or death of workers and people in the surrounding locality, damage to
property and environment. The study on Risk Assessment in LPG/Propane
using industry demands first-hand in depth knowledge of the accident
scenario possibilities and probability of the hazards responsible for damage to
the property and health of the general public. Hence, the first step in hazard
analysis is to quantify the substances released. There are well-defined
parameters for quantification that include flash point, degree of flammability,
explosion, toxicity etc. Besides this, the subjectivity factor of location,
engineering design and systems implementation during operation (production
and maintenance) are important and involve the engineering aspects of the
Risk Assessment. In addition to these, Consequence Analysis of an
emergency situation at the industrial site and risk management are the two
most important factors of Risk Analysis concerning hazardous installations in
the industries24, 46.49.

Hence, the Environmental Impact and Risk Assessment for LPG

Installations in Automobile Industries detailing the release scenarios and
consequence analysis for these LPG handling industries are to be studied.
This study explains the Environmental consequences associated with LPG
storages, located and installed particularly in Automobile industries in
Tamilnadu. At present, the LPG utilizing automobile industries are not
required to conduct Environment Impact Assessment studies since they are
not listed in the EIA Notification issued by the Ministry of Environment and
Forest. Even though these industries do not have the requirement for the EIA
study, the rise in the number of industries utilizing LPG for energy purpose
due to its convenience, availability and other technical requirements has
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become a serious concern, requiring special attention from the perspective of

the Government and other stakeholders. The environment impact from these
industries taking into account of the hazard potential of LPG Bullets is to be
studied.

1.3 LPG BULLET INSTALLATION IN AUTOMOBILE

INDUSTRIES

1.3.1 Features of LPG

With its intrinsically clean burning characteristics, LPG offers a

practical avenue for clean air since use of LPG reduces black carbon and
particulate matter emissions, which not only compromise outdoor and indoor
air quality but can cause serious health problems.

Since LPG is a low carbon fuel, it is used in thousands of industrial

and commercial applications. It is cleaner than any other fossil fuel, highly
energy efficient and safe to use. LPG is one of the most preferred energy
sources today because of its immense benefits.

LPG is an energy-rich fuel source with a higher calorific value per

unit than other commonly used fuels, including coal, natural gas, diesel,
petrol, fuel oils and biomass-derived alcohols. LPG generates fewer carbon
emissions than gasoline (petrol) and has similar emissions when compared
with diesel. Therefore, it can make a positive contribution toward
improvement of air quality when compared to diesel, heating oil and solid
fuels. In addition to these factors, LPG is immediately available and supports
the use of renewable technologies. The advantages of using LPG as an energy
source are:

Increased fuel savings

High rate of heating – as high as 400 °C per hour

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Uniformity in temperature and precise temperature control

Better heat transfer with LPG firing

No wastage of fuel due to spillage and adulteration

Uniformity and increased end product quality

Lower maintenance costs of burners, ovens and furnaces

Lower shut down time of machinery

Cleaner burning and sulfur-free emission

1.3.2 Mode of Storage of LPG

Refrigerated storage is used to store large volumes of LPG. The

main form of LPG storage is in special tanks known as 'pressure tanks'.
Commonly, these pressure tanks are termed as 'bulk tanks' or LPG
Bullets/Spheres. Automobile industries have installed bullets/spheres in their
premises to store the LPG. Gas suppliers to store large volumes of LPG use
refrigerated storage. Since LPG has a high coefficient of expansion in its
liquid phase, the tanks are never completely filled with liquid (tanks are filled
to approximately 85% of their water capacity), the remaining space being
taken up with vapour (often referred to as the vapour space) to facilitate
expansion without allowing the liquid to become 100% full (often known as
hydraulically full)
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Figure 1.1 LPG Bullets

1.3.3 Working Features of a LPG Bullet

As LPG gas (vapour) is drawn from the tank, the vapour pressure in
the tank falls and the liquid boils, producing more vapour and restoring the
pressure to maintain boiling, the liquid absorbs heat from itself, from the
metal of the tank in contact with the liquid (known as the wetted surface area)
and from the air surrounding the tank. The available gas 'off take', therefore,
is dependent upon the surface area of the tank, the quantity of liquid within
the tank and the temperature. The low temperature of the liquid (often
indicating excess off take) may be indicated as 'sweating' (where the water
vapour in air condenses on the wetted surface area of the tank) and if the off
take is large enough 'frosting' (where the condensed water vapour freezes)
occurs on the walls of the tank.

When the liquid temperature rises, for instance in summer, the

vapour pressure increases and when the liquid temperature drops, the vapour
pressure also drops. Under normal Indian conditions, the pressure will range
between 2-9 bars. These are designed as per the recommendations in IS-2825
/ASME Sec VIII Dl-1 codes and the material of construction is SA-516/ IS-
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2062/ IS-2002/SS-304 or as per the specific requirement of the customer.

Steel used for the tank and its fittings meets the Low Temperature Carbon
Steel criteria and is tested thoroughly before fabrication. During fabrication,
stringent quality norms are followed. The vessels are inspected stage wise by
Inspection Engineers / Third party Inspectors as per the recommendations of
the relevant code and the Chief Controller of Explosives norms. Qualified
welders perform welding of joineries. Finally, it is hydro tested and de-
hydrated with dry nitrogen. Each tank undergoes various NDT and other
inspection stages and tests like Penetration Test, Radiographic Examination
and the Hydro test are conducted before dispatch.

These storage tanks are equipped with all standard instruments and
controls like Rochester gauge, excess flow check valves, safety valves,
pressure gauges, LPG Transfer compressor, valves, pipes, drains, pressure
regulators, water sprinkling system, gas leak detection system and control
panel. Most LPG storage tanks in standby-plant service are steel, non-
refrigerated pressure vessels. Tanks are available in many sizes for both above
the ground and underground services. New LPG tanks are built to ASME
standards and are designed for maximum working pressure.

1.4 STATEMENT OF PROBLEM

The earlier studies by the researchers focussed on the risk

associated with the hazardous materials. Specific studies on LPG were not
undertaken, despite the fact that the LPG was a hazardous substance
consumed in large quantities. However, LPG is favoured over other fuels like
coal, oil and electricity, which are fast becoming scarce these days. Hence,
hazard scenario created by the intensive use of LPG is required to be studied
and hence, a systematic study covering risks, safety, health and environment
is essential. Automobile industries in India have grown concomitantly with
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the production of components. Therefore it is necessary to study the pattern of

consumption of LPG and hazards attributed to LPG installation.

Since Risk analysis is considered as an integral component of

environmental impact study, the release scenarios and consequence analysis
for LPG handling industries need to be focussed upon.

The current guidelines of the Ministry of Environment, Forest and

Wild Life, Government of India with the EPAct, 1986 do not include LPG as
a hazardous material. As a result, these industries are not required to carry out
environmental impact assessment study. Nevertheless, LPG utilizing
automobile industries has to necessarily conduct environmental impact
assessment studies.

Therefore, it is imperative that the government gives their attention

to protect the society at large and averting the possible impact on
environment.

1.5 PURPOSEOF THIS STUDY

LPG/Propane has been increasingly used in automobile industries

for the heat treatment process. Increase in use of LPG has resulted in its
substantial release into the ambient environment inflicting damage to property
and environment besides having near fatal to fatal effects on the residents
around the area.

The purpose of this study is

(1) to have knowledge on the impending environmental

consequences associated with LPG Bullets used in the
automobile industry in the State of Tamilnadu.
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(2) to understand whether the LPG Bullets are installed in a safe

location capable of handling the emergency situations in an
effective manner.

(3) to study the consequence scenarios like BLEVE, Thermal

Radiations, Vapour Cloud Explosions and impact on
environment due to LPG releases from the installation and
usage of the LPG Bullets in Automobile industries.

1.6 SCOPE AND OBJECTIVE OF THE STUDY

The scope of the Study is to cover LPG/Propane installation in

automobile industries located in the state of Tamilnadu. Many leading
automobile companies such as Hyundai, Nissan, Ford, BMW, Daimler,
Mahindra and Mahindra, Ashok Leyland, L&T Foundry, Lakshmi Machinery
Works etc., have their manufacturing as well as supply facilities in
Tamilnadu, utilizing LPG as a fuel to meet their energy requirements.
Automobile industries storing bulk quantities of LPG in their premises were
focused upon. These industries use and store LPG in the range of 4.6 MT to
1350 MT. Samples from thirty-five automobile industries out of one hundred
and twenty five units were taken for this study. These shortlisted industries
are located in Tamilnadu.

Research studies on safety, health and environmental impact have

been found to be scarce and case studies on accidents and other risks
associated with the automobile industries were not documented. These case
studies done on risk featured an entire range of activities without any specific
focus. No specific study was conducted with special reference to LPG storage
facilities and their associated EIA aspects. However, the documents of ILO
provided information related to the accidents.
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The Objectives of this study are:

to conduct Environmental Impact and Risk Assessment study

in the automobile industries located in Tamilnadu, where large
quantities of Liquid Petroleum Gas (LPG) / Propane are used.

to assess the environmental impact caused by the release of

LPG from its storage and other auxiliary facilities.

to review the hazards to workers and people in the

surrounding areas, damage to property and environment due to
the release of LPG.

to study and assess the parameters for quantification which

include flash point, degree of flammability, explosion, toxicity
etc.

to study and assess the influence of various factors such as

location, engineering design and systems implementation
during operation (production and maintenance).

to carry out Consequence Analysis of an emergency situation

at the industrial site and risk management in hazardous
installations of LPG handling industries.

to recommend improvement of the operational and

maintenance procedure for enhancing reliability and safety.

to check the environmental acceptability of the proposals

compared to the capacity of the site and the environment.

to ensure that resources are used appropriately and efficiently.

to identify the appropriate measures to mitigate the potential

impacts of LPG releases.
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to facilitate decision-making including setting the

environmental terms and conditions for implementing the
proposals of LPG handling automobile industries.

to avoid irreversible changes and damage to the environment.

to enhance the social aspects of proposals and to protect the

environment, ecology, health and safety.

to obtain primary information and acquire knowledge of

possible accident scenarios and probability of the hazards,
which are responsible for damage to property and public
health.

to enable planners to use the findings of the study while

sanctioning clearance for LPG handling automobile industries.

1.7 ORGANISATION OF THE THESIS

The thesis has been organized into six chapters as given below:

Chapter 1 provides the introductory details of the research work.

The need for the study, scope and objectives of the investigation, details of
LPG, its advantages and the organization of Thesis.

Chapter 2 describes the literature review highlighting the details of

the research work carried out pertaining to the studies on environmental
impacts and risk assessment of LPG bulk storages, modeling worst case
scenarios and past accident histories.

Chapter 3 presents the methodology adopted for the research plan

and research tool developed on line with statutory obligations and data
required for compilation of research tool.
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Chapter 4 presents the details of selection of the model, risk

assessment for various release scenarios such as thermal radiation due to fire,
shock wave pressure due to explosion, damage distances computation and
consolidation of results.

Chapter 5 summarizes the statistical analysis of observed data,

findings and discussion of results.

Chapters 6 present the conclusions, future scope of the research

area and follow up on the work done in the thesis.