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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


Bottling Capacity Existing : 138 TMTPA Proposed: 232 TMTPA

Total Land Area

: 93.35 ACRES

Green belt Area

: 25 ACRES

Bulk LPG Storage Facilities

Sphere Existing Bullets Bullet Additional Existing 3150 MT 2 x 1400 MT 2 x 100 1 x 150 MT 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

Product Name LPG. Bottle gas, Liquefied hydrocarbon gas. LPG Mixture of propane and butane Gas Colourless Odorless/stanche d Insoluble UN No. 1075 Label / Class Red: Flammable Liquid / 2.1 Trade name Formula




Boiling Point / Range , deg. C Melting / Freezing Point , deg. C Vapor Density (Air =1) Specific Gravity , 20 deg. C Dyn. Viscosity (PA.S 30 deg. C) Molecular Weight. 1 138 1.5 to 2.0 0.53 to 0.57 Vapor Pressure at 65 deg. C, 16.9 kg/cm2

Physical State Appearance Odor Solubility in Water Calorific Value (Kcal / Kg.)



Flammability Extinguishing Media Special Procedures Highly explosive Dangerous Auto Ignition Temp. deg. C Explosive Limits , % 405-450 1.8 9.6

CO2, DCP. Water spray may be used to control and confine LPG fires. 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)


Material and construction failures Corrosion Gasket failures


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 Zone A Zone B Radiation (KW/M2) 37.5 12.5 Distance in meter 524 908 Affected population Plant Personnel Kanekal village Kacharaknahalli Dasarahalli Gidlapura Donnasandra Makanahalli Devalapura Vagatta Neighboring industries 80 443 472 495 176 1811 1582 482 1103 400

Zone C


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 CUM FIRE PUMPS 8 Nos. diesel driven water pumps of 410 / 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 IOCL, Terminal BPC Terminal HPCL Installation PETRONET Roles and responsibilities Traffic control and smooth evacuation of trucks Assist the Rescue Team members Assist Auxilliary team members Assist Auxilliary team members

Fire Fighting Organisation Chart

FIRE IN CHIEF: Sr. Plant Manager Alternate FIRE IN CHIEF: Manager (P)
FIRE COMBAT TEAM Team In Charge: Flo or Officer AUXILIARY TEAM Team In Charge: Manager (P) RESCUE TEAM Team In Charge: Asst. Manager (F)

Alternate team Incharge: Officer (Bulk Operations) Assisted by: 1. Tally o perator 1 2. Tally o perator 2 3. Segregation 1 4. Segregation 2 5. Pump Ho use 1 6. TLD 7. Carousel Tare wt. 1 8. Carousel Tare wt. 2 9. Evacuation 10. 11. 12. 13. ICU Gantry operato r 1 Gantry operato r 2 Security guard 1 (Main

Alternate team Incharge: S&D Alternate team Incharge : officer Accounts officer-II Assisted by: 1. Dy. Manager (P) 2. Safety Officer 3. Maintenance Officer 4. Maint enanc e operator 1 5. Maint enanc e operator 2 6. Employees on Relief 7. Security guard 3 (Stores) 8. Security guard 4 (Gate 2) Assisted by: 1. A O - II 2. Sr. Assistant

(Main gate) 14. Security guard 2 gate) 15. Security guard 3 (Patrolling)

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.