Transcript Slide 1

Control of chemical substances in India
which covers recent chemical
Substances related major accidents in
India as well as relevant laws &
regulations
Presenter
A.G.Shingore
National Safety council , India
(i) “Isolated storage” means storage of a hazardous
chemical, other than storage associated with
an installation on the same site specified in
Schedule 4 where that storage involves at
least the quantities of that chemical set out in
Schedule 2.
Schedule 2
e.g. Chemical
Threshold qty in tonnes
1. Ammonia
2. Chlorine
3. Bromine
4. Ethylene oxide
5. Hydrogen cyanide
60
10
50
5
5
Schedule 3
e.g. Chemical
1. Iso benzene
2. Benzidine
3. Benzidine salts
4. Ethion
5. Phorate
Threshold qty in Kgs
100
1
1
100
100
Schedule 5
e.g
Authorities with
legal backing
1. Chief Inspector of Factories
Duties &
corresponding Rule
1.Notification of major
accidents as per rule
5(1) & 5 (2)
(1) General responsibilities of the Occupier
during Industrial activity.
* Isolated storage of hazardous chemicals .
* Hazardous chemicals which satisfies any
of the criteria laid down in the Rule.
* Identify major accident hazards.
* Prevention of major accidents & limit their
consequences to persons & the
environment
(2) Notification of Major Accident:* Notify & inform to concerned authority
within 48 hrs.
* Full analysis of major accident through
concerned authority .
* Steps taken to avoid any repetition of such
occurrence on a site.
* Compilation of information regarding major
accidents from concerned authority.
(3) Approval & Notification of sites :
* Approval granted for industrial activity
from concerned authority.
* Notify for threshold quantity more of an
additional hazardous chemical
(4) Safety Reports & Safety Audit Reports :
* Preparation of safety report on industrial
activity .
* Submission of report to concerned
authority.
Safety Reports & Safety Audit Reports
(contd..)
* Preparation of safety report in
consultation with concerned authority on
industrial activity .
* Submission of report to concerned
authority.
* Independent safety audit with the help of
an expert, not associated with such
industrial activities.
* Updating of safety reports for
modifications & or new activity.
( 5 ) Preparation of On Site Emergency Plan by
the Occupier :* Prepare & keep up to date on site emergency
plan to deal with major accidents.
* Information to the every person on the site
who is affected by the plan .
* Mock drill of the on site emergency plan &
submit the report to concerned authority.
( 6 ) Preparation of Off Site Emergency Plans by
the Authority :* Prepare & keep up to date off site emergency
plan to deal with off site emergencies.
* Provision of information from occupier to
concerned authority on industrial activity.
* Rehearsal of the off site emergency plan by
the concerned authority.
( 7) Information to be given to persons liable to
be affected by major accident.:* Appropriate steps to inform persons outside
the site either directly or through District
Emergency Authority about :
a) Nature of the major accident hazard
b) Safety measures, Do’s & Don’ts which
should be adopted in the event of major
accident .
( 8 ) Collection , Development & Dissemination
of Information
* Arrange to obtain or develop information in
the form of safety data sheet & access to the
information.
* Hazardous chemical handle by occupier
shall ensure that the information is recorded
accurately & reflects the scientific evidence
used in making hazard determination
* Container of hazardous chemical shall be
clearly labelled or marked to identify :
a) Contains of the container
b) Name & address of the manufacturer or
importer.
c) Physical, chemical & toxicological data.
(9) Import of hazardous chemicals :
* Person responsible for importing hazardous
chemicals in India shall provide the
information pertaining to:
a) Name & address of the person receiving
concerned in India.
b) The port of entry in India.
c) Mode of transport from the exporting
country in India.
d) Quantity of chemical (s) being imported
e) Complete product safety information.
Import of hazardous chemicals – (contd..)
f) Safety measures to avoid likely cause
of major accident.
g) Safety & environmental considerations.
h) Appropriate steps regarding safe
handling & storage of hazardous
chemicals while off loading the
consignment within the port premises.
i) Maintain the records of hazardous
chemicals imported
j) Transportation of hazardous chemical
from port to the ultimate destination is in
accordance with the central motor
vehicles Rules, 1989
Releavent Laws & Regulations,
1. Manufacture , Storage & Import of
Hazardous Chemicals Rules, 1989.
* Notification of site.
* Safety reports & safety audits.
2. Control of Industrial Major Accidents Hazards
Rules, 2003.
* Duties of chief inspector
* General duties of Occupier
Releavent Laws & Regulations,
3. Central Motor Vehicles Act, 1988 & Central
Motor Vehicles Rules, 1989.
* Road tanker fitness
* Transport emergency card ( TREM CARD)
4. Chemical Accidents ( Emergency Planning,
Preparedness & Response) Rule 1996
* Preparation of On site emergency plan
* Periodic mock drills
Releavent Laws & Regulations,
5. Public liability Insurance Act 1991.
* Insurance policy for people around the
vicinity by occupier
6. Petroleum Act 1934 & Rules 1976
* License for storage & use of Petroleum
products.
* Safety & fire fighting provisions for
storage
Releavent Laws & Regulations,
7. Explosive Act, 1884
* License for storage & use of explosives.
* Safety & fire fighting provisions for
storage
8. The Gas cylinder Rules, 2004
* License for storage & use of compressed
gas cylinder.
* Safety & fire fighting provisions for
storage
Accident – 1
a) Name of Industry
b) Type of Accident
:
Century Rayon
Chemical Ind. Ltd.
:
Explosion
Acid Burn.
c) Description
:
i) Installation of new Sulfuric acid tank was
going on.
ii) Two employees were doing their job on top
of the tank.
iii) suddenly the near by another acid tank got
exploded due to ignition source of fabrication
Accident – 1 ( contd..)
d) Consequences :
i) Two fatality, three
serious injured
ii) Pollution of work
place environment
iii) Loss of Property
e) Root Causes
:
i) Nescent hydrogen caught
fire.
ii) Hot work permission very
near to acid filled tank.
Accident – 2
a) Name of Industry
:
Paschim Chemicals
b) Type of Accident
:
Explosion &
Chemical Burn.
c) Description
:
i) During trial batch on plant & completion of
solvent & acid addition heating was started.
ii) After 15 min. pressure observed on reactor
indicator.
iii) Solvent vapours came out through flange
joints of reactor.
iv) Resulted in explosion due to electrical spark.
Accident – 2 ( contd..)
d) Consequences :
i) Three fatality, three
serious injured
ii) Less productivity
e) Root Causes
:
i) Non-flameproof electrical
installations
ii) Hazard identification & Risk
assessment & control was
inadequate.
Accident – 3
a) Name of Industry
:
Shrihari Chemicals
b) Type of Accident
:
Acid Burn.
c) Description
:
i) Reactor pressurised due to exothermic
reaction containing oleum & solvent.
ii) The mixture came out from reactor manhole.
iii) Two workers working below the reactor
injured due to splashing of acid & during
treatment they died.
Accident – 3 ( contd..)
d) Consequences :
i) Two fatality
ii) Pollution in work place
environment.
e) Root Causes
:
i) High rate of oleum addition
due to failure of orifice.
ii) Hazard operatability
( HAZOP ) study &
interlocks were not
appropriate.
Accident – 4
a) Name of Industry
:
Anshul Chemicals
b) Type of Accident
:
Release of Toxic Gas
c) Description
:
i) Chlorination was started at 9.00 p.m.
approximately 300 Kgs chlorine was passed.
ii) Reactor containing intermediate chemicals.
ii) At about 10.30 p.m. it was observed that
release of toxic gas from scrubber vent.
iv) Dispersed around the area.
v) Employees of near by industries were
affected by inhalation.
Accident – 4 ( contd..)
d) Consequences :
i) Respiratory problem to
employees & near by
villagers.
ii) Ambient air Pollution.
e) Root Causes :
i) Failure of scrubbing system.
ii) Leak detectors & alarms
were not in operation.
iii) Preventive Maintenance.
Accident – 5
a) Name of Industry
:
Jyoti chemicals
b) Type of Accident
:
Explosion
c) Description
:
i) Reaction containing flammable mixture
completed.
ii) Batch transferred to another kettle.
iii) Applied inert gas to avoid flammable
containment in the system.
iv) As soon as nitrogen gas applied explosion
took place in the system.
Accident – 5 ( contd..)
d) Consequences :
i) Two fatality & five injured.
ii) Loss of property.
e) Root Causes :
i) Instead of inert gas air was
applied.
ii) No system to ensure the
specific inert gas or air in
the cylinder.
Accident – 6
a) Name of Industry
:
Nirmal colourants ltd.
b) Type of Accident
:
Fire
c) Description
:
i) Charging of solid material from HDPE bags to
kettle going on.
ii) Fire took place due to static charge .
Accident – 6 ( contd..)
d) Consequences :
i) One fatal & Three injured.
e) Root Causes :
i) Earthing & bonding was not
adequately provided to
neutralize the static charge
generated.
ii) Potential hazard involved in
the process was not captured
properly by using hazard
identification techniques
like HAZOP study.
Accident – 7
a) Name of Industry
:
Unichem Laboratories.
b) Type of Accident
:
Chemical Burn
c) Description
:
i) Mixed acid charging in the reactor was in
progress.
ii) Level gauge of mixed acid measuring vessel
broken.
iii) Mixed acid splashed on the body of two
employees.
Accident – 7 ( contd..)
d) Consequences :
i) Two injured seriously.
e) Root Causes
:
i) Inadequate preventive
maintenance.
ii) Employees not aware about
potential hazard involved in the
operation.
iii) Lack of awareness training.
Accident – 8
a) Name of Industry
:
KDL biotech limited.
b) Type of Accident
:
Fire
c) Description
:
i) Solvent unloading from tanker to drums
having 200 lits capacity was in progress.
ii) 50% of solvent unloaded in HDPE drums.
iii) Fire took place near tanker.
iv) Solvent storage godown also caught fire.
Accident – 8 ( contd..)
d) Consequences :
i) One fatal & nine injured .
ii) Loss of property.
e) Root Causes
:
i) Static charge generated during
unloading solvent from tanker
to drum.
ii) No proper earthing & bonding
arrangement while unloading
solvent from tanker to drum to
neutralize the static charge.
iii) Lack of awareness training.
Accident – 9
a) Name of Industry
:
Ispat limited.
b) Type of Accident
:
suffocation
c) Description
:
i) Two workers were doing maintenance work
inside the kettle.
ii) Personnel from production started charging
CO in the same kettle.
iii) Assuming that it is empty & ready for
charging next batch.
iv) Due to inhalation of carbon monoxide two
workers died in the kettle.
Accident – 9 ( contd..)
d) Consequences :
i) Two fatal .
e) Root Causes
:
i) Ineffectiveness of work permit
system .
ii) Lack of awareness training.
Accident – 10
a) Name of Industry
b) Type of Accident
c) Description
:
Gharda chemicals.
:
Release of poisonous gas
:
i) During addition of solvent in agrochemicals
intermediate kettle.
ii) Toxic & poisonous gas started releasing from
flange joints .
iii) Shop floor workers affected due to inhalation
of poisonous gas.
Accident – 10 ( contd..)
d) Consequences :
i) Two fatal & three injured
e) Root Causes
:
i) Hazard not identified & risk was
not evaluated before starting
the batch.
ii) Improper MOC of gasket.
iii) No proper scrubbing system.
Accident – 11
a) Name of Industry
b) Type of Accident
:
Leakage of Bromine
during transportation.
:
Release of Toxic gas
c) Description
:
i) Transportation of Bromine carried out
through glass bottle having 3 Kgs capacity in
wooden box by goods vehicle.
ii) During transportation few bottles broken &
started leaking.
iii) Due to leakage near by area affected with
bromine gas.
Accident – 11 (contd..)
d) Consequences :
i) People around the area
affected due to inhalation.
e) Root Causes
:
i) Inadequate packing of
bromine bottle.
ii) Untrained driver.