Details of Storage of Hazardous Materials in Bulk

NAME OF
HAZARDOUS
SUBSTANCE

MAX. STORAGE
CAP.[Qty.]

PLACE OF
ITS
STORAGE

OPERATING
PRESSURE
AND TEMP.

TYPE OF
HAZARD

Furnace Oil/

27 KLX 2 Nos
U/G tanks

MS Tank

Atmospheric
Ambient

Fire

1.
2.
3.
4.
5.

CONTROL MEASURE
PROVIDED

Flame proof plant,

pumping transfer, close
process, etc.
Double Static
earthing
Jumper clips on
flanges
Hydrant system
Fire extinguishers
Fencing and No
Smoking and prohibited
area.
Tanker unloading
procedure.

Lightening arrestor on all chimneys and building provided.

Fencing and caution notes and hazard identification boards displayed.
. Only authorized person are permitted in storage tank farm area.
. Safety permit for hazardous material loading unloading is prepared and implemented.
Static earthing provision is made at all loading unloading points of flammable chemical storage
tank farm area.
6. TREM CARD provided to all transporters and trained for transportation Emergency of Hazardous
chemicals.
7. . Fire hydrant system and water sprinkler system installed at tank farm area.
8. . Caution note, safety posters, stickers and emergency preparedness
9.
10. Nitrogen blanketing for flammable liquid/ gas storage tanks.
11. b) Pressure ( Maximum and Minimum ) cutoff and gauge provided.
12. c) DCS operational process plan with 100 % foolproof safety logics are provided for process as
well as storage safety.
13. d) Level gauges on storage tanks.
14. e) Static bonding of pipeline flanges.
15. f) Dyke wall provided surround above ground storage tanks.
16. g) Safety valve and other venting system provided on pressure storage vessels.
17. h) All pumps flameproof type and double mechanical seal type.
18. i) All pipeline and tanks painted as per IS colour code.
19. j) Jumpers and static earthing provision made on all flanges and tanks.
20. k) Caution note and Material identification, capacity displayed on all storage tanks.
21. l) Water sprinklers surrounding Ammonia storage tank and EO storage tank.
22. m) Matur curtain sprinkler will be provided for Acid storage tanks leakage spillage.
23. n) Mosture absorbent (Silica gel provision will be made on sulfuric, Oleum , SO3
24.
25. Pipelines
26. a) Jumper connections on flanges to prevent build up of static electricity charge.
27. b) Proper supports and clamping are provided
28. c) Double earthing provided to all electrical motors.
29. d) Colour code as Per IS maintained.
30. Operations and maintenance of the plant is being in accordance with the well-established safe
practices. Some of the guidelines are as follows:-

31.
32.
33.
34.
35.
36.
37.
38.
39.

a) Periodic testing of hoses for leakages and continuity.

b) Earthing of all plant equipment and earthing of vehicles under unloading operations.
c) Annual testing of all safety relief valves.
d) Planned preventive maintenance of different equipment for their safety and reliable operations.
e) Inspection of the storage tanks as per prefixed inspection schedule for thickness measurement,
joint and weld efficiency etc.
f) Comprehensive color code scheme to identify different medium pipes.
g) Strict compliance of safety work permit system.
h) Proper maintenance of earth pits.
i) Strict compliance of security procedures like issue of identify badges for outsides, gate pass
system for vehicles, checking of spark arrestors fitted to the tank lorries etc.
j) Strict enforcement of no smoking regime.
k) Periodic training and refresher

40.
41.
42.
43. FIRE FIGHTING FACILITIES.
44.
45. Internal hydrant system
46. Portable extinguishers
47.
48. 8.8.4 FIRE PROTECTION SYSTEMS
49. These systems are proposed to protect the plant by means of different fire protection facilities and
consist of
50. Hydrant system for exterior as well as internal protection of various buildings/areas of the plant.
51. Portable extinguishers and hand appliances for extinguishing small fires in different areas of the
plant.
52. Water cum foam monitor to be provided in bulk fuel storage area.
53. Fire water pumps.
54. Two (2) independent motor driven pumps each of sufficient capacity and head are proposed for
the hydrant systems which is capable to extinguish Fire or cooling purpose.
55.
56. 8.8.5 HYDRANT SYSTEM.
57.
58. Adequate number of fire hydrants and monitors will be provided at various
locations in and around the buildings and other plant areas. The hydrants will
be provided on a network of hydrant mains drawing water from the hydrant
pump, which starts automatically due to drop of pressure in the event of
operating the hydrant valves. We are suggesting you to go for TAC approved
hydrant system for foolproof safety and benefit from fire policy
PROCESS SAFETY MANAGEMENT

Hazard & Operability (HAZOP) studies

Failure Tree Analysis (FTA)

Event Tree Analysis (ETA)

Primary Hazard Analysis (PHA) using Dow Index

Risk Assessment (with risk ranking technique)

3.0 ELECTRICAL RISK ASSESSMENT

Review of Hazardous Area Classification

Lightning Protection Risk Assessment

Identification & Control of Electro-Static Hazards

Review of electrical Preventive Maintenance System

Electrical Risk Assessment (fire, shock explosion) using Semi-Quantitative Risk Ranking
(SQRR) technique

4.0 FIRE RISK ASSESSMENT

Identification & assessment of fire risks during operations in receipt, storage, transfer and
handling of chemicals (raw materials and finished products)

Identification & control of ignition sources in areas where flammable chemicals are stored /
handled / transferred
o

Review of chemical compatibility in storage areas and to suggest appropriate fire

loss control measures

Review of fire detection measures adopted in the plant & to suggest suitable
improvement measures

Review of the various active (fire hydrant, sprinkler, portable fire extinguishers) and
passive fire protection requirements for chemical storage and handling areas and to
suggest improvements as necessary

Review of contractor safety awareness (chemical spill, fire fighting, emergency

communication, knowledge of plant hazards & safety regulations) and to
recommend suitable improvement measures to enhance contractor safety

Review of safety awareness and safety training requirements ( training

identification and efficacy) of plant employees with respect to hazards present in
the plant

Fire risk assessment will be carried out based on techniques like Matrix method, Hani Raafat Risk
Calculator. The consequence, likelihood and exposure of each hazard are arrived using a
systematic approach and will help to determine the relative importance of hazard and focus on
significant risks.
5.0 RISK ANALYSIS & EMERGENCY PLAN

Identification of scenarios of potential disasters / emergencies leading to loss of life ,

property damage etc. and qualitative assessment of their likelihood.

Quantitative risk assessment for selected scenarios of major credible events.

Recommendations for risk control measures wherever applicable.

Preparation of onsite emergency preparedness plan

6.0 RISK MANAGEMENT & INSURANCE PLANNING

Identification of all major internal and external pure risks including the natural risks and
analysis of the impact of above risks

Review of existing risk control measures and offering comments

Scrutiny of all existing major insurance policies in respect of:

o

Rationalization of basic rate of premium and widening of covers

Applicability / eligibility of discounts in premium

Application of suitable clauses, warranties and conditions

Identification of possible areas for refund of premium and suggestions regarding procedure
for the same

Selection of insurance coverage on the basis of risk analysis

Providing guidelines for fixation of sum insured and illustrate the same on a selected
equipment

Evaluation of business interruption exposure due to identified risks

Providing guidelines on documentation requirements, procedures for claims under various

policies, evaluation of insurers

B. Risk Management Training

Specialized and focussed training, if imparted effectively, can contribute significantly to Risk
Management. Expert faculty, carefully selected training module, interactive and participate
approach, useful training material, case studies and syndicate exercises could help in having
effective risk management system in place. The training topics for bulk drug industry could be:

Chemical Safety

Safety with Compressed gases

Solvent Safety

Hazard Identification Techniques

Industrial Risk Management

Fire Prevention and Protection

Electrical Risk Management

Emergency Preparedness

Safety Management system

Accident Prevention

Personal Protective Equipment