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Profile of Devanagunthi LPG Bottling Plant Plant is situated at Devanagunthi. • 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
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 : 93.35 ACRES • Green belt Area : 25 ACRES
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 BTPGLNwagons.
NAME OF PRODUCT / CHEMICAL : LPG IDENTITY OF MATERIAL : Product Name LPG. Bottle gas, Liquefied hydrocarbon gas. UN No. 1075 Label / Class Red: Flammable Liquid / 2.1 Trade name LPG Formula Mixture of propane and butane HAZCHEM Code 2WE PHYSICAL AND CHEMICAL PROPERTIES Physical State Gas Boiling Point / Range , deg. C 1 Vapor Pressure at 65 deg. C, 16.9 kg/cm2 Appearance Colourless Melting / Freezing Point , deg. C 138 Odor Odorless/stanched Vapor Density (Air =1) 1.5 to 2.0 Solubility in Water Insoluble Specific Gravity , 20 deg. C 0.53 to 0.57 Calorific Value (Kcal / Kg.) 11400 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 Material Safety Data
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
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)
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.
Fire Fighting Organisation Chart FIRE IN CHIEF: Sr. Plant Manager Alternate FIRE IN CHIEF: Manager (P)
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.