Interfacing Analog to Digital Data Converters ee3404.pdf
FFBL Emergency Response Plan - Fire - Ammonia - Chlorine (10-10-2018).pptx
1.
2. FFBL management recognizes the significance to conduct its business in
a manner which will proactively protect the safety of all employees, the
interest of its neighbors, and preservation of the environment along with
Company’s own investment.
We are therefore determined to maintain an injury free environment by
giving safety a priority over all other issues.
FFBL SAFETY POLICY
3. .... to minimize the risk to their lives
by implementing an effective, well
coordinated safety program with
proper planning and control.
“PEOPLE -OUR ASSET” …
4. AMMONIA PLANT
UREA PLANT
DAP
PLANT
UTILITIES
PLANT
PRODUCT
HANDLING
& SHIPMENT
AMMONIA
STEAM
STEAM
AIR
UF - 85
CO2
PHOSPHORIC ACID
SULPHURIC ACID
SAND
COATING OIL
RAW WATER
DEMIN. WATER
INSTRUMENT AIR
POWER
NITROGEN
NATURAL GAS
NATURAL GAS
WASTE WATER
TREATMENT
“We are the only producer of Granular Urea & DAP in Pakistan having a
market share of 10% & 50%, respectively”
OVERVIEW – PROCESS PLANTS
5. Definitions
• Administrative controls
– Procedures for checking performance of employees on a plant
and task e.g. vessels entry, hot work & LOTO etc.
• Engineering controls
– Systems or interlocks involving the operation of physical
components without human interventions e.g. sensors,
transmitters, valves & dykes for containment etc.
• Consequence Analysis
– Development of potential scenarios, describing hazardous
events due to failure of engineering or administrative controls
e.g. Fire scenarios, Ammonia/Chlorine leakage etc.
• Facility:
– Physical structure/area within which a process/process segment
is operated e.g. FFBL plant, pipelines, warehouse etc.
6. Definitions
• Fire
– A combustion process accompanied by heat, flame and
light.
• Hazard
– Anything that has potential to cause harm to person,
property, equipment or environment.
• Risk
– Combination of likelihood that a hazard will occur and
consequence of the hazard.
• Explosion:
– Rapid increase in volume and release of energy in
extreme manner, usually with the generation of high
temperature and release of gases or
– A release of energy that causes a blast.
7. Why Emergency plan is necessary?
• To ensure employees know what to
do in emergency.
• Prevent harm to people
• Comply with the law
• Minimise the direct and indirect costs
• To increase staff morale
• To promote positive safety culture
8. Safety Critical Equipment
• Devices, equipment and systems whose failure could result in
– Serious personal injury or irreversible health effects
– Significant property loss
– Environmental impact
• Safety critical equipment could be
– Any plant equipment (vessel, pipeline, valve etc.) containing
hazardous material in significant amount e.g. Ammonia storage
tank.
– Systems, interlocks, instrument and controls that prevent loss of
containment of hazardous materials e.g. interlocking of HVAC
and DDEG with release of CO2 in protected areas.
– Equipment to mitigate the loss of containment of hazardous
materials e.g. firefighting equipment, hoses, hydrants,
emergency response communication equipment, safety showers
etc.
11. 11
Emergency
– potentially life-threatening situation, usually occurring suddenly and
unexpectedly.
Immediate response is essential
– Speed in responding can mean the difference between life and death or
between minimal damage and major damage
– Preparation is planning for emergencies
Plan, practice, evaluate, adjust
EMERGENCY PREPARATION
12. The 02 most dangerous scenarios which could lead to a disaster in any industry
are
FIRE
CHEMICAL RELEASE
13. • Bhopal gas tragedy, India
• December 2-3, 1984
• Estimated loss – Around 15,000 since
the tragedy and some 500,000 were
exposed to the deadly gases. It is, by far,
the worst industrial disaster of recent
times
What went wrong- Gas leakage
Worst Industrial Disasters that Shock the World
14. • Chernobyl disaster, Ukraine
• April 26, 1986
• Estimated loss- 50 people were killed
in the explosion. Some 4,000 cancer
deaths were observed following the
disaster
What Went Wrong - Reaction going out
of control .
Worst Industrial Disasters that Shock the World
15. • Piper Alpha disaster, North Sea
• July 6, 1988
• Estimated loss- Some 167 men lost
their lives with a total loss of US$ 3.4
billion. This makes it one of the worst
offshore oil disasters
What went wrong- Explosion followed by
Fire
.
Worst Industrial Disasters that Shook the World
16.
17.
18. 2013 Lac-Megantic, Canada Railcar Explosion
North Carolina Emergency Management
Town of approximately 6,000 people, 47 were killed
Credit: The Canadian Press/ Paul
Chiasson
Credit: The Canadian Press/ Ryan
Remiorz
20. 2013 West, Texas
North Carolina Emergency Management
- Neal Langerman, chemical and health safety
officer at the American Chemical Society
"The West, Texas, first responders were
doing the best they could under the
circumstances…The failure was in the
community, county, and state leadership
to provide emergency planning and
implementation guidance… I don't think
it's appropriate to beat up on what the
first responders did at the time of
detonation, but everything that led up to
it - preparedness and preparation - was
lacking,"
• A fire was reported at 7:19 PM
on April 17,2013.
• Explosion reported 20 mins.
after first responders arrived
• February 2012 Tier II filing did
not list ammonium nitrate
• Apartments and nursing homes
within a few hundred yards of the
plant
Source: Reuters
Fertilizer Plant Explosion
21. The world we live in today is an industrial one. All around us people make,
move and use products created from chemical that can be hazardous chemical
humans. As a result, there is a remote possibility that a hazardous chemical
could be spilled during transportation accident or a manufacturing accident.
CHEMICAL HAZARDS
22. Main Emergencies in FFBL
• Fire
• Chlorine release
• Ammonia release
• Flammable gas release and explosion
• Note: Emergency planning for these hazardous events should be
based on worst scenario.
• Chemical plant blast
in China
23. The people who might be at risk
• Operation staff
• Process
• Maintenance staff
• Lone workers i.e. cleaners
• Workers in isolated spaces
• Contractors
• Visitors
• Special persons i.e. disabled persons
• Could be any employee….
24. Training of employees to minimize injury and possible loss of human life &
company resources during emergency situation.
EMERGENCY PREPAREDNESS
25. • FIRE
– Weekly Fire Drill
– Live Fire Drill (Monthly)
• AMMONIA RELEASE
– Biannual NH3 dry run (Full scale mock drill)
– Emergency plan ready in place
– Table drills/ emergency handling discussion in rotating shifts
• CHLORINE RELEASE
– Mock drills
– Emergency plan ready in place
– Emergency handling discussion in rotating shifts
• SAFETY TALKS
– Weekly safety talks in rotating shift groups.
– Every Monday morning in general shift.
EMERGENCY PREPAREDNESS
26. • Emergency action plan should be in place.
• Every individual involved should be trained.
HOW TO ACHIEVE
27. OSHA Emergency Action Plan 1910.38
• Written and oral emergency action plans
• Minimum elements of an emergency action plan
(Discussed in next slide)
• Employee alarm system
• Training
• Review of emergency action plan
28. Min. Elements for Emergency Action Plan
OSHA 1910.38 (c)
• Procedures for reporting a fire or other emergency;
• Procedures for emergency evacuation, including type of evacuation
and exit route assignments;
• Procedures to be followed by employees who remain to operate
critical plant operations before they evacuate;
• Procedures to account for all employees after evacuation;
• Procedures to be followed by employees performing rescue or
medical duties; and
• The name or job title of every employee who may be contacted by
employees who need more information about the plan or an
explanation of their duties under the plan.
30. ROLE OF INDIVIDUAL IN DIFFERENT AREAS
PRODUCTIVE PERSONS
• In affected unit personnel seeing a loss of containment indicent,
immediately report to the respective control room & safety unit.
• Have gas masks and breathing apparatus available for use. Check the
wind direction.
• Keep yourself available for further instructions from your shift engineer.
Carefully understand those and question if the instructions are not
clear.
• Isolate the affected equipment if possible from the rest of the plant to
prevent further damage or aggravation off the situation.
• Take only calculated risk
• Move out of the operating area if asked by the shift engineer and reach
the safe assembly area.
EMERGENCY RESPONSE
31. • Un affected unit persons stay on the job as far as possible.
• Have gas masks and breathing apparatus available for use. Check the
wind direction.
• Carefully understand supervisor instructions. Question if instructions
are not clear.
• Take only calculated risk to carry out the assigned job.
• For evacuation, reach the safe assembly Area.
EMERGENCY RESPONSE
32. Role of unproductive persons
• All the outsiders working in open area check wind direction leave area
through the safe route & should reached near by shelter.
• The should used wet cloth to protect breathing
• Take all measures to stop entry of ammonia gas into your room by
closing doors, windows and blocking all openings with wet cloth
• Close (not lock) all doors, windows etc.
• Insert wet cloth all openings
• Breath through a wet cloth in case of difficulty. Store some water
• Turn off all air conditioners and air handling units
• Do not leave the room, wait for further instructions.
• No vehicle movement allowed, park aside vehicle & switched off the
engine, leave keys inside and take shelter in nearby building.
EMERGENCY RESPONSE
33. FIRE WATER NETWORK
Capacity of dedicated firewater reservoir 5000 m3
• Hydrants 72 Nos
• Monitor 11 Nos
• Working pressure 10 Bars
FIRE WATER PUMPS
• Jockey (30 m3 / hr) 02 Nos
• Electrical driven pump (600m3 per hr) 01 No
• Diesel engine driven pump (600M3 per hr) 01 No
FIRE TRUCKS 02 Nos
• Water 5000 Liters
• Foam 1000 Liters
• DCP (Dry chemical powder) 225 Kgs
FIRE FIGHTING FACILITIES
34. Chlorine Is used in utilities plant for cooling tower
Water treatment in gaseous form and is supplied in 900 kg cylinders, its
leakage is localized emergency.
In this BCC need not to be established and ICC will serve as control center.
CHLORINE RELEASE EMERGENCY HANDLING
35. CHLORINE MSDS
PHYSICAL PROPERTIES OTHER CHARACTERISTICS
Boiling point C -34
GREENISH YELLOW GAS, WITH PUNGENT ODOR .
The vapour is heavier than air and may travel along
the ground.
At local heating of steel equipment a chlorine iron fire
may develop.
Mixtures of hydrogen, acetylene and ammonia are
explosive, they can ignite even by the effect intense
sunlight.
At normal temperatures dry chlorine does not attack
steel, copper, bronze etc. Moist chlorine is strongly
corrosive.
Reacts violently with many organic compounds,
phosphorus and (finely dispersed) metals. Attacks all
metals in the presence of moisture.
The substance is corrosive to the eyes, the skin and
the respiratory tract. Inhalation of vapour and/or fumes
may cause shortness of breath (lung edema). Serious
cases may be fatal.
Melting point C -102
Relative density (water-1) 1.4
Relative vapour density
(air=1) 2.5
Vapour pressure in bar at 20 C 6.8
Solubility in water
g/100 ml at 20 C 0.7
Relative molecular mass 70.9
MAC in ppm
MAC in mg/m3
1
3
36. • Leakage from piping control system at Cl2 skid
downstream of cylinder:
CHLORINE RELEASE EMERGENCY HANDLING GUIDELINES
• In case of leakage alarm will sound on DCS in UCR.
• In case of leakage Area Operator and all other personnel in the vicinity of Cl2 skid will
immediately evacuate the area considering wind direction and inform UCR
• Utilities Shift Engineer / Panel Operator after confirming the leakage will announce
regarding leakage on public address PA system to keep away from affected area.
• Utilities shift engineer will also inform coordination Engineer and Safety Section
about the leakage.
• Coordination engineer will instruct Ammonia Unit personnel to keep away from
affected area.
• Safety section will reach affected area with Fire Truck / Scott air pack.
• Coordination Engineer will arrange to cordon off area on Ammonia plant site. Utilities
• Shift Engineer will arrange to cordon off area of Utilities side.
• Utilities Shift Engineer will depute one or two persons to wear Scot air pack and
isolate Cl2 cylinder.
• Safety section / Utilities Operations personnel will rescue any causalities wearing
Scott air pack or multipurpose cartridge mask available in UCR.
37. • Ammonia is a penetrating, intensely pungent odorous and strongly irritating
gas.
• It is lighter than air and soluble in water.
• The substance partially absorbs in the human body by inhalation.
• Chemical Formula is NH3
• Made up of one part nitrogen (N) and three parts hydrogen (H3)
• One of the most widely used sources of nitrogen for plant growth.
• Anhydrous means "without water."
• Because NH3 contains no water, it is attracted to any form of moisture.
• Most deaths from anhydrous ammonia are caused by severe damage to the
throat and lungs from a direct blast to the face.
• When large amounts are inhaled, the throat swells shut and victims suffocate.
• Exposure to vapors or liquid also can cause blindness.
• If exposed to NH3 immediately flush the exposed body area(s) with water for at
least 15 minutes
• Seek medical attention immediately after emergency first aid treatment
AMMONIA
38. • We insist on safety equipment and strict procedures for everyone follow.
• Provided leak detectors, warning alarm and automatic shutdown of our leak
control.
• In the unlikely event that and accidental released should occur FFBL
employee are trained.
• Exposure to the liquid ammonia may cause severe burn to skin & damage
the eyes.
• Excessive inhalation of the vapour causes severe damage to the lungs,
leading to death.
FFBL CONTROL MEASURE FOR AMMONIA RELEASE
39. We want to share with you basic information about a chemical we have on site
called anhydrous ammonia. We make it at ammonia plant and used in Urea
and DAP for manufacturing of Urea DAP fertilizer
WHAT YOU SHOULD KNOW ABOUT AMMONIA
40. Anhyd-06
• Caustic (alkali) burns
• Freezing burns
• Inhalation danger to
lining of mouth, throat
and lungs
• Does not support
respiration – suffocation
danger
• Especially dangerous to
eyes
Agrochemicals and Security: Security and Anhydrous Ammonia
AMMONIA HAZARD
41. AMMONIA MSDS
PHYSICAL PROPERTIES OTHER CHARACTERISTICS
Boiling point C -33 Ammonia is a colorless, intensely pungent gas
(anhydrous ammonia). It can be liquefied under increased
pressure. Under normal pressure liquefied ammonia
evaporates very rapidly, through it cools considerably
down to temperatures of – 33°C Gaseous ammonia is
readily absorbed by water. Such solutions contain up to
35% of ammonia. They are called ammonium hydroxide
or aqueous ammonia.
Liquefied ammonia and highly concentrated ammonium
hydroxide have a strongly caustic effect on the skin, the
mucous membranes and eyes. Liquefied ammonia can
also cause frostbite.
Highly concentrated gaseous ammonia can cause severe
cauterization. Its pungent smell serves as an early
warning and thus prevents in general, serious injuries to
health. The real danger lies beyond the limited of
tolerance. While actions of gaseous ammonia below the
limit of tolerance give no reasons to suspect injuries.
Physiological effects of ammonia of various
concentrations are described in the table below:
Melting point C -78
Flash point C flammable gas
Auto ignition temperature C 650
Relative vapour density
(air=1) 0.6
Vapour pressure in bar at 26
C
10
Solubility in water
G/100 ml at 20 C 53
Explosive limits, vol. % in air 15-29
Relative molecular mass 17.0
MAC in ppm
MAC in mg/m3
25
18
42. AMMONIA THRESHOLD LIMITS FOR HUMAN BEINGS
AMMONIA
VAPOR PPM
EFFECTS ON
UNPROTECTED HUMANS
EXPOSURE PERIOD
< 25 (TLV) No Effect No Limit
50 (TWA) Least Detectable Odor 8 hrs
500 (IDLH) Causes Irritation to Throat
1 hour
(Ordinarily No Serious Results Following
in Short Exposure i.e. < 1 hrs)
700 Causes Irritation to Eyes --
1700
Causes Convulsive
Coughing
No Exposure Permissible
(May be Fatal After ½ hrs)
5000 TO
10,000
Causes Respiratory Spasm,
Strangulation Asphsic
No permissible
(Rapidly Fatal)
Source = OSHA
TLV = Threshold Limit Value
TWA = Time Weighted Average
IDLH = Immediately Dangerous to Life and Health
43. Source
Type Ammonia Storage Tank
Dimensions, m D = 25 : H = 16
Holdup, Tons 2,500
Size of Weld Opening 12" x 6"
Meteorological Data
Wind Speed, m/sec 2.0
Wind Direction NW
Stability Class F
Ambient Temperature, °C 25
Humidity, % 60
Ground Conditions Open Country
INPUT DATA
44. • Ammonia Release from Storage Tank Roof due to Weld Failure
CASE SCENARIO
45. • Emissions Parameters
– Source Location
– Source Type / Size
– Extent of Damage
• Meteorological Conditions
– Wind Speed and Direction
– Atmospheric Turbulence (Stability Class)
– Ambient Air Temperature / Humidity / Cloud Cover
• Ground Conditions
DISPERSION MODEL - INPUT DATA
46. • Mathematical simulation of how air pollutants disperse in the ambient
atmosphere
Gaussian / Brigg Equations are used
DISPERSION MODELING
47. The term Dispersion includes
- Advection: Moving Downwind
- Diffusion: Spreading Crosswind
DISPERSION
48. Threat
Zone
NH3
Conc.
Effects Results
ERPG-1 < 25 ppm Mild
Coughing, Eye
Irritation
ERPG-2 < 150ppm Reversible
Chest Pain,
Impaired
Vision
ERPG-3 > 750 ppm Irreversible
Narrowing of
Throat, Coma,
Death
DISPERSION MODEL – OUTPUT
49. Threat Zone Description NH3 Conc. Effects
IDLH
Immediate Danger to
Life & Health
< 300 ppm
No reversible effects for < 30 min.
exposure
TC-50 Toxic Concentration < 1,100 ppm
50% irreversible effects for > 10 min.
exposure
LC-50 Lethal Concentration > 2,600 ppm 50% deaths for > 10 min. exposure
Threat Zones can also be defined manually [ SAIPEM ]
DISPERSION MODEL – OUT PUT
50. * Model Run: Gaussian
* Threat Zones:
LC-50 : 0.7 km [10 min.]
TC-50 : 1.1 km [10 min.]
IDLH : 2.4 km [30 min.]
OUTPUT
51. DISPERSION MODEL ON MAP
1.0 km
2.0 km
2.5 km
2.4 km IDLH
1.1 km TC-50
0.7 km LC-50
53. • Means of escape
– Route that leads to a safe place outdoors
– Must be properly signed
– Provided with emergency lighting
– May be two or more (depending upon the number of people and severity of risk
involved)
• Factors influence the means of escape
– Travel distance
– Number of available escape routes
– Escape routes width
– Design of any doors in the escape routes
– Provision of suitable assembly points
Building Evacuation
54. • Assembly point is a place where workers gather together once they
have evacuated a building.
• This allows roll calls to be taken for missing person to be identified.
• Assembly points should be
– At a safe distant to building
– At a safe location
– At a location where further escape is possible, if needed
– Out of the way of fire-fighters
– Clearly signed
Assembly Points
55. • Check all areas in the building to ensure that everyone is aware off
evacuation.
• To help someone where necessary.
• Give special assistance to the disabled persons. This may require
the use of special “Evacuation chair”.
• Investigate the site of the fire.
Fire Marshals
56. • Allow workers to practice emergency procedures.
• To ensure fast and effective response as per procedure.
• To ensure all workers behave in an appropriate manner.
• Record of drills, learning points and follow up actions should be
kept.
Mock Drills
