Hazard Identification An Assessments, in Chlor-Alkali Industry

05 December 2011
Hazard Identification & Risk Assessment

in ChlorAlkali Industry
Under the Auspices of Alkali Manufacturers Association at GACL Dahej
D.D.Chhaya
15th December, 2011
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Hazard identification & Risk Assessment in ChlorAlkali Industry

15th December, 2011
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05 December 2011
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Slide 3
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15th December, 2011
DNV Business Assurance. All rights reserved. Slide 4
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05 December 2011
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15th December, 2011
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05 December 2011
Disaster Management Means damage Control
The first duty of Business is to survive, and the

guiding principle of Business economics is not
the maximisation of profit - it is the avoidance
of loss
PETER DRUCKER
Loss can be avoided by reducing rework / accidents

This can be achieved by control of activities.
Control of activities require systematic approach.
This can be achieved by assessing your hazards & risks
Having a structured safety and loss control Management system.
Risk Management Hierarchy
Hazard Identification and Risk Assessment is the Preventive Step
It is Logical to Start the Technical Session with Prevention

15th December, 2011
Slide 8,
DNV Business Assurance. All rights reserved. rev 1
4
05 December 2011
Identified Sources of chlorine leak in Caustic

Alkali Industry
Acknowledgment CPCB September 2008, CPCB
http://www.cpcb.nic.in/upload/NewItems/NewItem_137_chlorine_package.pdf
Brine section
Cell house
Chlorine drying section
Chlorine liquefaction section (sniff)
Liquid chlorine pump
Chlorine evaporator
Chlorine storage tanks (sniff)
Leakage of sniff (unliquifiable) gas line
Chlorine cylinder filling
Excess chlorine treatment section (DC tower)
Chlorine absorption in bleach liquor plant
Hydrochloric acid plant
5 kg per tonne of HCl product is lost during start-up period
HCl loss through air if acid could not be sold or there is a dearth of storage

15th December, 2011
Sources of chlorine leak in Caustic Alkali

Industry
Tail gas scrubber
Hypo vent stack
Power failures
Failure of chlorine compressor and/or suction device
Voltage fluctuation and consequent load fluctuation or tripping of pumps
Miscellaneous
Leakage of chlorine from pump glands, flange joints, corroded pipes and
valves.
Handling and transfer of chlorine from one vessel to another
Cleaning of chlorine tankers, cylinders, drums etc.
Improper or insufficient treatment of spent brine or its leakage
Treatment to these are kept out of scope of this presentation as covered

by eminent scholers under the auspices of The CPCB

15th December, 2011
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05 December 2011
Together we shall cover

Learning from Indian Experience with Chlorine Leaks and Some
incidences abroad as covered in public domain
Relevance of Disaster Management Seminar for Civic Awareness
Hazard & Risk Definitions (Disaster is a special type of Incidence)
How to Identify Hazards of Chlorine and Alkali
How to Evaluate Risks?
Sample from reported activities to determine Criticality
11
Indian Experience with Chlorine Disasters
D.D.Chhaya
15th December, 2011
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05 December 2011
Some incidences
Thanks to media coverage on chlorine leak incidences

that offer a considerable learning opportunity
Chlorine leaks reported in public domain are not

confined to only to manufacturing industry but
activities are relevant to caustic chlorine industry

15th December, 2011
Chlorine Handling Percolated to District

Panchayat Level
Dist panchayat to observe Chlorination Day on Sept. 20
TNN Sep 18, 2011
KOCHI: The district panchayat has decided to observe

September 20 as Chlorination Day. As part of the
programme chlorine will be made available at all
panchayats and community health centers in the district.

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05 December 2011
Chlorine Leaks
Industry Related Incidences
Haryana Yahoo News
January 29, 2011 Hirapur
The Haryana administration on Saturday evacuated people from
two villages after they detected a chlorine gas leak at a nearby
factory. 17 hospitalised
The villagers were not aware of the factory or its functions, as its
gates were always locked.
The gas leak began on Friday 27 January, 2011, but the local
administration reacted after the gas spread to the neighboring
village of Naryala, and when people complained of breathing
problems.
"We have controlled 70 percent of the gas and the rest we will have
to control," said District Commissioner.
15th December, 2011
Chlorine Leaks
Chlorine gas leak at Dahej plant affects 250

TNN Dec 21, 2002,
A chlorine gas leakage from a Caustic Chlorine

plant at Dahej in Bharuch district affected about
250 people. The leakage took place in the
scrubber tower of the hypochlorate section of
the plant.

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05 December 2011
Chlorine Leaks
Industry related incidences
Punjab Newsline Network

Saturday, 04 October 2008
RUPNAGAR: One worker died and six others have
fallen ill after the leakage of chlorine gas in a plant at
Nangal.
The incident occurred yesterday when workers, working
with a salt contractor of the company, were taking a bath
at a tap inside the plant area. Suddenly, the chlorine
gas started leaking from a pipe as a result of which
seven workers, who had inhaled the gas started feeling
breathlessness.
15th December, 2011
Chlorine Leaks
Express News Service October 19, 2008: Ammonia gas

leak at Ankleshwar, led to the death of a woman living near the
gas factory. Her sons condition is stated to be critical.
Chlorine leak: EARLIER, the Gujarat Pollution Control Board
(GPCB) had issued a notice to one chemical factory after a
chlorine gas leak incident at Ankleshwar.
The Hindu - Tamil Nadu Chennai
Monday, Sep 27, 2010
Panic prevailed in Sathyamoorthy Nagar, Manali, on Sunday
evening following a leak in a chorine gas pipeline. Fire and foam
tenders were rushed to the spot to contain the leak and a fire in
one of the pipes.

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05 December 2011
Chlorine Leaks
Transportation
The Hindu, Oct 19, 2006 Elluru, Andhra

One person and four buffalos were killed and 150 people were
hospitalised following a freak case of chlorine leakage near Gutala
in West Godavari district. There was leakage in one of the 12
chlorine cylinders being transported from a sugar factory at
Saggonda to a paper mill at Vendra .
Gujarat Economic Times
Monday, September 06, 2010
Rajkot: Nearly a hundred people were hospitalised following a
chlorine gas leakage on Rajkot-Morbi highway. A truck carrying
nearly 20 chlorine cylinder overturned after driver lost control over
the wheel.

15th December, 2011
Train Transport - Chlorine Disaster

June 28, 2004 - The collision of two trains near Macdona, Texas
caused a release of liquefied chlorine from one of the train's tank cars.
The chlorine vaporized, engulfed the area and led to the deaths of the
train conductor and two local residents.
January 6, 2005 - In Graniteville, South Carolina, a Norfolk Southern
train collided with a stationary train, leading to a derailment, and the
release of an estimated 120,000 pounds of chlorine. The derailment
and resulting chlorine release caused 9 deaths, led to over 500
persons seeking medical treatment for possible chlorine exposure and
the mandatory evacuation of over 5,000 residents.

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05 December 2011
Chlorine Leaks
Abandoned Cylinders
Express News Service
Jul 24, 2009 Mumbai Twelve villagers from Kathai, Dhondi and
Talodi villages in Bhiwandi admitted to Hospital. They were affected
due to chlorine leak from four abandoned chlorine cylinders, which
were used for water purification two decades back.
Andhra Pradesh The Hindu April 10, 2010 KAKINADA,
53 speech impaired school children, five constables hospitalized
following leakage of chlorine gas from a cylinder at scrap dealer's
yard. By the time a team of the Fire and Safety Department arrived,
the cylinder, which had been disposed of long ago, was almost
empty. The scrap dealer told the police that the cylinder was lying
underground and surfaced recently when the site was dug up for
road expansion. It was a part of large quantity of scrap purchased
from a fertilizer factory a decade ago.

15th December, 2011
Chlorine Leaks
Unclaimed Cylinders
Mumbai | Agency: DNA Wednesday, Jul 14, 2010

Sewri chlorine leak sends 123 to hospital including dock workers,
students from a nearby maritime college hostel and firemen.
Nearly 60kg of chlorine bottled in a cylinder lying unclaimed in the
Mumbai Port Trust (MbPT) dock at Haji Bunder in Sewri for ten
years leaked due to corrosion and spread early on Wednesday
morning. The consequences could have been disastrous had five
other gas-filled cylinders at the warehouse with larger proportions of
chlorine leaked. Each of these contained 850-900kg of chlorine as
compared to 110kg that was present in the leaking cylinder.

15th December, 2011
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05 December 2011
Chlorine Leaks
Municipal Water Supply/ Sewage Treatment
Orissa Times of India - Monday, Jun 21, 2010

At least 35 people were taken ill, some even falling
unconscious, after chlorine gas leaked from a cylinder of
water supply department in Berhampur district of Orissa.
The cylinder leaked when someone allegedly tried to
remove the brass nozzle.
Gujarat - TNN Oct 21, 2002, Ahmedabad:
Five persons admitted to VS Hospital after inhalation of
chlorine gas leaking from one of three abandoned 100-
kg chlorine cylinders near Pirana sewage treatment
plant at Gyaspur village. Doctors said that one person,
of Vatva was semi-conscious when brought in.

15th December, 2011
Chlorine Leaks
Goa Times of India- Sep 18, 2011
PANAJI: Chlorine gas leaked from a cylinder near the pump room in
the Kala Academy compound in Panaji, slightly injuring one person
late Saturday evening.
Maharashtra : Pune Jan 18, 2011, Agency: PTI, DNA
Twenty-four people, including one corporator and some fire brigade
personnel, were hospitalised following leak of chlorine gas in the
wee hours of Tuesday from a cylinder at the sewage treatment plant
(STP) at Bhatnagar, in Pimpri.
One of the valves of a cylinder out of 12 stored was damaged.
The spread of the toxic gas caused panic among the 30,000-odd
residents.

15th December, 2011
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05 December 2011
Chlorine Leaks
Union Territory, Chandigarh - Times of India
May 21, 2011,
Recurrence of chlorine leakage
Chlorine gas leakage at a tube well in Manimajra under municipal
corporation, which affected 15 people on May 10, 2010. about a
year ago
On Saturday night, 21st May 2011, there was a similar leak from
three chlorine cylinders out of 11 lying in open at MC public health
department's tube well in Sector 15. As a result, 20 persons had to
be rushed to Government Multispeciality Hospital. Ten workers of
the public works department, including four women, who were
sleeping in shanties next to the tube well, were the worst affected.

15th December, 2011
One common denominator in most of the

cases
Inadequacy in Hazard Recognition The
first step in Hazard Identification and Risk
Assessment
Abandoned chlorine cylinders for two decades
Unclaimed chlorine cylinders nearly a decade back
Chlorine cylinders sold to scrap dealer
People bathing near potential source of chlorine
leak
Attempt to remove brass nozzle from a cylinder
Transportation of cylinders by truck or rail
Likely lack of awareness of legal requirement for
transportation

15th December, 2011
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05 December 2011
Some Case Studies

Shewri Port Chlorine Gas Leak Case Study by Rakesh Kumar Sharma,
Raman Chawla, and Surendra Kumar, Brig SK Mazumdar
Chlorine leak incident at a Chlorinated Paraffin Wax factory in Gujarat by
Mr Harbhajan Singh Seghal
Chlorine Gas Leak: A School Incident in Andhra Pradesh by Reddy CR
Ram
Chlorine leakage from bonnet of a valve in a bullet a case study by R. K.
Gangopadhyay, S. K. Das+ and M. Mukherjee*
Review of Graniteville, South Carolina Chlorine Rail Disaster by Stephen
Brittle
Massive leak of Liquified Chlorine Gas at Handerson, Navada by J. Gordon
Routley
There is also a session on case studies in this seminar hence out of
scope of this presentation.

15th December, 2011
Understanding Hazards &

Risks
General Definitions
D.D.Chhaya
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05 December 2011
Incident & interested party

Incident
Work related event(s) in which an injury or ill health

(regardless of severity) or fatality occurred,or could have occurred
OHSAS 18001, clause 3.9
NOTE 1 An accident is an incident which has given rise to injury, ill health or fatality.
NOTE 2 An incident where no injury, ill health, or fatality occurs may also be referred to as a near-
miss, near-hit, close call or dangerous occurrence.
NOTE 3 An emergency situation (see 4.4.7) is a particular type of Incident
Interested party
Person or group, inside or outside the place of work concerned
with or affected by the OH & S performance of an organization
29
Hazard & hazard identification

Hazard
Source, situation or act with a potential for harm in terms

of human injury or ill health or a combination of these
Hazard Identification
Process of recognizing that a hazard exists and defining
its characteristics
30
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D.D.Chhaya
15th December, 2011
Secret of Success in Managing EHS

Emergencies
32
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05 December 2011
SAFETY DEPENDS on ........
HARDWARE SOFTWARE
the plant and upkeep The organisation
HUMAN WARE
The people
SAFETY DEPENDS on ........

Critical task Recruitment and
and procedures placement
Planned Inspection Accident incident
Engineering and change reporting/analysis
Rules and Work permit

Procurement
SOFTWARE Emergency
HARDWARE
The organisation preparedness
Maintenance the plant and upkeep
System review
Materials and Services
management
HUMAN WARE Leadership

Health and Hygiene The people
Training
Personal and Group Communications Leadership
Task Observation Knowledge
PPE skill
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05 December 2011
Occupational Health
Goals of Proactive Safety Management
Identify all Loss

Exposures
Monitor the Plan Evaluate the Risk in

Each Exposure
Implement the Plan Develop a Plan
Ask The question
What can go wrong?

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05 December 2011
Identify All Hazards
Planned Inspections
Group Meetings
Accident/Incident Investigations and
Analyses
Employee Surveys
OHS Management System Audits
Hazard Surveys
Other Activities

15th December, 2011
examples of ..................
RISKS
HAZARDS Severity
slips, falls Injuries
lifting and handling hazards MINOR - cuts, bruises,
operation hazards irritation
M AJOR - burns, concussion ,
dismantling
fractures , deafness, lung
maintenance, repair disorders
commissioning SEVERE - poisoning, fatal
injury, cancer, multiple
fire and explosion
fracture
vehicle
violence
inhalation
Likelihood
number of personnel exposed
eye damage hazards
frequency and duration of
skin contact exposure
electric shocks failure and shutdown
contractors etc ....... unsafe acts being performed
19
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Occupational Health
Identification
Evaluation
Control

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Identification
Categories of Health Hazards
Chemical Biological
Physical
Ergonomic

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05 December 2011
Occupational Health hazards

Chemical Physical
Dust/fibres Noise
Fumes Vibration
smokes Temperature
mists/aerosols Radiation
Gases Illumination
Vapours
Biological Ergonomic @
Virus, bacteria, fungi etc Lifting, repetitive motion,

pressure, fatigue
Identification
Resources
Material Safety Data Sheets Experience
Knowledge of Work Investigation Reports

Processes Professional Assistance
Effective Inspections First Aid and Medical Reports
Task Analysis and Structured Health Hazard
Observations Surveys
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Evaluation
Evaluation Variables
Inhalation
Absorption
Ingestion
Injection

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Evaluation
Evaluation Variables
Chemical Concentration Previous Work Experience
Route of Exposure Drug Interactions
Length of Exposure Chemical Formulation
Frequency of Exposure Controls in Use
Individual Variations Temperature and Humidity
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Evaluation
Types of Exposure
Acute - An intense exposure over a relatively short period of

time.
Chronic - A prolonged exposure occurring over a period of days,

weeks or years.

15th December, 2011
Evaluation
Threshold Limit Value
Threshold limit values refer to airborne concentrations of substances and

represent conditions under which it is believed that nearly all workers may
be repeatedly exposed day after day without adverse effects.
American Conference of Government Industrial Hygienists

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05 December 2011
Evaluation
Categories of TLVs
TLV-TWA (Time-Weighted Average)
TLV-STEL (Short-Term Exposure Limit)
TLV-C (Ceiling)
TLV-SKIN (Skin-Contact Limit)

15th December, 2011
Hazard Identification Methodology

You need to consider.
The methodology to be used

Involvement of employees
Any legal requirements
Criteria for hazard identification
Frequency
Competence requirements
Criteria for process evaluation

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Hazard Identification - Considerations

Routine Non Routine
Activities of all persons
Human Behaviour, Capabilities and Other Human Factors
Hazards outside or in vicinity of workplace
Infrastructure, Equipment and Materials
Changes / Modifications, Temporary or Permanent
Legal Obligations
Design of Workplace, Work Organization and Procedures
Including Adaptability to Human Behaviours

15th December, 2011
Possible Hazard Identification Methodologies

Fault Tree Analysis
FMEA
HAZOP
Patrolling for Observing

Critical Task Analysis
Event Tree Analysis
Accident/Incident Analysis
Near Miss Reports
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05 December 2011
Risk Assessment
D.D.Chhaya
15th December, 2011
Risk Management Process(ISO

31000:2009)
Establish the Context

Communicate and Consultation
Monitor and Review

Risk Assessment
Risk Identification
Risk Analysis
Risk Evaluation
Risk Treatment
AS/NZS 4360:2004
Slide
52, rev 1
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Why Emergency / Disaster?
Disasters that could have been avoided happen for

three main reasons.
These are:
1. Risk not recognised (often results in no

controls!)
2. Incorrect prioritisation of risk
3. Lack of management response.
Slide
53, rev 1
Why Is Risk Identification So Important?
When risks are not identified, organisations will not have any
planned control or contingency measures in place.
It is often the punch that the boxer does not see that knocks
him out!

15th December, 2011
Slide
DNV Business Assurance. All rights reserved. 54, rev 1
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05 December 2011
Risk

15th December, 2011
Remember - Emerging Risks
Business Risk
Invisible risk
Intelligence gap
Visible risk
Time

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Slide
DNV Business Assurance. All rights reserved. 56, rev 1
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05 December 2011
RISK
LIKELIHOOD = frequency of event occurring e.g. number of
events per year, number of events per 1000 working hours etc.
CONSEQUENCE can be expressed in many ways, e.g. number

of deaths, number of injuries, monetary loss, repair cost etc.
The combination of the likelihood and consequence of a specified

hazardous event occurring.
Risk can also be expressed as probability and extent of damage or
loss.
RISK ASSESSMENT
Core Concept
If direct exposure leads to a certain severity, then

- Risk = Severity X Probability.
If probability is based on exposure, then

- Risk = Severity X Probability X Exposure

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ACCIDENT RATIO
1 MAJOR INJURY
MINOR INJURY
10
PROPERTY DAMAGES
30
NEAR ACCIDENTS
600
Our efforts should be directed to the many significant opportunities of near misses for
control of accidental losses
The Loss Causation Model
Lack of Basic Immediate

Control Causes Causes Incident Loss
Inadequate
Undesired
Program Substandard People
Personal Event
Program Acts Property
Factors That Could/
Standards Substandard Environment
Job Factors Does Lead
Compliance to Conditions Process
to a Loss
Standards
Threshold
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Immediate Causes
Lack of Basic Immediate Incident Loss
Control Causes Causes
Substandard Conditions Substandard Acts or Practices

Inadequate guards / barriers Failure to warn
Inadequate PPE Failure to obey rules
Defective tools / equipment Failure to follow procedures
- Faulty detectors, alarms Removing safety devices
Congestion Improper lifting
Inadequate warning system Failure to use PPE
Disorder Failure to Servicing operating equipment
Inadequate ventilation Horseplay
Inadequate illumination
Basic Causes
System / Job Factors Personal Factors

Inadequate Leadership Inadequate Capability
- Practice, Preparations
Inadequate Engineering
Inadequate Purchasing
Inadequate / Lack of Knowledge
Inadequate Tools and Equipment Inadequate/ Lack of Skill
Inadequate Infrastructure Stress
Inadequate Maintenance Improper Motivation
Wear and Tear
Abuse and Misuse
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Lack of Control
Inadequate System
Inadequate System Standards
Inadequate Compliance with Standards
ACCIDENT CAUSATION MODEL
Lack of Basic Immediate

causes Incident Loss
control causes
LOSS CONTROL MODEL
64
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Risk Assessment
Risk Assessment process asks the questions:
What can go wrong? (Identification)
How serious would it be?
Severity
How likely is it to happen?

Probability (frequency or likelihood)
Risk level (magnitude) is a resultant of Severity &

Probability

15th December, 2011
Prepare procedure PLANNING
IDENTIFY HAZARDS
HAZARD ANALYSES
Likelihood of Consequences of
occurrences occurrences
Extreme Moderate
High risk Low risk
risk risk
Establish significant risks - Prepare risk reduction program
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05 December 2011
RISK ASSESSMENT
Ten Steps for Effective Risk Assessment:
1. Ensure the process is 4. Look at the big picture

practical & realistic
5. Start by identifying the
2. Involve as many people hazards
as possible
6. Assess the risks
3. Use an appropriately
systematic approach
RISK ASSESSMENT
Ten Steps for Effective Risk Assessment: (cont)
7. Be realistic, not 10. Always record the

idealistic assessment
8. Identify who is at risk include:
9. Start with the simple - All assumptions
methods, use more - Justifications
systematic methods as
necessary
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05 December 2011
RISK ASSESSMENT
Basic Objectives: Build the culture and provide

the tools to...
Identify and correct major

sources of risk, and
Implement controls to
preserve the gains.
General Industries
RISK ASSESSMENT
Event Modeling
Hazop
S FMEA
T
R Fault Tree
U
C Potential Problem Analysis
T
U Group Risk Assessment
R What If Technique
E
Checklist
Simple Risk Assessment
Minutes TIME Weeks
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Use of GRA
Concept and Design
Stages
Routine Hazard
Identification and Analysis
Proposed Changes
Pre-Start Up Safety
Developing Standard
Reviews
Work Practices
Due Diligence
Safety and Operability
Reviews
Group Risk Assessment
A Semi-Quantitative Approach to OH&S 4.3.1
A practical way to evaluate...

- Activities, Products, and
Services
- Work Situations
- Processes
- Loss Exposures, Risks,
Hazards
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Issues for Consideration

Before Conducting a GRA
Define the purpose and ultimate use of the risk

assessment.
Define the parameters of the system(s) to be analyzed.
List categories of principal concern.
List known assumptions and constraints.
Identify historical data sources to be used.
Identify time constraints that govern the risk assessment.
Identify personnel required to support the risk assessment
at various stages.
Define methods to be used.

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GRA Process Considerations
1. Identify an Appropriate Facilitator

Unbiased
Familiar with process or problem being
addressed
Able to manage the GRA process, not the
problem
Able to ensure the completeness and integrity of
the assessment

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05 December 2011

2. Assemble a Team
2 to 6 participants
Diverse perspectives
Include those most immediately affected
Familiar with process or problem being
considered
Able to put aside personal bias
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3. Establish Parameters
Establish Low, Medium and High

Parameters for Probability and
Impact/Severity

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05 December 2011
Risk Criteria
Defining the pain threshold for
Major Loss...
Serious Loss... } Significant
Minor Loss
...affecting the OHS situation

15th December, 2011
Risk Criteria (example)

Generic Risk Criteria
RATING IMPACT PROBABILITY
S Disabling injury, loss of body part Repetitive event

or fatality. At least once per year
P Loss of function of facility for Several times in the life cycle of a
extended period, with business project
High
consequences, major quality Has happened frequently in similar
deviation. circumstances
E Reportable violation, toxic release. Greater than 50% chance of occurring.
D High repair cost (typically >$100K)
S Medical aid injury. Infrequent event

P Short duration loss of function, May only happen occasionally (less
serious quality deviation, medium than once per year)
Medium
business impact. Has been observed in similar
E Non-reportable spill, non-toxic circumstances
release. 10 to 50% chance of occurring.
D Moderate repair cost (typically
>$10K, <100K)
S First aid injury. Unlikely event

P Brief interruption or minor quality Never happened to date
deviation. May happen less than once in 10 years
Low E Minor leak, non-toxic fugitive Has never been observed but is still felt
emission. to be a possibility
D Low repair cost (typically <$10K.) Less than 10% chance of occurring.
S - Personnel Safety P - Business/Production E - Environmental D - Damage

Figure 1. Generic Risk Criteria
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05 December 2011
4. Establish Risk Acceptance Criteria
The team must reach agreement on the extent of risk that is

acceptable and unacceptable for the situation being
considered.
Unacceptable Risk Level

H Action required immediately.
M Risk Controls Required
Acceptable Risk
L Controls may be justified.
5. Obtain Records and Information
Designs, Drawings Quality Specifications

Investigation Records Training Needs Analysis
Employee Concern Logs PPE Analysis
Joint Committee Findings Maintenance Records
Inspection Reports Manufacturer Recommendations
Problem-Solving Team Reports
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05 December 2011
6. Conduct the Group Risk Assessment
Be prepared to change risk assessment methods and

upgrade to more comprehensive and systematic methods
if necessary.
GRA Data
Types of Data to be Recorded
Names of Participants
Dates of GRA
Risk Criteria and Rankings
GRA Worksheets
Conclusions
Follow-Up Actions

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05 December 2011
7. Record Data and Follow Up
As evidence of due-diligence
To maximize the benefit of the GRA process

15th December, 2011
RISK ASSESSMENT EXERCISE

Columns
1. Activity/Item
2. Condition: Routine/Non-
routine/Emergency
3. Hazard/Concern
4. Consequence explanation
5. Consequence Rating
6. Likelihood explanation
7. Likelihood Rating
8. Risk Rating
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05 December 2011
GROUP RISK ASSESSMENT
Item Concern Impact Impact Probability Prob. Risk Controls Residual

rating rating level risk
Chlorine Joint URT ailment, M Frequent H H Use PPE, Leak Test, replace M
withdrawal leak Eye Irritation defective fittings
from
cylinder/s
Lifting & Failure Hand & Finger H Rare L M Strict legal compliance and L
positioning of lifting or other body six monthly evaluation of
of chlorine tools parts injury legal compliance
cylinder
Toolbox talk, training, use
of taglines
Chlorine Nozzle Chlorine H Infrequent L H Segregation of filled and L

cylinder leak u/s plume spread empty cylinders with labels,
stocking of valve, over long quarterly inspection of
Valve distance nozzles and valves
failures
Caution : This rating is only for an illustration and not intended to be applicable to all
chlorine handling units
Risk Level Table
L M H
Probability
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05 December 2011
Criteria for Risk Assessment on a 5 point

scale
MEASURES OF LIKELIHOOD
Level Descriptor Example detailed description
1 Rare May only occur in exceptional circumstances (Eg:- More than 5 years)
2 Unlikely Could occur some time (Eg:- Once in 5 years)
3 Possible Might occur some time (eg:- Every Year)
4 Likely Will probably occur at some time (eg:- Every Month)
5 Almost certain Is expected to occur in many circumstances (eg:- Every week)

15th December, 2011
CRITERIA FOR RISK ASSESSMENT
MEASURES OF SEVERITY
Level Descriptor Example detailed description
1 Insignificant No injuries
2 Minor First aid treatment
3 Moderate Medical treatment required
4 Major Extensive injuries (e.g permanent disability)
5 Catastrophic Fatality

15th December, 2011
44
05 December 2011
RISK ASSESSMENT MATRIX

LIKELIHOOD SEVERITY
Insignificant Minor Moderate Major Catastrophic

1 2 3 4 5
RISK
Almost Certain
ASSESSMENT
M M H E E
5 (5) (10) (15) (20) (25) MATRIX
Likely M M H E E
4 (4) (8) (12) (16) (20)
Possible L M M H E
3 (3) (6) (9) (12) (15)
Unlikely L L M M H
2 (2) (4) (6) (8) (10)
Rare L L L M H
1 (1) (2) (3) (4) (5)

15th December, 2011
GROUP RISK ASSESSMENT
Sl. No. Activity Concern D/I/ ENV/ Present Control Additional Control
Legislation*
Likelihood
Risk Level
Residual
Severity
Existing
Measures
Control
Risk
N/ABN OHS
What? How?
Emergency When? Who?
12 Bulk Road accident Indirect ENV TREM Card 3 3 5 5 225 Training drivers for 15
transportatio causing issued to drivers defensive driving &
n of chlorine release of Emergency OHS MSDS, involvement
cylinders by chlorine due of transporters &
truck to damaged drivers in mock
cylinders drill, Route survey,
On route helpline
37 Scrapping Corrosion Indirect ENV Decontaminatio 2 1 1 5 10 Not required 10
and disposal giving rise to n SOP before
of chlorine release of Abnormal OHS disposal
cylinders chlorine (non-
routine)
56 Chlorine Chlorine leak Direct ENV Annual 3 1 1 5 15 scheduled 10
transfer through thickness replacement of
through gaskets or Normal OHS survey, moisture pipe
pipeline due to control,
corrosion
*Legislative compliance overrides all other components of risk assessment

Caution : This rating is only for an illustration and not intended to be applicable to all chlorine handling unit
45
05 December 2011
OHS Risk Management
The essence of risk management is to avoid high

risks, manage medium risks, and live with low
risks.

15th December, 2011
Example of control of chlorine emmission

In August 2002, at DPC Enterprisesa hose ruptured involving a 48,000
pound release of chlorine due to a ruptured transfer hose. Hundreds of
residents were evacuated, 63 residents sought medical attention and three
were admitted to the hospital.
In August 2005 at Honeywell International's Baton Rouge chemical plant
when chlorine began to escape from a railcar due to a transfer hose failure.
There, the emergency shutdown system functioned properly and the
release lasted less than one minute. There was no impact to the
surrounding community.
Investigator Lisa Long said, "In contrast to the 2002 incident at DPC, the
rapid and successful activation of the emergency shutdown system at
Honeywell prevented a major release and limited off-site impacts to the
surrounding community."

15th December, 2011
46
05 December 2011
TYPES OF EMERGENCY
1. SOCIAL
Related to individual.
2. NATURAL CALAMITIES
Heavy rain Flood Lightening
Earth Quack Storm Hurricane / Tornado
Extreme temp.
3. MAN-MADE EMERGENCY
Civil disturbance War / Bombing over the works

Strikes Sabotage / Crime Dam break
Transportation stoppage Area fire Road
accident Plane crush over a works Act of
terrorism effect works
Contd
15th December, 2011
4. INDUSTRIAL EMERGENCY
Toxic gas release Hydrocarbon leakages

Fire /Fire with explosion Accidents in near plants
Off-site spills of chemicals Work accident
Hazardous or Radioactive material Sudden shut down
of plants.
It is necessary that one should consider all foreseeable

Emergencies and prepare procedure for handling Emergencies of
all types, including management of major Emergencies or
Disasters.

15th December, 2011
47
05 December 2011
LEGAL PROVISIONS
For facing any emergency in most orderly

and disciplined manner and to create a
strongly operating mechanism, It is
essential to derive a OnSite Emergency
Plan and OffSite Emergency Plan as
mentioned under various statutes.
Contd

15th December, 2011
Factories Act, 1948 and GFR made there under:

Under Section 41- (B) (i) and (iv),
Compulsory disclosure of information by the Occupier.
Under GFR-68 J (12), preparation of On Site

Emergency Plan by the Occupier.
Manufacture, Storage and Import of Hazardous

Chemicals Rule 1989.
Under Rule 13 ; Preparation of On Site Emergency Plan by

the occupier.
Details to be furnished as per Schedule 11.
Occupier shall ensure that a MOCK DRILL of the

On Site Emergency Plan is conducted every SIX MONTHS.
48
05 December 2011
Chemical Accidents Rule 1996

Under Rule 3, Constitution of Central Crisis Group to review
district OnSite Emergency Plans
Under Rule 6, Constitution of Central Crisis
Group. The APEX body for the state of deal with major
Chemical Accidents and provide expert guidance.
Under Rule 8, Constitution of The District and Local crisis
group by The State Government . The APEX body in the
district to deal with major Chemical Accidents.
Reviews the OnSite Emergency Plan"
Assist in preparation of OffSite Emergency Plan"
One full scale Mock Drill of chemical accident at a site
EACH YEAR.
Educate the population and train personnel Handling
Emergency.
ASSESMENT OF RISK
When assessing the potential for loss and damage, account
should be taken of
Population densities in the areas likely to be affected.

Meteorological data on prevailing winds.
Possibility of contaminating drains, corps and water
supplies.
Presence of Radioactive Sources.
Possible effects of the collapse of tall structures.

15th December, 2011
49
05 December 2011
Objectives of
EMERGENCY PREPAREDNESS PLAN
1. SAFEGUARD lives both at site neighborhood.
2. CONTAIN the incident and bring it under CONTROL by

mobilising and gearing up internal and external resources.
3. MINIMISE damage to property and neighbouring

environmental.
4. RESCUE and TREATMENT of causalities.
5. EVACUATION of persons to safe areas.
Contd.
15th December, 2011
6. IDENTIFICATION of persons affected,

notification of relatives, extending necessary
assistance, etc.
7. PRESERVATION of information, records, etc.
8. WELFARE assistance to causalities.
9. COLLECTION and LOGGING of information,

regarding latest status, action etc.
10. PROVIDING relevant information to relevant

persons / agencies. i.e. police, direct /
statutory and news media,etc.
11. COORDINATION between various agencies.
12. WARNING and ADVISING the persons who are

likely to be affected.

15th December, 2011
DNV Business Assurance. All rights reserved. ********
50
05 December 2011
A STRONG OPERATING BASE FOR FACING ANY EMERGENCY
By proper planning on various aspects such as

A. Communication plan.
B. Fire Service plan.
C. Medical Service plan.
D. Safety Section plan.
E. Security Section plan.
Contd.
15th December, 2011
F. Evacuation & Rehabilitation plan.
G. Mutual Aid plan.
H. Training and Exercises plan.
I. Documentation plan.
J. Defining key personnel for all plants and fixing

centralized authority.
K. Individual and collective role plan.
**********

15th December, 2011
51
05 December 2011
Competence, Infrastructure, Structure & Systems
1.KNOWLEDGE OF:
JOB.
PROCESS.
PLANT LAY OUT.
HAZARDS.
EMERGENCY SAFETY EQUIPMENT
AVAILABILITY AND THEIR USE.
EMERGENCY HANDLING PROCEDURES.
2. SKILL:
Practical approach to problem.

15th December, 2011
3. ALERTNESS:
Important factor no substitute for this trait.
4. CENTRALISED AUTHORITY:
Too many cooks spoils the broth.
5. OPEN MINDEDNESS:
All persons jointly involved in dealing with
emergencies should be able to frankly pool all
resources.
6. READY AVAILABILITY OF TOOLS / SAFETY EQUIPMENTS:
Fire & Safety devices upkeep and usability is most
important factor.

15th December, 2011
52
05 December 2011
EMERGENCY
On Site Off Site
On Site Services PLANT C / R

Mutual Aid
FIRE From
SAFETY Neighboring
OCG
IMC Industries
TRANSPORT
CENTROL CONTROL ROOM Civic
SECURITY
Authorities
TELEPHONE
External Services
COLLECTOR Hospitals
POLICE COMMISSIONER
HOSPITALS.
www.dnvba.com

15th December, 2011
53

Hazard Identification An Assessments, in Chlor-Alkali Industry

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05 December 2011

Hazard Identification & Risk Assessment

DNV Business Assurance. All rights reserved.

DET NORSKE VERITAS

*An independent autonomous

*300 offices in 100 countries with

*Over 65000 certificates all

Hazard identification & Risk Assessment in ChlorAlkali Industry

Accredited under 23 national

Hazard identification & Risk Assessment in ChlorAlkali Industry

DNV Business Assurance

Hazard identification & Risk Assessment in ChlorAlkali Industry

DNV Office At Vadodara

Hazard identification & Risk Assessment in ChlorAlkali Industry

Disaster Management Means damage Control

The first duty of Business is to survive, and the

Loss can be avoided by reducing rework / accidents

Risk Management Hierarchy

Hazard Identification and Risk Assessment is the Preventive Step

It is Logical to Start the Technical Session with Prevention

Hazard identification & Risk Assessment in ChlorAlkali Industry

Identified Sources of chlorine leak in Caustic

Hazard identification & Risk Assessment in ChlorAlkali Industry

Sources of chlorine leak in Caustic Alkali

Treatment to these are kept out of scope of this presentation as covered

Hazard identification & Risk Assessment in ChlorAlkali Industry

Together we shall cover

Indian Experience with Chlorine Disasters

DNV Business Assurance. All rights reserved.

Thanks to media coverage on chlorine leak incidences

Chlorine leaks reported in public domain are not

Hazard identification & Risk Assessment in ChlorAlkali Industry

Chlorine Handling Percolated to District

TNN Sep 18, 2011

KOCHI: The district panchayat has decided to observe

Hazard identification & Risk Assessment in ChlorAlkali Industry

Chlorine gas leak at Dahej plant affects 250

A chlorine gas leakage from a Caustic Chlorine

Hazard identification & Risk Assessment in ChlorAlkali Industry

Punjab Newsline Network

Express News Service October 19, 2008: Ammonia gas

Hazard identification & Risk Assessment in ChlorAlkali Industry

The Hindu, Oct 19, 2006 Elluru, Andhra

Hazard identification & Risk Assessment in ChlorAlkali Industry

Train Transport - Chlorine Disaster

Hazard identification & Risk Assessment in ChlorAlkali Industry

Hazard identification & Risk Assessment in ChlorAlkali Industry

Mumbai | Agency: DNA Wednesday, Jul 14, 2010

Hazard identification & Risk Assessment in ChlorAlkali Industry

Orissa Times of India - Monday, Jun 21, 2010

Hazard identification & Risk Assessment in ChlorAlkali Industry

Hazard identification & Risk Assessment in ChlorAlkali Industry

One common denominator in most of the

Hazard identification & Risk Assessment in ChlorAlkali Industry

Some Case Studies

Hazard identification & Risk Assessment in ChlorAlkali Industry

Understanding Hazards &

DNV Business Assurance. All rights reserved.

Incident & interested party

Work related event(s) in which an injury or ill health

Hazard & hazard identification

Source, situation or act with a potential for harm in terms

DNV Business Assurance. All rights reserved.