Control of chemical substances in India which covers recent chemical Substances related major accidents in India as well as relevant laws & regulations

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
2

• 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
  60
• 2. Chlorine
  10
• 3. Bromine
  50
• 4. Ethylene oxide
  5
• 5. Hydrogen cyanide 5

3
Schedule 3 e.g.
Chemical Threshold qty in Kgs
1. Iso benzene
100 2. Benzidine
1 3. Benzidine salts
1 4. Ethion
100 5.
Phorate
100
4

• Schedule 5
• e.g
• Authorities with
  Duties
• legal backing
  corresponding Rule
• Chief Inspector of Factories
  1.Notification of major
• 
  accidents as per rule
• 
  5(1) 5 (2)

5
(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
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(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.
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(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.
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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.

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( 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.
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( 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.
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( 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, Dos Donts
which should be adopted in the event
of major accident .
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( 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.
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(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.

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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
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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
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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
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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
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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
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Recent Chemical Substances Related Accidents
in India

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Accident 1 a) Name of Industry
Century
Rayon
Chemical Ind. Ltd. b) Type of Accident

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

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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.

22
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.

23
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.


24
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.
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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.

26
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.
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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.


28
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.
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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.


30
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 .
31
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.


32
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.
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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.



34
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.
35
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.



36
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.
37
Accident 9 ( contd..) d) Consequences
i) Two fatal .
e) Root Causes
i) Ineffectiveness of
work permit
system . ii) Lack
of awareness training.


38
Accident 10 a) Name of Industry
Gharda chemicals. b) Type of
Accident Release of poisonous
gas
c) Description 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.
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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.


40
Accident 11 a) Name of Industry
Leakage of Bromine
during
transportation. b) Type of Accident
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.
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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.