Profile of Devanagunthi LPG Bottling Plant is situated

Profile of Devanagunthi LPG Bottling Plant is situated at Devanagunthi. 45 Km from Banglore Dist HQ. 46 47 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

Indane bottling plant Layout

Major Activities ØLPG receipt by rail and road, Storage, bottling & Despatch ØLoading of LPG bullet trucks for Auto LPG Dispensing stations and other bottling plants

Bulk LPG Receipt Ø Source of Receipt : Rail Wagons from Mangalore and Hazira and road tankers from CPCL Ø 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 LPG Storage Facilities

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 BTPGLN wagons.

Population in nearby Villages

Material Safety Data IDENTITY OF MATERIAL : Product Name Trade name Formula LPG. Bottle gas, Liquefied hydrocarbon gas. LPG UN No. 1075 Mixture of propane and butane HAZCHEM Code 2 WE Physical State Gas Appearance Colourless Odorless/stanche d Insoluble Calorific Value (Kcal / Kg. ) 11400 Red: Flammable Liquid / 2. 1 Vapor Pressure at 65 deg. C, 16. 9 kg/cm 2 PHYSICAL AND CHEMICAL PROPERTIES Boiling Point / Range , deg. C Melting / Freezing Point , deg. C Vapor Density (Air =1) 1 Specific Gravity , 20 deg. C 0. 53 to 0. 57 Dyn. Viscosity (PA. S 30 deg. C) Molecular Weight. Solubility in Water Label / Class 138 1. 5 to 2. 0 FIRE AND EXPLOSIVE DATA Explosivity Highly explosive Auto Ignition Temp. deg. C 405 -450 Flammability Dangerous Explosive Limits , % 1. 8 – 9. 6 Extinguishing Media CO 2, 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

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 q Jet Fire q Pool Fire q BLEVE q Flash Fire q UVCE Ø Asphyxia Ø Cold Burns Ø Metal brittleness due to Low temperature

Consequences Analysis Damages are caused due to • Heat radiation • Overpressure effect from explosions • Toxic effect

Exposure time, heat radiation and damage levels

Damage distance for BLEVE

Damage contour for catastrophic failure of 1400 MT sphere

Zone A – 37. 5 Kw/M 2 – 524 M rad – 100% lethality (Plant personnel)

Zone B Zone - B 12. 5 Kw/M 2 – 908 M rad – 1% lethal (Kanekkal Village)

Zone C - 4. 0 Kw/M 2 - 1830 M - First Degree burns (Kacharakanahalli, Dasarahalli, Giddapura, Doddasandra)

Risk intensity

Mitigation measures Ø Gas Monitoring System Ø Air/Vapor Extraction System Ø Remote control Valve Ø Emergency Trip Button Ø Manual Call point Ø 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 / Hr. capacity each. JOCKY PUMPS • 2 Nos. of 24 Cum /Hr. CUM

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 Ø Dedicated Vehicle for emergency transportation is available round the clock. Ø 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: Ø Emergency trip Buttons & Manual Call Point Ø Remote Control Valves Ø 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 Ø Prevention - incorporates all those activities that eleminate the probabilityof disaster occuring on-site. Ø Preparedness - includes all activities necessary to ensure a high degree of readiness Ø Response- measures taken during an incident which minimise damage to life and property. Ø 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 Ø makes initial assessment of incident and determine the need for evacuation. Ø ensure that all personnel are accounted for. Ø ensure that outside agencies are communicated as per DMP as follows: v v v v v 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.