Lpg Project.pdf

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CHAPTER 1 INTRODUCTION, SCOPE AND OBJECTIVES OF THE STUDY

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INTRODUCTION The major challenges to be met by the world population of the 21st

century are safety, health and environmental (SHE) risks. The concern for managing them continues to prevail and tends to increase year after year due to the exponential growth of industries. International agencies viz., United Nations

Environment

Program

(UNEP),

United

Nations

Industrial

Development Organization (UNIDO) and International Labor Organization (ILO)

periodically

review

the

ongoing

regional

development

in

industrialization, urbanization, environment, health of the community and risks in industrial operations. India being a signatory of the above agencies is obliged to comply with the guidelines, regulations and planning process as suggested by those agencies from time to time. Besides, the national agencies such as Directorate of Industrial Safety and Health, Director General Factory Advice Service and Labour Institutes (DGFASLI), Ministry of Labour and Employment, Government of India, Petroleum and Explosives Safety Organization, Manufacture Storage Import of Hazardous Chemical Rules (MSIHC Rules 1989 & amended 2000) etc., provide guidelines and stipulate standards for storage and handling of hazardous materials etc. to be complied with by industries.

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Environmental Impact Assessment is considered to be one of the tools in the management of safety, health and environment risks. The Planning Commission of India conceived the concept of Environmental Impact Assessment (EIA) in India during 1976-1977. The commission was designated the task of examining cursorily river-valley projects from the environmental standpoint and addressed the Department of Science and Technology (DST), Government of India. This was subsequently extended to cover other projects in need of approval by the Public Investment Board (Ministry of Finance, Government of India). These were administrative decisions without any legislative support. The Government of India, therefore, enacted the Environment (Protection) Act, 1986 (in the Ministry of Environment and Forest-MOEF). The Act enunciates set of legal instruments. The decisions taken by the Government was to make environment impact assessment as a statutory requirement before setting up of any production activity in any part of the country. Risk Assessment, which is an integral part of EIA, provides operable scientific frameworks for protecting the environment and for decision-making. The scientific approach for conducting the risk assessment study is essential to sustain long term benefits not only for the industry but also for the overall general environmental resources including air, water, land and noise affecting the public in the vicinity of the Industrial site. Energy is a basic need for operations. Liquefied Petroleum Gas LPG / Propane is commonly and continuously used in industries as an energy source (e.g. heat treatment, power generation and drying etc). Consequently, there is a substantial release of end products (Green house gases) after combustion of LPG causing death, injury to persons and damage to the properties. Energy, environment, safety, etc. exclusively with the use of LPG have not been given due consideration by the planners as well as scientists.

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The study on risk assessment in LPG / Propane using industry demands first-hand knowledge of the accident scenario. Also, a number of institutions in India have studied possibilities and probabilities of the hazards occurring within the industrial premises due to LPG storage. There are welldefined parameters for quantification of flue gas release. These include flash point, degree of flammability, explosion, toxicity to humans etc. Besides the location of industry, the engineering design and systems implementation during operation (production and maintenance) are important. Consequence Analysis of an emergency situation at the industrial site and risk management is the most important factors of risk analysis concerning hazardous installations. 1.2

ROLE OF ENVIRONMENT RISK ASSESSMENT (ERA) IN EIA PROCESS One of the key components of EIA process is Environment Risk

Assessment (ERA). ERA is the development of EIA and Risk Assessment. ERA provides theoretical and scientific frameworks for environmental protection, decision making and for setting up of any Industry. With the rapid economic growth and globalization movement, development of new industries with sophisticated technologies is on the rise at an alarming rate all over the world. However, it is imperative that a systematic approach be adopted before setting up of a new industry, taking into consideration various safety issues, health and environmental aspects of the inhabitants living in the surrounding areas to safeguard them from possible accidents / incidents arising out of the industrial activity. The scientific approach of conducting an Environment Risk Assessment study before setting up of an industry is essential to sustain long term benefit not only for the industry but also for the general environment and the inhabitants living in the area24, 46,49.

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The use of LPG / Propane is continuously on the increase in industries as a standard energy source for various purposes including heat treatment processes. Consequently, there is a substantial release of LPG and other hazardous materials into the ambient environment causing personal injury or death of workers and people in the surrounding locality, damage to property and environment. The study on Risk Assessment in LPG/Propane using industry demands first-hand in depth knowledge of the accident scenario possibilities and probability of the hazards responsible for damage to the property and health of the general public. Hence, the first step in hazard analysis is to quantify the substances released. There are well-defined parameters for quantification that include flash point, degree of flammability, explosion, toxicity etc. Besides this, the subjectivity factor of location, engineering design and systems implementation during operation (production and maintenance) are important and involve the engineering aspects of the Risk Assessment. In addition to these, Consequence Analysis of an emergency situation at the industrial site and risk management are the two most important factors of Risk Analysis concerning hazardous installations in the industries24, 46.49. Hence, the Environmental Impact and Risk Assessment for LPG Installations in Automobile Industries detailing the release scenarios and consequence analysis for these LPG handling industries are to be studied. This study explains the Environmental consequences associated with LPG storages, located and installed particularly in Automobile industries in Tamilnadu. At present, the LPG utilizing automobile industries are not required to conduct Environment Impact Assessment studies since they are not listed in the EIA Notification issued by the Ministry of Environment and Forest. Even though these industries do not have the requirement for the EIA study, the rise in the number of industries utilizing LPG for energy purpose due to its convenience, availability and other technical requirements has

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become a serious concern, requiring special attention from the perspective of the Government and other stakeholders. The environment impact from these industries taking into account of the hazard potential of LPG Bullets is to be studied. 1.3

LPG

BULLET

INSTALLATION

IN

AUTOMOBILE

INDUSTRIES 1.3.1

Features of LPG With its intrinsically clean burning characteristics, LPG offers a

practical avenue for clean air since use of LPG reduces black carbon and particulate matter emissions, which not only compromise outdoor and indoor air quality but can cause serious health problems. Since LPG is a low carbon fuel, it is used in thousands of industrial and commercial applications. It is cleaner than any other fossil fuel, highly energy efficient and safe to use. LPG is one of the most preferred energy sources today because of its immense benefits. LPG is an energy-rich fuel source with a higher calorific value per unit than other commonly used fuels, including coal, natural gas, diesel, petrol, fuel oils and biomass-derived alcohols. LPG generates fewer carbon emissions than gasoline (petrol) and has similar emissions when compared with diesel. Therefore, it can make a positive contribution toward improvement of air quality when compared to diesel, heating oil and solid fuels. In addition to these factors, LPG is immediately available and supports the use of renewable technologies. The advantages of using LPG as an energy source are: Increased fuel savings High rate of heating – as high as 400 °C per hour

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Uniformity in temperature and precise temperature control Better heat transfer with LPG firing No wastage of fuel due to spillage and adulteration Uniformity and increased end product quality Lower maintenance costs of burners, ovens and furnaces Lower shut down time of machinery Cleaner burning and sulfur-free emission 1.3.2

Mode of Storage of LPG Refrigerated storage is used to store large volumes of LPG. The

main form of LPG storage is in special tanks known as 'pressure tanks'. Commonly, these pressure tanks are termed as 'bulk tanks' or LPG Bullets/Spheres. Automobile industries have installed bullets/spheres in their premises to store the LPG. Gas suppliers to store large volumes of LPG use refrigerated storage. Since LPG has a high coefficient of expansion in its liquid phase, the tanks are never completely filled with liquid (tanks are filled to approximately 85% of their water capacity), the remaining space being taken up with vapour (often referred to as the vapour space) to facilitate expansion without allowing the liquid to become 100% full (often known as hydraulically full)

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Figure 1.1 LPG Bullets 1.3.3

Working Features of a LPG Bullet As LPG gas (vapour) is drawn from the tank, the vapour pressure in

the tank falls and the liquid boils, producing more vapour and restoring the pressure to maintain boiling, the liquid absorbs heat from itself, from the metal of the tank in contact with the liquid (known as the wetted surface area) and from the air surrounding the tank. The available gas 'off take', therefore, is dependent upon the surface area of the tank, the quantity of liquid within the tank and the temperature. The low temperature of the liquid (often indicating excess off take) may be indicated as 'sweating' (where the water vapour in air condenses on the wetted surface area of the tank) and if the off take is large enough 'frosting' (where the condensed water vapour freezes) occurs on the walls of the tank. When the liquid temperature rises, for instance in summer, the vapour pressure increases and when the liquid temperature drops, the vapour pressure also drops. Under normal Indian conditions, the pressure will range between 2-9 bars. These are designed as per the recommendations in IS-2825 /ASME Sec VIII Dl-1 codes and the material of construction is SA-516/ IS-

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2062/ IS-2002/SS-304 or as per the specific requirement of the customer. Steel used for the tank and its fittings meets the Low Temperature Carbon Steel criteria and is tested thoroughly before fabrication. During fabrication, stringent quality norms are followed. The vessels are inspected stage wise by Inspection Engineers / Third party Inspectors as per the recommendations of the relevant code and the Chief Controller of Explosives norms. Qualified welders perform welding of joineries. Finally, it is hydro tested and dehydrated with dry nitrogen. Each tank undergoes various NDT and other inspection stages and tests like Penetration Test, Radiographic Examination and the Hydro test are conducted before dispatch. These storage tanks are equipped with all standard instruments and controls like Rochester gauge, excess flow check valves, safety valves, pressure gauges, LPG Transfer compressor, valves, pipes, drains, pressure regulators, water sprinkling system, gas leak detection system and control panel. Most LPG storage tanks in standby-plant service are steel, nonrefrigerated pressure vessels. Tanks are available in many sizes for both above the ground and underground services. New LPG tanks are built to ASME standards and are designed for maximum working pressure. 1.4

STATEMENT OF PROBLEM The earlier studies by the researchers focussed on the risk

associated with the hazardous materials. Specific studies on LPG were not undertaken, despite the fact that the LPG was a hazardous substance consumed in large quantities. However, LPG is favoured over other fuels like coal, oil and electricity, which are fast becoming scarce these days. Hence, hazard scenario created by the intensive use of LPG is required to be studied and hence, a systematic study covering risks, safety, health and environment is essential. Automobile industries in India have grown concomitantly with

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the production of components. Therefore it is necessary to study the pattern of consumption of LPG and hazards attributed to LPG installation. Since Risk analysis is considered as an integral component of environmental impact study, the release scenarios and consequence analysis for LPG handling industries need to be focussed upon. The current guidelines of the Ministry of Environment, Forest and Wild Life, Government of India with the EPAct, 1986 do not include LPG as a hazardous material. As a result, these industries are not required to carry out environmental impact assessment study. Nevertheless, LPG utilizing automobile industries has to necessarily conduct environmental impact assessment studies. Therefore, it is imperative that the government gives their attention to protect the society at large and averting the possible impact on environment. 1.5

PURPOSEOF THIS STUDY LPG/Propane has been increasingly used in automobile industries

for the heat treatment process. Increase in use of LPG has resulted in its substantial release into the ambient environment inflicting damage to property and environment besides having near fatal to fatal effects on the residents around the area. The purpose of this study is (1) to have knowledge on the impending environmental consequences associated with LPG Bullets used in the automobile industry in the State of Tamilnadu.

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(2) to understand whether the LPG Bullets are installed in a safe location capable of handling the emergency situations in an effective manner. (3) to study the consequence scenarios like BLEVE, Thermal Radiations, Vapour Cloud Explosions and impact on environment due to LPG releases from the installation and usage of the LPG Bullets in Automobile industries. 1.6

SCOPE AND OBJECTIVE OF THE STUDY The scope of the Study is to cover LPG/Propane installation in

automobile industries located in the state of Tamilnadu. Many leading automobile companies such as Hyundai, Nissan, Ford, BMW, Daimler, Mahindra and Mahindra, Ashok Leyland, L&T Foundry, Lakshmi Machinery Works etc., have their manufacturing as well as supply facilities in Tamilnadu, utilizing LPG as a fuel to meet their energy requirements. Automobile industries storing bulk quantities of LPG in their premises were focused upon. These industries use and store LPG in the range of 4.6 MT to 1350 MT. Samples from thirty-five automobile industries out of one hundred and twenty five units were taken for this study. These shortlisted industries are located in Tamilnadu. Research studies on safety, health and environmental impact have been found to be scarce and case studies on accidents and other risks associated with the automobile industries were not documented. These case studies done on risk featured an entire range of activities without any specific focus. No specific study was conducted with special reference to LPG storage facilities and their associated EIA aspects. However, the documents of ILO provided information related to the accidents.

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The Objectives of this study are: to conduct Environmental Impact and Risk Assessment study in the automobile industries located in Tamilnadu, where large quantities of Liquid Petroleum Gas (LPG) / Propane are used. to assess the environmental impact caused by the release of LPG from its storage and other auxiliary facilities. to review the hazards to workers and people in the surrounding areas, damage to property and environment due to the release of LPG. to study and assess the parameters for quantification which include flash point, degree of flammability, explosion, toxicity etc. to study and assess the influence of various factors such as location, engineering design and systems implementation during operation (production and maintenance). to carry out Consequence Analysis of an emergency situation at the industrial site and risk management in hazardous installations of LPG handling industries. to

recommend

improvement

of

the

operational

and

maintenance procedure for enhancing reliability and safety. to check the environmental acceptability of the proposals compared to the capacity of the site and the environment. to ensure that resources are used appropriately and efficiently. to identify the appropriate measures to mitigate the potential impacts of LPG releases.

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to

facilitate

decision-making

including

setting

the

environmental terms and conditions for implementing the proposals of LPG handling automobile industries. to avoid irreversible changes and damage to the environment. to enhance the social aspects of proposals and to protect the environment, ecology, health and safety. to obtain primary information and acquire knowledge of possible accident scenarios and probability of the hazards, which are responsible for damage to property and public health. to enable planners to use the findings of the study while sanctioning clearance for LPG handling automobile industries. 1.7

ORGANISATION OF THE THESIS The thesis has been organized into six chapters as given below: Chapter 1 provides the introductory details of the research work.

The need for the study, scope and objectives of the investigation, details of LPG, its advantages and the organization of Thesis. Chapter 2 describes the literature review highlighting the details of the research work carried out pertaining to the studies on environmental impacts and risk assessment of LPG bulk storages, modeling worst case scenarios and past accident histories. Chapter 3 presents the methodology adopted for the research plan and research tool developed on line with statutory obligations and data required for compilation of research tool.

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Chapter 4 presents the details of selection of the model, risk assessment for various release scenarios such as thermal radiation due to fire, shock wave pressure due to explosion, damage distances computation and consolidation of results. Chapter 5 summarizes the statistical analysis of observed data, findings and discussion of results. Chapters 6 present the conclusions, future scope of the research area and follow up on the work done in the thesis.