1. DISASTER MANAGEMENT PLAN of Bellary District Deputy Director of Factories Bellary

2. Bellary District Map
Disaster Management Plan of Bellary

3. Bellary Industrial Map
Disaster Management Plan of Bellary

4. BELLARY DISTRICT Bellary District came into existence in 1800 A.D.
It has 7 Taluks
Bellary, Hospet, Sandur, Siraguppa, Kudligi, Hadagli & Hagaribommanahalli.
Population of Bellary District – About 20 lakhs
Total geographical area – 8,13,196 Hectares
Forest area – Hectares
Disaster Management Plan of Bellary

5. Industries Registered under Factories Act.
Rice and Oil Mills
154
Cotton Ginning 44
Sponge Iron/ Rolling Mills 47
Integrated steel plants 1
Power plant 5
Coke oven plant 2
Industrial Gases 3
Sugar Plant
Others 96
Total
354

6. FACTORIES Major Accident Hazard Factories – 04
Potentially Hazard Factories – 05
Hazardous Factories – 57
Disaster Management Plan of Bellary

7. Major Accident Hazard Industries
1. M/s. J S W Steels Ltd. Toranagallu
2. M/s. Jindal Prax Air Oxygen Co. Ltd. Toranagallu.
3. M/s. Bellary Oxygen Co. Ltd, Toranagallu.
4. M/s. B O C India (P) Ltd, Toranagallu
All are located in the JSW complex, Toranagallu.
Disaster Management Plan of Bellary

8. Potentially Hazard Industries.
1. M/s. J S W Energy Ltd, Toranagallu.
2. M/s. Bellary Thermal Power Station,Kudathini.
3. M/s. Monsanto India Ltd, Bellary.
4. M/s. United Galva (P) Ltd. Bellary
5. M/s. JAMIPOL, Toranagallu.
Disaster Management Plan of Bellary

9. Hazardous Industries Total industries – 57
Mainly Sponge Iron, Hydel power, Coke oven plants, Oxygen Re-filling plants, etc,.
On-Site Emergency Plan of all the hazardous industries have been approved by Director of Factories & Boilers, Bangalore
Disaster Management Plan of Bellary

10. Inventory of hazardous materials in the district
1. M/s. J.S.W. Steels ltd., Toranagallu.
LPG – 2 x 18 MT.
Gas Holders containing Carbon Monoxide
i) Corex Gas Holder : 1,00,000 M3
ii) Blast furnace –Gas Holder : 50,000 M3
iii) LD Gas Holder : 30,000 M3
iv) Blast furnace - Gas Holder : 50,000 M3
v) Coke oven -Gas Holder : 50,000 M3
LD Gas Holder : 50,000 M3
Total = 3,30,000 M3
Chlorine – 6 x 1 MT
Hydrogen Gas Holder – 3 x 81 M3
Disaster Management Plan of Bellary

11. 2.M/s. Jindal Prax Air Oxygen Co. Ltd, Toranagallu
Liquid oxygen – 1000 MT
3. Bellary Oxygen Company Ltd,. Toranagallu
Liquid Oxygen – 1000 MT
4. BOC India Ltd,. Thoranagallu
Disaster Management Plan of Bellary

12. Potentially Hazard Industries
1. JSW Energy Ltd,. Thoranagallu
Chlorine – 6 x 1 MT
2. Bellary Thermal Power Station
Chlorine – 8 x 1 MT
3. Monsanto India Ltd,. Bellary
LPG – 2 x 7 MT
Disaster Management Plan of Bellary

13. 4. United Galva Pvt. Ltd,. Bellary LPG – 2 x 7.46 MT
5. United Spirits Ltd,. Hospet
Spirit – 2.0 Million liters
6. JAMIPOL Thoranagallu
Calcium Carbide – 500 MT
Disaster Management Plan of Bellary

14. Worst Case Scenarios In The District
Release of toxic and flammable gas
Failure of 1,00,000 M3 Corex/Blast Furnace Gas holder containing carbon monoxide (CO). (Threshold Limit Value(TLV) 50 ppm)
Release of toxic gas
Rupture of chlorine tonner and release of 900 kgs of chlorine Leakage. (Threshold Limit Value 3ppm)
Disaster Management Plan of Bellary

15. Vapour cloud explosion
Boiling Liquid expanding Vapor Explosion (BLEVE) -Rupture of 18 MT LPG Bullet- explosion and fire.
Hydrogen Gas explosion
Explosion of 81 cum hydrogen bullet
Explosion of cryogenic liquid tank
Rupture of liquid Oxygen tank causing Cold Burns
Disaster Management Plan of Bellary

16. Hazard Index Matrix of Bellary Dist
Name of the industry
Toxic release
Explosion
Fire
Cold burn
JSW Steels Ltd √
JPOCL
Bellary Oxygen Co.Ltd
BOC India Ltd

17. District Administration
Bellary District Crisis Group constituted & meetings conducted Periodically.
Prepared Off-Site Emergency Plan for Bellary district in the year 2006.
Updated as on May 2009
Off-site Emergency Plan is Available in The Bellary District Website
Disaster Management Plan of Bellary

18. Mutual aid amongst MAH & Hazard Industries is being practiced.
Periodical Mock drills are being conducted at MAH & Potentially Hazard industries involving District Authorities
On-Site Emergency plans have been re-viewed & have been approved by the Director of Factories & Boilers, Bangalore.
Mutual aid amongst MAH & Hazard Industries is being practiced.
The safety and health status of 2 MAH Industries have been reviewed by the site appraisal committee.
Disaster Management Plan of Bellary

19. Mock Drill conducted in presence of District Administration
Disaster Management Plan of Bellary

20. Involvement of Local Elected representatives in the Mock Drill
Disaster Management Plan of Bellary

21. Major Accidents in Bellary
NO Major Chemical Accidents/Disasters has occurred in the Bellary District
Disaster Management Plan of Bellary

22. Creating awareness amongst the Workers & Neighboring Public by
Circulating pamphlets
Distributing
Safety Hand Books in Kannada & English
Handbook on Hazardous Chemicals
Safety quiz Booklet for workers
Involvement of workers & Public in the mock drill
Disaster Management Plan of Bellary

23. Conducting safety quiz Competition for workers
Inter Industry competition to create awareness on safety
Conducting training programme for Engineers, Supervisors & Middle Management On safety
Disaster Management Plan of Bellary

24. Disaster Management Plan of Bellary

25. Bellary District Crisis Group Meetings/Mock Drills
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

26. Disaster Management Plan of Bellary
COREX GAS
Corex gas contains Carbon Monoxide 43%.
Blast Furnace gas contains 24 % CO and
Colorless, Odorless, and Poisonous gas
Highly In-flammable
Density : 0.97 ( Air=1) it is lighter than Air
Lower explosive Limit : 12.5 %
Upper Explosive Limit : 74.5 %
The threshold value of CO gas in atmosphere
is 50 ppm for 8 hours gas exposure
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

27. Disaster Management Plan of Bellary
CO Concentration In Air
Effects
00 to 50 ppm
Can work safely for 8 hours exposure
50 to 100 ppm
Can work safely for 4 hours exposure
100 – 200 ppm
Mild headache after 2-3 hours exposure
200 – 400 ppm
Nausea and mild headache after 1-2 hours of exposure, occipital headache after 2-3 hours of exposure
ppm
Headache, dizziness and nausea after 3-4 hours of exposure
800 – 1600 ppm
All the above symptoms in 20 minutes exposure collapse, unconsciousness and probability of death after 2 hours of exposure
1600 – 3200 ppm
All the above symptoms in 5-12 minutes exposure and death in 30 minutes
3200 – 6400 ppm
All the above symptoms in 1-2 minutes and death in 15 minutes exposure
12800 ppm
Effect instantaneous death in 1-4 minutes
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

28. Severity Analysis for Carbon monoxide in Corex / Blast Furnace gas –
Industry Wise
S.No
Industry
Persons Likely to be affected
Safety distance in Metres
> 800 M
Zone A
100 M
Zone B
250 M
Zone C
400 M 1
JSW Steel Limited 10 15 25
discomfort for long exposure 2
JSW Energy Company Limited 5 3
Jindal Praxair Oxygen Company Ltd 4.
Bellary Oxygen Co.Pvt.Ltd 5.
BOC India Ltd
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

29. Disaster Management Plan of Bellary
LIQUID CHLORINE
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

30. Disaster Management Plan of Bellary
Severity Analysis for Chlorine - Industry wise
Sl.No
Industry
Persons
Likely to be affected
Safety distance in Metres > 500 M
Zone A
100 M
Zone B
250 M
Zone C
400 M 1
JSW Steel Limited 50
250
500
Discomfort for long exposure needs immediate first aid 2
JSW Energy Company Limited
300 3.
BTPS
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

31. Liquid Petroleum Gas (LPG)
Properties
Colorless Gas with
Pungent Smell
Vapor density
Heavier than air
Lower
Explosive
Limit
1.8 %
Upper
9.6 %
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

32. Disaster Management Plan of Bellary
Hydrogen Gas
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

33. Properties of Hydrogen Gas
Odorless , Colorless Compressed Liquefied Gas
The gas mixes well with air, explosive mixtures are easily formed.
The gas is lighter than air.
Extremely flammable. Many reactions may cause fire or explosion.
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

34. Disaster Management Plan of Bellary
Severity Analysis for Liquid Oxygen
Sl.No
Industry
Persons Likely to be affected
Safety distance in Metres > 500 M
Zone A
100 M
Zone B
250 M
Zone C
400 M 1
Jindal Praxair Oxygen Company Ltd 10
Immediate evacuation as it supports Combustion 2.
Bellary Oxygen Co.Pvt.Ltd 3.
BOC India Ltd
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

35. Disaster Management Plan of Bellary
Severity Analysis for Rectified Spirit
Sl. No
Industry
Persons Likely to be affected
Safety distance in Metres > 500 M
Zone A
100 M
Zone B
250 M
Zone C
400 M 1
United Spirits ltd 25 30 50
Immediate evacuation as it is high fire potential hazard
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

36. Disaster Management Plan of Bellary
Thank You
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

37. Disaster Management Plan of Bellary
The main focus of the Chemical Accident (Emergency Planning, Preparedness & Response) Rules 1996.
Provide scope to deal with major chemical accidents in MAH Units and to provide expert guidance for handling major chemical accidents.
Constitution of Crisis Groups for management of chemical accidents - Central, State, District
Identification of Major Accident Hazard Installations;
Defines - Major Accident Hazard Units,
- Major Chemical Accident
- Hazardous chemicals.
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

38. Disaster Management Plan of Bellary
Hazardous chemicals - Chemical Substances having hazardous properties viz., toxic, flammable, reactive and explosive Chemicals have been defined as Hazardous Chemicals.
Major Chemical Accident means - an occurrence including any particular emission, fire or explosion involving one or more hazardous chemicals and resulting from uncontrolled development in the course of industrial activity leading to serious effects both immediate or delayed, inside or outside the installations likely to cause substantial loss of life and property including adverse effects on the environment.
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

39. Disaster Management Plan of Bellary
Major Accident Hazard Installations means - isolated storage and industrial activity at a site- handling of hazardous chemicals equal to or, in excess of the threshold quantities specified.
For example
LPG 15MT
Chlorine 10MT
Ammonia 50MT
Liquid Oxygen 200MT
Highly flammable liquids 10000MT
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

40. Disaster Management Plan of Bellary
Central Crisis Group - apex body at the Centre(G.O.I) to deal with major chemical accidents and provide expert guidance in handling MCA
Secretary Govt., of India (MOF) -Chair person
Jt. Secretary(Env.and Forest) – Member Secretary
19 Government & non Govt. officers
State Crisis Group
Chief Secretary to Govt., - Chair Person
Pr.Secretary to Govt., Labour - Member Secretary
9 Government Officers and 2 Non Govt. agencies
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

41. Deputy Commissioner - Chair Person
District Crisis Group - apex body in the district to deal with major chemical accidents and to provide expert guidance for handling chemical accidents.
Deputy Commissioner - Chair Person
Deputy Director of Factories - Member Secretary
In the state of Karnataka - about 70 MAH factories have been identified in 16 districts
Bellary - 3 MAH Factories.
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

42. IN PURSUANT TO THE RULE 8 OF THE CHEMICAL ACCIDENT RULES, 1996,
Government of Karnataka
Vide GO No. KAE 68 KABANI 2006 dated
has constituted District Crisis Group for the Bellary District.
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

43. Disaster Management Plan of Bellary
Main Functions of the DCG - Rule 9 of CA Rules, 1996,
Assist in the preparation of district off site emergency plan;
Review all the on site emergency plan of MAH units;
Assist the district administration in the management of chemical accident at a site lying within the district;
Continuously monitor every chemical accident;
Ensure continuous information flow from the district to the state regarding chemical accident and mitigation efforts.
Forward a report of chemical accident if any to SCG
Conduct one full scale mock rehearsal of chemical accident - off site emergency plan and submit report to DCG
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

44. MAH Units in the Bellary District
1. JSW Steel Ltd
Steel Manufacturing, Around 5000 workmen
LPG-36 MT ( 2 bullets ),Chlorine- 3MT and Corex Gas – 1.3 Lakh cubic meter
2. Jindal Praxair Oxygen Company Limited,
Oxygen, Nitrogen & Argon manufacturing, Around 100 workmen;
Liquid Oxygen MT and Corex Gas as Fuel online.
3. Bellary Oxygen Co. Ltd.
Liquid Oxygen-1000 MT
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

45. Disaster Management Plan of Bellary
POTENTIAL HAZARDOUS INDUSTRIES
JSW Energy Limited,
Chlorine- 1x6 MT.and Corex Gas as Fuel online.
2. Monsanto India Limited,
LPG- 14MT
3. United Galva Ltd.,
LPG MT
4. Pampasara Distilleries Limited,
Spirit- 2.0 Million Gallons.
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

46. STATUS OF THE MAH AND POTENTIAL HAZARDOUS INDUSTRIES
All factories are functioning;
All factories have revised their on site emergency plans recently;
The Hazardous Chemical stored (Total Qty.)
LPG – 64.92MT
Corex Gas – 1.3 Lakh cubic meter
Chlorine - 9 tonners
Liquid Oxygen MT
Spirit –2.0 Million Litres
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

47. Disaster Management Plan of Bellary
Previous meetings of the DCG - Bellary
1. 15/03/1999
2. 27/07/1999
3.23/06/2000
4. 22/12/2000
5. 28/11/2002
2003 & 2004 witnessing of On Site Emergency Plan Mock Drill on 4th December.
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

48. Disaster Management Plan of Bellary
TASKS BEFORE THE DCG
Review the strength and weaknesses of the onsite emergency plans prepared by the MAH Units.
Review of Off site emergency plan and suggests changes.
Create Public Awareness among the workers and the neighboring public.
Provide expert guidance/advise to the management to carryout out audits to ensure integrity of the system.
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary

49. Disaster Management Plan of Bellary
THANK YOU
By Deputy Commissioner, Bellary
Disaster Management Plan of Bellary