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P. Srinivas and M. Elangovan
ERPG-1 is the maximum airborne concentration below which people could be
exposed for up to 1 h without experiencing any adverse health effects.
From the above, it was observed that red (life-threatening zone) is up to 2.5 km,
orange (health effects which impair an individuals ability) is up to 4.2 km, and yellow
(without any adverse effects) is up to 9.7 km; hence, residential colony can be located
outside the EPRG-2 (orange zone), so that people at residential colony will not have
any adverse effects when TDI vapor release from spillage site.
Onsite emergency preparedness plan will be implemented for plant people who
are at ERPG-3 (red zone), and this plan consists of emergency declaring procedure, incident controller, alarm system, assembly points, emergency vehicle, emergency lighting (DG Set), escape respirators, etc. By implementing a emergency
preparedness plan, plant people will be protected from TDI vapor exposure.
3.2 Handling/Process Area
In rocket industry for solid propellant manufacturing TDI processed/handled which
involves hoppers/bins, ball valves, hoses, and pipe fittings, any of these components
failure may lead to TDI spillage, and people may effect due to toxic vapor exposure
[4], and hence, risk assessment is carried out at TDI handling area by failure modes
effect analysis (FMEA).
To identify the various ways in which components, systems, or processes can fail
to fulfill their design intent, failure modes effect analysis (FMEA) is used. FMEA
specifies the following:
• All probable modes of failure for the various parts of a system (which is observed
to fail or to perform incorrectly)
• On system, these failures affect
• The failure mechanisms and
• How to avoid the failures and/or mitigate the effects of the failures on the system?
FMEA estimate the failure of each component in system by reviewing the components in the machinery and equipment. The failure modes of each components and
their resulting effects are recorded in FMEA form. Probability of occurence (P),
severity (S), and detection (D) is found out by this reviews from that risk priority
number (RPN) evaluated by multiplying occurence, severity, and detection [5]. Risk
priority number gives clear idea about which activity is most hazardous and where
we need to more attention to reduce the failure rate.
RPN = Occurence(P) × Severity(S) × Detection(D)
P. Srinivas and M. Elangovan
ERPG-1 is the maximum airborne concentration below which people could be
exposed for up to 1 h without experiencing any adverse health effects.
From the above, it was observed that red (life-threatening zone) is up to 2.5 km,
orange (health effects which impair an individuals ability) is up to 4.2 km, and yellow
(without any adverse effects) is up to 9.7 km; hence, residential colony can be located
outside the EPRG-2 (orange zone), so that people at residential colony will not have
any adverse effects when TDI vapor release from spillage site.
Onsite emergency preparedness plan will be implemented for plant people who
are at ERPG-3 (red zone), and this plan consists of emergency declaring procedure, incident controller, alarm system, assembly points, emergency vehicle, emergency lighting (DG Set), escape respirators, etc. By implementing a emergency
preparedness plan, plant people will be protected from TDI vapor exposure.
3.2 Handling/Process Area
In rocket industry for solid propellant manufacturing TDI processed/handled which
involves hoppers/bins, ball valves, hoses, and pipe fittings, any of these components
failure may lead to TDI spillage, and people may effect due to toxic vapor exposure
[4], and hence, risk assessment is carried out at TDI handling area by failure modes
effect analysis (FMEA).
To identify the various ways in which components, systems, or processes can fail
to fulfill their design intent, failure modes effect analysis (FMEA) is used. FMEA
specifies the following:
• All probable modes of failure for the various parts of a system (which is observed
to fail or to perform incorrectly)
• On system, these failures affect
• The failure mechanisms and
• How to avoid the failures and/or mitigate the effects of the failures on the system?
FMEA estimate the failure of each component in system by reviewing the components in the machinery and equipment. The failure modes of each components and
their resulting effects are recorded in FMEA form. Probability of occurence (P),
severity (S), and detection (D) is found out by this reviews from that risk priority
number (RPN) evaluated by multiplying occurence, severity, and detection [5]. Risk
priority number gives clear idea about which activity is most hazardous and where
we need to more attention to reduce the failure rate.
RPN = Occurence(P) × Severity(S) × Detection(D)