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ADDITIONAL STUDIES…7 156 7.1 R & R ACTION PLAN No R & R action plan would be required as the proposed establishment of distillery project would be undertaken in existing premises of sugar factory by JSL Dhawarwadi, Dist.: Satara. 7.2 RISK ASSESSMENT Proposed distillery shall be implemented by the project proponents in the premises of existing integrated project complex of JSL. The risk assessment and hazard management study was done by Mr. Vinod Sahasrabudde who is the Functional Area Expert (FAE) and Mr. Gandhar Ghanekar who is Associate Functional Area (FAA) for Risk & Hazard (RH) of EEIPL. The proposed project would be formulated in such a fashion and manner so that utmost care of safety norms and Environment Protection Act shall be taken care of. 7.3 POTENTIAL RISK PRONE AREAS IN INTEGRATED JSL COMPLEX Table 7.1 Details of Onsite Possible Hazardous Areas in JSL Complex Sr. No. Hazardous Area Hazard Identified Safety Measures Measures Implemented / Planned by JSL 1 Boiler Area Explosion IBR rules for design, maintenance and operation of boilers by certified boiler attendants is mandatory. This existing boiler in co-gen plant is being operated as per IBR rules. Also, the proposed boiler under distillery would be installed as per IBR rules. 2 All over the plant Lightening To design & install adequate number of best available lightening arrestors. Lightening arrestors at critical locations like coal & bagasse yard, biogas distillery section will be installed. 3 Electrocut ion Lose fitting Regular maintenance, internal safety audit, & external safety audit at regular intervals. Regular maintenance is being done under existing sugar factory. Same procedure would be followed under as new distillery project. 4 Electrical rooms Fire & Electrocuti on Regular maintenance, internal safety audit, & external safety audit at regular intervals. Regular maintenance is being done under existing sugar factory. Same procedure would be followed under as new distillery project. 5 Transform er area Fire & Electrocuti on Regular maintenance, internal safety audit, and external safety audit at regular intervals. Regular maintenance is being done under existing sugar factory. Same procedure would be followed under as new distillery project. 6 Cable tunnel Fire & Electrocuti on Regular maintenance, internal safety audit, and external safety audit at regular intervals. Regular maintenance is being done under existing sugar factory. Same procedure would be followed under as new distillery project.

7.1 R & R ACTION PLAN JSL 7.2 RISK ASSESSMENT 7.3

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Page 1: 7.1 R & R ACTION PLAN JSL 7.2 RISK ASSESSMENT 7.3

ADDITIONAL STUDIES…7

156

7.1 R & R ACTION PLAN

No R & R action plan would be required as the proposed establishment of distillery project

would be undertaken in existing premises of sugar factory by JSL Dhawarwadi, Dist.: Satara.

7.2 RISK ASSESSMENT

Proposed distillery shall be implemented by the project proponents in the premises of existing

integrated project complex of JSL. The risk assessment and hazard management study was

done by Mr. Vinod Sahasrabudde who is the Functional Area Expert (FAE) and

Mr. Gandhar Ghanekar who is Associate Functional Area (FAA) for Risk & Hazard (RH)

of EEIPL. The proposed project would be formulated in such a fashion and manner so that

utmost care of safety norms and Environment Protection Act shall be taken care of.

7.3 POTENTIAL RISK PRONE AREAS IN INTEGRATED JSL COMPLEX

Table 7.1 Details of Onsite Possible Hazardous Areas in JSL Complex

Sr.

No.

Hazardous

Area

Hazard

Identified

Safety Measures Measures Implemented /

Planned by JSL

1 Boiler

Area

Explosion IBR rules for design,

maintenance and

operation of boilers by

certified boiler attendants

is mandatory.

This existing boiler in co-gen

plant is being operated as per

IBR rules. Also, the proposed

boiler under distillery would be

installed as per IBR rules.

2 All over

the plant

Lightening To design & install

adequate number of best

available lightening

arrestors.

Lightening arrestors at critical

locations like coal & bagasse

yard, biogas distillery section

will be installed.

3 Electrocut

ion

Lose fitting Regular maintenance,

internal safety audit, &

external safety audit at

regular intervals.

Regular maintenance is being

done under existing sugar

factory. Same procedure would

be followed under as new

distillery project.

4 Electrical

rooms

Fire &

Electrocuti

on

Regular maintenance,

internal safety audit, &

external safety audit at

regular intervals.

Regular maintenance is being

done under existing sugar

factory. Same procedure would

be followed under as new

distillery project.

5 Transform

er area

Fire &

Electrocuti

on

Regular maintenance,

internal safety audit, and

external safety audit at

regular intervals.

Regular maintenance is being

done under existing sugar

factory. Same procedure would

be followed under as new

distillery project.

6 Cable

tunnel

Fire &

Electrocuti

on

Regular maintenance,

internal safety audit, and

external safety audit at

regular intervals.

Regular maintenance is being

done under existing sugar

factory. Same procedure would

be followed under as new

distillery project.

Page 2: 7.1 R & R ACTION PLAN JSL 7.2 RISK ASSESSMENT 7.3

ADDITIONAL STUDIES…7

157

Sr.

No.

Hazardous

Area

Hazard

Identified

Safety Measures Measures Implemented /

Planned by JSL

8 Fuel

storage

area

(Bagasse

& Coal)

Fire Fire hydrant around

storage area. Continuous

supervision to extinguish

small fires using water

caused by heat in

atmosphere.

Fire hydrant lines will be laid

around fuel storage area.

9 Alcohol

productio

n area

Fire &

Alcohol

vapour

release

HAZOP study for

production, Alcohol

Storage area & adequate

safety instrumentation

with alarms & interlocks

to be incorporated to make

design & plant operation

intrinsically safe.

HAZOP studies w.r.t distillery

operations would be carried

out.

10 Distillery

(Ethanol

storage

tank)

Fire Fire hydrant to be laid

around with foam fighting

arrangements. Design of

fire fighting system to be

as per OISD 117

standards.

OISD Standards would be

followed for fire hydrant

system.

7.4 RISK PRONE AREAS IN SUGAR & CO-GENERATION OF JSL

7.4.1 Boiler Operations

Boiler operation is main operation which provides steam throughout plant for various

process operations. Bagasse is a prime fuel for boiler and the area is allotted for bagasse

storage is 5,000 Sq.m open space and ash generated is stored on site on open space

30,000MT. Bagasse storage is covered with fire hydrant.

Mitigation Measures Onsite

• Boiler is designed as per IBR rules

• Bagasse is covered with fire hydrant line

• Overhead High Tension (H.T.) wires are avoided

• Lightning arrestor are placed at the top of the molasses tank for preventation of fire.

7.4.2 Storage of Molasses

Molasses is used mainly for production of Ethyl Alcohol, RS and ENA. At present, factory is

having two mild steel molasses storage tank of 4,000 MT capacity each. Proper care will be

taken by sugar factory to cool down molasses before it goes to molasses storage tank. Tanks

are well equipped with suitable pump for recirculation of molasses. A two months stored

molasses is ideal for fermentation. Molasses will be pumped through pipeline, from the sugar

factory storage tank to distillery day molasses tank. Industry will install 10,000 MT capacity

molasses tank in distillery section.

Page 3: 7.1 R & R ACTION PLAN JSL 7.2 RISK ASSESSMENT 7.3

ADDITIONAL STUDIES…7

158

Mitigation Measures for Proposed Molasses Storage Tank

1. Molasses will be stored in good quality and leak proof steel tanks. Bund walls will be

constructed around the tank.

2. Volume of bund = 1.2 x volume of the highest capacity storage tank.

3. Continuous mixing of molasses will be done.

4. If there is increase in temperature beyond 300C, external cooling of tanks will be

provided. A temperature recorder will be provided to tanks with high temp. alarm system.

5. If there is leakage –

a. Leakage will be washed out, diluted and properly treated in effluent treatment plant

and then it will be recycled. Arrangements will be made for collection of leakage, also

for recycle and pumping to the effluent treatment plant.

b. Replacement of leaky gaskets and joints, it will be done strictly by following work

permit system.

i. Leakage of pipelines, welding repairs will be attended /carried out as far as

possible outside the plant. Necessary hot work permit will be issued after taking

necessary precautions and fire fighting measures for onsite hot work. It will be

only issued the concerned authority before any hot work in undertaken.

ii. Leakage through pump gland will be reduced to the minimum with the installation

of mechanical seals.

c. To attend all major leakage in tanks the following procedure will be followed.

i. Material will be transferred to other tank.

ii. The tank will be prepared for welding repairs by making sure that it is positively

isolated with blinds. Vessels will be examined by ensuring that it is free of the

chemicals and gases by air analysis before any hot work is undertaken.

iii. This will be done by skilled workers.

Table 7.2 Details Regarding Molasses Tank

Sr. No Unit Tank No 1 Tank No 2

1 Height 975 Cm 1096 Cm

2 Diameter 22.5 Mtr. 23 Mtr.

3 Capacity 4000 M3 4000 M

3

4 External Cooling system Provided Provided

5 Storage Area 490.86 Sq. M

Page 4: 7.1 R & R ACTION PLAN JSL 7.2 RISK ASSESSMENT 7.3

7.4.3 Storage and Handling of Sulphur

Sulphur is stored in a closed shed of area

transferred manually to the SO2

hazards in storage and handling sulphur.

Hazards in Sulphur Storage –

• Dust Explosion

• Fire

� Dust Explosion

As Sulphur is stored and handled in granular form, there is always some dust formation

which can lead to dust explosion. D

ignited, which results to a very rapid

products. This in turn creates a subsequent pressure rise of explosive

capable of damaging plant, buildings

be initiated by dust particles less than 500 microns diameter.

� Conditions for a Dust Explosion

Following conditions are necessary before a dust explosion can take place.

• Dust must be combustible.

• Dust cloud must be of explosive concentration, i.e. between lower

limits for the dusts.

• Sulphur is a flammable substance in both the solid and liquid states. The dust is

characterized by a very low ignition point of 190°C compared to other combustible dusts,

and dust clouds are readily ignited by weak frictional sparks. Dusts containing 25% or

more elemental Sulphur may be almost as explosive as pure sulphur.

• There must be sufficient oxygen in the atmosphere to support and sustain combustion.

• A source of ignition must be present.

ADDITIONAL STUDIES…7

159

Figure 7.1 Molasses Tank

andling of Sulphur: Exposure to dust, dust explosion

a closed shed of area 72 MT in warehouses of 150.96 sq m

production unit as per the requirement. Following are the

ulphur.

handled in granular form, there is always some dust formation

ch can lead to dust explosion. Dust explosion occurs when a fine dust formation

very rapid burning and the release of large quantities of gaseous

creates a subsequent pressure rise of explosive force which can be

plant, buildings. It is generally considered that a dust explosion can only

be initiated by dust particles less than 500 microns diameter.

xplosion

Following conditions are necessary before a dust explosion can take place.

cloud must be of explosive concentration, i.e. between lower & upper explosion

substance in both the solid and liquid states. The dust is

characterized by a very low ignition point of 190°C compared to other combustible dusts,

and dust clouds are readily ignited by weak frictional sparks. Dusts containing 25% or

r may be almost as explosive as pure sulphur.

There must be sufficient oxygen in the atmosphere to support and sustain combustion.

A source of ignition must be present.

ADDITIONAL STUDIES…7

sq m area. It is

Following are the

handled in granular form, there is always some dust formation

dust formation in air is

tities of gaseous

force which can be

. It is generally considered that a dust explosion can only

upper explosion

substance in both the solid and liquid states. The dust is

characterized by a very low ignition point of 190°C compared to other combustible dusts,

and dust clouds are readily ignited by weak frictional sparks. Dusts containing 25% or

There must be sufficient oxygen in the atmosphere to support and sustain combustion.

Page 5: 7.1 R & R ACTION PLAN JSL 7.2 RISK ASSESSMENT 7.3

ADDITIONAL STUDIES…7

160

• The dust must be fine enough to support an explosion.

• If these above conditions will be avoided then, dust explosion can be prevented.

Mitigation Measures

Explosion Prevention: Dust explosions can be prevented by ensuring that the following

conditions -

• Formation and suspensions of Sulphur dust in air will be avoided.

• Storage shed is constructed with a minimum number of horizontal surfaces to avoid dust

accumulation. The improvisations will be done in safety of sulphur storage.

• All sources of ignition have been excluded. The same will be followed all the time.

� Fire in Sulphur Storage

There is a risk of fire in Sulphur storage as ignition temperature is low 1900C. Solid and

liquid sulphur will burn to produce Sulphur dioxide gas, which is extremely irritating and

toxic. The effects of the fire hazard itself are slight.

Mitigation Measures

• Smoking & use of matches are prohibited in all areas where sulphur dust is present.

• Naked flames, lights, use of gas cutting & welding equipment are prohibited during the

normal operation of the plant.

• Repair work which involves use of flames, heat, and hand and power tools in the areas

where sulphur may be present, it will be allowed only after getting hot work permit from

the concerned authority.

7.4.4 Safety Precautions at Sulphur dioxide Plant (SO2 section)

SO2 production is very important area of sugar manufacturing operations because of

sulphitation of the sugar syrup. Flow chart of SO2 is presented at figure 7.2.

• Plant has standard SO2 production unit. Existing production capacity is adequate to cater

to the additional requirement of SO2 for increased production. Unit produces required

amount of SO2 at required rate by changing sulphur feed to unit, it is melted & charged to

burner chamber, & where in air at controlled rate is fed to burner to produce SO2. Gas at

high temp of 400 0C to 600

0C is cooled to 60

0C and sent to user unit through 100/ 150

mm piping at 1.5 to 1.7 atm pressure. This unit is designed for incite production and use

of SO2. There is practically no inventory of gas in Sulphur burner unit & inventory of gas

is in pipeline from unit to sulphiter only.

Page 6: 7.1 R & R ACTION PLAN JSL 7.2 RISK ASSESSMENT 7.3

Figure 7.2 Sulphur Dioxide Production Flow Chart

� Safety Measures for SO2 Section

• Before the plant start up and every six months,

equipments and piping carrying s

• Alarm system in case of SO2

existing plant.

• SO2 leak detectors have been installed.

• Emergency shutdown procedure and

local language.

• Mock drills are being carried out as per on

• In case of leakage is noticed from a flange joint, emergency shutdown plant

• Only trained person deals

apparatus, and area around SO

immediately.

• In case of major leakage, onsite emergency plan for the entire plant wil

and if necessary Govt. authorities

activated.

• LED panelled temperature sensors have been installed in the SO

7.4.5 Co-generation Plant Safety

Existing Co-generation is 10 MW

following standard safety features

1. Turbine is interlocked with high and low steam inlet pressure

ADDITIONAL STUDIES…7

161

Figure 7.2 Sulphur Dioxide Production Flow Chart

Section.

the plant start up and every six months, pressure test and thickness

and piping carrying sulphur dioxide are carried out.

2 leakage to warn all workers of has already been installed in

leak detectors have been installed.

hutdown procedure and action is displayed in the SO2 production area in

carried out as per on-site emergency plan.

In case of leakage is noticed from a flange joint, emergency shutdown plant is

with the situations using safety appliances and breathing

apparatus, and area around SO2 production unit and part of the main plant

In case of major leakage, onsite emergency plan for the entire plant will be put in action

and if necessary Govt. authorities will be alerted and off site emergency plan

temperature sensors have been installed in the SO2 production unit

generation Plant Safety

10 MW. This plant is fully automated with interlocks, alarms

following standard safety features.

interlocked with high and low steam inlet pressure.

ADDITIONAL STUDIES…7

pressure test and thickness test of all the

een installed in

production area in the

is ordered.

with the situations using safety appliances and breathing

production unit and part of the main plant is vacated

l be put in action

off site emergency plan will be

production unit.

. This plant is fully automated with interlocks, alarms

Page 7: 7.1 R & R ACTION PLAN JSL 7.2 RISK ASSESSMENT 7.3

ADDITIONAL STUDIES…7

162

2. Turbine is interlocked with high vibration of any bearing of turbine, gear box, and

alternator.

3. Turbine is interlocked with any bearing high temperature.

4. High axial displacement of the rotor is installed.

5. Turbine is interlocked with high lube oil temperature.

6. For reduction of noise, all steam outlets are provided with silencers.

7. Pressure safety relief valves are provided on steam drum and steam lines.

8. In addition to mechanical SRVs (Safety Relief Valves) and Electrometric Safety Relief

valve is provided.

9. Smoke leak detector alarm is provided with alarm.

10. Turbine and power generation plant is PLC operated sequential start up and shutdown

procedure built in. The plant is equipped with standard instrumentation, alarms, and

interlocks, trips such high speed trip, bearing vibration, bearing oil circulation, oil

temperature, turbine alignment.

11. Auto start jockey pumps will be used for fire fighting with low pressure interlock which

will auto start the pump. Standard operating procedure may be referred at Appendix-F

7.5 RISK PRONE AREAS IN ALCOHOL MANUFACTURING UNIT AND

MITIGATION MEASURES

This facility, particularly ethanol separation unit would be fully automated and operated

through PLC. Qualitative Risk analysis, HAZOP studies will be carried out for new unit and

all the recommendations, particularly related to safety, like instrumentation modifications,

installation of alarms, interlocks, to eliminate possible hazards due to process upsets will be

in place before plant commissioning.

7.5.1 Boiler operations

New 21 TPH boiler will be installed for steam requirement distillery operations. Boiler will

be designed as per IBR rules and proper care will be taken for operations. Coal will be the

main fuel for boiler used for distillery operations-

� Coal Storage

• Coal storage unit is will be maintained equipped with for stacking of coal in heaps.

Adequate dust suppression measures will be provided to prevent fugitive emission and

also risk of fire.

• Coal ash transported in tankers will be covered and closed and so that there will be no

chance of spillage during transportation.

• Workers will be trained to vigilant and keep water hose with ready water supply to

extinguish small fires during hot season.

• Fire fighting measures, alarm measures and fire hydrant line will be provided around the

coal storage area for effectively dealing with fire.

7.5.2 Storage of Alcohol

A) Calculation for Fire and Explosion (F & E ) Index

Preliminary estimate for the calculation of radius of exposure by multiplying F & EI by 0.84

is done. Assumptions are as follows:

Page 8: 7.1 R & R ACTION PLAN JSL 7.2 RISK ASSESSMENT 7.3

ADDITIONAL STUDIES…7

163

Material Factor (MF) value of 16 calculated based on the basis of NF value 3 and flash point

of 55 0F. Material Factor as per standard table is 16 and calculating General Process Hazard

(GPH) and Special Process Hazard (SPH) factors as 1.5 and 2.6, based on above ground

storage conditions.

F& EI index calculated is = 62.4

Based on following criterion of F& EI values, hazard is rated slightly on higher side.

Table 7.3 F & EI Rating

Sr. No. Value of F & E I Rating

1 1 to 45 Light Hazard

2 46 to 60 Moderate Hazard

3 61 to 95 High Hazard

4 96 and above Severe Hazard

B) Details On Fire fighting System Around the Alcohol Storage Area

i. Guidelines in OISD 117 will be followed, while designing fire fighting system around the

alcohol storage area.

ii. Main components of the fire system are fire water storage, fire water pumps and

distribution piping network will be designed as per the codes.

iii. Fire water system installation will be designed to meet the fire water flow requirement.

iv. Fire water flow rate for a tank farm will be segregated of the following :-

• Water flow calculated for cooling a tank on fire at a rate of 3 lpm / m² of tank shell

area. Water flow calculated for exposure protection for all other tanks falling within

a radius of (R +30) meters from centre of the tank on fire (R-Radius of tank on fire)

and situated in the same dyke at a rate of 3 lpm/m² of tank shell area.

• Foam water requirement will be calculated based on 5 lpm/m2 of tank area.

• For water flow calculations, all tanks farms having class A or B petroleum storage

will be considered irrespective of diameter of tanks and whether fixed water spray

system is provided or not.

• Water flow required for applying foam on a single largest tank by way of fixed foam

system, where provided, or by use of water/foam monitors.

• Various combinations will be considered in the tank farm for arriving at different fire

water flow rate and the largest rate to be considered for design.

• Fire water flow rate for supplementary streams will be based on using 4 single

hydrant outlets and 1 monitor simultaneously.

• Capacity of each hydrant outlet as 36 M3/Hr and each monitor as 144 M

3/Hr

minimum will be considered at a pressure of 7 kg/cm2g.

• Fire hydrant system, with necessary alarm systems, piping, with required number of

hydrant points, hose boxes, pump, auxiliary pump to operate, auxiliary power

generator/ backup will be designed as per relevant IS standards.

• The static fire fighting pumps conform to the requirements given in IS 12469: 1988.

The capacity of pumps will be worked out based on requirements of output and

pressure for the system. 171 M3/Hr, @ 7 Kg/Cm

2. Provision will be made for

standby pumps fed from different source of power at the rate of 50 % of aggregate

number of pumps, subject to minimum of one and maximum of two.

• Fire fighting hydrant system in the entire plant will be laid as per IS 909: 1975

standard with hose reels.

Page 9: 7.1 R & R ACTION PLAN JSL 7.2 RISK ASSESSMENT 7.3

ADDITIONAL STUDIES…7

164

• For determining water requirement, pump capacity, pump discharge, foam fire

fighting arrangements will be design the same as per OISD 117 standards.

C) Header Pressure

Fire water system will be designed for a minimum residual pressure of 7 Kg/cm2

(g) at

hydraulically remoted points in the installation considering of single largest risk scenario.

D) Storage

i. Water for the fire fighting will be stored in easily accessible surface, underground or

above ground tanks of steel, concrete or masonry.

ii. The effective capacity of the reservoir / tank above the level of suction point will be

minimum 4 hours aggregate rated capacity of pumps. However, where reliable make up

water supply is 50% or more of design flow rate, the storage capacity may be reduced to 3

hours aggregate rated capacity of pumps.

E) Others Measures

i. Frequent checking of pipe lines and storage units will be done.

ii. Welding will not be done near combustible material storage.

iii. Disaster / emergency prepared plan will be prepared as per the guidelines and rules

amended in Factory’s act.

iv. Regular mock drills and trainings for success of emergency plan during actual emergency

will be carried out. Emergency procedures will be laid down clearly and convincingly to

everyone on site, particularly the key personnel & essential workers. Record will be

maintained for same.

v. Safety policy, Environment, Health policy will be formulated and will be displayed at all

prominent places in the plant and offices.

vi. There is properly equipped Occupational Health Care in the factory premise/ the present

one will be suitably augmented with increased facilities to take care of the workers to be

employed in the new expansion plant as per the Factory’s Act 74 W.

vii. Regular medical check-up of workers will be carried out and proper records must be

maintained. Details of tests to be carried out will be finalized with OHC doctor and will

be informed. The company is timely taking medical checkups for the seasonal and

permanent workers.

viii. Representation of the OISD norms is given in Figure 7.3

Page 10: 7.1 R & R ACTION PLAN JSL 7.2 RISK ASSESSMENT 7.3

Figure 7.3

Table 7.4

Sr.

No.

Raw

Material

Scenario of

Spillage/

Leakage

1 Ethanol Pool fire •

Worst case scenario can be referred at

ADDITIONAL STUDIES…7

165

Ethanol Storage Tank Represenation

Table 7.4 Worst Case Scenario

Area of Spread Mitigation Measures

Red : less than 10M (10.0 kW/ (Sq M) =

potentially lethal

within 60 sec)

Orange : 13M (5.0kW/ (Sq M) = 2

nd

degree burns within

60 sec)

Yellow:21M (2.0 kW/ (Sq M) =

pain within 60 sec)

• Small Spill: Dilute with water

mop up, or absorb with an inert

dry material &

appropriate waste disposal

container.

• Large Spill: Flammable liquid.

Keep away from heat. Keep away

from sources of ignition. Stop leak

if without risk. Absorb with DRY

earth, sand or other non

combustible material. Do not

touch spilled material. Prevent

entry into sewers, basements or

confined areas; dike if needed. Be

careful that the product is not

present at a concentration level

above TLV. Check TLV on the

MSDS and with local authorities.

Worst case scenario can be referred at Appendix-G

ADDITIONAL STUDIES…7

Mitigation Measures

: Dilute with water &

mop up, or absorb with an inert

place in an

appropriate waste disposal

Flammable liquid.

Keep away from heat. Keep away

from sources of ignition. Stop leak

if without risk. Absorb with DRY

, sand or other non-

combustible material. Do not

touch spilled material. Prevent

entry into sewers, basements or

confined areas; dike if needed. Be

careful that the product is not

present at a concentration level

above TLV. Check TLV on the

ocal authorities.

Page 11: 7.1 R & R ACTION PLAN JSL 7.2 RISK ASSESSMENT 7.3

ADDITIONAL STUDIES…7

166

7.7 FIRE TRIANGLE

Following representation will be displayed at the premises of the distillery area for better

understanding of the fire safety.

Figure 7.4 Fire Triangle

Mitigation Measures for Leakages and Fire

• Approval from (CCOE) Chief Controller of Explosives’ will be procured in addition to

regular factory inspector and other statutory approval will be procured.

• With respect to the Petroleum Act, Petroleum rules, 2002, following important measures

with respect to tank layout and factory layout will be followed.

a. Minimum Clear distance between two tanks will be 0.5 D or 15 meters away from

the highest capacity of the tank in the tank farm.

b. Tanker vehicle loading / unloading centre of the bay area will be minimum 15

meters away from the tanks storage periphery to prevent chemical escape.

c. Boundary fencing will be minimum 20 M away from periphery to avoid leakage.

d. All the tanks will be placed within the area surrounded by dyke wall, constructed as

per standard design and construction norms.

e. Volume within dyke wall will be more than largest storage tank inside dyke wall.

f. Provision of spare tank for pumping large alcohol spillage or leakage by proving

sump and pump connection.

g. In case spare tank is not provided, pump piping will be provided such that large

leakage can be pumped to a suitable process tank.

h. All pump motors and other electrical fittings will be flame proof of suitable class.

i. Chilled water condenser will be provided over the tanks to avoid alcohol loss.

j. Suitable and proper safety measures will be installed on the tanks.

k. Tanks will provided with level indicating instruments with high & low level alarms.

l. Eye wash and showers will be installed in distillery section.

m. All the safety measures like hooter, flash smoke detectors, sensors, fire fighting

arrangements, hose pumps will be installed for the safety.

7.7.1 Fire Fighting Arrangements on Site

• Fire tender is available at factory premises and safety mock drills and the frequency is 3

times in month for betterment of safety.

• The fire hydrant line will be drawn around bagasse storage with jokey pumps. A new tank

will be installed at time of establishment of distillery.

• Assembly points have been marked on site for emergency situations.

• Evaporation vent is situated at the top of molasses tanks & 1 lightning arrestor is there on

top of same. Fire extinguishers have been installed on sugar industry premises are-

Page 12: 7.1 R & R ACTION PLAN JSL 7.2 RISK ASSESSMENT 7.3

ADDITIONAL STUDIES…7

167

Table 7.5 Fire Extinguishers list

Sr.

No

Location Type of fire

Extinguisher

Capacity of

Extinguisher

Refilling date

(Service Date)

Due date

1 Petrol Pump

Co2

4.5 Kgs 19-Sep-16 18-Sep-17

2 Sugar boiling House 4.5 Kgs 19-Sep-16 18-Sep-17

3 Juice Section 4.5 Kgs 19-Sep-16 18-Sep-17

4 Mill Fibrilizer 4.5 Kgs 19-Sep-16 18-Sep-17

5 Mill (Electric Panel) 4.5 Kgs 19-Sep-16 18-Sep-17

6 DG Set Stand 4.5 Kgs 19-Sep-16 18-Sep-17

7 DG Set Stand 4.5 Kgs 19-Sep-16 18-Sep-17

8 Power house 4.5 Kgs 19-Sep-16 18-Sep-17

9 Power house 4.5 Kgs 13-Aug-16 12-Aug17

10 Boiler 4.5 Kgs 13-Aug-16 12-Aug 17

11 Turbine 4.5 Kgs 19-Sep-16 18-Sep-17

12 Turbine 4.5 Kgs 19-Sep-16 18-Sep-17

13 Switch yard 4.5 Kgs 19-Sep-16 18-Sep-17

14 Switch yard

Dry

Chemical

Powder

(Bicarbonate)

5 Kgs 19-Sep-16 18-Sep-17

15 Petrol Pump 5 Kgs 19-Sep-16 18-Sep-17

16 Sugar Godown 5 Kgs 19-Sep-16 18-Sep-17

17 Sugar Godown 5 Kgs 19-Sep-16 18-Sep-17

18 Sugar Godown 5 Kgs 19-Sep-16 18-Sep-17

19 Sugar house Stand 5 Kgs 19-Sep-16 18-Sep-17

20 Sugar boiling House 5 Kgs 19-Sep-16 18-Sep-17

21 Pan 5 Kgs 19-Sep-16 18-Sep-17

22 Petrol Pump 5 Kgs 19-Sep-16 18-Sep-17

23 Petrol Pump 5 Kgs 19-Sep-16 18-Sep-17

24 Boiler/Mill Stand 5 Kgs 13-Aug-16 12-Aug 17

25 Turbine 5 Kgs 13-Aug-16 12-Aug 17

26 Store 5 Kgs 13-Aug-16 12-Aug 17

27 Boiler 5 Kgs 13-Aug-16 12-Aug 17

28 Open Godown

Dry

Chemical

Powder

(For class

A,B,C)

4.5 Kgs 13-Aug-16 12-Aug 17

29 Sugar Godown 4.5 Kgs 13-Aug-16 12-Aug 17

30 Factory Inside Office 4.5 Kgs 13-Aug-16 12-Aug 17

31 Boiler Stand 4.5 Kgs 19-Sep-16 18-Sep-17

32 Store 4.5 Kgs 19-Sep-16 18-Sep-17

33 Sugar house Stand 4.5 Kgs 19-Sep-16 18-Sep-17

34 New buld.LAB. 4.5 Kgs 19-Sep-16 18-Sep-17

35 Sugar Godown 4.5 Kgs 19-Sep-16 18-Sep-17

36 Cane Yard 4.5 Kgs 19-Sep-16 18-Sep-17

37 Sugar house 4.5 Kgs 19-Sep-16 18-Sep-17

38 Sugar Godown 4.5 Kgs 19-Sep-16 18-Sep-17

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ADDITIONAL STUDIES…7

168

7.8 OCCUPATIONAL HEALTH ASPECTS AND MEDICAL PROVISION IN THE

FACTORY

Effects of Alcohol on health:

It reacts vigorously with oxidizing materials. TLV for 8 hr. is 1000 ppm (ACGIH). Minimum

identifiable concentration has been reported as 350 ppm. Exposure to concentrations of 5000

- 10000 ppm results in irritation of eyes and mucous membranes of the upper respiratory

tract. Effects of exposure to higher concentration of alcohol in the atmosphere are given in

the following table.

Table 7.6 Effect of Ethyl Alcohol

Sr.

No.

Concentration

(mg/l)

Concentration

(Ppm)

Effects on Human

1 10-20 5300 –10,640 Some transient coughing & smarting of eyes &

nose, not tolerable.

2 30 15,960 Continuous lacrimation and marked coughing;

could be tolerated with discomfort.

3 40 21,280 Just tolerable for short period

4 > 40 >21,280 Intolerable

To prevent injury to workers, standard PPEs will be provided. In addition, sufficient number

of Self-Contained Breathing Apparatus (SCBA) will be provided to be used in case of major

alcohol leakage to avoid exposure to higher levels of alcohol. All precautionary methods will

be adopted by the company to reduce the risk of exposure of employees to occupational

safety and health hazards.

7.8.1 Medical check-up

Pre & post medical check-ups are done for all the employees. Employees are regularly

examined and the medical records will be maintained for each employee. Pulmonary function

test and periodical medical check-up are being done once in every year. Check- up reports

can be referred at Appendix- H

Following tests will be conducted for each worker for proposed activity.

• Lung Function Test

• Radiology – X-ray

• Pulmonary Function Test

• Audiometric Test

• General clinical examination with emphasis on respiratory system

• Pre employment examinations

• Periodical medical examinations at the time of employment and after completion of

employment.

7.8.2 Occupational Health Centre (OHC)

Standard Medical facilities are available on site and it will be upgraded and designed as per

rule and will be provided in the OHC for proposed project.

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ADDITIONAL STUDIES…7

169

Some important are illustrated below:

1. Well equipped first aid boxes will be provided in each section of the factory.

2. Snake bite Lancet will be made available for immediate action on snake bite.

3. In case of need, factory will be having dispensary to give effective medical facility to

workers. In dispensary, sufficient stock of medicines will be available to provide to

workers in case of any major emergent situation.

4. A vehicle with First aid Kit will be always available to shift the sick/injured person to

District Hospital.

5. Ambulance will be made available 24X7 in factory to deal with the emergency situations.

Existing safety measures on site can be referred at Appendix- I

7.9 ONSITE AND OFFSITE EMERGENCY PLAN

On site and off site emergency plan will be made according to the Factory’s Act. Also some

systematic format will be followed as it is followed for existing plant of sugar manufacturing.

The objectives of disaster management plan are as follow -

• Controlling the disaster, localizing the disaster and eliminating the hazard.

• Welfare of person managing the disaster.

• Head count and rescue operations.

• Treatment of injured.

• Safeguarding others by timely evacuation.

• Minimizing damage to property and environment.

• Informing and assisting relatives.

• Informing and collaborating with statutory authorities.

• Informing the news media.

• Preserving records and organizing investigations.

• Investigating and taking steps to prevent recurrence.

• Resorting normalcy.

Prerequisites for a good disaster management plan have been given below:

• Management's commitment to safety.

• Emergency organization.

• A good public address system in the complex with one or two jeeps with PA system for

use in surrounding areas also.

• ‘Duty Team’ for silent-hour coverage, approved emergency control centers & assembly

points.

• Written guidelines for the duty team members.

• List of key personnel, experts, doctors, village leaders, authorities with their locations and

telephone numbers (both office and residence).

• Clear-cut definition of role of individuals.

• Adequate means of communication with good back-up facility for telephone system.

Also, alternative methods of communication like wireless, etc. should be available.

• Training, Regular rehearsals including alarms at least once / quarter.

• Fire and safety manuals (Both common and plant wise).

• Operating and Maintenance Manuals.

• Strong conviction that “prevention is better than cure”. Therefore, more emphasis should

be made to prevent disasters.

• Warehouse safety manual.