CHAPTER– 6 ADDITIONAL STUDIES (RISK ASSESSMENT AND

Draft Environmental Impact Assessment Report 2014

135 M/s Ugar Sugar Works Ltd.Ugar Khurd, Tal: Athani, Dist: Belgaum

CHAPTER– 6

ADDITIONAL STUDIES

(RISK ASSESSMENT AND DISASTER

MANAGEMENT PLAN)



Risk Assessment

General Assessment:

The environment is at risk of exposure during transportation, storage, disposal, or

destruction of ethyl alcohol. In almost every scenario, the threat of environmental

exposure is contingent upon the proper handling of the chemical substance. Accidental

spills, large or small, can result in fire, explosion, and possible contamination of the

surrounding environmental mediums (water, soil, and air).

1. Introduction

The word 'disaster' is synonymous with 'emergency' as defined by the Ministry of

Environment and Forests (MoEF). An emergency occurring in the proposed

Enhancement plant is one that may affect several sections within it and/ or may cause

serious injuries, loss of lives, extensive damage to environment or property or serious

disruption outside the plant. It will require the best use of internal resources and the use

of outside resources to handle it effectively. It may happen usually as the result of a

malfunction of the normal operating procedures. It is imperative to conduct risk analysis

for all the projects where hazardous materials, fuels are handled.

The following have been addressed as part of the risk analysis.

ü Introduction

ü Hazard Identification and Risk Analysis

ü Risk Reducing Measures

The Introduction deals with the objective and methodology of carrying out the risk

analysis. Hazard Identification and Risk Analysis discusses about the various types of

hazards associated with the operation of the Plant due to process, storage & handling,

human errors, electric failures and natural calamities. It also presents the calculated

frequencies of occurrence of different accident scenarios for the identified potential

hazard occurrence in the proposed plant and the details of consequence modelling/

analysis for the identified potential accidents/disaster scenarios in the plant. Risk

Reducing Measures based on the calculated frequencies and consequences.

An industry with its complex nature of activities involving various plant machineries, raw

materials, products, operations, intermediates and environmental discharge has a

number of associated hazards. A minor failure can lead to major failure resulting into a

disaster causing heavy losses to life, property and environmental. Risk assessment

studies are being conducted to ensure safety and reliability of any new plant, through a



systematic and scientific methods to identify possible failures and prevent their

occurrences before they actually cause disasters and production loss.

Accidents can occur in any industry despite of taking efforts to prevent them. The

suffering and damage as a result of the accident is determined by the potential for loss

surrounding the event, but by taking correct action at the time of the occurrence of the

incidence the full potential loss can largely avoided and effective action will be possible if

a pre-planned and practiced procedure for handling major emergencies utilizing the

combined resources of factory and the outside emergency services is in existence.

The best way of managing an emergency lies in its prevention it is recognized that in

spite of our best efforts to prevent emergencies by good engineering design and

construction, reliable safety system careful selection of personnel & training, audits and

inspections, use of state of art technology and sophisticated equipments etc. things can

still go wrong therefore it is essential to properly prepare, develop and update

emergency plans and rehearse them and be prepared for emergencies. The objective of

the emergency plan is to contain and control incidence to safe guard the employees and

any one nearby who might be affected and to minimize property loss & to protect the

environment.

2. Safety, Health & Environment Policy:

Safety Policy:

01. We believe that accidents are preventable and health hazards can be minimized by

Training and Retraining of the employees.

02. We will comply all the legislation & rules regarding Safety & Health.

03. We are committed to provide safe machinery, equipment, methods & tools and to

continual improvement in Health and Environment (HSE) performance.

04. Our Policy is to maintain Safety beyond compromise.

05. We believe that rules are sacred and must be observed.



06. While on duty, we will concentrate on our job.

07. Care & Caution is our guide in the life.

08. Safety, Security & Punctuality keep us always happy.

09. Our Motto – No Accidents due to human failure.

10. Our employees are more valuable than anything and we expect the employees to

follow the HSE norms.

Environment Policy:

We shall –

1. Conduct our operation in an environment friendly manner and to comply with the

relevant regulation and prevent pollution.

2. Strive for continuous improvement in our environmental performance by setting

challenging targets.

3. Conduct necessary programmes to enhance environmental awareness amongst

our employees and the general populace around plant and site.

4. Strive to conduct industrial and commercial operation in such a way that the

quality of the environment now and in the future is preserved.

5. Make wastes and effluents value added products in an environment friendly

manner.

6. Demonstrate our commitment through involvement of all employees for

achievement of environmental performance.

3. Identification of Hazards Sugar and Co generation Plant :

Sl. Operatio



No

.

n /

Process /

Departme

nt

Hazards

Identification.

Precautionary measures taken. Remark.

1 Cane

yard /

sugar

cane

milling

1) Movement of

trucks and tractors

in haphazard

manner may

cause accident.

1) For smooth movement of vehicles

route marking is done properly and

two-way traffic is arranged separately

for incoming and outgoing of cane and

controlled by adequate security staff.

Driving license & other legal

documents are checked strictly at

entry gate.

In case of

any

emergency

the units will

be tripped

immediately

by using

tripping

devices.

2) The sugar cane

is lifted through

crane & there are

chance of cane

bundle being

dropped.

2) Safety Helmets and training is

provided to the workers working near

cane lifting area.

3) Collapse of

EOT crane due to

damaged wire

rope and improper

clamping

3) Cranes,wire ropes and lifting

tackles are tasted once in a year by

competent Authority and routine

preventive maintenance will carried

out.

4) Miss-operation

of cranes due to

defect in eyes of

crane operators

may cause of

accident.

4)Eye testing of cane operators will be

done periodically.

5) Unguarded

machinery

5) All rotating dangerous machines in

mill section are provided with

adequate guards.



6) Slippery floor 6) Floor washing is done regularly.

7) Flying of

Bagasse particles

7) Suitable face mask are provided

and flying of Bagasse will be

minimized at possible extent.

8) Electrical short

circuiting

8) Suitable fire extinguisher are kept

and loose electrical connections are

avoided.



2 Clarificati

on

section

1) Leakage of So2

gas

1) All sulphur Burners and related

pipelines are tested properly during

off-season and necessary preventive

maintenance will be taken to avoid

any damage in season. Workers are

provided with necessary PPEs.

Safety

shower cum

Eye wash

fountain is

installed at

working

area.

2) Contact with

lime dust & milk of

Lime.

2) Workers are provided with

necessary PPEs.

Sufficient

ventilation is

provided.

3) Slippery floor 3) Leakage of juice and water will be

avoided.

4) Heat stress at

sulphur furnace

4) Necessary ventilation is provided

and workers are provided with

suitable PPEs.

3 Evaporati

on and

Pan

boiling

section.

1) Slippery floors

and walk ways.

As explained above.

Sufficient

free air flow

is

maintained

& air cooler

& pedestal

fans are

installed at

pan floor &

at

evaporator

section

2) Juice leakage

from valves.

3) Heat stress in

surrounding area.

4) Un-guarded

crystallizer units.

4 Centrifug

al section

1) Machine

operators are

exposing to

noise,vibration and

heat stress.

1) All operators are provided with

necessary PPEs



2) Leakage of

steam,hot water

due to which

slippery floor

causes.

2) As explained above.

3) Unguarded

machineries.

3) All rotating dangerous machines

are well guarded and properly

covered with inter locking

arrangement.

4) All

centrifugal

machines

are tested

once in a

year from

competent

authority.

4) Collapse of

centrifugal

machines due to

imbalance of

basket & shaft.

4) During off-season and season

preventive maintenance will be

prepared for testing of shafts &

baskets.

5) Electrical short

circuiting.

5) As explained above.



5 Sugar

drying

and

cooling /

packing

Godown.

1) Lot of dust,

noise and

vibration.

As explained above.

2) Fire hazards

due to loose wiring

/ defective

electrical

appliances.

As explained above.

3) Un-guarded

Hopper drives.

As explained above.

4) Back injury due

to improper

handling of bags.

Training to the workers regarding

safe handling of sugar bags.

5) Entanglement

of persons on the

moving conveyors.

Pull card system provided.

6) Slippage and

falling of bags in

sugar Godown.

The pyramid system of bag stacking

is followed

Proper ventilation will be provided. 7) Ventilation

6 Boiler

section.

1) Failure of

pressure parts &

explosion.

As sugar industry is a seasonal one

during off-season all the pressure

parts are tested for its thickness, and

if necessary replacement of tubes

and other pressure parts will be

carried out with the permission of

statutory bodies.

Boiler are

manufacture

d by reputed

manufacture

s registered

with

statutary

authorities

and repair

work if any

will be

2) High Temp work

area.

Lagging of all high temperate lines

and steam lines to avoid heat

dissipation in working area.

3) Fire at Bagasse Separate high pressure fire hydrant



yard. line is provided. carried out

by IBR

approved

contractors.

7 Co-

generatio

n Plant (

Turbine &

Power

House)

1) Noise

Less noise equipment are selected

and regular preventive maintenance

to keep the noise level to minimum.

2) Fire

The sound proof control room panel

is provided and minimum numbers of

workers with minimum duration with

PPE's like ear plugs and Muffs.

Sand buckets and fire extinguisher

are provided and workers are

trained.

3) Shock

Operators are issued Shock

resistance rubber hand gloves &

safety shoes. Electrical grade rubber

Mat is also provided to all panel

board control room. Also chart is

displayed regarding First-aid if

person got electrical shock.



8 Switch

Yard

1) Fire

In Switch Yard only hazard is Fire &

Electrical Shock. Suitable and

Sufficient Fire extinguishers are kept

near Transformer. Person’s are also

trained in fire extinguisher operation.

Total switch yard area is barricaded

to avoid unauthorized entry inside the

premises. Caution boards are also

displayed. Electrical grade rubber

mat is provided wherever necessary.

2) Electrical Shock

9 Diesel

Storage

tank.

1) Fire

We have storage of 130 KL of HSD

inside the factory for power house

use during emergency.

1) Suitable and sufficient fire

extinguisher are kept and person's

are trained.

2) Sand buckets are also provided

near HSD tanks.

2) Leakage of

HSD.

3) Suitable Dyke wall with proper

drainage arrangement is provided.

4) Permission / License is obtained

from legal authorities & it is get

Renewed time to time.

5) Storage area is completely

barricaded to avoid unauthorized

entry of person.

6) Smoking is strictly prohibited &

sign boards are also displayed.

7) Tanks are properly Earthed to

avoid static electricity.

8) Tanks is constructed as per



applicable IS standards.

10 Molasses

Tanks

1) We have

storage of 34000

MT of molasses in

tanks. There is

source of ordinary

fire hazards;

Molasses when

stored for a long

time without being

turned over there

is likelihood of

spontaneous

combustion. No

flame or smoke

will be seen but

whole content

becomes solid

mode of ashes.

Hence it should

not be allow to be

stored for a long

time and it should

be always kept in

semisolid

condition.

External water cooling arrangement

is done so that during summer,

Molasses temperature will be kept

normal.

2) Spillage due to

failure of Tanks

overflow and

leakages.

. Dyke walls are provided so that

spilled molasses will be collected in

that Dyke wall.

. Constructed as per applicable IS

Standard by the reputed fabricators.

. Hydro static test is carried out



periodically during off-season and

any leakages found will be rectified.

Safety Precautions During Storage and Handling of Hazardous Material

Bagasse & Coal :

Bagasse & coal are the main sources of fire in sugar factory especially dried Bagasse is

highly combustible in nature. It catches fire automatically by way of spontaneous

combustion without external sources if it is stored for a long time. The fine bagasse will

accumulate in all workplace like electrical cables,steam pipes. If they are not cleared

periodically they will catch the fire and lead to big loss to industry. The bagasse and coal

will come under Class ' A ' fire which needs to be extinguished by water spray method

only. We propose to store coal in separate coal yard and separate fire hydrant system

will be made after storage of coal in coal yard.

Existing Control Measures at Bagasse Yard.

Bagasse yard is open area where large amount of bagasse being stored. At present we

are having two bagasse yard one is outside the factory premises & another one is inside

factory premises at boiler section.

1) At outside factory premises we are having storage capacity of 40000 MT of baled

bagasse.

a) We are having two fire hydrant 10HP pumps with 50 mt head connected to water

well.

b) Water is sprayed through hydrant points total 36 points with fire hose & fire

hydrant valve.

c) In summer season one separate fire fighting team will be formed to keep

continuous watch and for spraying water near bagasse stack so that surrounding

area is kept cool.

d) Round the clock security is working to avoid unauthorized entry inside premises.



e) Smoking is strictly prohibited & sign boards are also displayed.

f) Water well is connected to both river water & bore well water.

g) Lighting arrestors are also provided to protect against Lighting.

h) Telephone arrangement is made during emergency. Telephone no 407

i) Security persons are with full fledged communication system.

2) In boiler area also where small amount of bagasse is being stored, we are having two

Separated fire hydrant line covering entire bagasse yard & belt conveyors. One line is

having 6 hydrant points connected to delivery of +ve section of four pumps having

capacity 45 lit / sec pressure 5 kg/cm2 & head of 50mtr. Another high pressure fire

hydrant pump line is having 14 hydrant points connected to pump of 7 kg pressure.

Discharge 2000LPM & head 70 mtrs with + ve section. Both pumps are connected to

water reservoir of capacity 5 Lakh Lit used for both fire fighting and process & water is

supplied to reservoir directly from river water through high pressure pumps. Also we are

having DG set to run the pumps during power failure. Same precautionary measure

taken as at out side bagasse yard area.

Health Hazard:

Bagasse is very hazardous especially dried & fine bagasse for health of the workers

working there. Due to prolonged inhalation of fine bagasse a disease may occur i.e

Bagassosis. Hence due attention must be given to health of the workers.

Measures:

1) Suitable face masks & goggles will be provided to workers working in that place,

strict use will be enforced.

2) Periodical medical checkup of workers will be done & health records will be

maintained.



Sulphur storage & preparation of SO2 gas:

Sulphur will be used in our industry for the manufacture of SO2 gas. The oxygen present

in the air reacts with sulphur & SO2 is formed. This gas is used for clarification of juice &

syrup.

Hazards of SO2 Gas:

So2 is one of the most widely encountered contaminants in the workplace.So2 is an

irritant gas. It may enter the body through the respiratory tract and cause respiratory

problems. In sugar industry So2 poisoning will be of chronic in nature. The substance

has local irritant action & produces a sensation of burning & pain in nose & throat.

Safety & Health Measures:

1) Sufficient ventilation is maintained in this work.

2) Workers are provided with gas mask to prevent inhalation of So2 gas.

3) Safety shoes, goggles, hand gloves & aprons are provided to the workers to

protect from the heat & fire.

4) Periodical medical checkup of the workers will be done and health records will be

maintained.

5) Smoking & eatables will be strictly avoided in that area.

6) Safe operating procedures will be displayed.

7) Eye wash fountain is installed at work area.

Hazards in Sulphur Storage:

Sulphur is highly combustible material. It comes under class ' A ' fire. we are having

200mt of sulphur storage in godown.

Measures taken:

1) Full fledged fire hydrant system will be provided.

2) Suitable fire extinguishers are kept in godowns.

3) Smoking is strictly prohibited.



4) Godown is kept with locking arrangement.

5) Suitable PPE's (Personal Protective Equipment) are provided those handling sulphur.

6) Adequate ventilation and natural lighting is provided.

7) Cautionary boards are displayed.

HCL Storage:

We are having storage capacity of 30 MT for boiler make up water treatment & HCL is

required is stored in FRP storage tanks. The only hazard in this area is release toxic

vapor.

The following remedial measures are taken.

1) Storage of HCL in FRP tanks, which will be located in the area free from all

ignition sources.

2) Sufficient water is provided during emergency.

3) All vents are taken to open area where there is no danger to workers.

4) People working in this area will be fully trained during emergency.

5) Handling of HCL is totally by mechanical system. So that there should be no

spillage all joints are leak proof.

6) Cautionary notices & instructions will be displayed.

7) Smoking & eatables are strictly avoided in this area.

8) Dyke wall is provided to storage tank.

9) Eye wash fountain is provided at working area.

H2So4 STORAGE:

We are storing H2so4 at D.M.Plant for water treatment purpose.H2so4 is stored in

carboys and kept in a separate room and carboys are kept on sand. Total storage

capacity 5MT.

Measures will be taken:

1) H2so4 is highly corrosive chemical and it is kept in separate room.

2) Sufficient ventilation is provided.

3) Cautionary boards are displayed.

4) All required PPE's are provided for handling H2so4.



5) Eye wash fountain is provided near D. M. plant area.

6) Safe operating procedures are displayed.

Sugar Godowns:

Since sugar is combustible material due importance is to be given for fire safety in sugar

storage godown. Sugar is packed in gunny bags and PP bags and stored in sugar

godown. We are having 19 sugar godowns of storing capacity 15 lakhs of sugar bags.

Falling of sugar bag bunches on workers is a major concern. Hence due importance is

given while stacking of sugar bags so that there is no slippage of bags from stack.

Precautionary Measures:

1) Suitable fire extinguishers are kept in sugar godown.

2) Smoking is strictly prohibited.

3) All electrical arrangement is flame proof.

4) Sufficient ventilation will be provided to godowns.

5) Sugar is stacked properly to avoid slippage of bags.

6) Sugar bags are stacked in pyramid shape. Only well experienced contractor is

engaged in sugar bag stacking work.

7) Training is given to concerned workers regarding safety precautions to be taken

while handling of sugar bags in sugar godowns.

Noise & hazards & control measures.

Noise is one of most common health hazards found in the work place. Exposure to

excessive noise can cause noise induced hearing loss. In Sugar Industry high level

noise areas are

1) Generator room.

2) Turbine house.

3) Boiler house.

4) Centrifugal Machines.

5) Noise due to steam leakages.

6) Compressor room.



Noise control measures are divided into the following categories:

1) Elimination

2) Substitution

3) Isolation

4) Engineering control at source and in transmission path.

5) Personal Protection Equipments.

All above methods will be tried to reduce the noise level in the factory and ensured that

there will be no bad effects noise in the work place.

In addition to this following steps will be taken-

1) Suitable Personal Protective Equipments are provided for workers expose to

noise like Ear plugs,Ear Muffs etc.

2) Acoustic measures will be provided wherever necessary.

3) Periodical medical checkup of workers is being done and necessary action will be

taken.

4) Noise aspects are taken care in the design process of the plant.

5) Noise level departments layout is designed in such way that noise will not effect

other departments.

6) Noise level is measured periodically and if exceeds prescribed normal then

necessary action will be taken.

7) Training and Education of workers.

Safety Precautions while Operating ESP (Electrostatic Precipitator)

We have installed two numbers ESP for 80T & 70T Krupp boilers for controlling

environment pollution. The only hazard present is Fire & Explosion.

Causes:

1) Unburnt % in fly ash

2) Prolong accumulation / storage of fly ash.

3) Air ingress

4) Excess Carbon Monoxide generation during upset conditions



Control Measures:

1) Control over combustion

2) Periodic checking of ash

3) In order to ensure the air tightness each of the by-pass chute opening should

have air tight blanks. The blank will be allowed to open only after I D fan stops.

4) Carbon Monoxide monitoring kit to be installed at upstream and well ahead of

ESP.

5) Fix a carbon monoxide monitor well upstream of ESP- with a tripping logic for all

T/R sets while carbon monoxide set point goes above the set point.

6) Main equipment (boiler) operation should be efficient so that proper combustion

happen and reducing the risk of carbon monoxide generation.

7) The ESP should be maintained properly for all tightness so that ambient air

ingress can be controlled within permissible limit. Regular checking door

gasket will reduces the chances of such air ingress by 85%.

Do's & Don’t of ESP operation of boiler:

Many of times ESP cannot be commissioned at boiler because of low temperature

interlock, which is associated to lower boiler load. in that situation you cannot start up T /

R sets because of low temperature interlock, but you need to run all ESP auxiliaries at

all the time including the ash handling system and the bypass chute remains closed at

all time please note that during start up the chances of accident are more due to process

instability & high carryover of unburnt. For more details of operation and safety

measures please refer operation and maintenance manual given by the manufacture

and kept at boiler section.

Identification of Hazards in Distillery Plant:

Sl

.

N

o

Operation

/ Process /

Departmen

t

Hazards

Identification.

Precautionary measures

taken.

Remark.

1 Fermentati

on section

1) Fire

1.All electrical appliances are

flame proof like motors,lighting

etc,.

In case of any

emergency

the units will



2) Fermentation

odour

3) Slippery floor

4)Un- guarded

machinery

5) Noise

6)Leakage of

fermentation wash

2.Suitable fire extinguisher are

kept in section

3.Smoking and using of mobile

is strictly prohibited.

4) Unauthorized person's entry

is restricted.

5) No smoking boards are

displayed.

7) Full fledged fire hydrant

system is provided to cover the

entire area.

1. Adequate ventilation is

provided.

2.Workers are provide suitable

PPE

3. Good housekeeping is

maintained.

1. All pumps, pipelines, are well

maintained. And are checked

periodically to avoid leakages.

2. Necessary gutters are

provided to avoid overflow.

3. Floor washing is done in every

shift.

All rotating dangerous

machineries in this section's are

provided with adequate guards.

Workers are provided with

suitable PPE's.

be tripped

immediately

by using

tripping

devices.

Safety shower



7) Static electricity

1. Suitable dye wall will be

provided. So that spilled

fermented wash will be collected

in dye wall.

2. All tanks are constructed as

per IS standard by the reputed

fabricators.

3. Every year thickness testing

will be done & necessary action

will be taken. Proper earthing is

provided to all tanks, to avoid

static electricity Hazards.

cum Eye wash

fountain is

installed at

working area.

Sl

.

N

o

Operation

/ Process /

Departmen

t

Hazards

Identification.

Precautionary measures

taken.

Remark.

2 Distillation

section

1) Fire

2) Noise

3)Leakage of

Distillation

As explained above.

3 Ware

House

1) Fire

2) Leakage of

Denatured spirit.


4) Loading

/unloading of spirit.

As explained above.

1. Proper earthing is done to

vehicles & tans before filling.



2.Proper checking of pipeline

tanks and pumps

3. Before transfer, take

approval from Electrician &

using flame proof pump, tube

light, No naked light, No

smoking zone.

4. Keeping fire extinguisher,

water line ready at ware

house.

4 R.S./ N.S.

ware

house

1) Fire

2) Leakage of

Rectified spirit.

3) Leakage of

Neutral spirit.


5) Slippery floor

As explained above.

5 Ethanol

ware

house

1) Fire

2) Leakage of

Ethanol


4) Slippery floor

As explained above.



Sl.

No

Operation /

Process /

Department

Hazards Identification.

Precautionary measures taken.

Remark.

6 Cask ware

house

1) Fire

2) Leakage of Malted

spirit.


4) Slippery floor

As explained above.

7 IML Section/

Bottling ware

house.

1)Fire hazards due to

loose wiring / defective

electrical appliances.

2)Back injury due to

improper handling of box.

3)Entanglement of

persons on the moving

conveyors.

4) Ventilation

5)Flying/strucking of

glass pieces due to

broken bottles.

Routine preventive maintenance will

be carried out.

Suitable fire extinguisher are kept

and loose electrical connections are

avoided.

Training to the workers regarding

safe handling of box.

Pull card system& Emergency

switches are provided.

Proper ventilation will be provided.

Workers are provided with safety

goggle,hand gloves & gumboots for

handling bottles.

As Explained above



6)Leakage of blending

vat

8 Packed

liquor ware

house

1) Fire

2)Leakage of alcohol

As Explained above

4. Risk Involved Through Risk Analysis.

1) Fire & explosion.

2) Electrical Shock.

3) Bursting of boiler.

4) Electrical short circuiting.

5) Collapse of tall structures.

6) Failure of machinery.

7) Leakage of Hazardous / toxic materials like Co2 gas

5. Severity / severity mapping:

If any emergency occur, the severity of the incident will be within factory premises & not

outside the premises at any cost.

6. Identification of emergency in each hazard activity:

It is already defined in this on site emergency plan in heading “ Identification of hazards

in sugar & cogen plant.”

7. Mitigation measures required:

It is already defined in this on site emergency plan in heading “ Identification of hazards

in sugar & co-generation plant.”

8. Mitigation measures possessed by industry:

We are having following mitigation measures in our industry.

1) Full fledged fire fighter of capacity 4500 lit & additional Foam tank of 500lit

Capacity.

2) Fire hydrant system at bagasse yard, belt conveyors, Entire distillery & IML

section.



3) Suitable PPE's like safety shoes, helmet, goggles, mask.

4) We are having separate Ambulance facility round the clock.

5) Emergency siren.

6) Emergency organization.

7) Well trained fire fighters & first aider.

8) Full fledged occupational health centre.

9. Identification of Mutual aid partners:

We have not defined any mutual aid partners; we have sufficient resources at our own to

mitigate the emergency. if at all required we will call nearest Fire stations like Athani,

Chikkodi etc.

10. Identification of resource suppliers:

We have not identified the resources suppliers. We are having our own.

11. Alert Action plan (Action on site):

1. The effective handling of an emergency will depend on the decision and

action taken at the time, based on the situation and seriousness of the

incident. Each and every incident cannot be foreseen and hence it is not

practicable to include every action which may be required to be taken in a

given situation, however certain actions which are of general nature must be

considered in the emergency management plan. Hence suitable guidelines for

all major foreseeable incidences must be included in the emergency

management plan.

2. Incident controller shall initiate all such actions as essential on the shop floor.

3. Evacuate all the personal on the shop floor not required for controlling the

situation or hazard.

4. Shall immediately grasp the problem / hazard and shall give instructions to

the concerned teams to act in a manner required to control the situation.

5. In case of fire, shall ring up the fire force.

6. Simultaneously shall call the workman in the fire fighting procedures and

organize controlling / extinguishing the fire.

7. With the view to ensure that declarer / controller of emergency shall have

assistance from the teams former.



12. Control room :

The security office shall function as the control room since security office is ideally

situated nearer to the main gate and away from the plant there shall be no problem with

regard to vapor / smoke of any toxic substances affecting security office. However,

should there be a situation where/ when entire premises have to be declared as

emergency the control room shall operate from the FSS office which is outside the main

gate. Required communication facility like walky talkies, mobiles & telephone facility is

provided. Required resources like PPE's, fire extinguishers, firefighting equipments like

fire hose, valves are kept in security office. Important telephone numbers list is displayed

at control room.

13. Site Plan:

Site plan is enclosed.

14. MSDS:

Major chemical MSDS are enclosed.

15. List of Important Telephone Numbers:

Fire fighter 265 / 273

Ambulance 265 / 273

Telephone operator 09

Hospital / Medical Officer 277

Chief engineer 250

Manager Administration 205

Safety officer 434

Security 267

Distillery I / c 261

Shift engineer / chemist

Boiler Engineer

268

423



16. ON SITE EMERGENCY STRUCTURE:

Sl.

No.

Designation Personnel Responsible Scope of responsibilities

1. INCIDENT

CONTROLLER

(In charge of the

scene of the

incident)

CHIEF ENINGEER will be

the incident controller

during the general shift and

whenever present in the

works.

SECURITY OFFICER

/SECURITY WATCHMAN.

will be the incident

controller during all 24 hrs &

holidays also.

1) As soon as he has been

made aware of an

incidence, the incident

controller should decide

whether a major

emergency exists or is

likely. If so he should

immediately activate the

onsite emergency plan

2) He should assume duties

of the site main controller

pending the latter’s arrival,

in particular to:

1. Ensure the emergency

services have been

called.

2. Direct the shutting

down and evacuation

of the areas likely to be

affected.

3. Ensure the key

personal have been

summoned

3) His main function,

however, is to direct all

operations at scene of the

incident as follows.

Ø Rescue and fire

fighting operations

until the arrival of fire



brigade.

Ø Search for casualties

Ø Evacuation of non-

essential workers to

assembly areas.

Ø Set up a

communications point

with telephone or in

case of failure of

telephone

communication use

walky-talky messenger

contact with the

emergency control

center.

Ø Give advice and

information as

requested to the

emergency services.

Sl.

No.

Designation Personnel Responsible Scope of responsibilities

2. SITE MAIN

CONTROLLER

Managing Director: Will be

site main controller during

general shift.

SECURITY OFFICER/

WATCHMAN SECURITY:

Will be site main controller

during all 24 hrs & holidays

also.

Ø The Site main

controller should go to

the emergency control

center and take charge

from the incident

controller for over all

control

Ø If he decides that a

major emergency

exists or is likely, he

should ensure that the

emergency services



have been called and

the on site plan is

activated.

Ø He shall take over the

situation and shall start

in such a manner as to

control the situation

and curb it as soon as

possible.

Ø Control the traffic

movement within the

works.

Ø Issue authorized

statements to the news

media.

Ø Control rehabilitation of

affected areas after

emergency.

Ø Ensure that proper

consideration is given

to the preservation of

evidence.



Emergency organization:

Communication Team

Team A Team B Team C

Team D

Communication Team:

1) Manager (Administration)

2) Security officer

3) Shift Telephone Operator

4) Head Timekeeper

Team A

1) Shift Engineer/Boiler Engineer

2) Shift Chemist

3) Electrical Engineer.

4) Fire fighting team

1) Shri R.T.Patil

2) Shri M.G.Mataguli

3) Shri L.S.Ganennavar

4) Shri D.V.Gharge

5) Shri C.S.Khurd

6) Shri B.H.Jagli

7) Shri M.R.Hukkeri

8) Shri R.T. Visapure

9) Shri A.L.Mallewade

SITE MAIN CONTROLLER – Managing Director

INCIDENT CONTROLLER – CHIEF ENGINEER



Team B

1) Chief Chemist

2) Workshop I/c

3) Dy. Manager (P)

4) Timekeeper

5) Distillery & IML Incharge.

Team C

1) Factory Manager

2) Safety Officer

3) Medical Officer

4) Environment Engineer

5) Motor Department I/c

Team D

Personnel’s which are not included in emergency action team.

Role of communication team:

Manager (Administration)

Ø Proceed to control center and take orders from main site controller.

Ø Arrange mutual aid/fire brigades as requested by main site controller.

Ø Inform police if advised by main site controller.

Ø Inform neighbouring factories.

Ø Requisition vehicles and ambulance as required.

Security Officer/Watchman

After getting information activate the siren.

Control Traffic at the gate.

Arrange a guard at gate to inform incoming essential personal of the nature of

emergency.

Prevent unauthorized entry.

Depute guard to control traffic and block roads at the scene of emergency.

Inform about location of emergency to mutual aid / city fire brigade.

Assemble all the victims at assembly point.



Telephone operator.

On receipt of information in case of siren is not yet actuated, inform security personal to

blow siren.

Inform security so that guards are released to control traffic around the emergency-

visitors are kept out.

Await further instructions from site main controller and keep telephone free from

incoming calls.

Inform others as directed by site main controller.

ROLE OF ACTION TEAM A:

Inform site main controller / telephone operator of location and nature of emergency.

Switch off electrical supply.

Alert every occupant to leave the area to reach the assembly point safely.

Simultaneously trained employees to start fire fighting and rescue operation

Follow instruction of incident controller / site main controller.

Ensure that fire hydrant systems / pumps are in good condition.

Provide engineering assistance to incident controller/ site main controller.

Proceed to scene of emergency.

Consult area supervisor regarding special precautions if any.

Decide line of action in consultation with incident controller/ site main controller.

Keep stock e.g. water, personal protective equipments.

ROLE OF ACTION TEAM B:

Ensure that fire pumps are operating normally.

Shut off power.

Shut down the plant in consultation with incident controller/ site controller.

Evacuate to assembly points in a single line by the safest route without panic

Stand in lines assembly point for ease of head count.

Section in charge has to take head count and locate missing persons if any.

Follow instruction from incident controller/ site main controller.

Get back to your work place (if safe) and when all clear signal is received from site main

controller.



ROLE OF ACTION TEAM C:

Safety/Environment Officer.

Approach the site of incidence immediately

Be in contact with incidence controller/ site main controller.

Coordinate between incidence controller/ site main controller and other key personal.

Check evacuation and head count is done properly at assembly point near the affected

area.

Follow instructions from main site controller.

Notify evacuation squad if required.

Medical Officer

Keep ambulance ready to proceed to scene of emergency at short notice.

Priorities casualties for treatment.

Considered casualties for special treatment.

Arrange hospitalization, additional ambulances.

Call trained first aid members for assistance.

M.T.D. In charge

Arrange transport as required.

Arrange driver for ambulance.

Requisition vehicles, drivers as necessary for evacuation.

First aid team:

1) Shri D V Patil

2) Shri D.D.Datar

3) Shri P.A.Herawade

4) Shri M.B.Kumbhar

5) Shri R.Y.Shirgannavar

6) Shri S.B.Patil

8) Shri R.B.Vasawade

9) Shri R.M.Billur

10) Shri N.P.Savant

Proceed to affected area / medical center as requested and render all assistance.



ROLE OF ACTION TEAM D:

Leave the site immediately by the safest route to assembling point.

Assist in head count at assembly point.

Avoid panic.

Do not go to scene of emergency unless specifically instructed by site main controller

Do not re enter site unless directed personally or announced.

17. Types of emergencies considered:

A major Emergency or disaster occurring at works is the one that may affect several

departments within works and may cause serious injuries, loss of life, extensive damage

to property or serious disruption outside the works. Usually a major emergency is the

result of malfunctioning or bypassing of inbuilt safety devices and systems. Deviation

from the normal operating procedure. Emergency disasters could be due to natural

causes or manmade causes they include.

1) Fire and explosion

2) Bursting of Boiler

3) Leakage/Spillage of Effluent/molasses/chemicals ( Spent wash/ Effluent)/

chemicals/spirit/flammable materials/Alcohol ( Spent wash/ Effluent)

4) Malfunctioning of E.T.P

5) Plane crash over the works

6) War (affecting works e.g. Bombing over the works)

7) Over flow of E.T.P (Discharge Pumps failure)

8) Toxic releases like Methane & Co2 gas

18. Objectives:

The main objective of the emergency plan should be to make optimum use of all

available resources both internal and external to achieve the followings.

Ø Contain the extent of emergency and cascading effects of the original

emergency and bring the incident under control with priority to saving life and

preventing further injury.

Ø Controlling the original incident and prevent an onsite emergency from turning

in to an offsite emergency report.

Ø Mitigate the consequences of the emergency by arranging rescue and



treatment casualties.

Ø Safe guard over the people.

Ø Minimize the damage to environment property.

Ø Identify any fatalities and notify the relatives.

Ø Provide for the need of relatives.

Ø Secure the safe rehabilitation of affected areas.

Provide authentic and authoritative information to the news media through the

Companies authorized person.

19. Safe Assembly Points and Emergency Exits:

We have marketed and identified assembly points at following Work places where

nearby workers can gather safely during emergency.

1) Main gate.

2) In front of distillery section.

3) In front of civil department.

4) Sugar cooling tower (i.e. In front of Godown No.7)

5) Co generation Cooling tower.

6) Co generation ash bed area.

7) M.T.D. Front area.

Also we have marked and identified section wise emergency exits and gangways and

shown in annex II. We have trained all workers in respect of above points.

20. Notification of Emergency/Duties of employee during emergency:

1) If the employee notices the symptoms of fire, leakage of chemical or any other

unusual occurrences he has to inform the Security Department through

Telephone No 273 and Safety Department Telephone No 434, Electrical

Department Telephone No 256, Workshop Incharge Telephone No 259, If the

telephone is out of order send a special messenger to the Security Department.

Also he has to specify the exact location and cause for the first inform the shift

Incharge who is at all times on the shop floor shall identify the same, he shall

report to the chief engineer.

2) Use the suitable fire extinguisher available in the department if there is leakage of

chemicals do not allow anybody to touch or smoke nearby and flush with water



and in case of electrical short circuit use appropriate fire extinguisher don’t use

water in case of electric short circuit.

3) If the fire seems to be uncontrollable call fire brigade/fire fighting team & also

inform them exact location & causes of fire so that they will come with right type

of fire extinguishers.

4) Immediately arrange for removing the combustibles nearby.

5) Cool the surrounding area with the help of fire hydrant water.

6) Fire fighting operations or approach should be from the opposite direction of

smoke.

7) In case anybody trapped must wear breathing apparatus before enter into the

smoke for rescue.

8) Clear the public gathering.

Security Department:

a) Order the fire crew to reach the spot at shortest possible time.

b) Arrange to start the fire hydrant pump.

c) Barricade the area.

d) Instruct the main gate person to keep open the gate full for fire brigade entry.

e) Instruct one security guard to come along with the fire brigade from the gate to

avoid searching the spot.

f) Arrange to remove the nearby fire prone wastes.

Safety Department:

a) Visit the spot immediately has quick check over the spot for explosives

combustible Materials etc.

b) Arrange for switching off the electrical mains pertaining to that area.

c) If the area is covered with dense smoke, see that the people must wear

respirators.

d) If anybody falls down on the ground because of the suffocation arrange for the

medical treatment.

21. Declaration of Emergency:

Under this plan the Chief Engineer is identified and nominated as the

DECLARER/CONTROLLER OF EMERGENCY. No sooner he gets information from

shift in-charge ,he shall move to the place of hazard/calamity & he shall assess the



situation & decide to declare emergency either in particular section or in the entire plant.

If the Emergency is to be declared in one section the other plant will work normally.

He shall start functioning in such a manner as to control the situation & curb it as soon

as possible. Only the site main controller should declare the end of emergency and such

declaration should be made only after his fully satisfied the following things.

· All fires have been extinguished.

· There is no risk of re-ignition.

· Source of emission of hazardous gas has been effectively isolated.

· All gas clouds have been disposed and

· No toxic contamination exists.

· After considering all these aspects and satisfying him that the site is safe to

enter the emergency reader may order entry to restore the normalcy. he shall

then arrange for blowing the siren three times which indicates an all clear

signal.

22. Warning system:

· One electrical operated hooter siren & steam blown siren installed on the top

roof of the Factory. It can be heard throughout the factory premises and

nearby outside area also. The siren will be blown to indicate the emergency.

· Internal telephones & Walky –Talkies and Mobiles are available from all

places to inform emergency at a time at any time.

· On getting the warning all those should act as per the role mentioned in the

action team.

23. Emergency Shutdown of Various Sections:

The only hazards i.e. expected in the factory are fire: immediate action to be taken in

each of the sections for the purpose of emergency shutdown would be as under.

1) MILL SECTION

Stop D.C. Drives.

2) BOILER SECTION

Stop the Boiler.



3) CLARIFICATION SECTION

Switch of the pumps & steam Valves.

4) BOILING HOUSE & PAN SECTION:

Switch of the Machines, Valves & pumps.

5) Turbine House.

Stop the Turbines.

At Distillery / IML Section

1) CUT OF MAINS SUPPLY

2) DISTILLERY SECTION

Stop all distillations.

3) BOILER SECTION

Stop the Boilers.

4) BOTTLE FILLING SECTION:

Switch off the filling lines and stop filling.

5) PACKING SECTION:

Stop packing.

6) STOP ETHNOL PROCESS.

24. Evacuation of Personnel:

Siren will blown within short note many times in addition to the shouting for evacuation

and security staff] runs to each department to drive out the person safe place. When a

major accident occurs and if there is case of workmen has supervisory personnel

fainting or losing consciousness any other type of accident, it shall be the responsibility

of Team-B to evacuate them in the vehicle to our dispensary after providing necessary



First Aid in the office. The well laid out roads in around the plant in factory premises and

they should choose the safest road to come out from the plant.

25. Accounting of personal:

Accounting of personnel will be done at each assembly point by timekeeper & section

Incharge. Total strength will be tallied with actual attendance at timekeeper office. If

anybody is missing immediately inform to any one of emergency team for necessary

action. When persons engaged in the department or in emergency the section in

charges are responsible to bring out the employee to safe place and make arrangement

for their medical treatment, department head also visits the site of emergency to ensure

that nobody has been trapped. The persons who have trained in the First Aid and

Firefighting also quick check up for ensuring that nobody has been trapped. It shall be

the responsibility of Team B to immediately take stock of the personnel on duty and

cross check with the personnel who have come out of the plant / have got stuck-up. This

team shall co-ordinates with team D and ensure that all personnel are accounted for. It is

also essential for team ' B ' to counter check with the security if any visitors or transport

workers have entered the plant and if so they should also be accounted for.

26. Controlling of Emergency:

The declarer / controller of emergency shall take steps to train all the teams & shall draw

up an action plan forthwith. The maintenance in charge is marked as Work incident

controller and he shall act as the Incharge at the site of the hazard to control the entire

operations.

27. Arrangements for medical treatment:

We have full fledged own occupational health center with all facilities & required staff to

treat injured during emergency & also we will shift the injured persons to nearby

hospitals & if higher treatment is required we can arrange to shift the injured persons to

Miraj city hospital which we have close contact.



28. Information to the relatives of injured:

Chief engineer & Dy. Manager (Personal) will inform the relatives of injured through

phone & messengers.

29. Information to the government authorities:

Manager (A& P), CE & Dy. Manager (Personal) will communicate govt. authorities

regarding emergency occurred and status.

30. Law and Order:

We have close contact with the Kagwad Police station to meet our emergency

requirement.

The Dy. Director of Factories & Director of Factories, Member secretary and State

Pollution Control Board, shall also be informed.

31. All Clear Signals:

Once the emergency is controlled and normalcy regained completely and the

DECLARER / CONTROLLER OF EMERGENCY is of the opinion that there is no further

hazard involved there and the work can go on normally, he shall then arrange for

blowing the siren three times which indicates an all clear signal.

32. Emergency Transport Facility:

We have sufficient vehicles to transport injured persons. We are having separate motor

department of our own & they have the facility to control the situation also we have one

full fledged ambulance ready round the clock.

33. Drawing of fire hydrant and Extinguishers:

Details are enclosed in (Annexure II & III) & location of fire extinguishers is given below

Location wise Fire Extinguisher Details

Sr.

No.

Location Type Capacity Qty.

1 Sulphur House CO2 4.5 kg. 2 Nos.

2 -do- D.C.P. 10 kg. 1 No.



3 Boiling House CO2 4.5 kg. 2 Nos.

4 -do- D.C.P. 10 kg. 1 No.

5 Sugar House CO2 4.5 kg. 2 Nos.

6 -do- D.C.P. 10 kg. 1 No.

7 Shift In-charge Cabin. CO2 4.5 kg. 2 Nos.

8 -do- D.C.P. 10 kg. 2 Nos.

9 Mill Turbine CO2 4.5 kg. 2 Nos.

10 -do- D.C.P. 10 kg. 1 No.

11 -do- CO2 22.5 kg. 1 No.

12 Workshop CO2 4.5 kg. 1 No.

13 -do- D.C.P. 10 kg. 2 Nos.

14 Store Water type

CO2

9 Ltr. 3 Nos.

15 Civil CO2 4.5 kg. 1 No.

16 -do- D.C.P. 10 kg. 1 No.

17 Main Gate CO2 4.5 kg. 2 Nos.

18 -do- D.C.P. 10 kg. 1 No.

19 Weighbridge CO2 4.5 kg. 1 No.

20 -do- D.C.P. 10 kg. 1 No

21 Material Godown Water type

CO2

9 Ltr. 1 No.

22 Sulphur Godown Water type

CO2

9 Ltr. 3 Nos.

23 M.T.D. CO2 4.5 kg. 1 No.

24 -do- D.C.P. 10 kg. 1 No.

25 Sugar Godown Water type

CO2

9 Ltr. 2 Nos.

26 Belt Conveyor CO2 4.5 kg. 1 No.

27 -do- D.C.P. 10 kg. 1 No.

28 Diesel Tank Foam type 9 Ltr. 5 Nos.

29 Switch yard D.C.P. 22 kg. 2 Nos.

30 -do- CO2 22.5 kg. 1 No.

31 Cogen Cooling Tower CO2 9 Ltr. 1 No.

32 Back TFR D.C.P. 22 kg. 1 No.



33 Triveni Turbine down side. CO2 22.5 kg. 2 Nos.

34 Centrifugal CO2 22.5 kg. 1 No.

35 80 T. Boiler CO2 22.5 kg. 1 No.

36 TFR D.C.P. 22.5 kg. 2 Nos.

37 33x66 Mill TFR CO2 22.5 kg. 2 Ns.

38 42x84 Mill TFR CO2 22.5 kg. 1 No.

39 42x84 Mill CO2 22.5 kg. 1 No.

40 D.C. Drive D.C.P. 10 kg. 1 No.

41 Power House CO2 4.5 kgs. 2 Nos.

42 -do- D.C.P. 10 kg. 1 No.

43 Paras Boiler CO2 4.5 kg. 1 No.

44 -do- D.C.P. 10 kg. 1 No.

45 70 T. Boiler D.C.P. 10 kg. 1 No.

46 Boiler Compressor CO2 4.5 kg. 1 No.

47 Paras Boiler I.D. CO2 4.5 kg. 1 No.

48 70 T. Boiler I.D. CO2 4.5 kg. 1 No.

49 Cogen. TFR CO2 22.5 kg. 1 No.

50 Cogen. Turbine CO2 4.5 kg. 1 No.

51 -do- D.C.P. 22.5 kg. 5 Nos

At Distillery & IML Section:

Location wise Fire Extinguisher Details

Sr.

No.

Location Type Capacity Qty.

1 Distillery (old) D.C.P. 10 kg. 1 No.

2 Distillery (old) D.C.P. 5 kg. 1 No.

3 Distillery (old) Main Panel

Board. D.C.P. 4.5 kg. 1 No.

4 Distillery (old) Pump House D.C.P. 5 kg. 1 No.

5 Distillery (old) D.N.S.

Warehouse D.C.P. 5 kg. 1 No.

6 Praj Distillery Panel Board CO2 4.5 kg. 2 Nos.



7 Praj Distillery warehouse Water type 9 Ltr. 1 No.

8 Distillery Column No. 2 D.C.P. 10 kg. 1 No.

9 Distillery Col. No. 4 D.C.P. 5 kg. 1 No.

10 Fermentation House D.C.P. 5 kg. 2 Nos.

11 Packed liquor ware house D.C.P 5kg 2Nos

12 Packed liquor ware house Water Type 9lit 2Nos

13 IML bottling CO2 22.5kg 2Nos

14 IML bottling D.C.P 10 kg. 2Nos

34. Location of First Aid Boxes.

We have kept and maintained First Aid Boxes with prescribed medicines in all sections.

Location of First Aid Boxes is given below.

Sl No. Location

1 T. K. OFFICE

2 DISTILLERY (PRAJ)

3 DISTILLERY (IMFL)

4 SULPHUR HOUSE / CHEMICAL

5 PAN SECTION (CHEMICAL)

6 SUGAR HOUSE

7 BELT

8 M.T.D.

9 KRUPP BOILER

10 PARAS BOILER

11 POWER HOUSE

12 D. M. PLANT

13 SWITCH YARD

14 CIVIL

15 COGEN. TURBINE

16 42”x 84” Mill

17 33”x 66” Mill

18 WORKSHOP – Welder

19 WORKSHOP – Moulder shop



20 FIRE FIGHTER

21 AMBULANCE

22 ENVIRONMENT DEPT.

23 TRAINING CENTRE

35. Electrical drawings:

Details are enclosed in (Annexure IV)

36. Display of prominent telephone numbers of at least:

Deputy Commissioner (0831) 2407200

Superintendent of / Local Police (0831) 2405204

Local Police Kagawad (08339) 264633

Fire Services Athani

Chikkodi

Sadalga

(08289) 251740

(08338) 273333

(08338)251900

Hospitals – Ugar sugar hospital

Wanless Hospital Miraj

(08339) 272230

(0233) 222329

Occupier / Manager (08339) 272230

Directorate of Factories & Boilers (080) 26531201

Karnataka State Pollution Control

Board Bangalore, Belgaum

(080) 25581383

(0831)2459121

Blood Bank – Dr.Shirgaokar Blood

Bank Sangli.

(0233) 2372376

Vasantdada Blood Bank Miraj (0233) 2222319



37. Key personal of the industry:

Name of the Person Designation Telephone number

P.V.Shirgaokar Executive VC 9972022205

S.S.Shirgaokar Managing Director 9972022206

N.S.Shirgaokar Joint Managing Director 9972024447

C.S.Shirgaokar Joint Managing Director 9972024448

G.N.Bellary DGM (A&P) 9900559181

S.N.Gurav Dy. Manager (P) 7259186058

D.K.Pendse DGM(Sugar) / Factory

Manager

9900559190

R.B.Shegunshi Safety Officer 9972372425

S.S.Sardesai DGM El ( Sugar

&Cogen)

9900559160

C.G.Pimpalkar DGM ( Process) 9900559188

B.N.Akiwate DGM (Cogen) 9900559162

N.B.Kagwade Dy.CE (cogen) 9972372423

M.B.Joshi CE El (Sugar & Cogen) 9900559177

Dr.B.V.Zadbuke Medical Officer 9740979188

Dr.S.M.Pattanshetty Chief Env. Manager 9900559179

D.B.Patil Distillery I / c 9972372427

B.T.Viapure

S.V.Shula

IML Manager

IML Incharge

9900559168

9972372428

Namdev Kharade Security Officer 9740083842

38. Waste disposal:

Waste should be disposed off in scientific manner. Debris should be collected in tractor

and trailers and dumped for land filling purpose. For this state rules and regulations

regarding waste disposal will be considered.

*****

Documents

CHAPTER– 6 ADDITIONAL STUDIES (RISK ASSESSMENT AND