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Environmental Impact Assessment (EIA) Report Proposed Expansion in Manufacturing of Synthetic Organic Resins

Chapter-8: Risk and Safety Management

Page | 8.1

CHAPTER – 8 RISK AND SAFETY MANAGEMENT

8.1 PREAMBLE

Increasing use of hazardous chemicals as raw materials, intermediates and finished

products has attracted attention of the Government and the public at large in view of the

chemical disasters. The serious nature of the accidents, which cause damage to the

plant, personnel and public, has compelled industries to pay maximum attention to the

safety issues and also to effectively manage the hazardous material and operations. It

is mandatory for the industries handling hazardous chemical to maintain specified

safety standards and generate an on-site emergency plan and keep it linked with off

site emergency plan.

The Risk Assessment Study and safety management for the proposed expansion

project of Natural Petrochemicals Pvt. Ltd. has been carried out and the details are

elaborated in this chapter. Based on the findings & recommendations of RA report

management plan for the proposed expansion has also been prepared and included.

Risk Assessment is defined as a continuous and integrated process of identification,

evaluation and measurement of risks, along with their potential impact on the

organization.

The benefits of risk assessment include the following:

Prevention or reduction in occurance of accidents.

Mitigation of the severity and/or consequences by way of improved process

techniques, fire protection systems, arrangements of storage, inventory

monitoring to fit production requirements.

Development of confidences in employees by improving competency.

Preparedness and prompt response to deal with any accident.

The safety management includes the implementation of preventive methods or accident

prevention methods to avoid incident or accident and handling of emergency in case of

accident.

Environmental Impact Assessment (EIA) ReportProposed Expansion in Manufacturing of Synthetic Organic Resins


Page | 8.2

8.2 OBJECTIVE, PHILOSOPHY AND METHODOLOGY OF RISK ASSESSMENT

8.2.1 Objective

The principle objective of this study is to identify major risks in the manufacturing

process and to evaluate on-site & off-site consequences of identified hazard scenarios.

Pointers are then given for effective mitigation of hazards in terms of suggestions for

effective disaster management, suggesting minimum preventive and protective

measures & change of practices to ensure safety.

8.2.2 Philosophy

The following aspects and areas have been covered in this study;

Identification of major risk areas.

Hazard identification / Identification of failure cases.

Consequential analysis of probable risks / failure cases;

o Determination of the probable risk by Releasing of chemical due to leakage of

storage tank and catastrophic failure.

o Risk assessment on the basis of the above evaluation & risk acceptability.

o Minimum preventive & protective measures to be taken to minimize risks to

maximum possible extent.

Giving pointers for effective disaster management.

Suggesting measures to further lower the probability of risk.

8.2.3 Methodology

Design data, built in safety systems are studied. Discussions are held with officials.

Safety related individual system is discussed. Hazard identification exercise is

conducted taking into consideration of materials, material handling methods, operating

procedures, built in safety in reactors, operating parameters and safety measures to be

taken in proposed plant. Few areas like process building, storage of hazardous

chemicals, to evaluate safety systems in the event of any abnormalities occurring.

Containment failure scenario related to storage area is considered for hazard Analysis

and consequences of such containment failures are considered in detail. Thus, this

study is mainly oriented towards actual risks rather than chronic risks.



Page | 8.3

8.3 HAZARDOUS MATERIAL, PROCESS AND SAFETY MANAGEMENT

The proposed project includes manufacturing of various bulk drugs and drug

intermediates along with the existing products. Manufacturing of these synthetic organic

chemicals required raw materials are listed in Chapter-2, Section-2.8 with hazardous

identification.

8.3.1 Hazardous Chemicals

None of the product is defined as hazardous in MSIHC rules but may fall under the

definition of hazardous material/chemicals either due to its hazardous and toxic nature.

Most of the raw materials fall under the definition of hazardous chemical. The details of

hazardous chemicals are given in Table 8.1.



Page | 8.4

Table 8.1: Details of Hazardous Chemicals

Sr. No.

Name of Chemicals

CAS No. State Colour Odor Sp.

GravityVapour Density

Boiling Point ºC

Melting Point

ºC

Flash Point

ºC

Explosive limitSolubility in

water Hazardous

Characteristics LEL UEL% %

1. Styrene (Monomer)

100-42-5 Clear viscous

liquid Colorless

Sweetish, Aeromatic

0.906 3.59 145.2 (-) 30.6 31.1 1.1 6.1 Very slightly

soluble in cold water

Hazardous, Flammable

2. Ethylene Glycol

107-21-1 Viscous liquid Colorless Odorless 1.113 2.1 196-198 (-) 13 110 3.2 15.3 Miscible in all proportions

Hazardous, slightly Flammable

3. Diethylene Glycol

11-46-6 Clear Viscous

liquid Colorless Odorless 1.12 3.66 245.8 (-) 8 138 2 12.3 Easily soluble

Hazardous, Flammable

4. Propylene Glycol

57-55-6 Clear oily liquid Colorless Odorless 1.0361 2.6 188.2 (-) 59 99 2.6 12.5 Miscible Hazardous, slightly

Flammable

5. Dipropylene Glycol

25265-71-8

Slightly Viscous liquid

Colorless Odorless 1.0252 4.63 231.9 -- 99 2.6 12.5 Miscible Slightly Hazardous

6. Phthalic Anhydride

85-44-9 Solid (Crystals

Solid) White

Characteri-stic acrid, choking

1.53 6.6 295 131 151.67 1.7 10.4 Very slightly

soluble in cold water

Hazardous, flammable in

presence of heat, corrosive, toxic

7. Terephthalic Acid

100-21-0 Solid (Powdered

Solid) Off-white -- -- 5.74 -- 300 260 -- -- Insoluble Hazardous, Toxic

8. Maliec Anhydride

108-31-6 Scales White Aeromatic 1.32 3.4 202 51 - 53 103 1.4 7.1 Soluble

(decomposition)

Hazardous, flammable, corrosive,

sensitizing, toxic

9. Isopthalic Acid

121-91-5 Fine crystals White Almost

Odorless 1.54 -- -- 345-348 -- -- Slightly soluble

Slightly Hazardous, toxic

10. Xylene 1330-20-7 Liquid Colorless Aromatic

hydrocarbon odor

-- -- 134-140 -- 37.7 -- -- Insoluble Hazardous, flammable



Page | 8.5

8.3.2 Safety Measures for Transportation, Storage & Handling of chemicals

Styrene is received by road tankers stored in tanks and Xylene is received in drums.

Solvent unloading standard procedure is in place and implemented for safe

unloading of road tanker.

Static earthing provision is made for tanker unloading.

Flexible steel hose is used for unloading from the tanker.

Flame proof electric motor is used during loading/unloading.

NRV is provided on pump discharge line.

Fixed pipeline with pumps is provided for transfer to vessel.

TERM CARD is provided to all transporters and they are trained for transportation

Emergency of hazardous chemicals.

Drum handling trolleys are used for transportation of drums up to plant.

Muffler on the silencer of the tanker during entering in factory premises.

Safety permit system is followed for loading and unloading.

Isolate storage is provided with wire fencing under lock and key.

Only authorized person is permitted in storage area.

Display Boards are provided on all storage tanks which includes the name of the

chemicals and storage capacity.

Caution note, hazardous identification board is provided.

On-site detectors for fire based on heat &/or smoke detection with alarm system is

provided as required.

Fire extinguishers and fire hydrant system are provided as per requirement.

First aids boxes are provided at different places wherever required.

Water showering system is provided to the flammable chemicals storage area,

wherever required to avoid the vaporization due to increase in atmosphere

temperature.

Hazardous Chemical storage area is declared as “NO SMOKE ZONE”.

Hazardous material handling is carried out by using all PPE with proper ventilation &

under supervision.

8.3.3 Critical Safety Measures for Process Units

Critical safety measures are the most important aspect of selection of process

technology to ensure safety in production unit. For the safety in production area some

important critical safety measures are provided within the process technology/



Page | 8.6

equipment itself & put continue efforts for developing new technology/equipment.

Company ensures such provision in the technology /equipment /machineries at time of

purchase. The details of the critical safety measures for process unit are as below;

Any reaction upsets is confined to the reaction vessel itself as defined quantity of raw

materials are issued to the reaction vessel by metering pumps/load cells.

Process parameters control is provided vide Standard Operating Procedures.

Materials are transferred by pumping through pipeline or by vacuum from drums.

All reactors are connected to vapor condensers system.

Hazardous materials are transferred by pipelines and in control manners.

Trained person is engaged for handling of hazardous materials.

Proper safety precautions are taken during handling of hazardous materials.

Solvents and flammable material storage area is kept away from the process plant and

required quantity of material is charge in reactor by pump or by gravity.

Further all the vessels are examined periodically by a recognized competent person.

All the vessels and equipments are well earthed appropriately and well protected

against Static Electricity. Also for draining in drums proper earthing facilities are

provided.

Temperature indicators are provided near all reactors.

Caution note, safety posters, stickers, periodic training & updation in safety and

emergency preparedness plan are displayed and conducted.

Flame proof light fittings are installed in the plant.

All the Plant Personnel are provided with Personal Protection Equipments to protect

against any adverse health effect during operations, leakage, spillages or splash. PPE

like Helmets, Safety Shoes and Safety Glasses are provided to the employees.

Material Safety Data Sheets of raw materials & products are kept readily available at

the shop floor.

8.3.4 Safety Measures For Preventive Maintenance

The safety measures in form of the general Do's & Don'ts for safety in process & other

plant area are as below:

Do not work on equipments without permission from plant head and maintenance

head.

Make sure equipment is empty and fluxed with nitrogen and air.

Check VOC content for flammable and make sure that no flammable vapour contents.



Page | 8.7

Keep proper and adequate fire extinguisher near work area.

Use proper PPE.

Do not allow any employment without pre-medical check-up or without checking

fitness.

Check all motors are disconnected and fuse pulled out before maintenance.

Work in any equipment must be conducted in presence of supervisor.

Make sure all process lines are disconnected.

Additional safety measures in form of the checklist covering Do's & Don'ts of

preventive maintenance, strengthening of EHS are updated timely and made available

to all concern department & personnel.

8.3.5 Safety measures to prevent spillage / leakage of toxic chemicals

The preventive maintenance are planned and carried out as per plan to avoid the failure

of valve, pipe lines and other component of transferring line. The spillage is confined to

the dyke area underneath the vessel. The resultant splash of such chemicals result in

exposure of toxic chemicals to employees. Facilities like Safety shower and eye wash

fountains are provided in the plant area, which can be used to decontaminate the

affected employees.

Suitable decontamination procedure is used to decontaminate the spilled or leaked

material. The SOP for decontamination is reared with all related department. The

followings are some measures taken for handling the toxic chemicals safely;

Safety equipments like electric siren, safety belts, safey shower etc are provided at

some places in plant as per the requirement and Suitable personal protective

equipment like splash goggles, gloves and protective clothes are provided while

handling the toxic chemicals.

The installation of all the equipment is as per guidelines of provision of Gujarat

Factories Rule 1963.

All the toxic chemicals are stored under adequate safe condition.

The storage of corrosive and toxic chemicals are segregated from each other.

The piping is examined thoroughly every year for finding out any defects; and a defect

is removed forthwith. The record of such examination is maintained.

Smoking is prohibited inside the factory. Train employees are employed for handling of

toxic and corrosive chemicals.

All pipe joints are provided with heavy duty champion gaskets to prevent any leakage.



Page | 8.8

Self breathing apparatus are provided and workers are trained about their use also.

Dyke wall is provided to area where hazardous chemicals are stored.

Spare barrels of sufficient quantity are kept ready for any emergency spillage or

leakage.

Drum trolley is used for the movement of drums of hazardous chemicals.

Liquid chemicals are transferred by mechanical seal pump through closed pipeline.

8.4 OCCUPATIONAL HEALTH & SAFETY PROGRAM

The main effects of chemicals especially VOCs are anticipated in proposed expansion.

No other source of adverse effects on occupation health & safety is likely to occur.

However, MSDS of hazardous chemicals are made available with the management as

well as concern personnel working with the materials or area likely to be affected by the

materials. Following are the key safety measure which has already been taken and will

be updated timely;

Provision of drinking water supply for the employees as per standard of the drinking

water as per WHO guidelines.

Availability of proper sanitary facilities for the employees so that they do not suffer from

any health ailments.

Provision of all necessary equipment like portable detector, online detectors and other

laboratory equipments as mentioned above for regular monitoring of workplace air and

other conditions (VOC, Temperature, Humidity and Light Intensity etc.).

Provision of suitable personal protective equipment like safety gloves, helmets,

safety belts, as described below in Table 8.2 to personnel in the plant and

compulsory use of these PPEs for all workers.

Table 8.2: Details of Personal Protective Equipments

Item Nos. Safety Helmet 83 Safety Goggles 50 Safety Shoes 70 Rubber Gloves 04 Eye Wash Fountain 02 Gum Boots 02 Nose Mask 30 Safety Belt 04 Organic Vapor Mask 03 Self Contained Breathing Apparatus 01



Page | 8.9

Provision of ear muffs/ ear plugs to the workers exposed to higher noise level.

Provision of first –AID boxes (Containing Tincture iodine, Eye Drops, Burnol,

Soframycin (ointment), Sterilized cotton wool, Band-aid, Antiseptic Solution (Sevlon),

Bandage, Rose Water, etc) at various places in the premises.

Organize training program for information on accident prevention, proper control and

maintenance of equipment, first aid training and safe material handling practices.

Availability of MSDS and antidotes of the chemical used at the place of use.

Installation of fire hydrant system and fire extinguishers at required places.

Regular monitoring of work area to measure airborne contamination and to control

fugutue emissins.

Protection of storage area with Dyke wall.

Provision of adequate ventilation in process area so that airborne contamination does

not exceed threshold limit value.

Monitoring of occupational hazards like noise, ventilation, chemical exposure at

frequent intervals.

Provision of proximity suits and self-breathing apparatus.

Display various instruction boards, cautionary notices etc. at different locations.

As described in Chapter-6, unit has already made necessary tie-up with nearby

hospital for the medical assistance in case of any emergency. Medical officers are

appointed for the periodical health check-up of the employees. Periodical health

check-up reports of all the employees are being maintained and the reports of two

employees are given in Annexure-13 for reference.

In addition to the above, unit will maintain health records in Form 33 as per the factory

act as well as in format attached as Annexure-14.

In addition to the above, unit has allocated Rs. 2 Lacs for various purposes like purchase

of personal protective equipments, medical facilities, hire of ambulance etc. to ensure the

occupation health and safety of company employees, contract & sub-contract workers.

8.5 RISK ASSESSMENT STUDY

Chemical process industries have undergone tremendous changes during last five

decades. Process conditions such as pressure & temperature have become severe;

concentration of stored energy has increased. The scale of possible fire, explosion,

toxic release, body injuries and occupational diseases has grown considerably. These



Page | 8.10

factors have greatly increased the risk for major industrial disasters, involving loss of

human lives, plant & property and environmental degradation.

Identification analysis and assessment of hazard and risk are very useful in providing

information to risk management. It provides basis for what should be the type and

capacity of its on-site and off-site emergency plan also what types of safety measures

are required. Risk and consequence analysis is carried out considering storage and

handling of various hazardous raw materials, intermediates and products as well as

manufacturing process. The objectives considered for Risk Assessment study are as

follows;

To assess the risk involved in transporting, storing & processing raw material up to

final product.

To define Emergencies including risk & Environment impact assessment.

To evaluate the risk and to get the complete view of the available facilities.

To take appropriate action to control the incidents.

To safe guard employees and people in vicinity.

To minimize damage to property and neighboring environment.

To inform the employees, general public & Government authority aboutvarious

type of hazards, assessed risk, safe guards provided, residual riskif any, and role

to be played by them in the event of emergency.

To inform Police, fire brigade, District authority and statutory authority for providing

help during emergency.

To work out a plan with all provisions to handle emergencies and to provide training to

employees through mock rehearsals.

To rescue and give treatment to the casualties and to count the number of injured

persons.

8.5.1 Identification of High Risk Areas

It is observed that the storage areas pose fire/explosion hazards which may lead to

major accident event. In the process areas it is observed that inventories of chemicals

are very low & so there are not deemed to pose major off-site hazards. Thus, the

quantitative risk assessment studies are limited to unit and some extent in vicinity.



Page | 8.11

8.5.2 Modes of Failure

Storages system can fail in different ways depending on the materials stored, storage

conditions & may involve systems in their vicinity. Conditions such as over filling, over

pressure, missile, lightening or bomb attack, earthquake & resultant replier or release

scenarios have been identified. Outcomes of such incidents are determined by

presence of ignition either immediate or delayed. As can be seen depending upon

modes of failure different scenarios are possible viz:

1. Continuous release

2. Instantaneous release

This may be of gas / liquid depending upon type of material stored/released & its

characteristics. More examples, a liquid boiling at ambient conditions, will immediately

be converted to gas upon exposure to atmosphere.

An instantaneous release is any release occurring for a period less than 15 seconds.

Failure mode responsible for instantaneous releases may be catastrophic failure of

chemical storage tank / drum. For an instantaneous gas release important parameters

are release height & quantity released whereas for instantaneous liquid release,

important parameters are amount spilled, spill area & pool temperature, evaporation

rate, vapour mass etc.

Continuous release occurs when the material is released over a period greater than 15

seconds. For a continuous gas release, important parameters include height of leak

above ground, emission rate & total time of release. For continuous liquid release

important parameters are spill rates, duration, area & pool temperature, evaporation

rate and vapor mass or Gas mass.

8.5.3 Maximum Credible Accident Analysis and Its Mitigation Measures

A Maximum Credible Accident (MCA) can be characterized as the worst credible

accident. In other words: an accident in an activity, resulting in the maximum

consequence distance that is still believed to be possible. A MCA-analysis does not

include a quantification of the probability of occurrence of the accident. Another aspect,

in which the pessimistic approach of MCA studies appears, is the atmospheric condition

that is used for dispersion calculations.



Page | 8.12

The Maximum Credible Loss (MCL) scenarios have been developed for the Facility.

The MCL cases considered, attempt to include the worst “Credible” incidents-what

constitutes a credible incident is always subjective. Nevertheless, guidelines have

evolved over the years and based on basic engineering judgment, the cases have been

found to be credible and modeling for assessing vulnerability zones is prepared

accordingly.

The objective of the study is Emergency planning, hence only holistic & conservative

assumptions are used for obvious reasons. Hence, though the outcomes may look

pessimistic, the planning for emergency concept should be borne in mind whilst

interpreting the results.

In Consequence analysis, geographical location of the source of potential release plays

an important role. Consideration of a large number of scenarios in the same

geographical location serves little purpose if the dominant scenario has been identified

and duly considered.

The Consequence Analysis has been done for selected scenarios by ALOHA (version

5.4.1.2) of EPA.The details of software used for MCA analysis are described below.

A computer based version ALOHA 5.4.1.2 is used to calculate toxic and explosive

effect of the accidental release of liquid chemicals within the plant area.

ALOHA (Areal Locations of Hazardous Atmosphere) is a computer program

designed especially for use by people responding to chemical release as well as for

emergency planning and training.

ALOHA was jointly developed by the National Oceanic and Atmospheric

Administration (NOAA) and the Environment Protection Agency (EPA).

The mathematical model is based on the Emergency Response Planning

Guidelines (ERPGs) which gives Toxic Levels of Concern (LOCs) to predict the

area where a toxic liquid concentration might be high enough to harm people.

ALOHA models key hazards-toxicity, flammability, thermal radiation (Heat), and

over pressure (expansion blast force)-related to chemical releases that result in

toxic gas dispersion, fire and/or explosion.



Page | 8.13

8.5.4 Consequences Analysis

From the raw materials Styrene Monomer and Xylene have been taken for the

consequences analysis considering their hazardous nature. Storage condition and

threshold value of these chemicals are mentioned in the Table 8.3 & 8.4. Other

properties are given in Table 8.1.

Table 8.3: Storage details of Hazardous Chemicals

Sr. No.

Hazardous chemicals

Physical form

Type of storage

Size of Storage

Unit

Qty. of Storage

Unit

Maximum Storage Capacity

Storage PressureKg/cm2

StorageTemp.

ºC

1 Styrene Monomer

Clear Viscous Liquid

Tank 250 KL 3 750 KL ATM At RT

2 Xylene Liquid Drum 200 Kg 50 10 MT ATM At RT

Table 8.4: Threshold values of the Hazardous Chemicals

Sr. No.

Chemicals Threshold Value (ppm)

ERPG-1 / TEEL-1 ERPG-2 / TEEL-2 ERPG-3 / TEEL-3

1. Styrene Monomer 50 250 1000

2. Xylene 150 200 900

ERPG: Emergency Response Planning Guidelines (For Styrene Monomer) TEEL: Temporary Emergency Exposure Limits (For Xylene)

8.5.4.1 Definitions & Explanation of Terms Used

ERPG-1 : Emergency Response Planning Guidelines (ERPG) The maximum concentration in air below which it is believed nearly all individuals could be exposed for up to one hour without experiencing other than mild transient adverse health effects or perceiving a clearly defined objectionable odor.

ERPG-2 : The maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 hour without experiencing or developing irreversible or other serious health effects or symptoms which could impair an individual's ability to take protective action.

ERPG-3 : The maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 hour without experiencing or developing life-threatening health effects.

TEEL-1 : Temporary Emergency Exposure Limits (TEEL). TEELs are intended for use until AEGLs or ERPGs are adopted for chemicals. TEEL-1 is the airborne concentration (expressed as ppm [parts per million] or mg/m3 [milligrams per cubic meter]) of a substance above which it is predicted that the general population, including susceptible individuals, when exposed for more than one hour, could experience notable discomfort, irritation, or certain asymptomatic, nonsensory effects. However, these effects are not disabling and are



Page | 8.14

transient and reversible upon cessation of exposure.

TEEL-2 : TEEL-2 is the airborne concentration (expressed as ppm or mg/m3) of a substance above which it is predicted that the general population, including susceptible individuals, when exposed for more than one hour, could experience irreversible or other serious, long-lasting, adverse health effects or an impaired ability to escape.

TEEL-3 : TEEL-3 is the airborne concentration (expressed as ppm or mg/m3) of a substance above which it is predicted that the general population, including susceptible individuals, when exposed for more than one hour, could experience life-threatening adverse health effects or death.

AEGL-1 : Acute Exposure Guideline Levels (AEGL) The airborne concentration of a substance above which it is predicted that the general population, including susceptible individuals, could experience notable discomfort, irritation, or certain asymptomatic nonsensory effects. However, the effects are not disabling and are transient and reversible upon cessation of exposure.

AEGL-2 : The airborne concentration of a substance above which it is predicted that the general population, including susceptible individuals, could experience irreversible or other serious, long-lasting adverse health effects or an impaired ability to escape.

AEGL-3 : The airborne concentration of a substance above which it is predicted that the general population, including susceptible individuals, could experience life-threatening health effects or death.

IDLH : IDLH is an estimate of the maximum concentration in the air to which a healthy worker could be exposed without suffering permanent or escape-impairing health effects.

LEL : LEL is the minimum concentration of fuel in the air needed for a fire or an explosion to occur if an ignition source is present. If the concentration is below the LEL, there is not enough fuel in the air to sustain a fire or an explosion -- it is too lean.

UEL : UEL is the maximum concentration of fuel in the air that can sustain a fire or an explosion if an ignition source is present. If the concentration is above the UEL, there is not enough oxygen to sustain a fire or an explosion -- it is too rich (much like an engine that cannot start because it has been flooded with gasoline).

STEL : The concentration to which workers can be exposed continuously for a short period of time without suffering from (1) Irritation (2) Chronic or Irreversible tissue damage (3) Narcosis of sufficient degree to increase injury, impair self-rescue or materially reduce work efficiency and provide that the daily TLV-TWA is not exceeded.

TWA : The time-weighted average concentration for a normal 8-hour workday and a 40-hour workweek, to which nearly all workers may be repeatedly exposed, day by day, without adverse effect.

Source Strength

: The source strength is either the rate the chemical enters the atmosphere or the burn rate, depending on the scenario. A chemical may escape very quickly (so that source strength is high), as when a pressurized container is ruptured, or more slowly over a longer period of time (so that source strength is low), as when a puddle evaporates.



Page | 8.15

Threat zone : It represents the area within which the hazard level (toxicity, flammability, thermal radiation, or overpressure) is predicted to exceed the Level of Concern (LOC) at some time after a release begins.

Evaporation Puddle

: Choose Puddle from the Source submenu under the set up menu to model a liquid that has spilled and formed a puddle on the ground. ALOHA can model the puddle either as an evaporating puddle or, if the chemical is flammable, as a Pool Fire.Choose Puddle when a puddle has already formed on the ground and is not changing in area. If liquid is continuing to leak from a tank and spilling into a puddle (so that the puddle's area and volume are increasing) choose Tank from the Source submenu instead. Check the "Tank source" help topic to learn more about this option.

Toxic Threat zone

: A Toxic Level of Concern (LOC) is a threshold concentration of an airborne pollutant, usually the concentration above which a hazard may exist.

Flammable Threat zone

: A Flammable Level of Concern (LOC) is a threshold concentration of fuel in the air above which a flammable hazard may exist. Generally, this LOC will be some fraction of the Lower Explosive Limit (LEL).

Threat zone of thermal radiation from jetfire

: The thermal radiation effects that people experience depend upon the length of time they are exposed to a specific thermal radiation level. Longer exposure durations, even at a lower thermal radiation level, can produce serious physiological effects. The threat zones displayed by ALOHA represent thermal radiation levels; the accompanying text indicates the effects on people who are exposed to those thermal radiation levels but are able to seek shelter within one minute. Below are some effects at specific thermal radiation levels and durations (on bare skin): 2 kW/(sq m) -- people will feel pain after 45 seconds and receive second-

degree burns after 3 minutes; 5 kW/(sq m) -- people will feel pain after 13 seconds and receive second-

degree burns after 40 seconds; and 10 kW/ (sq m) -- people will feel pain after 5 seconds and receive second-

degree burns after 14 seconds.

Threat at point

: It represents the specific information about the hazards at point of interest (such as schools and hospitals) in and around the threat zones.

8.5.4.2 Possible Accident Scenario

Different possible ways of occurrence of any accidents due to storage/usage of above

hazardous chemicals are prescribed here below;

Scenario-A: Release of chemical due to leakage and form evaporating puddle (Not

burning)

Scenario-B: Release of chemical due to leakage and form burning puddle (Pool fire)

Scenario-C: Release of chemical due to catastrophic failure (BLEVE)

Atmospheric conditions assumed at the time of accidents are mentioned in Table 8.5.



Page | 8.16

Table 8.5: Atmospheric Conditions Assumed

Particulars Details

Wind (Max) 6.8 meter/second

Ground Roughness Open Country

Cloud Cover 1 tenth

Air Temperature 19.83° C

Stability Class D

Relative Humidity 43.97%

1) STYRENE MONOMER

The possibilities of source strength considered at the time of accidents due to leackage

of Styrene Monomer from hole of 0.5 inches diameter at bottom of tank are mentioned

in Table 8.6.

Table 8.6: Source Strength considered for Styrene Monomer

Particulars Value

Tank diameter 6.5 m

Tank height 7.6 m

Tank volume 250 m3

Opening diameter 0.5 inches

Opening from tank bottom 0 m

Internal temperature 19.83 ºC Scenario-1A: Release of Styrene due to leakage from tank and form evaporating puddle (Not burning) a) Source Strength

In case of Styrene escape from tank by a hole of 0.5 inch, then maximum average

sustained release rate will be 5.1 kg/min and hence approx. 178 Kg of Styrene will be

released in about 1 hour. Isopleths results are given in Figure 8.1.



Page | 8.17

Figure 8.1: Source Strength in case of Styrene escape

b) Threat Zone

Toxic Threat Zone

Model output of Toxic threat zone for Styrene release is given in Table 8.7. Threat zone

was not drawn because effects of near-field patchiness make dispersion predictions

less reliable for short distances.

Table 8.7: Threat zone of toxic liquid concentration

Threat Zone Concentration, ppm Threat Zone, m

Horizontal Direction

Vertical Direction

Red 1000 (ERPG-3) 10 Orange 250 (ERPG-2) 13 Yellow 50 (ERPG-1) 32

Flammable Threat Zone:

Model output of the flammable threat zone for chemical release is given in Table 8.8.

Table 8.8: Flammable area of vapor cloud

Threat Zone

Concentration, ppm

Threat Zone

Horizontal Direction

Vertical Direction

Red 6,600 (60 % LEL) 10 m

Yellow 1,100 (10 % LEL) < 10 m



Page | 8.18

Isopleths result of flammable threat zone showing area of vapor cloud at LEL value was

not drawn because effect of near field patchiness make dispersion prediction less

reliable for short distance.

c) Threat at Point

In case of leakage of Styrene from tank, the significant effects will be upto 32 meter in

case of toxic threat zone with concentration of 50 ppm. Effect has been worked out at a

point in downwind direction within the premises at about 500 meters distance from the

source. Maximum concentration of styrene estimated at described point is 1.02 ppm at

outdoor and 0.434 ppm in indoor and Isopleths for the same is shown in Figure 8.2.

Figure 8.2: Isopleths result of Toxic threat at a point for Styrene Monomer

Scenario-1B: Release of Styrene Monomer due to leakage & form burning puddle

(pool fire)

a) Source Strength

Styrene Monomer is below its flash point and is unlikely to catch on fire. However,

considering worst case, model has been run for such case. When styrene monomer



Page | 8.19

escaped from tank and forms a burning puddle, maximum burn rate in this case will be

28.6 kg/min considering maximum attentive time of 60 min. Moreover, puddle will be

spread to a diameter of 2.9 m. Isopleths results are given in Figure 8.3.

Figure 8.3: Source Strength in case of Styrene Monomer escapes (pool fire)

b) Threat zone of thermal radiation from pool fire

Model output of the threat zone of thermal radiation from pool fire is given in Table 8.9.

Isopleths results are given in Figure 8.4.

Table 8.9: Threat zone of thermal radiation from pool fire

Threat Zone

Thermal Radiation from fire ball, kw/m2 Threat Zone

Radial Distance Red 10 (Potentially lethal within 60 sec.) 11 m

Orange 5 (2nd degree burns within 60 sec) 14 m

Yellow 2 (Pain within 60 sec) 18 m



Page | 8.20

Figure 8.4: Thermal radiation at a point in case of Styrene Monomer escapes (pool fire)

c) Threat at point

Effect has been worked out at a point in downwind direction within the premises at

about 500 meters distance from the source and no significant radiation observed at

selected point.

Scenario-1C: Release of chemical due to catastrophic failure (BLEVE)

a) Source Strength

Styrene Monomer is below its flash point and is unlikely to catch on fire. However,

considering worst case, model has been run for such case. When styrene monomer will

be released from tank as a liquid and forms a fire ball, diameter of fire ball will be 354 m

and burn duration will be 20 seconds.



Page | 8.21

b) Threat Zone of thermal radiation

Model output and Isopleths result of the threat zone of thermal radiation is given in

Table 8.10 & Figure 8.5.

Table 8.10: Threat zone of thermal radiation from BLEVE

Threat Zone

Thermal Radiation from fire ball, kw/m2 Threat Zone Radial

Distance Red 10 (Potentially lethal within 60 sec.) 733 m



Figure 8.5: Isopleths result of threat zone of thermal radiation from BLEVE



Page | 8.22

c) Threat at point

Effect has been worked out at a point in downwind direction within the premises at

about 500 meters distance from the source. The maximum thermal radiation estimated

at point will be 20.5 kW/m2. Persons working in the area upto 500 m distance from the

source will get potentially lethal within 60 seconds.

2) XYLENE

The possibilities of source strength considered at the time of accidents due to Xylene

are mentioned in Table 8.11.

Table 8.11: Source Strength considered for Xylene

Particulars Value

Drum Diameter 0.65 mDrum Height 0.7 mDrum volume 0.23 m3

InternalTemperature 19.83° CChemical Mass in cylinder 200 Kg Scenario – A & B Circular Opening Diameter 0.5 inchesOpening from Drum bottom 0 mGround Type Concrete Scenario – C Percentage of Tank Mass in Fireball 100%

Scenario-2A: Release of Xylene due to leakage and form evaporating puddle (Not

burning)

a) Source Strength

When Xylene will escapes from drum and formed an evaporating puddle, Maximum

average sustained release rate in this case will be 987 gms/min considering maximum

attentive time of 1 min or more and puddle spread to a diameter of 7.3 m. Isopleths

results are given in Figure 8.6.



Page | 8.23

Figure 8.6: Source Strength in case of Xylene escapes

b) Threat Zone

Toxic threat zone

Model output of the Toxic threat zone and isopleths for chemical release are given in

Table 8.12. Isopleths result was not drawn because effect of near field patchiness

make dispersion prediction less reliable for short distance.

Table 8.12: Toxic Threat zone

Threat Zone Concentration

(ppm) Threat Zone

Horizontal Direction Vertical Direction

Red 900 (TEEL-3) < 10 m

Orange 200 (TEEL-2) < 10 m

Yellow 150 (TEEL-1) < 10 m

Flammable threat zone:

Model output of the flammable threat zone for chemical release is given in Table 8.13.

Isopleths result was not drawn because effect of near field patchiness make dispersion

prediction less reliable for short distance.

Table 8.13: Flammable area of vapor cloud

Threat Zone

Concentration, ppm

Threat Zone Horizontal Direction Vertical Direction

Red 6,600 (60 % LEL) < 10 m

Yellow 1,100 (10 % LEL) < 10 m



Page | 8.24

c) Threat at point

In case of leakage of Xylene, the significant effects will be within 10 m in case of toxic

threat zone with concentration of 1,100 ppm. Effect has been worked out at a point in

downwind direction at 500 m within the premises from the source. Maximum

concentration of Xylene estimated at described point is 0.197 ppm at outdoor and 0.103

ppm in indoor and Isopleths for the same is shown in Figure 8.7.

Figure 8.7: Isopleths result of Toxic threat at a point for Xylene

Scenario-2B: Release of Xylene due to leakage and form burning puddle (pool

fire)

a) Source Strength

When Xylene will escape from drum and forms a burning puddle, maximum burn rate in

this case will be 6.14 kg/min considering maximum attentive time of 33 seconds.

Puddle spread to a diameter of 1.3 m.



Page | 8.25

Figure 8.8: Source Strength in case of Xylene escapes (pool fire)

b) Threat zone of thermal radiation from pool fire

Model output of the threat zone of thermal radiation from pool fire is given in Table

8.14. Isopleths result was not drawn because effect of near field patchiness make

dispersion prediction less reliable for short distance.

Table 8.14: Threat zone of thermal radiation from pool fire

Threat Zone

Thermal Radiation from fire ball, kw/m2 Threat Zone

Radial Distance Red 10 (Potentially lethal within 60 sec.) < 10 m

Orange 5 (2nd degree burns within 60 sec) < 10 m

Yellow 2 (Pain within 60 sec) < 10 m

c) Threat at point

Effect has been worked out at a point in downwind direction at about 500 m distance

from the source within the premises and no significant concentration or effect observed

at given distance.

Scenario-2C: Release of chemical due to catastrophic failure (BLEVE)

a) Source Strength

When Xylene will escape from drum and forms a fire ball, diameter of fire ball will be 34

m and burn duration will be 3 seconds.



Page | 8.26

b) Threat Zone of thermal radiation

Model output and Isopleths result of the threat zone of thermal radiation is given in

Table 8.15 & Figure 8.9.

Table 8.15: Threat zone of thermal radiation from BLEVE

Threat Zone

Thermal Radiation from fire ball, kw/m2 Threat Zone Radial

Distance

Red 10 (Potentially lethal within 60 sec.) 78 m



Figure 8.9: Isopleths result of threat zone of thermal radiation from BLEVE

c) Threat at point

Effect has been worked out at a point in downwind direction at about 500 m distance

rom the source within the premises. The maximum thermal radiation estimated at point

will be 0.22 kW/m2. No significant effect observed at such low concentration at given

distance.



Page | 8.27

8.6 RISK MITIGATIVE MEASURES

Unit has already taken all the risk mitigative measures in the existing plant.

Photographs showing safety management in existing plant are given in Annexure-16.

However, following measures are recommended for the proposed expansion.

Layout and location of hazardous chemical storage should be based on natural and

mechanical ventilation.

For any case of fire emergency, standard type of Fire extinguishers should be

provided in the storage area as well as required places in the plant.

Regular inspection of all tanks/ drums of hazardous chemicals should be carried out

before it is taken to the storage area and damaged drums should be separated and

disposed to avoid the possibility of catastrophic rupture.

All equipments related to hazardous chemical storage should be maintained and

calibrated regularly.

A trained person should be deployed for handling operation.

First-aid facility and first-aid trained person should be available at the time of

handling operation.

The adequate and suitable personnel protective equipments should be provided to

the operating workers.

SOP for handling should be displayed in local language for safe operating

procedure.

8.6.1. Fire Fighting System

Adequate system is provided by the unit for fire fighting as described below;

Sufficient numbers of Fire extinguishers are installed in all plants and storage area

as given below in Table 8.16.

An above ground Fire Hydrant System as described below has been installed in the

plant with rings around all blocks to achieve maximum coverage.

o Water reservoir - 500 m3

o Type of Hazard- Chemical, Ordinary Hazard

o Total no. of Fire Hydrant including landing Values, Water monitor-28 Nos.

o Diesel operated pump of 273 m3/hr capacity

o No. of Hose Boxes-20 nos.

o No. of Hoses- 30 reels



Page | 8.28

o No. of Nozzles - 21

Separate Water storage tank is provided for fire water as well as process water

requirement.

D.G. Sets is provided for emergency power.

Mock drill & training is conducted at scheduled intervals.

Fire fighting team members and rescue squad members as listed in Table 8.17 are

available at any time in the premises.

In addition to this, in case of any emergency help will be taken from the following

companies.

Name of Company Contact Person Contact number

Ratnamani Metal & Tubes Ltd. Mr.Haribandhav Barik 9099052117

Met Trade India Ltd. Mr.Kundan Suman 9909960206

Renaissance Corporation Ltd. Mr.Kuldeep Gautam 9714009111

Table 8.16: Details of Fire Extinguishers

Sr. No.

Area Location Type Capacity

1 Main Gate Security Office DCP 10 Kg 2 Admin Office Admin Office ABC 2 Kg 3 Admin Office Commercial Dept. ABC 2 Kg 4 Pump House Pump House DCP 5 Kg 5 Q/C Dept Lab Room DCP 10 Kg 6 Canteen Near Kitchen DCP 10 Kg 7 Styrene Tank Farm Front side of tank-1 M.Foam 45 liter 8 Styrene Tank Farm Front side of tank-1 M.Foam 45 liter 9 Styrene Tank Farm Front side of tank-2 M.Foam 45 liter

10 Styrene Tank Farm Front side of tank-2 M.Foam 45 liter Store/Ware House

11 Load Out Front side of load out M.Foam 45 liter 12 Load Out Near Load out gate DCP 10 Kg 13 Entarnce-1 Front side of Entrance-1 DCP 10 Kg 14 Entrance-1 Front side of Entrance-1 DCP 10 Kg 15 Store Office In Store office DCP 5 Kg 16 Store Office Near Store office M.Foam 45 liter 17 Entrance-2 Front side of Entrance-2 DCP 10 Kg 18 Entrance-2 Front side of Entrance-2 DCP 10 Kg 19 Exist Near Exist DCP 10 Kg 20 Exist Near Exist DCP 10 Kg 21 Raw material storage Malice Stock DCP 5 Kg 22 Raw material storage Malice Stock DCP 5 Kg 23 Raw material storage Monomer Stock DCP 10 Kg



Page | 8.29

Sr. No.

Area Location Type Capacity

Utility 24 MCC Room Near MCC Room entrance Co2 4.5 Kg 25 Utility Near motor Co2 22.5 Kg 26 DG House DG House DCP 5 Kg 27 Transformer Near Transformer gate Co2 4.5 Kg 28 Glycol tank Near Glycol tank M.Foam 45 liter

New Utility 29 Entrance Near welding/cutting area DCP 10 Kg 30 New Boiler Near Boiler DCP 5 Kg 31 MCC Room Front side of MCC Room gate Co2 6.5 Kg

Process Plant 32 Ground floor Near front Entrance gate M.Foam 9 liter 33 Ground floor Near front Entrance gate M.Foam 9 liter 34 Ground floor Near Stair case DCP 10 Kg 35 Ground floor Near Stair case DCP 10 Kg 36 Ground floor Front side of Hoist-2 DCP 10 Kg 37 Ground floor Near Holding tank-1 DCP 10 Kg 38 Ground floor Near Holding tank-2 DCP 10 Kg 39 1st Floor Near Stair case DCP 5 Kg 40 1st Floor Near Hoist-2 DCP 5 Kg 41 1st Floor Near Blender-5 DCP 5 Kg 42 1st Floor Near Hoist-1 DCP 5 Kg 43 1st Floor Near Stair case DCP 10 Kg 44 2nd Floor Near Stair case DCP 5 Kg 45 2nd Floor Near Hoist-2 DCP 5 Kg 46 2nd Floor Near Reactor-5 DCP 5 Kg 47 2nd Floor Near Hoist-1 DCP 5 Kg 48 2nd Floor Near Stair case DCP 10 Kg

Total Fire Extinguisher:

Sr. No Types of Extinguisher Total Nos.1 DCP 33 2 CO2 04 3 Foam 09 4 ABC 02 5 Sand Buckets Stand 06

Table 8.17: List of Fire Fighting & Rescue Squad Members

Fire Fighting Squad First Aider (Rescue Squad)

Mr. Digvijay Narayan Mr. Sanjay Dhabi

Mr. Sankar Samant Mr. Praveen Chavda

Mr. Surendra Verma Mr. G.C.Yadav

Mr. Sunil Kumar Sharma Mr. Dharmaraj



Page | 8.30

Mr. Pratap Swain Mr. Amit Shukla

Mr. Sankarsen Nahka Mr. Vishal Kumar

Mr. Rajendra Yadav Mr. Praveen Kumar Ved

Mr. Nawal Matoliya Mr. Motibhai Patel

Mr. Shishram Rar

Mr. Avinash Tomar

8.6.2. Emergency Management

Emergency Planning

Emergency siren and wind sock is installed.

On Site emergency Plan is prepared.

Tele communication system and mobile phone is used in case of emergency

situations for communication.

First Aid Boxes and First Aid Centre are made at site.

Safety Practices in the Work Area

Unit provides information to all employees about the potential hazards of contact

with chemicals and trains them in appropriate first-aid procedures.

Chemical handling areas are clearly marked and restricted to qualified, trained

personnel only.

Emergency Procedures

In case of emergenciesfirst aid and emergency response procedures are

adopted

Transportation Emergencies

In emergency situations resulting from vehicle accidents:

Notify the local police, fire departments, emergency responders and the carrier.

Isolate the area.

Any person not dressed in proper protective clothing and not using a NIOSH

approved self-contained breathing apparatus should be kept a safe distance

away.

Call to the supplier.

Seek immediate medical assistance for those injured and follow recommended

first aid procedures.

Leaking Containers

When handling a leaking bottle personal protective clothing, goggles and NIOSH



Page | 8.31

approved self contained breathing equipment must be worn.

Clear contaminated area of non-essential personnel and send them to assembly

point.

There should be provision of proper ventilation. Scrub the floors and equipment

with soap and water.

First Aid Procedure

For skin contact, immediately flush skin with plenty of water for at least 15

minutes while removing contaminated clothing and shoes.

To avoid the risk of static discharges and gas ignition, soak contaminated

clothing thoroughly with water before removing it. Wash clothing before reuse.

Clean shoes thoroughly before reuse. Get medical attention immediately.

In all cases of injury, obtain immediate medical attention.

Provide emergency personnel with information about all materials used by the

person

8.7 ONSITE EMERGENCY PLAN AND DISASTER MANAGEMENT PLAN

As emergency is said to have risen when operators in the plant are not able to cope

with a potential hazardous situation i.e. loss of an incident causes the plant to go

beyond its normal operating conditions, thus creating danger. When such an

emergency evolves, chain of events which affect the normal working within the factory

area and / or which may cause injuries, loss of life, substantial damage to property and

environment both inside and around the factory takes place and a DISASTER is said to

have occurred.

Various steps involved in Disaster Management Plan can be summarized as follows:

1. Minimize risk occurrence (Prevention)

2. Rapid Control (emergency response)

3. Effectively rehabitate damaged areas (Restoration)

Disaster Management Plan is evolved by careful scrutiny and interlinking of

a. Types and causes of disaster

b. Technical know-how

c. Resource availability

Types of Disaster:

a. Due to Fire and Explosion

b. Due to Vapour Cloud



Page | 8.32

c. Due to Toxic Gas Release from:

i. Within the Unit

ii. External Sources

d. Hurricane, Flood, Cyclone and other Natural Calamities

This plan is developed to make best possible use of resources to:

Reduce possibilities of accident.

Contain the incident and control it with minimum damage.

Safeguard others

Rescue the victims and treat them suitable.

Identify the persons affected/ dead.

Inform relatives of the causalities.

Provide authorative information to the news media.

Preserve relevant records and equipment needed as evidence incase of any inquiry.

Rehabilitate the affected areas.

The primary purpose of the on-site emergency plan is to control and contain the

incident and so as to prevent from spreading to nearby plant. It is not possible to

cover every eventuality in the plan and the successful handling of the emergency

will depend on appropriate action and decisions being taken on the spot. Onsite

emergency plan prepared by the unit is described hereunder;

8.7.1 Emergency Control Centre

For the purpose of handling emergency, the following Emergency Control Centres has

been identified.

During normal working hours - The Administrative Office

During other times - The Security Office

All communications to and from will originate at this control centre. The Emergency

Control Center will have the following;

a. List of important telephone numbers such as Police, Fire Brigade, Hospitals, and

other outside Emergency Services, etc. as given below;

Services Description/Place Contact. No Police Anjar 02836-243259 Fire Brigade Gandhidham 02836-270176,

02836-270439 Hospital Govt.Dispensary 02836-260608



Page | 8.33

Ram Baugh 02836-220263 Jivatram mangatrai 02836-260836 St.Joseph 02836-230160

Ambulance Gandhidham 02836-225636 Co. Doctor Divine life, Adipur 02836-263245

b. List of key Personnel with addresses and telephone numbers.

Name Contact numbers Mr.D.R.Karwasra 9714009140 Mr.S.T.Pillai 9714009148 Mr.Pradeep Garnayak 9714009149 Mr.Harshvardhan Sharma 9714009107 Mr.Amit Shukla 9714022209 Mr.Surendra Verma 9714009128 Mr.Digvijay Narayan 9714055592 Mr.Sankar Samanta 9714009156

c. List of Fire and Rescue Squad Members

d. Plant layout indicating storage of hazardous materials

e. Details of Fire Extinguishers and Fire Hydrant System

f. List of Personal Protective Equipment

g. Details of First Aid box

h. Details of Mutual Aid Scheme Members

8.7.2 Assembly Points

In case of an EMERGENCY the employees should assemble near the defined

Assembly Points, as indicated below:

Near parking area (Between Accounts office and Canteen)

Near RCL gate.

Wind direction to be determined by the wind socks installed on top of the utility-1

Building. The employees should run perpendicular to the wind direction and not against

/ along the wind direction.

8.7.3 Codification of Sirens

Sr. No.

Sirens Indicates Authority

1. 1 minute continous On site Emergency (alert) Incident controller 2. 30 second continous Emergency Controlled (all clear) Site controller

Note:



Page | 8.34

Emergency siren to be sounded only if required

All employees in areas other than affected to continue work unless emergency siren

is blown.

No emergency organization member will leave the emergency spot unless `All

Clear’ siren blown.

Emergency siren is tested on every Friday at 11:30 am.

8.7.4 Training and Education

Experience with on site –emergency planning has proved the need of training and

rehearsal. Major emergency procedure should be laid down clearly and convincingly to

everyone on site particularly Key Personnel and Essential workers. It is obvious that in

house or outdoor training is essential. The duties and responsibilities of each person

and the emergency procedure to be followed by him should be very clear.

a. Seminar/refresher guidance On Site Emergency Plan.

Seminar: Seminar is conducted in house. Awareness sessions shall be conducted to

explain the plan to all associated concerned employees.

b. Induction program:

Safety officer shall explain onsite emergency plan to all new employees during

induction program

8.7.5 Mock Rehearsal

Inform all the employees about mock drill.

Fix the date for mock drill.

Observers will not be involved in the exercise. They will monitor the Mock drill.

Emergency Siren / alarm will be raised.

After hearing the Siren / alarm, Emergency procedure will be followed as mentioned

in the OEP.

Observer will note down the activities with respect to the time.

8.7.6 Updating the Plan

On Site Emergency Management plan will be reviewed annually or any significant

incident or any change in regulation.



Page | 8.35

8.7.7 Key Personnel & their Responsibilities

a) Site Controller

He will retain overall responsibility for the factory and its personnel. As soon as he is

informed of the emergency he shall proceed to the control room and meet the P&A.

Manager. His duties shall be:

Assess the magnitude of the situation and decide if staff needs to be evacuated

from their assembly points.

Exercise direct operational control over areas other than those affected.

Maintain a continuous review of possible development and assess in consultation

with Incident Controller and other Key personnel as to whether shutting down of the

plant or any section of the plant and evacuation of persons is required.

Liaison with Senior Officials of Police, Fire Brigade, Directorate of Industrial Safety,

provide advice on possible effects on areas outside the factory premises.

Control rehabilitation of affected areas on discontinuation of emergency.

Issue authorised statements to news media, and ensure that evidence is preserved

for inquiries to be conducted by statutory authorities.

b) Incident Controller

On hearing of an emergency siren he will rush to the scene of the occurrence and take

overall charge and report to Site Controller. On arrival he will assess the scale of

emergency and decide if major emergency exists or is likely and inform the

Communication Officer accordingly.

Direct all operations within the affected areas with the priorities for safety of

personnel minimise damage to the plant, property and minimise loss of materials.

Pending arrival of Site Controller, assume the duties of his post and, in particular.

Direct the shutting down and evacuation of plant and areas likely to be adversely

affected by the emergency.

Ensure that all Key personnel and outside help are called in.

Provide advice and information to the Fire squad & Security Officer and the local fire

service as and when they arrive.

Ensure that all non-essential workers/staff of the areas affected are evacuated to

the appropriate assembly points, and the areas are searched for casualties.



Page | 8.36

In the event of failure of electric supply and internal telephones, set up

communication point and establish contact with Emergency Control Centre.

Report on all significant developments to the P & A manager.

Have regard to the need for preservation of evidence so as to facilitate any inquiry

into the causes and circumstances, which caused or escalated the emergency.

c) Human Resources Manager

He will also work as liaison Officer and will be stationed at the Main Entrance (Security

Office near Main Gate) during the emergency. He will under the direction of the site

Controller handle police, press and other inquiries, receive reports from roll-call leaders

from assembly points and pass on the absentee information to the Incident Controller.

His responsibilities shall include;

To ensure that casualties receive adequate attention, to arrange additional help if

required and information relatives.

To control traffic movements into the factory and ensuring that alternative transport

is available when need arises.

When emergency is prolonged, arrange for the relief of personnel and organise

refreshments / catering facility.

From information received, advise the Site Controller of the situation, recommending

(if necessary) evacuation of staff from assembly points.

Recruit suitable staff to act as runners between the Incident Controller and himself if

the telephone and other system of communication fails due to whatsoever reasons.

Maintain prior agreed inventory in the control centre.

In case of prolonged emergency involving risk to outside areas by wind-blown

materials, contact local Meteorological Office to receive early notification of changes

in weather conditions.

d) Security Officer

On hearing alarm advice fire squad and security staff in the factory of the incident zone

and cancel the alarm. He will also announce through telephone or messengers to the

HR Manager, Incident Controller and Site Controller that incident has occurred in such

and such zone. He will open the gates nearest to the incident and stand by to direct the

emergency service.



Page | 8.37

On hearing the emergency alarm, he will immediately contact Site Controller and on his

advice call the local fire brigade. In case fire is discovered but no alarm is sounding he

shall receive information about location from the person discovering the fire and

thereafter immediately consult the Site Incident Controller and make announcement on

telephone telling the staff location of the incident and to evacuate to their assembly

points. He will continue to operate the switchboard advising the calls connected with

the incident to the Communications Officer.

e) Departmental Head

The Departmental head wherein the incident has taken place will report to Incident

Controller and provide assistance as required. They will decide which members of their

staff they require at the scene.

f) First-aid Teams

The Personnel Manager shall keep in security the roll call lists for the fire and first-aid

teams on duty. Each Departmental Head for his shift-team appoints roll call leaders

and first aiders. Roll call leaders shall check their rolls as members of the services

report for emergency duty. Names of any unaccounted for absentees will be informed

to the Security Officer.

Members of first-aid Teams will report to the Incident Controller on hearing of the alarm

in daytime. The Emergency vehicle driver, if safe to do so, shall collect the emergency

vehicle and park nearest to the scene of the incident. First aider shall inform the

incident controller that the Emergency Vehicle is leaving the site, giving the name of

the patient and destination i.e. hospital or doctor’s room and request the Incident

Controller to inform the destination (hospital, etc.) advising them about the casualties

reaching there.

g) Factory Fire Squad Personnel

The duty Fire fighting Squad under the command of the Security Officer shall be

responsible for fire fighting and rescue. On hearing the alarm, they shall proceed to the

place of incident. The men at security gate shall find out the location of the emergency

and proceed to the site of the occurrence. At the incident scene, a team members

detailed for this purpose will check squad members against roll-call sheet. At the site,

all the squad members will respond to the advice and information given by the Incident



Page | 8.38

Controller On arrival of the local fire brigade, they will also assist in fire-fighting work

with the advice of the Incident Controller.

8.7.8 Emergency Organization Chart

8.7.9 Emergency Action Plan

Any one noticing emergency situation like fire, explosion, toxic gas leakage etc. Must

DO’s Attract the nearby person/employee by shouting “FIRE – FIRE – FIRE”.

Seek help from the persons working nearby.

Try to control the incident at its initial stage with available means/sources quickly.

Inform Shift In-charge / Duty Officer (In Night Shift) about the Incident.

DON’Ts Do not be panicky.

Do not run – Walk fast.

Incident Controller Must

DO’s A. If Fire / Other Incidents Are Controllable

Approach the emergency site immediately taking note of wind direction.

Assess the situation.

Inform Security Officer, Tell – NAME, TYPE OF INCIDENT, ACTION TAKEN, HELP

NEEDED and Order Security Officer/Guard to inform all KEY persons.

Take lead in controlling emergency until such time concerned Section Manager

takes over the charge.

Site controller

Incident Controller

Fire fighting Squad, First aid Squad, HR Department, Engineering, Security Department, EHS Department,

Shift in charge



Page | 8.39

DON’TS Do not be panicky.

Do not lose temperament.

B. If Fire/Othr Incidents Are Not Controllable

In addition to above (A)

Order to blow emergency `ALERT’ Siren (1 minute continuous).

Organize Fire fighting / rescue team members to control the Incident.

Take stock of situation if required shut down the plant / process in affected area.

Call Fire Brigade if situation demands.

Evacuate affected area.

Organize head count of the plant.

Act as INCIDENT CONTROLLER till such time senior person takes charges as

indicated in Emergency organisation

Note:

1) Messenger will wait until such time Security Officer arrives.

2) Also inform Telephone Operator.

Security Officer / Guard Must

DO’s Do not allow any vehicle to come inside the factory.

Do not entertain any outside call except for emergency purpose.

Do not allow visitors to move around.

Inform all key persons about location and type of emergency.

Follow this sequence – Inform concerned HOD/Section Head, Main Site Controller,

Main Incident Controller & Safety Officer and other KEY persons.

Inform Main Site Controller about Government visitors, if any.

DON’Ts Do not entertain any outside call except for emergency purpose.

Do not allow visitor to move around, from reception.

Security Guard Must



Page | 8.40

DO’s Immediately report at Security Gate in shortest possible time.

Follow instructions of Officer In-charge.

Assist in controlling emergency.

Assist in controlling contractors, vehicle movement and mob.

Assist in cordoning off the area.

Take note of wind direction while approaching emergency site.

Render all possible help for controlling overall situation.

DON’Ts Do not leave the site unless asked to do so.

Emergency Vehicle Driver

DO’s Immediately start vehicle and reach rescue squad assembly point (near security

gate).

Rescue squad members to emergency site.

Take vehicle near to emergency site as directed.

Take note of wind direction.

Reverse the emergency vehicle for quick transports of injured, if any.

Keep vehicle engine running.

Always be on Driver’s seat of the vehicle.

Take the injured to the hospital as directed.

DON’Ts Do not leave the vehicle.

Do not take the vehicle very near to the site.

Site Controller

DO’s Will approach emergency site immediately / Assess the situation.

Consult Incident Controller.

Consult advising Committee Members.

Instruct Main Incident Controller.



Page | 8.41

Communicate to higher ups and Govt. authorities, if required.

Decide upon need for evacuation and blow `Disaster Siren’.

After getting satisfied with the situation, give instruction to blow ALL CLEAR Siren.

DON’Ts Do not instruct to blow ALL CLEAR siren unless the situation is fully under control.

Don’t evacuate the entire plant unless the situation demands.

Fire Fighting Squad on Hearing Siren

DO’s Inform fellow employees/Officers.

Report to Fire Squad Assembly point.

Find out emergency location.

Approach emergency site immediately.

Take quick action as per the instructions from Incident controller.

Bring emergency under control as early as possible.

DON’Ts Do not leave process/equipment in UNSAFE CONDITION.

Do not leave emergency site unless ALL CLEAR siren blown.

Do not use improper fire extinguisher.

Do not be panicky.

Rescue Squad

DO’s Report to assembly point near Gate.

Get in touch with security about location and type of emergency.

Approach emergency site quickly with Breathing Apparatus set and First Aid box.

Get in touch with incident controller.

Follow instructions of Incident controller.

Render first aid to the injured, hospitalize, if required.

Accompany him to hospital and assist Doctor / Nurse.

Search for missing person in that area, if required.

Help in head count.



Page | 8.42

All general employees except those who are in emergency organization on hearing

siren

DO’s Be alert and be available if required.

Wait for further instructions.

Bring down the process/plant/equipment in SAFE CONDITION in case of

DISASTER siren as per instructions from Incident Controller.

Approach respective safe assembling points route as taking note of wind direction.

Help in taking roll call.

After hearing ALL CLEAR, go back to the departments.

Start the work again after setting instruction from Incident controller.

DON’Ts Do not be panicky. Do not run.

Do not approach emergency site unless asked for.

Do not engage telephone except for emergency purpose. Keep lines free.

Technical Team: Engineering Department/ Environmnet, Safety and Health Department

on Hearing Siren

DO’s Be available in Engineering Department at respective location for any help.

Approach emergency site with required with tools and equipments and should work

on instructions of Incident controller.

Help Incident Controller to provide technical assistance.

Isolate lines, process equipments, if required by Incident Controller.

Provide emergency equipments like Fire Extinguisher, Hoses, etc., if asked by

Incident Controller.

Provide stopgap arrangements as per the requirement of Incident Controller.

Carry out electrical isolation of area as per instructions from Incident Controller.

Advisory Committee (All Department Heads)



Page | 8.43

DO’s Approach emergency site as early as possible.

Render advice to Main Incident Controller and Main Site Controller to control

emergency.

Communication Committee – (HR & Commercial)

DO’s Consult Main Site Controller

Give necessary instructions to security / Telephone Operator.

Give instruction to Security to control traffic / crowd.

Look after injured; communicate with the family members, if situation demands.

Arrange transportation, if required.

DON’Ts Do not communicate to any one or brief press without permission of Main Site

Controller.

General Intructions

DO’S Stop work at height. / Stop all hot works.

Stop all vessel entry.

Take note of wind direction.

On hearing Disaster Siren evacuates as per evacuation route without running and

panicky and assembles at respective safe Assembly Points.

DON’Ts Do not use telephone except for emergency purpose.

Do not start work at height, vessel entry, hot work unless permit conditions are

verified.

Do not allow unauthorized person to approach emergency site.

Plant Emergency Evacuation Plan is enclosed as Figure 8.10.



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Figure 8.10: Plant Emergency Evacuation Plan



Page | 8.45

8.8 OFF SITE EMERGENCY PLAN

The Off site emergency plan is made based on events, which could affect people and

Environment out side the premises. The off site plan is largely a matter of ensuring the

co-ordination of proposed services and their readiness as far as possible, for the

specific hazards and problems, which may arise in as incident. Briefly two main

purposes of the plan are as under:

To provide the local district authorities, police, fire brigade, doctors etc. the basic

information of risk and environmental impact assessment and to appraise them of

the consequences and the protection / prevention measures and control plans and

to seek their help to communicate with the public in case of major emergency.

To assist the district authorities for preparing the off site emergency plan for the

district or particular area. We have made our key personnel and other fully aware

about this aspect. The function of the off site plans are as under:

Structure of the off site emergency plan includes the following:-

Organizational set up-Incident controller /Site main controller, Key personnel, etc

Communication facilities - List of important telephones

Specialized emergency equipment - Fire fighting equipment

Specialized Knowledge - Trained people

Voluntary Organization - Details of organization

Chemical information - MSDS of hazardous substances

Meteorological information - Weather condition, Wind velocity etc

Humanitarian arrangement - Transport, First aid, Ambulance

Role of the factory management

The on site and off site plans are come together so that the emergency services are call

upon at the appropriate time and are provided with accurate information and a correct

assessment of situation.

Role of local authority

Generally the duty to prepare the off-site plan lies with the local authority. They may

have appointed an emergency planning officer (EPO) to prepare whole range of

different emergency within the local authority area.



Page | 8.46

Role of fire authority

The control of a fire is normally the responsibility of the senior fire brigade officer who

would take over the handling of fire from the Incident Controller on arrival at the site.

Role of police

The overall control of an emergency is normally assumed by the police with a senior

officer designated as emergency coordinating officer. Formal duties of the police during

emergency include protection of life and property and controlling traffic movements.

Role of health authorities

Health authorities, including doctors, surgeons, hospitals, ambulances etc. have a vital

role to play following a major accident and they should form an integral part of the

emergency plan. Major off site incidents are likely to require medical equipments and

facilities in addition to those available locally.

Role of the “mutual aid” agencies

Some types of mutual aids are available from the surrounding factories, as per need, as

a part of the on site and off site emergency plan.

The role of the factory inspectorate

In the event of an accident, the factory inspector will assist the District Emergency

Authority for information and help in getting mutual aid from surrounding factories.

Unit maintains the records of details of emergency occur, corrective preventive

measures taken and in future the same practice will be continue. Unit has displayed the

details like list of assembly points, name of the persons involve in the safety team like

site controller, incident controller etc.

8.9 EARTHQUAKE HISTORY & MANAGEMENT PLAN

As per the earthquake sensitivity index, study area lies in Zone V, which is referred as

Very High Damage Risk Zone (MSK > IX). Seismic zone map of Gujarat is given in

Figure 8.11.



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Figure 8.11: Seismic Zone Map of Gujarat

Source: http://www.isr.gujarat.gov.in/Seismic_Zoning_India.shtm

Two damaging earthquakes are known to have struck the Kutch Peninsula during the

last two centuries, namely, the 1819 earthquake that killed more than 2000 people and

wiped out several centres of human settlements in the Rann and the more recent event

in 1956 that killed 115 people and damaged a large part of the town of Anjar.

The 26 January 2001 earthquake that occurred in Gujarat is the most disastrous

earthquake in India’s recent history. The earthquake occurred in Gujarat on 26 January

2001, India's 52nd Republic Day, at 08:46 AM local time and lasted for over two

minutes. The epicentre was about 9 km south-southwest of the village of Chobari in

Bhachau Taluka of Kutch Districtof Gujarat, India. This location is about 35 km away

from the Project site in North-North-East direction.

The earthquake reached a magnitude of between 7.6 and 7.7 on the moment

magnitude scale and had a maximum felt intensity of X (Intense) on the Mercalli

intensity scale. The quake killed around 20,000 people (including 18 in South

eastern Pakistan), injured another 1,67,000 and destroyed nearly 400,000 homes. This



Page | 8.48

was an intraplate earthquake, one that occurred at a distance from an active plate

boundary, so the area was not well prepared. The shock waves spread 700 km. 21

districts were affected and 600,000 people left homeless.

Unit has prepared all the existing sturture considering the earthquake risk in the area

and for proposed expansion all the structures will be earthquake resists. Training is

given to all the employees about such natural disaster. General Management plan for

earthquake is described hereunder;

Do's & Dont's:

Before an Earthquake

Repair deep plaster cracks in ceilings and foundations. Get expert advice if there

are signs of structural defects.

Anchor overhead lighting fixtures to the ceiling.

Follow BIS codes relevant to your area for building standards

Fasten shelves securely to walls.

Place large or heavy objects on lower shelves.

Store breakable items such as bottled foods, glass, and china in low, closed

cabinets with latches.

Hang heavy items such as pictures and mirrors away from beds, settees, and

anywhere that people sit.

Brace overhead light and fan fixtures.

Repair defective electrical wiring and leaky gas connections. These are potential fire

risks.

Secure water heaters, LPG cylinders etc., by strapping them to the walls or bolting

to the floor.

Store weed killers, pesticides, and flammable products securely in closed cabinets

with latches and on bottom shelves.

Identify safe places indoors and outdoors.

o Under strong dining table, bed

o Against an inside wall

o Away from where glass could shatter around windows, mirrors, pictures, or

where heavy bookcases or other heavy furniture could fall over

o In the open, away from buildings, trees, telephone and electrical lines, flyovers

and bridges



Page | 8.49

Know emergency telephone numbers (such as those of doctors, hospitals, the

police, etc)

Educate yourself and family members

Have a disaster emergency kit ready

Develop an emergency communication plan

o In case family members are separated from one another during an earthquake (a

real possibility during the day when adults are at work and children are at

school), develop a plan for reuniting after the disaster.

o Ask an out-of-state relative or friend to serve as the 'family contact' after the

disaster; it is often easier to call long distance. Make sure everyone in the family

knows the name, address, and phone number of the contact person.

Help your community get ready

o Publish a special section in your local newspaper with emergency information on

earthquakes. Localize the information by printing the phone numbers of local

emergency services offices and hospitals.

o Conduct week-long series on locating hazards in the home.

o Work with local emergency services and officials to prepare special reports for

people with mobility impairment on what to do during an earthquake.

o Provide tips on conducting earthquake drills in the home.

o Interview representatives of the gas, electric, and water companies about

shutting off utilities.

o Work together in your community to apply your knowledge to building codes,

retrofitting programmes, hazard hunts, and neighborhood and family emergency

plans.

During an Earthquake

Stay as safe as possible during an earthquake. Be aware that some earthquakes are

actually foreshocks and a larger earthquake might occur. Minimize your movements to

a few steps that reach a nearby safe place and stay indoors until the shaking has

stopped and you are sure exiting is safe.

If indoors,

DROP to the ground; take COVER by getting under a sturdy table or other piece of

furniture; and HOLD ON until the shaking stops. If there is no a table or desk near



Page | 8.50

you, cover your face and head with your arms and crouch in an inside corner of the

building.

Protect yourself by staying under the lintel of an inner door, in the corner of a room,

under a table or even under a bed.

Stay away from glass, windows, outside doors and walls, and anything that could

fall, (such as lighting fixtures or furniture).

Stay in bed if you are there when the earthquake strikes. Hold on and protect your

head with a pillow, unless you are under a heavy light fixture that could fall. In that

case, move to the nearest safe place.

Use a doorway for shelter only if it is in close proximity to you and if you know it is a

strongly supported, load bearing doorway.

Stay inside until the shaking stops and it is safe to go outside. Research has shown

that most injuries occur when people inside buildings attempt to move to a different

location inside the building or try to leave.

Be aware that the electricity may go out or the sprinkler systems or fire alarms may

turn on.

If outdoors,

Do not move from where you are. However, move away from buildings, trees,

streetlights, and utility wires.

If you are in open space, stay there until the shaking stops. The greatest danger

exists directly outside buildings; at exits; and alongside exterior walls. Most

earthquake-related casualties result from collapsing walls, flying glass, and falling

objects.

If in a moving vehicle,

Stop as quickly as safety permits and stay in the vehicle. Avoid stopping near or

under buildings, trees, overpasses, and utility wires.

Proceed cautiously once the earthquake has stopped. Avoid roads, bridges, or

ramps that might have been damaged by the earthquake.

If trapped under debris,

Do not light a match.

Do not move about or kick up dust.

Cover your mouth with a handkerchief or clothing.



Page | 8.51

Tap on a pipe or wall so rescuers can locate you. Use a whistle if one is available.

Shout only as a last resort. Shouting can cause you to inhale dangerous amounts of

dust.

After an Earthquake

Keep calm, switch on the radio/TV and obey any instructions you hear on it.

Keep away from beaches and low banks of rivers. Huge waves may sweep in.

Be prepared to expect aftershocks.

Turn off the water, gas and electricity.

Do not smoke and do not light matches or use a cigarette lighter. Do not turn on

switches. There may be gas leaks or short-circuits. Use a torch.

If there is a fire, try to put it out. If you cannot, call the fire brigade.

If people are seriously injured, do not move them unless they are in danger.

Immediately clean up any inflammable products that may have spilled (alcohol,

paint, etc).

If you know that people have been buried, tell the rescue teams. Do not rush and do

not worsen the situation of injured persons or your own situation.

Avoid places where there are loose electric wires and do not touch any metal object

in contact with them.

Do not drink water from open containers without having examined it and filtered it

through a sieve, a filter or an ordinary clean cloth.

If your home is badly damaged, you will have to leave it. Collect water containers,

food, and ordinary and special medicines (for persons with heart complaints,

diabetes, etc.)

Do not re-enter badly damaged buildings and do not go near damaged structures.

8.10 LANDSLIDE HAZARD MAP & MITIGATION PLAN

Landslides are downward and outward movement of slope materials such as rock

debris and earth, under the influence of gravity. A landslide hazard zonation map of

India is given below as Figure 8.12.



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Figure 8.12: Landslide Hazard Zonation Map of India

Source: Website of National Disaster Management Authority (NDMA), Government of India

The above map shows the areas of different hazard zones in various states of India and

from the same one may note that Himalayas of Northwest and Northeast India and the

Western Ghats are two regions of high vulnerability and are landslide prone. Kutch

district falls under the area having very low hazard due to landslide. However, general

mitigation measures suggested by NDMA are given hereunder;



Page | 8.53

Do's & Dont's

We can stop loss of life and prepare ourselves in the wake of landslides. The

Government of India has made plans to identify the areas where landslides occur

repeatedly. This is achieved through Landslide Hazard Zonation (LHZ) maps which

show areas in different colours. Red, Yellow and Green signify as dangerous, caution

and safe in Hilly regions of Coast, Himalayas and rough terrain. NDMA has published

Guidelines on Landslides and Snow Avalanches as given on its website.

Keep drains clean.

Direct storm water away from slopes.

Inspect drains for - litter, leaves, plastic bags, rubble etc.

Keep the weep holes open.

Don’t let the water go waste or store above your house.

Grow more trees that can hold the soil through roots,

Identify areas of rock fall and subsidence of buildings, cracks that indicate landslides

and move to safer areas. Even muddy river waters indicate landslides upstream.

Notice such signals and contact the nearest District Head Quarters.

Ensure that toe of slope is not cut, remains protected, don’t uproot trees unless

revegetation is planned.

Recover and build

Remain calm and be alert and awake, listen to warnings of heavy and prolonged

period of rainfall from weather station, if your home is located below a debris

covered area move away to safer place, listen to sounds of rock fall, moving debris

and cracking of trees, or cracks in ground or any movement. Keep a battery

operated ready for the night.

Call and help rescue teams, keep drinking water containers, first aid kit and

essential medicines and avoid entering damaged houses.

Watch for flooding if close to river, help others who need help especially elderly

people, children and women, seek advice from local authorities for rebuilding

damaged houses, roads etc.

Report any damage of roads, power and telephone lines to concerned authorities.



Page | 8.54

Emergency Kit Contents

Battery operated torch, Extra batteries, Battery operated radio, First aid kit and

manual, Emergency food (dry items) and water (packed and sealed), Candles and

matches in a waterproof container, Knife, Chlorine tablets or powdered water

purifiers, Can opener, Essential medicines, Cash, Aadhar Card and Ration Card,

Thick ropes and cords, Sturdy shoes

Documents

Environmental Impact Assessment (EIA) Report Proposed ...environmentclearance.nic.in/writereaddata/online/RiskAssessment/... · Environmental Impact Assessment (EIA) Report Proposed