INCREASE OF LIMESTONE PRODUCTION FROM 0.12 MTPA to …environmentclearance.nic.in/writereaddata/online/... · proposed for enhancement of cement production capacity from 0.066 MTPA

Malkhed Limestone Mine, South India Cements Ltd.,Malkhed Village, Sedam Taluk, Gulbarga District, Karnataka

0 B.S. Envi-Tech (P) Ltd., Hyd.

RISK ASSESSMENT REPORT

For

INCREASE OF LIMESTONE PRODUCTION FROM0.12 MTPA to 1.45 MTPA

FROMMALKHED LIMESTONE MINE

Of

M/s. SOUTH INDIA CEMENTS LIMITEDMalkhed Village, Sedam Taluk, Gulbarga District, Karnataka

Prepared By

B.S. ENVI-TECH (P) LTDSecunderabad – 500 017



RISK ASSESSMENTAND

EMERGENCY PREPAREDNESS PLAN

CONTENTS

1.0 INTRODUCTION2.0 RISK IDENTIFICATION3.0 RISK EVALUATION4.0 RISK ASSESSMENT & PRIORITIZATION5.0 RISK CONTROLS6.0 RISK – BASED AUDITING7.0 EMERGENCY MANAGEMENT PROGRAMS8.0 TRAINING

1.0 INTRODUCTION

M/s. SOUTH INDIA CEMENTS LIMITED (SICL), has commissioned aCement Plant in the year 1985-86 with a cement production capacityof 0.066 Million Tonnes Per Annum (MTPA) and the required limestoneis met from captive mine i.e Malkhed Limestone Mine at the rate of0.12 MTPA near Malkhed Village, Sedam Taluk, Gulbarga District,Karnataka.

The cement plant was intermittently in operation up to 2005. Theplant became sick during August 1993 due to financial constraintsand accordingly registered with BIFR, New Delhi.

New resourceful management has associated with the promoters andtaken up revival of the existing plant operations. To make iteconomically viable, and considering the market demand, SICL hasproposed for enhancement of cement production capacity from 0.066MTPA to 1.00 MTPA to make plant viable.

For meeting this requirement SICL proposes to enhance the limestoneproduction from 0.12 MTPA to 1.45 MTPA from captive mine i.eMalkhed Limestone covering an extent of 64.73 ha (159.38 Acres).

The proposed activity is categorized as Category - A project as perEnvironmental Impact Assessment (EIA) Notification SO 1533, of 14-09-2006. It necessitates obtaining the Environmental Clearance fromMinistry of Environment and Forests (MoEF).

As per the requirement of EIA notification, SICL had submitted the



necessary application to MoEF for approval of Terms of Reference(TOR). MoEF has prescribed additional Terms of Reference to beincorporated in the EIA report vide letter no. J-11015/287/2011-IA.II(M) dated 18-07-2012

The subject Report is Risk Assessment Report which is part of FinalEIA Report and is being submitted as a separate report for uploadingon Website of MOEF

The limestone deposit in this area is massive in nature and ofsedimentary formation, without any overburden capping. Winning ofmineral and development of faces is done by mechanized opencastmining method with deephole drilling and blasting practices, usingheavy earth moving machinery for transporting the mineral from themine. The deposit being hard and compact, the bench height ismaintained at a maximum of 9-10 mts. and the sides are adequatelysloped or secured so as to prevent danger from fall of sides. The widthof the bench is maintained not less than 25 mts. The overall pit slopeof 450 shall be maintained, to avoid collapse or fall of sides duringpost mining period. The periphery of the working pit would be fencedwith barbed wire, of suitable spacing as specified by the circularsissued by Directorate- General of Mines Safety. The fencing shall bechecked inspected by the competent persons to avoid unauthorizedpersons entering into the Mine.

High risk accidents like subsidence, landslides, earth Quake, tailingdam failures etc are not existent/ associated in this kind of deposit. Incase of sudden irruption of fire in the machines to safe guard the menand machinery, an action plan called Emergency Plan/ DisasterManagement Plan prepared by the Manager of the Mine is as detailedbelow:

Disaster Management Plan (DMP) has been introduced as a tool fordealing with any serious event that might lead to great harm/damage,so as to attempt to minimize the consequences of such an event,prevent loss of life, avoid consequential damage, localize theeffects/prevent them from spreading to the immediate neighbourhood,etc. In order to ensure that the DMP is effective, Risk ManagementPlan, involving the following is formulated and implemented.

1. Risk identification, Risk evaluation2. Risk assessment and prioritization3. Risk Controls.4. Auditing of the system



2.0 RISK IDENTIFICATION

The first step in Disaster management is the risk identification. All theactivities having potential for exposure to such risks were identified,under the following elements-

PEOPLE : Occupational health & safetyEQUIPMENT : Equipment / property damageMATERIAL : Resource depletion / resource wastageENVIRONMENT : Air pollution, water pollution, land contamination,

noise pollution, house keeping

The identification was done based on: Inventory of activities, trades & tasks List of critical equipments & processes Study of past accidents, break downs, near-misses Experiences of concerned persons Experiences of neighbouring mines Incidents mentioned in various circulars issued by Statutory

agencies

The mining operations at this mine have been classified as follows:1. Preparation of drilling area and marking of blast-holes2. Primary drilling3. Sampling and testing blast hole cuttings4. Blasting

3.0 RISK EVALUATION

The risks identified are evaluated to judge their relative importance orsignificance on the different elements detailed earlier. This evaluationof impact was done under 3 conditions, which are the combination ofcertain criteria with scores. These conditions are

Normal operating condition: These conditions, which exist as aresult of routine operations according to normal operating procedure.Ex. Dripping of oil from connecting flanges while unloading HSD.

Abnormal operating conditions: Those conditions which exists as aresult of non-routine operations or unforeseen happenings.Breakdowns and start and stop situations are considered as abnormalcondition.

Emergency conditions: Accidents, fire, explosion, etc. are consideredpotential emergency situation. A five component rating scale has beenevolved using the following evaluation criteria.



i) Legislation ii) Impact iii) Occurrence iv) Control v) Detection

4.0 RISK ASSESSMENT & PRIORITIZATION

A quantification method was evolved using a simple 3 level scale of1,2,3. Suitable explanation for each level under each criteria is givenbelow. The rating is done on a 5-component scale as detailed above.

RATING SCALE

Normal, Abnormal & Emergency conditions :A. Legislation

scorecriteria

B. Impact score criteria C. Occurrencescore criteria

Y. Meetinglegislation

N. Not meetingLegislation

NA.NoLegislation

1. Fatal or permanentdisabling injury / accidentor loss of body part / longterm health effects.2. Medical aid injury ortemporary disability orshort term health effects.3. First aid injury/slightinj- jury, temporary healtheffects

3. Several times aday or continuous

2. once a day

1. Once a month orless frequent

D. Controls score criteria E. Detection score criteria3. Absence of effectivecontrols.2. Mechanism in place butnot

possible.1. Available & effective

3. Above 8 hours.2. Between 1 & 8 hours.

1. Immediately

Formulae : Total score (F) = B X C X D X E

5.0 RISK CONTROLS

After identification of critical risks, controls were imposed through 3possible alternatives, namely

Termination : Termination of the risks by such activities, that theycease to exist. Usually these are specific actions that can beimplemented in short term. Examples are securing a ladder on theground, which was initially kept unsecured.

Treatment : Improvement can be achieved through treatment ofcritical risks associated with different activities, through formulation



and implementation of performance improvement programmes asdetailed below

Sl.No.

Programme

01 Usage of cage for tyre inflation02 Traffic signals & road dividers in mines roads03 Reduction of sharp turns in mine haul roads04 Procurement of the fire fighting system for HEMM05 Modification of coupling guards, providing of safety meshes

near conveyors, toe guards in conveyor gallery, plat-forms,ladders & hand rails

06 Development of plantation07 Formulation of code of practice for hired trucks

Tolerance : Toleration was inevitable, wherever risks were not easilyamenable for performance improvements, or improvementprogrammes could not be taken up on account of non-availability ofresources. However, such activities are carried out so as to maintainpresent level of performance.

Deployment of hired equipment, and treatment of their operatingpersonnel:

(A)The personnel operating the hired equipment are -

1. Imparted Initial (basic) and refresher training2. Provided Personnel Protective Equipment3. Not allowed to work beyond normal working periods.4. Subjected to Periodical medical examination

(B) The hired equipment is maintained in good working order asfollows:

1. Daily inspection of machine by competent engineer to ensure safetyof the machine.2. Regular inspection and prompt supervision3. Reliability of machines are maintained

6.0 RISK – BASED AUDITING

Risk assessment facilitates appropriate attention of the managementfor higher risk items, in terms of treatment, planning, Monitoringand/or auditing.



Risk based auditing is a strategy to establish the amount of auditingrequired based on the risk priority and level of existing controls. It isimperative that if control risk are high (ie. inadequate or partialexisting controls) and inherent risks are high (ie. significant and highrisks) then only a low detection risk can be tolerated (ie. Extremeamount of auditing is required). All high risks require an extremeamount of auditing.

Risk control action plan:

The control effort and urgency in proportion to risk tolerance isdecided as given in the table below:

RISKLEVEL

ACTION AND TIME SCALE

Trivial No action is required.Tolerable No additional controls are required; consideration may

be given to more cost-effective solutions orimprovements that impose additional cost burden.Monitoring is required to ensure that controls aremaintained.

Moderate Efforts should be made to reduce the risk, but the costof prevention should be care fully measured andlimited risk reduction measures should beimplemented.

Substantial Work should not be started until the risk has beenreduced. Considerable resources may have to beallocated to reduce the risk. When the risk involveswork in progress, urgent action should be taken.

Intolerable Work should not be started or continued until the riskhas been reduced. If it is not possible to reduce therisk even with unlimited resources, work has to remainprohibited.



GUIDANCE MODEL DEVELOPED FOR IDENTIFICATION HAZARDSIdentify Hazards

Remove Hazard Stop Assessment

Has control measure created new hazard?

Evaluate the most important consequences

Evaluate risk Do precautions meet legal standards?

Is risk acceptable? Implement plan to reduce risk (control

Review periodically and if ever changes occur

No

Yes

No

Yes

No

Yes

measure)

ACTIVITY WISE RISK ASSESSMENTSl.No.

Activity/hazard

Persons atrisk

Risk Existingcontrolmeasure

s

Likely-hood

ofharm

Severityof harm

Risk level

01 Drillingoperations

Drillers andhelpers

1) Noisegeneration2) Slipperyofaccessories3) Injurywhilehandling

accessories

Adequate

Unlikely

Slightlyharmful

Trivial

02 Handlingofexplosives

1) Blastersand helpers2)Surrounding employeesand if publicdwell-ingsare nearby

1) Noisegeneration& air blast2) Groundvibration3) Flyingfragments4) Impropersheltering5) Straycurrents &lightening

Adequate

Unlikely

Extremelyharmful

Substantial



Sl.No.

Activity/hazard

Persons atrisk


s

Likely-hood

ofharm

Severityof harm

Risk level

03 Machines Operators,mechanicsand helpers

1)Mechanical2) Hydraulic3) Auto-electrical4)Operational5)Maintenance6) Safety &housekeeping

Adequate

Unlikely

Slightlyharmful

Tolerable

04 Electrical Electrician,wiremen andhelpers

1) Directcontact withlive circuit2)Formationof anelectric arc3) Fire4) Defectiveinstallation5) Defectivemaintenance6)Unauthorizedinterference

Adequate

Unlikely

Extremelyharmful

Substantial

05 Gascuttingandweldingwork

Welders andhelpers

1) Eyedamage2) Skininjuries3) Burns4)Inhalationof toxicgases5) Electricalshock

Adequate

Unlikely

Extremelyharmful

Substantial

06 Excavator,loadingequipmentoperation

Operatorsand helpers

1)Unauthorized operation2) Swingover cabinof trucks3) Undercutting inface4) Not using

Adequate

Unlikely

Slightlyharmful

Trivial



Sl.No.

Activity/hazard

Persons atrisk


s

Likely-hood

ofharm

Severityof harm

Risk level

safetydevices5) Startingwithoutwarning

07 Haulingequipments

Operators,helpers andco-workers

1)Unauthorized operation2) Operatingat unsafespeed3) Makingsafetydevices

inoperative4) Not usingsafetydevices5) Usingunsafeequipment6)Unauthorized riding

Adequate

Unlikely

Moreharmful

Moderate

7.0 EMERGENCY MANAGEMENT PROGRAMS

Managing emergencies is integral to risk management. Whileinherently safe design, operational practices, maintenance proceduresand monitoring activities cover the prevention of emergencies,emergency response planning and emergency preparedness are part ofmining activities. An emergency prepared ness plan has beenformulated to deal with events likely to cause serious dislocation ofwork, loss of property, production, human life, and generaldeterioration in the levels of morale of the employees.

EMERGENCY PLAN OF THE MINE

The emergency plan of this mine encompasses the following areasrequiring attention of the “Emergency Organization” constituted forthe purpose.

Effective communication Medical aid Law & order



Public relation Control measures Rescue or recovery work Industrial relations

The following are the guidelines for the Emergency Plan:

a) The duties and responsibilities of each mine official are clearly speltout.

b) Each member is trained to be thorough in their respective dutiesand responsibilities, in order to avoid any confusion in thedischarge of the same.

c) Tools and tackles that are required in the emergency are arrangedproperly and systematically.

d) The Emergency Plans and the system to be followed in case ofemergency are displayed on the notice board of the Mine Office andat places frequented by the employees.

e) Mock drills are conducted once every six months, to ensure that (i)there are no shortcomings in the plan and (ii) there are no teethingproblems in its execution.

f) The standard operating procedure in the local vernacular is issuedto all the employees so as to create awareness in order to functioneffectively in an emergency.

Accordingly, in case of any emergency, for instantaneous response,the following procedures are followed to control and deal effectivelywith the situation.

Information is given to the key persons (senior level) and to Lower levelpersonnel, whose services are needed in that situation, in theorganization, to enable them to arrange rescue / recovery.

Asst Mangers are the shift in charges and responsible for the safety ofindividual shifts.

The details of nearest Police station, Hospital and Fire station and thecontact details are as under.

Police Station: Location: Sedam

Hospital: Location: Sedam

Fire Station: Location is Gulbarga

To carry out/ implement the above responsibilities the Mines Dept hasemployed required staff and executives which will be strengthened



further. The organizational structure to control emergencies is asfollows:

Mines manager:• After assessing the situation , implement the emergency plan• Sound emergency siren to alert and call all mines officials• Arrange for withdrawal of men and machines from the affected

area• Proceed to control room and establish action groups , distribute

duty cards and clarify doubts , if any• Organize relief and medical facilities• Arrange for rescue teams

8.0 TRAINING

The training of mine personnel will be conducted regularly withrespect to environmental protection. Training facilities are envisagedin the cement plant and the same will be extended to mine staff too.

Documents

INCREASE OF LIMESTONE PRODUCTION FROM 0.12 MTPA to …environmentclearance.nic.in/writereaddata/online/... · proposed for enhancement of cement production capacity from 0.066 MTPA