RISK ASSESSMENT 1.0 Hazard

In practical terms, hazard identification is a thorough look at the workplace and processes to

identify those things, situations, processes that may cause harm, particularly to the working

force and nearby population. After identification of the potential hazards, one has to evaluate

it potential to cause harm and then decide what type of control measures shall be taken to

control it from the happening. Hazard identification is very important tool as it is integral

part of a good occupational health and safety management plan. The aim of the hazard

identification process is to reduce level of risk by taking precautions or initiating control

during project execution. The various hazard analysis techniques that may be applied are

Hazard and Operability (HAZOP) studies, Fault – Tree Analysis (FTA), event –tree analysis

and failure and effects mode analysis.

1.1 Hazard Identification & Risk Assessment (HIRA)

The purpose of a Hazard Identification and Risk Assessment (HIRA) is to understand what

risks or threats to public safety, property or the environment exist

Figure 7.1 : Hazard Identification & Risk Assessment (HIRA) process

Hazard Identification and Risk Assessment (HIRA) Process,

Identification of hazards

Analyze or evaluate the risk associated with the hazards

Determine appropriate ways to eliminate or control the hazards

Evaluate the likelihood of an injury or illness occurring, and its severity

Review of all available health and safety information about the hazard including MSDS,

manufacturer’s literature, information from organizations and results of testing

Identify actions necessary to eliminate or control the risk

Monitoring to confirm the risk is controlled

Keep any documentation or records that may be necessary. Documentation may include

detailing the process used to assess the risk, outlining any evaluations, or detailing how

conclusions were made.

1.2 Identification Hazard

Details of major anticipated risks from the Hazards is given in Table 7.1

Table 7.1: Hazards of the proposed plant

Sr. No.

Name Description Severity Hazard

1. Transportations of raw

material

Molasses Major Exposure

Yeast, urea Minor Exposure & inhalation

Sulphuric Acid, Di ammonium Phosphate,

Anti- foam reagent,

Caustic soda

Major Exposure & inhalation

2. Storage of Molasses

Products and

byproducts

Molasses, RS/ ENA/

Technical Alcohol,

fusel oil

Major Explosion, Fire

3. Manufacturing process

Fermentation Major Fire

Distillation Unit Major Heat & fire

Power Plant Major Heat fire &

electrocution 4. Utilities D.G set, Boiler, Turbine Major Heat, fire &

electrocution

5. Other accidents Leakages from the vessels, Catastrophic

rupture of

pressure vessels

and Storage Tanks

Major Exposure & fire

1.3 Risk Assessment

Risk analysis deals with the identification and quantification of risks, the plant equivalent

and personnel are exposed to, due to accidents resulting from the hazards present in the

factory. Risk classification table is given in Table 7.2.

Table 7.2: Risk classification and score table

1.4 Potential risk and mitigation measures for during construction phase

Risk impact and mitigation measures during construction phase are describes in Table 7.3

Table 7.3: Risk Impact and rating matrix during construction phase

Activity Associated

Hazards

Health impact Risk

rating

Proposed mitigation

and control measures

Site Leveling Vehicular

movement,

Insect / snake

bite

Physical injury,

and organ

damage

M Providing PPEs to

workers

Appointing the qualified

persons for the

particular job.

Speed limit control

Providing Training

Loading and

Unloading of

material

Accidents Physical Injury M Providing PPEs to

workers

Training to workers

Excavation Falling

objects or

objects near an

excavation

Slips, trips,

and falls

Property Loss

Physical injury

M Work Permit System

will be followed.

Excavated material

will be stacked safely.

Area will be

barricaded

Training to workers

PPEs will be provided

Construction Structure

may fall down

Workers may

fall down

from the

height.

Physical Injury

Physically

handicapped

Property

Loss

H Work Permit System

will be followed.

Height work permit

will be issued to the

person.

Safety belt will be

provided to workers

Training to workers

Cutting and

Welding

Fire or explosion

Electric

shock from

electrical

welding

Physical Injury

Burn Injury

Property loss

H Standards Work

Procedure

Training will be

provided

Proper PPEs will be

Provided.

Regular monitoring of

electrical equipment’s

to avoid loose

connection

Area will be

barricaded

Installation

of

Machineries.

Structure

may collapse

Property loss

Physical Injury

M Only authorized

person will operate

the machine

Appropriate

platform will be

designed as per the

load bearing

calculation.

1.5 Potential risk and mitigation measures during operation phase

1.5.1 Boiler Operation

The potential risk and its mitigation measures for Boiler operation is given in Table 7.4.

Table 7.4: Risk Impact and rating matrix for Boiler operation

Activity Associated

Hazards

Health impact Risk

rating

Proposed mitigation

and control measures

Working near

Boiler

High noise Noise induced

hearing loss

M Required PPEs need to

be used PPEs

Boiler

maintenance

Mechanical

hazard

Physical

injury

M Regular monitoring

for checking leakages

Individual vigilance

and proper training to

worker for proper

handling

Provision of First aid

box

High Pressure

Steam

Explosion Risk of

severe

injury, damage

to equipment

H Required PPEs

Good housekeeping

Regular monitoring of

the storage facility

Flammable

chemicals stored away

from the source of

ignition

Firefighting facility

Provision of First aid

Box

Incomplete

Combustion

Asphyxiation

from carbon

monoxide

Possible

fatality

H Online CO monitors

Regular checking of

workplace

Individual alertness

and precaution

Maintenance

work

Slips, Trips

and Falls

Physical

injury

M PPEs Individual

alertness and

precaution

Electrical

maintenance

work

Electricity Electric

shock,

Possible

burns

H Regular checking

and maintenance

of electrical units PPEs

Provision of First aid

box

Maintenance

of burner

Burn injury Severe

Physical

injury or

burn

M PPES will be provided.

Work will be carried out

under proper

supervision.

Follow of SOPs.

Individual alertness

and precaution is

important

Provision of First aid box

1.6 Risk during D.G. set operation

Table 7.5:

Risk Impact and rating matrix for D.G. set operation

Activity Associated

Hazards

Health impact Risk

rating

Proposed mitigation

and control measures

Working

near DG

High noise Noise induced

hearing loss

M Use of PPEs

Acoustic enclosure

Maintenance Fire Burns,

Serious injury

H Restricted Entry

Use of flame proof

fittings

Use of PPEs

HSD Storage Leakage /

Fire

Risk of severe

physical

injury and

burn

H Storage will be away

from ignition source

Regular monitoring to

check the leakages and

spillages

Firefighting facility

will be provided

PPEs will be provided

First aid box

DG set

maintenance

Mechanical

Hazard

Physical injury M PPEs

Leakage and heat

in the joint will be

checked before

maintenance

First aid box at

approachable place

1.7 Hazard & associated Risk of storage and handling of raw material

Impact matric for risk associated with storage and handling of material is given in Table 7.6.

Grain and alcohol storage Tanks details are given in Table 7.8. Material safety data sheets

for Chemicals are enclosed as Annexures.

Table 7.6: Impact matrix of Storage and handling of raw material

Activity Associated

Hazards

Health impact Risk

rating

Proposed mitigation

and control measures

Storage,

handling,

loading &

Unloading of

material

Exposure,

leakage,

Fire,

Explosion

Physical Injury,

burn, Eye

irritation and

respiratory

problem

H Provision of Eye wash

Inspection and

regular monitoring of

storage area.

Training to Workers

for proper handling

PPEs will be provided

as Nose mask, Hand

gloves.

Proper system for

loading operation to

prevents spillage

Provision of level

indicators for storage

Tanks

Spill kit for Acid and

other chemicals

Proper ventilation

First Aid boxes

Transportation Fire, accident,

leakage

Burns, Serious

injury

H Fire fighting

Training to driver

MSDS

Trem Card

First Aid Box

1.8 Hazard & associated Risk of Molasses storage tank

Molasses can ferment if excessive moisture contamination is allowed. Fermentation can

yield carbon dioxide with possible traces of ethanol or volatile fatty acids (e.g. acetic,

propionic, lactic, or butyric) and if exposed to a spark or flame may result in an explosion.

Fermentation may also occur in dilute surface layers formed by condensation from the

headspace above the liquid.

Table 7.7: Impact matrix of storage of molasses

Activity Associated

Hazards

Health impact Risk

rating

Proposed mitigation

and control measures

Storage and

Handling

Explosion May cause slight

irritation

May cause irritation

H Proper ventilation

shall be provided

Inspection and

regular monitoring of

storage area

Training to Workers

for proper handling

PPEs will be provided

as Nose mask, Hand

gloves.

Provision of level

indicators for storage

Tanks.

If causes eye irritation

wash area with soap,

flood eye with water

and water

1.9 Risk associated with alcohol storage and its mitigation measures

Material Safety Data Sheet (MSDS) for ethyl alcohol is enclosed as Annexure. Impact matric of

risk associated with storage and transportation of alcohol along with control and mitigation

measures are given in Table 7.9.

Table 7.9: Impact matric of risk associated Alcohol storage

Activity Associated

Hazards

Health impact Risk

rating

Proposed mitigation

and control measures

Storage

of Alcohol

Exposure,

inhalation,

ingestion &

Fire

Exposure to over

1000 ppm may

cause headache,

drowsiness and

lassitude, loss of

appetite, and

inability to

concentrate. Throat

Irritation

Ingestion causes

depression of

central nervous

system, nausea,

vomiting, and

diarrhea

H Storage

Storage will be

away from process

area with well-

ventilation.

Avoid all possible

sources of ignition like

spark or flame.

Use spark/flame

proof hand tools

Electrical wiring will

be flame proof type

Based on the

leakage quantity,

wiped out with or

Liquid or vapor

may cause eye and

skin irritation

Burn injury

dilute by spraying the

water to suppress the

vapors

Control measures in

case of over exposure

If victim is

conscious and able

to swallow, then give

water or milk to drink

to dilute the contents

in the stomach

Look out for

medical help

Skin or Eye exposure

Immediately flush

affected area with plenty

of water. Eyes should be

flushed for at least 15

Minutes with water.

PPEs will be provided to

avoid exposure.

1.10 Risk associated with work area of distillation

Table 7.10: Impact matric of risk associated distillation area

Sr.

No.

Activity Associated

Hazards

Health

impact

Risk

rating

Proposed Control and

mitigation measures

1. Working near

Distillation

column

Heat & Fire Physical

injury &

burning

H PPEs

Firefighting facility

First aid box

Periodic checking of all

parts

1.11 Safety Measures Recommendation

1.11.1 Storage and material handling area

Proper ventilation shall be provided

Area will be marked as “No smoking Zone”

Use of proper PPEs

Pressure relief valves shall be provided

Provision of Safety valves and rupture disk

Provision of fire hydrant system along with other portable fire extinguishers

Adequate distance between the storage Tanks

Provision of dyke wall to the Tanks

Proper earthing to the Tanks

1.11.2 Reactor Safety

Provision will be made for temperature & pressure indicators

Heating & cooling Jacket will be provided to maintain the temperature

Pressure switch with hooter shall be provided

Pressure safety valve will be provided

Double earthing shall be provided

1.11.3 DG Sets

Acoustic enclosures to be provided

Entry near the unit shall be restricted

Qualified and highly trained engineers shall be appointed

1.11.4 Boiler

Work permit system will be evolved and will be followed during maintenance work

Proper ventilation shall be maintained

Entry shall be allowed only after proper checking of gases, if any

Worker should be trained properly

Working should be under supervision of qualified and trained personnel

1.11.5 Storage and Handling of Alcohol

Keeping away from oxidizers, heat and flames.

Avoidance of plastics, rubber and coatings in the storage area.

Cool, dry, and ventilated storage and closed containers.

Leakage should be washed out and diluted.

Regular monitoring and maintenance to avoid leakages.

If major leakage in tanks can be mitigated by transferring the material to other tank.

Transfer the material to other tank.

Grounding of the container and transferring of equipment to eliminate static electric sparks.

In case of any emergency following measures would be taken:

First Aid Measures

Use of extinguishing media surrounding the fire as water, dry chemicals (BC or ABC powder)

sand, dolomite, etc

Foam system for firefighting will be provided to control fire from the alcohol storage tank.

The foam thus produced will suppress fire by separating the fuel from the air (oxygen), and

hence avoiding the fire and explosion to occur in the tank. Foam would blanket the fuel surface

smothering the fire. The fuel will also be cooled by the water content of the foam. The foam

blanket suppresses the release of flammable vapors that can mix with the air.

Special Fire Fighting Procedures; Keeping the fire upwind. Shutting down of all possible

sources of ignition, keeping of run-off water out of sewers and water sources. Avoidance of

water in straight hose stream which will scatter and spread fire. Use of spray or fog nozzles

will be promoted, cool containers will be exposed to flames with water from the side until

well after the fire is out.

1.11.6 Molasses storage

Store in good quality ventilated and leak-proof tanks (mild steel, stainless steel,

polyethylene, PVC) at ambient temperatures, out of moisture.

Continuous mixing of molasses should be done.

If there is increase in temperature beyond 30˚C external cooling of tanks should be provided.

A temperature recorder should be provided to the tanks.

Avoid microbiological contamination or dilution with water.

Regular monitoring and maintenance to avoid leakages.

1.11.7 Building & workspace

Adequate space will be provided for equipment repair or removal

Equipment maintenance shops will be set up with appropriate safety provisions for hazards

associated with maintenance activities

Lightning protection will be provided

1.11.8 Electric items

Medium and high voltage cables will be completely enclosed

Electrical equipment will be grounded adequately

Wiring will be properly insulated, grounded, and non-exposed

Emergency shutoff switch, clearly labeled, at all machinery units will be provided

DG set will be provided as stand by source of power

Maintenance tools with insulated handles will be provided

1.11.9 Fire

The fire protection system is to provide for early detection, alarm, containment and

suppression of fires. The complete fire protection system will comprise of the following. Fire

hydrant network will be provided for firefighting in the entire project area along with

following firefighting equipment will be provided

Different type of Fire Extinguishers, Detectors and fire Alarm shall be provided

Fire hydrant system

Fire Tender with chemicals foam and required arrangement for firefighting to control the

fire from the alcohol storage

Foam system shall be contain aqueous film forming compound of 3 to 6% alcohol

resistance foam concentrated with ISI mark 4889

Water storage Tank exclusively for firefighting operation

Rubber mat will be used near panel area

Periodical training to the identified supervisors and Employees in the field of Firefighting and

safety

Emergency exits at specific locations and will be marked on the layout

Cautionary note, safety posters, stickers will be displayed at appropriate locations

First Aid boxes will be made available at appropriate locations

Emergency Control Center Provision shall be made to establish an Emergency Control Centre

(ECC) from which emergency operations are directed and coordinated. This center is

activated as soon as on–site emergency is declared. ECC is equipped with adequate

communication systems in the form of telephones (Emergency telephone numbers.) and

other equipment’s to allow unhampered organizations and other nearby facility personnel.

1.12 Disaster Management Plan

1.12.1 Definition

A major emergency in a works is one, which has the potential to cause serious injury or loss of life.

It may cause extensive damage to property and serious disruption both inside and outside the

works. It would normally require the assistance of emergency services to handle it effectively.

1.12.1 Scope

An important element of mitigation is emergency planning, i.e. identifying accident possibility,

assessing the consequences of such accidents and deciding on the emergency procedures, both on

site and off site that would need to be implemented in the event of an emergency.

Emergency planning is just one aspect of safety and cannot be considered in isolation from M/s

Orange Distillery & Beverages Pvt Ltd , molasses/grain based distillery, fully endorses this fact

and hence before starting to prepare the plan, works management will ensure that the necessary

standards, appropriate to safety legislation, are in place.

1.12.3 Objective

The overall objectives of the emergency plan will be:

To localize the emergency and, eliminate it; and

To minimize the effects of the accident on people and property.

Elimination will require prompt action by operations and works emergency staff using, for

example, fire–fighting equipment, water sprays etc.

Minimizing the effects may include rescue, first aid, evacuation, rehabilitation and giving

information promptly to people living nearby the project site.

1.12.4 Identification of Hazards

The following types of hazards may be identified at M/s Orange Distillery & Beverages Pvt Ltd,

molasses / grain based distillery:

Fire in Electric Panels, Oil room and Diesel storage.

Waste treatment processes.

Cleaning of Equipment’s and Tanks, which have held chemical substances.

To deal the above emergencies, the Emergency Plan is prepared.

1.12.5 Emergency Planning

1.12.5.1 General

Disaster Management Plan for an industrial unit is necessarily a combination of various actions

which are to be taken in a very short time but in a present sequence to deal effectively and

efficiently with any disaster, emergency or major accident with an aim to keep the loss of men,

material, plant/machinery etc. to the minimum.

The main functions of the Disaster Management Cell are to prepare a detailed Disaster

Management Plan, which includes:

Identification of various types of expected disaster depending upon the type of the industrial

unit.

Identification of various groups, agencies, departments etc. necessary for dealing with a

specific disaster effectively.

Preparation – by intensive training of relevant teams/groups within the organization to deal

with a specific disaster and keep them in readiness.

Establishment of an early detection system for the disaster.

Development of a reliable instant information/communication system.

Organization and mobilization of all the concerned departments/ organizations / groups and

agencies instantly when needed.

A major disaster that can be expected in this proposed distillery be due to fire.

1.12.5.2 Emergency Planning for Disaster due to Fire

Cable rooms, transformer, unit, auxiliary transformers, oil tanks, etc. within the plant are the likely

areas for which disaster management plan is to be made to deal with any eventuality of fire. Stores,

workshop, canteen and administrative building will be included.

1.12.5.3 Classification of Fire

Class (A)

Fire involving combustible materials like wood, paper, cloth and bagasse etc.

Class (B)

Fire due to liquid materials like oil, diesel, petroleum products and all inflammables.

Class (C)

Fires involving domestic and industrial gases like butane and propane etc.

Class (D)

Metal fires etc.

Class (E)

Electrical fires due to short circuiting etc.

1.12.6 Need of Establishing a Fire Fighting Group

A small spark of fire may result into loss of machines and the damage by fire may high economic

losses. This type of losses can be avoided by preventing and controlling the fire instantly for which

fire–fighting group will be established.

Establish which would house and keep in readiness, the following types of equipment and

arrangements.

CO2 extinguishers

Dry powder chemical extinguishers

Foam extinguishers

80 mm. spray hoses

Fire brigade

Fire hydrant

Protocol (chemical to combat oil fires).

In order to avoid fire in cable galleries, all the power and control cables of FRLS type (fire resistant

low smoke) will be used.

1.12.7 Inspection

Fire alarm panel (electrical) will cover the entire plant. The inspection group will periodically

inspect fire extinguishers in fire stations and machines and other places.

The groups will display emergency telephone number boards at vital points.

The group will regularly carry out general inspection for fire.

1.12.8 Procedure for Extinguishing Fire

The following steps will be taken during a fire accident in the system:

As soon as the message is received about fire, one of the systems will be diverted to the place

of the fire accident along with a staff member.

Simultaneously plant fire station will be informed by phone walkie for fire brigades and fire

stations of nearby area.

In the meanwhile, the pipe system will be operated to obtain maximum pressure on output.

In case cables are within the reach of fire, power supply will be tripped and the cables

shifted.

1.12.9 Fire Fighting with Water

Adequate and reliable arrangement is required for fighting the fire with water such as:

1. Provision for Fire brigade and Fire hydrant.

2. Arrangement of pipelines along and around all vulnerable areas.

3. Provision of valves at appropriate points to enable supply of water at the required place/area

or divert the same to another direction/pipe line.

4. Provision of overhead tanks which will be providing with the water during power failure and

it would work by the gravitational force.

1.12.10 Sources of Water for Fire Fighting

The following two sources of water have been considered for firefighting:

Overhead Tank

Raw Water Reservoir

1.12.11 Fire Fighting with Fire Extinguishers

To deal with fire – other than carbonaceous fires, which can be deal with by water – suitable fire

extinguishers are required to do the job effectively. It is therefore, necessary to keep adequate

number of extinguishers in readiness at easily approachable places. Adequate number of fire

stations would be installed. Further, other spray groups from the system will be diverted to the

spot.

In case of fire in the belt, belt will be cut near the burning portion to save the remaining parts.

After extinguishing the fire, the area will be well prepared for reuse.

1.13 On–Site Emergency Plan

1.13.1 Introduction

The views of the possible hazards that can arise out of the daily operations in the distillery plant,

various measures are adopted to prevent the occurrence of a major accident. This comprises of:

Built in safety measures, alarms, trips and interlocks etc.

Standard safe operating and maintenance procedures permit system etc.

Training of all the involved staff in normal and emergency operating procedures.

Training of all employees in safety, fire fighting and first aid.

However, in spite of these precautions, it is required to foresee situation of major accident and

plan for taking timely action to minimize the effects of such incident on the safety and health of

persons working in the plant as well as those living around the premises.

1.14 Preparation of Plan

1.14.1 Alarm System

A siren shall be provided under the control of Security office in the plant premises to give warning.

In case of emergencies this will be used on the instructions to shift in charge that is positioned

round the clock. The warning signal for emergency shall be as follows:

Emergency Siren: Waxing and waning sound for 3 minutes.

All clear signal: Continuous siren for one minute.

1.14.2 Communication

Walkies & Talkies are located at strategic locations; internal telephone system EPBX with

external P&T telephones would be provided.

1.15 Fire Protection System

1.15.1 Fire Fighting System

The fire protection system for the unit is to provide for early detection, alarm, containment and

suppression of fires. The fire detection and protection system has been planned to meet the above

objective an all–statutory and insurance requirement of Tariff Advisory Committee (TAC) of India.

The complete fire protection system will comprise of the following.

(a) Fire brigade

Automatic / manual fire detection & alarm system

(b) Fire Hydrant

Fire hydrant will be provided at all around in the plant as per TAC Norms.

(c) Portable fire extinguishers

Various areas of the plant will have one or more of the above system depending upon the

particular nature of risk involved in that area.

(d) Portable Chemical Fire Extinguishers

These are intended as a first line of defense, and hence will be stationed at strategic locations in

different buildings and also for outdoor facilities. Portable fire extinguishers will be foam type;

carbon dioxide type and multipurpose dry chemical (MPDC) type.

(e) Fire Detection and Alarm System

Fire detection and alarm system an effective means of detection, visual indication of fire location

and audible alarm of any fire at its incipient stage. This system will comprise fire alarm panels,

automatic fire detectors, manual call points and fire siren (hooter).

The main fire alarm panel will provide both visual and audible alarm of fire in any protected areas

of the plant.

Manual break glass type fire alarms will be provided at strategic locations where high hazards

exits.

Automatic fire detectors will be provided for coal handling areas and in plant areas such as control

rooms, switchgear rooms, cable galleries etc.

1.15.2 First Aid

A first aid centre with adequate facilities shall be provided. It shall be maintained round the clock

by a compounder cum dresser and a doctor. An Ambulance shall also be provided at site to carry

affected people to hospital.

1.15.3 Security

The security requirements of the company premises shall be taken care of by CSO assisted by a Fire

In charge. The team, apart from the normal security functions will manage the role required during

a disaster management operation as a part of the crisis control team.

1.15.4 Safety

The safety wing led by a Safety Manager will meet the requirement of emergencies round the clock.

The required safety appliances shall be distributed at different locations of the plant to meet any

eventualities. Poster/placards reflecting safety awareness will be placed at different locations in

the plant area.

1.15.5 Evacuation Procedure

As the major hazard is only due to fire, which has more or less localized impact no mass evacuation,

procedures are required. Evacuation would involve only the people working very close to the fire

area.

1.15.6 Emergency Control Center

Provision is made to establish an Emergency Control Centre (ECC) from which emergency

operations are directed and coordinated. This center is activated as soon as on–site emergency is

declared.

The ECC consists of one room, located in an area that offers minimal risk being directly exposed to

possible accidents.

During an emergency, the Emergency Management Staff, including the site controller will gather

in the ECC. Therefore, the ECC is equipped with adequate communication systems in the form of

telephones and other equipment to allow unhampered organizations and other nearby facility

personnel.

The ECC provides shelter to its occupants against the most common accidents; in addition, the

ECC’s communication systems are protected from possible shutdown. The ECC has its own

emergency lighting arrangement and electric communication systems operation.

Only a limited and prearranged number of people are admitted to the ECC, when in use. This

eliminates unnecessary interference and reduces confusion.

The ECC is always ready for operation and provided with the equipment and supplies necessary

during the emergency such as:

Updated copies of the On–site Disaster Management Plan.

Emergency telephone numbers.

The names, phone number, and address of external agencies, response organizations and

neighboring facilities.

The adequate number of telephone (more than two).

Emergency lights.

List of fire extinguishers with their type no. and location, capacity, etc.

Personal protective equipment.

Safety helmets – List of quantity & location.

Clock.

Status boards/message board.

Material safety data sheets for chemicals handled at the facility.

Several maps of the facility including drainage system for surrounding area showing:

Areas where hazardous materials are stored.

Plot plans of storage tanks, routes of pipelines, all water permanent lines etc.

The locations where personal protective equipment are stored.

The position of pumping stations and other water sources.

Roads and plant entrances.

Assembly areas.

Lay out of Hydrant lines.

1.15.7 Communication Equipment and Alarm Systems

This kind of equipment is absolutely vital for notifying accident; make the emergency known

both inside and outside of the facility, and coordinating, the response actions among the various

groups involved in response operations.

In particular, this equipment is used to communicate within the facility; communicate between

the facility and outside organizations; and inform the public.

Different communications systems can vary in effectiveness, depending on the task. The most

common types installed in the plant are given below.

1.15.8 Sirens

These are audible alarm systems commonly used in facilities. In case of any emergency siren will

be operated short intermittently for 1.5 minutes.

An alarm does more than just emergency warning. It also instructs people to carry out specific

assignments, such as reach to assembly point for further instructions and actions, or carry out

protective measures; this can be achieved only if the people are familiar with the alarm systems

and are trained to respond to it.

1.15.9 Personal Protective Equipment

This equipment is used mainly for three reasons; to protect personnel from a hazard while

performing rescue/accident control operations, to do maintenance and repair work under

hazardous conditions, and for escape purposes. The list of Personal Protective Equipment

provided at the facility and their locations are available in ECC.

Effective command and control accomplish these functions necessitates personal trained in this

On–site Disaster Management Plan with adequate facilities and equipment and equipment to

carry out their duties and functions.

1.15.10 Off- Site Emergency Preparedness Plan

The task of preparing the off- site emergency plan lies with the district collector. However the

off site plans will be prepared with the help of the local district authorities. The proposed plan

will be based on the following guidelines.

Plan of Co–Ordination

(A) Liaison with

1. External Authority:

Sub Divisional Officer (SDO)

Principal Medical Officer (PMO).

Dy. SP.

Fire Officer.

Local Panchayat Officials.

B.D.O.

External Agencies

Press.

Fire Station.

Police.

Medical.

Voluntary Organization.

Railway.

Roadways

Private Bus Services

(B) Making plan in advance By Management and External

Authorities/Agencies Govt. Hospital.

(C) Roll and Statutory duties of outside agencies.

Traffic Centre.

Assisting the Medical and Evacuation team.

Preventing unauthorised entry of personnel into the affected areas.

Control on lookers.

(D) Duties of Public Relation officer (PRO)

To keep liaison with Govt.

To publish/release news in the new papers.

(E) S.D.O.

To restore law & order.

To help in getting aid from other Administrative Authorities.

(F) Duties of Medical Officer

A full time Medical officer and he will discharge duties during any emergency.

He shall:

Send the adequate medical staff to the emergency operation center for ensuring immediate

medical attention.

Organise for transporting the injured to the hospitals wherein arrangements are made to

handle such emergencies. The nearby hospitals should be identified in advance.

Inform all the nearby hospitals of the situation and appraise them of the antidotes that would

be necessary for treatment, if any.

Make arrangements for requisitioning for extra ambulances for movement of the injured to

Hospital.

Ensure that records of blood group of all employees are easily accessible and enough blood

of the specific group is available for casualties.

(G) Duties of B.D.O. (Block Development Officer)

To control the spread of rumours.

(H) Declaring the Major Emergency

By putting notice on notice Board.

By publication in the News Papers.

Announcement by P.A. System in nearby villages.

1.15.11 Procedure for Testing & Updating the Plan

Simulated emergency preparedness exercises and mock fire fighting exercises including mutual

aid scheme resources and in conservation with district emergency authority to be carried out

time to time.

1.15.12 Disclosure of Information to Worker & Public Awareness System in Existence or

Anticipated

Safety awareness among workers by conserving various training programmes and Seminars,

competition, slogans etc.

Practical exercise.

Distribution and practices of safety Instructions. Safety Quiz contests.

Display of Safety Posters & Safety Slogans.

Developing Safety Instructions for every Job and ensuring these instructions/booklets or

manuals by the workers.

1.16 Occupational Health and Safety

Large industries, multifarious activities are involved during construction, erection, testing,

commissioning, operation & maintenance, the men, materials and machines are the basic inputs.

Along with the boons, the industrializations generally bring several problems one of them is

occupational health and safety.

The industrial planner, therefore, has to properly plan and take the steps to minimize the

impacts of industrialization and to ensure appropriate occupational health, safety including fire

plans. All these activities again may be classified under construction & erection, and operation &

maintenance. The proposed safety plan is given below:

1.16.1 Occupational Health

Occupational health needs attention both during construction & erection and operation &

maintenance phases. However, the problem varies both in magnitude and variety in the above

phases.

1.16.2 Construction & Erection

The Occupational health problems envisaged at this stage can mainly be due to constructional

accident and noise.

To overcome these hazards, in addition to arrangements to reduce it within TLV's personnel

protective equipments shall also need to be supplied to workers.

1.16.3 Operation and Maintenance

The problem of occupational health, in the operation and maintenance phase is hearing loss due

to noise. Suitable personnel protective equipments should be given to employees.

The working personnel be given the following appropriate personnel protective equipments.

Industrial Safety Helmet.

Crash Helmets.

Face shield with replacement acrylic vision.

Zero power plain goggles with cut type filters on both ends.

Zero power goggles with cut type filters on both sides and blue colour glasses.

Welder's equipment for eye & face protection.

Cylindrical type earplug.

Earmuffs.

Self Contained breathing apparatus.

Leather apron.

Aluminised fiberglass fix proximity suit with hood and gloves.

Boiler suit.

Safety belt/line man's safety belt.

Leather hand gloves.

Canvas cum leather hand gloves with leather palm.

Electrical safety shoes without steel tie.

Gum Boots.

1.17 Safety and Emergency Plan

Safety of both men and materials during construction and operation phases is of concern. The

preparedness of an industry for the occurrence of possible disasters is known as emergency

plan, which described as Disaster Management Plan (DMP) above. Safety requirement during

construction, operation and maintenance phases the safety policy with the following

regulations may be observed.

To allocate sufficient resources to maintain safe and healthy conditions of work.

To take steps to ensure that all known safety factors are taken into account in the design,

construction, operation and maintenance of plants, machinery and equipment.

To ensure that adequate safety instructions are given to all employees.

To provide wherever necessary protective equipment, safety appliances and clothing, and to

ensure their proper use.

To inform employees about materials, equipments or processes used in their work, which are

known to be potentially hazardous to health or safety.

To keep all operations and methods of work under regular review for making necessary

changes from the point of view of safety in the light of experience and aptitude knowledge.

To provide appropriate facilities for first aid and prompt treatment of injuries and illness at

work.

To provide appropriate instruction, training, retraining and supervision to employees in health

& safety, first aid and to ensure that adequate publicity is given to these matters.

To ensure proper implementation of fire prevention methods and an appropriate fire fighting

service together with training facilities for personnel involved in this service.

To ensure that professional advice is made available wherever potentially hazardous situations

exist or might arise.

To organize collection, analysis and presentation of data on accident, sickness and incident

involving personal injury or injury to health with a view to taking corrective, remedial and

preventive action.

To organize collection, analysis and preventive action.

To promote through the established machinery, joint consultation in health and safety matters

to ensure effective participation by all employees.

To publish/notify regulations, instructions and notices in the common language of employees.

To prepare separate safety rules for each types of occupation/processes involved in a project.

To ensure regular safety inspection by a competent person at suitable intervals of all buildings,

equipments, work places and operations.

In operation, the safety guidelines have to be framed in consultation with manufacturer's and

be implemented.

1.18 Safety Organization

1.18.1 Construction & Erection Phase

A Qualified and Experienced safety officer has to be posted. The responsibilities of the safety

Officers include identification of the hazardous condition and unsafe acts of workers and advise

on corrective ac action, organize training programmes and provide professional expert advice

on various issues related to occupational safety and health. He is also responsible to ensure

compliance of Safety Rules/Statutory provisions.

1.18..2 Operation & Maintenance Phase

When the construction is complete the posting of safety officers shall be in accordance with the

requirement of Factories Act and their duties and responsibilities shall be as defined thereof.

1.18.3 Safety Circle

In order to fully develop the capabilities in identification of hazardous processes and improving

safety and health, safety Circle would be constituted in each area of work. The circle would

consist of 4-5 employees from that area. The circle normally shall meet for about an hour every

week.

1.19 Health and Safety Monitoring Plan

All the potential occupational hazardous workplace such as chlorine storage area, acid and alkali

storage areas will be monitored regularly. The health of employees working in these areas will

be monitored once in a year for early detection of any ailment due to exposure to hazardous

chemicals.