chapter 8 risk and safety management · chapter-8: risk & safety management page | 8.1 chapter...

Gokul Agro Resources Ltd., Anjar

Environmental Impact Assessment Report Proposed Project for Manufacturing of Synthetic Organic Chemicals

Chapter-8: Risk & Safety Management

Page | 8.1

CHAPTER – 8 RISK AND SAFETY MANAGEMENT

8.1 INTRODUCTION

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 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.

The Risk Assessment Study for the proposed project of M/s. Gokul Agro Resources

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 project

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.

Confidences develop in employees by improving competency.

Preparedness and prompt response to deal with any accident.




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 expansion project is for the manufacturing of synthetic organic chemical

(various castor oil derivatives) which will require various raw materials as listed in

Annexure 17 with hazardous identification. Physical characteristic as well as

hazardous details of raw materials and products in form of MSDS are enclosed in

Annexure 18.

8.3.1 Hazardous Chemicals

None of the product are defined namely as hazardous in MSIHC rules but may fall

under the definition of hazardous material/chemicals either due to flammability or

toxicity especially the product in liquid form due to use of solvents. Many of the raw

materials to be required for manufacturing of the proposed products fall under the

definition of hazardous material/chemicals.

8.3.2 Safety Measures for Transportation, Storage & Handling

General safety measures for transportation, storage & handling are listed below.

Layout and location of hazardous chemical storage tank will be based on natural

and mechanical ventilation.

All the storage area for the hazardous chemicals will be provided with Dyke wall and

transferring pumps which will help to reduce the risk of tank leakages.

Spare barrels/tanks of sufficient quantity will be kept ready for any emergency spillage

or leakage.

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

and damaged drums will be separated and disposed to avoid the possibility of

catastrophic rupture.

Display Boards will be provided on all storage tanks which include the name of the

chemicals, storage Material of construction, Calibration of tanks and date of

Painting.

The level indicators will be placed on all storage tanks to know the exact liquid level

inside the tank and to avoid the accidental spillage or overflow.

Proper earthing will be provided to all storage tanks to prevent the firing due to static

charge.

Breather Valves and Flame arrestors will be provided on flammable liquid storage

tanks to prevent the firing.




Page | 8.4

All equipments related to hazardous chemical storage will be maintained and

calibrated regularly.

NRV provision will be made on all pump discharge line.

Drum trolley will be used for the movement of drums of hazardous chemicals to

avoid accident due to manual error.

SOP for handling will be displayed in local language for safe operating procedure.

Proper inventory of hazardous chemicals will be maintained and buffer stock will be

kept as minimum as possible.

Standard procedure for unloading will be in place and will be implemented for safe

unloading of road tanker.

Static earthing provision will be made for tanker unloading.

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

Water showering system (Automated sprinkling system) will be provided to the

flammable liquid storage tanks, wherever required to avoid the vaporization due to

increase in atmosphere temperature.

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

be provided as required.

Adequate firefighting system will be provided as required. Details of the same are

elaborated in Section 8.6.2.

First aids boxes will also be provided at prominent places in the plant.

Area will be declared as “NO SMOKE ZONE”.

Specific Safety measures for storage and handling of toxic chemicals like Methanol,

Ammonia and Hydrogen are given as follows.

8.3.2.1. Storage and handling of Methanol:

It will be labeled properly and kept in a cool and well-ventilated designated storage

areain a tightly closed container.

Proper earthing will be provided while handling

Firehydrant points and sand buckets will be provided in case of hazard

All possible sources of ignition will be avoided.

Contact with skin and eyes will be avoided by wearing suitable protective

equipments like gloves, lab coat, splash goggles, and vapor respirator.




Page | 8.5

8.3.2.2. Storage and handling of Ammonia

It will be labled properly and stored in a cool, well-ventilated and fire resistant area

in a tightly closed container. Outside or detached storage will be preferred.

Containers of liq. ammonia will be protected from physical damage and should be

separated from oxidizers, combustible materials, heat, sparks, and open flame.

Explosion proof electrical service will be installed in storage areas.

8.3.2.3. Storage and handling of Hydrogen

It will be stored in a well-protected, well-ventilated and dry area and separated from

combustible matierals.

Cylinders will never be allowed to reach a temperature exceeding 52 °C

Cylinders will be separated from oxygen cylinders or other oxidizers by a minimum

distance of 20 ft, or by a barrier of noncombustible material at least 5 ft.

Cylinders will be stored upright with valve protection cap in place and firmly secured

to prevent falling or being knowcked over.

Provision of suitable hand truck for movement of cylinder will be made to avoid

physical damage from rolling, sliding or dropping accidently.

It will be kept well away from all the possible sources of ignition and all electrical

equipments will be made explosion proof.

In order to avoid self-ignitaion of hydrogen, cylinder valve will only be opened after

connecting it.

Leakages will be checked with leak detection solutions, never with flames.

Object (e.g. wrench, screwdriver, nails etc.) will not be inserted into valve cap

openings, which may damage valve causing a leak to occur.

Piping and equipments will be adequately designed to withstand pressure to be

encounterd.

Check valve and other protective apparatures will be used in any line or piping from

the cylinder to prevent reverse flow.

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 must be provided within the process




Page | 8.6

technology/equipment itself. The details of the general critical safety measures for

process unit are as below;

Any reaction upsets will be confined to the reaction vessel itself as defined quantity

of charges of raw materials will be issued to the reaction vessel/Day tank by

metering pumps/load cells.

Process parameters control will be provided vide Standard Operating Procedures.

All reaction vents will be connected to either vapor condensers system or gaseoue

scrubber system.

Trained person will be engaged for handling of hazardous materials.

Proper safety precautions will be taken during handling of hazardous materials.

Further all the vessels will be examined periodically by a recognized competent

person.

All the vessels and equipments will be well earthed appropriately and well protected

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

been provided.

Temperature indicators will be provided near all reactor and distillation systems.

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

emergency preparedness plan will be displayed and conducted.

The details of specific safety measures for various process of the proposed units are

given below;

8.3.3.1. Reactor Charging

Charging of raw materials will be done in a reactor with mechanical Seal and

required safety devices.

Before process initiation, reactor will be checked for any leakages.

Runaway scenario is a quite common cause of accident. The proper

assessment by using reactivity and reaction data from laboratory experiments

or past experiences will be evaluated to prevent accidents due to runaway

reactions.

For avoiding direct contact of raw material, charging of raw material will be

done through permanent lines.




Page | 8.7

8.3.3.2. Hydrogenation

Reaction vessel will be equipped with pressure relief valve and frangible disk to

allow venting of vessel

Pressure and temperature of the reactor will be controlled so as to avoid high

pressure during hydrogenation.

If hydrogen is continuously fed into the reaction system, an excess flow valve will be

installed to prevent leakage.

An approved means of leak detection and an emergency shutoff or excess flow

control will be provided when using hydrogen gas in pressurized piping above a

guage pressure of 15 psi.

Handling of catalyst in the hydrogenation has risk associate with fire. Hence, solvent

will be added to the catalyst under nitrogen blanketing.

Charging of hydrogen into the reactor may pose a hazard. To overcome, transfer

reagents like ammonium format or hydrazine monohydrate will be used while

charging hydrogen

8.3.3.3. Sulfonation

Sulfonation reactor will be equipped with stirrer, glass lined or stainless steel

reaction vessel with a provision of heating & cooling to control the temperature of

the reaction between 70 – 80 °C.

Raw material will be first added to the reaction vessel and then sulfuric acid will be

added slowly over a period of several hours.

Since the reaction will be exhothermic, sulfuric acid addition rate will be determined

by the ability to remove heat of the reaction.

After completion of sulfonation reaction, sulfuric acid will be separated and will be

neutralized before sending it to effluent treatment.

8.3.3.4. Ethoxylation

Ethoxylation reaction mainly involves ethylene oxide as a reagent which is highly

toxic and reactive in nature. Hence, stainless steel will be used as MOC for reactor.

Flange gasket material used will be chosen so as to avoid reaction with ethylene

oxide and fire resistant.

To avoid ethylene oxide accumulation, agitation or circulation will be controlled

before allowing ethylene oxide injection. Ethylene oxide injection will be interrupted

in case of agitation failure.




Page | 8.8

Emergency relief vent will be provided for severe runaway reaction scenario.

8.3.3.5. Filtration

At the time of separating catalyst from crude product, there is a possibility of hot

vapour release or spillage of process material from filter or pipinig.

Trained personnel should be available during separation of process material.

Proper collection system should be available in order to avoid dropping of the

material on the floor.

8.3.3.6. Distillation

At the time of carrying out distillation of Crude product there will be possibility of organic

vapour release and spillage of crude material from the system.

Distillation column pressure and temperature data will be regularly monitoried and

assessment of properties of solvent will be evaluated to avoid fire/explosion

scenarios.

Loss of cooling media in the condenser system could lead to increase in

vapor/gases of distillate and rise in temperature and pressure could trigger

decomposition of substance in the column. Therefore, cooling media circulation will

be continuous monitored.

Loss of vaccum in the Colum could increase boiling point of the mixture and could

trigger decomposition in reboiler. To avoid vaccum loss vaccum and temperature

gauges will be monitored and caliberated at regular intervals.

8.3.3.7. Drying

Product material is cooled and passed in dryer where thermal energy is required to

convert slurry into dry cake formation. Depending on the temperature, the drying takes

place below the boiling point or at the boiling point of liquid to be removed.

Drying process will be carried out at particular temperature so as to avoid

generation of excess vapor from the crude product, which may be volatile in nature.

Temperature of the dyer will be monitored and maintanined so as to avoid

decomposition of finished product.

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:




Page | 8.9

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

Use proper PPE.

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

contents.

Keep proper and adequate fire extinguisher near work area.

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.

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

head.

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

fitness.

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

maintenance, strengthening of HSE, manufacturing utility staff for safety related

measures will be updated timely and will be made available to all concern department &

personnel.

8.3.5 Safety measures to prevent spillage / leakage of toxic chemicals

The preventive maintenance will be planned and carried out as per plan to avoid the

failure of valve, pipe lines and other component of transferring line. The spillage will be

confined to the dyke area underneath the vessel. The resultant splash of such

chemicals will result in exposure of toxic chemicals to employees. Facilities like Safety

shower and eye wash fountains will be provided in the plant area, which can be used to

decontaminate the affected employees. The followings are some measures to be taken

for handling the toxic chemicals safely;

Safety equipments like electric siren, safey shower etc. will be provided at various

places in plant and suitable personal protective equipment like splash goggles, gloves

and protective clothes are provided while handling the toxic chemicals

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

The piping will be examined thoroughly every year for finding out any defects; and a

defect will be removed forthwith. The record of such examination will be maintained.

Smoking will be prohibited inside the factory. Employees will be properly trained for

handling of toxic and corrosive chemicals.

All pipe joints will be provided with heavy duty gaskets to prevent any leakage.




Page | 8.10

Self breathing apparatus will be provided and workers will be trained about their use

also.

Dyke wall will be provided to the hazardous chemicals storage area.

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

leakage.

VOC detectors will be installed and LDAR program will be implemented.

8.4 OCCUPATIONAL HEALTH & SAFETY PROGRAM

The main effects of chemicals especially VOCs are anticipated in proposed project. No

other source of adverse effects on occupation health & safety is likely to occur.

However, MSDS of hazardous chemicals will be prepared & made available with the

management as well as concern personnel working with the materials or area likely to

be affected by the materials.

In general following are the key safety measure recommended for the proposed project.

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 proposed for regular monitoring of workplace air and

other conditions.

Establish the safety policy.

Provision of proximity suits and self- breathing apparatus.

Provision and compulsory use of necessary PPEs like helmate, safety goggles, face

mask, hand gloves and safety shoes etc. for all workers.

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.

Monitoring of occupational hazards like noise, ventilation, chemical exposure will be

carried out at frequent intervals.




Page | 8.11

Regular work place monitoring will be carried out as per details given in Section 6.2

of Chapter 6.

Provision of occupational health center (OHC) and part time qualified medical officer

as per factories act guidelines.

Pre medical checkup at the time of employment and regular medical check of

employees will be carried out as per details given in Section 6.2 of Chapter 6. Unit

will maintain all the records in Form 32 & 33 as per Factories Act guidelines. Copies

of health register (Form 32) and pre medical check up (Form 33) at the time of

employment is attached as Annexure 19.

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

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 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 and Government authority about various

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

be played by them in the event of emergency.




Page | 8.12

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 ofinjured

persons.

Matrix given in Figure 8.1 describes methodology adopted for Risk Assement study.

Figure 8.1: Risk Assessment Methodology

START

Facility, process and meteorological data collection

Listing out hazardous operations & storage details

Identification of failure scenarios & quantification of probable hazard associated for risk assessment

Defining parameters for each chemical and each hazard

Defining release type (continuous / instantaneous) & determine release rate

Simulation of different credible scenario for consequence modeling

Prepare Summary of Credible Scenario

Evaluate potential risk associated to the surrounding

Suggest mitigation measures for the risk associated

END




Page | 8.13

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 inventory 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.

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

road tanker. 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/ Catastrophic Failure and Its Mitigation

Measure

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




Page | 8.14

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. Flow chart given in Figure 8.2 is considered for

modeling various scenarios for accidental release of chemical.

Figure 8.2: Accidental release of chemical




Page | 8.15

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 5.4.6) of EPA.The details of software used for MCA analysis are

described below;

A computer based version ALOHA 5.4.6 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.

8.5.4 Consequences Analysis

From the proposed raw materials, chemicals listed in Table 8.1 have been taken for the

consequences analysis considering their hazardous / flammable / toxic nature. Details




Page | 8.16

of these chemicals in the form of MSDS are enclosed as Annexure 18. Storage details

and threshold value of these chemicals are mentioned in the Table 8.1.

Table-8.1: Storage details and Threshold Values of Hazardous Chemicals

Sr. No.

Name of Liquid

chemical

Details of Storage Unit

Maximum Storage Capacity

Storage Pressure &

Temp.

Threshold Value (ppm) IDLH Value (ppm) Type

Packing Size

AEGL-3 /PAC - 3

AEGL-2/ PAC-2

AEGL-1 /PAC-3

1. Ammonia Gas Cylinder 50 kg 6,000 kg Ambient 1,100 160 30 300

2. Ethylene

Diamine

HDPE

Drum 200 Lit 2,000 Lit Ambient 20 9.7 -- 1,000

3. Ethylene

Oxide Gas Cylinder 50 kg 500 kg Ambient 200 45 -- 800

4. Hydrogen Gas Cylinder 50 kg 2,000 kg Ambient 4,00,000 2,30,000 65,000 --

5. Methanol HDPE Tank

10,000 Lit 60,000 Lit Ambient 7,200 2,100 530 6,000

8.5.4.1 Definitions & Explanation of Terms Used

AEGL-1 : It 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,

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 : It 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,

could experience irreversible or other serious, long-lasting adverse health effects or

an impaired ability to escape.

AEGL-3 : It is the airborne concentration, expressed as parts per million (ppm) or milligrams

per cubic meter (mg/m3), 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.




Page | 8.17

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.

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

: If 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.

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)




Page | 8.18

Atmospheric conditions assumed at the time of accidents are mentioned in Table 8.2.

Table 8.2: Atmospheric Condition Assumed

Particulars Details

Wind 3.0 meters/second

Ground Roughness Urban

Cloud Cover 4 tenths

Air Temperature 32° C

Stability Class D

Relative Humidity 50%

Detailed Maximum Credible Accident scenarios for all the stored hazardous chemicals

are given in Annexure 20.

8.5.4.3 Summary of MCA Scenarios

Summary of different credible accident scenarios for prediction of risk are given in

Table 8.3.

Table 8.3: Summary of MCA Scenarios

Sr. No.

Hazardous Chemicals

SCENARIO A Toxic Threat Zone, m

*SCENARIO B Thermal Radiation from

pool fire, m

*SCENARIO C Thermal Radiation from Catastrophic Rupture, m

Red Orange Yellow Red Orange Yellow Red Orange Yellow

1 Ammonia (Gas)

73 194 451 -- -- -- -- -- --

2 Ethylene Diamine

56 84 -- -- -- -- 60 86 135

3 Ethylene Oxide

208 469 -- -- -- -- -- -- --

4 Hydrogen 11 14 28 -- -- -- -- -- --

5 Methanol <10 <10 19 <10 <10 <10 166 240 375

*THERMAL RADIATION INTENSITY RED: 10 kW/sq.m. (Potentially lethal within 60 sec) ORANGE: 5.0 kW/sq. m. (2nd Degree burn within 60 sec) YELLOW: 2.0 kW/sq. m. (Pain within 60 sec)

Maximum distance of toxic threat zone is observed at 469 m from leakage of

Ethylene Oxide, which is confined within the industrial zone.

Risk of thermal radiation from pool fire is confined to 10 m distance within project

premise.




Page | 8.19

Maximum distance of thermal radiation from catastrophic rupture is obverted at 375 m,

which is observed within the industrial zone.

Effects of toxic, flammable and explosive hazard have been worked out at a distance of

500 m in downwind direction and there is no toxic threat and thermal radiation from

catastrophic rupture is observed.

Nearest distance of human settlement at village Meghpar Borichi is 650 m from project

site. Hence, there will be no significant threat to human from toxic, flammable and

explosive hazard.

8.6 RISK MITIGATIVE MEASURES

Based on the risk assessment analysis following precautionary mitigation measures are

recommended for the proposed project.

The installation of all the equipment will be as per guidelines of provision of Gujarat

Factories Rule 1963.

Hazardous chemicals will be stored in small sized multiple containers so as to avoid

major hazard associated with large sized containers.

Proper Control of the operating parameters, mainly temperature, vacuums, cooling

media circulation, during plant operation and solvent recovery.

For any case of fire emergency, standard type of Fire fighing equipments and fire

extinguishers will be provided in the storage area as well as required places in the

plant.

Smoking will be prohibited inside the factory.

The adequate and suitable personnel protective equipments will be provide to the

operating workers.

First-Aid facility and First-aid trained person will be available at the time of handling

operation.

8.6.1 Emergency Management

Possible emergencies due to chemical spillage, fire in chemical storage areas, and

toxic gas release from storage of hazardous chemicals are elaborated in Table 8.4, 8.5

and Table 8.6.




Page | 8.20

Table 8.4: Possible Emergency - Spillage in chemical storage area (Spill Control Plan)

Location Scenario

considered Action by

Hazard Consequence

Possible Causes

Action to be taken Remedial measures to prevent recurrence of such incident

Chemical Storage area

Small spillage

Toxic vapour Exposure to drum handling operators.

Drum /Cylinder puncher or damage, wrong Storage method.

Find out drum leakage

Raise alarm immediately for warning if large spillage observed.

Do not enter in confined room if spillage is inside a confined room.

Do not touch any electrical switches in spillage area.

Stop all hot work in this area.

Call fire and Safety department.

Cordon the area.

Evacuate non essential persons from the affected area immediately.

Inform the area in-charge.

Try to control situation at department level with available resources with full PPEs.

Identify the spillage material and refer MSDS for control plan.

Segregate leakage drum from the area.

Inform the Site main Controller (SMC) in detail.

Open all doors and windows in this area.

Take decision to declare onsite emergency.

Spill control and neutralization team member try to control spread material in more area by absorbing material and dry sand.


FLP type light fittings shall be provided.

Proper ventilation shall be made available in Drum storage area.

Proper label and identification board stickers shall be provided in the storage area.

Proper inventory of hazardous chemicals should be maintained and buffer stock should be kept as minimum as possible.

Conductive drum pallets shall be provided.

Drum handling trolley / stackers/fork lift shall be used for drum handling.

Materials shall be stored as per its

Compatibility study and separate area shall be made available for flammable, corrosive and toxic chemical drums storage.

Dyke wall will be provided to area where hazardous chemicals will be stored.

Smoking and other spark, flame generating items shall be banned from the entry Gate.

NFPA labels shall be provided on

Large spillage

Fire in case of ignition source available within LEL-UEL % concentration




Page | 8.21

Location Scenario


Hazard Consequence

Possible Causes


If material is toxic or flammable, special precautions needs to be taken as per chemical expert Key person guide line.

Do not spray water or Foam on spilled material.

Do not drain spilled material in any trench.

Collect the spilled material in close container and send to ETP for further neutralization of the residual contents.

Administer first aid to the victim.

Make arrangement to send injured person/s to Hospital.

If off site emergency situation occur –Inform to following agencies Request for Mutual aiders, local authorities like – DISH office, Collectorate office, Disaster management cell, Police, fire brigade, nearby hospital, local GPCB office

drums for hazard identification of the chemicals.

Exhaust shall be provided at ground level in drum storage area.

Drum loading unloading procedures are prepared and implemented.

Liquid chemicals will be transferred by mechanical seal pump through closed pipeline.

Table 8.5: Possible Emergency - Fire in chemical storage area

Location Scenario


Hazard Consequence

Possible Causes



Small spillage

Fire in drum storage area

Drum leakage or damage,

Raise fire siren or shout Fire…Fire….Fire…

Evacuate the area immediately.

Inform the area incharge.


FLP type light fittings shall be Large BLEVE of drums




Page | 8.22

Location Scenario


Hazard Consequence

Possible Causes


spillage Improper storage Method. Ignition source like electrical source, Friction etc. BLEVE due to overpressure in drum

Inform Incident Controller in detail.

Call fire department immediately and help them in fire fighting.


If it is found uncontrollable condition by department level inform Site Main Controller for onsite emergency situation.

Declare on site emergency if required.

Remove unburned drums from the site if possible without any risk.

Start fire hydrant system or water hose rill and spray water on uninvolved drums in fire for cooling purpose.

Use foam fire extinguishers for firefighting of solvent fire.

Do not enter in fire prone area.

If fire found uncontrollable condition call fire brigade and mutual aider for help.

In case of BLEVE fire, immediate evacuate the area up to 50 meters of the area surrounding.

All hazardous activates stop at site.

Inform nearby company to remove hazardous material or inventory from the compound wall.

Ensure search and rescue and

provided.

Proper ventilation shall be made available in Drum storage area.

Proper label and identification board stickers shall be provided in the storage area.

Conductive drum pallets shall be provided.

Drum handling trolley / stackers/fork lift shall be used for drum handling.

Materials shall be stored as per its

Compatibility study and separate area shall be made available for flammable, corrosive and toxic chemical drums storage.

Smoking and other spark, flame generating items shall be banned from the entry Gate.

NFPA labels shall be provided on drums for hazard identification of the chemicals.

Exhaust shall be provided at ground level in drum storage area.

Drum loading unloading procedures are prepared and implemented.




Page | 8.23

Location Scenario


Hazard Consequence

Possible Causes


causalities receive attention.


Make arrangement to send injured person/s to Hospital and inform victim’s family.

If off site emergency situation occur –Inform to following agencies. Request for Mutual aiders, local authorities like – DISH office, Collectorate office, Disaster management cell, Police, fire brigade, nearby hospital, local GPCB office.

Table 8.6: Possible Emergency – Toxic Gas Release

Location Hazard Consequence

Possible Causes



Potential injury / fatality from large release

Toxic Gas Release Reactor / Heater Failure, Leakage in Process Line, Plugging of reactor outlet

Activate audio visual alarm

Evacuate the area immediately.

Inform the area incharge.

Inform Incident Controller in detail.

Call fire department immediately and help them in fire fighting.


If it is found uncontrollable condition by department level inform Site Main Controller for onsite emergency

Provide accurate gas monitoring system on site.

Minimize on-site storage

Develop procedure for tank inspection and maintenance

Develop purge system to remove gas to another tank.

Provide temperature control inside reactor with authomatic shut-down of gas flow to the reactor.

Design collection system to remove and purify/recycle or discard




Page | 8.24

Location Hazard Consequence

Possible Causes


situation.

Declare on site emergency if required.

All hazardous activates stop at site.

Inform nearby company to remove hazardous material or inventory from the compound wall.

Ensure search and rescue and causalities receive attention.


Make arrangement to send injured person/s to Hospital and inform victim’s family.

If off site emergency situation occur –Inform to following agencies. Request for Mutual aiders, local authorities like – DISH office, Collectorate office, Disaster management cell, Police, fire brigade, nearby hospital, local GPCB office.

unreacted gas.

Design control system to detect excess gases in exhaust and shut down gas flow.

Provide control system to detect extreme temperature variations and activate backup cooling system.

Diver flow to temporary storage tank

Provide relief valve on reactor with outlet to a temporary storage tank


Provide training to employees in the area.




Page | 8.25

8.6.2 Firefighting System

Adequate fire fighting system has been provided by the unit for existing plant for fire

fighting. Unit will establish similar type of fire fighting system for the proposed project

as described below.

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

and details of existing and proposed fire control equipments are given in Table 8.7

and 8.8.

Fire hydrant system is installed in the existing plant and details of fire hydrant

system are given in Table 8.9.

Separate underground fire water tank of 300 KL is provided with diesel driven pump

and Jockey Pump. Details of Fire water pump is given in Table 8.10

D.G. Sets are provided for emergency power.

Mock drill & training are scheduled and conducted at regular intervals.

Fire fighting team members are available at any time in the premises. Details of fire

fighting team members are given in Table 8.11

Nearest fire station is located at Emergency response center, near Rajvi hotel

railway corssing at a distance of approximate 3 km.

Table 8.7: Details of Fire Extinguishers for Existing Plant

Sr. No.

Area Location Type Of Fire Extinguisher

Capacity

1 BSS Gate Security Office ABC 5 KG

2 Store

Out Side ABC 5 KG

3 Inside ABC 5 KG

4 Lab

Out Side ABC 5 KG

5 Inside ABC 5 KG

6 On Lab First Floor

Out Side ABC 5 KG

7 Inside ABC 5 KG

8 Electrical Sub Station

Inside CO2 6.5 KG

9 Near L T Panel CO2 6.5 KG

10 D G Shed

Inside CO2 6.5 KG

11 Out Side ABC 5 KG

12 Lunch Room Out Side ABC 5 KG

13 Chemical Storage Tank Area

Caustice Tank Mech. Foam 50 LTR.

14 Sulphuric Tank Mech. Foam 50 LTR.

15 Hydrogen Unloading Area

Out Side CO2 6.5 KG

16 Near Bullet CO2 6.5 KG

17

Hydrogen Plant

Ground Floor Area ABC 5 KG

18 Ground Floor Area ABC 5 KG

19 Second Floor Area ABC 5 KG




Page | 8.26

Sr. No.


Capacity


21 Panel Room CO2 6.5 KG

22

12 HSA Plant



24 First Floor Area ABC 5 KG




28 Third Floor Area ABC 5 KG



31

Flaking Area








38

Finish Godown

Loading Point No.-1 ABC 5 KG

39 Loading Point No.-2 ABC 5 KG





44 Office Area ABC 5 KG

45 Fork Lift Parking CO2 6.5 KG

46 Weigh Bridge Office Outside ABC 5 KG

47 Security Office Office Outside ABC 5 KG

Summary

ABC 5 KG: 36 Nos.

CO2 6.5 KG: 9 Nos.

Mech. Foam 50 Lit.: 2 Nos.

Table 8.8: Details of Fire Extinguishers for Proposed Project

Sr. No.


Capacity

1 Store

Out Side ABC 4 KG

2 Inside ABC 4 KG

3 Lab

Out Side ABC 4 KG

4 Inside ABC 4 KG

5 On Lab First Floor Out Side ABC 4 KG

6 Transformer Room Inside CO2 4.5 KG

7 Electrical Sub Station

Out Side ABC 4 KG

8 Near L T Panel CO2 4.5 KG

9 D G Shed

Inside CO2 4.5 KG


11 Lunch Room Out Side ABC 4 KG




Page | 8.27

Sr. No.


Capacity

12 Chemical Storage Tank Area

Caustice Tank MEC. FOAM 50 LTR.

13 Sulphuric Tank MEC. FOAM 50 LTR.

14 Hydrogen Unloading Area

Out Side CO2 4.5 KG

15 Near Bullet CO2 4.5 KG

16

Hydrogen Plant





20 Panel Room CO2 4 KG

21

12 HSA Plant









29 Panel Room CO2 4 KG

30

Flaking Area




33 First Floor Near Panel CO2 4.5 KG



36

Finish Go-Down

Electrical Panel CO2 4.5 KG

37 Office Area ABC 4 KG

38 Fork Lift Parking ABC 4 KG

39 Electrical Panel CO2 4.5 KG

40 Weigh Bridge

Out Side ABC 4 KG


42 Security Office Out Side ABC 4 KG

Summary

ABC 6 KG: 30 Nos.

CO2 6.5 KG: 10 Nos.

Mech. Foam 50 Lit: 2 Nos.

Table 8.9: Details of Fire Hydrants for Existing Plant

Sr. No.

Location of Fire Hydrants At GRSL Unit

Sr. No.

Location of Fire Hydrants at Solvent Extraction Unit

1. Admin Nr. Temple 1. Nr. Boiler

2. Admin back side 2. Nr. Solvent Plant

3. Canteen 3. Soya Solvent Tank

4. Grass Godown Back Side 4. Soya Solvent Plant Nr. Cooling Tower

5. Cooling Tower Nr. Grass 5. Soya Solvent Plant Silo Side Godown




Page | 8.28

Sr. No.

Location of Fire Hydrants At GRSL Unit

Sr. No.

Location of Fire Hydrants at Solvent Extraction Unit

6. Packing Inside Loading Point 6. Soya Solvent Plant Silo Side

7. Packing front of Loading Point 7. Soya Solvent Plant Prep Side

8. Packing front of tanker Point 8. Soya Solvent Plant Prep Side

9. Packing Inside 9. Soya seed unloading

10. Packing front of tanker Point 10. New Godown Gate No.-1

11. Packing Ist Flour 11. New Godown Gate No.-2

12. Packing front of tanker Point 12. New Godown Gate No.-3

13. Front of Technical Office 13. New Godown Gate No.-4

14. P.B.D.O. 14. New Godown Gate No.-5

15. Hydrogen Unloading Point 15. New Godown Gate No.-6

16. Boiler Coal Yard 16. New Godown Gate No.-7

17. Instrument Office Back Side 17. D.O.C. Godown N/G. Side

18. Old Refinery Ground Flour 18. D.O.C. Godown Back Side

19. Old Refinery Ist Flour 19. D.O.C. Godown Gate No.-1

20. Old Refinery IINd Flour 20. D.O.C. Godown Gate No.-2

21. Old Refinery IIIrd Flour 21. D.O.C. Godown Gate No.-3

22. Nr. F. O. Tank 22. D.O.C. Godown Back Side

23. Old Refinery Back Side Nr. Cooling tower

23. Castor Solvent Main Gate

24. Tanker Yard Back side 24. Castor Solvent Hexane Tank

25. Tanker Yard Back Side 25. Castor Solvent Cooling Tower

26. Tanker Yard Back Side Nr. Scrap Yard 26. Castor Solvent S/T Tank

27. Tanker Point 27. Castor Solvent Ladder

28. Castor Solvent ETP

29. Castor Unloading near Silo

30. Oil Mill Backside

Table 8.10: Details of fire-water pump

S. No.

Item Location kW/HP Flow Line Pressure Make

Rated Max Low High Motor Pump

1 Main Pump GARL Refinery

55/75 172

m³/hr 183

m³/hr 2 Kg/cm²

Manual Off

CG Jhonson

2 Jockey Pump GARL Refinery

11/15 50

m³/hr 68

m³/hr 4 Kg/cm² 7 Kg/cm² CG Jhonson

3 DG Pump GARL Refinery

68/92 172

m³/hr 325

m³/hr Manual ON

Manual Off

Kirloskar Jhonson

4 Main Pump GARL SEP 55/75 172

m³/hr 183

m³/hr 2 Kg/cm²

Manual Off

CG Jhonson

5 Jockey Pump GARL SEP 11/15 50

m³/hr 68

m³/hr 4 Kg/cm² 7 Kg/cm² CG Jhonson

6 DG Pump GARL SEP 68/92 172

m³/hr 325

m³/hr Manual ON

Manual Off

Kirloskar Jhonson




Page | 8.29

Table 8.11: Details of fire-fighting team members

Sr. No.

Name of Team

Member

Employee No.

Department Sr. No.

Name of Team

Member

Employee No.

Department

1. Bhavesh Rathod

F0669 Electrical,

GRSL

19. R. P.

Bhadoriya F0919

SEP Prep & Plant 2. Harin

Chauhan F1184 20.

Shailandra Yadav

F0914

3. Rajesh Patel F0636 Stores 21. Popatsinh

Rathod F0501

Utility 4. Nilesh Motiwala

F1431 Instrument Department

22. Manoharsinh

D F0776

5. Dinesh Kachhadia

F0671 23. Devedra

Jhala F01158

6. Hitesh - Ammonia

Plant 24.

Mahendra Patel

F1617

Maintenance 7. Pankaj Patel F1328

Packing

25. Dilip Patel F1740

8. Suresh Prajapati

F1519 26. Pratik Patel T1591

9. Ashish Bhati T1621 27. D. C. Rajput F0712 Castor Seed Unloading

10. Mihirkumar Patel

F0845

Refinery IV

28. Golasingh

Rajput F1746

Cold Press 11. Rajkumar

navgode F3628 29. D. V. Rajput F1238

12. Govind Rajput F1367 30. Chirag Patel T0907 New Oil Mill

13. Roy Raju F1065

Pump House

31. Mahesh Thakor

F0738

Old Oil Mill 14. Piyush Patel F1704 32.

Kanuji Vaghela

F0744

15. Gajendra Sharma

T1631 33. Vishal Gupta F1365 Castor 400 TPD

16. Manish Yadav F1306

Refinery I & II

34. N. D. Jha F0789 Castor 600

TPD 17. Karamshibhai Desai

F0253 35. Padam Tomar

F1567

18. Rahul Pathak F1398

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:




Page | 8.30

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

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.

Following three staged activities suggested as they are co-related and provide

better points for emergency preparedness, emergency action and subsequent




Page | 8.31

follow up. Details of key personnel for on-site / off-site emergencies are given in Table

8.12.

Table 8.12: Responsible key personnel for on-site/off-site emergency

Sr. No.

Name & location of

plant

Telephone number

Person available on this phone

Name Designation

Designation or duty under on site / off site

emergency plan

Residence

Phone number

Address

1 Admin building

02836-295260 Ext - 105

Mr. Hitesh Thakkar

CEO Site main controller

9879112501

Gokul residency Opp. company

2 Technical Office

02836-295260 Ext - 157

Mr. S D Saraswat

G M Plant Dy. Site main controller

9879113764

Gokul duplex Opp. Company

3 Admin building

02836-295260 Ext - 113

Mr. Biren Kumar Dash

DGM HR Evacuate person to safe place

9879112480


4 Technical Office

02836-295260 Ext - 175

Mr. Ajay Mehta

Sr. Safety officer

Co coordinator 9879112471


5 Technical office

02836-295260 Ext - 174

Mr. Ashwin Patel

Sr. Mngr. Ele isolation 9879512567 Adipur Gandhidham

6 Technical office

02836-295260 Ext - 146

Mr. V P Singh

Dy. mngr Utility

Utility/ fire pump activation

9879112841


8 Technical office

02836-295260 Ext - 155

Mr. Rajesh Patel

Technical Eng.

Medical arrangement

9879114524


9 Store 02836-295260 Ext - 144

Mr. Rajendra Jadeja

Asst. Mngr. Rescue & fire fighting operation

9879113764 Adipur Gandhidham

10 Main gate 02836-295260 Ext - 101

Mr. Ajit Maheshwari

Sr. Security officer

Traffic controlling- transportation arrangement

9099999711 Anjar

8.7.1 Pre-emergency activity

The following are the details of Pre-emergency plan:

Internal Safety Survey

It is conducted by Safety department.

To identify various hazards in plant area.

To check protective equipment of workability.

To check various Safety installations.

To check fire fighting equipments, water shower etc.




Page | 8.32

To suggest extra modification required.

Third Party Survey

Experts of consultants conduct Third Party Survey.

To identify various hazards inside the factory.

To conduct survey on available Safety equipments.

To check built in safety system for its efficiency.

To suggest modification/new additions in the system.

Non-Destructive Testing (NDT)

To prepare a list of equipments / pipelines for non-Destructive testing.

To prepare a plan for replacements/repairs as per testing reports.

To maintain Plant wise record to compare with the last period.

Safety valve Testing

To prepare a lists in the plant.

To prepare a periodic schedule for their testing & maintaining record.

To prepare a plan for replacements/repairs.

Fire Fighting system Testing

To prepare a list of fire hydrants, Fire Fighting appliances, Fire water pumps and

other available appliances and maintain the record.

To plan for testing schedule.

To replace defective equipments/accessories.

To check fire water pumps capacity.

To check all fire fighting equipments/appliances under fire services for operability.

Mock drills

Internal mock drill is conducted for training the workers.

Periodic drills are conducted to check the performance of workers and equipments.

To know the draw backs/defects of the system and its corrective actions.

Training

To operate regular training of employees for handling various safety equipments.

To train workers for fire emergency.

To educate workers for different type of emergency.

Personal Protective Equipments (PPE)

To arrange for sufficient quantity of personal protective equipments.

To train workers to use each PPE.

To maintain them in good condition.




Page | 8.33

Communication

To maintain internal/external communication system in good working condition.

Main emergency siren is tested on every Monday at 12:30 PM

To modify the siren sound for emergency. In all type of main emergency siren is

wailing for 2 minutes.

To install wind-sacks to indicate wind direction.

Emergency Lights

To check and maintain the emergency lights in control room and selected areas.

To keep sufficient number of torches in supervisor’s cabin/plant and in each

department.

Emergency Control Room

To identify the place of emergency control room.

To identify the alternative emergency control room.

To keep sufficient quantity of PPE in control rooms.

To provide proper telephone system in emergency control room.

To provide plan of the factory showing hazardous points and emergency control

point in emergency control room.

Assembly Points

To identify the location for assembling the plant emergency staff and co-ordinate in

case of emergency. There are four assembly points marked in the existing plant.

To utilize the services of others to fix assembly points for non essential workers and

to assemble in case of emergency.

Liaison with State Authorities

To keep liaison with police, fire brigade, Factory Inspector, Collector, local hospital

and keep them informed.

To inform them about the requirement in advance.

To keep them informed about mock drills.

8.7.2 Emergency Time Activities

Under these activities, the staff in the plant at various levels with pre-assigned duties is

expected to work in a coordinated manner to meet emergency situation, remove the

emergency conditions and bring the plant to normal with the help of resources

available within and out side the plant. Availability and correct use of different means of




Page | 8.34

communication and control is an important time activity. Sequence of action in case of

various types of emergencies (Fire and Leakage of chemicals):

Any person noticing fire or explosion or leakage of chemicals from pipeline or other

equipment, should attract attention of nearby personnel by using or siren available

within premises.

The area is checked clear of people and organize emergency shut down of the

plant/ equipment.

The total quantity of chemical leaked is ascertained and discharge of Air pollutants

through stack is stopped.

Other persons in the area will help the injured persons to go out of the

place i.e. at open area and immediately arrange for first aid.

Simultaneously by Telephone he will contact the emergency control centre.

He will inform the Incident controllers and key personnel depending upon the nature

of emergency.

He will also guide the out side agency emergency aid services till the Incident

Controller/ Site Main Controller reaches to the site of Incident.

As soon as Incident controller/Site Main Controller reaches to the site of incident he

will take charge of the situation and guide/advice in tackling the emergency.

It is necessary to know that every one on the site should be accounted for and that

the relatives of causalities have been informed. As plant is small there is no

problem of accounting the personnel. It is necessary to have an up dated list of the

names of people at site on Holidays and weekly off days.

If the situation is not likely to be controlled by the available sources incident

controller/Site Main controller will assess the situation and declare the emergency

as “OFF SITE EMERGENCY”.

The incident controller/Site Main Controller will continue to do the available

resources to control and contain the emergency till the outside authorities and aid

services reaches to the incident site.

After District Authority reaches to the site, he will extend all the necessary help,

assistance and give required information/data as when required to control & contain

the emergency.

8.7.3 Post – Emergency Activities

A post-emergency base activity of steps taken after the emergency is over so as to

establish the reasons of the emergency and preventive measures to be taken.




Page | 8.35

The main steps involve:

Collection of records

Conducting inquiries and preventive measures.

Making Insurance claims

Inquiry reports and suggestions Implementations

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. Details of off-site

emergency control are given in Table 8.13.

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




Page | 8.36

Table 8.13: Details of off-site emergency contact

Sr. No.

Name/ Designation

Service Phone number

Office Residence

1 Emergency Service Fire, medical,

police 108 --

2 District collector All emergency 02832 - 250350 --

3 Factory inspector Factory related 02836 - 260020 260262

4 Chief fire authority Fire 02836 - 270178/76 270267

5 Dy. Sp – Mr. Chaudhari Police 02836 – 243254 M - 9925318111

--

6 Dist. Medical officer Medical 02832 - 250150 250554

7 Dep. Engg GEB Electric 02836 – 242546 M - 9879202256

--

8 Technical expert IFFCO All emergency 02836 -

270640/223125 --

9 Technical expert IOC All emergency 02836 -

270262/270805 --

10 Police station Gandhidham Police 02836 - 232500 --

11 Police station Anjar Police 02836 - 240100 --

12 Police station Adipur Police 02836 - 260615 M - 9879155315

--

13 Fire station Gandhidham Fire 02836 - 231610 --

14 Fire station Kandla Fire 02836 - 270539 --

15 Civil hospital Gandhidham (Ram bag)

Medical 02836 -

261626/260608 --

16 Govt. hospital Anjar Medical 02836 - 245753 --

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.

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.




Page | 8.37

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 will maintain the records of details of emergency occur, corrective preventive

measures to be taken. Unit will display the details like list of assembly points, name of

the persons involve in the safety team like site controller, incident controller etc.

chapter 8 risk and safety management · chapter-8: risk & safety management page | 8.1 chapter...

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