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Environmental Impact Assessment Report for Expansion Project of Synthetic Organic Manufacturing Unit at Tarapur MIDC, Palghar, Maharashtra SEEPL/EIA/F/IND/GSL/001/2016-17/00 CHAPTER 7: ADDITIONAL STUDIES Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 1 CHAPTER 7: ADDITIONAL STUDIES 7.1 Public Hearing “Public Consultation” refers to the process by which the concerns of local affected persons and others who have plausible stake in the environmental impacts of the project or activity are ascertained with a view to taking into account all the material concerns in the project or activity design as appropriate. M/s Galaxy Surfactants Ltd. will commence the project activity Tarapur MIDC at plot no. G-59. As per the OM No. J-11013/36/2014-IA-I dated 10 th December 2014 public hearing is not mandatory for the industries which are established in industrial estate or parks notified prior to 14.06.2006 i.e. the EIA notification, 2006 coming into force. 7.2 Risk Assessment 7.2.1 Introduction As indicated in the earlier chapter the proposed facility to manufacture Specialty chemicals poses various types of hazards due to storage, handling and manipulation of different chemicals, which are indicated in Chapter no. 2 In order to study the risks envisaged by the activities, the following methodology was adopted. 7.2.1.1 Detailed study of all manufacturing activities 7.2.1.2 The factory would be manufacturing about 29 different products with total production quantity of 3472 MT/A. The hazop studies have been carried out for the products. 7.2.1.3 A detailed scrutiny of various chemicals which would be stored on the site was done. Aloha is performed for the raw materials which are mentioned below, Table No. 7.1: List of Tanks in CCOE Area Sr.No Name of the Raw Materials Capacity Nature Qty Area MOC 1 Cyclohexane 20 MT Underground 1 Tank CCOE SS316L

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Page 1: Environmental Impact Assessment Report for Expansion ...environmentclearance.nic.in/.../12102016UEYF32EJChapter7.pdf · Environmental Impact Assessment Report for Expansion Project

Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra

SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 1

CHAPTER 7: ADDITIONAL STUDIES

7.1 Public Hearing

“Public Consultation” refers to the process by which the concerns of local affected persons and

others who have plausible stake in the environmental impacts of the project or activity are

ascertained with a view to taking into account all the material concerns in the project or activity

design as appropriate. M/s Galaxy Surfactants Ltd. will commence the project activity Tarapur

MIDC at plot no. G-59. As per the OM No. J-11013/36/2014-IA-I dated 10th December 2014

public hearing is not mandatory for the industries which are established in industrial estate or

parks notified prior to 14.06.2006 i.e. the EIA notification, 2006 coming into force.

7.2 Risk Assessment

7.2.1 Introduction

As indicated in the earlier chapter the proposed facility to manufacture Specialty

chemicals poses various types of hazards due to storage, handling and manipulation of

different chemicals, which are indicated in Chapter no. 2

In order to study the risks envisaged by the activities, the following methodology was

adopted.

7.2.1.1 Detailed study of all manufacturing activities

7.2.1.2 The factory would be manufacturing about 29 different products with total

production quantity of 3472 MT/A. The hazop studies have been carried out for

the products.

7.2.1.3 A detailed scrutiny of various chemicals which would be stored on the site was

done. Aloha is performed for the raw materials which are mentioned below,

Table No. 7.1: List of Tanks in CCOE Area

Sr.No Name of the RawMaterials Capacity Nature

Qty Area MOC

1 Cyclohexane 20 MT Underground 1 Tank CCOE SS316L

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Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra

SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 2

2Toluene 15 MT Underground

1 Tank CCOE SS316L

3Methanol 15 MT Underground

1 Tank CCOE SS316L

4Ethyl Acetate 15 MT Underground

1 Tank CCOE SS316L

5IPA 15 MT Underground

1 Tank CCOE SS316L

Table No 7.2: Gas Storage Details

The Gas Storage Details are tabulated below -

Sr.No.

Gas Type Storagepressurebar

Diameter,m

Length /height, m

Capacity, Area

1 Hydrogen Cylinder(150 )

150 atm. 0.2 m 1.6m 45 lit CCOE

2 TrimethylamineGas

Tank 4 bar 2.2 m 3 m 10 MT CCOE

Table No. 7.1: List of Tanks in Non CCOE Area (Considered for Aloha)

Sr.NoRaw materials Proposed

consumptionMax.Storage State Storage type

TPM MT1. Thionyl Chloride 81.40 40.00 Liquid Above ground Storage tank

2. 2-Ethyl hexanol 169.25 50 LiquidAbove ground Storage tank

3. Benzyl Chloride 28.75 30.00 LiquidAbove ground Storage tank

4. Acetic Acid 50 30 Liquid Above ground Storage tank

5. HCl solution 15.21 50.00 Liquid Above ground Storage tank

7.2.1.4 M.S.D.S.s

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Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra

SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 3

Brief M.S.D.S.s of all the above chemicals and other raw materials which would be used in the

manufacturing processes of products are used as reference for preparation of hazop & risk

assessment study.

7.2.1.5 A Quantitative Risk Assessment based on the software ALOHA – Areal Locations of

Hazardous Atmospheres was carried out. The criteria failure scenarios considered for ALOHA

depend on the type of storage whether above ground/ underground, physical state of the chemical

stored, chemical properties of the chemical.

The summary of the ALOHA footprints are attached as Annexure 7.1

Table No 7.3: Summary of Aloha Footprints

Substance Failure Scenario No. Effectsconsidered

LOC Distance,m

Tri methylAmine

Direct Source Tri methylAmine/01

Toxic area ofvapor cloud

AEGL-3 380 ppm 351 meters

AEGL-2 120 ppm 659 metersAEGL-1 8 ppm 2.7

kilometers

Tri methylAmine/02

Flammable Areaof Vapor Cloud

12000ppm =60% LEL =FlamePockets

42 meters

2000 ppm= 10% LEL

126 meters

Tri methylAmine/03

Overpressure(blast force)from vaporcloud explosion

8.0 psi LOC wasneverexceeded

3.5 psi 29 meters1.0 psi 54 meters

Flammablechemicalescaping fromtank (not

Tri methylAmine/04

Toxic Area ofVapor Cloud

AEGL-3 380 ppm 1.1kilometers

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Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra

SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 4

burning)

AEGL-2 120 ppm 1.7kilometers

AEGL-1 8 ppm 4.4kilometers

Tri methylAmine/05

Flammable Areaof Vapor Cloud

12000ppm =60% LEL =FlamePockets

330 meters

2000 ppm= 10% LEL

624 meters

Tri methylAmine/06

Overpressure(blast force)from vaporcloud explosion

8.0 psi LOC wasneverexceeded

3.5 psi 288 meters1.0 psi 368 meters

Flammablechemical isburning as itescapes fromtank

Tri methylAmine/07

10.0kW/(sq m)

80 meters

5.0kW/(sq m)

124 meters

2.0kW/(sq m)

201 meters

BLEVE offlammable liquidin verticalcylindrical tank

Tri methylAmine/08

10.0kW/(sq m)

136 meters

5.0kW/(sq m)

193 meters

2.0kW/(sq m)

301 meters

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Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra

SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 5

Hydrogen Catastrophicfailure of cylinder

Hydrogen/01 Toxic area ofvapor cloud

AEGL-3 400000ppm

11

AEGL -2

230000ppm

14

AEGL -1

65000ppm

28

Hydrogen / 02 Flammable areaof vapor cloud

24000ppm =60% LEL

64

4000 ppm= 10%LEL

157

Hydrogen / 03 Blast area ofvapour cloudexplosion

8.0 psi < 10

3.5 psi < 101.0 psi < 10

failure of outletpipeline, pig tail(Chemical notburning)

Hydrogen / 04 Toxic area ofvapor cloud

AEGL-3 400000ppm

20

AEGL -2

230000ppm

52

AEGL -1

65000 ppm 119

Hydrogen/ 05 Flammable areaof vapor cloud

24000ppm =60% LEL

< 10

4000 ppm= 10%LEL

22

Hydrogen / 06 Blast area ofvapour cloudexplosion

-- --

failure of outletpipeline, pig tail(Chemical

Hydrogen / 07 Thermalradiation fromjet fire

10 kw/sq m. < 10

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Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra

SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 6

burning)5 kw/sq m. < 102 kw/sq m. < 10

Isopropanol

Direct Source –20% leakagethrough transferpump

Isoproponal /01 Toxic area ofvapor cloud

PAC-3 12000ppm

20

PAC-2 400 ppm 146PAC -1 400 ppm 146

Isoproponal /02

Flammable areaof vapor cloud

12000ppm =60% LEL

17

2000 ppm= 10%LEL

43

Isoproponal /03

Blast area ofvapour cloudexplosion

8.0 psi --

3.5 psi 141.0 psi 22

Road Tankerrupture

Isoproponal /04

Toxic area ofvapor cloud

PAC-3 12000ppm

--

PAC-2 400 ppm 112PAC -1 400 ppm 112

Isoproponal /05

Flammable areaof vapor cloud

12000ppm =60% LEL

< 10

2000 ppm= 10%LEL

42

Isoproponal /06

Blast area ofvapour cloudexplosion

--

EthylAcetate

Direct Source –20% leakage

Ethyl Acetate/01

Toxic area ofvapor cloud

PAC-3 10000ppm

20

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Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra

SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 7

through transferpump

PAC-2 400 ppm 127PAC -1 400 ppm 127

Ethyl Acetate /02

Flammable areaof vapor cloud

13080ppm =60% LEL

17

2150 ppm= 10%LEL

46

Ethyl Acetate /03

Blast area ofvapour cloudexplosion

8.0 psi --

3.5 psi 131.0 psi 30

Road Tankerrupture

Ethyl Acetate /04

Toxic area ofvapor cloud

PAC-3 10000ppm

19

PAC-2 400 ppm 134PAC -1 400 ppm 134

Ethyl Acetate /05

Flammable areaof vapor cloud

13080ppm =60% LEL

15

2150 ppm= 10%LEL

47

Ethyl Acetate /06

Blast area ofvapour cloudexplosion

8.0 psi --

3.5 psi 101.0 psi 15

Methanol Road Tankerrupture

Methanol /01 Toxic area ofvapor cloud

AEGL-3 7200 ppm 624

AEGL-2 2100 ppm 1100AEGL-1 530 ppm 1800

Methanol / 02 Flammable areaof vapor cloud

43800ppm =

235

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Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra

SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 8

60% LEL7180 ppm= 10%LEL

679

Methanol / 03 Blast area ofvapour cloudexplosion

8.0 psi --

3.5 psi --1.0 psi 192

Direct Source –20% leakagethrough transferpump

Methanol / 04 Toxic area ofvapor cloud

AEGL-3 7200 ppm 42

AEGL-2 2100 ppm 82AEGL-1 530 ppm 170

Methanol / 05 Flammable areaof vapor cloud

43800ppm =60% LEL

17

7180 ppm= 10%LEL

53

Methanol / 06 Blast area ofvapour cloudexplosion

8.0 psi --

3.5 psi --1.0 psi 14

Toluene Road tankerrupture

Toluene /01 Toxic area ofvapor cloud

AEGL-3 4500 ppm 520

AEGL-2 1200 ppm 869AEGL-1 200 ppm 1700

Toluene / 02 Flammable areaof vapor cloud

6600 ppm= 60%LEL

443

1100 ppm= 10%LEL

897

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Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra

SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 9

Toluene / 03 Blast area ofvapour cloudexplosion

8.0 psi --

3.5 psi 3701.0 psi 455

Direct Source –20% leakagethrough transferpump

Toluene / 04 Toxic area ofvapor cloud

AEGL-3 4500 ppm 36

AEGL-2 1200 ppm 75AEGL-1 200 ppm 215

Toluene / 05 Flammable areaof vapor cloud

6600 ppm= 60%LEL

31

1100 ppm= 10%LEL

78

Toluene / 06 Blast area ofvapour cloudexplosion

8.0 psi --

3.5 psi --1.0 psi 13

Cyclohexane

Road tanker Cyclohexane/01

Toxic area ofvapor cloud

AEGL-3 8600 ppm 363

AEGL-2 2900 ppm 567AEGL-1 -- --

Cyclohexane /02

Flammable areaof vapor cloud

7200 ppm =60% LEL

392

1200 ppm =10% LEL

792

Cyclohexane /03

Blast area ofvapour cloudexplosion

8.0 psi --

3.5 psi 3291.0 psi 411

Direct Source – Cyclohexane / Toxic area of AEGL-3 8600 ppm 23

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Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra

SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 10

20% leakagethrough transferpump

04 vapor cloud

AEGL-2 2900 ppm 43AEGL-1 -- --

Cyclohexane /05

Flammable areaof vapor cloud

7200 ppm =60% LEL

25

1200 ppm =10% LEL

67

Cyclohexane /06

Blast area ofvapour cloudexplosion

8.0 psi --

3.5 psi 171.0 psi 37

Aceticacid

Direct Source –20% leakagethrough transferpump

Acetic acid/01

Toxic area ofvapor cloud

AEGL-3 250 ppm 164

AEGL-2 35 ppm 459AEGL-1 5 ppm 1300

Acetic acid /02

Flammable areaof vapor cloud

24000 ppm= 60% LEL

29

4000 ppm= 10% LEL

72

Acetic acid /03

Blast area ofvapour cloudexplosion

8.0 psi --

3.5 psi 181.0 psi 34

The entire contentsof the storage tankgettingaccumulated in thedyke enclosurebecause of failureof the tank –

Acetic acid /04

Toxic area ofvapor cloud

AEGL-3 250 ppm 23

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Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra

SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 11

Chemical notburning

AEGL-2 35 ppm 96AEGL-1 5 ppm 264

Acetic acid /05

Flammable areaof vapor cloud

24000 ppm= 60% LEL

--

4000 ppm= 10% LEL

< 10

Acetic acid /06

Blast area ofvapour cloudexplosion

--

The entirecontents of thestorage tankgettingaccumulated inthe dykeenclosurebecause offailure of thetank – Chemicalburning.

Acetic acid/07

Thermalradiation frompool fire.

10 kw/sq m. 12

5 kw/sq m. 182 kw/sq m. 29

Hydrochloric acid

The entire contentsof the storage tankgettingaccumulated in thedyke enclosurebecause of failureof the tank –Chemical notburning

HCl / 01 Toxic area ofvapor cloud

AEGL-3 100 ppm 54

AEGL-2 22ppm 129AEGL-1 1.8 ppm 467

BenzylChloride

Direct Source –20% leakagethrough transferpump

BenzylChloride/01

Toxic area ofvapor cloud

ERPG-3 50 ppm 175 meters

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Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra

SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 12

ERPG-2 10 ppm 411 metersERPG-1 1 ppm 1.4

kilometers

BenzylChloride/02

FlammableArea of VaporCloud

6600 ppm= 60%LEL =FlamePockets

11

1100 ppm= 10%LEL

31

BenzylChloride/03

Overpressure(blast force)from vaporcloudexplosion

8.0 psi --

3.5 psi 131.0 psi 29

The entirecontents of thestorage tankgettingaccumulated inthe dykeenclosurebecause offailure of thetank – Chemicalnot burning

BenzylChloride/04

Toxic area ofvapor cloud

ERPG-3 50 ppm 10

ERPG-2 10 ppm 22ERPG-1 1 ppm 82

BenzylChloride/05

FlammableArea of VaporCloud

6600 ppm= 60%LEL =FlamePockets

10

1100 ppm= 10%

10

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Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra

SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 13

LEL

BenzylChloride/06

Overpressure(blast force)from vaporcloudexplosion

-- --

The entirecontents of thestorage tankgettingaccumulated inthe dykeenclosurebecause offailure of thetank – Chemicalburning

BenzylChloride/07

Thermalradiation frompool fire

10.0kW/(sq m)

13

5.0kW/(sq m)

17

2.0kW/(sq m)

25

2-ETHYLHEXANOL

Direct Source –20% leakagethrough transferpump

2-ETHYLHEXANOL/01

Toxic area ofvapor cloud

ERPG-3 200 ppm 73 meters

ERPG-2 100 ppm 105 metersERPG-1 0.1 ppm 3.9

kilometers

2-ETHYLHEXANOL/02

FlammableArea of VaporCloud

5280 ppm= 60%LEL

11

880 ppm =10% LEL

31

2-ETHYLHEXANOL/03

Overpressure(blast force)from vapor

8.0 psi --

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Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra

SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 14

cloudexplosion

3.5 psi 141.0 psi 32

The entirecontents of thestorage tankgettingaccumulated inthe dykeenclosurebecause offailure of thetank – Chemicalnot burning

2-ETHYLHEXANOL/04

Toxic area ofvapor cloud

ERPG-3 200 ppm <10

ERPG-2 100 ppm <10ERPG-1 0.1 ppm 125

2-ETHYLHEXANOL/05

FlammableArea of VaporCloud

5280 ppm= 60%LEL

<10

880 ppm =10% LEL

<10

2-ETHYLHEXANOL/06

Overpressure(blast force)from vaporcloudexplosion

-- --

The entirecontents of thestorage tankgettingaccumulated inthe dykeenclosurebecause offailure of thetank – Chemicalburning

2-ETHYLHEXANOL/07

Thermalradiation frompool fire

10.0kW/(sq m)

18

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Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra

SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 15

5.0kW/(sq m)

24

2.0kW/(sq m)

35

THIONYLCHLORIDE

Direct Source –20% leakagethrough transferpump

THIONYLCHLORIDE/01

Toxic area ofvapor cloud

AEGL-3 14 439

AEGL-2 2.4 1.1 KmAEGL-1 - -

THIONYLCHLORIDE/02

Toxic area ofvapor cloud

AEGL-3 14 428

AEGL-2 2.4 1.1 KmAEGL-1 - -

Interpretation

The probability of failure of the entire tank etc, which is considered in the above scenario is veryless. However to further reduce the same, following precautions would be taken,

A) For Underground Solvent Storage Tanks & Above ground tanks

The tanks will be fabricated taking into account the corrosion resistance properties of the

material of construction.

The tank will be provided with water sprinkler arrangement so as to cool the same in

summer season

The tanks will be provided with breather valves and will have nitrogen blanketing

arrangement wherever required

Dyke wall of adequate volume (110%) capacity of the tank will be constructed around the

tanks.

The dyke enclosure will be lined with impervious coating

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Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra

SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 16

Regular inspection of the tank, transfer pipelines and dyke will be done visually and

records maintained.

Wherever required, the tanks would be covered under a license under Petroleum Rules

from PESO.

It is recommended to establish foam monitor in the solvent tank yard farm.

B) For Hydrogen Cylinders

1. The licensed premises shall not be used for any purpose other than for keeping of compressed

gas filled in cylinders.

2. Compressed gas cylinders shall be stored only in the storage shed, which shall be constructed

of suitable non-flammable materials provided that, when only non-flammable gas filled in

cylinder is stored, the beams, rafters, columns, windows and doors may be of wood.

3. The storage shed shall be adequately ventilated near the ground level and near or in the roof.

4. As far as possible, different types of gases should not be stored in the same shed. Where

different types of gas cylinders are stored in the same shed, cylinders may be grouped together

depending on the nature of the gas contained therein e.g. flammable gas cylinders shall be

separated from cylinders containing oxidizing gases by an intervening space of one meter or by a

fire resisting partition wall in between them and cylinders containing toxic gases shall be

segregated from the cylinders containing non-toxic gases by a suitable partition wall.

5. The following distances shall be kept clear at all times, between any building, public place,

public road or any adjoining property which may be built upon and the storage shed used for the

storage of liquefied petroleum gas cylinder: Quantity of compressed gas in Minimum distance to

be Cylinder kept clear Kg. Metres 0 -- 101 – 101 -- 2000 3 2001 -- 3000 4 3001 -- 4000 5 4001 --

6000 6 6001 -- 8000 7 8001 -- 10000 8 10001 -- 12000 9 12001 -- 20000 12 over 20000 15

Provided that the distance specified above may be reduced by the Chief Controller (i) where

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Environmental Impact Assessment Report for Expansion Project of Synthetic OrganicManufacturing Unit at Tarapur MIDC, Palghar, Maharashtra

SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 17

screen walls are provided or other special precautions taken, or (ii) where there are special

circumstances which in the opinion of the Chief Controller would justify such reduction.

6. Notwithstanding anything contained in condition 5 above, cylinders containing liquefied

petroleum gas exceeding 100 Kg. but not exceeding 500 Kg. may be kept in a storage shed

forming part of, or attached to a building, provided that it is separated there from by a substantial

partition and the only means of access to it is from outside air, such a storage shed shall not be

situated under any staircase or near other entrances to, or exits from the rest of the building or

other buildings.

7. A shed used for storage of liquefied petroleum gas cylinders shall be surrounded by a suitable

brick masonry compound wall of 1.8 meters high with a 1.2 meter wide gate to prevent

unauthorized person from having access to the shed and its safety zone.

8. Thin wall cylinders shall not be stacked in a horizontal position, provided that in case of

liquefied petroleum gas cylinders, the following method of stacking may be permitted:- (i) filled

cylinders shall be stored vertically and not be stacked more than 2 high; (ii) empty cylinders if

stored vertically, shall not be stacked more than 3 high and; if stored horizontally, shall not be

stacked more than 5 high; (iii) the pile of the cylinders shall be kept stable by using chocks at the

ends; (iv) at least 60 centimeter wide gangway, to permit access and maneuvering of cylinders,

shall be left between stacks of single or double rows and between stacks and walls,

9. True chemical name(s) of the gases shall be prominently displayed in the storage shed.

10. The storage shed shall be in the charge of a competent person.

11. Any accident, fire, explosion or untoward incident occurred within the licensed premises shall

be immediately reported to the Chief Controller (Gram “EXPLOSIVES”, Nagpur, E-

[email protected]), Controller, District Magistrate and the Officer-in-Charge of

the nearest Police Station and by quickest mode of communication.

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SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 18

13. No shed used for storage of flammable gases shall be opened and no handling of the gas

cylinders shall be permitted between the hours of sunset and sunrise, except where approved

electric lighting is exclusively used.

14. The storage shed and the area surrounding it shall at all times be kept clean and free from all

flammable materials, waste vegetation and, rubbish.

15. (a) No fire, furnace or other source of heat or light other than flameproof electric light and

fittings shall be allowed in the storage shed and within the safety zone required to be maintained

under condition 5. (b) No person shall smoke in the storage shed or carry matches, fuses, mobile

phones or other appliances producing ignition in the premises. Conspicuous ‘No smoking signs in

Hindi, English and the regional language shall be pasted or hung up at prominent places outside

the storage shed.

16. The licensee shall provide at the licensed premises a minimum of two potable foam

type/ordinary chemical type fire extinguishers of 10 kg. Each BIS marked or approved which

shall be kept ready at a convenient location for immediate use in the event of any fire in addition

to other fire fighting for other mitigating facilities required for flammable or toxic gases.

7.2.2 DOW INDEX

The Dow index has been calculated for chemicals stored in tank farm. Dow Index has beencalculated separately for F.O and HSD Tank area, CCOE U.G Tank area and Non CCOE TankArea.

Table No. 7.4 Storage details of Furnace Oil and LDO Tank.

Sr.No Raw MaterialTank/ Drum

CapacityKL.

Quantity atany

given time

No. ofTanks

Flash PointOC

1 Furnace Oil 40 KL 40 KL 1 662 LDO 20 KL 20 KL 1 66

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SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 19

Since, the flash point of Furnace Oil & LDO is the same, the DOW Index is performed for FOconsidering total volume is 60 KL of FO.

Tank No. -- Equipment Name FO 60 KLBasic Material for Materialfactor

MS Drums Density, kg/l 0.97Properties of materialN h 0 N f 2 N r 0 M.F. 10Boil.pt.

-- 0F -- 0C Flash pt. 150 0F 66 0C

HC = Heat ofComb.

18700 BTU / lb

Quantity of thematerial

60000 l 58200 kg 128309.04 LbStorage conditions Temp 30 0C Pressure 1.0 bar

Penalty factorrange

Penalty factorused1.General Process

HazardBase Factor 1.00 1.00

Exothermic Chemical Reaction 0.30 to 1.25 0.00Endothermic Processes 0.20 to 0.40 0.00

Material handling and transfer 0.25 to 1.05 0.40Enclosed or Indoor Process Units 0.25 to 0.90 0.00

Access 0.20 to 0.35 0.00Drainage and Spill Control 0.25 to 0.50 0.00

General Process Hazard Factor ( F1 ) 1.4

2.Special ProcessHazard

Base Factor 1.00 1.00Toxic material(s) 0.20 to 0.80 0.00Sub atmospheric pressure (< 500 mmHg)

0.50 0.00Operation in or near flammable range

_____inerted ______noninerted

0.00 to 0.80

1. Tank farm storage flammableliquids

0.50 0.002. Process upset or purge failure 0.30 0.003. Always in contact of Flame

process

0.80 0.00

Dust Explosion 0.25 to 2.00 0.00Pressure Operating pressure psig

Relief setting ________psig

0.00

Low temperature 0.20 to 0.30 0.00Quantity of flammable / unstablematerial1. Liquids or gases in process 0.12. Liquids or gases in storage 0.6

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SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 20

3. Combustible Solids in Storage, Dustin Process

0.00

Corrosion & Erosion 0.10 to 0.75 0.10Leakage - Joints & Packing 0.10 to 1.50 0.10Use of Fired Equipment 0.00Hot oil heat exchange system 0.15 to 1.15 0.00Rotating Equipment 0.50 0.00Special Process Hazard Factor ( F2 ) 1.9

Process Unit Hazard Factor ( F3 = F1 x F2) 2.66Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 26.6Degree of Hazard Light

The calculations for Dow Fire and Explosion Index is given and from the calculations it is seenthat the storage will have a Dow Index of 26.6 indicating Light hazard potential.

Table No. 7.5 Degree of Hazard for F & EI

Degree of Hazard for F & EIF & EI Index Range Degree of Hazard

1-60 Light61-96 Moderate

97-127 Intermediate128-158 Heavy159-up Severe

RECOMMENDED MINIMUM FEATURES ACCORDING TODOW FIRE AND EXPLOSION INDEX

Preventive & ProtectiveFeatures

Fire & Explosion Index Number Index for the present case

0-20

20-40 40-60

60-75

75-90

>90 26.6

Suggested Recommended Featurerequired

1) Fireproofing 1 2 2 3 4 4 √

2) Water spray

a) directional 1 2 3 3 4 4 √b) area 1 2 3 3 4 4 √c) curtain 1 1 2 2 2 4 √

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3) Special instrumentation

a) temperature 1 2 3 3 4 4 √b) pressure 1 2 3 3 3 4 √c) flow control 1 2 3 4 4 4 √

4) Dust, blowdown, spillcontrol

1 1 2 3 3 4 √

5) Internal examination 1 2 3 3 4 4 √

6) Combustible gasmonitors

a) signal alarm 1 1 2 3 3 4 √b) actuate equipment 1 1 2 2 3 4 √

7) Remote operation 1 1 2 3 3 4 √

8) Diking, (NotApplicable as barrelstorage)

1 4 4 4 4 4 √

9) Blast & barrier wallsseparation

1 1 2 3 4 4 √

1) Feature optional 2) Feature suggested 3) Feature recommended 4) Feature required

Dow index for chemicals stored in non CCOE storage tanks

Sr. No Raw MaterialTank/ Drum

CapacityMT.

No. ofTanks

Flash PointOC

1 Acetic acid 30 1 392 Epichlorohydrin 10 -- 31

1. Acetic acid

Tank No. -- Equipment Name Acetic acid 30 MTBasic Material for Materialfactor

MS Tank Sp. gravity 1.049Properties of materialN h 3 N f 2 N r 0 M.F. 14

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Boil.pt.

-- 0F -- 0C Flash pt. 103 0F 39 0C

HC = Heat ofComb.

5600 BTU / lb

Quantity of thematerial

-- l 30000 kg -- LbStorage conditions Temp 30 0C Pressure 1.0 bar

Penalty factorrange

Penalty factorused1.General Process

HazardBase Factor 1.00 1.00

Exothermic Chemical Reaction 0.30 to 1.25 0.00Endothermic Processes 0.20 to 0.40 0.00

Material handling and transfer 0.25 to 1.05 0.40Enclosed or Indoor Process Units 0.25 to 0.90 0.00

Access 0.20 to 0.35 0.00Drainage and Spill Control 0.25 to 0.50 0.00

General Process Hazard Factor ( F1 ) 1.4

2.Special ProcessHazard

Base Factor 1.00 1.00Toxic material(s) 0.20 to 0.80 0.6Sub atmospheric pressure (< 500 mmHg)

0.50 0.00Operation in or near flammable range

_____inerted ______noninerted

0.00 to 0.80

1. Tank farm storage flammableliquids

0.50 0.002. Process upset or purge failure 0.30 0.003. Always in contact of Flame

process

0.80 0.00

Dust Explosion 0.25 to 2.00 0.00Pressure Operating pressure psig

Relief setting ________psig

0.00

Low temperature 0.20 to 0.30 0.00Quantity of flammable / unstablematerial1. Liquids or gases in process 0.12. Liquids or gases in storage 0.63. Combustible Solids in Storage, Dustin Process

0.00

Corrosion & Erosion 0.10 to 0.75 0.10Leakage - Joints & Packing 0.10 to 1.50 0.10Use of Fired Equipment 0.00Hot oil heat exchange system 0.15 to 1.15 0.00Rotating Equipment 0.50 0.00Special Process Hazard Factor ( F2 ) 2.5

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Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 23

Process Unit Hazard Factor ( F3 = F1 x F2) 3.5Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 49Degree of Hazard Light

The calculations for Dow Fire and Explosion Index is given and from the calculations it is seenthat the storage will have a Dow Index of 49 indicating light hazard potential.

2. Epichlorohydrin

Tank No. -- Equipment Name Epichlorohydrin drumsBasic Material for Material factor HDPE

DrumsDensity, g/cc 1.18

Properties of materialN h 3 N f 3 N r 2 M.F. 24Boil. pt. 241 0F 116 0C Flash pt. 88 0F 31 0CHC = Heat of Comb. 7200 BTU / lbQuantity of the material -- l 10000 kg -- LbStorage conditions Temp 32 0C Pressure 1.0 bar

Penalty factorrange

Penalty factor used

1.GeneralProcessHazard Base Factor 1.00 1.00

Exothermic Chemical Reaction 0.30 to 1.25 0.00Endothermic Processes 0.20 to 0.40 0.00Material handling and transfer 0.25 to 1.05 0.6Enclosed or Indoor Process Units 0.25 to 0.90 0.00Access 0.20 to 0.35 0.00Drainage and Spill Control 0.25 to 0.50 0.00General Process Hazard Factor ( F1 ) 1.6

2.SpecialProcessHazard

Base Factor 1.00

1.00Toxic material(s) 0.20 to 0.80 0.6Sub atmospheric pressure (< 500 mm Hg) 0.50 0.00Operation in or near flammable range

_____inerted ______noninerted0.00 to 0.80

0.00

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Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 24

1. Tank farm storage flammable liquids 0.50 0.02. Process upset or purge failure 0.30 0.003. Always in contact of Flame process 0.80 0.00

Dust Explosion 0.25 to 2.00 0.00Pressure Operating pressure psigRelief setting ________ psig 0.0Low temperature 0.20 to 0.30 0.00Quantity of flammable / unstable material1. Liquids or gases in process 0.02. Liquids or gases in storage 0.103. Combustible Solids in Storage, Dust inProcess

0.00

Corrosion & Erosion 0.10 to 0.75 0.10Leakage - Joints & Packing 0.10 to 1.50 0.10Use of Fired Equipment 0.00Hot oil heat exchange system 0.15 to 1.15 0.00Rotating Equipment 0.50 0.00Special Process Hazard Factor ( F2 ) 1.9

Process Unit Hazard Factor ( F3 = F1 x F2) 3.04Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 72.96Degree of Hazard ModerateRadius of exposure 18.6 mArea of exposure 1086.83 sq. m.

The calculations for Dow Fire and Explosion Index is given and from the calculations it is seenthat the storage will have a Dow Index of 72.96 indicating moderate hazard potential.

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SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 25

RECOMMENDED MINIMUM FEATURES ACCORDING TODOW FIRE AND EXPLOSION INDEX

Preventive & ProtectiveFeatures

Fire & Explosion Index Number Index for the present case

0-20 20-40 40-60 60-75 75-90 >90 72.96

Suggested Recommended Feature

required1) Fireproofing 1 2 2 3 4 4 √

2) Water spray

a) directional 1 2 3 3 4 4 √

b) area 1 2 3 3 4 4 √c) curtain 1 1 2 2 2 4 √

3) Special instrumentation

a) temperature 1 2 3 3 4 4 √

b) pressure 1 2 3 3 3 4 √

c) flow control 1 2 3 4 4 4 √

4) Dust, blowdown, spill

control

1 1 2 3 3 4 √

5) Internal examination 1 2 3 3 4 4 √

6) Combustible gas

monitors

a) signal alarm 1 1 2 3 3 4 √

b) actuate equipment 1 1 2 2 3 4 √

7) Remote operation 1 1 2 3 3 4 √

8) Diking, (Not Applicable as

barrel storage)

1 4 4 4 4 4 √

9) Blast & barrier walls

separation1 1 2 3 4 4 √

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1) Feature optional 2) Feature suggested 3) Feature recommended 4) Feature required

7.2.3 MONDS INDEX

Introduction

The principle and general approach used in the DOW method of hazard evaluation have beenfurther developed by ICI Mond Division, Their revised Mond fire, explosive and toxicity index isa series of papers by lewis (1979). The main development made to the DOW Index in the MondIndex are:

1. It covers a wider range of process and storage installation2. It covers the processing of chemicals with explosive properties3. A calculation procedure is included to allow for the off-setting effects of good design and

control and safety instrumentation4. The procedure has been extended to cover plant layout5. Separate indices are calculated to access the hazards of fire, internal explosion and aerial

explosion.

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SEEPL/EIA/F/IND/GSL/001/2016-17/00CHAPTER 7: ADDITIONAL STUDIES

Sadekar Enviro Engineers Pvt. Ltd Chapter 7- 27

Table No. 7.6: Monds Toxicity index of toxic chemicals

Sr.

Raw Materials Quantity

MT

FlashPoint,

0C

UNClassification

HealthHazard

Threshold

LimitValue

Flammability/

Reactivity

Mondindex

Degree

1 Phosphoruspentoxide

20 NA 8 3 2mg/m3

Corrosive/Toxic

7.37 Moderate

2 Cautic lyesolution

50 NA 8 3 2mg/m3

Corrosive 7.00 Moderate

3 epichlorohydrin 10 31 8 3 NA Corrosive 8.12 Moderate

4Con.

Hydrochloricacid

50NA 8 3 5

Corrosive 7.25 Moderate

5 Acetic acid 30 39 8 3 100 Corrosive/Toxic

4.63 Light

6 Acrylamide 25 138 8 3 2mg/m3

Toxic 7.7 Moderate

7 Thionylchloride

40 NF 8 4 5mg/m3

Corrosive/Toxic

8.7 Moderate

Monds Index CalculationToxicity Index : Th + Ts (1+GPH+SPH)

100

Where, SPH = Special Process Hazard

GPH = General Process Hazard

Th = Toxicity factor based on the NFPA hazard index (0 – 4)

Ts = Correction factor (additional penalty) for toxicity based on Maximum

Allowable Concentration (MAC) value in ppm

Th (Toxicity Factor): For TEA will be 250 from the table no. 6.6 as the Nh factor for TEA is 3

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Ts (Correction Factor): For TEA will be 125 from the table no. 6.7 as the MAC is 2 ppm

Table No. 7.7 Toxicity factor Index

NFPA Index Number Toxicity Factor (Th)

0 0

1 50

2 125

3 250

4 325

Table No. 7.8 Correction factor for Toxicity

MAC (in ppm) Ts

5 and below 125

Between 5 and 50 75

50 and more 50

Table No. 7.9 Toxicity Index

The resulting TI values are ranked into three categories:1-5 Light6-9 Moderate10-up High

1. Monds Index Calculation for Phosphorus pentoxide

Th (Toxicity Factor): For Phosphorus pentoxide will be 250 from the table as the Nh factor for

Phosphorus pentoxide is 3

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Ts (Correction Factor): For Phosphorus pentoxide will be 125 from the table as the MAC is 2

ppm.

General & Special Process Hazard

1.General Process

Hazard

Base Factor 1.00 1.0Exothermic Chemical Reaction 0.30 to 1.25 0.3Endothermic Processes 0.20 to 0.40 0.00Material handling and transfer 0.25 to 1.05 0.0Enclosed or Indoor Process Units 0.25 to 0.90 0.0Access 0.20 to 0.35 0.0Drainage and Spill Control 0.25 to 0.50 0.0General Process Hazard Factor ( F1 ) 1.3

2.Special Process

Hazard

Base Factor 1.00 1.0Toxic material(s) 0.20 to 0.80 0.6Sub atmospheric pressure (< 500 mm

Hg)

0.50 0.00Operation in or near flammable range

_____inerted ______noninerted

0.00 to 0.80 0.00

1. Tank farm storage flammable

liquids

0.50 0.002. Process upset or purge failure 0.30 0.003. Always in Flammable range

process

0.80 0.00

Dust Explosion 0.25 to 2.00 0.00Pressure Operating pressure psig

Relief setting ________

psig

0.00

Low temperature 0.20 to 0.30 0.00Quantity of flammable / unstable

material1. Liquids or gases in process 0.002. Liquids or gases in storage 0.0

3. Combustible Solids in Storage, Dust

in Process

0.00

Corrosion & Erosion 0.10 to 0.75 0.0Leakage - Joints & Packing 0.10 to 1.50 0.00Use of Fired Equipment 0.00Hot oil heat exchange system 0.15 to 1.15 0.0Rotating Equipment 0.50 0.00Special Process Hazard Factor ( F2 ) 1.6

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Therefore from the above table the GPH and SPH is coming to be around 1.3 and 1.6

respectively.

Calculation of Toxicity Index:

Toxicity Index : Th + Ts*(1+GPH+SPH)/ 100

Toxicity Index : [250 + 125* (1 + 1.3+1.6)]/100

Toxicity Index : 7.00

The Toxicity Index for phosphorus pentoxide is calculated to be around 7.00 which indicatethat the degree of hazard is moderate.

2. Monds Index Calculation for caustic lye solution

Th (Toxicity Factor): For caustic lye will be 250 from the table as the Nh factor for caustic lye is 3

Ts (Correction Factor): For caustic lye will be 125 from the table as the TLV is 2 mg/m3.

General & Special Process Hazard

1.General Process

Hazard

Base Factor 1.00 1.0Exothermic Chemical Reaction 0.30 to 1.25 0.0Endothermic Processes 0.20 to 0.40 0.00Material handling and transfer 0.25 to 1.05 0.0Enclosed or Indoor Process Units 0.25 to 0.90 0.0Access 0.20 to 0.35 0.0Drainage and Spill Control 0.25 to 0.50 0.0General Process Hazard Factor ( F1 ) 1.0

2.Special Process

Hazard

Base Factor 1.00 1.0Toxic material(s) 0.20 to 0.80 0.6Sub atmospheric pressure (< 500 mm

Hg)

0.50 0.00

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Operation in or near flammable range

_____inerted ______noninerted

0.00 to 0.80 0.00

1. Tank farm storage flammable

liquids

0.50 0.002. Process upset or purge failure 0.30 0.003. Always in Flammable range

process

0.80 0.00

Dust Explosion 0.25 to 2.00 0.00Pressure Operating pressure psig

Relief setting ________

psig

0.00

Low temperature 0.20 to 0.30 0.00Quantity of flammable / unstable

material1. Liquids or gases in process 0.002. Liquids or gases in storage 0.0

3. Combustible Solids in Storage, Dust

in Process

0.00

Corrosion & Erosion 0.10 to 0.75 0.0Leakage - Joints & Packing 0.10 to 1.50 0.30Use of Fired Equipment 0.00Hot oil heat exchange system 0.15 to 1.15 0.0Rotating Equipment 0.50 0.00Special Process Hazard Factor ( F2 ) 1.6

Therefore from the above table the GPH and SPH is coming to be around 1.0 and 1.6

respectively.

Calculation of Toxicity Index:

Toxicity Index : Th + Ts*(1+GPH+SPH)/ 100

Toxicity Index : [250 + 125* (1 + 1.0+1.6)]/100

Toxicity Index : 7.00

The Toxicity Index for caustic lye is calculated to be around 7.00 which indicate that thedegree of hazard is moderate.

3. Monds index for epichlorohydrin drums

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Th (Toxicity Factor): For TEA will be 250 from the table as the Nh factor is 3

Ts (Correction Factor): Ts will be 125 from the table as the MAC is 2 ppm

Tank No. -- Equipment Name Epichlorohydrin 10 MTBasic Material for Materialfactor

HDPE Drums Density, g/cc 1.18Properties of materialN h 3 N f 2 N r 3 M.F. 29Boil.pt.

-- 0F 116 0C Flash pt. 87 0F 31 0C

HC = Heat ofComb.

-8143 BTU / lb

Quantity of thematerial

l 10000 kg Lb

Storage conditions Temp 30 0C Pressure 1.0 barPenalty factor

rangePenalty factor

used1.General ProcessHazard

Base Factor 1.00 1.00

Exothermic Chemical Reaction 0.30 to 1.25 0.00Endothermic Processes 0.20 to 0.40 0.00

Material handling and transfer 0.25 to 1.05 0.6Enclosed or Indoor Process Units 0.25 to 0.90 0.00

Access 0.20 to 0.35 0.00Drainage and Spill Control 0.25 to 0.50 0.00

General Process Hazard Factor ( F1 ) 1.6

2.Special ProcessHazard

Base Factor 1.00 1.00Toxic material(s) 0.20 to 0.80 0.6Sub atmospheric pressure (< 500 mmHg)

0.50 0.00Operation in or near flammable range

_____inerted ______noninerted

0.00 to 0.800.00

1. Tank farm storage flammableliquids

0.50 0.02. Process upset or purge failure 0.30 0.003. Always in contact of Flame

process

0.80 0.00

Dust Explosion 0.25 to 2.00 0.00Pressure Operating pressure psig

Relief setting ________psig

0.0

Low temperature 0.20 to 0.30 0.00Quantity of flammable / unstablematerial1. Liquids or gases in process 0.0

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2. Liquids or gases in storage 0.13. Combustible Solids in Storage, Dustin Process

0.00

Corrosion & Erosion 0.10 to 0.75 0.10Leakage - Joints & Packing 0.10 to 1.50 0.10Use of Fired Equipment 0.00Hot oil heat exchange system 0.15 to 1.15 0.00Rotating Equipment 0.50 0.00Special Process Hazard Factor ( F2 ) 1.9

The Toxicity Index for epichlorohydrin is calculated to be around 8.125 which indicate that

the degree of hazard is Moderate from above table.

4. Monds Index Calculation for Acetic acid

Th (Toxicity Factor): For Acetic acid will be 250 from the table as the Nh factor for Acetic Acid is

3

Ts (Correction Factor): For Acetic acid will be 50 from the table as the MAC is 100 ppm

General & Special Process Hazard

1.General Process

Hazard

Base Factor 1.00 1.00Exothermic Chemical Reaction 0.30 to 1.25 0.3Endothermic Processes 0.20 to 0.40 0.00Material handling and transfer 0.25 to 1.05 0.85Enclosed or Indoor Process Units 0.25 to 0.90 0.3Access 0.20 to 0.35 0.35Drainage and Spill Control 0.25 to 0.50 0.5General Process Hazard Factor ( F1 ) 3.3

2.Special Process

Hazard

Base Factor 1.00 1.00Toxic material(s) 0.20 to 0.80 0.4Sub atmospheric pressure (< 500 mm

Hg)

0.50 0.00Operation in or near flammable range

_____inerted ______noninerted

0.00 to 0.80 0.00

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1. Tank farm storage flammable

liquids

0.50 0.502. Process upset or purge failure 0.30 0.003. Always in Flammable range

process

0.80 0.00

Dust Explosion 0.25 to 2.00 0.00Pressure Operating pressure psig

Relief setting ________

psig

0.00

Low temperature 0.20 to 0.30 0.00Quantity of flammable / unstable

material1. Liquids or gases in process 0.002. Liquids or gases in storage 0.16

3. Combustible Solids in Storage, Dust

in Process

0.00

Corrosion & Erosion 0.10 to 0.75 0.10Leakage - Joints & Packing 0.10 to 1.50 0.30Use of Fired Equipment 0.00Hot oil heat exchange system 0.15 to 1.15 0.0Rotating Equipment 0.50 0.00Special Process Hazard Factor ( F2 ) 2.46

Therefore from the above table the GPH and SPH is coming to be around 3.3 and 2.46

respectively.

Calculation of Toxicity Index:

Toxicity Index : Th + Ts*(1+GPH+SPH)/ 100

Toxicity Index : [250 + 50(1 + 3.3+2.46)]/100

Toxicity Index : 4.63

The Toxicity Index for Acetic Acid is calculated to be around 4.63 which indicate that thedegree of hazard is light.

5. Monds Index for Hydrochloric acid

Th (Toxicity Factor): For HCl will be 250 from the above table as the Nh factor for HCl is 3

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Ts (Correction Factor): For HCl will be 125 from the table as the MAC is 2 ppm.

General & Special Process Hazard

1.General ProcessHazard

Base Factor 1.00 1.00Exothermic Chemical Reaction 0.30 to 1.25 0.00Endothermic Processes 0.20 to 0.40 0.00Material handling and transfer 0.25 to 1.05 0.00Enclosed or Indoor Process Units 0.25 to 0.90 0.00Access 0.20 to 0.35 0.00Drainage and Spill Control 0.25 to 0.50 0.00General Process Hazard Factor ( F1 ) 1.00

2.Special ProcessHazard

Base Factor 1.00 1.00Toxic material(s) 0.20 to 0.80 0.6Sub atmospheric pressure (< 500 mmHg)

0.50 0.00Operation in or near flammable range

_____inerted ______noninerted

0.00 to 0.80

1. Tank farm storage flammableliquids

0.50 0.02. Process upset or purge failure 0.30 0.003. Always in Flammable range

process

0.80 0.00

Dust Explosion 0.25 to 2.00 0.00Pressure Operating pressure psig

Relief setting ________psig

0.00

Low temperature 0.20 to 0.30 0.00Quantity of flammable / unstablematerial1. Liquids or gases in process 0.00

2. Liquids or gases in storage 0.003. Combustible Solids in Storage, Dust

in Process0.00

Corrosion & Erosion 0.10 to 0.75 0.10Leakage - Joints & Packing 0.10 to 1.50 0.10Use of Fired Equipment 0.00Hot oil heat exchange system 0.15 to 1.15 0.00Rotating Equipment 0.50 0.00Special Process Hazard Factor ( F2 ) 1.8

Therefore from the above table the GPH and SPH is coming to be around 1.00 and 1.8 respectively.

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Calculation of Toxicity Index:

Toxicity Index : Th + Ts (1+GPH+SPH)

100

Toxicity Index : [250 + 125 (1 + 1.00 + 1.8)]/100

Toxicity Index : 725

The Toxicity Index for HCl is calculated to be around 7.25 which indicate that the degree ofhazard is moderate.

6. Monds Index for Acrylamide

Th (Toxicity Factor): For acrylamide will be 250 from the table as the Nh factor for

acrylamide is 3

Ts (Correction Factor): For acrylamide will be 125 from the table as the MAC is 2 mg/m3

General & Special Process Hazard

1.General Process

Hazard

Base Factor 1.00 1.00Exothermic Chemical Reaction 0.30 to 1.25 0.0Endothermic Processes 0.20 to 0.40 0.00Material handling and transfer 0.25 to 1.05 0.2Enclosed or Indoor Process Units 0.25 to 0.90 0.0Access 0.20 to 0.35 0.0Drainage and Spill Control 0.25 to 0.50 0.0General Process Hazard Factor ( F1 ) 1.2

2.Special Process

Hazard

Base Factor 1.00 1.00Toxic material(s) 0.20 to 0.80 0.6Sub atmospheric pressure (< 500 mm

Hg)

0.50 0.00Operation in or near flammable range

_____inerted ______noninerted

0.00 to 0.80 0.00

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1. Tank farm storage flammable

liquids

0.50 0.002. Process upset or purge failure 0.30 0.003. Always in Flammable range

process

0.80 0.00

Dust Explosion 0.25 to 2.00 0.00Pressure Operating pressure psig

Relief setting ________

psig

0.00

Low temperature 0.20 to 0.30 0.00Quantity of flammable / unstable

material1. Liquids or gases in process 0.002. Liquids or gases in storage 0.16

3. Combustible Solids in Storage, Dust

in Process

0.00

Corrosion & Erosion 0.10 to 0.75 0.10Leakage - Joints & Packing 0.10 to 1.50 0.10Use of Fired Equipment 0.00Hot oil heat exchange system 0.15 to 1.15 0.0Rotating Equipment 0.50 0.00Special Process Hazard Factor ( F2 ) 1.96

Therefore from the above table the GPH and SPH is coming to be around 1.2 and 1.96

respectively.

Calculation of Toxicity Index:

Toxicity Index : Th + Ts*(1+GPH+SPH)/ 100

Toxicity Index : [250 + 125 (1 + 1.2+1.96)]/100

Toxicity Index : 7.7

The Toxicity Index for acrylamide is calculated to be around 7.7 which indicate that thedegree of hazard is moderate.

7. Monds Index for Thionyl chloride

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Th (Toxicity Factor): For thionyl chloride will be 325 from the table as the Nh factor for

thionyl chloride is 4.

Ts (Correction Factor): For thionyl chloride will be 125 from the table as the MAC is 5 ppm

General & Special Process Hazard

1.General Process

Hazard

Base Factor 1.00 1.00Exothermic Chemical Reaction 0.30 to 1.25 0.0Endothermic Processes 0.20 to 0.40 0.00Material handling and transfer 0.25 to 1.05 0.2Enclosed or Indoor Process Units 0.25 to 0.90 0.0Access 0.20 to 0.35 0.0Drainage and Spill Control 0.25 to 0.50 0.0General Process Hazard Factor ( F1 ) 1.2

2.Special Process

Hazard

Base Factor 1.00 1.00Toxic material(s) 0.20 to 0.80 0.8Sub atmospheric pressure (< 500 mm

Hg)

0.50 0.00Operation in or near flammable range

_____inerted ______noninerted

0.00 to 0.80 0.00

1. Tank farm storage flammable

liquids

0.50 0.002. Process upset or purge failure 0.30 0.003. Always in Flammable range

process

0.80 0.00

Dust Explosion 0.25 to 2.00 0.00Pressure Operating pressure psig

Relief setting ________

psig

0.00

Low temperature 0.20 to 0.30 0.00Quantity of flammable / unstable

material1. Liquids or gases in process 0.002. Liquids or gases in storage 0.16

3. Combustible Solids in Storage, Dust

in Process

0.00

Corrosion & Erosion 0.10 to 0.75 0.10Leakage - Joints & Packing 0.10 to 1.50 0.10Use of Fired Equipment 0.00Hot oil heat exchange system 0.15 to 1.15 0.0

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Rotating Equipment 0.50 0.00Special Process Hazard Factor ( F2 ) 2.16

Therefore from the above table the GPH and SPH is coming to be around 1.2 and 2.16

respectively.

Calculation of Toxicity Index:

Toxicity Index : Th + Ts*(1+GPH+SPH)/ 100

Toxicity Index : [325 + 125 (1 + 1.2+2.16)]/100

Toxicity Index : 8.7

The Toxicity Index for thionyl chloride is calculated to be around 8.7 which indicate thatthe degree of hazard is moderate.

Recommendations for storage:

• MSDS of all the raw materials will be provided in the storage area.

• Raw material will be segregated and stored by compatibility.

• The material will be stacked in cabinets away from the source of ignition & heat.

• Spill kit will be provided.

• Training will be given to employees to handle hazardous and toxic chemicals.

• PPEs like full body suit, glove, goggles, mask will be provided to employees for handlingtoxic & hazardous raw materials.

• Storage area will be provided with sufficient ventilation.

Earthing will be provided to eliminate risk of fire.

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7.3 HAZOP Study

Hazop study has been carried out for all hazardous operations and process. It is attached asAnnexure 7.1.

7.4 DISASTER MANAGEMENT PLAN

Objectives of Disaster Management Plan [DMP]The Disaster Management Plan (DMP) is aimed to ensure safety of life, protection ofenvironment, protection of installation, restoration of production and salvage operations in thesame order of priorities. For effective implementation of the DMP, it should be widely circulatedand personnel training through rehearsals/drills should be organized. Further, the managementshould be able to demonstrate that its assessment of the consequences as good supportingevidence. To tackle the consequences of a major emergency inside the factory or immediatevicinity of the factory, a DMP has to be formulated and this planned emergency document iscalled "Disaster Management Plan". The objective of the Industrial Disaster Management Plan isto make use of the combined resources of the plant and the outside services to achieve thefollowing:

Effect the rescue and medical treatment of causalities Safeguard other people

Minimize damage to property and the environment Initially contain and ultimately bring the incident under control

Identify any dead Provide for the needs of relatives Provide authoritative information to the news media

Secure the safe rehabilitation of affected area Preserve relevant records and equipment for the subsequent inquiry into the cause and

circumstances of the emergency. In effect, it is to optimize operational efficiency to rescuerehabilitation and render medical help and to restore normalcy.

7.4.1 Onsite Emergency Plan

Salient Features of the Project

Name of Project M/s Glaxy surfactants Ltd.

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Address (Plant) Plot No: G-59, Tarapur MIDC, Boisar, Palghar,Dist : Palghar, Maharashtra, India

Nature of the Project Production of specialty chemicalsCapacity 4132 MT/monthMan Power 177Name of Site Head Mr. Milind PatilKey Persons in the Emergency Plan Site Manager

Corporate EHS HeadEHS ManagerSr. ExecutiveSafety OfficerFire OfficerChemist

OBJECTIVES OF THE PLAN

On-Site emergency preparedness plan has the following objectives:

1. Safeguard lives and property at site and in its vicinity area.2. Contain the incident and bring it under control;3. Minimize damage to lives, property and environment;4. Rescue and treat casualties;5. To train the people to act efficiently and with confidence in an emergency.6. Evacuate people to safe areas;7. To minimize its occurrence.

7.4.1.1 Pre – Emergency Plans -

Pre – Emergency means the preparatory stage of the plan. It should be ensured that the preparedplan contains all required provisions and details of facility to handle and to contain the emergencysituation successfully. The unit has to consider maximum and possible worst scenario foremergency purpose while planning. The unit has to develop and maintain the essential facilities,so that the emergency can be controlled and the damages are minimized in the shortest periodwith proper use of all available resources.

The unit should be duly prepared and ready all the time to encounter any possible emergency,while it may strike or not. Being a specialty chemicals Manufacturing unit various type of

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chemicals are used possessing varied types of hazards and knowing the hazards of the chemical,stored, handled or processed in the factory, the quick response action must be created within unit.

The structure of the plan may vary depending on the number of employees, materials, process,and availability of recourses, location of site, size and complexity of the unit. It should ensure towork out a plan with possibilities of various emergencies with likely to arise within unit. Furtherthe periodical rehearsal is also to be carried out to check and examine the effectiveness, awarenessand preparedness of the plan as well as services. The emergency planning is not a substitute forgood design, plant operating and maintenance practices. Therefore, the Onsite Emergency ActionPlan must be followed to avoid emergency

7.4.1.2 Periodic Checking Schedule-

To check availability, work ability and take necessary actions for replacement and maintenance, ifrequired. Check resources of water. Keep all emergency and essential Telephone Nos. withcontact persons, suppliers for the same handy. Contact details may be displayed on the boardsinstalled at prominent locations in the plant and offices. Maintain the co- ordination with otherfire – services. Also the Firefighting system and PPE should be checked if they are in workingcondition and proper maintenance should be done.

7.4.1.3 Preventive Maintenance (To Avoid Emergency)

A scheduled periodical preventative maintenance and inspection of the plants, Reactors,centrifuges, equipment’s, storage tanks, air compressors, D.G. Sets etc. are as per laid downprocedures and check that records are maintained properly. Check the test, examination andcertification have been carried out within reasonable period.

7.4.1.4 Training

By imparting an effective training to the plant supervisors, inspectors, and education and trainingof the workers from time to time, the awareness is to be kept alive all the time to ensure safetyawareness, preparedness for emergency situations, good housekeeping, discipline, etc. Display ofsafety slogans, operative instructions and motivation for safety should be made part of thecompany’s normal activities. All the persons earmarked for the emergency services are to betrained to respond to the emergency. The company conducts internal & external training forEnvironment Health & safety. The training is conducted at a documented frequency. The externaltraining is conducted six monthly and internal training is conducted every month.

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7.4.1.5 Monitoring the Environment

Continuous and periodic monitoring of environment is required for detection of a possibledamage or a risky situation arises.

7.4.1.6 Mock Drill

Organize the periodical mock drill / rehearsal as per suggested format by creating an emergencysituation so as to verify preparedness and awareness as well as shortcomings on the part of theperson to overcome the same. Provide sufficient time prior to mock drill to the emergencyservices and public for proper response to exercise and provide training also. Record thedeficiencies of the system during the trial and take appropriate actions to improve the efficiencyof the plan in terms of preparedness and response.

7.4.1.7 Maintenance of Records

Keep the records of the monitoring conditions, safety systems, storage levels, process condition,etc. and maintain the log- books, registers etc. Keep the M.S.D.S. and onsite emergency plan withrequired details. The solvent and trimethyl amine tanker unloading and handling sheet is prepared.It will be duly filled by the workers and SOP for unloading shall be followed strictly.

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Work Instructions for Unloading Of Solvents

(Ethyl Acetate / Toluene / 2-Ethyl hexanol/ LDO)

A. Precautions:

Check level of the tank in which you are planning to unload the tanker

Check vents line of storage tank. It must be open through flame arrestor.

Unloading hose must be metallic.

Check whether safety instruments e.g. fire extinguishers are in place.

Check for muffler (flame arrester to tanker flue gas exhaust)

B. Procedure:1. Before entering the tanker into the UG tank area ask the driver for his driving license,

cleaner, Spark arrestor, Trem card etc.

2. After receiving the tanker slowly in tank area park the vehicle at required position

with providing stopper & remove the key.

3. Wear the required the PPEs(safety Goggle, safety shoes, helmet & gloves.

4. Connect tanker to the earth.

5. Take a clean & dry bucket; Keep it below the outlet valve of the vehicle.

6. Start opening the blind flange fitted to tanker outlet valve.

7. While opening blind flange, first open ground side bolt about 2-3 threads.

8. Make loose any other adjacent bolt, so that the contents of the line will be drain into the

bucket.

9. Remove the blind flange, connect one end of the SS hose to the receiver line and other to the

tanker.

10. Check all the connections are properly fitted & provide the jumpers to all required places.

11. Start unloading into the UG tank by slowly opening unloading valve of the tanker.

12. If there are compartments, open all the valves slowly.

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13. Keep safe distance (around 3 meters) while unloading into UG tank & keep watch on level ofthe storage tank.

14. After complete unloading, remove the hose connected to the tanker first & then from thereceiver line by repeating procedure 5-8.

15. Remove the earth connection of the tanker.

16. Solvent which is collected in bucket is pour into Solvent tank.

17. Take care of no spillages of the solvent; If spillage occurs then spreading sand on it.

Ask driver to remove tanker slowly out of the UG tank area by removing stopper & Retuningvehicle key

Protocols of handling TMA gas

1. The storage tank will be stainless steel

2. The TMA gas in the storage tank will be kept under nitrogen pressure of about 3-4 kgf/cm2

3. The temperature of the TMA gas in the storage tank will be maintained between <20 ° C.

4. The handling area of TMA gas will be flameproof

5. The storage tank and pipelines will be properly earthed using jump-overs over flanges toprevent generation of static charges

6. The vent of the TMA gas will be connected to the scrubber system

7. 2- Level transmitter, 2- pressure transmitter and 2- temperature transmitter will be providedover storage tank of TMA gas to control and monitor the parameters through DCS system

8. Control valve will be provided on chilled water line to control the temperature of thestorage tank

9. The pipe line to transfer TMA gas to reactor will be insulated to avoid increase intemperature

10. The reaction will be controlled through DCs system with adequate interlocks to avoid humanerror. Reactor will be equipped with Pressure transmitter, level transmitter and temperaturetransmitter to control the process parameters through DCS system.

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11. Gas concentration monitors will be installed in the gas storage section as well as near reactorto monitor the concentration of TMA gas in the area

12. Emergency vent will be connected to the stack with diluents

13. The electrical equipments in the reactor area will also be of flameproof type

14. Showers and eye washers will be provided in the storage area as well as near to reactor area

7.4.1.8 Emergency Control Room

The equipped Emergency Control Room should be in working order. The plant layout maps,drawing, storage details, Material safety Data Sheets (MSDS), emergency operations, manualsetc. should be kept and should be updated continuously. List of essential telephone Nos. is alsomaintained up to date. The senior and expert person should be posted as in charge of the controlroom.

7.4.1.9 Command & Control

The organization chart, for the emergency plan has been given which explains the chart ofcommand, channel of information flow, and actions as required during the emergency. The singleorganizational structure has been created on striking emergency and the same shall be continuedtill the emergency over. The Shift Supervisor shall take the initial charge as incident controller; hewill be coordinating with various agencies effectively to combat the situation. The security officeroom will be used as emergency control Room. The security gate will be used as Assembly point.The Factory Manager will act as site main controller for the unit. On arrival, he will supervise allactivities with the help of asst. Plant in- charge. The duties & responsibilities have been definedas per below.

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7.4.1.10 Identification of Hazards

The type of hazards have been identified in the previous section accordingly and riskquantification is also been done for all the raw materials.

7.4.3 List of fire extinguishers & fire buckets provided

Type of extinguishers and location

Sr.no.

Type Units

1 ABC type Fire Extinguishers6 kg 129 kg 10

2 FOAM type Fire Extinguishers9 L 5

50 L 43 CO2 type Fire Extinguishers

2 kg 14.5 kg 56.5 kg 6

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Table – 7.10 Type of Fire Extinguishers

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7.4.4 Fire Hydrant details

SRNO

DESCRIPTION LOCATION

MATERIAL QTY REMARK

1.Fire Hydrant inplant

G-59plant Fire Hydrant hose box 21

Fire Hydrantsite

2. ' ' Fire Hydrant box keys 21 ''

3. ' 'Fire Hydrant hose boxhammer 21 ''

4. ' ' Fire Hydrant nozzels 21 ''5. ' ' Fire Hydrant TPB nozzel 0 ''

6. ' 'Fire Hydrant box ( F )Spanner 0 ''

7. ' 'Fire Hydrant hose pipe7.5M 12 ''

8. ' 'Fire Hydrant hose pipe15M 27 ''

9. ' ' Singal door hose box 10 ''10. ' ' Double door hose box 16 ''11. ' ' Fire Hydrant stand post 21 ''

12. ' 'Fire Hydrant site Hose reeldrums 7 ''

13. ' ' Fire Hydrant spinkler 71 ''14. ' ' Old MCP ( siten) 315. ' ' Old MCP pannel 116. ' ' New MCP 1117. ' ' Water release point 318. ' ' Hooter 7

19. ' 'New Fire hydrant detectionpannel 2

20. ' 'Fire Hydrant air releasevalve 3

21. ' ' Deluge valve 1Fire Hydrant

site

22. ' ' Heat Detector 20 ''

23. ' ' Smoke Detector 48 ''24. ' ' Emergency Safety Shower 2

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25. ' ' Fire sand bucket 16

26. ' 'Etp In line Inductor (Foam

generation) 1

27. ' 'Fire Hydrant etp site foamtroly 0

28. ' '(foam trolly foam ore-40 lit

)………

29. ' ' sv 2' 2' 0Fire Hydrant

site

30. ' ' sv 2' 4' 0 ''

31. ' ' sv 2' 6' 0 ''

32. ' ' P.G. 2' 9 ''

33. ' ' P.G. 2' 0 ''

34. ' ' P.G. 2' 0 ''

35. ' ' NRV 2' 0 ''

36. ' ' NRV 2' 0 ''

37. ' ' NRV 2' 0 ''

38. ' ' B .FLY all 0 ''39. ' ' pressure guage 040. ' ' '' 0

Table No. 7.11 : Location of fire hydrants points and quantity.

7.4.5 Fire Fighting Systems

Please fill the following informationFire Fighting Tank DetailsCapacity of Fire Fighting tanks 400 m3.Type of tank Overhead/ Below head overheadMaterial of Construction RCC

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Pump Capacity of fire fighting tank Jockey Pump-10.8 m3/hr.Main Pump-171 m3/hr.Diesel Pump-171 m3/hr.

No of assembly points 1No of exit points for emergencyevacuation

10

Fire Hydrant system Yes

7.4.6 Flow Diagram showing Key Persons involved in Emergency Situation and theirhierarchy.

PLANT HEAD

ASSISTANT MANAGER

(EHS)

EXECUTIVE EHS

EHS OFFICER

`ETP

CHEMISTETP

OPERATOR

FIREOFFICER

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7.4.7 Emergency Responsibilities

The responsibilities of the key personnel are appended below.

Sr. Executive

On knowing about emergency, rushes to ECC.

Helps the Incident Controller in containment of the emergency.

Ensures fire pumps in operating conditions and instructs pump house operator to be ready

for any emergency with standby arrangement.

Guides the fire fighting crew i.e. firemen, trained plant personnel and security staff.

Organizes shifting the fire fighting facilities to the emergency site, if required.

Takes guidance of the Incident Controller for firefighting as well as assesses the

requirements of outside help.

Arranges to control the traffic at the gate and the incident area.

Directs the security staff to the incident site to take part in the emergency operations under

his guidance and supervision.

Evacuates the people in the plant or in the nearby areas as advised by Site Controller.

Searches for casualties and arranges proper aid for them.

Assembles a search and evacuation team.

Arranges for safety equipment for the members of this team.

Decides which paths the evacuated workers should follow.

Maintains law and order in the area and, if necessary, seeks the help of police.

7.4.8 EHS Manager - Medical, Mutual Aid, Rehabilitation, Transport and Communication

In the event of failure of electric supply and thereby internal telephone, sets up

communication point and establishes contact with the Emergency Control Centre (ECC).

Organizes medical treatment to the injured and, if necessary, arrange to shift the injured to

nearby hospitals.

Mobilizes extra medical help from outside, if necessary.

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Keeps a list of qualified first aiders of the factory and seeks their assistance.

Maintains first aid and medical emergency requirements.

Makes sure that all safety equipment is made available to the emergency team.

Assists Site Controller with necessary data and to coordinate the emergency activities.

Assists Site Controller in updating the emergency plan, organizing mock drills,

verification of inventory of emergency facilities and furnishing report to Site Controller.

Maintains liaison with Civil Administration.

Ensures availability of canteen facilities and maintenance of rehabilitation centre.

He will liaise with Site Controller/Incident Controller.

Ensures transportation facility.

Ensures availability of necessary cash for rescue/rehabilitation and emergency

expenditure.

Controls rehabilitation of affected areas on discontinuation of emergency.

Makes available diesel/petrol for transport vehicles engaged in emergency operation.

7.4.9 EHS Manager - Essential Services

He would assist Site Controller and Incident Controller.

Maintains essential services like Diesel Generator, Water, Fire Water, compressed

Air/Instrument Air and power supply for lighting.

He would plan alternate facilities in the event of power failure, to maintain essential

services such as lighting, refrigeration plant etc.

He would organize separate electrical connections for all utilities and emergency services

so that in the event of emergency or fires, essential services and utilities are not affected.

Gives necessary instructions regarding emergency electrical supply, isolation of certain

sections etc. to shift in charge and electricians.

Ensures availability of adequate quantities of protective equipment and other emergency

materials, spares etc.

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7.4.10 General Responsibilities of Employees during an Emergency

During an emergency, it becomes more enhanced and pronounced when an emergency warning is

raised; the workers, if they are in charge of process equipment, should adopt safe and emergency

shut down and attend to any prescribed duty as essential employee. If no such responsibility is

assigned, he should adopt a safe course to assembly point and await instructions. He should not

resort to spread panic. On the other hand, he must assist emergency personnel towards objectives

of DMP.

7.4.11 Emergency Facilities

7.4.11.1 Emergency Control Centre (ECC)

M/s Galaxy surfactants Ltd has established an Emergency Control Centre. It has external

telephone, telefax and telex facility. All the Site Controller/ Incident Controller Officers, Senior

Personnel would be located here. The following information and equipment will be provided at

the Emergency Control Centre (ECC):

Intercom, telephone

P and T telephone

Safe contained breathing apparatus

Fire suit/gas tight goggles/gloves/helmets

Hand tools, wind direction/velocities indicators

Public address megaphone, hand bell, telephone directories

(Internal, P and T) factory layout, site plan

Emergency lamps/torch lights/batteries

Plan indicating locations of hazard inventories, plant control room, sources of safety

equipment, work road plan, assembly points, rescue location, vulnerable zones, and escape

routes

Hazard chart

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Emergency shut-down procedures

Nominal roll of employees

List of key personnel, list of essential employees, list of Emergency Co-ordinators

Duties of key personnel

Addresses with telephone numbers of key personnel, emergency coordinator, and essential

employees.

Important addresses and telephone numbers including Government agencies, neighboring

industries and sources of help, outside experts, chemical fact sheets, population details

around the factory.

7.4.11.2 Assembly Point

Number of assemblies depending upon the plant location would be identified wherein employees

who are not directly connected with the disaster management would be assembled for safety and

rescue. Emergency breathing apparatus, minimum facilities like water etc. would be organized. In

view of the size of plant, different locations are earmarked as assembly points. Depending upon

the location of hazard, the assembly points are to be used.

7.4.11.3 Emergency Power Supply

Plant facilities would be connected to Generator and would be placed in auto mode. Thus, water

pumps, plant’s lighting and emergency control centre, administrative building and other auxiliary

services are connected to emergency power supply. In all the blocks, flameproof type emergency

lamps would be provided.

7.4.11.4 Fire Fighting Facilities

First Aid and Firefighting equipment suitable for emergency are maintained well in each section

in the plant. This would be developed according to the statutory requirements. However, fire

hydrant line covering major areas has been laid. Fire alarms have been located in the bulk storage

areas.

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7.4.11.5 Location of Wind Sock

Windsocks exist in the plant

7.4.11.6 Emergency Medical Facilities

Stretchers, gas masks and general first aid materials for dealing with chemical burns, fire burns

etc. will be maintained in the medical centre as well as in the emergency control room. Private

medical practitioners’ help would be sought. Government hospital would be approached for

emergency help. Apart from plant first aid facilities, external facilities would be augmented.

Names of medical personnel and medical facilities in the area would be Prepared and updated.

Necessary specific medicines for emergency Treatment of burns patients and for those affected by

toxicity would be maintained. Breathing apparatus and other emergency medical equipment

would be provided and maintained. The help of nearby industrial managements in this regard

would be taken on mutual support basis.

7.4.12 Emergency Actions

7.4.12.1 Emergency Warning

Communication of emergency will be made familiar to the personnel inside the plant and people

outside. An emergency warning system has already been established in the plant.

7.4.12.2 Emergency Shutdown

There are a number of facilities which can be provided to help deal with hazardous conditions,

when a tank is on fire. The suggested arrangements are:

Stop feed

Dilute contents

Remove heat

Deluge with water

Transfer contents. Whether a given method is appropriate depends on the particular case.

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Cessation of agitation may be the best action in some instances but not in others. Stopping

of the feed may require the provision of bypass arrangements.

Methods of removing additional heat include removal through the normal cooling arrangements

or use of an emergency cooling system. Cooling facilities, which use vaporizing liquid, may be

particularly effective, since a large increase in vaporization can be obtained by dropping pressure.

7.4.12.3 Evacuation of Personnel

There could be more number of persons in the storage area and other areas in the vicinity. The

area would have adequate number of exits and staircases. In the event of an emergency,

unconnected personnel have to escape to assembly point. Operators have to take emergency

shutdown procedure and escape. Time Office maintains a copy of deployment of employees in

each shift. If necessary, persons can be evacuated by rescue teams.

7.4.12.4 All Clear Signal

Also, at the end of an emergency, after discussing with Incident Controllers and Emergency Co-

coordinators, the Site Controller orders an all clear signal. When it becomes essential, the Site

Controller communicates to the District Emergency Authority, Police, and Fire Service personnel

regarding help required or development of the situation into an Off-Site Emergency.

7.4.13 General

7.4.13.1 Employee Information

During an emergency, employees would be warned by raising siren in specific pattern. Employees

would be given training of escape routes, taking shelter, protecting from toxic effects. Employees

would be provided with information related to fire hazards, antidotes and first aid measures.

Those who would be designated as key personnel and essential employees should be given

training in emergency response.

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7.4.13.2 Public Information and Warning

The industrial disaster effects related to this plant may mostly be confined to the plant area. The

detailed risk analysis has indicated that the pool fire effects would not be felt outside. However,

as an abundant precaution, the information related to chemicals in use would be furnished to

District Emergency Authority (normally the Collector) for necessary dissemination to general

public and for any use during an offsite emergency.

7.4.13.3 Co-ordination with Local Authorities

Keeping in view the nature of the emergency, two levels of co-ordination are proposed. In the

case of an On Site Emergency, resources within the organization would be mobilized and in the

event of an extreme emergency, local authorities’ help should be sought.

In the event of an emergency developing into an offsite emergency, local authority And District

Emergency Authority (normally the Collector) would be apprised and Under his supervision, the

Off Site Disaster Management Plan would be exercised. For this purpose, the facilities that are

available locally, i.e. medical, transport, personnel, rescue accommodation, voluntary

organizations etc. would be mustered. Necessary rehearsals and training in the form of mock

drills should be organized.

7.5 Off-Site Emergency Preparedness PlanThe off-site plan will be prepared with the help of the local district authorities. The proposed plan

will be based on the following guidelines.

7.5.1 Introduction

Off-site emergency plan follows the on-site emergency plan. When the consequences of an

emergency situation go beyond the plant boundaries, it becomes an off-site emergency. Off-site

emergency is essentially the responsibility of the public administration. However, the factory

management will provide the public administration with the technical information relating to the

nature, quantum and probable consequences on the neighboring population. The off-site plan in

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detail will be based on those events, which are most likely to occur, but other less likely events,

which have severe consequence, will also be considered. Incidents, which have very severe

consequences yet have a small probability of occurrence, should also be considered during the

preparation of the plan. However, the key feature of a good off-site emergency plan is flexibility

in its application to emergencies other than those specifically included in the formation of the

plan.

The roles of the various parties who will be involved in the implementation of an off-site plan are

described below. Depending on local arrangements, the responsibility for the off-site plan should

either rest with the works management or, with the local authority. Either way, the plan should

identify an emergency coordinating officer, who would take the overall command of the off-site

activities. As with the on-site plan, an emergency control centre should be set up within which the

emergency coordinating officer can operate. An early decision will be required in many cases on

the advice to be given to people living "within range" of the accident; in particular, whether they

should be evacuated or told to go indoor. In the latter case, the decision can regularly be reviewed

in the event of an escalation of the incident.

Consideration of evacuation may include the following factors:

In the case of a major fire but without explosion risk (e.g. an oil storage tank), only houses

close to the fire are likely to need evacuation, although a severe smoke hazard may require

this to be reviewed periodically

If a fire is escalating and in turn threatening a store of hazardous material, it might be

necessary to evacuate people nearby, but only if there is time; if insufficient time exists,

people should be advised to stay indoors and shield themselves from the fire For release or

potential release of toxic materials, limited evacuation may be appropriate downwind if

there is time. The decision would depend partly on the type of housing "at risk".

Conventional housing of solid construction with windows closed offers substantial

protection from the effects of a toxic cloud, while shanty house, which can exist close to

factories, offers little or no protection

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7.5.2 Aspects Proposed to be considered in the Off-Site Emergency Plan

The main aspects, which should be included in the emergency plan, are:

7.5.2.1 Organization

Details of command structure, warning systems, implementation procedures, emergency control

centers. Names and appointments of incident controller, site main controller, their deputies and

other key personnel.

7.5.2.2 Communications

Identification of personnel involved, communication centre, call signs, network, lists of telephone

numbers.

7.5.2.3 Specialized knowledge

Details of specialist bodies, firms and people upon whom it may be necessary to call e.g. those

with specialized chemical knowledge, laboratories.

7.5.2.4 Voluntary organizations

Details of organizers, telephone numbers, resources etc.

7.5.2.5 Chemical information

Details of the hazardous substances stored or processed on each site and a summary of the risk

associated with them.

7.5.2.6 Meteorological information

Arrangements for obtaining details of weather conditions prevailing at the time and weather

forecasts.

7.5.2.7 Humanitarian arrangements

Transport, evacuation centers, emergency feeding treatment of injured, First aid, ambulances,

temporary mortuaries.

7.5.2.8 Public information

Arrangements for: (a) dealing with the media press office; (b) informing relatives, etc.

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7.5.2.9 Assessment

Arrangements for: (a) collecting information on the causes of the emergency; (b) reviewing the

efficiency and effectiveness of all aspects of the emergency plan.

7.5.2.10 Role of the Emergency Co-ordinating Officer

The various emergency services should be co-ordinated by an emergency co-ordinating officer

(ECO), who will be designated by the District Collector. The ECO should liaise closely with the

Site Controller. Again, depending on local arrangements, for very severe incidents with major or

prolonged off-site consequences, the external control should be passed on to a senior local

authority administrator or even an administrator appointed by the central or state government.

7.5.2.11 Role of the Local Authority

The duty to prepare the off-site plan lies with the local authorities. The emergency planning

officer (EPO) appointed should carry out his duty in preparing for a whole range of different

emergencies within the local authority area. The EPO should liase with the works, to obtain the

information to provide the basis for the plan. This liaison should ensure that the plan is

continually kept up to date.

It will be the responsibility of the EPO to ensure that all those organizations, which will be

involved off site in, handling the emergency, know of their role and are able to accept it by having

for example, sufficient staff and appropriate equipment to cover their particular responsibilities.

Rehearsals for off-site plans should be organized by the EPO.

7.5.2.12 Role of Police

Formal duties of the police during an emergency include protecting life and property and

controlling traffic movements. Their functions should include controlling bystanders, evacuating

the public, identifying the dead and dealing with casualties, and informing relatives of dead or

injured.

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7.5.2.13 Role of Fire Authorities

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

would take over the handling of the fire from the site incident controller on arrival at the site. The

senior fire brigade officer should also have a similar responsibility for other events, such as

explosions and toxic release. Fire authorities in the region should be apprised about the location

of all stores of flammable materials, water and foam supply points, and fire-fighting equipment.

They should be involved in on-site emergency rehearsals both as participants and, on occasion, as

observers of exercises involving on-site personnel.

7.5.2.14 Role of Health Authorities

Health authorities, including doctors, surgeons, hospitals, ambulances, and similar other

persons/institutions should have a vital part to play following a major accident, and they should

form an integral part of the emergency plan. For major fires, injuries should be the result of the

effects of thermal radiation to a varying degree, and the knowledge and experience to handle this

in all but extreme cases may be generally available in most hospitals. For major toxic releases, the

effects vary according to the chemical in question, and the health authorities should be apprised

about the likely toxic releases from the plant, which will enable them to deal with the aftermath of

a toxic release with treatment appropriate to such casualties. Major off-site incidents are likely to

require medical equipment and facilities in additional to those available locally, and a medical

"mutual aid" scheme should exist to enable the assistance of neighboring authorities to be

obtained in the event of an emergency.

7.5.2.15 Role of Government Safety Authority

This will be the factory inspectorate available in the region. Inspectors are likely to want to satisfy

themselves that the organization responsible for producing the off-site plan has made adequate

arrangements for handling emergencies of all types including major emergencies. They may wish

to see well documented procedures and evidence of exercise undertaken to test the plan. In the

event of an accident, local arrangements regarding the role of the factory inspector will apply.

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These may vary from keeping a watch to a close involvement in advising on operations. While the

industry will activate the DMP and take necessary alleviating measures and arrange to extend all

medical and security support, the factory inspectorate may be the only external agency with

equipment and resources to carry out appropriate tests to assess the impact.

7.5.3 External agencies contact details involved during emergency

Off site Emergency Plan

1. No. and names of nearest Hospitals from the industry, their address, telephone no and distancesfrom industry. ( Minimum 3 hospitals)

Sr.No.

NameofHospital

Address Telephone Distances

1 TIMAHospital

MIDC Tarapur, Near Khaira FateBoisar, Dist. Palghar

02525278444,02525278666

2.5km

TMRCTHospital

J-70,MIDC Tarapur, Boisar, Dist. Palghar 02525 27030802525 270309

2.0km

SaiLeelaHospital

Ground Floor, Satyam Building, Opp. BalajiSweets, Otaswal, Boisar, Dist. Palghar

0226167785 1.5km

2. No. and names of nearest Police Station from the industry, their address, telephone no anddistances from industry.

Sr No Name of Police Station Address Telephone Distances1 MIDC Police Station MIDC Police

Station, NavapurRd., Camlin Naka,MIDC Tarapur,Boisar, Dist.Palghar.

02525 272444 1.5km

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3. No. and names of nearest Fire Station from the industry, their address, telephone no anddistances from industry.

Sr No Name of FireStation

Address Telephone Distances

1 Boisar Fire Station Boisar Fire Station, NavapurRd, Camlin Naka, MIDCTarapur, Boisar, Dist. Palghar.

02525 27200002525 272262

1.5km

4. Names of nearest MIDC from the industry, their address, telephone no

Sr No Name of MIDC Address Telephone Distances1 Maharashtra Industrial

DevelopmentCorpn.Tarapue

MIDCTarapur,Takinaka,NavapurRd.,Dist.Palghar.

02525272389 1.5km

5. Names of nearest Municipality from the industry, their address, telephone no

Sr No Name of Municipality Address Telephone Distances1 Gram Panchyat

KolawadeGram PanchyatKolawade,PO.TAPP,Boisar,Tal.Palghar,Dist.Palghar.

02525 645340 1.5 km

6. Names of nearest Pollution Control Department from the industry, their address, telephoneno

Sr No Name of PCD Address Telephone Distances1 Maharashtra Pollution

Control Board, MIDCTarapur

MPCB Tarapur,Chitralaya, BoisarTarapur Rd. Boisar,Dist. Palghar

02525 273314 1.5km

7.6 Socio Economic status of the study area

Introduction

Social Impact Assessment (SIA) is an integral part of project planning and policy evaluation and

part of EIA report due the importance that social considerations must be included in the decision

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process. Social Impact Assessment (SIA) is understood as a process of assessing and managing

the impacts of a project, plan, program or policy on people. Social impacts include all social and

cultural consequences to human populations of any public or private actions that alter the ways in

which people live, work, play, relate to one another, organize to meet their needs, and generally

cope as members of society. Cultural impacts involve changes to the norms, values, and beliefs of

individuals that guide and rationalize their cognition of themselves and their society.

In general, the SIA process includes:

1. Understanding, managing, and controlling change.

2. Predicting probable impacts from change strategies or development projects that are to be

implemented.

3. Identifying, developing, and implementing mitigation strategies in order to minimize

potential social impacts

4. Developing and implementing monitoring programs to identify unanticipated social

impacts that may develop as a result of the social change.

5. Developing and implementing mitigation mechanisms to deal with unexpected impacts as

they develop.

6. Evaluating social impacts caused by earlier developments, projects, technological change,

specific technology, and government policy.

Aim of the study:

1. The present endeavour is to understand the socio-economic situation in the vicinity of the

proposed plant and assess the impact on the socio-economic factors of the proposed plant.

2. Secondary data were collected through various sources namely:-

3. Census of India, 2011

4. Economic Survey of Maharashtra 2013-14

5. District Social and Economic Survey of Palghar District

Table 7.12: Palghar Taluka, Palghar District, population figures for 2011

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2011 Male Female PersonUrban 86,842 69,608 1,56,480Rural 1,65,149 1,59,637 3,24,786Total 2,51,991 2,29,245 4,81,236

Source: Census of India, 2011& 2001

From the secondary data it is evident that male population was comparatively high in both the

rural & urban areas in Palghar Taluka

Table 7.13: Palghar Taluka, Palghar District child population in the age group 0 to 6 figures

for 2011

2011 Boys Girls TotalUrban 10,57 9,724 20,298Rural 20,736 20,381 41,117Total 31,310 30,105 61,415

Source: Census of India, 2011

Off the total 61,415 child population (in age group of 0 to 6) of Palghar Taluka, the population of

girl child was observed to be slightly lower than that of boys.

Table 7.14: Literacy rates by residence and sex - 2011

PalgharTehsil

Literacy rateRural

Person Male FemaleUrban 88.09 92.25 82.98Rural 75.56 83.15 67.69Total 80.69 87.05 73.63

Source: Census of India, 2011

As per the data published by Census of India, it is observed that literacy rate amongst the males

was comparatively higher in both the urban & rural areas.

Table 7.15: Basic Amenities

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Palghar TehsilFacilities/Amenities No. of villages

Total number of inhabited villages in the CD block 200No. of villages with electrification 200

No. of villages with S.T bus facility 179

No. of villages with commerce bank office 17

No. of villages with primary school 193

No. of villages with healthrelated facilities

Primary health entre 9

Primary health sub centre 61

Maternity & child welfarecentre

9

T.B centre 9

Hospital - allopathic 9

Dispensary 30

Veterinary hospital 9

Mobile health clinic 6

Family welfare centre 9

Medical practioner (withMBBS degree)

5

Medical practioner (withother degree)

116

Medicine shop 20

No. of villages with anganwadi 199

No. of villages with postoffice

Post office 20

Sub post office 35

Post & telegraph office 20

No. of villages with primary agricultural supply institutes 130

Source: Census of India 2011

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As per the Census of India 2011, 200 villages in Palghar, Tehsil are inhabited off which all

villages have electric supply, 179 villages have facilities of State Transport, 193 villages have pre

primary schools/aanganwadis. It is observed that medical/health related & post office facilities

are present only in selective villages.

Industrial profile of Palgahr District

Palghar Districts have one MIDC (Maharashtra Industrial Development Corporation) industrial

area, three Government Cooperative industrial colonies which host 5757 small registered

industries, 1883 small temporary registered industries & 427 large/medium scale industries. The

industries belong to textile, chemical, engineering & steel production categories.

Table 7.16: Taluka wise industrial profile

Sr. No. Taluka No. of industries Investment (Lakhs) Employment (No. of people)

1 Palghar 276 2,65,267 22,012

2 Vasai 45 29,130 2,197

3 Talasri 19 7,219 8,05

4 Vikramgad 0 0 0

5 Wada 80 4,00,897 9,195

6 Jawhar 0 0 0

7 Dahanu 7 1,597 7,69

8 Mokhada 0 0 0

Source: Official website of Collector Office Palghar :

http://collectorpalghar.in/industry.php?english=English

Social Commitments

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It is anticipated that the proposed project & related activities will generate further employment for

the local people which will help to increase income of the local people to some extent. The project

proponent is also actively involved in CSR activities & in continuation with same Project

Proponent will undertake locale specific CSR activities such as distribution of school stationery in

nearby schools at the project area.

R&R details in respect of land in line with state Government policy.

The project is located in the MIDC area hence R & R scheme is not applicable for this project.