CHAPTER 7 ADDITIONAL STUDIES: RISK ASSESSMENT

ENVIRONMENT IMPACT ASSESSMENT REPORT For Proposed new project for Manufacturing of various types of Resin For Vim Coats

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CHAPTER 7

ADDITIONAL STUDIES: RISK ASSESSMENT


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7.1 RISK ASSESSMENT

Introduction

Hazard analysis involves the identification and quantification of the various hazards (unsafe conditions).

On the other hand, risk assessment deals with recognition and computation of risks, the equipment in the

plant and personnel are prone to, due to accidents resulting from the hazards present in the plant.

Risk assessment follows an extensive hazard analysis. It involves the identification and assessment of

risks the neighboring populations are exposed to as a result of hazards present. This requires a thorough

knowledge of failure probability, credible accident scenario, vulnerability of population etc. Much of this

information is difficult to get or generate. Consequently, the risk assessment is often confined to maximum

credible accident studies. It provides basis for what should be type and capacity of its on-site and off-site

emergency plan also what types of safety measures shall be required.

Objectives of Risk Assessment

The objectives considered for Risk Assessment study are as follows;

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

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

To take appropriate action to control the incidents.

To safe guard employees and people in vicinity.

To minimize damage to property and neighboring environment.

To inform the employees, general public and Government authority about various types of hazards,

assessed risk, safe guards provided, residual risk if any, and role to be played by them in the event of

emergency.

To inform Police, Fire Brigade, District authority and statutory authority for providing help during

emergency.

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

through mock rehearsals.

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

Approach to the study

Risk involves the occurrence or potential occurrence of some accidents consisting of an event or sequence

of events. The risk assessment study covers the following:

Identification of potential hazard area;

Identification of representative failure cases;

Visualization of the resulting scenarios in terms of fire and explosion;

Assess the overall damage potential of the identified hazardous events and the impact zones form the

accidental scenarios;


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Furnish the recommendations on the minimization of the worst accident possibilities

Preparation of Disaster Management Plan;

Emergency Plan, which includes Occupational and Health Safety Plan.

Methodology of Risk Assessment

Quantitative risk assessment (QRA) is a means of making a systematic assessment of the risks from

hazardous activities, and forming a rational evaluation of their significance, in order to provide input to a

decision- assessment is widely used, but strictly this refers to the purely numerical assessment of risks

without any evaluation of their significance. The study has been conducted based on the premises of a

traditional Quantitative Risk Assessment.

To carry out the quantitative Risk Assessment, following methodology was adopted. Identify Vulnerable

Zone for toxic dispersion, pool fire, Area on fire (Thermal Radiation), Flash Fire, and Explosion over

pressure (Vapor Cloud Explosion) by using software, named ALOHA.

ALOHA is a computer program designed especially for use by people responding to chemical accidents,

as well as for emergency planning and training. ALOHA can predict the rates at which chemical vapors

may escape into the atmosphere from broken gas pipes, leaking tanks and evaporating puddles. It can

then predict how a hazardous gas cloud might disperse in the atmosphere after an accidental chemical

release.

ALOHA is an air dispersion model, which you can use as a tool for predicting the movement and dispersion

of gases. It predicts pollutant concentrations downwind from the sources of a spill, taking into consideration

the physical characteristics of the spilled material. ALOHA also accounts for some of the physical

characteristics of the release site, weather conditions, and the circumstances of the release. Like many

computer programs, it can solve problems rapidly and provide results in a graphic, easy to use format.

This can be helpful during an emergency response or planning for such a response.

ALOHA provide output as amount of chemical discharged from the source as well as its concentration in

air it takes into account different levels of concentrations for a specified chemical.

Preliminary Risk Analysis

Preliminary Risk Analysis Preliminary risk analysis or hazard analysis a qualitative technique which

involves a disciplined analysis of the event sequences which could transform a potential hazard into an

accident. In this technique, the possible undesirable events are identified first and then analyzed

separately. For each undesirable events or hazards, possible improvements, or preventive measures are

then formulated.

The result from this methodology provides a basis for determining which categories of hazard should be

looked into more closely and which analysis methods are most suitable. Such an analysis also proved

valuable in the working environment to which activities lacking safety measures can be readily identified.


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With the aid of a frequency/ consequence diagram, the identified hazards can then be ranked according

to risk, allowing measures to be prioritized to prevent accidents.

Mitigation Measures

The purpose of mitigation is to identify measures that safeguard the environment and the community

affected by the proposal. Mitigation is both a creative and practical phase of the EIA process. It seeks to

find the best ways and means of avoiding, minimizing and remedying impacts. Mitigation measures must

be translated into action in the correct way and at the right time, if they are to be successful. This process

is referred to as impact management and takes place during project implementation. A written plan should

be prepared for this purpose, and includes a schedule of agreed actions. Opportunities for impact

mitigation will occur throughout the project cycle.

7.2 HAZARD IDENTIFICATION

Identification of hazards in the proposed project activity is of primary significance of the analysis, and

quantification. Hazard states the characteristics of system/plant/process that presents potential for an

accident. All the components of a system/plant/process need to be thoroughly examined to assess their

potential for initiating or propagating an unplanned event/sequence of events, which can be termed as an

accident.

A core challenge faced by emergency managers is how to prevent, prepare, mitigate, respond and recover

from a myriad of hazards. Several questions arise when faced with this challenge:

What hazards exist in my area?

How frequently do they occur?

How severe can their impact be on the community, infrastructure, property, and the environment?

Which hazards pose the greatest threat to the community?

A Hazard Identification and Risk Assessment (HIRA) assist emergency managers in answering these

questions. It is a systematic risk assessment tool that can be used to assess the risks of various hazards.

There are three reasons why a HIRA is useful to the emergency management profession It helps

emergency management professionals prepare for the worst and/or most likely risks. Allows for the

creation of exercises, training programs, and plans based on the most likely scenarios. Saves time and

resources by isolating hazards that cannot occur in the designated area.

Identification of Hazardous Areas

The procedure for QRA starts with identification of major risk areas in the installation. Operation carried

out in specialty chemical manufacturing unit usually come under certain board, general categories. In

plant, major risk areas are as follows:

Bulk storage area for Raw Materials at ambient temperature and atmospheric pressure.

Process Plant involving pumping, transportation, reactors, distillation, heating, cooling, etc.

Bulk loading and unloading from storage tanks to road takers and vice versa.


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Major Hazardous Areas

The major Hazardous chemicals to be stored, transported, handled and utilized within the plot area are

summarized. Other hazards and control measures are summarized in Table-7.1. Facilities / System for

process safety, transportation, firefighting system and emergency capabilities to be adopted are stated

below.

Table 7-1 Hazards and Control

Sr.

No.

Name of the

possible hazard

or emergency

Its sources &

reasons

Effects on

persons,

property &

environment

Place of its

Effect

Control Measures

Provided

1 ELECTRICITY

(1) Burning

(2) Fire

(3) Shock

Loose

Contacts,

Weak

earthling Short

Circuit

Improper

Insulation

Burning,

Shock, Death

Surrounding

the accident

area

Proper Earthing, Periodical

Checking of joints, proper

insulations of Equipments,

etc. Flame proof fitting in

solvent storage area,

bounding and jumpers to

all solvent barrier lines

provided.

2 HOUSE

KEEPING

(1) Physical

(2) Burning

(3) Fire

(4) Chemical

Exposure

Bad House

keeping

Physical /

Chemical

Thermal

Burn Injury

(Major /

Minor)

In all

surrounding

areas i.e.

Storage,

Plants

Proper Handling, regular

cleaning, Proper

placement of material

3 PIPE LINE

LEAKAGES

Spillages etc.

(1) Corrosion

(2) Toxic gas

release

Leaking of pipe

line due

to corrosion,

Loose

contact etc.

Physical /

Chemical

Thermal

Burn Injury(Major

/ Minor)

Plant area Proper maintenance,

Proper Selection of

Material for pipe lines,

Immediate attention,

Earthing provided, flame

proof-fitting, NO SMOKING

Boards displayed.

4 Structural

Failure

Inside the

factory

(Corrosion)

Injury/Death

to persons,

damage to

property

Within the

factory

Automatic operation

Periodic Testing of safety

valves Regular Inspection

and Maintenance


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5 Toxic Release Outside the

factory

injury/Death Within &

outside the

unit

Alarm, Evacuation rescue

& shelter/ Welfare

6 Natural

Calamity

Nature Injury / Death to

persons, damage

to property

Within &

outside the

unit

Alarm, Evacuation rescue

& shelter/ Welfare

7.3 CONSEQUENCE ANALYSIS

In a plant handling hazardous chemicals, the main hazard arises due to storage, handling & use of these

chemicals. If these chemicals are released into the atmosphere, they may cause damage due to resulting

fires or vapour clouds. Blast Overpressures depend upon the reactivity class of material between two

explosive limits.

Operating Parameters

Potential vapour release for the same material depends significantly on the operating conditions.

Especially for any liquefied gas, the operating conditions are very critical to assess the damage potential.

If we take up an example of ammonia, if it is stored at ambient temperature, say 30oC, and then the vapour

release potential of the inventory is much higher as compared to the case if it is stored at 0oC.

Inventory

Inventory Analysis is commonly used in understanding the relative hazards and short listing of release

scenarios. Inventory plays an important role in regard to the potential hazard. Larger the inventory of a

vessel or a system, larger the quantity of potential release. The potential vapour release (source strength)

depends upon the quantity of liquid release, the properties of the materials and the operating conditions

(pressure, temperature). If all these influencing parameters are combined into a matrix and vapour source

strength estimated for each release case, a ranking should become a credible exercise.

Loss of containment

Plant inventory can get discharged to Environment due to Loss of Containment. Certain features of

materials to be handled at the plant need to the clearly understood to firstly list out all significant release

cases and then to short list release scenarios for a detailed examination. Liquid release can be either

instantaneous or continuous. Failure of a vessel leading to an instantaneous outflow assumes the sudden

appearance of such a major crack that practically all of the contents above the crack shall be released in

a very short time.

The more likely event is the case of liquid release from a hole in a pipe connected to the vessel. The flow

rate is depending on the size of the hole as well as on the pressure, which was present, in front of the

hole, prior to the accident. Such pressure is basically dependent on the pressure in the vessel. The

vaporization of released liquid depends on the vapour pressure and weather conditions. Such


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consideration and others have been kept in mind both during the initial listing as well as during the short

listing procedure. In the study, Maximum Credible Loss accident methodology is to be used, therefore, the

largest potential hazard inventories have been considered for consequence estimation.

7.4 QUANTITY OF HAZARDOUS CHEMICALS

Details of quantity of each hazardous chemical (including solvents) to be stored, Material of Construction

of major hazardous chemical storage tanks, dyke details, threshold storage quantity as per schedules of

the Manufacture, Storage & Import of Hazardous Chemicals Rules of major hazardous chemicals. Size of

the biggest storage tank to be provided for each raw material & product etc. is given in table shown below;

Table 7-2 (A) Details of Products Storage

Sr.

No.

Name of

the

Finished

Product

Maximu

m

Storage

Quantity

in MT

Material

of

Construct

ion (MOC)

Threshold

storage limit

as per MSHIC

rules

Types of Hazard

(Toxic/flammables

/combustible/corr

osive/hazardous)

Physic

al State

Storage

in Drum/

Tank/

Vessel

1 Solvent

Based

resin

(Alkyd

Resin)

2 MT HDPE Not Applicable Non Flammable Liquid Tank

2 Synthetic

Varnish 3 MT HDPE Not Applicable Non Flammable Liquid Barrel

3 Acrylic

Resin 2 MT HDPE Not Applicable Non Flammable Liquid Tank

4 Amino

(MF/UF)

Resin

2 MT HDPE Not Applicable Non Flammable Liquid Tank

5 Industrial

Solvent 2 MT HDPE Not Applicable Non hazardous Liquid Tank

(B) Details of Raw Materials Storage


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Sr.

No.

Name of

the Raw

Material

Maximum

Storage

Quantity in

MT

Material

of

construc

tion

(MOC)

Threshold

storage limit

as per MSHIC

rules

Types of Hazard

(Toxic/flammables

/combustible/corr

osive/hazardous)

Physical

State

Storage in

Drum/

Tank/

Vessel

1 Non-

edible Oil 3 MT

HDPE

barrel Not Applicable Non-flammable Liquid Barrel

2 Phthalic

anhydride 4 MT HDPE

Item No. 508 of

Schedule-1 of

MSHIC rules of

1989. No Min.

Qty limit.

Flammable Solid Bag

3 Malic

Anhydride 4 MT

HDPE

bag

Item No. 352 of

Schedule-1 of

MSHIC rules of

1989. No Min.

Qty limit.

May be combustible

at high

temperature.

Solid Bag

4 Poly Ol 3 MT HDPE

tank Not Applicable Non Hazardous Liquid Tank

5 NaOH 0.20 MT HDPE

barrel Not Applicable Non-flammable Liquid Barrel

6 MTO 2 MT HDPE

barrel Not Applicable Flammable Solid Barrel

7 Xylene 3 MT HDPE

barrel Not Applicable Flammable Liquid Barrel

8 Resin 1 MT HDPE

barrel Not Applicable NA Liquid Barrel

9 Monomer 5 MT HDPE

tank Not Applicable NA Liquid Tank

10 Styrene 5 MT HDPE

tank

Item No. 583 of

Schedule-1 of

MSHIC rules of

1989. No Min.

Qty limit.

Flammable Liquid Tank

11 Solvent 4 MT HDPE

tank Not applicable NA Liquid Tank


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Sr.

No.

Name of

the Raw

Material

Maximum

Storage

Quantity in

MT

Material

of

construc

tion

(MOC)

Threshold

storage limit

as per MSHIC

rules

Types of Hazard

(Toxic/flammables

/combustible/corr

osive/hazardous)

Physical

State

Storage in

Drum/

Tank/

Vessel

12 Butanol 1 MT HDPE

tank Not Applicable Flammable Liquid Tank

13

Para

Formalde

hyde

3 MT HDPE

tank Not applicable Flammable Solid Tank

14 Melamine 5 MT HDPE

bag Not Applicable

May be combustible

at high temperature Solid Bag

15 Urea 3 MT HDPE

bag Not Applicable

May be combustible

at high temperature Solid Bag

16 Slope Oil 5 MT HDPE

barrel Not Applicable Flammable Solid barrel


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7.5 HAZARDOUS CHARACTERISTICS OF PRODUCTS AND RAW MATERIALS AS PER MSIHC RULES

The hazardous characteristics of products and raw materials as per manufacture, storage and import of Hazardous Chemical

(Amendment) rules, 2000 (MSIHC) is shown as below

Table 7-3 (A) Details of Hazardous characteristics of Product

Sr.

No.

Name of

the

Products

Physical

State

B.P. oC

F.P. oC

Flammable

limit %

TLV

mg/m3

Toxicity

level

Specific

Gravity

(Water=1)

Vapour

Density

(Air=1)

Odour

threshold

Ppm

Flammability

1 Solvent

based

Resin

(Alkyd

Resin)

Liquid 154 41 0.9 to 6 288 NA 0.96 >1 NA NA

2 Synthetic

Varnish Liquid NA NA NA NA NA NA NA NA NA

3 Acrylic

Resin Liquid

243

F 68 NA NA NA 0.96 3.9 NA NA

4 Amino

(MF/UF)

Resin

Liquid NA 33 NA NA

Acute9(LD50)

= 3300 mg/kg

(rat)

1.01 NA NA NA

5 Industrial

Solvent Liquid NA NA NA NA NA NA NA NA NA


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(B) Details of hazardous characteristic of raw Materials

Sr.

No.

Name of

the

Products

Physical

State

B.P. oC

F.P. oC UEL

LEL %

TLV

mg/m3

Toxicity

level

Specific

Gravity

(Water=

1)

Vapour

Density

(Air=1)

Odour

threshold

Ppm

Flammabili

ty

1 Non-edible

Oil Liquid NA NA NA NA NA 1.33 NA NA

Non-

flammable

2 Phthalic

anhydride Solid 295°C

CLOSED

CUP:

151.67°C

OPEN

CUP:

165°C

LOWER

: 1.7%

UPPER:

10.4%

6.1

mg/m3

ORAL

(LD50):

Acute: 1530

mg/kg [Rat]

1.53 NA NA Flammable

3 Malic

Anhydride Solid 202°C

CLOSED

CUP:

103.33°C

LOWER

: 1.4%

UPPER:

7.1%

1

mg/m3

ORAL

(LD50):

Acute: 481

mg/kg [Rat]

1.48 3.4 NA

May be

combustible

at high

temperature.

4 Poly Ol Liquid NA NA NA NA NA NA NA NA NA

5 NaOH Solid 1388°

C NA NA 2 ppm NA 2.13 NA Odorless

Non-

flammable

6 MTO Liquid 165°C

CLOSED

CUP:

35°C

LOWER

: 0.8%

100

ppm

ORAL

(LD50):

Acute: 5760

mg/kg [Rat]

0.861 4.69 100 Flammable


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Sr.

No.

Name of

the

Products

Physical

State

B.P. oC

F.P. oC UEL

LEL %

TLV

mg/m3

Toxicity

level

Specific

Gravity

(Water=

1)

Vapour

Density

(Air=1)

Odour

threshold

Ppm

Flammabili

ty

7 Xylene Liquid 138.5°

C

CLOSED

CUP:

24°C

OPEN

CUP:

37.8°C

LOWER

: 1%

UPPER:

7%

150

ppm

ORAL

(LD50):

Acute: 4300

mg/kg [Rat]

0.864 3.7 Sweetish. Flammable

8 Resin Liquid NA NA NA NA NA NA NA NA NA

9 Monomer Liquid NA NA NA NA NA NA NA NA NA

10 Styrene Liquid 145.2°

C

CLOSED

CUP:

31.1°C

OPEN

CUP:

36.7°C

LOWER

: 1.1%

UPPER:

6.1%

100

ppm

ORAL

(LD50):

Acute: 2650

mg/kg [Rat]

0.906 3.59 Sweetish.

Aromatic Flammable

11 Solvent Liquid NA NA NA NA NA NA NA NA NA

12 Butanol Liquid 117.7°

C

CLOSED

CUP:

28.9°C

OPEN

CUP:

36.1°C

LOWER

: 1.4%

UPPER:

11.2%

152

mg/m3

ORAL

(LD50):

Acute: 790

mg/kg [Rat.]

0.81 2.55 Vinous.

(Slight.) Flammable


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Sr.

No.

Name of

the

Products

Physical

State

B.P. oC

F.P. oC UEL

LEL %

TLV

mg/m3

Toxicity

level

Specific

Gravity

(Water=

1)

Vapour

Density

(Air=1)

Odour

threshold

Ppm

Flammabili

ty

13

Para

Formaldeh

yde

Solid NA

CLOSED

CUP:

70°C

LOWER

: 7%

UPPER:

73%

NA

ORAL

(LD50):

Acute: 800

mg/kg [Rat]

1.46 1.03

Formaldehyd

e

Pungent.

(Slight.)

Flammable

14 Melamine Solid NA

CLOSED

CUP:

Higher

than

93.3°C

NA NA

ORAL

(LD50):

Acute: 3161

mg/kg [Rat].

1.573 4.34 NA

May be

combustible

at high

temperature

15 Urea Solid NA NA NA NA

ORAL

(LD50):

Acute: 8471

mg/kg [Rat]

1.323 2.07

Almost

odorless

May be

combustible

at high

temperature

16 Slope Oil Liquid NA NA NA NA

Dermal

LD50

Rabbit =

2000 mg/kg

NA NA Slightly

pungent. Flammable


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Antidotes for Toxic Substance

Table 7-4 Toxic Substance

Sr. No. Toxic Substance Antidotes

1 styrene Use anti-bacterial cream in case of skin contact

2 urea Use anti-bacterial cream in case of skin contact

3 Para formadehyde Use emollient cream in case of skin contact

4 xylene Use anti-bacterial cream in case of skin contact

Minimization the Manual Handling of Hazardous Chemicals:

Forklifts will be used for unloading chemical bags, bags movements within plant, etc.

Cranes, hoists, pallet trucks, conveyors, etc. shall be used as per the requirement, to eliminate manual

handling.

Change the nature of the work

SOPs, work instructions will be prepared and followed.

Offer proper training – inexperienced workers are more likely to be injured.

Providing information, training, instruction and supervision

Avoiding spillage or overflow, including overflow protection on equipment and storage

7.6 PRECAUTION FOR STORAGE

Storage shall be in cool, dry well-ventilated location away from alkaline oxidizing agent, storing acid

nitroaromatic compound metal, heat, any area where the fire hazard may be acute.

Outside or detached storage shall be done for solvents storage and separate from incompatible

Dyke wall shall be provided to all storage tanks

Use corrosion resistant structural material in the storage area.

Effective ventilation should be applied to prevent accumulation of flammable vapours.

Quantities of all flammable substance should be kept to absolute minimum.

Vessel shall be bonded and grounded for transfer to avoid static sparks.

A closed system transfer of flammable /toxic chemical should be used to prevent emission of

flammable vapor.

Safety device such as automatic temp. Control sensor could be used to warm operators of overheating

in process vessels so that appropriate measure taken immediately.

Regular housekeeping should be practiced to minimize flammable dust accumulation.

Storage and use area shall be No smoking area.

Use non-sparking type tools and equipment, including explosion proof ventilation.


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Special protective equipment for maintenance breaks in or where exposures may exceed established

exposure levels.

Smoking, welding, flam cutting and other hot work should be prohibited where flammable material is

handled.

Avoiding cross contamination of street clothes. Safety shower and eye washer shall be installed near

storage area.

Lightening arrestor on all chimney and building shall be provided.

Safety permit system shall be followed for loading, unloading of hazardous chemical.

Fencing, caution note, hazardous identification board should be provided.

Only authorized person shall be permitted in storage tank area and register will be maintained.

Action plan for handling and safety system

Unload by gravitational flow pumping. Never used pressurized unloading.

Air Vent should be provided.

Avoid over heating which lead spillage and cause thermal expansion.

Used method for unloading truck or tanker, by pumping from top of vessel. NRV shall be provided on

pump discharge line.

Alternative vessel may be unloaded from top by pressuring with compressed nitrogen or from bottom

of pumping or nitrogen pressurization.

Any solidified material in vessel should be melted by applying low pressure (60 psig) steam or warm

water to vessel heating coil.

TERM CARD will be provided to all transporters and shall be trained for transportation Emergency of

hazardous chemicals.

Personal Protective Equipment (safety goggles, hand gloves, apron, masks, gum boots etc.) shall be

provided.

Step if a spill Occurs:

Stop or reduce the release of material, if it can be done safely.

If there are noxious vapors, evacuate and notify supervisor or emergency coordinator.

Eliminate all sources of ignition.

Evacuate all person not wearing protective equipment from the area of the spill or leak until cleanup

is complete.

Notify supervisor or emergency coordinator of the spill.

Do not walk through spilled product. Avoid skin contact and inhalation.

Stay upwind and keep out of low lying area.

For large spills and fires, immediately call your fire department.

Earthling /bonding shall be provided for static charges.


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Container shall be bonded and grounded for transfer to avoid static sparks.

Emergency equipment present on site

Fire extinguishers

Industrial first aid kit

Portable eye- wash station, capable of supplying 15 minutes of water.

Emergency shower

Ample supply of potable water for washing as well as for drinking purpose.

Emergency communication devices, such as mobile phone, or two way radios

Vehicle suitable for emergency transport

7.7 DETAILS OF THE STORAGE AREA

This includes; details of the storage area for flammable chemicals, details of flame proof electrical fittings,

DCP extinguishers and other safety measures proposed. Specific safety details / provisions for various

hazardous chemicals and detailed fire control plan for flammable substances and processes showing

hydrant pipeline network, provision of D.G.Sets, fire pumps, jockey pump, toxic gas detectors etc.

Table 7-5 Details of Proposed Fire Extinguishers as per IS 15683

Sr.

No.

Type of Fire Extinguishers Capacity Qty

1 ABC DCP Stored pressure type 06 KG 7

2 ABC DCP Stored Pressure type 02 KG 6

3 DCP BC TYPE 06 KG 8

4 MECHANICAL FOAM 50 LITRE 7

5 CO2 TYPE 4.5 KG 15

Above fire safety devices will be provided to protect plant from any malfunctioning of plant

equipments. Following fire protection systems will be provided.


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Figure 7-1 Fire hydrant Drawing

Fire Protection Measures

Water storage of adequate capacity to meet the requirements of water for firefighting purposes.

Fixed fire Installation will be installed such as Fire hydrants, Fire hose reel and automatic sprinkler

system will be provided.

HIRARC (Hazard Identification, Risk analysis and Risk Control) to be done for entire process, activity

and storage of chemicals.

Diesel driven pumps and headers to supply water to fire hydrant network.

Smoke, gas and spark detectors to be provided at chemical storage areas and process area.

Adequate Portable fire extinguishers, sand bucket, wheeled fire & safety equipment will be provided

at the required places.

Equipment required for personal safety like blankets, gloves, apron, gum boots, face mask helmets,

safety belts, first aid boxes etc. to be provided. Proximity suits and self-contained breathing apparatus

to be provided.

Dedicated, experienced Firefighting trained persons will be deployed.

Emergency evacuation plan will be prepared and displayed.

Emergency phone number will be displayed at strategic locations.

Emergency drills will be carried out periodically to ensure preparedness must continue.

All hot/cold work, height work and confined space jobs will be done with proper permit system.

Provision of flameproof electrical fittings / equipment’s.

Proper maintenance of earth pits and maintain record.

Strict enforcement of no smoking.


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Earthing and bonding to be provided to dissipate static electricity.

Periodic training and refresher courses to train the staff in safety firefighting.

Wind indicator should be provided at the highest level of the plant to know the wind direction.

Automatic sprinkler system for the flammable material storage may be provided as knock on effect in

case of fire is possible.

7.8 PRECAUTIONS DURING TRANSPORTATION OF HAZARDOUS CHEMICAL

LIQUIDS

Always use the road tankers having authorization/registration for transporting the said liquids.

Vendor will be asked to provide TREM CARD to Tanker Driver.

Tankers will have clearly marked identification of material being contained with mentioning Safety

Card.

Provide Flame Arrester on exhaust while entering tanker within premises.

Ensure Earthing Boss connection before starting any transferring.

SOP to cover routine checking of Tank farm area to be carried out for checking any spillage / leakage.

Tanks will be inspected physically daily for visual abnormality.

Readings of Temperature & Pressure will be noted, recorded & reported immediately in case of

abnormality.

Safety instruments like rupture disc, safety valves will be checked at defined duration.

Scheduled testing of tanks to be done for thickness testing.

Tanks to be painted on regular interval defined as per laws to protect them from atmospheric corrosion.

Barrels to be checked for proper fixing of bungs before sending it outside the premises.

Transportation, Unloading and Handling Procedure for Hazardous Chemicals

Table 7-6 Transportation, Unloading and Handling Procedure for Hazardous Chemicals

Sr.

No. Activity

Types of

possible

hazard

Mitigation Measures

1 Transportation

of Solvents by

road tanker

Leakage&

Spillage

Check the source of leakage point.

Do not touch damaged containers or spilled material unless

wearing appropriate protective clothing.

Stop leak if you can do it without risk.

Fire &

explosion

Use water spray to reduce vapors; do not put water directly

on leak, spill area or inside container.

Keep combustibles (wood, paper, oil, etc.) away from spilled

material.


Page 151 of 197

Sr.

No. Activity

Types of

possible

hazard

Mitigation Measures

Toxic release Isolate the area

Isolate the container

Training will be provided to driver and cleaner regarding the

safe driving, hazard of Flammable chemicals, emergency

handling.

TREM card will kept with TL.

Fire extinguishers will be kept with TL.

Flame arrestor will be provided to TL exhaust.

Instructions will be given not to stop road tanker in populated

area.

Clear Hazard Identification symbol and emergency telephone

number will be displayed as per HAZCHEM CODE.

Appropriate PPEs will be kept with TL.

2 Road tanker

unloading at

Project site.

Leakage&

Spillage





Fire &

explosion




material.





Spray the water on leakage

Priority will be given to Tanker to immediately enter the

storage premises at site and will not be kept waiting near the

gate or the main road.

Security person will check License, TREM CARD, Fire

extinguisher condition; Antidote Kit, required PPEs as per

SOP laid down.


Page 152 of 197

Sr.

No. Activity

Types of

possible

hazard

Mitigation Measures

Store officer will take sample as per sampling SOP from

sampling point.

Wheel stopper will be provided to TL at unloading platform.

The quantity remaining in the hose pipeline will be drained to

a small underground storage tank, which will be

subsequently transferred by nitrogen pressure to the main

storage tank thus ensuring complete closed conditions for

transfer from road tanker.

Finally earthing connection and wheel stopper will be

removed. Only day time unloading will be permitted.

3 Storage tank

safety

Leakage&

Spillage





Fire &

explosion




material.




SS storage tank will be provided as per IS code.

Dyke wall will be provided to storage tank.

Level transmitter will be provided with low level high level

auto cut-off provision.

Vent will be connected to water trap and vent of water trap

will be provided with flame arrestor.

Fire hydrant monitor with foam attachment facility will be

provided.

Dumping / Drain vessel/alternate vessel will be provided to

collect dyke wall spillage material.

Double Jumper clip will be provided to all Solvent handling

pipeline flanges.


Page 153 of 197

Sr.

No. Activity

Types of

possible

hazard

Mitigation Measures

4 Solvents

transfer

from

storage tank

to Day

tank

Leakage&

Spillage due

to Line rupture,

Flange

Gasket failure,

Fire,

Explosion,

Toxic release.

Double mechanical seal type FLP type pump will be

provided.

Double on / off switch will provided at tank farm and process

area near day tank. Pump auto cut off with day tank high

level will be provided.

Flame arrestor will be provided on day tank vent.

Over flow will be provided for additional safety and it will be

connected to main storage tank.

NRV will be provided on pump discharge line.

Double Jumper clip will be provided to all solvent handling

pipeline.

Double static earthing will be provided to day tank.

5 Solvent

transfer

From tank to

reactor

Leakage,

Spillage due to

Line rupture

Flange

Gasket failure,

Fire, Explosion,

Toxic release.

Gravity transfer.

Total quantity of day tank material will be charged in to

reactor at a time.

NRV will be provided on day tank outlet line.

Static earthing will be provided to storage tank.

Double Jumpers will be provided to pipeline flanges.

7.9 WORST-CASE SCENARIO

Risk assessment including prediction of the worst-case scenario and maximum credible accident

scenarios should be carried out. The worst-case scenario should take into account the maximum inventory

of storage at site at any point of time. The risk contours should be plotted on the plant layout map clearly

showing which of the facilities would be affected in case of an accident taking place. Based on the same,

proposed safeguard measures including On-Site / Off-Site Emergency Plan should be provided.

Table 7-7 Worst case scenario of chemical

Sr.

No.

Short

description of

scenario

Chemical

evolved

Types of

risk

Probabilit

y

Concentr

ation

Damage Distance

from source in

meter


Page 154 of 197

1 Release from

damage of drum

in storage area

Styrene

Monomer

Flammable unlikely 130 ppm

1100 ppm

51 meters`

22 meters

2 Flammable

chemical is

burning as it

escapes from

tank

Xylene Flammable Unlikely 10.0

kW/sq m

5.0 kW/

sq.m

17 meters

23 meters

3 Release from

damage of drum

in storage area

Butanol Flammable Unlikely 800 ppm

60 ppm

24 meters

153 meters

Definition & Explanation of Terms used

EPRG-1 : The maximum concentration in air below which it is believed nearly all individuals could

be exposed for up to one hour without experiencing other than mild transient adverse

health effects or perceiving a clearly defined objectionable odor.

EPRG-2 :

The maximum airborne concentration below which it is believed that nearly all individuals could

be exposed for up to 1 hour without experiencing or developing irreversible or other serious

health effects or symptoms which could impair an individual's ability to take protective action.

ERPG-3 : The maximum airborne concentration below which it is believed that nearly all individuals could

be exposed for up to 1 hour without experiencing or developing life threatening health effects.

AEGL-1 :

It is the airborne concentration (expressed as ppm or mg/m3) of a substance above which it is

predicted that the general population, including susceptible individuals, could experience

notable discomfort, irritation, or certain asymptomatic no sensory effects. However, the effects

are not disabling and are transient and reversible upon cessation of exposure.

AEGL-2 :

It is the airborne concentration (expressed as ppm or mg/m3) of a substance above which it is

predicted that the general population, including susceptible individuals, could experience

irreversible or other serious, long-lasting adverse health effects or an impaired ability to escape.

AEGL-3 :

It is the airborne concentration, expressed as parts per million (ppm) or milligrams per cubic

meter (mg/m3), of a substance above which it is predicted that the general population, including

susceptible individuals, could experience life-threatening health effects or death.

IDLH :

IDLH is an estimate of the maximum concentration in the air to which a healthy worker could

be exposed without suffering permanent or escape-impairing health effects.


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LEL : LEL is the minimum concentration of fuel in the air needed for a fire or an explosion to occur if

an ignition source is present. If the concentration is below the LEL, there is not enough fuel in

the air to sustain a fire or an explosion -- it is too lean.

UEL : UEL is the maximum concentration of fuel in the air that can sustain a fire or an explosion if an

ignition source is present. If the concentration is above the UEL, there is not enough oxygen to

sustain a fire or an explosion -- it is too rich (much like an engine that cannot start because it

has been flooded with gasoline).

STEL :

The concentration to which workers can be exposed continuously for a short period of time

without suffering from (1) Irritation (2) Chronic or Irreversible tissue damage (3) Narcosis of

sufficient degree to increase injury, impair self-rescue or materially reduce work efficiency and

provide that the daily TLV-TWA is not exceeded.

TWA :

The time-weighted average concentration for a normal 8-hour workday and a 40- hour

workweek, to which nearly all workers may be repeatedly exposed, day by day, without adverse

effect.

Source

Strength :

The source strength is either the rate the chemical enters the atmosphere or the burn rate,

depending on the scenario. A chemical may escape very quickly (so that source strength is

high), as when a pressurized container is ruptured, or more slowly over a longer period of time

(so that source strength is low), as when a puddle evaporates.

Threat

zone :

It represents the area within which the hazard level (toxicity, flammability, thermal radiation, or

overpressure) is predicted to exceed the Level of Concern (LOC) at some time after a release

begins.

Evaporation

Puddle :

If a liquid that has spilled and formed a puddle on the ground. ALOHA can model the puddle

either as an evaporating puddle or, if the chemical is flammable, as a Pool Fire.

Toxic Threat

Zone :

A Toxic Level of Concern (LOC) is a threshold concentration of an airborne pollutant, usually

the concentration above which a hazard may exist.

Flammable

Threat zone :

A Flammable Level of Concern (LOC) is a threshold concentration of fuel in the air above which

a flammable hazard may exist. Generally, this LOC will be some fraction of the Lower Explosive

Limit (LEL).

Threat zone

of thermal

radiation from

jet fire :

The thermal radiation effects that people experience depend upon the length of time they are

exposed to a specific thermal radiation level. Longer exposure durations, even at a lower

thermal radiation level, can produce serious physiological effects. The threat zones displayed

by ALOHA represent thermal radiation levels; the accompanying text indicates the effects on

people who are exposed to those thermal radiation levels but are able to seek shelter within

one minute. Below are some effects at specific thermal radiation levels and durations (on bare

skin):


Page 156 of 197

_ 2 kW/(sq m) -- people will feel pain after 45 seconds and receive second-degree burns after

3 minutes;

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

40 seconds; and

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

14 seconds.

Threat at

point :

It represents the specific information about the hazards at point of interest (such as schools and

hospitals) in and around the threat zones.

Worst Case scenario of Hazardous chemicals

1. Chemical Name: Styrene/Flammable chemicals

SITE DATA:

Location: VIM COATS, INDIA

Building Air Exchanges Per Hour: 0.73 (unsheltered single storied)

Time: January 11, 2018 1304 hours ST (using computer's clock)

CHEMICAL DATA:

Chemical Name: STYRENE MONOMER

CAS Number: 100-42-5 Molecular Weight: 104.15 g/mol

AEGL-1 (60 min): 20 ppm AEGL-2 (60 min): 130 ppm AEGL-3 (60 min): 1100 ppm

IDLH: 700 ppm LEL: 11000 ppm UEL: 61000 ppm

Ambient Boiling Point: 293.3° F

Vapor Pressure at Ambient Temperature: 0.013 atm

Ambient Saturation Concentration: 12,919 ppm or 1.29%

ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)

Wind: 3 meters/second from NNE at 3 meters

Ground Roughness: open country Cloud Cover: 5 tenths

Air Temperature: 33° C Stability Class: C

No Inversion Height Relative Humidity: 52%

SOURCE STRENGTH:

Leak from hole in vertical cylindrical tank

Flammable chemical escaping from tank (not burning)

Tank Diameter: 3 meters Tank Length: 6.5 meters


Page 157 of 197

Tank Volume: 45.9 cubic meters

Tank contains liquid Internal Temperature: 33° C

Chemical Mass in Tank: 38000 kilograms

Tank is 93% full

Circular Opening Diameter: 6 inches

Opening is 5 meters from tank bottom

Ground Type: Concrete

Ground Temperature: equal to ambient

Max Puddle Diameter: Unknown

Release Duration: ALOHA limited the duration to 1 hour

Max Average Sustained Release Rate: 57.8 pounds/min (averaged over a minute or more)

Total Amount Released: 3,296 pounds

Note: The chemical escaped as a liquid and formed an evaporating puddle.

The puddle spread to a diameter of 47 yards.

THREAT ZONE:

Model Run: Gaussian

Red : 24 yards --- (1100 ppm = AEGL-3 [60 min])

Note: Threat zone was not drawn because effects of near-field patchiness make dispersion predictions

less reliable for short distances.

Orange: 56 yards --- (130 ppm = AEGL-2 [60 min])


Page 158 of 197

Yellow: 259 yards --- (20 ppm = AEGL-1 [60 min])

Figure 7-2 Worst Case Scenario of styrene

2. Chemical Name: Xylene /Flammable chemicals

SITE DATA:




CHEMICAL DATA:

Chemical Name: XYLENE



Ambient Boiling Point: 144.4° C





Page 159 of 197





SOURCE STRENGTH:


Flammable chemical is burning as it escapes from tank

Tank Diameter: 1.5 meters Tank Length: 2 meters



Chemical Mass in Tank: 2500 kilograms

Tank is 81% full


Opening is 1.5 meters from tank bottom

Max Puddle Area: 1850 square meters

Max Flame Length: 12 meters Burn Duration: 2 minutes

Max Burn Rate: 131 kilograms/min

Total Amount Burned: 200 kilograms

Note: The chemical escaped as a liquid and formed a burning puddle.

The puddle spread to a diameter of 6.1 meters.

THREAT ZONE:

Threat Modeled: Thermal radiation from pool fire

Red : 17 meters --- (10.0 kW/(sq m) = potentially lethal within 60 sec)

Orange: 23 meters --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)

Yellow: 33 meters --- (2.0 kW/(sq m) = pain within 60 sec)


Page 160 of 197

Figure 7-3 worst case scenario of xylene

3. Chemical Name: Butanol /Flammable chemicals

SITE DATA:




CHEMICAL DATA:

Chemical Name: N-BUTYL ALCOHOL


PAC-1: 60 ppm PAC-2: 800 ppm PAC-3: 8000 ppm


Ambient Boiling Point: 118.7° C


Page 161 of 197








SOURCE STRENGTH:


Flammable chemical escaping from tank (not burning)

Tank Diameter: 3 meters Tank Length: 11.5 meters



Chemical Mass in Tank: 55,809 kilograms

Tank is 86% full


Opening is 8 meters from tank bottom

Ground Type: Concrete

Ground Temperature: equal to ambient

Max Puddle Area: 1850 square meters

Release Duration: ALOHA limited the duration to 1 hour

Max Average Sustained Release Rate: 31.2 kilograms/min

(averaged over a minute or more)

Total Amount Released: 1,610 kilograms

Note: The chemical escaped as a liquid and formed an evaporating puddle.

The puddle spread to a diameter of 49 meters.

THREAT ZONE:

Model Run: Gaussian

Red : 24 meters --- (8000 ppm = PAC-3)

Note: Threat zone was not drawn because effects of near-field patchiness

make dispersion predictions less reliable for short distances.


Page 162 of 197

Orange: 24 meters --- (800 ppm = PAC-2)

Note: Threat zone was not drawn because effects of near-field patchiness

make dispersion predictions less reliable for short distances.

Yellow: 153 meters --- (60 ppm = PAC-1)

Figure 7-4 worst case scenario of butanol

7.10 OCCUPATIONAL HEALTH IMPACT

Occupational health impact on the workers and mitigation measures proposed to avoid the human health

hazard along with the personal protective equipment to be provided. Provision of industrial hygienist and

monitoring of the occupational injury to workers as well as impact on the workers. Plan for periodic medical

checkup of the workers exposed. Details of work place ambient air quality monitoring plan as per Gujarat

Factories Rule.

Table 7-8 Occupational Hazards & Controls

Hazards Control Measures


Page 163 of 197

Noise Persons working in this area to be provided with Ear Plugs / Muffs.

Regular health Check-ups and records maintained in form 32 & 33 as per

GFR Requirements.

Audiometry test to be carried out for workers working in high noise area.

Acid and

Alkali Burn

Avoid manual handling by Chemical Dosing to be done by pumps.

Preventive Maintenance of Equipments & Flanges to avoid Leakages.

Safety Showers & Face Showers to be provided in all plants.

First aid kit & first aid training to be provided.

Gloves & Protective Clothing to be provided.

Chemical safety training to be conducted for awareness.

MSDS to be displayed in local language.

Store well ventilated place

Local exhaust / General dilution ventilation must be provided.

Exposure

of vapours,

fumes and

dust

Persons working in the Production area, it irritating the lung, skin, eye. Which

can be controlled by the engineering control by isolation.

Proper hygiene and decontamination facilities.

Assessment of levels of physical and chemical health hazards.

Control of hazards by various techniques.

Adequate awareness among the workers.

Engineering control is provided to decline potential health hazards.

Eye protection is provided with side shield, goggles, face Shield

Respiratory protection is provided at high dust level

Exhaust fans to be provided in production area for ventilation.

Local exhaust / General dilution ventilation must be provided.

Handling of with Safety goggles, face shield, hand gloves,

gumboot, protective clothing

Hygiene measures by hand wash, removing contaminated clothing.

Regular First Aid Training to be given to Workers

Carry out the pulmonary function test

Workplace monitoring should carried out

Liver function test and health surveillance program should be carried out.

Requisite PPE’s to be provided

1. Hand gloves

2. Safety goggles


Page 164 of 197

3. Chemical cartridge masks

4. Apron

5. Safety shoes/gum boots

6. Safety Helmet

7. Full body Safety harness with double lanyard

8. Ear plug/ Ear muff

PPE will be used. First aid will be provided. Suitable respiratory equipment, protective clothing gloves and eye

/face protection must be provided, Raw material should be kept away from heat, oxidizing substances and

source of ignition. Proper ventilation system is provided, Safety shower, eye washer must be provided

Workers Training

Unit shall establish separate training department for worker’s training. Workers training is first

step towards safety.

In this training program, workers will be trained for

Machine operating

Hazardous material handling

Emergency handling

First aid training

Use of PPE’s

Fire and Safety

7.11 ON SITE EMERGENCY PLAN

Introduction

An emergency in the premises has the potential to cause serious injury or loss of lives or extensive damage

to the property and/or environment and serious disruption both inside and outside the plant. In such cases

sometimes outside agencies are required to call for help in handling the situation. The causative factors

like plant/equipment failure, human error, earth quake, sabotage etc. will normally manifest in various

forms viz. Fire, Explosion, Toxic release, structure collapse etc.

This OEP lays down the code of conduct of all personnel in the Plants and the procedures to be adopted

by them in the event of an "Emergency". These procedures have been prepared taking into account the

minimum strength of manpower available at all times in the premises. The individuals under the direction

of the respective Team Leaders shall carry out the responsibilities assigned.

The emergency procedures outlined are suitable for round the clock coverage including holidays. These

emergency procedures shall be followed as outlined in the OEP during all shifts.


Page 165 of 197

Objectives

The overall objectives of Onsite Emergency Plan are:

To control the situation and if possible eliminate as quickly as possible.

To avoid confusion/panic and to attend the emergency with clear-cut line of action.

To minimize the loss of property to the plant as well as to our neighborhood.

To safe guard the non-affected areas.

To alert the neighborhood.

To arrange head-count and rescue operations.

Treatment of the injured.

To safeguard others by timely evacuation.

To prevent any cascade of emergencies.

Emergency

An emergency is the situation, which has potential to cause a large-scale damage or destruction to life or

property or Environment or combination of these within or outside the factory. Therefore it is essential to

have a laid down procedure to meet emergency systematically.

The "Emergency" specified in this plan will refer to occurrence of one or more of the following

natural/manmade events.

Fire

Explosion

Release of Toxic Gas/ Vapour

Spillage of flammable liquid /gas

Deliberate Sabotage, Terrorism, Air Raid etc.

Natural Calamities: - Lightening, Storm, Earthquake, Flood etc.

Collapsing of structure

Overturning of storage area containing flammable / toxic substances.

Medical help

First Aid Boxes have been provided at various strategic locations. Requisite number employees are trained

about First Aid, Liaison with nearest hospitals.

Communication system

Alarm Raising for Emergency by blowing the sirens installed

The siren will be used for raising the emergency alarm and also for all clear signals.

Emergency Siren: The wailing alarm will be sounded intermittently at fixed interval of 30 seconds for

a period of two minutes in case of emergency, such alarm will signify the employees that an emergency

has occurred and that the emergency services should be put into operation.


Page 166 of 197

Incident Controller after assessing the situation will declare that emergency is over. Till the Incident

Controller issues the declaration, all the leaders will adhere to the task and be present at the prescribed

location.

All clear signal will be sounded through continuous siren for 1 minute. Even after the emergency is

over a skeleton staff of the Rescue/Evacuation Team will be available at the site of emergency for at

least 30 minutes to ensure that the situation is absolutely free from danger.

After the emergency is over, all the team leaders should meet at the Emergency Control Center and

each team leader should submit a report to the Incident Controller about team performance and other

details observed.

In addition to the above systems, internal telephones, P.A. System, Mobile telephones, Computer

System etc. will be used for communication.

Assembly point

In case of emergency some locations are considered as Assembly Points. Depending on the wind direction

and location of emergency, Assembly Point will be declared. The employees should run across the wind

direction and not against the wind direction.

Depending upon the location of the emergency the Incident Controller will fix the Assembly Point and

Officer will announce the location of the Assembly Point. Employee’s attendance, visitors and contractors

workmen register will be made available at the Assembly Point for head count.

Emergency Control Center

Factory Manager Office will be declared as an Emergency control center. Emergency Control center is

facilities with:

Address and Telephone numbers of the Factory Inspectorate, Gujarat Pollution Control Board,

Police, Fire Brigade, Hospitals and OEP Team Members

Plant layout-indicating storage of hazardous materials, layout of fire Hydrants/extinguishers,

entrances/exits, roads etc.

Portable P.A. System, Manual Siren, flood lights, Torches, Pickaxe, Saw, Nylon Ropes.

Fire Blankets / Fire Proximity Suit, Breathing Apparatus, First Aid Box etc.

List of employees with address, telephone number, blood group etc.

Material Safety Data Sheets of all chemicals handled.

Mock Drill

Mock drills are carried out regularly to familiarize the staff with their roles, fire protection equipment/system

installed in the plant and use of personnel protective equipment. Senior officials monitor this and

shortcomings are thoroughly studied and necessary corrective measures are taken. Procedure for Mock

drills:

Inform all the employees about mock drills and the signal to be given.


Page 167 of 197

Fix the date and location of the emergency for mock drills.

Mock drills will be monitored by observers.

Raise the siren for emergency.

After hearing the siren the Incident Controller, Site Controller, Officers and Team Members should

actuate the “On-site Emergency Plan”.

7.12 OFF SITE ENERGENCY PLAN

Introduction

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

side the premises. The off-site plan is largely a matter of ensuring the co-ordination of proposed services

and their readiness as far as possible, for the specific hazards and problems, which may arise in as

incident.

Objectives

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

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

and the protection / prevention measures and control plans and to seek their help to communicate

with the public in case of major emergency.

To assist the district authorities for preparing the off-site emergency plan for the district or particular

area. We have made our key personnel and other fully aware about this aspect. The function of the

off-site plans is as under:

Structure of Off-site Emergency Plan

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

Communication facilities - List of important telephones

Specialized emergency equipment - Fire fighting equipment

Specialized Knowledge - Trained people

Voluntary Organization - Details of organization

Chemical information - MSDS of hazardous substances

Meteorological information - Weather condition, Wind velocity etc

Humanitarian arrangement - Transport, First aid, Ambulance

Role of deferent entities 7.12.4.1 Role of the factory management

The onsite and off-site plans are come together so that the emergency services are call upon at the

appropriate time and are provided with accurate information and a correct assessment of situation.


Page 168 of 197

7.12.4.2 Role of local authority

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

an emergency planning officer (EPO) to prepare whole range of different emergency within the local

authority area.

7.12.4.3 Role of Fire Authority

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

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

7.12.4.4 Role of Police

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

as emergency coordinating officer. Formal duties of the police during emergency include protection of

life and property and controlling traffic movements.

7.12.4.5 Role of health authorities

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

following a major accident and they should form an integral part of the emergency plan. Major off-site

incidents are likely to require medical equipments and facilities in addition to those available locally.

7.12.4.6 Role of the “Mutual Aid” Agonies

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

onsite and off-site emergency plan.

7.12.4.7 The Role of the factory inspectorate

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

information and help in getting mutual aid from surrounding factories. Unit will maintain the records of

details of emergency occur, corrective preventive measures to be taken. Unit will display the details like

list of assembly points, name of the persons involve in the safety team like site controller, incident

controller etc.

7.13 DO’S & DON’TS

DO’S

Wash affected part immediately with plenty of water.

Take the patients affected by toxic vapor to well-ventilated area.

In case of vapor inhalation/gas poisoning, immediately render first aid to the patient and then move

the patient to First Aid Center.

In case of vapour inhalation/gas poisoning, immediately render first aid to the patient and then move

to First Aid Center.

Use ear plug/muff in high noise area.

Work permit system to be followed before starting any hot work, vessel entry or working at height.

Barricade and mark hazardous/unsafe area.


Page 169 of 197

Ensure use of safety belt while working at height.

Electrical cables should be protected from water and from attack by corrosive substances.

Maintain good housing keeping, it will eliminate many unnecessary hazards.

Protruding nail should be pulled out or bent over.

All aisles, passage ways and stairways should be maintained, clean and unobstructed.

Employees must know the locations of fire extinguisher and fire e

During emergency be calm and do not get panicky.

Site Main Controller or Incident Controller can change the guideline based on prevailing situation.

Fire Operator / Fireman should be available at fire station till maintenance engineer take charge from

him. After that he will follow the instructions of incident controller.

Follow the instructions of Incident & site main controller.

Plants and unit may be stopped as per the instructions of site main controller and incident controller.

Those who are not required for handling emergency or running plants should move to assembly point.

All employees should guide visitors or contractors to approach assembly point.

One trained first aider must be available at the occupational health center and assist / co-ordinate

factory medical officer / male nurse during emergency.

Emergency vehicle should be available near security main gate with spark arrestor, and rush to the

emergency control center at the blowing of emergency siren. The driver of emergency vehicle will

follow the instructions of Incident Controller / Site Main Controller.

The shift engineer / Electrician to get ready to manage MCC as per the instructions Incident Controller

/ Site Main Controller.

DON’T’s

Smoking or carry cigarettes /bidis, match box, lighter, mobile phone or any instruments etc. in the

plant/battery limit area. It is prohibited.

Unauthorized entry into battery limits of every plant is prohibited.

Moving in the plant area without wearing safety helmet and safety shoes is not permitted. Wearing of

loose garments ornaments etc. in the plant area.

Cotton waste, paper, oil etc. should not be left in plant area.

Do not follow shortcuts, use proper roads, pathways, wherever provided.

Do not wear chappals or slippers in the plant.

No automobile vehicle should be allowed to enter in the plant area without muffler or exhaust.

Chewing of tobacco, betel nut, chewing gum and other such items are not allowed in any of process

utility area.

7.14 RISK REDUCTION MEASURES & RECOMMENDATION

Wind indicator should be provided at the highest level of the plant to know the wind direction.


Page 170 of 197

Automatic sprinkler system for the flammable material tanks (over ground tanks only) may be provided

as knock on effect in case of fire is possible.

Containment dykes with proper sloping and collection sumps should be provided so that any spillages

in the bulk storage and other handling areas shall not stagnate and shall be quickly lead away to a safe

distance from the source of leakage. This reduces the risk of any major fire on the bulk storages and

the risk to the environment shall be minimized/ eliminated.

Inspection of the storage tanks as per prefixed inspection schedule for thickness measurement, joint

and weld efficiency etc.

Provision of flameproof electrical fittings / equipment’s.

Proper maintenance of earth pits.

Strict compliance of security procedures like issue of identity badges for outsiders, gate passes system

for vehicles, checking of spark arrestors fitted to the tank lorries etc.

Strict enforcement of no smoking.

Periodic training and refresher courses to train the staff in safety firefighting.

Employee training and education will be carried out.

Emergency drills should be carried out periodically to ensure preparedness must continue.

Many operations involve use of highly toxic/flammable materials and these needs to be documented

as SOPs. These must be made and kept updated on priority.

Many of the raw materials used for resin are either toxic or flammable. It is therefore important to ensure

that these materials are stored in closed, well ventilated totally safe areas. A fire alarm system (heat

and smoke detection) should be provided for the storage area where the material is stored as toxic

fumes arise on combustion.

Loose drums of waste materials, often solvent laden, must be removed from the working areas and

close watch kept. Proper Earthing needs to be provided through plug type systems or through the

agitators/liquid.

Ventilation should be provided for any enclosed are where hydrocarbon or toxic vapors may

accumulate. Several such areas were noticed- these may be surveyed and tackled accordingly.

All personnel should be trained in handling emergency situations and should be apprised of their role

in handling emergency situation and to ensure adequacy of the emergency procedures simulated

exercise should be carried out. This was found wanting.

Flame arrestor should be provided.

Adequate number of caution boards highlighting the hazards of chemicals should be provided at critical

locations.

The health & physical hazards caused due to toxic, irritant, corrosive, flammable materials. All

chemicals are within Threshold Limit Value as per ACGIH.


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Monitoring of occupational hazards like noise, ventilation, chemical exposure etc. will be carried out

regularly and its record will be maintained.

CHAPTER 7 ADDITIONAL STUDIES: RISK ASSESSMENT

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