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ENVIRONMENT IMPACT ASSESSMENT REPORT M/S. AARTI INDUSTRIES LTD.(CUSTOM SYNTHESIS DIVISION),GIDC,VAPI

JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.,ANKLESHWAR 6.1

Chapter – 6

RISK ASSESSMENT & DISASTER

MANAGEMENT PLAN

In order to support the Environment Impact Assessment and Environment

Management Plan, following additional studies have been included in the report.

• Risk Assessment

• Disaster Management Plan

• Occupational Health and Safety Management System

6.1 RISK ASSESSMENT M/s. Aarti Industries Ltd. (Custom Synthesis Division) deals with various chemicals,

some of which are hazardous in nature by virtue of their intrinsic chemical properties

or their operating temperatures or pressures or a combination of them. Fire, explosion,

toxic release or combinations of them are the hazards associated with industrial plants

using hazardous chemicals. More comprehensive, systematic and sophisticated

methods of Safety Engineering, such as, Hazard Analysis and Quantitative Risk

Assessment have been developed to improve upon the integrity, reliability and safety

of industrial plants.

6.1.1 OBJECTIVES AND METHODOLOGY OF RISK

ASSESSMENT

Risk analysis 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 analysis 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.



6.1.1.1 OBJECTIVE OF RISK ASSESSMENT

Risk assessment is carried out for the following objectives:

1. To identify hazard and risk resulting from the hazards

2. To study and foresee the effects of such risks on the workers, public, property

and environment and to find out necessary control measures to prevent or

minimize risk.

3. To comply the legal requirement by various safety and environment laws of

the country.

4. To get the necessary information for Emergency planning and evacuation.

6.1.1.2 SCOPE OF THIS STUDY

It has been proposed to establish a facility for manufacturing of bulk drugs and its

Intermediates. The process deals with various hazardous chemicals. Hence, a

quantitative risk assessment (QRA) was under taken to assess the risk impacts

associated with the installation, and to establish whether these risks comply with the

applicable criteria. The QRA study in this report has specifically been conducted

considering the Terms of References (TOR) given by Industrial Projects Committee

of MoEF for Environment Clearance (EC).

The study covers following contents:

Objectives, methodology of risk assessment

Details on storage facilities

Process safety, transportation, fire fighting systems, safety features and

emergency capabilities to be adopted.

Identification of hazards

Consequence analysis

Recommendations on the basis of risk assessment

Disaster Management Plan.



6.1.1.3 METHODOLOGY TO CONDUCT RISK ASSESSMENT

Consequences of loss of containment can lead to hazardous situation in any industry

handling potentially hazardous materials. Following factors govern the severity of

consequence of the loss of containment.

• Intrinsic properties; flammability, instability and toxicity.

• Dispersive energy; pressure, temperature and state of matter.

• Quantity present

• Environmental factors; topography and weather.

Consequence analysis and calculations are effectively performed by computer

software using models validated over a number of applications. Consequence

modeling is carried out by PHAST of DNV Software.

PHAST contains data for a large number of chemicals and allows definition of

mixtures of any of these chemicals in the required proportion. The calculations by

PHAST involve following steps for each modeled failure case:

- Run discharge calculations based on physical conditions and leak size.

- Model first stage of release (for each weather category).

- Dispersion modeling taking into account weather conditions.

- In case of flammable gas release, calculate size of effect zone for fire and explosion.

6.1.2 DETAILS OF STORAGE FACILITIES The locations of storage of various chemicals have been marked on layout map

(Figure no. 6.2). Details of the raw materials have been given in the Table no. 6.1

no.A & 6.1-B.

Details of the chemicals stored at Storage Tank, Raw Material Stores, Cylinder

Storage Yard are stated in Table No 6.1 no. A



Figure : 6.1

Layout plan (locations of storage of various chemicals)



Table : 6.1-A

Storage Details of Raw Materials

Sr.No Raw Material

Max. Storage

Qty. Hazards Mode of Storage Capacity of

single Unit Mode of transportation Storage Location

1. 2-Amino-3-hydroxy

Propionic acid 5000 Kg Dust Explosin HDPE drum 50 Kg Truck Raw material stores

2. Methanol 19500 ltrs Fire Under Ground Tank 20000lts Tanker Storage Tank

3. Acetone 19500 ltrs Fire Under Ground Tank 20000lts Tanker Storage Tank

4. Thionyl chloride 5100 kg Toxic Release HDPE drum 300 Kg By Road Raw material stores

5. PCl5 8000 kg Toxic Release HDPE drum 40 Kg By Road Raw material stores

6. CHCl3 15000 lts Toxic Release Above Ground

Tank 15000lts By Road Storage Tank

7. CH3COCl 7000 kg Toxic Release HDPE drum 200 Liter By Road Raw material stores

8. Toluene 3000 kg Fire Under Ground Tank 2000 Liters Tanker

9. C4H9NO 4000 Kg Fire HDPE drum 200 Liter By Road

Storage Tank

Raw material stores

10. C5H8O 3000 Kg Fire HDPE drum 50 Kg By Road Raw material stores

11. C6H15NO 6000 Kg Fire HDPE drum 200 Liter By Road Raw material stores

12. Conc HCl 19000 ltrs Toxic Release Above Ground

Tank 20000lts Tanker Storage Tank

13. Activated charcoal 1000 kg - 30 kg Bags 30 Kg By Road Raw material stores



Sr.No Raw Material

Max. Storage



14. MDC 15000 ltrs Fire Above Ground

Tank 15000ltrs Tanker Storage Tank

15. PTSA 5000 kg Health Hazard Bags 50 Kg By Road Raw material stores

16. Pd catalyst 300 kg Fire, Explosion HDPE drum 12 Kg By Road Raw material stores

17. Hydrogen 3.0 ton Fire, Explosion Cylinder 6 Kg By Road Cylinder storage yard

18. C7H8O 2.0 ton Fire Storage tank 5000 Ltrs Tanker Storage Tank

19. Na2CO3 2000 kg Dust hazard Bags 25 Kg By Road Raw material stores

20. Na2SO4 1000 kg Dust hazard Bags 50 kg By Road Raw material stores

21. Dry HCl 47

Cylinder Toxic Release Cylinder 32 kg By Road Cylinder storage yard

22. Thiophenol 10000 Kg Health Hazard HDPE drum 200 Ltr HDPE

drum By Road Raw material stores

23. ONCB 10000 Kg Fire HDPE drum 200 Liter By Road Raw material stores

24. NaOH 3000 kg Health Hazard Bags 50 Kg By Road Raw material stores

25. DMF 10000 Kg Fire HDPE drum 200 Liter By Road Raw material stores

26. Reney nickel 300 kg Fire, explosion HDPE drum 25 Kg By Road Raw material stores

27. Phenyl

chloroformate 10000 Kg Toxic Release HDPE drum 200 Liter By Road Raw material stores

28. N- Hexane 10000 Kg Fire HDPE drum 190 Kg By Road Raw material stores



Sr.No Raw Material

Max. Storage



29. Phosphoric acid 1000 kg Toxic Release HDPE drum 25 Kg By Road Raw material stores

30. POCl3 5000 kg Toxic Release HDPE drum 25 Kg By Road Raw material stores

31. C10H10BrNO 10000 Kg Health Hazard Bags 50 Kg By Road Raw material stores

32. C8H8KNO2 10000 Kg Health Hazard Bags 50 Kg By Road Raw material stores

33. BrCH2COOC(CH3

)3 10000 Kg Health Hazard HDPE drum 25 Kg By Road Raw material stores

34. (CH3)3COK 5000 Kg Dust Explosion Bags 50 Kg By Road Raw material stores

35. NH2CH2CH2OH 5000 Kg Toxic HDPE drum 25 Liters By Road Raw material stores

36. IPA 10000 kg Fire MS drums 200 Lit By Road Raw material stores

37. C4H6O6 (Tartaric

Acid) 5000 Kg Health Hazard Bags 50 Kg By Road Raw material stores

38. Catalyst (ni) 3000 Kg Health Hazard HDPE drum 25 Kg By Road Raw material stores

39. NH3 500 Kg Toxic release Cylinder 50 Kg By Road Cylinder storage yard

40. C6H4CINO4S 5000 Kg Health Hazard HDPE drum 25 Kg By Road Raw material stores

41. C12H16O3 5000 Kg Health Hazard HDPE drum 25 Liters By Road Raw material stores

42. Cyclohexane 5000 kg Fire MS Drums 190 Kg By Road Raw material stores

43. C21H28O5 10000 Kg Health Hazard HDPE drum 200 Liter By Road Raw material stores

44. Acetic acid 4500 kg Health Hazard HDPE drum 30 Kg By Road Raw material stores

45. Acetic anhydride 4000 Kg Health Hazard HDPE drum 200 Liter By Road Raw material stores



Sr.No Raw Material

Max. Storage



46. Formic Acid 2000 kg Health Hazard HDPE drum 180 Kg By Road Raw material stores

47. KMnO4 5000 Kg Health Hazard HDPE drum 25 Liters By Road Raw material stores

48. Pottasium

hydroxide 1000 Kg Health Hazard Bags 50 Kg By Road Raw material stores

49. Ethylene dibromide 3000 kg Health Hazard HDPE drum 230 Kg By Road Raw material stores

50. Sodium sulphite 2000 kg Health Hazard HDPE drum 25 Kg By Road Raw material stores

51. Citric acid 5000 Kg Health Hazard HDPE drum 30 Kg By Road Raw material stores

52. C6H12O3

(DMTHF) 5000 Kg Fire HDPE drum 200 Liters By Road Raw material stores

53. Succindialdehyde 5000 Kg Fire Drum 25 Kg By Road Raw material stores

54. Methyl phenyl

acetate 5000 Kg Health Hazard HDPE drum 200 Kg By Road Raw material stores

55. Ethyl formate 3000 Kg Fire HDPE drum 200 Kg By Road Raw material stores

56. Lnorvoline,ethylest

er Hydrochloride 5000 Kg Health Hazard HDPE drum 50 Kg By Road Raw material stores

57. Pyruvic acid 2000 Kg Health Hazard,

Explosion Drum 25 Kg By Road Raw material stores

58. C23H29NO5S.C7H

8O3S.PTSA 10000 Kg Health Hazard HDPE drum 50 Kg By Road Raw material stores



Sr.No Raw Material

Max. Storage Qty.

Hazards Mode of Storage Capacity of single Unit

Mode of transportation Storage Location

59. Ethanol 5000 Kg Health Hazard HDPE drum 200 Liters By Road Raw material stores

60. Acetonitrile 2000 Kg Fire Drum 25 Kg By Road Raw material stores

61. L- phenyl alanine 2000 kg Dust Explosin Bags 25 Kg By Road Raw material stores

62. Formaldehyde 5000 Kg Health Hazard HDPE drum 200 Kg By Road Raw material stores

63. HBr 5000 kg Health Hazard HDPE drum 300 Kg By Road Raw material stores

64. Benzyl alcohol 19000 ltr Fire Under Ground Tank 20000 liters Tanker Storage Tank

65. PMPA 5000 kg Health Hazard MS drum 200 Kg By Road Raw material stores

66. n-Butanol 2500 kg Fire Storage tank 5000 liters Tanker Storage Tank

67. Sodium methoxide 1000 kg Health Hazard,

Fire MS drum 100 Kg By Road Raw material stores

68. MAA 5000 Kg Health Hazard Drum 50 Kg By Road Raw material stores

69. ATM 5000 Kg Health Hazard Drum 50 Kg By Road Raw material stores

70. DMA 2000 kg Health Hazard,

Explosion HDPE drum 200 Kg By Road Raw material stores

71. MCPBA 5000 Kg Health Hazard,

Fire MS drum 100 Kg By Road Raw material stores

72. Chloroform 15000 kl Health Hazard Above ground tank 20000 liters Tanker Storage Tank

73. Caffine 5000 Kg Dust

explosion Drum 50 Kg By Road Raw material stores



Sr.No Raw Material

Max. Storage


single Unit Mode of

transportation Storage Location

74. 4-methoxy phenyl

acetic acid 5000 Kg Health Hazard Bags 50 Kg By Road Raw material stores

75. Cyclohexanyle

ethyl amine 5000 Kg Health Hazard HDPE drum 200 Kg By Road Raw material stores

76. phosprous

oxychloride 5000 Kg Health Hazard Drum 25 Kg By Road Raw material stores

77. Orthoxylene 2500 kg Fire MS drum 170 Kg By Road Raw material stores

78. SBH 5000 Kg Health Hazard,

Fire HDPE Drum 50 Kg By Road Raw material stores

79. Salt. 7000 kg NA Bags 55 Kg By Road Raw material stores

80. Mandalic acid 2000 kg Dust explosion HDPE Drum 50 Kg By Road Raw material stores

81. Methyl formate 5000 Kg Health Hazard HDPE drum 300 Kg By Road Raw material stores

82. P2O5 3000 Kg Health Hazard Drum 25 Kg By Road Raw material stores

83. Cyano Acetic acid 10000 Kg Health Hazard HDPE Drum 50 Kg By Road Raw material stores

84. Ammonium Acetate 1000 kg Health Hazard Bags 50 Kg By Road Raw material stores

85. Bromine 1000 Kg Toxic Release Bottle 1.5 Kg By Road Raw material stores

86. BI 10000 kg Dust Explosion Fiber Drum 25 Kg By Road Raw material stores

87. Sod. BI Sulphate

1000 kg Dust Explosion Bags 50 Kg By Road Raw material stores



Sr.No Raw Material

Max. Storage


single Unit Mode of

transportation Storage Location

88. Sod. Bi Carbonate 1500 kg Dust Explosion Bags 50 Kg By Road Raw material stores

89. NMBA 10000 Kg Fire HDPE Drums 200 Kg By Road Raw material stores

90. Dry HCl 3000 Kg Toxic Release Cylinders 32 kg By Road Cylinder storage yard

91. Chlorin gas 5000 Kg Toxic Release Cylinders 1000 Kg By Road Cylinder storage yard

92. Liq Ammonia 5000 Kg Toxic Release HDPE Drums 40 Kg By Road Raw material stores

93. MDC 15000 ltr Fire Above GroundTank 20000 liters Tanker Storage Tank

94. AluminiumChloride 5000 kg Toxic Release Bags 25 Kg By Road Raw material stores

95. Acetyl chloride 7000 kg Toxic Release HDPE Drums 200 Kg By Road Raw material stores

96. 2,4 DFB 2500 kg Dust Explosion Fiber Drum 25 Kg By Road Raw material stores

97. Malic anhydride 3000 kg Dust Explosion Fiber Drum 25 Kg By Road Raw material stores

98. Activated carbon 1000 kg - Bags 30 Kg By Road Raw material stores



Table : 6.1-B

Hazardous properties of Chemicals

Sr.

No. Chemicals FP oC BP oC

SP.GR

.

VD

vs air

Vapour

Pressure mm

Hg @ 20oC

LEL

%

UEL

% IDLH LD50 ORAL LC50

1. Methanol 12 64.5 0.79 1.11 12.3KPa 6 36.5 - 5628 mg/kg [Rat].

64000 ppm 4 hours [Rat].

2. Acetone -20 56.2 0.79 2 24KPa 2.6 12.8 - 5800 mg/kg [Rat].

50100 mg/m 8 hours [Rat].

3. Thionyl chloride - 76 1.64 4.1 13.3KPa - - - - 500 ppm 1 hours [Rat].

4. Toluene 4.44 110.6 0.86 3.1 3.8KPa 1.1 7.1 - 636 mg/kg [Rat].


5. Conc HCl - -85 1.266 - 4227 kPa - - 50 ppm - -

6. Hydrogen - -423 - 0.07 760 mmHg @ -253 C 4 75 - - -

7. Dry HCl - -85 1.19 1.27 51.0 Kg/cm²g - - 50 ppm 900 mg/Kg (Oral – Rabbit)

3124 ppm/1 hr (Inhalation – Rat)

8. N- Hexane -22 69 0.66 3.0 124 mmHg 1.1 7.5 - >5 gm/kg oral-rat

>3367 ppm inhalation-rat

9. Phosphoric acid - 158 1.68 3.4 0.3 kPa - - - 1530 mg/kg [Rat].


10 IPA 18.3 82.5 0.84 2.07 4.4 kPa 2 12.7 - 5045 mg/kg [Rat].

12800 mg/kg [Rabbit].

11 NH3 - -33.4 0.59 - 114.4 psig 16 25 300 ppm - 2000 ppm (rat, 4 hours)

10. Cyclohexane -18 80.7 0.78 2.98 12.9 kPa 1.3 8.4 - 12705 mg/kg [Rat]. -



Sr.

No. Chemicals FP oC BP oC

SP.GR

.

VD

vs air

Vapour

Pressure mm

Hg @ 20oC

LEL

%

UEL

% IDLH LD50 ORAL LC50

11. Acetic acid 39 118.1 1.049 2.07 1.5 kPa 4 19.9 - 3310 mg/kg [Rat].

5620 ppm 1 hours [Mouse].

12. Ethylene dibromide - 131.4 2.18 6.48 11 mm of Hg - - - 108 mg/kg

[Rat]. 7150 ppm 4 hour(s)

[Rat].

13. Ethanol 12.78 78.5 0.789 1.59 5.7 kPa 3.3 19 - 7060 mg/kg [Rat].

20000 ppm 8 hours [Rat].

14. Acetonitrile 2 81.6 0.783 1.42 9.7kPa 4.4 16 - 2460 mg/kg [Rat.]. -

15. HBr - -66.9 2.812 3.636 kg/m3

3039 kPa at 93 OC - - 30 ppm

76 mg/kg (Intraperitoneal-rat)

2858 ppm for 60 minutes. (inhalation-

rat)

16. n-Butanol 34 117 0.81 2.55 0.6 kPa 1.4 11.2 - 790 mg/kg Oral, rat

8000 mg/kg Inhalation, rat

17. Sodium methoxide 33 - 1.1 1.1 - 7.3 36 - 2037 mg/kg [Rat]. -

18. Phosprous oxychloride - 107.2 1.67 5.3 28 mm of Hg - - - 380 mg/kg

[Rat]. 32 ppm 4 hour(s)

[Rat].

19. Bromine - 58.78 3.11 7.1 23.3 kPa - - - 2600 mg/kg [Rat]. -

20. Chlorin gas - -33.9 1.41 2.47 85.3 psig - - 10 ppm - 293 ppm, rat 1 hour



6.1.3 DETAILS OF SAFETY MEASURES

It is practically impossible to reduce the risk to zero. However, effective measures can

certainly reduce the risk considerably. The safety measures intend to reduce the risk

related to various hazards present at the work place.

The details of various safety measures adopted by M/s. Aarti Industries Ltd.(Custom

Synthesis Divisions) at various stages of project are as detailed below.

6.1.3.1 PROCESS SAFETY MEASURES IN EXISTING UNIT

• Safety measures have been adopted from the design stage itself.

• Safety Valve and pressure gauge are provided on reactor and its jacket

(if jacket is provided).

• To control reaction parameters and avoid run-away reactions, utility

like Chilling water, cooling water, vacuum lines, steam supply and

their alternatives are made available.

• Static earthing provision is made at design stage to all solvent handling

equipments, reactors, vessels & powder handling equipments.

• All the vessels and equipments are earthed appropriately and protected

against Static Electricity. Also for draining in drums proper earthing

facilities shall be provided.

• All emergency valves and switches and emergency handling facilities

are easily assessable.

• Free Fall of any flammable material in the vessel is avoided.

• All solvents and flammable material storage tanks is stored away from

the process plant and required quantity of material shall be charge in

reactor by pump.

• PPEs to protect against any adverse health effect during operations,

leakage, spillages or splash. PPE like Helmets, Safety Shoes, Safety

Glasses, Acid-Alkali Proof Gloves etc. is provided to the employees

and workers.



• Material Safety Data Sheets of Raw Materials & Products are made

readily available on the shop floor.

6.1.3.2 SAFETY MEASURES DURING TRANSPORTATION AND

UNLOADING OF TANKERS

• Transportation of raw materials is carried out in Drums on pallets

(through tank lorries) for liquid raw materials and solvents

• Static earthing provision is made for tanker unloading.

• Earthed Flexible Steel hose is used for solvent unloading from the road

tanker.

• Fixed pipelines with pumps are provided for solvent transfer up to

Day tanks/reactors.

• Double mechanical seal type pumps are installed.

• NRV provision has been made on all pump discharge line.

6.1.3.3 SYSTEM FOR FIRE FIGHTING

At M/s. Aarti Industries Ltd (Custom Synthesis Divisions), management has

developed a well-resourced and adequate fire fighting network. Some of the details

regarding the same areas under:

Table: 6.2

Details of fire fighting network

Type of Fire Extinguishes

Number of Fire

extinguishers

Fire Water

Reservoir Capacity

Fire Pump Capacity

Hydrant Pressure

Foam Type and

quantity

Other relevant details

ABC, DCP, CO2,Mechanical foam,

112 500m3

Mainpump-171m3/hr., Jokeypump-10.8m3/ hr, DG Engine-171m3/ hr

7.5kg/cm2

AFFF Quantity

- 700 liter.

Sand bucket

(9 lit.Capacity) -40

nos.



OTHER FIRE FIGHTING MEASURES PROPOSED FOR EXPANSION

PROJECT:

• Management shall consider the measures for fire prevention for the expansion

project at the project planning as well as commissioning stage to avoid any

outbreak of fire.

• Fire load calculation shall be carried out and Fire Extinguishers at different

locations shall be provided at appropriate locations as per the TAC guidelines.

• Working staff will be given training to operate DCP and CO2 extinguishers.

6.1.3.4 EMERGENCY CAPABILITIES

The details of Emergency Capabilities have been discussed in Disaster Management

Plan.

6.1.4 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.

6.1.4.1 IDENTIFICATION OF HAZARDOUS AREAS

The procedure for QRA starts with identification of major risk areas at site. At M/s.

Aarti Industries Ltd.(Custom Synthesis Divisions), major risk areas are as follows:

• Storage Tank

• Raw Material Stores

• Cylinder Storage Tank

The hazardous chemical storage area has been shown in Figure no. 6.2. The major

Hazardous chemicals to be stored, transported, handled and utilized within the plot

area are summarized in the Table no. 6.1-A and Table no. 6.1-B, in section no. 6.1.2.



6.1.4.2 IDENTIFICATION OF FAILURE CASES FOR HAZARDOUS

AREAS

Raw materials are being transported through roads by trucks and tankers. Mode of

storage is,

• Storage tanks

• Drums

In this regard, the failure cases which may lead to release of hazardous chemicals are

as under:

• Rupture of Drum

• Rupture of tank bottom valve

• Small gasket leaks in a flange joints.

6.1.5 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 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.

6.1.5.1 DAMAGE CRITERIA

In consequence analysis, use is made of a number of calculation models to estimate

the physical effects of an accident (spill of hazardous material) and to predict the

damage (lethality, injury, material destruction) of the effects. The calculations can

roughly be divided in three major groups:

a) Determination of the source strength parameters;

b) Determination of the consequential effects;

c) Determination of the damage or damage distances.



The basic physical effect models consist of the following.

SOURCE STRENGTH PARAMETERS

* Calculation of the outflow of liquid, vapour or gas out of a vessel or a pipe, in

case of rupture. Also two-phase outflow can be calculated.

* Calculation, in case of liquid outflow, of the instantaneous flash evaporation

and of the dimensions of the remaining liquid pool.

* Calculation of the evaporation rate, as a function of volatility of the material,

pool dimensions and wind velocity.

* Source strength equals pump capacities, etc. in some cases.

CONSEQUENTIAL EFFECTS

In a process plant, 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 dispersion of toxic vapour. Following paragraphs

gives details about various parameters affecting the consequences of a hazardous

event.

SELECTION OF DAMAGE CRITERIA

In Consequence Analysis studies, in principle three types of exposure to hazardous

effects are distinguished:

1. Heat radiation, from a jet, pool fire, a flash fire or a BLEVE.

2. Explosion

3. Toxic effects, from toxic materials or toxic combustion products.

In the next three paragraphs, the chosen damage criteria for Sr. No. 1 and 3 are given

and explained. Explosion is not included in this description as it is not relevant in

present study.

HEAT RADIATION

The consequence caused by exposure to heat radiation is a function of:

• The radiation energy onto the human body [kW/m2];



• The exposure duration [sec];

• The protection of the skin tissue (clothed or naked body).

• The limits for 1% of the exposed people to be killed due to heat radiation, and for

second-degree burns are given in the table herein:

Table: 6.3

Damages to Human Life Due to Heat Radiation

Exposure Duration Radiation for 1%

lethality (kW/m2)

Radiation for 2nd

degree burns

(kW/m2)

Radiation for first

degree burns

(kW/m2)

10 Sec 21.2 16 12.5

30 Sec 9.3 7.0 4.0

Since in practical situations, only the own employees will be exposed to heat radiation

in case of a fire, it is reasonable to assume the protection by clothing. It can be

assumed that people would be able to find a cover or a shield against thermal

radiation in 10 sec. time. Furthermore, 100% lethality may be assumed for all people

suffering from direct contact with flames, such as the pool fire, a flash fire or a jet

flame. The effects due to relatively lesser incident radiation intensity are given below.

Table: 6.4

Effects Due to Incident Radiation Intensity

Incident radiation –

kw/m2 Effect

25 Minimum Energy required for igniting wood (without flame contact).

100 % fatal in 1 min. Significant injury in 10 sec.

12.5 Minimum heat required to ignite wood (with flame contact). 1 % fatal

in 1 min. First degree burn in 10 sec.

4 Pain after 20 sec. Blistering unlikely.



INTOXICATION

The consequences from inhalation of a toxic vapour/gas are determined by the toxic

dose.

This dose D is basically determined by:

- Concentration of the vapour in air;

- Exposure duration.

Furthermore, of course, the breathing rates of the victim, as well as the specific toxic

mechanism unto the metabolism play an important role.

The dose is defined as D = Cn.t, with:

C = concentration of the toxic vapour, in [ppm] or [mg/m3];

t = exposure duration, in [sec] or [min];

n = exponent, mostly > 1.0; this exponent takes into account the fact that a

high concentration over a short period results in more serious injury

than a low concentration over a relatively longer period of exposure.

The value of n should be greater than zero but less than 5.

The given definition for D only holds if the concentration is more or less constant

over the exposure time; this may be the case for a (semi) continuous source. In case

of an instantaneous source, the concentration varies with time; the dose D must be

calculated with an integral equation:

D = ∫ Cn.dt

For a number of toxic materials, so-called Vulnerability Models (V.M.) have been

developed. The general equation for a V.M. (probit function) is:

Pr = a + b.ln (Cn.t), with

Pr = probit number, being a representation of the percentage of people suffering a certain kind of damage, for instance lethality

Pr = 2.67 means 1% of the population;

Pr = 5.00 means 50% of the population;

a and b material dependent numbers;

Cn.t = dose D, as explained above.



The values for a and b are mostly derived from experiments with animals;

occasionally, however, also human toxicity factors have been derived from accidents

in past. In case only animal experiments are available, the inhalation experiments with

rats seem to be best applicable for predicting the damage to people from acute

intoxication. Although much research in this field have been done over the past

decades, only for a limited number of toxic materials consequence models have been

developed. Often only quite scarce information is available to predict the damage

from an acute toxic exposition. Data transformation from oral intoxication data to

inhalation toxicity criteria is sometimes necessary. Generally, in safety evaluations

pessimistic assumptions are applied in these transformation calculations. The

calculated damage (distance) may be regarded as a maximum. For the purposes of a

response to a major incident, the IDLH value level has been chosen for the

‘wounded‘criteria. This type of injury will require medical attention.

6.1.5.2 ASSUMPTIONS FOR CONSEQUENCE ANALYSIS

For Consequence Analysis, assumptions regarding Meteorological, Pasquil Stability

Classes, Wind velocity, Ambient Temperature, Relative Humidity, Inventory, Ground

Roughness, Model used etc. are very important. In this report, the following

assumptions have been considered.

Table: 6.5

Weather data used for the study

Wind speed (m/s) Pasquill stability

1.5 F

1.5 D

5 D

6.1.5.3 SOFTWARE USED FOR CALCULATIONS

1. PHAST MICRO v. 6.51

2. CAMEO



6.1.5.4 SCENARIOS CONSIDERED FOR CONSEQUENCE

ANALYSIS

1. In this study, the scenarios for consequence analysis have been selected

considering:

• The physical and chemical properties of hazardous materials

• Hazards ranking by NFPA

• Operating and storage conditions of chemicals

2. Only catastrophic failure cases have been considered and not partial or small

failures. The objective of the study is emergency planning, hence only holistic

& conservative assumptions are used for obvious reasons. Hence though the

outcomes may look pessimistic, the planning for emergency concept should be

borne in mind whilst interpreting the results.

3. In this study, results of consequence analysis shall be used for;

a. Emergency Planning

b. Deciding Evacuation Routes

c. Deciding Location of Assembly Points and ECC

d. Resource Allocation for mitigation

4. Scenarios Identified for consequence analysis (Table no. 6.6).

Table : 6.6

Scenario identified for consequence analysis

Scenario Description of Scenario Pressure & Temp. Stored Quantity

Flammable Scenarios 1 Release of Methanol NTP 20 KL 2 Release of Acetone NTP 20 KL 3 Release of Toluene NTP 20 KL 4 Release of n-hexane NTP 190 Kg

Release of Toxic Chemicals 5 Release of HCl NTP 32 Kg (1 Cylinder) 6 Release of Ammonia NTP 50 Kg (1 Cylinder)



Table : 6.7

Scenario#1 – Release of Methanol

Release of Methanol due to failure of unloading hose from tanker Input Data Material Discharge Temperature Mass inventory of Material

Methanol 40oC 20 KL

Scenario Data Type of Event Hole Diameter

Failure of Unloading hose from tanker 100 mm

Late Pool Fire Results Distance (meter) Radiatio

n Level (KW/m2) 1.5/F 1.5/D

5/D

Effect if IHR at Height of simulation

25 19.1 19.3 20.3 Minimum Energy required for igniting wood (without flame contact). 100 % fatal in 1 min. Significant injury in 10 sec.

12.5 24.1 24.4 25.0 Minimum heat required to ignite wood (with flame contact). 1 % fatal in 1 min. First degree burn in 10 sec.

4 36.9 37.2 36.3 Pain after 20 sec. Blistering unlikely. Flash Fire Results

Distance (m) Concentratio

n (ppm)

Averaging Time Category 1.5/F Category 1.5/D Category 5/D

UFL (36000

0) 18.75 S 2.7 2.9 2.5

LFL (73000

) 18.75 S 2.9 3.1 3.2

LFL Frac

(36500)

18.75 S 4.0 3.5 3.6



Figure : 6.2

Risk contours for scenario#1: Risk Contous for Late Pool fire for 1.5/D weather

condition



Figure : 6.3

Risk contours for scenario#1: Risk Contous for Flash fire for LEL and 50% LEL



Figure : 6.4

Flash fire Envelope of Methanol



Table: 6.8

Scenario#2– Release of Acetone

Release of Acetone due to Leakage of unloading arm of tanker

Input Data

Material Discharge Temperature Mass inventory of Material

Acetone 40oC 20 KL

Scenario Data

Type of Event Hole Diameter

Leakage from unloading arm 100 mm

Pool Fire Results

Distance (meter) Radiation Level

(KW/m2) 1.5/F 1.5/D

5/D Effect if IHR at Height of simulation

25 23.4 23.4 26 Minimum Energy required for igniting wood (without flame contact). 100 % fatal in 1 min. Significant injury in 10 sec.


4 49.2 49.2 48.8 Pain after 20 sec. Blistering unlikely.

Flash Fire Results

Distance (m) Concentration (ppm)

Averaging Time

Category 1.5/F Category 1.5/D Category 5/D

UFL (128000) 18.75 S 3.5 2.8 2.4

LFL (26000) 18.75 S 18.5 20.1 9.7

LFL Frac (13000) 18.75 S 25.5 28 17.6



Figure : 6.5


condition



Figure : 6.6

Risk Contous for Flash fire for LEL and 50% LEL



Figure : 6.7

Flash Fire Envelope for Acetone



Table : 6.9

Scenario#3 – Release of Toluene

Release of Toluene due to failure of unloading arm of tanker Input Data


Toluene 40oC 20 KL

Scenario Data

Type of Event Hole Diameter

Tanker unloading arm failure 100 mm

Pool Fire Results

Distance (meter) Radiation Level

(KW/m2) 1.5/F 1.5/D 5/D


25 8.6 8.6 11.3 Minimum Energy required for igniting wood (without flame contact). 100 % fatal in 1 min. Significant injury in 10 sec.


4 20.6 20.6 21.8 Pain after 20 sec. Blistering unlikely.

Flash Fire Results

Distance (m) Concentration

(ppm)

Averaging Time Category 1.5/F Category 1.5/D Category 5/D

UFL (71000) 18.75 S 2.2 2.2 2.3

LFL (12000) 18.75 S 12.5 12.5 3.2

LFL Frac (6000) 18.75 S 17.8 19.4 9.7



Figure : 6.8


condition Concentration



Figure : 6.9

Risk Contous for Flash fire for LEL & 50% LEL



Figure : 6.10

Flash Fire Envelope for Toluene



Table : 6.10

Scenario#4 – Release of n-Hexane

Release of n-Hexane due to Catastrophic rupture of drum

Input Data


n-Hexane 40oC Drum Capacity:190 Kg

Scenario Data

Type of Event Mode of Failure: Catastrophic

Pool Fire Results

Distance (meter) Radiation Level (KW/m2) 1.5/F 1.5/D


25 7.97 7.98

Minimum Energy required for igniting wood (without flame contact). 100 % fatal in 1 min. Significant injury in 10 sec.

12.5 15.5 15.5

Minimum heat required to ignite wood (with flame contact). 1 % fatal in 1 min. First degree burn in 10 sec.

4 28.5 28.5 Pain after 20 sec. Blistering unlikely.

Flash Fire Results

Distance (m) Concentration

(ppm) Averaging Time

Category 1.5/F Category 1.5/D

UFL (76800) 18.75 S 3.8 3.2

LFL (10500) 18.75 S 10.5 13.3

LFL Frac (5250) 18.75 S 15.9 17.1



Figure : 6.11


condition



Figure : 6.12

Risk contour for flash fire for LEL & 50% LEL



Table : 6.11

Scenario#5– Release of HCl

Results:-

33 meter in downwind direction is considered as evacuation area.

Release Of HCl Due to 2 mm Leakage from Cylinder

Input Data

Material Discharge Temperature Mass inventory of Material to discharge

HCl 40oC Cylinder Capacity 32 Kg

Scenario Data

Type of Event Leakage size

Leakage In Cylinder 2 mm

Result

Downwind Distance (meter) IDLH Concentration Release Duration

Category 1.5/F Category 1.5/D Category 5/D

50 ppm 10 min. 32.4 15.1 No Hazard



Figure : 6.13

Risk contours for scenario#5: HCL



Table : 6.12

Scenario#6– Release of Ammonia

Release Of Ammonia Due to 3 mm Leakage from Cylinder

Input Data

Material Discharge Temperature Mass inventory of Material to discharge

Ammonia 40oC Cylinder Capacity: 50 Kg

Scenario Data Type of Event Leakage size Release rate

Leakage In Cylinder 3 mm 2 Kg/s

Result

Downwind Distance (meter) IDLH

Concentration Release Duration Category 1.5/F Category 1.5/D Category

5/D

300 ppm 10 min. 42.1 51.8 13.8

Results:-

52 meter in downwind direction is considered as evacuation area.



Figure : 6.14

Risk contours for scenario#6:



Figure : 6.15

Maximum concentration of footprint of Ammonia



6.1.5.5 Consequence Analysis Summary

Table : 6.13

Late Pool-Fire Scenarios

Ihr (kw/m2) distance in different weather condition Sr.

No. Scenario Radiation level 1.5F 1.5D 5 D

25 KW/M2 19.1 19.3 20.3

12.5 KW/M2 24.1 24.4 25.0 1 Release of Methanol

4 KW/M2 36.9 37.2 36.3

25 KW/M2 23.4 23.4 26

12.5 KW/M2 31.2 31.2 32.9 2 Release of Acetone

4 KW/M2 49.2 49.2 48.8

25 KW/M2 8.6 8.6 11.3

12.5 KW/M2 13.2 13.2 15.3 3 Release of Toluene

4 KW/M2 20.6 20.6 21.8

25 KW/M2 7.97 7.98 -

12.5 KW/M2 15.5 15.5 - 4 Release of n-Hexane

4 KW/M2 28.5 28.5 -

Table : 6.14

Flash Fire Scenarios

Distance (meter) Sr. No. Scenario Concentration

(ppm) Category 1.5/F Category 1.5/D Category 5/D

UFL (360000) 2.7 2.9 2.5

LFL (73000) 2.9 3.1 3.2 1 Release of Methanol

LFL Frac (36500) 4.0 3.5 3.6

UFL (128000) 3.5 2.8 2.4

LFL (26000) 18.5 20.1 9.7 2 Release of Acetone

LFL Frac (13000) 25.5 28 17.6

3 Release of UFL (71000) 2.2 2.2 2.3



LFL (12000) 12.5 12.5 3.2 Toluene

LFL Frac (6000) 17.8 19.4 9.7

UFL (76800) 3.8 3.2 -

LFL (10500) 10.5 13.3 - 4 Release of n-Hexane

LFL Frac (5250) 15.9 17.1 -

Table : 6.15

Toxic Release Scenarios

Downwind distance (meter) Sr. No. Scenario Idlh

concentration Category 1.5/F

Category 1.5/D

Category 5/D

1 Release of HCl 50 ppm 32.4 15.1 No Hazard

2 Release of Ammonia 300 ppm 42.1 51.8 13.8

6.1.6 RECOMMENDATIONS BASED ON CONSEQUENCE

ANALYSIS

1. Pool Fire Scenarios:

• Effect of heat radiation reaches to the farthest distance in weather condition

5D.

• Third degree burn radius (12.5 Kw/M2) is maximum in case of Acetone

(32.9m/5D) for same size of releases.

• It can be seen from the summarized table above that the maximum radius

(26m) of IHR 25 KW/m2 is reached in case of pool fire of Acetone in weather

condition of 5/D. The maximum radius of IHR 25 KW/M2 in case of

Methanol, Toluene, and n-Hexane is 20.3m (5D), 11.3m (5D), 7.98m (1.5D),

respectively.

• Toluene pool fire poses the least danger compared to the pool fires of all the

chemicals listed above for same sized leak and inventory.



2. Flash Fire Scenarios:

• Of all the chemicals listed above, Acetone vapor travels to the farthest

distance for the same sized leakage or releases in any weather condition.

• Vapor of Acetone (50 % LEL concentration) reaches as far as 28 meter. If it

gets an ignition sources in this radius, it may create a flash fire.

• Vapor of methanol (50 % LEL concentration) reaches up to 4 m only in 1.5/F

weather condition.

3. Dispersion Scenarios:

• The IDLH concentration (50 ppm) of HCl may reach up to 32.4 meter of 1.5/F

weather condition.

• The IDLH concentration (300 ppm) of Ammonia may reach up to 52 meter of

1.5/D weather condition.

• Evacuation plan to be designed considering the dispersion distances

summarized above.

6.1.7 OTHER RECOMMANDATIONS TO REDUCE THE RISK

OF FIRE, EXPLOSION AND TOXIC RELEASE (FOR

EXPANSION PROJECT)

1. Evacuation plan shall be made considering the dispersion distances

summarized above.

2. Structures, equipments and supports shall be designed considering the effects

of flash fire modeled above.

3. Fire detection and suppression facilities shall be used.

4. Procedures shall be developed for start-up and schedules shall be made for

regular inspection of plant machinery.

5. Fire load calculation will be carried out and fire fighting system shall be

installed accordingly.



6. Loading and unloading of wastes in storage tank shall only be done under the

supervision of the well trained and experienced staff.

1. SAFETY PRECAUTIONS TO BE CONSIDERED DURING

TRANSPORTATION AND HANDLING OF SOLVENTS LIKE TOLUENE,

METHANOL, HEXANE, ACETONE:

Table : 6.16

Safety precautions to be considered during Transportation and handling of solvents like

Toluene, Methanol, Hexane, Acetone:

Sr. No.

Activity Safety precautions

• Training will be provided to driver and cleaner regarding the safe driving, hazard of Flammable chemicals, emergency handling and use of SCBA sets.

• TREM card will be kept with TL.

• SCBA set will be 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.

• Hazard Identification symbol and emergency telephone number will be displayed as per HAZCHEM CODE.

• Appropriate PPEs will be kept with TL.

1 Transportation of Solvents (Toluene, Methanol, Hexane, Acetone) by road tanker

In case of leak or spill:

• Do not touch damaged containers or spilled material unless wearing appropriate protective clothing.

• Stop leak if you can do it without risk.

• 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. If a tank, rail car, or tank truck is involved in a fire, isolate it for 0.5 mi (800 m) in all directions; also consider initial evacuation for 0.5 mi (800 m) in all directions.

• Isolate the area

• Isolate the container



Sr. No.

Activity Safety precautions

2 Solvents transfer from storage tank to Day tank

• Double mechanical seal type FLP type pump shall be provided.

• Double on / off switch shall be provided at tank farm and process area near day tank. Pump auto cut off with day tank high level shall be provided.

• Flame arrestor shall be provided on day tank vent.

• Over flow shall be provided for additional safety and it shall be connected to main storage tank.

• NRV shall be provided on pump discharge line.

• Double Jumper clip shall be provided to all solvent handling pipelines.

• Double static earthing shall be provided to day tank.

3 Solvent transfer from Day tank to reactor.

• Total quantity of day tank material shall be charged in to reactor at a time.

• NRV shall be provided on day tank outlet line.

• Static earthing shall be provided to storage tank.

• Double Jumpers shall be provided to pipeline flanges.

2. FOR HAZARDOUS CHEMICAL STORAGE TANK FARM

• Class A petroleum products will be received through road tanker and stored in

storage tank as per petroleum rules.

• Tank farm will be constructed as per explosive department requirement and

separation distance will be maintained.

• Tanks shall be located and marked in designated area of hazardous chemical

storage.

• Color coding for the chemicals shall be observed in piping as distribution

network.

• Static earthing provision will be made for road tanker as well as storage tank.

• Flame arrestor with breather valve will be provided on vent line.

• Road tanker unloading procedure will be prepared and implemented.



• Fire load calculation will be done and as per fire load Hydrant System will be

provided as per NFPA std. and Fire extinguishers will be provided as per fire

load calculation.

• Spark arrestor will be provided to all vehicles in side premises.

• Flame proof type equipments and lighting will be provided.

• Lightening arrestor will be provided on the top of chimney.

• Trained and experience operator will be employed for tank farm area.

• NFPA label (hazard identification) capacity and content will be displayed on

storage tank.

• Solvents will be transferred by pump only in plant area and day tank will be

provided. Overflow line will be return to the storage tank or Pump On-Off

switch will be provided near day tank in plant.

• Jumpers will be provided on solvent handling pipe line flanges.

• Flexible SS hose will be used for road tanker unloading purpose and other

temperature connection.

• All tanks shall be uniformly tagged.

• Level indicator shall be provided in tanks.

• Industrial type electric fittings shall be provided.

• Adequate fire fighting equipments will be provided.

• Anti corrosive paint shall be done.

• Safety instruction board will be displayed.

3. FOR DRUM/CARBOY STORAGE AREA

• Proper ventilation will be provided in godown.

• Proper label and identification board /stickers will be provided in the

storage area.

• Conductive drum pallets will be provided.



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

• Separate dispensing room with local exhaust and static earthing provision

will be made.

• Materials will be stored as per its compatibility study and separate area will

be made for flammable, corrosive and toxic chemical drums storage.

• Smoking and other spark, flame generating item will be banned from the

Gate.

4. SAFETY PRECAUTIONS FOR CYLINDER STORAGE AREA:

Handling of Cylinder

• Store cylinders upright and secure them with a chain, strap, or cable to a

stationary building support or to a proper cylinder cart to prevent them from

tipping or falling.

• Completely close the valves, and keep the valve protection devices, such as

caps or guards, securely in place.

• Store cylinders in a dry, well-ventilated area at least 20 feet from

combustible materials. Do not keep cylinders in lockers. If they leak, a

buildup of flammable or other types of gases can occur inside the locker.

• Mark the storage area with proper precautionary signs, such as flammable,

oxidizer, or toxic.

• Place them in a location where they will not be subject to mechanical or

physical damage, heat, or electrical circuits to prevent possible explosion or

fire. Keep cylinders away from vehicle traffic.

• Store empty cylinders separate from full ones.

• Keep oxygen cylinders 20 feet away from fuel-gas cylinders, such as

acetylene, or separate them with a non-combustible barrier (such as a wall)

at least 5 feet high with a fire-resistance rating of at least one-half hour.



Transportation of Cylinders

• Most accidents or injuries involving cylinders happen when moving or

handling the gas cylinders.

• Use the right equipment, correct procedures, and sufficient number of

persons to lift and move cylinders to avoid personal injury and cylinder

damage.

• Wear protective footwear, safety glasses, and heavy gloves.

• Securely install the valve protection devices, such as caps or guards.

• Secure cylinders upright to a proper hand truck or cylinder cart designed for

the purpose.

• Don't drag or roll them – use a properly designed cart or hand truck.

• When using a crane, be sure to use proper cradles, nets, boats, or special

platforms designed for this purpose to prevent cylinders from falling.

• Prevent damage – handle carefully – avoid dropping or banging them.

• Do not lift by the protective cap/guard or use magnets or slings to lift or

move them since valves may be damaged or sheared off.

5. SAFETY PRECAUTIONS FOR CHLORINE GAS:

• Chlorine Cylinder shall be stored in well ventilated, isolated detached

building.

• Suitable hand truck shall be used to move cylinders.

• Pressure regulator appropriate for cylinder pressure and contents shall be used.

• Chlorine Detector and Alarm shall be installed.

• Suitable Plastic pipe work shall be used.

• Chlorine Cylinders shall be stored at 10-27oC.

• High temp. & pressure relief device shall be installed in Valve.

• Following table showing the effect of chlorine on human body.



Table : 6.17

Toxic Effect of Chlorine

Concentration Effect

0.03 – 0.1 ppm Range of odour threshold (many specify this as 0.08 ppm)

1 – 3 ppm May cause mild irritation of the eyes, nose, and throat

3 – 5 ppm

Stinging or burning in eyes, nose, and throat; may cause headache,

watering eyes, sneezing, coughing, breathing difficulty, bloody nose,

and blood tinged sputum

5 ppm or more Severe irritation of the eyes, nose, and respiratory Tract

14 – 25 ppm May be fatal after 30 minutes of exposure

25 ppm or more

Immediate breathing difficulty resulting in pulmonary edema (fluid

build-up in lungs), possibly causing suffocation and death 1000 ppm or

more Fatal after a few breaths

6. SAFETY PRECAUTIONS FOR BROMINE

• Glass lined or Lead-lined storage tank/vessel shall be used.

• All unused flanges of storage tank shall be kept tightly closed.

• Bromine pump discharge flanges shall be covered to avoid jet of Bromine

in case of leakage.

• Solution of sodium Hypochlorite shall be kept beneath the storage tank to

contain and neutralize any leakage from the tank.

• Bromine leak detectors shall be installed, preferably in diagonally opposite

directions.

• Suitable arrangement should be make to combat emergency of Major

Spillage.

• Bromine handling awareness training shall be arranged.

• Facility to isolate storage of bromine shall be provided.

• Storage of bromine shall be kept under monitoring, supervision and

surveillance.

• Work out emergency response plan shall be prepared for bromine handling.



• Following table shall be referred to in case of bromine leakage and actions

to be taken based on duration of exposure.

Table : 6.18

Final AEGLs for Bromine (7726-95-6)

7. SAFETY PRECAUTIONS FOR THIONYL CHLORIDE:

• Hand gloves, PVC apron, Face shield shall be used during handling.

• For safe handling of Thionyl Chloride, exhaust blower system shall be

connected to Caustic scrubber.

• Thionyl Chloride drum for pumping shall be opened near exhaust blower point

only.

• Vapor mask shall be used.

• Spark or static charge shall be avoided nearby working area.

• Complete scrubbing of HCl gas shall be checked during reaction through

caustic scrubber.

Table : 6.19

Antidotes for various chemicals

Chemicals Antidotes

Chlorine Deriphylline Inj., Phenobarbitone Inj., Phenobarbitone Tab.

Bromine Dexona, Avil

Thionyl Chloride Milk of Magnesia, Soda Water, Castor Oil, Soframycine

Exposure Period AEGL-1 AEGL-2 AEGL-3

10 minutes 0.033 ppm 0.55 ppm 19 ppm

30 minutes 0.033 ppm 0.33 ppm 12 ppm

60 minutes 0.033 ppm 0.24 ppm 8.5 ppm

4 hours 0.033 ppm 0.13 ppm 4.5 ppm

8 hours 0.033 ppm 0.095 ppm 3.3 ppm



6.2 DISASTER MANAGEMENT PLAN

6.2.1 DEFINING THE NATURE/LEVEL OF EMERGENCY

THE LEVEL OF EMERGENCY CAN BE CLASSIFIED IN THREE

CATEGORIES:

LEVEL - 1:

The leakage or emergency, which is confinable within the plant, premises. It may be

due to

a) Collapsing of equipment that do not affect outside premises.

b) Release of Chlorine Gas for short duration.

c) Small fire in the plant (due to leakage of solvent carrying pipeline).

LEVEL - 2:

The emergency, which is confinable within the factory premises. It may arise due to -

Leakage of Chlorine Gas for long duration.

Medium scale explosion confined to the factory premises.

Major fire (due to presence of flammable hydrocarbon in the working atmosphere)

inside the factory premises.

LEVEL - 3:

The emergency, which is not confinable within the factory premises and general

public in the vicinity likely to be affected. It may arise due to –

a) Heavy / Profuse leakage of toxic / flammable gases for a long duration

b) Explosion of high magnitude affecting the adjacent area

c) Major fire inside the factory premises.

6.2.2 OBJECTIVES OF EMERGENCY MANAGEMENT SYSTEM

The objectives of the emergency management system are summarized as under.

• To identify and assess types of emergencies due to different types of hazards.



• To work out plan with all provisions to handle emergencies and safeguard

employees and people in the vicinity of the factory.

• To provide for emergency preparedness and the periodical rehearsal of the plan.

• To plan mode of proper communication and actions to be followed in the event

of emergency.

• To keep all necessary information with respect to hazard/accident control and

emergency contacts in one document for easy and speedy reference.

• To inform employees, general public and the authorities about the hazards/risk if

any and the role to be played by them in the event of emergency.

• To control and contain the accident.

• To effect rescue and treatment of casualties.

• To inform and help relatives of casualties.

• To secure rehabilitation of affected area and restore normalcy.

• To provide information to media and government agencies.

• To preserve record, equipment etc. for investigating cause of emergency.

• To be ready for “mutual aid” if need arises to help neighboring units.

6.2.3 STRUCTURE OF EMERGENCY MANAGEMENT SYSTEM

The proposed structure of Emergency Management System includes the following

personnel’s;

• Site Main Controllers

• Incident Controllers and Deputy Incident Controllers

• Key Personnel’s

• Essential Workers

The other elements of Disaster Management Plan are:

• Assembly points

• Emergency control center



• Fire control arrangements

• Medical arrangements

• Other arrangements

6.2.3.1 ROLE OF SITE MAIN CONTROLLER

Plant head will be the site main controller. In absence of Plant Head, Safety In Charge

will act as a SMC. His task will be to co-ordinate all internal and external activities

from the Emergency Control Centre at Main Security Gate from where all operations

will be directed. He shall:

1. Immediately on being informed of the emergency and its location, will arrive

at the site, review the situation and control further actions.

2. Direct all Emergency Operations within the approved area with the following

priorities:

a. Personnel Safety,

b. Plant, Property and Environment Safety and

c. Minimum loss of production.

3. Co-ordinate to avail services from external agencies like fire brigade, hospitals

etc, if called for, following the declaration of major emergency. If necessary,

major installations in the vicinity may also be informed of the situation.

4. Exercise direct operational control of the unaffected section of the plant.

5. In consultation with the advisory team, expedite the shutting down of loading /

unloading operations of tankers and if necessary, instruct the supervisor /

security personnel to evacuate tankers.

6. Ensure that all employees are evacuated from the affected area and the

casualties, if any, are given necessary medical attention. Instruct P & A

Assistant / Security for rushing casualties to hospitals if required.

7. Liaise with fire and police officials, pollution control board officials and other

statutory bodies and advise them of all possible consequence effects outside

the premises.



8. Arrange for relief of personnel when emergency is prolonged.

9. Issue authorized statement or press release to the news – media.

10. Ensure preservation of evidence for enquiries to be conducted by statutory

authorities.

11. Authorize the sounding of “All Clear” and “Evacuation Siren”.

12. Arrange for obtaining the head – count of all personnel within the premises

and cross-checking with the data from records available for no. of persons

within the premises.

13. Nominate a person from advisory team, to maintain chronological log of event

during the entire period of emergency.

6.2.3.2 ROLE OF INCIDENT CONTROLLER AND DEPUTY

INCIDENT CONTROLLER

His primary duties are to take charge at the scene of the incident. In the initial stage he

may be required to take decisions involving the operation of the other plants or to stop

or continue any process and to take technical decisions to control the incident. The

deputy incident controller should take the charge of incident controller, if he is not

available due to any reason.

Responsibilities/Duties of Incident Controller and Deputy Incident Controller:

• Head of the concern department will act as incident controller.

• He shall take charge at the scene of incident.

• He shall immediately assess the gravity of risk and alert panel and field

operators to start controlling their respective section.

• He will work under the direction of the SMC, but till his arrival he may have

to execute following responsibilities.

• Ensure that all the Key Personnel are called.



• Direct for evacuation of plant and areas likely to be affected by the

emergency.

• He shall communicate to the SMC the type of outside help needed.

• He shall direct all emergency operations within the affected area with the

following priorities.

• Personnel safety, including of surrounding community.

• Minimum damage to Plant, Property and Environment.

• Appropriate actions to minimize loss of Production and Material.

• Give information to the head of fire fighting and rescue team and other

emergency services.

• Depending on the incident, instruct partial or total shut down, isolations,

depressurization, Nitrogen purging, fire fighting, rescue operations.

• Instruct upstream/downstream units to take emergency shutdown /cutting off

supply and other appropriate actions and emergency evacuation help etc.

• Direct for search of casualties.

• Evacuate non-essential workers/visitors/contractors to safe assembly points.

• Brief site main controller and keep him informed about the developments.

• Preserve evidences. This will be necessary for investigation for cause and

concluding preventive measures.

6.2.3.3 KEY PERSONNELS

Key Personnel are required to provide and to implement the decisions made by the

SMC in the light of information received on the developing situation at the time of

emergency. As necessary, they will decide the actions needed to shutdown plants,

evacuate personnel, carryout emergency engineering work, arrange for supplies of

equipments, utilities, carryout environment monitoring, provide catering facilities,

liaise with police, fire brigade and other local authorities, relative of casualties,

hospital, press & neighboring industries. Action at assembly points, outside shelters

and mutual aid center under the direction of the SMC. All the key personnel and other



called in so to assist shall report to the ECC. They shall be available at any time on

duty or on call or on oil duty or holiday.

6.2.3.4 ESSENTIAL WORKERS

A task force of essential trained workers (expert’s team) is available to get the work

done by the Incident Controller and the Site Main Controller. Such work will include:

1) Fire fighting and spill control till a Fire Brigade takes the charge.

2) To help the Fire Brigade and mutual aid teams, if it is so required.

3) Shutting down plant and making it safe.

4) Emergency engineering work e.g. isolating equipment, material process,

providing temporary by-pass lines, safe transfer of materials, urgent repairing

or replacement, electrical work, etc.

5) Provision of emergency power, water, lighting, instruments, equipments,

materials, etc.

6) Movement of equipment, special vehicle and transport to or from the scene of

the accident.

7) Search, evacuation, rescue and welfare.

8) The injured is given First Aid.

9) Moving tankers or other vehicles from area of risk.

10) Carrying out atmospheric test and pollution control.

11) Manning of assembly points to record the arrival of evacuated personnel.

Manning for outside shelters and welfare of evacuated persons there.

12) Assistance at causalities reception areas to record details of causalities.

13) Assistance at communication centers to handle out going and in coming calls

and to act as messengers if necessary.

14) Manning of works entrances in liaison with the police to direct emergency

vehicles entering the work, to control traffic leaving the works and to turn

away or make alternative safe arrangements for visitors, contractors and other

traffic arriving at the works.



15) Informing surrounding factories and the public as well as directed by the Site

Main Controller.

16) Any special help required.

OTHER ELEMENTS OF DMP:

6.2.3.5 ASSEMABLY POINT

In affected & vulnerable plants, all nonessential workers (who are not assigned any

emergency duty) will be evacuated from the area & they shall report to specified

Assembly Points. Assembly Points shall be located at a safe place, well away from

area of risk and least affected by the down wind direction. To ensure that workers do

not have to approach the affected area to reach the Assembly Point, proper exit routes

to be shown at appropriate places. Each Assembly Point shall be manned by a

nominated person to record the names and dept. At each Assembly Point duties of

Assembly Point In-charge shall also be displayed in brief. Before reaching an

Assembly Point or subsequently, if it is required to pass through an affected area or

due to presence of toxic substances. Suitable PPE's including respirators, helmet etc.,

shall be issued & made available with workers.

6.2.3.6 EMERGENCY CONTROL CENTER

The Emergency Control Center is the place or room from where the operations to

handle the emergency are directed and coordinated. Fire Control Room shall be

earmarked/identified as the alternative Emergency Control Room to be operated in

case of unfavorable wind direction. Adequate Telecommunication System is available

in the Emergency Control Room.

The ECC center shall be equipped with the following facilities.

1. Internal and external telephone including STD facility

2. Telephone directory

3. Telephone nos. of mutual aid centers

4. Factory layout plan

5. Map of the area

6. Employee blood group and their address



7. Messengers / Runners for sending messages

8. Adequate numbers of PPE'S

6.2.3.7 FIRE CONTROL ARRANGEMENTS

6.2.3.7.1 FIRE FIGHTING, GAS LEAK CONTROL AND RESCUE

OPERATION

A) Role of Manager (Fire and Safety) / Shift In-Charge (Fire & Safety)

1. Incident Controller will be the only person to direct the fire fighting and

Emergency operation. His duties include…

2. Keep the constant touch with the SMC / Incharge - EHS.

3. Direct the crew members to the scene of emergency and arrange replenishment

of Manpower / equipment / extinguishing media etc.

B) Role of EHS Representative:

1. On being notified about the location of fire/ gas leakage immediately proceed to

the help.

2. Decide his line of action in consultation with Incident controller and take

appropriate measures to handle the emergency.

3. Assessing the severity of the incident immediately report to emergency

controller about the gravity of the situation.

4. He will assess the extra requirement required if any from the neighboring

industry.

C) Fire crew members

1.On hearing fire alarm, emergency siren they shall immediately report to control

room and proceed to the scene of emergency and work under the direction of

IC/ Dy IC.

2.The personal availability at the scene of incident to be made optimize.



D) Emergency Squad Members

1. Total three fire emergency squads shall be made.

2. On hearing Emergency Siren, they shall immediately report to site main

controller, safety in charge or incident controller.

3. They shall combat the emergency situation as per the direction of site main

controller, safety in charge or incident controller.

4. They shall help for safe evacuation.

6.2.3.8 MEDICAL SERVICES

The roles of Medical officers are as follows;

(a) He will report immediately to the SMC/IC.

(b) He will render necessary treatment, at Occupational Health Center.

(c) He will arrange for Hospitalization and Treatment at outside hospitals, if

required.

(d) He will mobilize in getting the services of External medical agencies, other

Para –medical services etc. and transportation services etc.

(e) He will arrange for extra medical assistance/antidotes, from out, if required.

(f) He will arrange for first-aid trained volunteers for necessary help.

(g) He will liaise with the Government Health Authorities for treatment of the

affected persons nearby.

6.2.3.9 ROLE OF SECURITY IN-CHARGE (SECURITY OFFICER)

• On hearing the emergency siren, he shall find out the location of the incident

(fire / gas leak / spill / explosion) and inform the location of the same to the

key personnel coming to the plant.

• He will depute the security guards for managing gates and traffic control at the

incident site, & send remaining guards to the site of incident.

• He will prevent unauthorized entry in to the site

• He will render assistance as demanded by the safety in-charge.



• He will mobilize additional security force for help, if required.

• He will direct ambulance(s) and emergency vehicle(s) to the scene of incident.

• He will help evacuate persons within the scene of incident.

• As directed by the site main controller, he may be required to address the

public of surrounding villages for warning / evacuation.

6.2.3.10 ROLE OF MUTUAL-AID MEMBERS

• On receiving the call they shall proceed immediately with fire squad & fire

tenders.

• They will be guided to the place of the incident by the main gate security

guard.

• The fire squad in-charge will report to the safety in charge of the unit in which

the incident has occurred.

6.2.3.11 OTHER ARRANGEMENTS

Other arrangements include external transport, cranes, generator sets to supply

emergency power, environment monitoring equipment, rescue items etc. when

available resources do not meet the requirement.

STANDARD OPERATING PROCEDURE (EMERGENCY)

• As soon as emergency alarm is heard, all essential workers shall report to IC

or SMC.

• They shall carefully listen to the instructions given by IC or SMC

• According to the type of emergency/accident, they shall get equipped with

PPE/Fire fighting equipment and devices.

• The runner among the workers shall inform SMC/IC and key personnel if they

are not at site.

• The messenger amongst the workers shall deliver messages to nearby units as

per the instructions of SMC/IC.



• The in-charge of medical arrangements shall prepare first-aid and other

required facilities for the injured.

• The other essential workers shall try to control the emergency as per the

instructions given to IC.

• IC would keep SMC informed about the status of control measures being

taken at the site and ask for other requirements eg. Mutual aid, equipment etc.

if he find necessary.

• SMC would co-ordinate with outside agencies regarding control measures

being taken, need for external help, evacuation, medical treatment etc.

6.2.4 COMMMUNICATION SYSTEM

After the assessment of risk & their possible environmental impact and after making

an organization for the preparedness to control the emergency, the next most essential

step is to make us ready for Communication at the time of emergency.

Communication System is a Crucial Factor while handling emergency.

Company have quick & effective Communication System through which, any

situation, which can lead to emergency, can be informed or known to…

i. All persons working inside the plant.

ii. Key Personnel outside during normal working hours & during off-duty

hours.

iii. Outside emergency services, Statutory and Local Authorities and

iv. Neighboring facilities and public leaving in vicinity.

Each and every section, Plant & Department of the Factory shall be connected by

internal telephones. The Communication System begins with raising the alarm

declaring the emergency, Telephone messages and Procedure to communicate the

emergency to other persons & General Public.

6.2.4.1 RAISING THE ALARM

As soon as incident takes place inside the factory and is noticed by someone, the first

step is to raise the nearest manual emergency bell to alert the nearby people.



Next, he/she informs the security persons to raise the emergency siren located at the

factory gate. The security personnel shall sound the siren. The alarm sound informs

the I.C and the S.M.C that an emergency has been created and emergency

organization is to be activated. The I.C. rushes to the site and takes charge of the

scene.

Siren testing shall be done on every Monday at 17:30 Hrs (or any designated day)

with 30 second blow and shall be reported as per standard procedures defined in the

HSE documents.

6.2.4.2 DECLARING THE MAJOR EMERGENCY

Major emergency has to be declared after sufficient and through check because the

declaration of major emergency puts many agencies on action and it may disturb the

running system, which may be Costly at, time or its Consequence may be Serious.

Therefore major emergency must not be decided on whims or immature judgment or

without proper thought. Looking to all the above, we will have taken care to nominate

the persons who can declare the emergency; we will have selected them on the basis

of their knowledge & experience. These persons will be technically qualified and

experienced. They shall advice the Incident Controller or Site Main Controller

regarding the type of emergency. On being convinced, the Site Main Controller or

Incident Controller shall declare an ON-SITE emergency. The decision about major

emergency shall be taken as early as possible and without wasting time so that control

action can be started immediately.

6.2.4.3 TELEPHONE MESSAGES

After hearing the emergency alarm and during emergency or even while just receiving

the emergency message on phone, Telephone operator should be precise, sharp,

attentive and quick in receiving and noting the message and subsequently effective in

further Communication A form to record emergency telephone calls shall be available

with telephone operator or Person available in Emergency Control Center, who has to

record such calls during emergency. Telephonic messages shall be given out by the

telephone operator to Site main Controller and key personnel as per the instructions of

the Incident Controller. Telephonic messages shall also be given to authorities and

external agencies to describe the type of emergency. All details of emergency shall be



collected/delivered according to this format shall available with the telephone

operator.

6.2.4.4 COMMUNICATION OF EMERGENCY & STATUTORY

INFORMATION

COMMUNICATION OF EMERGENCY

An effective system to communicate emergency is available to communicate about

the emergency situation as mentioned below:

• Inside the factory i.e. workers including key personnel and essential workers,

on duty & inside during normal working hours.

• To key personnel and essential workers not on duty and outside during normal

working hours.

• To the outside emergency services and the Government authorities.

• To the neighboring factory & the General Public in the vicinity.

STATUTORY INFORMATION

a) Information to Workers

Set of Statutory information regarding types of hazards and their prevention and

control as directed in the Factories Act shall be prepared by the unit. This information

shall be printed in the local language and given in the form of booklet to all workers

including contract workers.

b) To the outside emergency services and authorities

Statutory information in the form of booklet shall be given to outside emergency

services and authorities.

c) To neighboring firms and the general public

Statutory information in the form of booklet will be given to neighbouring units and

the general public of the villages in the vicinity of the unit.



6.2.5 ACTION ON SITE

The activities related to emergency time activities shall be divided into two parts.

• Pre-emergency activities

• Post-emergency Activities

6.2.5.1 PRE-EMERGENCY ACTIVITIES

These activities are part of safe run of the plant and avoid emergency situation. They

are considered as the preparatory part of the Disaster Management. The details of

such activities are as follows:

1. INTERNAL SAFETY SURVEY

A safety committee to be constituted as per Factories Act. The nominated members of

the committee to be assigned the responsibility to conduct safety survey once in a

month before safety meeting. The internal safety survey includes –

• Identify various hazards in the factory

• Check whether protective equipments are in sound working condition

• Check various safety installations located at various plants for proper working

• Check sprinklers, showers, etc. in all plants

• Suggest extra modifications/ requirements to make systems more reliable

• Check presence of toxic gases by the help of dragger tube

2. THIRD PARTY SURVEY

A safety survey is carried out once in a year by an external agency. It includes –

• Inspection of building, structures for strength and stability

• Identify and study the hazards inside individual plants and within the factory

premises.

• Check safety system for its adequacy.

• Suggest modifications or additions in the operating practices and safety

system, if necessary.



Frequency of Third Party Safety Survey: Once in a year

3. PRESSURE VESSEL TESTING/ EXAMINATION

• A list of pressure vessels in the plant with details of operating conditions and

manufacturing details to be prepared.

• Preventive maintenance of valves & fittings on all pressure vessels (valves,

pipelines, pressure gauge, temperature recorders and emergency vent lines)

has to be carried out.

• Testing and examination of all pressure vessels is to be done as per the rules of

Factories Act by govt. certified competent person on due date.

• Records of testing and certificates issued by competent person are maintained

and shall be made available to Factory Inspector at the time of inspection.

4. NON-DESTRUCTIVE TESTING (NDT)

• A list of equipment and pipelines in the plant to be prepared which require

NDT as per the rules of Factories Act.

• Non-Destructive Testing (NDT) is to be conducted as per the rules under

Factories Act by govt. certified competent person on due dates.

• Records of testing and certificates is to be issued by competent person.

• Frequency of Non-Destructive Testing : Once in a year

5. SAFETY RELIEF VALVES TESTING

• A list of Safety Relief Valves installed on various equipment and pipelines in

the unit along with detailed specifications shall be prepared.

• A schedule for testing and calibration as per the rules under Factories Act by

govt. certified agencies on due dates shall be made.

• Records of testing and certificates issued by competent person shall be

maintained.

Frequency : Twice in a year



6. FIRE SYSTEM TESTING

• To prepare list of various fire-fighting equipment (Fire Extinguishers, etc.)

installed at various locations in the unit along with detailed specifications.

• To prepare schedule for testing of all these equipment and check operability

• To maintain record of testing and mark dates of testing on the equipment.

• To carry out repairs/replacement of defective equipment

7. MUTUAL AID SCHEME

• To prepare Mutual Aid Scheme and enter into agreement with the neighboring

units for getting or extending help during emergency

• To appoint coordinator for follow-up under mutual Aid Scheme

• To review the scheme once in a year with coordinators of neighboring units

w.r.t. scope of help, type of aid, contact persons, etc.

• To include the scheme in mock drills

8. MOCK-DRILLS

• To conduct minor mock drills to train employees about their role / duties

during

emergency

• To refresh training to the employees for fire fighting, spill control, use of

personal Protective equipments etc.

• To check whether various members of emergency control committee

remember their role / duties properly and to find out the faults and points of

improvement in their performance.

• To check whether the various equipment for emergency control are operating

Satisfactorily and find and rectify the draw-backs if any.

• To conduct major mock-drills with permission from the authorities



Mock drills shall be regularly conducted by our Emergency Control Organization and

the findings shall be analyzes to check whether employees are familiarized with the

emergency control procedures and what sort of training is required to be given.

9. SAFETY TRAINING

Regular training shall be organized for the employees for handling of safety

equipment, use of personal protective equipment, first-aid, etc. by internal/external

faculty, as well as by sending persons outside to attend safety programs etc. The

topics covered in safety training are –

• Training on fire fighting

• Training on spill control

• Training on toxic release control

• Training on good housekeeping

• Training on use of PPE

The records of the training programs shall be maintained by the Safety Dept. New

topics will be included in the safety training programs year by year to upgrade safety

knowledge among the workers.

10. PERSONAL PROTECTIVE EQUIPMENT

• Adequate number of personal protective equipment (aprons, hand gloves,

safety goggles, helmets, nose masks, safety belts, gas cartridges, self-breathing

apparatus, safety shoes etc.) suitable for plant operations shall be issued to

concerned employees and workers. The list of PPE given to worker is attached

as annexure-XX.

• Workers shall be trained for proper use of PPEs.

11. COMMUNICATION

Following means of communication shall be made available:

• Telephones

• Walkie-talkies



• Mobiles

• Public announcement system

• Emergency Siren

12. EMERGENCY LIGHTS

• Emergency lights shall be provided in appropriate areas.

• Sufficient number of emergency torch/ batteries shall be kept in ECC as well

as at the production site.

• For emergency purpose DG sets shall be made available in the factory as

stand-by in case of power failure.

• The D.G. sets shall be set to start functioning within two minutes of failure of

electricity.

13. EMERGENCY CONTROL ROOM

Emergency Control Room shall be equipped with all necessary items, documents,

telecommunication systems, PPE etc. required in case of an emergency.

14. ASSEMBLY POINTS

Assembly points shall be designated at appropriate locations.

15. LIAISON WITH STATE AUTHORITIES:

The procedure for liaison with state authorities shall be prepared and responsibilities

shall be assigned to concerned persons to serve the following purposes:

• To liaison with civil authorities, local hospitals, Fire-Brigade, Collector,

factories

Inspector, Police, etc regarding emergency activities and need for external aid.

• To keep the details regarding name, address & telephone numbers of various

govt. authorities and neighboring units available and update the details from

time to time.

• To inform about Mock-drill in advance and if required conduct mock-drill in

presence of any of these authorities.



• To submit report of Mock-drill conducted and the out comings with

photograph to

Factories Inspector.

16. HOSPITAL FACILITIES

• Occupational Health Centre shall be set up with First-Aid and medicines

• Health records (esp. blood-group records) of all employees shall be

maintained.

• List of blood donors shall be kept ready for reference.

17. STATUTORY INFORMATION

Statutory Information about chemicals handled in the unit, manufacturing process, the

hazards in the unit, methods of prevention and control, first aid measures etc. shall be

given to

- Workers

- Public and Neighboring units

- Government authorities & outside emergency services

6.2.5.2 POST EMERGENCY ACTIVITIES

These activities are to be carried out after an emergency, so as to establish the cause

of the emergency and decide the measures to be taken to prevent its re-occurrence.

These activities are

1. Collection of records of accident, injury, damage to property, buildings,

equipment, material and loss of production

2. Conducting enquiries and concluding preventive measures

3. Making insurance claim for the materialistic loss / damage

4. Implementation of enquiry report’s recommendations

5. Rehabilitation of affected persons within and outside the plant

6. Restarting the plant and normalizing the operations.



6.2.5.3 EMERGENCY TIME ACTIVITIES

The probable emergency situation that can arise in the unit and the corresponding

control actions are describes below.

1. FLAMMABLE RELEASES

Source / Incident – Fire involving spilled combustible material near or in flammable

storage areas

Control action –

1. Any one who notices fire shall sound emergency alarm.

2. SMC/IC who is at site, shall immediately rush to the scene and assess the

situation. For fire due to spillage of combustible material, he activates the on-

site plan as -

• He cuts off electric supply to that area and evacuates all the persons to safe

assembly points.

• He calls in DIC (if DIC is not present there) and asks essential workers to fight

fire with dry chemical / CO2 fire extinguisher or sand.

• He inform fire brigade telling them in briefly about kind of fire and type of

extinguishers required

• He informs mutual aid teams and asks for necessary help.

• He arranges first-aid / hospitalization for the affected persons.

• Fire officer on reaching the site, takes charge of the fire-fighting operations

• Mutual aid teams are asked for help in the form of first-aid, transport etc.

• If fire is growing, fire officer informs IC who alerts neighbouring units and

through SMC gets more fire-fighting help.

• Fire fighting shall be continued till fire is fully overcome

• After extinguishing fire, fire officer cools the entire area with water spray and

checks that no re-ignition is likely to occur. After that, he declares the area

safe.



• IC tells essential workers to sound all clear.

• The incident shall be recorded.

• SMC arranges to inform families / relatives of injured / dead.

• SMC issues authorized statement to press / media.

• SMC informs Factories Inspector about the incident and related information

2. TOXIC RELEASES

Source / Incident – Pressure release due to failure of

- Stuffing box gland packing

- Pressure release valve

- Vessel / pipeline failure

Control action –

1. Any one who notices the release shall sound emergency alarm.

2. SMC/IC who is at site, shall immediately rush to the scene and assess the

situation. For toxic release from a reactor, he activates the on-site plan as -

• He evacuates all the persons to safe assembly point.

• He calls in DIC (if DIC is not present there) and asks essential workers to

wear self-breathing apparatus and if the reaction is exothermic, start cooling

water flow in the reactor jacket and cool the reactor as soon as possible.

• The essential workers stop all the charging pumps of that reactor and the

nearby reactors.

• He informs mutual aid teams and asks for necessary help.

• He arranges first-aid / hospitalization for the affected persons.

• Mutual aid teams shall be asked for help in the form of first-aid, transport

etc.

• When the leak stops and the air sahll clear of toxic release, IC tells essential

workers to sound all clear.



• The vessel / rupture disc/gland packing will be attended by maintenance

department.

• The incident shall be recorded

• SMC arranges to inform families / relatives of injured / dead.

• SMC issues authorized statement to press / media.

• SMC informs Factories Inspector about the incident and related information

3. CHEMICAL SPILL

Most of the storage tanks shall be located in Storage Tank Yards. Dyke walls of

sufficient size will be connected around the tank yard. Neutralizing material shall be

kept nearby. For dilution, water connection will be provided on all sides of tank

farms. Sand buckets shall be provided for covering spillage of flammable / corrosive

materials.

4. EVACUATION & TRANSPORTATION

All non-essential workers shall be evacuated from incident area and adjacent areas to

safe assembly points. Assembly points shall be clearly marked and assembly point in-

charge will also be designated. The assembly point in-charge will be a well-trained

supervisor who shall keep record of persons arriving at the assembly point and direct

them for proper gathering. He shall also inform the ECC about the persons gathered

at the assembly point. Those in need of medical treatment shall be transported to first-

aid center / hospital as the case may be. In case of major emergency all non-essential

workers shall be transported to temporary shelter.

5. SAFE CLOSE-DOWN

As per the instructions from IC or SMC, some parts or full of the plant shall be closed

down by the essential workers. The procedure for safe shut-down and start-up will be

given in safety manual given to all workers.

6. USE OF MUTUAL AID

Mutual aid from neighboring units shall be called up as and when required. The aid

shall be taken under the supervision of SMC.



7. HELP OF EXTERNAL AUTHORIES

Outside authorities such as Police, District Emergency Authority (DEA), Factory

Inspector, Disaster Management Centre, GIDC officer, Industries Association,

Regional Pollution Control Board, nearby hospitals etc. shall be informed of the on-

site and off-site emergency plans and called in as per need.

8. MEDICAL TREATMENT

Injured workers shall be located and given prompt first-aid by essential workers and

key personnel. Those requiring medical treatment shall be taken to the hospital /

outside medical center.

9. ACCOUNTING FOR PERSONNEL

Through daily muster rolls and with the help of shift-in-charge the head count shall be

undertaken to find out whether persons are missing and if so immediate search shall

be carried out to locate them. The list shall include company employees, contract

workers as well as visitors. Help from local authority or fire-brigade shall be taken if

required. This list shall be kept with time keeper / security officer at any time and

shall be used to account for personnel. Injured shall be taken to hospitals and their

families/relatives shall be informed Casualties would be identified, their families and

local authority shall be informed.

10. ACCESS TO RECORDS

In order to inform families/relatives of injured/dead, a up-to-date list of names and

addresses of all the workers is maintained in addition to the muster roll where shift-

wise attendance is marked. Such list includes health records. This list will be

available at the ECC and one such copy shall be available at our head office.

11. PUBLIC RELATIONS

Our General Manager shall be the only nominated person to issue administrative

statement about the accident or emergency to news/media. No other person shall

divulge any information to any news / media person.



12. REHABILITATION

In case of Toxic release or chemical spillage, Senior Fire Brigade Officer would

ensure that the incident area shall be safe and cleaned up of all mess. Then only, he

would allow people to re-enter the location.

In case of fire, the Senior Fire-Brigade Officer shall ensure that the area is cooled

down and there are no chances of re-ignition. IC shall arrange for clean-up of the area

and then only people shall be allowed to re-enter the area for work.

Even when all clear has been given, great care shall be taken when re-entering

affected areas and no work in connection with the salvage, collection of evidence or

start up shall be taken up until a thorough examination of the area has been carried

out. The statutory powers of the Factory Inspector shall be kept in mind before any

evidence is disturbed. Particular care shall be taken to avoid the introduction of

possible sources of ignition, such as diesel engines, hand or power operated tools,

flame cutting equipment, etc. until it has been established that no flammable materials

are present where they could be ignited.

6.3 OCCUPATIONAL HEALTH AND SAFETY

For large industries, where multifarious activities are involved during construction,

erection, testing, commissioning, operation and maintenance; the men, materials and

machines are the basic inputs. Along with the boons, industrialization generally brings

several problems like occupational health and safety.

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

impacts of industrialization and to ensure appropriate occupational health and safety

including fire plans. All these activities again may be classified under construction

and erection, and operation and maintenance.

6.3.1 OCCUPATIONAL HEALTH

Occupational health needs attention both during construction & erection and operation

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

the above phases.



6.3.1.1 CONSTRUCTION AND ERECTION

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

constructional accident and noise. To overcome these hazards, in addition to

arrangements to reduce it within TLV's, necessary protective equipments shall be

supplied to workers.

6.3.1.2 OPERATION AND MAINTENANCE

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

primarily due to noise which could affect consultation. The necessary personal

protective equipments will be given to all the workers. The working personnel shall

be given the following appropriate personnel protective equipments.

• Industrial Safety Helmet;

• Welders equipment for eye and face protection;

• Cylindrical type earplug;

• Ear muffs;

• Safety belt/line man's safety belt;

• Leather hand gloves;

• Asbestos hand gloves;

• Acid/Alkali proof rubberized hand gloves;

• Canvas cum leather hand gloves with leather palm;

• Electrically tested electrical resistance hand gloves; and

• Industrial safety shoes with steel toe.

Details of existing Occupational, Safety Hazards and its control measures.

A detail of existing occupational, safety hazards and its control measure is covered in

following table.



Table: 6.20

Details existing occupational, safety hazards and its control measures.

Chemical Hazards Safe Control Measures

Safety hazards

Solvents. (Methanol, Ethyl acetate, Toluene, Benzyle Alcohol, Acetone, etc.)

Fire / Spillages

1. Closed system of handling.

2. Underground dedicated storage with flame arrestor

and breather valves.

3. Double earthing to underground storage and day tanks.

4. Double earthing to tankers during unloading.

5. Non sparking tools for methanol unloading and

handling.

6. Earthing bonding and jumpers to pipelines used for

methanol transfer.

7. Flameproof electric fitting.

8. Portable first aid fire fighting equipments like fire

extinguishers, foam trolleys, sand buckets, etc.

9. Dedicated adequate capacity wet fire hydrant system.

10. Material unloading permit system.

11. Trained operators for loading unloading.

12. Periodic fire fighting training to operators.

13. Periodic mock drills.

14. Restricted entry in the storage area.

15. Periodic medical checkup.

16. Strict adherence to standard operating procedures.

17. Trained supervisors for monitoring.

18. Compulsory PPE’s like, handgloves, Half face mask,

safety helmet, safety shoes to the operator.




Chloroform, MDC,

Thionyl Chloride, Acetyle chloride, POCl3, PCL5,

Ammonia, Dry HCl.,

etc.

Toxic Release.

1. No manual handling.

2. Closed system, connected to scrubbers for material

handling.

3. Spill lit to attend any accidental release.

3. Air Handling units for fresh air supply at work places.

4. Self contained breathing apparatus 06 nos.

5. Periodic internal work place monitoring and records in

Form no.37.

6. Daily VOC monitoring.

7. Isolated storages. Storage conditions maintained and

monitored.

8. Restricted entry to the storage areas.

9. Dry sand pits 02 nos are available to cover any

accidental spillages of fuming liquids.

10. Trained personnels for handling of materials.

11. Qualified supervisors for supervision.

12. Periodic training and mock drills.

13. Sufficient stock of PPE’s at site for use during normal

and during emergency.

Heath Hazard

Solvents and

Toxic / corrosive

chemicals.

Exposure of

toxic & corrosive fumes.

1. Induction training to compulsory to all company and

contract employees.

2. Closed handling of all chemicals.

3. All vents of storages & day tanks are connected to

scrubbers.

4. Scrubbers are effectively operated and monitored.

Records are maintained.

5. Standby equipments are available to

reduceenvironmetal pollution due to failure of existing

running equipments.

6. Standby power arrangement by diesel generators.

7. Periodic internal work place monitoring to check

concentration of chemicals handled in the area and




records in Form no.37.

8. Daily VOC monitoring.

9. Dedicated trained company employees for handling

hazardous chemical.

10. Wel furnished Occupational Health Centre.

11. Trained first aiders working round the shifts.

12. Haz. of chemicals displayed in different languages for

easy understanding.

13. Periodic health checkup of all company and contract

employees including Lung Function test, Vision test,

Liver Function test, blood platelets,etc.

14. Compulsorry use of PPE’s inside working area.

15. Periodic training to all company & contract employees

for chemical handling.

Solvents Exposure limits. 1.External agency periodic monitoring of concentration

of solvent vapours in the workplace has been carried out

and valves are wel within the permissible exposure limits

as given in the schedule -II of GFR, Rule 12-B.

2. Internally daily monitporing of VOC.

3. LDAR program has been implimented to check and

reduce the exposures.

4. Compulsorry PPE’s during material handling.

6.3.1.3 HOSPITAL FACILITIES

Client shall make formal agreements with nearby hospital having facilities to attend

fire and toxic effect cases for attending the affected persons in the emergency arising

out of accidents, if any.

6.3.1.4 FACTORY MEDICAL OFFICER

A qualified doctor shall be appointed as FMO on retainer ship basis. Apart from him,

Paramedical Staff shall be employed.



6.3.1.5 PROPOSED FACILITY TO BE MADE AVAILABLE AT OHC

A Room shall be provided to be operated as OHC. The centre shall be equipped with

following medical equipments:-

Table: 6.21

Details of medical equipments

1 Examination Table

2 Dressing Tables For performing Dressing

3 Glucometer For measurement of Blood Sugar

4 Vision chart To evaluate vision acuity

5 Nebuliser For relieving coughs & Breathing Difficulty

6 Infra red light For relieving muscular pain

7 Suction machine For cleaning airway

8 Autoclave machine For sterilizing cotton &dressing material

9 Weighing Machine For measuring body weight

10 Medical Oxygen Cylinder kit

11 Sphygmomanometer To measure blood pressure

12 Refrigerator To preserve medicines

13 Thermometer

6.3.1.6 AMBULANCE VAN

An ambulance van shall be made available 24 hours at Fire Station.

6.3.1.7 FIRST AID BOX

First Aid Boxes shall be made available at the different location in the plant. Training

shall be given to employees for First Aid.

6.3.1.8 PERIODIC MEDICAL EXAMINATION

Periodic Medical examination shall be conducted as per the following schedule;

(1) Workers employed shall be examined by a qualified medical practitioner/

Factory Medical Officer, in the following manner:

(a) Before employment, to ascertain physical fitness of the person



(b) During employment, once in a period of 6 months, to ascertain physical

fitness of the person to do the particular job;

(c) Once in a period of 6 months, to ascertain the health status of all the workers

in respect of occupational health hazards to which they are exposed and in

cases where in the opinion of the Factory Medical Officer it is necessary to

do so at a shorter interval in respect of any workers;

(d) In periodic and pre-medical examinations, various parameters will be

checked. Viz., LFT, Chest X-rays, Audiometry, Spirometry, Vision testing

(Far & Near vision, color vision and any other ocular defect) ECG and

other parameters as will be found necessary as per the opinion of Factory

Medical officer.

(2) No person shall be employed for the first time without a certificate of fitness

granted by the Factory Medical Officer.

Details of exposure specific health status evaluation of worker. If the workers’

health is being evaluated by pre designed format, chest x rays, Audiometry,

Spirometry, Vision testing (Far & Near vision, colour vision and any other

ocular defect) ECG, during pre placement and periodical examinations give the

details of the same. Details regarding last month analyzed data of

abovementioned parameters as per age, sex, duration of exposure and

department wise.

All the employees are passed through pre-medical examination.

Periodical medical examination is conducted every six month.

Following test are conducted during the medical examination.

• Physical Examination i.e Height, weight, pulse, blood group, blood pressure,

• Eye vision

• Haematology

• Differential count

• Urine examination (physical examination, chemical examination, microscopic

examination)



The medical report is reviewed and doctor’s suggestions are conveyed to the concern

employees.

Haemoglobin of few employees was found less than the requirement and all the

concern personnel were advised to take iron capsule as per the doctor’s

recommendation.Representative report of pre-medical examination of 4 emplyoee are

attaches as annexure-22 A.And periodical medical examination report of same 4

employee are attached as annexure-22 B

Annual report of heath status of workers with special reference to Occupational

Health and Safety.

Periodical medical examination is conducted every six month. The medical report is

reviewed and doctor’s suggestions are conveyed to the concern employees.

Haemoglobin of few employees was found less than the requirement and all the

concern personnel were advised to take iron capsule as per the doctor’s

recommendation.

No any worker was identified for any serious dieses.Summary of last medical

examination is enclosed as anexxure 22 C.

6.3.1.9 EMP FOR THE OCCUPATIONAL SAFETY & HEALTH

HAZARDS SO THAT SUCH EXPOSURE CAN BE KEPT WITHIN

PERMISSIBLE EXPOSURE LEVEL (PEL)/THRESHOLD LEVEL

VALUE (TLV) SO AS TO PROTECT HEALTH OF WORKERS.

1. It is proposed to formulate and implement an EMP for Occupational Safety

and Health with following aims…

• To keep air-borne concentration of toxic and hazardous chemicals below

PEL and TLV.

• Protect general health of workers likely to be exposed to such chemicals

• Providing training, guidelines, resources and facilities to concerned

department for occupational health hazards.



• Permanent changes to workplace procedures or work location to be done

if it is found necessary on the basis of findings from workplace

Monitoring Plan.

• It is proposed that this EMP be formulated on the guidelines issued by

Bureau of Indian Standards on OH&S Management Systems: IS

18001:2000 Occupational Health and Safety Management Systems

• Proposed EMP will be incorporated in Standard Operating Procedure

also.

• The proposed EMP will also include measure to keep air-born

concentration of toxic and hazardous chemicals below its PEL and TLV,

like…

• Leak Surveys

a. Separate storage for toxic chemicals

b. Exhaust Ventilation

c. Proper illumination

d. On-line detectors toxic chemicals like Chlorine and Bromine

e. Close processes to avoid spills and exposures

f. Atomization of process operations to hazards of manual handling of

chemicals

g. Supply of proper PPEs like Air mask, Berating canisters, SCBA sets,

On-line breathing apparatus at the places where there is possibility of

presence of toxic chemicals

h. Decontamination procedure for empty drums and carboys.

i. Regular maintenance program for pumps, equipment, instruments

handling toxic and corrosive chemicals

j. Display of warning boards

k. Training to persons handling toxic and corrosive chemicals



2. Workplace Monitoring Plan

• It is proposed that a Workplace Monitoring Plan to be prepared &

implemented in consultation with FMO and industrial hygienists.

• Each workplace must be evaluated to identify potential hazards from

toxic substances or harmful physical agents. Air-borne concentration of

toxic chemicals will be measured and record will be kept. Analysis report

of work place area monitoring is attached as annexure- XXIII.

• The current state-of-the-art exposure measurement model is as follows:

For purposes of measuring worker exposure across a single shift it is

sufficient t o place a reasonably accurate exposure measuring device on

the worker , within t he worker ’s breathing zone, and have it operate for

nearly the full shift. Client has been proposed to study the exposure data

when the plant is operative.

3. Health Evaluation of Workers

1. It is proposed that management will device a plan to check and evaluate

the exposure specific health status evaluation of workers

2. Workers will be checked for physical fitness with special reference to the

possible health hazards likely to be present where he/she is being

expected to work before being employed for that purpose. Basic

examinations like Liver Function tests, chest x ray, Audiometry,

Spirometry Vision testing (Far & Near vision, color vision and any other

ocular defect) ECG, etc. will be carried out. However, the parameters and

frequency of such examination will be decided in consultation with

Factory Medical Officer and Industrial Hygienists.

3. While in work, all the workers will be periodically examined for the health with specific reference to the hazards which they are likely to be exposed to during work. Health evaluation will be carried out considering the bodily functions likely to be affected during work. The parameters and frequency of such examination will be decided in consultation with Factory Medical Officer and Industrial Hygienists. Plan of monthly and yearly report of the health status of workers with special reference to Occupational Health and Safety.



6.3.2 SAFETY PLAN DURING PROJECT EXECUTION

STAGE (CONSTRUCTION & COMMISSIONING)

Safety of both men and materials during construction and operation phases is of

concern. Safety plan shall be prepared and implemented in the proposed project

activity. The preparedness of an industry for the occurrence of possible disasters is

known as emergency plan. The disaster in the plant is possible due to collapse of

structures and fire/explosion etc.

• The proposed project would formulate safety policy keeping in view the safety

requirement during construction, operation, maintenance phases, with the

following regulations:

• To allocate sufficient resources to maintain safe and healthy conditions of

work;

• To take steps to ensure that all known safety factors are taken into account in

the design, construction, operation and maintenance of plants, machinery

and equipment;

• To ensure that adequate safety instructions are given to all employees;

• To provide wherever necessary protective equipment, safety appliances and

clothing and to ensure their proper use;

• To inform employees about materials, equipment or processes used in their

work which are known to be potentially hazardous to health or safety;

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

necessary changes from the point of view of safety in the light of

experience and up to date knowledge;

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

and illness at work;

• To provide appropriate instruction, training, retraining and supervision to

employees in health and safety, first aid and to ensure that adequate

publicity is given to these matters;



• To ensure proper implementation of fire prevention methods and an

appropriate fire fighting service together with training facilities for

personnel involved in this service;

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

and incident involving people injury or injury to health with a view to

taking corrective, remedial and preventive action;

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

safety matters to ensure effective participation by all employees;

• To publish/notify regulations, instructions and notices in the common

language of employees;

• To prepare separate safety rules for each type of occupation/processes

involved in a plant; and

• To ensure regular safety inspection by a competent person at suitable intervals

of all buildings, equipments, work places and operations.

6.3.3 SAFETY ORGANIZATION

Construction and Erection Phase

A qualified and experienced safety officer shall be appointed. The responsibilities of

the safety officer include identification of the hazardous conditions and unsafe acts of

workers and advice on corrective actions, conduct safety audit, organize training

programs and provide professional expert advice on various issues related to

occupational safety and health. He is also responsible to ensure compliance of Safety

Rules/ Statutory Provisions.

Operation and Maintenance Phase

When the construction is completed the posting of safety officers shall be in

accordance with the requirement of Factories Act and their duties and responsibilities

shall be as defined there of.



A. Action plan for the implementation of OHS standards as per

OSHAS/USEPA.

• Standard operating procedures have been prepared for different type of activities.

• Regular training is imparted to the concern personnel to enhance the awareness of

standards.

• Hazard identification and risk assessment is carried for the activities performed at

the site.

• Hazard operability (HAZOP) study is performed for the manufacturing process

followed at the site.

• Environmental impact and assessment is performed.

• Stack air emission monitoring, work place monitored, ambient air monitoring,

drinking water quality monitoring and noise level monitoring is carried out

regularly.

• The measuring instruments are calibrated regularly.

• Preventive maintenance of the equipment and machines is performed regularly.

• Regular audit is conducted to ensure the compliance against the standards.

B. Plan and fund allocation to ensure the occupational health & safety of all

contracts and sub-contract workers.

The management is fully committed to ensure the occupational health & safety of all

workers at the site by providing appropriate personal protective equipments (PPEs),

and training.

There is no any limit of fund for occupational health & safety.

6.3.4 SAFETY CIRCLE

In order to fully develop the capabilities of the employees in identification of

hazardous processes and improving safety and health, safety circles would be

constituted in each area of work. The circle would consist of about five to six

employees from that area. The circle normally shall meet for about an hour every

week.



6.3.5 SAFETY TRAINING

Safety training shall be provided by the Safety Officers with the assistance of faculty

members called from Professional Safety Institutions and Universities. In addition to

regular employees, limited contractor labors shall also be provided safety training. To

create safety awareness safety films shall be shown to workers and leaflets shall be

distributed.

Some precautions and remedial measures proposed to be adopted to prevent fires are:

• Compartmentalization of cable galleries, use of proper sealing techniques of

cable passages and crevices in all directions would help in localizing and

identifying the area of occurrence of fire as well as ensure effective automatic

and manual fire fighting operations;

• Spread of fire in horizontal direction would be checked by providing fire stops

for cable shafts;

• Reliable and dependable type of fire detection system with proper zoning and

interlocks for alarms are effective protection methods for conveyor galleries;

• Housekeeping of high standard helps in eliminating the causes of fire and

regular fire watching system strengthens fire prevention and fire fighting; and

• Proper fire watching by all concerned would be ensured.

6.4 TRAINING, REHERASAL (MOCK DRILLS) & RECORDS

REGARDING DMP

6.4.1 NEED OF TRAINNING & REHEARASAL

Training is important in order to –

• Teach workers how to handle chemicals safely, how to act as a

runner/messenger, how to use PPE, how to start and shut down the plant, how

to carry out emergency repairs etc.

• Teach one to be a safe and alert worker.

• To ensure right actions by person at right time.



Rehearsal is essential for -

• Explaining and making key personnel and essential workers aware of their

role in case of an emergency.

• Testing the emergency procedure, emergency arrangements and ability of all

involved with it to grasp the procedure and implement the same.

• Testing the effectiveness of communication system including the alternative

arrangement in case of failure.

• Testing the speed of mobilization of resources, search, rescue and treatment of

casualties, emergency isolation and shut down.

• Detecting the shortcomings in the emergency plan and incorporating remedial

measures.

Allowing professional emergency services to test their parts of the plan and testing

co-ordination.

• Building confidence in workers which is helpful in facing real situations.

Training shall be given to regular employees and contract personnel also. Effective

and latest teaching aids will be used to train workers and supervisory staff. Such

training courses shall be conducted once in a year and co-ordination with offsite

personnel shall be sought during such training. Records will be maintained for

training.

6.4.2 MOCK DRILLS

To evaluate the effectiveness of emergency preparedness and to spread the awareness

among employees mock drill shall be carried out at the interval of every three months.

After completion of the mock drill, summary report shall be made and corrections

shall be done if any weakness has been observed.

Frequency of mock drills:

• On-site emergency : Once every 6 months

• Off-site emergency : Once every year



6.4.3 SOME CHECK POINTS

Following points can be checked at the time of training/assessing the adequacy of the

Emergency Plan.

• Does the plan cover the range of incidents that can realistically be anticipated?

• Have the consequences of the various incidents considered been adequately

assessed?

• Are there sufficient resources in terms of personnel and equipment on the site

to carry out the Emergency Plan for the various incidents in conjunction with

the public emergency services?

• Have the time scales been assesses correctly?

• Is there a logical sequence of actions for each person given a role in the plan?

Whether key personnel, especially the nominated incident controllers,

consulted in the preparation of the plan?

• Is there 24 hours cover, to take account of absences due to sickness and

holidays, minimum shift manning, operator only periods, silent hours,

shutdown periods, only security personnel being present, or for unmanned

sites etc.?

• Is there satisfactory co-operation with the local emergency services and

district emergency planning officers?

• At sites where an off-site plan to protect people and the environment outside

the site in the event of an incident is appropriate what is the procedure for

initiating the off-site plan and is this satisfactory?

6.4.4 RECORDS AND UPDATING THE PLAN

All records of On-Site and Off-Site Emergency Plan and modifications by experience and suggestion, the rehearsals and conclusions of such plans and the enquiries shall be well maintained and preserved. The necessary data bank shall be also maintained for the utility of industries and others. New information and the deficiencies identified during the rehearsal is reviewed and incorporated in the document for continual updating of the plan and such information shall be communicated to the concerned authorities.

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