Final draft EIA report

Annexure No 5

Annexure No 6

Annexure No 7

Annexure No 8

Annexure No 9

Land Documents

Saurashtra Chemicals Limited (Soda Ash Plant)

Vill:Chhaya, Tal & Dist:PorbandarTag: LAND POSSESSION DOCUMENTS

ANNEXURE: 9 LAND POSSESSION DOCUMENT

Environmental Impact Assessment Report

M/s Saurashtra Chemicals (Division of Nirma Ltd),

BIRLASAGAR, PORBANDAR GUJARAT.

T. R. Associates (Ahmedabad) NABET Accredited

Annexure 10 : Additional Studies 7.1

Annexure: 10

ADDITIONAL STUDIES 7.1 Risk Assessment 7.1.1 Overview of Project M/s. Saurastra Chemicals Division of Nirma Ltdis located at Birlasager, Village-Chhaya, Ta.& Dist.-Porbandar. The site is situated at21°37’39.19”N latitude and 69°37’34.06” E longitude. Unit has a total land area of 518974 m2. Plant layout of existing manufacturing facility is given in Chapter 2 of this report.The same layout space allocated for proposed expansion of Soda Ash, Sodium Carbonate and Co generation Power Plant. 7.1.2 Objective and Scope The main objective of risk assessment study is to propose an approach to carry out risk analysis and management of industrial prototype hazard. The risk assessment essentially includes hazards identification, consequence analysis, risk assessment/evaluation and risk mitigation. For chemical industries, risk assessment is used for determining the risk associated with use, handling, transportation and storage of chemicals and other hazardous substances. Quantitative Risk Assessments (QRAs) are done if dangerous substances are thought to be present at a location (e.g. industrial sites and transportation routes) in amounts that can endanger the environment. Scope of the Study;

Hazard Identification - Identifying sources of accidents involving release of hazardous material in the atmosphere and the various ways (that is scenarios) they could occur

Consequence Assessment - Estimating the probable zone of impact of accidents as well as the scale and/or probability of damages with respect to human beings and plant equipment and other structuresusing relevant models like ALOHA

Accident Frequency Assessment - Computation of the average likelihood of accidents Risk Estimation - Combining accident consequence and frequency to obtain risk

distribution within and beyond a process plant 7.1.3 Risk Assessment Methodology

Information on Location, Layout, Process Parameters Hazard Identification Select Most Credible Scenario which can culminate into an accident out of several major

and minor. Select Worst Case Scenario which has the highest potential to cause an accident of

maximum damage Estimate Consequences: in the plant in the form of fire, explosion and toxic effects

7.2 Hazard Identification and Risk Assessment (HIRA) The hazard identification and risk assessment is used to identify possible accidents and






estimate their frequency and consequences. While identifying hazards only those areas of plants having potential risk are used further for risk analysis. Hazard is considered as characteristic of system/plant/process that presents potential of causing harm to people, property and the environment. Hence, all the components of a system/plant/process are thoroughly examined to assess their potential for initiating or propagating an unplanned event/sequence of events, which can be termed as an accident. 7.2.1 Hazard Identification Methods Hazard identification method usedfor the proposed expansion project is given below.

Identification of major hazardous units based on Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 of Government of India (as amended in 2000); Hazard Indices: Identification of hazardous units and segments of plants and storage units based on relative ranking technique.

7.2.2 Identification of Hazardous Chemicals used within Premises Following chemicals to be stored and utilized within the premises falls under Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 (as amended in 2000). List of Hazardous Chemicals is given below. Amongst the below described raw materials and products, some are the hazardous chemicals as per the MSIHC Rules, 2000. Chemical and physical properties of raw materials are given in Table 7.1






7.2.3.: Storage details of Product and raw materials Details of the raw materials and products with storage are given in Table 7.1 (A) and (B) respectively.

Table 7.1 (A) - Storage Details of Raw Materials

Sr. No. Name of Raw Material

Physical State

Mode of storage/MOC

No. of Units / Nos.

stored at a time

Capacity of Storage

of each unit

Area of Storage

Total Capacity of

storage

Storage temp &

Pressure

1. Lime Stone Solid Open Yard 1 500000 T

5268 m2 and 13,100 m2 outside the

plant premises

500000 T NTP

2. Salt Solid Open Yard 1 900000 T 89168 m2 900000 T NTP 3. Coke Solid Open Yard 1 9000 T 15732 m2 9000 T NTP

4. Ammonia Liquid Carbon Steel

Closed Tank(2 Nos)

2 28 MT (each) 4350 m2 56 T 6 kg/cm2

5. Sodium Sulphite Liquid

MS with rubber lined

Closed Tank(4 Nos)

4 100 m3 (each) 188.5 m2 400 m3 NTP

Table 7.1 (B) - Storage Details of Product

Sr. No. INPUT Physical

State

Mode of storage/

MOC

Nos of storage

Capacity of Storage of each unit

Area of Storage

Total Capacity of

storage

Storage temp &

Pressure






1. Light Soda Ash Solid MS Silo

Old Godown (RCC)– 7

1861 T

1828.64 M3

186 T

NTP

New Godown – 7

1712.83 M3

RCC- Go down 1 5000 T 6477 sq. meter 5000 T

2. Dense Soda Ash Solid RCC- Go down 1

MS Silo 2 121 T 98 m3 121 T

3. Refined BI Carbonate Solid

MS Silo 1 187 T 120.52 M3 300 T

RCC- Go down 1 300 T 332.6 sq. Meter 300 T

Table 7.2 - Storage Details of Fuel

Sr. No. INPUT Physical

State Mode of

storage/MOC Nos of

storage

Capacity of Storage

of each unit

Area of Storage

Total Capacity

of storage

Storage temp &

Pressure

1. Coal Solid MS Structure Shed PVC Sheet 1 6000 T

22366 m2 6000 T NTP

2. Pet Coke Solid MS Structure Shed PVC Sheet 1 9000 T 9000 T

3. HSD / LDO Liquid MS Closed Tanks (3 Nos) 3

15 KL 50 KL 4.9 KL

117.95 m2 69.5 KL

Note:

Unit has obtained permission from PESO, Nagpur for Storage of Ammonia Bullet. Copy of the same is Attached in Annexure 11 Unit has obtained license from DISH (Directorate Industrial Safety & Health). Copy of the same is Attached in Annexure 12





Annexure No 10 : Additional Studies 7.5

Table 7.3- Chemical and Physical Properties of Hazardous Chemicals

Sr. No. Chemicals TLV

Toxicity Level Flammable Limit Chemical

Class (As per MSIHC

Rules)

NFPA rating Vapor pressure

LD50 Oral

mg/ Kg

LD50 Dermal mg/Kg

LC50 mg/l LEL% UEL% FP °C BP °C

Class (As per

petroleum classificati

on)

1. Ammonia 25ppm (ACGIH

TLV)

350 mg/kg (Rat )

Or 504 ppm

(Rat )

NA NA NA NA NA 36 °C NA Highly Toxic Health – 3

Flammability – 1 Instability - 0

1200 kPa @ 25 °C

Note: * Hazardous chemicals as per MSIHC rule, 2000 The Toxicity level of hazardous chemicals as per Manufacture, Storage and Import of Hazardous Chemical (Amendment) Rules, 2000 (MSIHC) is shown as below: Table 7.4 - Toxicity of Chemicals capable of producing MAHs[1]

Sr. No. Toxicity Oral Toxicity

LD50 (mg/kg) Dermal Toxicity LD50 (mg/kg)

Inhalation Toxicity LC50 (mg/l)

1. Extremely Toxic >5 <40 <0.5 2. Highly Toxic >5- 50 >40-200 <0.5-2.0 3. Toxic >50-200 >200-1000 >2-10






Table 7.5 - Identification of Hazards associated with Storage of Raw Materials

Sr. No.

Name of material

stored

Hazard Rating Systems

Type of hazard / Risk

involved Causes Effect

Existing Control Measures Provided

Proposed risk reductionmeasures

1.

Ammonia Bullet (28 MT MS Bullet X 2) (Area : Ammonia Tank farm)

25ppm (ACGIH TLV) ACGIH TWA : 25 ppm NFPA Ratings: Health – 3 Flammability – 1 Instability - 0

Toxic Dispersion Exposure to ammonia Liquid spillage

Leakage of Ammonia

Storage tank over pressure

Glands/seal leaks in valves, pumps Hose/pipe failure, leakage

AmmoniaToxication Suffocation Irritatio Burn injury in case of fire)

All Control measures as per SMPV rules

Bullet is provided withpressure relief mechanism

Ammonia Detectors with alarm

Magnetic level indicator. Antidote for Ammonia i.e.

MILK OF MAGNESIA is Provided

Auto weighting system (load cell)

Safety valves. Earthing of the tank. Bonding of the pipe lines. Water drencher. Fire hydrants. Self-contained breathing set. Flame proof electrical

equipment & fitting. In-charge of trained operator

round the clock. More Details are describe in

point 7.8.1

To scrub out thegaseous ammonia incase of leakage ascrubber ofadequate capacityshould be provided

A pump to transferliquid ammonia fromleaking tank todump tank shouldbe provided.






Table 7.6–Identification of Process Hazards Name of

hazardous process and

operation

Event Type of Hazard Type of Risk Involved /

Type Of Injury

Existing Control Measures Provided Proposed risk

reduction measures

Ammonia Absorption

Sampling activity by operator

Exposure to ammonia

Ammonia Toxication. Suffocation. Trap in confinedspace

Sample Line has been extended up to laboratory

Arrangement for eye wash to be made in laboratory Proper ventilation to be ensured in laboratory

Leakage of ammonia

Exposure to ammonia

Ammonia Toxication. Suffocation. Trap in confinedspace

Dual lines have been laidout from supply to userend.

Triple redundant system. Process parameters canbe controlled

andmonitored from local paneland from the control room nodes

In case of inaccessibility to this control centers, process can be controlled and monitored from manager view panels from a remote location.

Antidote for Ammonia i.e. MILK OF MAGNESIA is Provided

--

Carbonation Operationof drawliquor linewith steam.

Hot steam & Condensate Burn injury Adequate PPEs are Provided --

Carbon Dioxide – CO2 Gas

High concentration of CO2Inhalation can affect respiratory system – i.e. Breathing related Problem

Closed System is provided for CO2

Concentration levels of carbon dioxide above about 1 % are dangerous. It is






Name of hazardous

process and operation


Type Of Injury


reduction measures

recommended to do continuous monitoring with alarms to indicate unsafe conditions before and during potential personnel exposure.

Calcinations Calcinercleaning, washing & inspection.

Mechanical Hazards& Exposure to hot gases.

Body injury& Burn injury

LOTO procedure for electrical isolation is followed and steam header is positively isolated. Permit procedure is followed Adequate PPEs are Provided

--

Co-generation

Power Plant

Operation ofSwitch

Maintenanceof feederbreaker

Leakage ofsteam

Electric shock Burn injury

Adequate PPEs are Provided Attendant is available for vigilance Rubber mat is available near control panel Safety tags. Are available when maintenance is carried out Permit procedure is followed

--

Work near turbine in highnoise area.

High noise Noiseinducedhearing loss.

PPEs like earmuff and earplug are used by areaoperator --

At Turbine Floor : Operation of

Mechanical Hazard, Electric shock

Injury & Burn injury

Relevant are used by area workers /operator and training is also provided --






Name of hazardous



Type Of Injury


reduction measures

lube oilpumps, Centrifuge Cleaning,Pump suction Strainercleaning.

to the workers / operators

Ashconveying system Dust Dust exposure Adequate PPEs are Provided --

Fuel feeding to boiler

Coal dustexposure to Nearlyworking workers

Dust Exposure / Silicosis

PPEs like Dust mask etc used by areaoperator --

Storage of1000 L HSD tank (D G Set)

Fire/ Explosion Burn injury

Area is identified as nosmoking zone Flame proof fitting is available in this

area Earthing and bonding is available.

--

55 degree tilting of truck for unloading (Truck Tripler Area)

Skidding of truck

Injury toconcernpersonnel,

Accident

Stoppers are available for rear wheel of truck toavoid slipping

Anti-skid device is available --

Sea Pump House

Sea Water Intake Line Screen , Jetting(every month) Under water operation

Sinking Fatality

This operation is done by professional sea divers.

Air line is provided to sea divers Personnel vigilance is ensured Training is imparted to sea divers.

--






Name of hazardous



Type Of Injury


reduction measures

Lime Kiln

Feedpipe cleaning / maintenance

CO exposure, Fall Hazard, Confined space

CO Toxication Personal Injury

Fall hazard is avoided byproviding compartments

Manual entry is permittedonly after checking CO concentration

Feeding and Air blower isstopped before carrying out the job

Chimney exhaust isopened. Vessel Entry permitprocedure is

followed

Personnel vigilanceto be ensured

Stand by person to be made available

Means of communication to be made available

Clinker Removal / Cleaning ofbucket bootarea by hand picking / etc

Dust & High Noise

Dustexposure&Hearing Loss Adequate PPEs are Provided --

Handling ofhot Milk ofLime

Hot liquidSlipperyfloors

Burn Injury skid Chemical Burns

Operator vigilance. PPEs are worn by operatorand

workers

Safety shower with eye wash stationto be made available in the areas where hot Milk of Lime is stored or handled






7.2.4 Credible Accident Sources/ Worst Case Scenarios

Maximum Credible Accident (MCA) scenario indicates most believable, reasonable, likely or possible accident scenario and damage distance based on it. MCA scenario takes into account the effect of existing control measures also. It considers the malfunctioning of the control system, opening of safety valve/failure of safety valve, leakages from flange joint, pipe line etc. and failing of some safety devise.

Worst-case scenario (rarely possible) is defined as the release of the largest quantity of a regulated substance from a single vessel or process line failure that results in the greatest distance to an end point, e.g. catastrophic failure. It considers the failure of all control systems and release of the whole mass resulting in maximum damage.

Based on the storage and properties of the chemicals at the unit, the some typical scenarios relevant for MCA analysis is given in the following Table 7.7.

Table 7.7 - Scenarios Considered for MCA Analysis

Sr. No. Chemical Storage

Quantity Pool Fire

Flash fire

Toxic Dispersion

Worst case

scenario

1. Ammonia 2 X 28 MT Bullet - --

7.3 Consequence Modeling Hazardous incidents start with a discharge of a flammable or toxic material from its normal containment. Discharge can take place from a crack or fracture of process vessels or pipe work, an open valve or from an emergency vent. The release may be in the form of gas, liquid, or two phase flashing of gas-liquid. 7.4 Damage Criteria The storage and unloading at the storage facility may lead to fire and explosion hazards. The damage criteria due to an accidental release of any hydrocarbon arise from fire and explosion. 7.4.1 Fire Damage

Table 7.8 tabulates the damage effect on equipment and people due to thermal radiation intensity whereas; the effect of incident radiation intensity and exposure time on lethality is given in Table 7.9.

Table 7.8 - Damage Due to Incident Radiation Intensities

Sr. No.

Incident Radiation (kW/m2)

Type of Damage Intensity

Damage to Equipment Damage to People

1 37.5 Damage to process equipment 100% lethality in 1 min. 1% lethality in 10 sec.

2 25.0 Minimum energy required to ignite

wood at in definitely long exposure without aflame

50% lethality in 1 min. Significant injury in 10 sec.






Sr. No.

Incident Radiation (kW/m2)

Type of Damage Intensity

Damage to Equipment Damage to People

3 19.0 Maximum thermal radiation intensity

allowed on thermally unprotected adjoining equipment

---

4 12.5 Minimum energy to ignite with a flame; melts plastic tubing 1% lethality in 1 min.

5 4.5 ---

Causes pain if duration is longer than 20 sec. However blistering is un-likely (First degree burns)

6 1.6 --- Causes no discomfort on long exposures

Table 7.9 - Radiation Exposure and Lethality

Radiation Intensity (kW/m2)

Exposure Time (seconds) Lethality (%) Degree of Burns

1.6 -- 0 No discomfort even after long exposure

4.5 20 0 1st 4.5 50 0 1st 8.0 20 0 1st 8.0 50 <1 3rd 8.0 60 <1 3rd

12.0 20 <1 2nd 12.0 50 8 3rd 12.5 -- 1 -- 25.0 -- 50 -- 37.5 -- 100 --

7.4.2Damage due to explosion

Explosion is a sudden and violent release of energy accompanied by the generation of pressure wave and a loud noise. The rate of energy release is very large and has potential to cause injury to the people, damage the plant and nearby property etc.

Table 7.10 - Damage Due to Peak Over Pressure Human Injury Structural Damage

Peak Over Pressure (bar) Type of Damage Peak Over

Pressure (bar) Type of Damage

5 -8 100% lethality 0.3 Heavy(90% damage) 3.5 –5 50% lethality 0.1 Repairable (10% damage)

2 -3 Threshold lethality 0.03 Damage of Glass 1.33 - 2 Severe lung damage 0.01 Crack of Windows 1 - 11/3 50% Ear drum rupture - -

7.4.3 Effect due to toxic gas release Various approaches are used to determine the consequences of toxic gases:

• IDLH • AEGL






IDLH (Immediate Danger to Life or Health) is the maximum concentration from which escape is possible within 30 minutes without any escape-impairing symptoms or irreversible health effects. AEGL (Acute Exposure Guideline Levels) are exposure guidelines designed to helpresponders deal with emergencies involving chemical spills or other catastrophic eventswhere members of the general public are exposed to a hazardous airborne chemical. (Acute exposures are single, non-repetitive exposures that don't exceed 8 hours.) 7.4.4 Details of Model Used for Consequence Analysis

ALOHA provide output as amount of chemical discharged from the source as well as its concentration in air it takes into account different levels of concentrations for a specified chemical.

Software used for calculation is ALOHA (AREAL LOCATIONS OF HAZARDOUS ATMOSPHERES) which is a computer program designed especially for use by people responding to chemical accidents, as well as for emergency planning and training. ALOHA can predict the rates at which chemical vapors may escape into the atmosphere from broken gas pipes, leaking tanks and evaporating puddles. It can then predict how a hazardous gas cloud might disperse in the atmosphere after an accidental chemical release. ALOHA provides output as amount of chemical discharged from the source as well as its concentration in air it takes in to account different levels of concentrations for a specified chemical. Different concentration levels are given below:

AEGL 3:is the airborne concentration, expressed as parts per million (ppm) or milligrams per cubic meter (mg/m3), of substance above which it is predicted that the general population, including susceptible individuals, could experience life-threatening health effects or death. AEGL 2:is the airborne concentration (expressed as ppm or mg/m3) of a substance above which it is predicted that the general population, including susceptible individuals, could experience irreversible or other serious, long-lasting adverse health effects or an impaired ability to escape. AEGL 1:is the airborne concentration (expressed as ppm or mg/m3) of a substance above which it is predicted that the general population, including susceptible individuals, could experience notable discomfort, irritation, or certain asymptomatic no sensory effects. However, the effects are not disabling and are transient and reversible upon cessation of exposure. IDLH: The Immediately Dangerous to Life or Health (IDLH) level. A chemical's IDLH is an estimate of the maximum concentration in the air to which a healthy worker could be exposed without suffering permanent or escape-impairing health effects. Input data for ALOHA are as below: Weather Data:

Average Wind Speed: 5 m/sec & 1.5 m/sec Average Ambient Temperature: 40 °C, 22 °C Average Humidity: 25%, 68% Atmosphere Stability Class: D (windy day time), F (Extreme calm, night time)

Chemical Properties:






Chemical properties of each hazardous chemical stored within premises are given in Table 7.3.






Table 7.11 - Consequence analysis and Damage Distance (Failure of raw material storage tanks)

* Threat zone was not drawn because effects of near-field patchiness make dispersion predictions less reliable for short distances.

Name of Chemical

Type of Impact

Flammable (Distance in meter) Toxic Dispersion

Pool Fire (meter)

Fire Ball (BLEVE) Worst Case

Scenario (meter)

Flash fire (Flammable Area of

Vapor Cloud) (meter) AEGL(3)/

IDLH AEGL(2) AEGL(1) Radiation Intensity(kW/m2) 37.5 25 4.5 37.5 25 4.5 UEL LEL

Fatalities 100% 50% - 100% 50% - - - Wind Speed

Stability Class

Ammonia (28 MT MS Bullet X 2)

5 D <10 <10 <10 N.A N.A N.A

*11 meters --- (90000

ppm = 60% LEL = Flame

Pockets)

*27 meters --- (15000

ppm = 10% LEL)

72 meters --- (1100

ppm = AEGL-3

[60 min])

196 meters --- (160 ppm

= AEGL-2 [60 min])

492 meters --- (30 ppm =

AEGL-1 [60 min])

1.5 F <10 <10 <10 N.A N.A N.A

*17 meters --- (90000

ppm = 60% LEL = Flame

Pockets)

*42 meters --- (15000

ppm = 10% LEL)

113 meters ---

(1100 ppm = AEGL-3 [60 min])

305 meters --- (160 ppm

= AEGL-2 [60 min])

755 meters --- (30 ppm =

AEGL-1 [60 min])

CO2 Gas[Scenario release rate considered

(20 MT/ Hr)]

5 D N.A N.A N.A N.A N.A N.A N.A N.A At IDLH = 40000 & STEL 5000 ppm Threat zone was not drawn because

the ground level concentrations never exceed the LOC.

1.5 F N.A N.A N.A N.A N.A N.A N.A N.A






Figure 7.1 –AmmoniaToxic Dispersion- Worst Case Scenario (1.5 m/s weather condition – stability class F)

N






Figure 7.2 – AmmoniaToxic Dispersion(5 m/s weather condition – stability class D)

N






7.5 Estimation of Effect of Damage / Impact Identification

From the dispersion modeling of Ammonia, It is observed that the threat zone is maximum for Ammonia from Ammonia Bullet. Percentage fatality from different incident outcome cases and level of concerns are given below: Table 7.12 - Estimation of Effect of Damage

Chemical Incident outcome

case

Level of

concern

Treat zone

distance

% fatality

Likely hood of

occurrence

Magnitude of Impact/ Damage

Ammonia Toxic Dispersion AEGL -3 72

meters 100 Very Unlikely High

All the threat zones in the unit are super imposed on Google image. Figure 7.1 &7.2 shows the map of vulnerable areas corresponding to different individual outcome cases. Figure 7.1 gives the location, where individual risk is found to be a maximum at locations within premises. A broadly acceptable level of individual risk as per the ALARP (AS LOW AS REASONABLY PRACTICABLE) concept of HSE, UK is 10-6/year.

7.6 Summary

It may be noted that in dispersion modeling, the wind direction and air temperature, atmospheric stability are found to be the deciding factors for the threat zones.

The present risk assessment study shows that existing unit of M/s.Saurashtra Chemical(Division of Nirma Ltd.)having storages of hazardous chemicals mainly Ammonia could have potential for damage to those inside and outside the industry. Workers working within premises of industry as well as of adjoining small unit may affect in case of accidental leakages from Ammonia.

A maximum threat zone of AEGL (3)approximately 113meters is observed in the case of release of Ammonia in very calm weather condition. So, it is recommended to evacuate the area in radius of 113 meters in downwind direction in case of emergency of this magnitude.

7.7 Risk Reduction Measures

7.7.1 Existing Risk reduction for Ammonia Bullet

Periodic thickness test of ammonia storage bullet is being carried out. Bullets are covered with sprinkler network Storage area is well-ventilated, away from plant Two ammonia detectors (with alarm) are provided in storage area. Bullet is provided with pressure relief mechanism Magnetic level indicator is provided






Auto weighting system (load cell) Safety valves are provided Earthing of the tank is provided Bonding of the pipe lines. Water drencher is provided Fire hydrants are provided Self-contained breathing apparatus (SCBA) is provided. Flame proof electrical equipment & fittings are provided at Ammonia Plant In-charge of trained operator round the clock is provided One empty bullet is available to transfer liquid inventory from one bullet to another Bullet is provided with pressure relief mechanism.PRVs are calibrated and tested

regularly Permit procedure is followed and PPEs are worn by concern persons Open & well-ventilated area in provided for ammonia storage Dual lines have been laid out from supply to use rend Triple redundant system. Process parameters can be controlled and monitored from local panel and from the

control room nodes In case of inaccessibility to this control centers, process can be controlled and monitored

from manager view panels from a remote location

7.7.2 Proposed Risk reduction Measures

For Ammonia Bullet

To scrub out the gaseous ammonia incase of leakage scrubber of adequate capacity should be provided.

A pump to transfer liquid ammonia from leaking tank to dump tank should be provided. LDAR program to be implemented for ammonia.

For Carbon Dioxide (CO2) Gas

Concentration levels of carbon dioxide above about 1 % are dangerous. It is recommended to do continuous monitoring with alarms to indicate unsafe conditions before and during potential personnel exposure.

7.8 Occupational Health Surveillance Program

Introduction

Medical surveillance program (also termed as medical surveillance for workers) can aid in the early recognition of a relationship between exposure to a hazard and disease, in the assurance of the safety of new substances, and as an indicator of the effectiveness of existing control measures. It is the systematic collection, analysis, and dissemination of disease data on groups of workers and is designed to detect early signs of work-related illness.






The Factories Act, 1948 and the rules framed there under provide for pre-employment and periodical medical examinations of workers employed in industries with hazardous processes and dangerous operations under section 41-C and section 87 respectively. Chemicals Exposed to Workers Directly or indirectly are Ammonia other chemicals as described in raw material storage inventory.

Action plan for Occupational Health and safety of workers

One Medical Officer and four paramedical staff are available at Occupational Health Center (OHC) at plant premises. Plant employees, workers from worker colony and villagers of nearby villages are treated here.

The pre-employment medical is being carried out by Factory Medical Officer (FMO) in the factory.

Yearly medical check – up done by FMO for each employee on regular basis and medical record is being maintained in the factory.

Good housekeeping, use of PPE, Engineering controls, Enclosure processes, display of safety boards, SOP of loading / unloading, local exhaust ventilation, safety shower etc. All necessary safety measures are being taken.

Workers are being trained on safe material handling of hazardous chemicals. The safe operating procedure for hazardous chemicals storage, handling & transporting

are Prepared & displayed. Control the noise at source by substitution, isolation, segregation, barriers is being done.

7.8.1 Treatment Facilities Provided to Workers affected by accidental Spillage of Chemicals / or any other injury One Medical Officer and four paramedical staff are available at Occupational Health Center (OHC) at plant premises. So, relevant treatment facilities are provided at the factory site.

7.8.2 Minimization of the Manual Handling of Hazardous Substance

Employers and employees are regularly examining their workplaces to detect any unsafe or unhealthful conditions, practices, or equipment and taking corrective action. Flameproof electrical motor & transfer chemicals through the pipelines are provided. Minimize lifting of raw materials, heavy loads by using appropriate platforms, trolleys, etc. Avoid the moving, manual handling of hazardous material. The automatic material transfer systems are adopted wherever possible.

7.9 Disaster Management Plan

7.9.1 Disaster A disaster is a catastrophic situation in which the day-to-day patterns of life are, in many instances, suddenly disrupted and people are plunged into helplessness and suffering and as a result need protection, clothing, shelter, medical and social care and other, necessities






of life. There are two types of emergency control plans (1) On site emergency plan and (2) Off site emergency or disaster plan.

7.9.2 On-Site Emergency Plan

Objectives of the Plan 1. To protect persons and properly of the factory in case of all kinds of accidents, dangerous

occurrences (Rule 103, Gujarat Factories Rules), emergencies and disasters happening in or affecting the plant at any time.

2. To inform people and surroundings about above happening if it is likely to adversely affect them.

3. To inform authorities including helping agencies (doctors, hospitals, fire, police, transport etc.) in advance, and also at the time of actual happening.

4. To identify, assess, foresee and work out various kinds of possible hazards, their places, potential and damaging capacity and area in case of above happenings. Review, revise, redesign, replace or reconstruct the process, plant, vessels and control measures if so assessed.

5. To work out a plan with detailed instructions to cope up with above happenings, based on personnel, equipment and records. Levels of hazardous substances shall be minimised to the extent possible. Establish machinery for rescue and recuperation operations, total loss control and prevention of harms and recurrence of above happenings. Ensure that absolute safety and security is achieved within the shortest time.

7.9.3 Site Plan of the Factory and Surrounding

Unit has prepared a plan of the factory premises and surroundings showing therein the areas of various hazards such' as fire, explosion, toxic release etc., and also location of assembly points, equipment room, personal protective equipment room, telephone room, first aid or, emergency control room, main gate, emergency gates, normal wind direction, north direction. The same has been given inChapter No.2 of EIA report. 7.9.4 Types of Overall Emergencies Fire (small and big), explosion, toxic exposure, strike, storm, flood and other hazardous possible situations shall be described with reasons. Sources of hazard from outside or neighboring plants, tanks, structure etc. shall be mentioned.

Table 7.13 - Types of Emergencies

Sr. No.

Type of emergency including disaster

(Major Class) May arise due to At (Place)

People and area likely to

be affected

1 Release of Toxic Gas i.e. Ammonia

Leakages from tank/pipes/valves

Tank farm area, process area

Plant Operator, Labors, workers

Admin staff 2 Fire Spillage or leakages at Ammonia Bullet Tank Farm Area






Sr. No.

Type of emergency including disaster

(Major Class) May arise due to At (Place)

People and area likely to

be affected

3 Fire / Explosion

Failure of critical parts, or low water level/ HSDunloadingfrom tanker.(By pumps)

Boiler / Utilities Area

4 Spillage of flammable liquid/gas Loading and unloading Utility

5 Natural Calamities: -

Lightening, Storm, Earthquake, Flood etc.

-- --

6

Collapsing of structure Overturning of tanker

containing flammable/toxic substances

-- --

7.9.5 Assessment of In-plant Hazards

Detailed hazard assessment of in-plant and control measures provided in Section 7.3, Table No. 7.3 & 7.4 of EIA report. Storage Hazards and Controls, Process Hazards and Controls are described in same topic.

7.9.6 Emergency Organizations and Functions The organizational set-up is necessary for chain of commands during emergency situation, which may arise in the premises. The system is described in following Subsections.

ON SITE EMERGENCY SQUAD

Site main Controller

Incident Controller

Dy. Incident Controller

Other necessary Persons (Key Persons)

Essential Workers






Figure 7.3Organizational Set-up

Members of above teams will be available during all shifts and holidays. Protective equipment, lifting gears, fire control points etc.; will be provided in sufficient numbers and their locations will be well informed. Necessary vehicles will be kept ready to shift persons in case of emergency.

EMERGENCY ORGANISATION In spite of the best possible preventive and precautionary measures taken for averting any






hazard or emergency. There may arise some emergency situation, which if promptly and methodically dealt with pre-planned compact methods with –substantially minimized in terms of members and even severity.

It is rather difficult to envisage and detail every action, which should be taken in various types of emergencies. The basic philosophy is to get the key personnel, if necessary disciplines that have knowledge and back ground, to quickly assess the gravity of the situation decides the actions and gives necessary directions to his fellow men.

To deal with such an emergency situations, an on -site emergency squad has been formed. In absence of any members, the next senior man in the squad will take charge and handle the situation in the best possible way be can till the arrival of main controller.

The main duties of the INCIDENT CONTROLLER(Team name are attached in Annexure A.) will be as under: -

He will assess the scale of the emergency and decide whether to treat it as on site emergency or to declare as off-site emergency.

If he thinks fit and decides the emergency to the dealt as off site emergency, he will inform the site main controller accordingly and as assume duties as main controller till the site main controller arrives

For onsite emergencies, he will Direct the shunting down and evacuation of the areas likely to he affected by

the emergency. Direct all the operations with in the affected area to ensure- Ensure Safety of personnel’s. Minimize damage to plant property and environment.

To minimize losses of material Direct, rescue and firefighting operations until arrival of outside fire brigade He will hand over the charge to outside fire brigade and help them in all

possible ways, they require. Search for casualties. Arrange for sending the casualties to hospital.

Evacuate all non-essential workers assembly point Keep in touch with emergency control center. Take all steps, he thinks necessary to control the situation in consultation with site main

controller. Preserve all such evidences as may be necessary, to ascertain the cause of such

emergency and which will keep in averting such emergencies in future.

The duties of the DEPUTY INCIDENT CONTROLLER are similar to that of incident controller, in his absence and to assist him in all possible ways as needs. The name of deputy incident controller are attached in Annexure B.

The duties of the SITE MAIN CONTROLLER (Team name are attached in Annexure C.) will be as under:-

On information, he will rush to the site of the incident take stock of the situation and

relive incident controller of him compulsory duties as main controller.






Communicate the information to all key personnel as well as all the senior officials of the works.

He will explain the gravity of situation to all of them as also the emergent line of action to be followed.

Arrange to shift the victims if any, for medical treatment. Direct the concerned personnel for contacting the concerned outside agencies for

necessary help. Continuously review and assess the possible developments to determine the best

probable course. Check that all key personnel as well others contacted, have arrived at the scene and co-

ordinate the activities of required services. Arrange for evacuation of the area of all non-essential personnel as well as informing

and evacuation of the neighbor –hood popular likely to be affected. Keep in touch with the progress of the victims, if any and arranges for informing the

relatives, if necessary. Liaison with outside agencies. In case of prolonged emergencies, involving the risk to outside areas as well by wind

blow, contact local meteorological office to get information of impending changes in weather conditions.

Control traffic movement inside the factory. Arrange for chronological record of events for course of actions as well as for future

alertness to avoid recurrence. If emergency is prolonged, arrange for the relief of personnel and for catering

facilities. Issue authorized statement to news media, if so required in consultation with the

President / Vice President (Personnel). Ensure that proper consideration is given for the preservation of the evidence. Arrange

for photograph or Video recording, if thinks fit. Control rehabilitation of the affected areas and victims on cessation of emergency,

assess the situation for starting the plant and give clearance accordingly on normalization of conditions.

KEY PERSONS

All the key persons have been appropriately selected and assigned the job in an emergency and are supposed to carry out their duties scrupulously. The key persons have been tabulated in AnnexureD.

SAFETY DEPTT. Safety officer will arrive at the site, assess the situation, supervise the steps being

taken advice accordingly and help in the use of protective and other emergency safety appliances.

He shall mobilize the personal protective and other safety appliances from other plants, stores and outside agencies, if need be.

In case of fire incidences, he will arrange for all available and suitable fire extinguishers and take all steps necessary control and contain the fire.

In case of large scale Fire, he will arrange to call fire brigade after consulting President/Vice President (Personnel) and co-ordinate fully with fire brigade and other services.

He will Investigate in the causes suggest remedial measures and submit a






comprehensive report to all concerned personnel. Keep in touch with the progress of victim. Ensure that all the emergency procedures are informed in time.

SECURITY DEPTT. Mobilize, as many people possible from the available security force for firefighting

evacuation, restricting the movement on-lockers and others. Direct the fire brigade to the site of the fire and stand in readiness for any help. In case of toxic gas release, arrange for collecting all the employees and other, at the

security gate and other assembly points or as per the directive of the main controller. Inform the district authorities /Police after consulting administration if necessary.

POLLUTION CONTROL He will arrange for reducing the pollutant and take all necessary steps to see

that minimum persons are affected by adverse effect of the pollutants. He will work in passion with the main controller and will advise him and be ready for

any help.

TRANSPORT

He will make available all the vehicles like car, ambulance, jeep drivers, for shifting victims for Medicare other movements and for any other emergency needs.

Work in close co-operation with the main controller, safety and security personnel. Plan for additional man power (Drivers, etc.) for any emergency need.

ENGINEERING CONTROL

This wills solely controlled by main controller and all the engineering personnel should be in readiness for whatever helps needed.

He will decide whether the plant shut down is needed or not and incase of shut down, he will instruct all concerned personals for proper actions for shut down.

MEDICAL AID

Checking the nature of injury, give appropriate First Aid treatment and in case of serious/Fatality he will arrange for admitting the victim/victims to Civil Hospital.

In case of serious/Fatality, he will inform the Co. Doctor, Safety Officer, Factory Manager and Personnel officer.

After consulting administrative head, he will inform security chief to inform Police in case of very serious/fatalities.

PERSONNEL DEPTT. To arrive at the site and report to site main controller. To take head count as per the attendance for all the regular employees, casuals,

badlies and also contract labors. To arrange for round the clock persons at nursing home/hospital to look after the

needs of victims/affected persons. To arrange for getting emergency medicines prescribed by hospital doctors from

outside. To arrange to inform the relatives of the victims and pacify them. To arrange for assorting the close relatives to nursing home/hospitals. To arrange for shifting the victim from City Civil Hospital to any other hospital in

bigger cities after consulting city civil hospital authorities.






To look after the Welfare of affected person/persons and their relatives. In case of very serious/fatal accidents, to arrange to inform the Factory Inspectorate

telepathically with inn two hours followed by detailed report in form No.21 within 24 hours.

To arrange to inform the Controller of Explosives Baroda, in case of fire /explosion in licensed installations.

To prepare a detailed and up to –date record of all affected personals with their local/permanent addresses.

Ensure round the clock presence of senior persons in the factory.

ADMINISTRATION Ensure that telephone operator has conveyed the message to all key personals. Telephone operator should keep the board including P. &T., free, to the extent

possible, for all incoming /outing calls. To receive any message from outside and pass on to the concerned

persons/department. To keep close liaison with the main control room. He will contact the site main controller for detailed. Information for preparation of sketches, write up details etc. or press report and

inform the media after consultation with V.P. G.M.(O). Ensure that the press does not publish any unauthentic news or the distorted version

of the official news.

ESSENTIAL PERSONS/WORKERS (Annexed in Annexure E.) All the Essential workers will work under Incident Controller/Site main controller. The duties of the essential workers will include.

To be at the site and available for assignment of any work. To help Incident controller /Site main controller and be ready to carry out any duty

given to them. Help in shutting down the plant, if necessary, to make it safe. Help the firefighting, control gas or spills, till the fire brigade arrives on scene and

takes the charge. To help fire brigade in all possible way, as they require. Attend to any emergency engineering work like isolating the equipment, process,

providing temporary by-pass lines, safe electrical work etc. Starting of emergency power, water lighting instruments equipment, etc. Attend to evacuation, rescue, and first aid and welfare activities. Moving the tankers/other vehicles from the areas of risk. Manning the assembly point and taking stock of the evacuated persons, search for

missing ones and consoling them and keeping them cool. And instruct them to allay the fear and be away from rumors.

Arranging for welfare of evacuated persons. Assistance to casualties, informing their relatives and to see the welfare of casualties

and their relatives. Assistance to communication center to handle out-going and in –coming calls and to

act as messengers, if necessary. To help the security personnel at the gate, for regulating the entries of vehicles,

arranging for visitors or other traffic arriving at the works. Informing surrounding areas and the public as directed by the site main controller. Any other help required.






All essential workers, shift wise have been tabulated in annexure. ASSEMBLY POINT

Unit has fixed assembly points have been annexed in Annexure F

EMERGENCY CONTROL CENTER (Annexed in Annexure G.) Unit has emergency control center at the main gate. The following will be available:

o Telephone facilities & Emergency telephone list. o Plans of the factory showing chart. o Hazard points chart. o Assembly points chart. o Location of factory & the surrounding Areas, population chart. o CO2 Fire extinguishers Nos. 4 o DCP Fire extinguishers Nos. 4 o FOAM Fire extinguishers Nos. 4 o B.A.Set o Emergency vehicles Ambulance. o A copy of ON Site emergency plan. o A copy of OFF Site emergency plan. o Personal Protective Equipments.

FIRE AND TOIXICITY CONTROL ARRANGEMENTS.

Industry has provided sufficient nos. of firefightingequipment of the appropriate types at allstrategic places throughout the factory. Extra quantities areavailable in safety maintenance room. Extra help from fire brigade if required is available at short notice from fire brigade station about 2.5 K.M. away. The concerned information has been tabulated in Annexure H

Table 7.14 - Fire Pump Details Fire Water Reservoir :-3 water storage tank with capacity of 734.305m3, 3930 m3 and 2634 m3 Other Source of Water:Khambhala Reservoir, R.O.Plant, Distillate water, Flash Water, SeaWater. Pump Detail Number of

Pump Head Capacity (Flow)

M3/Hr KW/HP

Electrical driven pump 1 88 m 273 96.50 kw Diesel 1 88 m 273 90.35 kw Jockey pump 1 88 m 25 13.78 kw Sprinkler system at Coal Yard 1 102 m 45 30 kw Sprinkler system at Crusher House 1 80 m 50 22 kw Fire Tender Porbandar Nagarpalika Total 5 666

Number of Hydrant Area / Plant Nos. Of Hydrant with Hose Box Nos. Of Monitors Total 75 27 Details of Fire Extinguishers are given in Annexure - U

Table 7.15 - Safety equipment details

Sr. No. Equipment Requirement Actual

1 De powder (50% of fire extinguishers ) 350 kg 350 kg 2 CO2 Cartridges ( 50% of fire extinguishers )

200 gms (10 kg DCP 35 Nos 55 Nos

3 As above 2 Kg ( 75 Kg DCP ) -- --






4 Sand scoops 20 Nos 25 Nos 5 Safety helmets As per Requirement As per Requirement 6 Water curtain nozzles 75 75 7 Stretchers 1 3 8 First aid box with anti-snake serum Only First Aid Box 18 Only First Aid Box 18 9 Rubber hand gloves As per Requirement As per Requirement

10 Explosive meter 1 2 11 Fire entry suit w/o breathing apparatus -- -- 12 Resuscitator -- -- 13 Electric siren with 3 km range 1 1 14 Hand operated siren -- -- 15 Water gel blandest -- -- 16 Red/green flags for fire drill -- -- 17 Pressure type self contained breathing

apparatus with spare cylinder (30 minutes) 7 9

18 Safety Shower 4 4

MEDICAL ARRANGEMENTS The concerned information regarding arrangements for first Aid Medical Center Etc. are detailed in Annexure I TRANSPORT AND EVACUATIONS ARRANGEMENTS Industry’s transport department is well equipped with fleet of vehicles for any emergency. The vehicles from company contractor can also be deployed for the purpose. Extra help can able be taken from Porbandar Municipality, as well as collectorate.The details are annexed in Annexure J POLLUTION CONTROL ARRANGEMENTS Unit has provided adequate treatment facilities like electrostatic precipitators, scrubbers, etc wherever required. The details have been given earlier under Environmental Impact Assessment at 1.2.3Details have been tabulated in Annexure K OTHER ARRANGEMENTS Industry has all the necessary type of equipment available in factory and can be deployed for any emergency purposes. The only hazardous and toxic material is Ammonia for which Unit would not require any specialist. All the necessary information in this regard has been tabulated under Annexure L.

7.9.7 Assembly Points The assembly points for gathering workers / Admin staff is fixed and clearly marked as per the wind direction on plant layout as well as on site. In case of emergency some locations are considered as Assembly Points. Depending on the wind direction and location of emergency, Assembly Point is declared. The employees should run across the wind direction and not against the wind direction. Assemble Points are drawn in Figure 7.4.






Figure 7.4 Plant Layout showing Assemble Points

D

A

B

C






7.9.8 COMMUNICATION SYSTEM

RAISING ALARM & SIRENS Unit has provided electronic alarm over liquid ammonia tanks. In the cases of any emergency or disaster, the affected sections of the plant will in consultation with site main controller inform the Time Office to blow the distress siren. The siren will Blow breaking at every one minute till the disaster or emergency continuous. When everything is O.K. and the emergency is over, all clean signals by a continuous siren for 3 Mts. will be blown for informing neighboring populace, Unit has fleet of jeeps which can be fitted with loud-speakers and which will inform whatever small populace nearby, within seconds. All these and relevant information has been tabulated in Annexure M

INTERNAL TELEPHONES Industry has a good net of internal telephones and a complete list of all internal telephone, even extending to colony residence, have been provided to all the department and hence anybody of any departments can be contacted immediately. The information regarding important persons to be contacted, with their internal telephones, has been annexed in Annexure N

EXTERNAL TELEPHONE All the important persons in the factory are provided with the external telephones .All List of all such telephones have been given to important personals l. A list of all-important externals Nos. is available in emergency control center. Latest telephone directory is also kept at hand. All the above information have been tabulated in Annexure O

DECLARING THE MAJOR EMERGENCY Unit has a set of nominated person in succession that can declare the major emergency. The object is that any of the senior personal like-Sit e main controller incident controller. Deputy incident controller can take the charge in absence of other. They will declare the major emergency and put the on site/off site emergency plans into actions.

A list of persons authorized to declare major emergencies have been tabulated in Annexure P

TELEPHONE MESSAGES Industry has provided regular telephone exchange, manned with highly trained and experienced telephone operators for contacts with outside parties as well as internal communications, however for such emergencies, extra personals will be deployed to cop-up with the increased loads, as well as some essential workers as runners .The format in Annexure Q will be kept handy for proper records. COMMUNICATION OF EMERGENCY All statutory information and other relevant information as per the guidelines will be given






to all the workers.

Copies of Annexure A to E duly up-dated will be kept handy in the emergency control center for call in of any person outside their normal duty hours.

On sitting any emergency due to fire or toxic release the fire brigade will be informed immediately and will try level best to control the situation-till their arrival land will fully co-operate with them in mitigating the situations. The other agencies like Government control room, Police, District Emergency authorities, and factory Inspectorate will also be informed forthwith.

For informing the localities nearby and the public areas, likely to be affected, will be informed by breaking siren as well as through other communication channels as early as possible, once the emergency is seen to be uncontrollable land likely to turn into a major emergency.

All these statutory information are annexed in Annexure R

SEPARATIONS DISTANCE The separations distance from hazardous installation to category .A installations is about 8.00 Mtr and that between hazardous installation and category ‘c’ installations are more than 1,000 Mts. The above information have been annexed in Annexure S

EMERGENCY INSTRUCTION BOOKLET Industry has put down this plan, emergency duties for different squads member. The information regarding the above have been tabulated in Annexure T RAISING ALARM & SIRENS Unit has provided electronic alarm over liquid ammonia tanks.

In the cases of any emergency or disaster, the affected sections of the plant will in consultation with site main controller inform the Time Office to blow the distress siren. The siren will Blow breaking at every one minute till the disaster or emergency continuous. When everything is O.K. and the emergency is over, all clean signals by a continuous siren for 3 Mts. will be blown for informing neighboring populace, Unit has fleet of jeeps which can be fitted with loud-speakers and which will inform whatever small populace nearby, within seconds. All these and relevant information has been tabulated in Annexure M INTERNAL TELEPHONES Industry has a good net of internal telephones and a complete list of all internal telephone, even extending to colony residence, have been provided to all the department and hence anybody of any departments can be contacted immediately. The information regarding important persons to be contacted, with their internal telephones, has






been annexed in Annexure N EXTERNAL TELEPHONE All the important persons in the factory are provided with the external telephones .All List of all such telephones have been given to important personals l. A list of all-important externals Nos. is available in emergency control center. Latest telephone directory is also kept at hand. All the above information have been tabulated in Annexure O DECLARING THE MAJOR EMERGENCY Unit has a set of nominated person in succession that can declare the major emergency. The object is that any of the senior personal like-Sit e main controller incident controller. Deputy incident controller can take the charge in absence of other. They will declare the major emergency and put the on site/off site emergency plans into actions. A list of persons authorized to declare major emergencies have been tabulated in Annexure P

TELEPHONE MESSAGES

Industry has provided regular telephone exchange, manned with highly trained and experienced telephone operators for contacts with outside parties as well as internal communications, however for such emergencies, extra personals will be deployed to cop-up with the increased loads, as well as some essential workers as runners .The format in Annexure Q will be kept handy for proper records.

COMMUNICATION OF EMERGENCY All statutory information and other relevant information as per the guidelines will be given to all the workers.

Copies of Annexure A to E duly up-dated will be kept handy in the emergency control center for call in of any person outside their normal duty hours.

On sitting any emergency due to fire or toxic release the fire brigade will be informed immediately and will try level best to control the situation-till their arrival land will fully co-operate with them in mitigating the situations. The other agencies like Government control room, Police, District Emergency authorities, and factory Inspectorate will also be informed forthwith.

For informing the localities nearby and the public areas, likely to be affected, will be informed by breaking siren as well as through other communication channels as early as possible, once the emergency is seen to be uncontrollable land likely to turn into a major emergency.

All these statutory information are annexed in Annexure R SEPARATIONS DISTANCE The separations distance from hazardous installation to category .A installations is about 8.00






Mtr and that between hazardous installation and category ‘c’ installations are more than 1,000 Mts. The above information have been annexed in Annexure S

EMERGENCY INSTRUCTION BOOKLET Industry has put down this plan, emergency duties for different squads member. The information regarding the above have been tabulated in Annexure T Co – related activities PRE-EMERGENCY ACTIVITIES The following are the details of pre-emergency activities Internal safety survey is carried out by Unit’s own Maintenance Depts.

All valves, safety valves, pressure and temperature gauges. : Once a fortnight All pumps, pipes joints, etc. : Once a month. All PPEs : Two week All tanks, pressure vessels, Reactions vessels, etc. : Once in six months.

THIRD PARTY SERVICES If necessary, unit will get third party survey for hazards, steps for prevention and precautionary measures.

PRESSURE VESSEL TESTING Industry’s N.D.T. Dept. tests all the hazardous pressure vessels. Every six months. Every two years, Unit get such tanks (Pressure vessels) checked by a competent third party agency, as per the statutory requirements.

NON DESTRUCTIVE TESTING Unit has regular N.D.T. Dept. & NDT engineers test every pipeline, pressure vessels, reaction tanks etc. Six monthly and corrective actions,necessary repairs/replacements are initiated.

SAFETY RELIEF VALVE TESTING Unit’s maintenance staff tests all safety valves/relief valves periodically.

FIRE SYSTEM TESTING All portable fire-fighting equipment are tested, every week, as per schedule and intermittently sometimes, as is necessary. Fire hydrants, sprinklers etc. are also tested periodically for their operability. MUTUAL AID SCHEME Industry is self-sufficient unit and Unit do not have any nearby Factory/Industry for mutual help. MOCK DRILLS Unit trains their workers in safe job methods and emergency planning.






TRAINING Unit has trained workers in handling various safety equipment as well as firefighting equipment.

PROTECTIVE EQUIPMENTS Industry has provided dust mask, goggles, hand gloves, rubber as well as Asbestos, shoes, face shield, helmets, gas masks, canister as well as Self Breathing Apparatus type to workers, working in hazardous areas.

It will provide the following PPEs in plant control room for any emergency use. 1. Canister gas mask. 2. Self Breathing Apparatus 3. Goggles 4. Dust mask 5. Safety hand gloves

COMMUNICATIONS Industry maintain internal as well as external communication network is good condition. Factory siren of more than 5 KMs range, which can be sounded in breaking tones of every minute five times in cases of any emergency and “All clear” continuous siren for 3 Mts. Unit has also arrangements for informing whatever then populace within sizable distance.

EMERGENCY LIGHTS Unit has emergency lights installed in the plant and control rooms. Unit also have emergency power unit to cop – up with the adverse situations.

EMERGENCY CONTROL CENTRE Industry has fixed emergency control center, details of which are given in chapter III of section I.

PLANT ASSEMBLE AND ASSEMBLY POINTS Unit has fixed assembly points, the details are given in chapter IV of section I.

LIASON WITH STATE AUTHORITIES Industry is in liaison with factory inspectorate, fire brigade, district collector, local police, hospital authorities etc. and are well kept informed of the latest position.

HOSPITAL FACILITIES

Industry will be utilizing their own Saukem Medical Center, Civil Hospital, ESI hospital and other such hospitals as per the need of the emergency. It will keep the blood group of each worker. It will fully acquaint the doctors about the nature of emergencies and probable cause of the effects to the victim to facilitate the doctor to decide about his line of action. A primary blood donor list will be maintained in the factory, however such list will be






maintained in the factory, however such list of the donors are easily available from Civil hospital, which is only about 2.5 KMs from factory and can be reached within minutes. OUTSIDE SHELTERS Industry can very well and easily manage for outside shelters for the affected persons in schools, medical centers etc which are more than a kilometer away from hazardous areas and safe for such shelter.

STATUTORY INFORMATION All statutory information will be given to all workers, general public and the govt. Authorities as per the need of the situation. A list of statutory information’s will also be kept in the emergency control center.

EMERGENCY TIME ACTIVITIES The duties of the different emergency squads, key personnel and others all designated persons are pre – assigned and others all designated persons are pre – assigned and supposed to co – operate fully and work in a co – oriented manner to meet the challenge of overcoming the emergency with least possible damage, to man and property and normalize the plant with the help of the resources available within and from outside agencies.

POST EMERGENCY ACTIVITIES

Investing the causes leading to such emergency. Suggesting proper preventive and other pre–cautionary measures to avoid

recurrence of such incidences. Preparation and circulating of enquiry reports. Making Insurance claims. To rehabilitate the affected persons. To start and normalize the plant.

CONTORLLING EMERGENCY For emergency due to toxic release fires etc. details of duties of site main controller. Incident controller, Deputy Incident Controller are given in chapter III of section I

The tanks being in open, ventilated area the chances of explosion are practically nil, yet the emergency actions plan, assigns specific duties. For speedy actions, use of ready information, provided in different annexure is recommended.

Industry has fixed open space near the gates as assembly points. All non-essential workers will, first, be evacuated from the incident areas and the evacuees will be asked to collect near main gate.

In case of toxic release of gas, the assembly points will be fixed by the main side or incident controller in the opposite direction of the wind flow land the workers will be instructed not to go down wind, till toxic release is under control.

SAFE CLOSE DOWN Shut down procedures are well defined and all the staff as well as workers are well strained and experienced in the safe close down. The incident controller will over all supervise the situation.






USE OF MUTUAL AID All the related information’s are detailed in Annexure H MEDICAL TREATMENT All injured workers will be given prompt first aid treatment in control room /first aid center and if necessary they will be sent to Civil Hospital in ambulance .For all first aid center as well as Saukem Medical Center are will equipped.

ACCOUNTING FOR PERSONNEL Industry’s time office keeps the records of daily attendance of all workers, company, contractors, badli, causal, etc. It also have the list of persons department –wise and hence the accounting is not difficult.

ASSESS TO RECORDS Factory maintains information about near relatives of all it’s employees and can be contacted in any emergency.

PUBLIC RELATIONS Executive Director, Executive Vice President (Operations), Sr. Vice President (Personnel & Administration) are authorized to give relevant information to press and public relations in case of any major emergency.

REHABILITATION

Before rehabilitation and restart of plants, site main controller will decide as to safe condition. In case of toxic release, he will ascertain that source of emission has been effectively isolated neutralized and there is no danger of any gas, in the atmosphere .He will also ascertain in that all the gas pockets are completely removed. He will also thoroughly examine the conditions before giving all clear signal for re-start of the plant and rehabilitation. Only after clearance of all debris etc. he will give a restart signal and rehabilitate the workers.

Medical Arrangement

First Aid Boxes will be provided at various strategic locations. Requisite numbers of employees are trained about First Aid, Liaison with nearest hospitals. General Procedures and Responsibilities

Mock drill: Mock drills are carried out regularly to familiarize the staff with their roles, fire protection equipment/system installed in the plant and use of personnel protective equipment. Wind Socks: Wind direction is determined with the help of installed windsocks.






Offsite Emergency Preparedness Plan

Offsite emergency plan would follow the onsite emergency plan. When the consequences of an emergency situation go beyond the plant boundaries, it becomes an offsite emergency. As the off-site emergency plan is to be prepared by the Government, a Central Control Committee or Group shall be formed under the Chairmanship of the area head. For example, assume a district structure and District Collector (is the Chairman of the District Control Committee (DCC). Offsite emergency plan: -

In the manufacture of soda ash by solve process, unit has to use one and the only toxic as well as hazardous chemical, viz. ammonia, which is also sometimes explosive and flammable at very high temperature of 650 deg. C and the concentration in air to the true of 16 to 25 %, which is extremely rare. In view of the toxic mature of ammonia, it may affect the outside areas also, in situations, when there is sudden release of large quantities of the gas. The possibilities of the above situations, through very remote, warrant us to prepare an off-site emergency plan to immediately inform the populace likely to be affected, evacuate if necessary, to a safer place and to instruct them the safety measures, to safe- guard themselves. With the above in view, Unit has prepared an offsite emergency plan. Industry has designated site main controller, incident controller and deputy Incident controller as well, to lead the situation, guide and control all the arrangements and bring the disaster under control. It has arranged well-set communications system, procedure for identification of personnel, emergency action squad, emergency telephone list, and key personals, for various emergency duties. It also has fleet of vehicles for emergency movements/evacuation purposes and some special equipment for special purposes. For off-site emergency, Unit would take the help of outside authorities also. Meteorological in formations are also collected, to serve as guidelines e.g. for evacuation or moving to safer place. Press-public relations are arranged. Medical aid to victims will be arranged. Rehabilitations will be arranged when the situation is well within control and if is ascertained that there is no longer any danger. In case of fire or toxic gas release, the workers who find it first, will shout “Fire Fire” or “Gas Gas” as the case may be and run. Inform his Supervisor /any senior staff, who is seen first. who in turn will inform his high-ups, all the concerned persons and then with the help of essential workers, he will drive away all the fire by using appropriate portable fire extinguishers/try to close the valve of the gas leaking line, using proper respirators. If needed fire brigade will also be called in and pressed into service.






STRUCTURE OF THE OFF-SITE PLAN The offside emergency squad is as under: -

COLLECTOR / GOVT. AGENCIES &

SITE MAIN CONTROLLER MAIN

INCIDENT CONTROLLER DEPUTY

INCIDENT CONTROLLER

Operation staff Maintenance staff Safety

In absence of any member of the squad, the next senior most person will take the charge. The following arrangements are well organized, in advance:

Co-ordination arrangements. Warning systems. Implementation procedures, Communication systems, Control

center. Assembly points. Specialized emergency equipments like heavy-duty vehicles. Special instructions list. Weather data. Transport, including ambulance. First aid/medical treatment. Public information and public relations system. Dealings with outside district

authorities. Reporting and recommending preventive/precautionary measures to avoid re-

occurrence of such incidences.

ROLE OF FACTORY MANAGEMENT The site main controller will provide a copy of this on-site/offsite emergency plan to district authorities, factory inspectorate, key personals and all those closely connected with various types of emergencies, to facilitate themselves to be well prepared in advance to meet any situations. A list of the persons to whom this plan is circulated has been listed on front “Circulation” page.

ROLE OF EMERGENCY CO-ORDINATION OFFICER (ECO) The ECO is either senior police official or a district authority, but their role will be utilized for outs ide security/evacuation/public control, in extreme situations involving off-site emergency.

ROLE OF LOCAL AUTHORITY The local authority like and emergency planning office (EPO) or a senior local officer, will prepare an off-site plan and circulate amongst all concerned persons to be well acquainted for their respective role in an emergency.

It will be the responsibility of the EPO. Or the local authority to inform “Public, rail/road traffic new media consulting President/Vice president (Personnel)/Vice President works.






He will also, by a large, give all necessary instructions, follow up measures, precautionary and protective measures, develop viable public awareness system, etc.

ROLE OF FIRE AUTHORITIES

Whenever fire brigade is called, by local authorities of the company the fire brigade officer will take complete charge of the situation from the Incident Controller, on arrival at the site.

Fire brigade official will also take control in cases of toxics release/explosion.

ROLE OF POLICE AND EVACUATION AUTHORITIES.

Role of police is required only for law and order control outside the factory, in cases of large-scale off-site emergency.

ROLE OF MUTUAL AID AGENCIES. To be searched out MUTUAL AID AGENCIES.

ROLE OF FACTORY INSPECTORATE

Factory inspectorate will be supplied with copy of the on-site/off-site emergency plan by the factory and will be ready to accommodate and act on wherever guide-lines and advise in regard to adequate arrangements for handling all types of emergencies.

9. LDAR (Leak Detection and Repair)

It is known that leaking equipment, such as valves, pumps, and connectors, are the largest source of emissions of volatile organic compounds (VOCs) and volatile hazardous air pollutants (VHAPs) from chemical manufacturing units.

Table 7.16 - List of Volatile Compounds (VOCs) Sr. No.

Chemicals /Solvent

TLV/ TWA

Flammable Limit Chemical Class

(As per MSIHC Rules)

NFPA Ratting

Vapour Pressure

FP °C

BP °C

Class (As per

Petroleum Classification)

1. Ammonia 25ppm (ACGIH

TLV) NA 36

°C -- Highly Toxic

Health – 3 Flammability

– 1 Instability -

0

1200 kPa @ 25 °C

Leak detection and repair (LDAR) programme will be applicable to list of solvents given in table 7.13 & their related components from which chances of VOC generation as per CPCB guidelines are as follows :

a. Block valves; b. Control valves; c. Pump seals; d. Pressure relief valves; e. Flanges – Heat Exchangers;






f. Flanges – Piping; g. Connectors – Piping; h. Open ended lines; i. Sampling connections. Equipment and line sizes more than 2.54 cm are to be covered.

LDAR programmer would be applicable to components (given in Above table) for following products/compounds: (i) hydrocarbon gases; (ii) Light liquid with vapor pressure @ 20°C > 1.0 kPa; and (iii) Heavy liquid with vapour pressure @ 20°C between 0.3 to 1.0 kPa. LDAR program would not be applicable for,

(i) heavy liquids with vapor pressure < 0.3 kPa, it will be desirable to check for liquid dripping as indication of leak

(ii) Equipment and line sizes less than 2.54 cm, less than 300 hr service and in vacuum service.

(iii) Equipment and piping during start up and shut down. (iv) Pumps (canned, diaphragm, magnetic), Valves (Diaphragm, bellow) and close loop

Sampling points; and (v) Non accessible points to the extent of 5% of total plant.

Following frequency of monitoring of leaks and schedule for repair of leaks shall be followed:

Table 7.17–Frequency of Monitoring of Leaks Sr. No.

Component Frequency of monitoring

Repair schedule

Responsibility

1 Valves/ Flanges Quarterly

Repair will be started within 5 working days and shall be completed within 15 working days after detection of leak for solvents.

Environment Health & Safety

Officer

2 Pump seals Quarterly 3 Pressure relief devices Quarterly 4 Pressure relief devices (after

venting) Within 24 hours

5 Heat Exchangers Quarterly 6 Process drains Annually

7 Pump seals with visible liquid dripping

Weekly Immediately

8 Any component with visible leaks

Weekly Immediately

9 Any component after repair / replacement

Within a week -

Following types of monitoring methods may be judiciously employed for detection of leaks: 1. Photo ionization detector (PID) or flame ionization detector (FID) Instrumental method of

measurement of leaks; 2. Audio, visual and olfactory (AVO) leak detection; and 3. Soap bubble method.






Data on time of measurement & concentration value for leak detection; time of repair of leak; and time of measurement & concentration value after repair of leak should be documented for all the components.

Bibliography [1] "Manufacture, Storage and Import of Hazardous Chemical (Ammendment) Rules,"

New Delhi, 2000. [2] L. Technica, "Techniques for Assessing Industrial Hazards - A manual," World Bank

Technical Paper, vol. 55, 1988. [3] V. Marshall, "How lethal are explosions and toxic escapes," Chem. Eng. (London), vol.

8, no. 24, pp. 573 - 577, 1977. [4] d. P. U. d. Haag, Guideline for Quantitative Risk Assessment - Purple Book, 2005. [5] I. A. o. O. &. G. Producers, "Storage Incident Frequencies," in Risk Assessment Data

Directory, OGP Publications, 2010.

ANNEXURE A: INCIDENT CONTROLLER

Sr. No.

Name Designation Place of availability Phone No.

Factory Resi. Factory Resi.

1 Wet Mech Dy.Manager Wet Mech Wet Mech Ex-12 286

2 Dry Section Sr.Engineer Dry Section Dry Section B-90 335

3 RBC Plant Sr.Engineer RBC Plant RBC Plant B-65 227

4 Calciner Sr.Engineer Calciner Calciner B-66 199

5 Power Plant Sr.Engineer Power Plant Power Plant B-35 218

Annexure B:- Dy.Incident Controller

Sr.

No.

Name

Designation

Qualification

Place of availability

Phone No.

Factory

Resi.

Factory

Resi.

1

Sh.K.H.Baria

Engg.

B.E.

Calciner

C-93

282

536

2

Sh.R.K.Sahal

Sr.Engineer

B.S.

Calciner

B-18

266

589

3

Sh.R.N.Trivedi

Sr.Engineer

D.M.E.

Dry.Mech

B-65

272

560

4

Sh.P.K.Singh

Sr.Engineer

M.Sc.

Dry Section

B-90

210

696

5

Sh.U.A.Dhruv

Sr.Engineer

B.E.

Calciner

B-66

199

536

6

Sh.B.G.Vithalani

Sr.Engineer

D.M.E.

Power Plant

B-35

218

593

Annexure C:- SITE MAIN CONTROLLER

Sr. No. SITE MAIN CONTROLLERS

Name in priority order

Designation qualification Place of availability Phone no.

In the Factory

Residence

address

In the Factory

Residence

1

Shri H.U.Doshi

GM (O)

B.E.(Chem)

Tech. block

Birla colony Ex-2

104

504

In Absence of

2

Shri S.V.Herma

Consultant

B.E.

Tech block Birla colony Ex-4

103

503

3

Shri D.S.Chandrak

Consultant

B.E.

Tech block

Birla colony Ex-8

113

513

]

Annexure D:- KEY PERSONS

Sr.

No. Department Name Designation Qualification Place of availability Phone No. Next

Factory Resid. Factory Resid.

Name

Place of availability Phone No. Factory Resid. Factory Resid.

1 Safety Shri K.M.Mehta Consultant BE Tech Block Ex-10 178 543 Shri Y.M.chotai Sr.Engineer B-38 101 401

2 Security &

Administration Shri (Ret.)P.N.Nair Manager P.G.D.F.T.

Security Office

B-11 121 461 Shri N. Jadeja Secruity

Office C-94 201 571

3 Fire & Gas

Control Shri D.S.Chandrakar Consultant B.E.

Technical Block

EX-8 113 513 Shri D.S.Chandrakar Consultant Ex-8 113 513

4 Medical Dr.N.V.Dhamecha Sr.Manager M.B.B.S. First Aid

Room City

Shri D.P.Raval

First Aid Room

City 193 -

6 Transport Shri (Ret.)P.N.Nair Manager P.G.D.F.T. Security

Office B-11 121 461

Shift Security Officer

Transport Office

201

7 Lime Kiln Shri D. S. Chandrakar Consultant B. E. Technical

Block Ex. 113 513

Shri P.K.Singh Manager(P)

Dry Section B-90 210 584

8 Production Shri D.S.Chandrakar Consultant B.E. Technical

Block EX-8 113 513

Shri A.K.Singh .Manager(P)

Wet Sec. B-12 286 456

9 Material

Management Shri Anay Awasthi Sr.Officer

R.M.Office Block

B-4 177 531

10 Stores Shri P. N Vakani Sr. Dy. M General

Stores B-5 154 446

11 Personnel Shri M V Bhuptani Factory

Manager M.S.W.

LLB Technical

Block B-48 191 445 Shri Sudhir Barot

HRD Office

B-64 239

12 Water & Utilities Shri K.M.Mehta Consultant B.E.(Elect.)

Technical Block

Ex-10 178 543

13 Civil Shri R.T.Mehta Sr.Engg B.E.(Civil) Civil Office B-36 270 481

14 Godown Shri Sanjeev Gupta Manager LLB R/M Site B-16 131 547 Shri Balbir Singh R/M Site B-54 273 499

Annexure-E- Essential Persons

Sr. No. Name DesignationTrained for work Place of availability Phone Numbers STAFF Factory Residence Factory Residence

1 Sh.Anil Kumar Menon Sr.Eng. Rescue, Fire & Evaluation Wet sec B-60 274 2211582 2 Sh.H.R.Nathawani Sr.Eng. :do: Wet sec B-24 274 3 Sh.L.H.Gorania Sr.Eng. :do: Wet sec C-98 274 418 4 Sh.K.J.Pandit Sr.Eng. :do: Wet Mech City 170 5 Sh.Dharmesh Shah Sr.Eng. :do: Wet Mech Colony 170 6 Sh.Rajesh Pankhania Sr.Eng. :do: Wet Mech City 170 423 7 Sh.Kiran Golwala Sr.Eng. :do: Wet C-101 171 587 8 Sh.S.B.Thanki Sr.Eng. :do: Pump Sec City 165 2243512 9 Sh.Vinay Lakhotia Sr.Eng. :do: Calciner B-33 114 469

10 Sh.P.S.Pithadia Sr.Eng. :do: TPS B-43 114 422 11 Sh.R.H.Pankhania Sr.Eng. :do: Dry. Mech B-51 248 578 12 Sh.V.S.Joshi Sr.Eng. :do: Dry. Mech City 248 13 Sh.D.M.Thanki Sr.Eng. :do: TPS B-93 276 570 14 Sh.B.K.Sida Chemist :do: D.M.Plant B-96 198 15 Sh.D.P.Thanki Sr.Eng. :do: Electric B-5 253 630 16 Sh.Dinesh Patel Sr.Eng. :do: Electric B-88 164 610 17 Sh.Manoj Jangid Sr.Officer :do: HRD B-40 239 627 18 Sh.Nirmalsingh Jadeja Joint Officer :do: Security C-96 189

Annexure-E- Essential Persons (CONTD.)

Sr.No. Name Designatio Trained for work Place of availability Phone Numbers Factory Residence Factory Residence

WORKERS 1 Sh.R.H.Maradia Operator :do: Wet prod. city 172 2 Sh.Hanif Mansuri Operator :do: Wet prod. city 172 3 Sh.L.K.Singharakhia Operator :do: Wet prod. D-121 172 4 Sh.Deepak Joshi Operator :do: Wet prod. city 183 5 Sh.S.B.Rathod Fitter :do: Wet Mech D-69 171 6 Sh.Deepak Khushari Fitter :do: Wet Mech city 224 7 Sh.G.C.Joshi Fitter :do: Wet Mech city 171 8 Sh.Hiralal Jadav Fitter :do: Wet Mech D-148 171 9 Sh.B.S.Ratnu Welder :do: Wet Mech D-249 171

10 Sh.M.C.Pillai Welder :do: Wet Mech D-191 171 11 Sh.G.P.Thanki Operator :do: Dry Prod D-165 257 12 Sh.Omprakash D. Operator :do: Dry Prod city 235 13 Sh.Dhanji Poona Operator :do: Dry Prod city 216 14 Sh.Jaysukh Bharthi Operator :do: Dry Prod D-149 258 15 Sh.Muru Natha Operator :do: Dry Prod city 258 16 Sh.N.D.Parmar Operator :do: Dry Prod city 276 17 Sh.Vallabh Zina Operator :do: Dry Prod city 235 18 Sh.Vinodrai Modga Operator :do: Dry Prod D-154 235 19 Sh.N.T.Patel Operator :do: Dry Prod city 235 20 Sh.Raju Shrinivasan Attendent :do: Dry Prod D-274 235


Sr.No. Name Designation Trained for work Place of availability Phone Numbers

Factory Residence Factory Residence WORKERS

21 Sh.Premji Rama Fitter Resque,Fire,Evacuation Dry Mech City 248 22 Sh.Jora Shiva Fitter :do: Dry Mech D-289 248 23 Sh.Parash Mal Fitter :do: Dry Mech D-22 248 24 Sh.Naresh Bhimji Fitter :do: Dry Mech City 248 25 Sh.Dinesh Kara Fitter :do: Dry Mech City 248 26 Sh.Paresh Ghanshyam Fitter :do: Dry Mech City 248 27 Sh.K.C.Vyas Operator :do: RBC Plant City 282 28 Sh.K.M.Rana Attendent :do: RBC Plant City 282 29 Sh.Mohd.Salim Fitter :do: RBC Plant City 282 30 Sh.Naran Deva Fitter :do: RBC Plant City 282 31 Sh.Bhikhu Abha Fitter :do: RBC Plant City 282 32 Sh.Pratap Virji Fitter :do: RBC Plant D-54 282 33 Sh.N.D.Chavda Operator :do: TPS City 114 34 Sh.Ratansinh Gohel Operator :do: TPS City 114 35 Sh.Devshi Bhadrecha Operator :do: TPS D-163 114 36 Sh.Suresh Maru Operator :do: TPS City 114 37 Sh.Lalit Kotia Operator :do: TPS City 114 38 Sh.Nathubha B. Operator :do: TPS City 114 39 Sh.Anil Umrania Operator :do: TPS City 114 40 Sh.Bharat mehta Operator :do: TPS City 114 41 Sh.Hitesh Bhardwaj Operator :do: TPS City 114 42 Sh.Jagdish Chavda Operator :do: TPS City 114 43 Sh.Narendra Parmar Operator :do: TPS City 114


Sr.No. Name Designation Trained for work Place of availability Phone Numbers Factory Residence Factory Residence

WORKERS 44 Sh.Dilip Trivedi Attendent Resque,Fire,Evacuation TPS City 114 45 Sh.Gautam Vyas Attendent :do: TPS City 114 46 Sh.Harnish Purohit Attendent :do: TPS City 114 47 Sh.Mandan Jadav Attendent :do: TPS D-16 114 48 Sh.Mukesh Dayashankar Attendent :do: TPS D-19 114 49 Sh.Parbat Solanki Attendent :do: TPS D-188 114 50 Sh.Samat Nakum Attendent :do: TPS City 114 51 Sh.Upendra Erda Attendent :do: TPS City 114 52 Sh.Bhavsinh Barad Attendent :do: TPS City 114 53 Sh.Bharatsinh Jadeja Attendent :do: TPS D-30 114 54 Sh.Kalpesh Dattani Attendent :do: TPS City 114 55 Sh.Mukesh Vadolia Attendent :do: TPS City 114 56 Sh.Prakash Sudra Attendent :do: TPS D-59 114 57 Sh.Rajendra Modha Attendent :do: TPS D-10 114 58 Sh.N.J.Mehta Attendent :do: TPS City 114 59 Sh.Karsan Odedara Attendent :do: TPS D-229 114 60 Sh.Pravin Sharma Attendent :do: TPS City 114 61 Sh.Mahavir Gajubha Attendent :do: TPS D-171 114 62 Sh.Pooransingh H. Attendent :do: TPS City 114 63 Sh.Devji Velji Attendent :do: TPS City 114 64 Sh.R.A.Nayak Ammonia Op :do: Ammonia D-110 283 65 Sh.Niesh Parmar Ammonia Op :do: Ammonia D-190 283 66 Sh.Jeshang Solanki Ammonia Op :do: Ammonia D-80 283


Sr.No. Name Designation Trained for work Place of availability Phone Numbers Factory Residence Factory Residence WORKERS

67 Sh.Khem Bahadur Gurung AO(S) :do: Security S - 6 201 68 Sh.Bhagta Bahadur Gurung AO(S) :do: Security S - 16 201 69 Sh.Amar Singh AO(S) :do: Security S - 52 201 70 Sh.Puran Singh AO(S) :do: Security S - 19 201 71 Sh.Raja Arjan SGD :do: Security City 201 72 Sh.Nathu Ala SGD :do: Security City 201 73 Sh.Jai Singh SGD :do: Security S - 7 201 74 Sh.Oghubha T. SGD :do: Security D - 172 201

ANNEXURE - F :SAFE ASSEMBLY POINTS

Identification Location Sr. no. of Assembly Point

Accommodation Capacity

AT THE TIME OF EMERGENCY

Name Desig. Place of Phone no. Availability

PPE that

In the Factory

Resi. Addres

In the Factory

Resi.

1

Laxmi Narayan Temple

800 people

Mr.Sudhir Barot

Sr.Officer HRD

HRD Office

B-64,Birla colony

239

2 RM gate 900 people Capt.P.Nayar Manager Security

Main Gate B-11,Birla colony 121 461

3 Salt Works G - 12

1500 people Mr.Sudhir Barot

Sr.Officer HRD

HRD Office B-64,Birla colony 239

4 Admn block 900 people Capt.P.Nayar Sr.Manager Security

Main Gate B-11,Birla colony 121 461

As per Ann-20As per Ann-20As per Ann-20

As per Ann-20

ANNEXURE - G : EMERGENCY CONTROL CENTRE LOCATION OF THE CENTRE : (1) Security office TELEPHONE NOS. OF THE CENTRE : (1) 201

Sr.no. Items kept in the centre [see (1) to (14) Page 17]

Numbers or Quantity

Person who will handle or operate this item.

Its period of operation Notes

Last

Present

1

2

3

4

5

6

7

8

9

10

11

12

13

14

Safety gloves

Safety goggles

Dust mask

Canister gas mask

Air supply line breathing apparatus Portable fire extinguishers

a. CO2 type

b. DCP type

c. Foam type

On site plan copy

Off site plan copy

Hand Gloves

Gum boot Safety belt

10

10

10

2

1

12

4

4

4

1

1

10

10

5

Security Personnel &

First Aider who are

trained in fire fighting

& first aid.

Routine

Checking

Routine Checking

ANNEXURE - H : F IRE & TOXICITY CONTROL ARRANGEMENTS

FOR FLAMMABLE & TOXIC SUBSTANCE STORAGE SEE ANNEXURE - 4 & FOR THEIR PROCESSES

SEE ANNEXURE - 6. FOR KEY PERSONNEL & ESSENTIAL PERSONS SEE ANNEXURE 17 & 18.

FIRE WATER : NO. OF RESERVOIERS : NO. OF TANKS 1, TOTAL QUANTITY : 9 LACS Gallons

OTHER SOURCE & CAPACITY

NO. OF HYDRANT POINTS

NO. OF FIRE PUMPS, TYPE & CAPA- CITY

NO. OF HOSE REALS

& TOTAL LENGTH

NO. OF FIRE TENDERS & CAPA- CITY

NO. OF SPRINKLERS / MONITORS ALTRNATE POWER ARRANGEMENT

CO2 EXTINGUSIHERS

FIXED PORTABLE LIFTING HEIGHT

PRESSURE LIFTING HEIGHT

PRESSURE

1 2 3 4 5 6 7 8 9 10 11

----

2

2 Four 15 mts.

Nil

Over head

4-5 kg/cm2

NA

NA

D.G.sets

6.8 kg - 2 no. And 22.5 kg - 1

DRY POWDER TYPE FOAM TYPE WATER JET PRODUCTS OTHER

EXTINGUISHERS PERSONAL PROTECTIVE EQUIPMENTS

TYPE OF POWDER & TOTAL

QUANTITY

NO. OF PORTABLE

CEASE FIRE BRAND DCP

TYPE OF FOAMAND TOTAL QUANTITY

NO. OF PORABLE

EXTINGUISHER EXTINGHISHER TONNERS NO. AND SIZE OF Blankets

OTHER JET PRODUCTS QUANTITY

SODA ACID TYPE

NO. OR QTY.

RESPIRATORY NON-RESPIRATORY

TYPE NOS. TYPE NOS.

12 D.C.P 10 kg

13 2

14 ----

15 Chemical

foam9 kgs

16 0

17 Nil

18 Nil

19 Nil

20 Nil

21 Nil

22 23 24 25

* BA sets * Air supplied

* Canister gas mask

2 nos 1 no 2 nos

Gloves Goggles Face - shield Boots

12 12

As per Ann - 18

12 12

Final draft EIA report

Documents

Transcript of Final draft EIA report