16.01.2013 Guj Ahirsalt Alled Kutch Eia 6

AHIR SALT AND ALLIED PRODUCTS PVT. LTD.
ISOLATED LIQUID STORAGE TERMINAL AT VILLAGE MITHIROHAR, TALUKA GANDHIDHAM, DISTRICT KUTCH
ADDITIONAL STUDIES
Figure 7-20: VCE risk contour of Cyclohexanone release due to catastrophic rupture of tank at 2.0/F at predominant wind direction SW
Figure 7-21: VCE risk contour of Cyclohexanone release due to catastrophic rupture of tank at 2.0/F at 2nd predominant wind direction NW
KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2012
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Figure 7-22: VCE risk contour of Acetone release due to catastrophic rupture of tank at 2.0/F at predominant wind direction SW
Figure 7-23: VCE risk contour of Acetone release due to catastrophic rupture of tank at 2.0/F at 2nd predominant wind direction NW
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Figure 7-24: VCE risk contour of Hexane release due to catastrophic rupture of tank at 2.0/F at predominant wind direction SW
7.2.9 x x x x
Conclusions
The effect of jet fire and late pool fire due to 10 mm leak scenario is confined to the site boundary The possibility of cascade effect of tank fire is reduced to an extent by providing bund to each tank The centre of vapor cloud explosion for the chemicals due to catastrophic rupture (worst case scenario) of tank, such as Acetone, P-Xylene, Nonene, Cyclohexanone crosses the site boundary The risk contour of late explosion superimposed on site layout clearly indicates that the centre of explosion is far away from the site or any neighboring industrial facility, the explosion centre of worst case scenarios are lying in non-habitat area, mostly in open saltpan and over mud terrain The intensity of 0.4 bar (Sufficient to cause destruction of house and minor structure) pressure touches the illegal encroachment in intertidal zone due to catastrophic rupture (worst case scenario) of hexane tank A concrete wall of a good fire rating capacity will be erected along the site boundary and development of green belt along the site periphery is also envisaged which will result in restriction of radiation within site boundary Spillage will be transferred to vacant tank to restrict the spreading of pool
7.3
Occupational Health Hazard and Mitigations
Main objectives of installation are to receive, store and dispatch of liquid chemicals and allied products for customers, as providing transit storage facilities on hire basis. Installation receives liquid chemicals
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from ship by pipe lines, store these chemicals in storage tanks and then as per customers requisition, fill the tankers/lorries to dispatch the final destination of chemicals viz. to the various companies of the customers. Various types of petroleum class A, B, C liquids, other liquid chemicals and allied products are to be stored at an installation. The activity of installation will be carried out only day time, with employing maximum less than 30 workers, including security / watchman. The Installation is to be started as earliest. The unit has obtained the necessary legal permission from the different Authorities, as required. 7.3.1 Anticipated Types of Liquid chemicals
Installation will store and handle the various liquid chemicals in closed conditions only. It cannot be specified that the particular tank will contain particular chemical for particular period, because of uncertainty in supply of chemicals by customers. However, anticipated hazardous liquid Chemicals are given in Table 3-6. 7.3.2 Potential Hazards and Personnel Protective Equipment for Various Chemicals
Possible Exposure of Chemicals Generally, handling and storage of chemicals will be carried out by enclosed system by use of pipe lines and power driven pump-sets. So, possibility of exposure of any chemicals during transfer and storage will be minimized. However due to failure in operation system or safety system exposure of chemicals to workers can not be ignored, the some of the operation and safety system failure examples are given below;
Technical Errors
Design defects, fatigue, metal failure, corrosion etc.
Human Errors
Neglecting Safety instructions, deviating from specifies procedure etc.
Lack of Information
Warning procedures, non-disclosure of line of treatment etc
Organisation Errors
Poor emergency planning and coordination, poor communication with public, non-compliance with mock drills / exercises etc; which are required for ensuring a state of quick response and preparedness. However, the sudden leakage / spillage of liquid chemicals from storage-tank, pipe lines, joints, pump set, filling, tankers/trucks, etc cannot be over ruled. It may spread out side for shorter period, if controlled immediately. In case major leak or catastrophic failure, then, it may turn into serious incident or disaster/ emergency, if not controlled. Further, if leaking chemical is flammable in nature, then if it get any source of ignition, then it catch fire and turn into Fire emergency depending upon quantity and property of liquid chemical. if liquid have toxic property, then it may turn into toxic type of disaster/emergency. Thus, properties of chemicals, type
KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2012 177
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of container, containers quantity, weather conditions etc are effective factors of the gravity of disaster/emergency. The effect can be further, compounded by the micro-meteorology of the area, wind speed and direction, rate of precipitation, toxicity / quantity of chemical released, population in the reach of release, probability of formation of lethal mixtures (fuel-air of other mixtures) and other industrial activities being performed in closer vicinity. Impact of Chemical Accidents/Disasters Accidents on chemical which are near missing or minor types, do not much impact or damage, but in case of major accidents, involved large volume of inventories of hazardous chemicals or high toll of injuries, or release of toxic gas or spillage of hazardous chemicals or explosion, called as Major Chemical Accident/Emergency/Disaster; cause extensive loss of life, damage to property and adverse effect on environment. Further, emergency situation arises all of sudden and at most unexpected time with high potential to cause havoc. In addition to above, the major consequences of chemical disaster include impact on livestock, flora and fauna, the environment (air, soil, water) and tremendous losses to the industries. Acetone
Chemical Profile
Clear colorless liquid with a sweetish odour, flash point 0 F, less dense than water. Vapours are heavier than air, used as a solvent in paint and nail polish removers.
Route of Entry
Inhalation, Ingestion, Skin & Eyes
Level Concentration
TLV STEL IDLH 500 ppm; 8 hr Time Weighted Avg (TWA): 750 ppm , 15 min Short Term Exposure Limit (STEL):. 2500 ppm
Health Hazard Toxicology

Lipid soluble solvent causes CNS effects similar to ethanol.
Inhalation
Nausea, vomiting, headache, excitement, faintness, fatigue, and bronchial irritation may result from inhalation exposure. With high concentration exposures, systemic toxicity can occur similar to that seen with ingestion.
Skin
Repeated dermal exposure to liquid acetone can cause defatting and drying of the skin, and brittle nails. Chemical burns may develop after prolonged exposure. Systemic toxicity after dermal exposure
ADDITIONAL STUDIES
is rare, but may occur if large surface areas are exposed to high concentrations, primarily in young children due to larger surface area to volume and more rapid dermal penetration.
Eyes
Acetone and its vapors are mildly irritating to the eyes and mucous membranes. Corneal erosions are a rare effect after high concentration exposure.
Mild to Moderate Intoxication

Mild CNS depression, mild metabolic acidosis, nausea, vomiting, hyperglycemia and ketosis (mimicking diabetic ketoacidosis) may be seen, most often after ingestions, but occasionally after inhalation or severe dermal exposure.
Severe Intoxication
Severe CNS depression, coma, seizures, tachycardia, hypotension, gastrointestinal bleeding, and respiratory depression are rare effects seen with serious intoxication, most commonly after ingestion.
Proposed Personnel Protective Equipments for Mitigation

x x x x Personnel Protective equipment made from natural rubber, viton, neoprene, polyvinyl alcohol, neoprene/natural rubber, or nitrile, polyethylene or chlorinated polyethylene will be used. Safety Goggles or suitable eye protection will be used to prevent eye contact. Appropriate personnel protective clothing will be provided to prevent skin contact. Chemical protective gloves, boots and goggles will be used for protection.
Benzene
Chemical Profile
Clear colorless liquid with a petroleum-like odor, flash point less than 0 F. Less dense than water and slightly soluble in water. Hence floats on water. Vapors are heavier than air.
Route of Entry
Level Concentration
TLV STEL IDLH 0.5 ppm; 8 hr Time Weighted Avg (TWA): 2.5 ppm (Skin.); 15 min Short Term Exposure Limit (STEL): 500 ppm
Health Hazard Inhalation

x Lower levels (700 to 3,000 ppm) can cause drowsiness, dizziness, tachycardia, headaches, tremors, confusion and unconsciousness. Exposure to high air concentrations (3,000 ppm or higher) may cause acute poisoning, characterized by the narcotic action of benzene on the CNS.
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The anesthetic action of benzene is similar to that of other anesthetic gases, consisting of a preliminary stage of excitation followed by depression and, if exposure is continued, seizures, paralysis, ventricular arrhythmias and death due to respiratory failure. Most individuals can begin to smell benzene in air at 1.5 to 4.7 parts per million (ppm) and detect the odor of benzene in water at 2 ppm. Brief exposure (5 to 10 minutes) to very high benzene air concentrations (10,000 to 20,000 ppm) can result in death.
Ingestion
x Benzene taste in water begins at 0.5 to 4.5 ppm. Ingestion of 9 to 12 g of benzene has caused vomiting, tachycardia, staggering gait, somnolence, loss of consciousness and delirium, followed by chemical pneumonitis and collapse, with initial stimulation followed by abrupt CNS depression. At moderate concentrations, pallor, dizziness and excitation, followed by flushing, dyspnea, chest constriction, headache and weakness may occur. Clinical signs from ingestion of higher concentrations may include euphoria and excitation, followed by fatigue, coma and death.
x x
Skin
Locally, benzene has a strong irritating effect, producing erythema, burning and, in more severe cases, edema and blistering.
Eyes
Eyes: Causes pain redness.
Carcinogenicity
The agent (mixture) is carcinogenic to humans. The exposure circumstance entails exposures that are carcinogenic to humans.
Proposed Personnel Protective Equipments for Mitigation

x x Protective clothing consisting of coveralls or other full body clothing will be worn and will be changed at least twice weekly. Safety showers, eye-wash fountains, and cleansing facilities will be installed and maintained, where there is a possibility of benzene contact to eyes or skin. Like Truck Loading Gantry, Chemical Pump house, etc. Neoprene gloves will be worn If skin contact is unavoidable. Hydrocarbon vapor canister, supplied air or a hose mask; hydrocarbon insoluble rubber or plastic gloves; chemical goggles or face splash shield; Apron made of hydrocarbon-insoluble apron such as neoprene will be used to prevent skin contact. Wear appropriate personnel protective clothing Chemical goggles or face splash shield will be used to prevent eye contact.
x x x x x
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Iso Propyl Alcohol
Chemical Profile
Volatile, colorless liquid with a sharp musty odor like rubbing alcohol and flash point is 53F. Vapors are heavier than air and mildly irritating to the eyes, nose, and throat. Density is approximately 6.5 lb / gal. Used in making cosmetics, skin and hair preparations, pharmaceuticals, perfumes, lacquer formulations, dye solutions, antifreezes, soaps, window cleaners. It is sold in 70% aqueous solution as rubbing alcohol.
Route of Entry
Level Concentration
TLV STEL IDLH 200 ppm; 8 hr Time Weighted Avg (TWA) 400 ppm ; 15 min Short Term Exposure Limit (STEL) 2000 ppm

Respiratory depression and failure can occur in cases of severe poisoning from inhalation.
Ingestion
If ingested causes drunkenness and vomiting.
Toxicity
Mild To Moderate Toxicity: May include CNS depression, dysarthria, ataxia, nystagmus, similar to ethanol intoxication, nausea/vomiting, flushing, headache, tachycardia, mild hyperglycemia, ketonuria, and ketonemia WITHOUT metabolic acidosis.
Skin
Repeated dermal application can cause systemic toxicity (primarily CNS depression), especially in infants and young children, because of more extensive dermal absorption and greater surface area-tovolume ratios.
Eyes
Splash or vapour exposure causes irritation.
Proposed Personnel Protective Equipment for Mitigation

x x x Appropriate personnel protective clothing will be wear to prevent skin contact. Safety Goggles will be used to prevent eye contact. The worker will instruct to wash the skin when it becomes contaminated.
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Work clothing that becomes wet will be immediately removed due to its flammability hazard (i.e. for liquids with flash point < 37.78 C)
Hexane
Chemical Profile
Clear colorless liquids with a petroleum-like odor. Flash points -9 F. It is less dense than water and insoluble in water. Vapors are heavier than air. Used as a solvent, paint thinner and chemical reaction medium.
Route of Entry
Level Concentration
TLV STEL IDLH 50 ppm, skin. 8 hr Time Weighted Avg (TWA) -na; 15 min Short Term Exposure Limit (STEL) 1100 ppm

Inhalation causes irritation of respiratory tract, cough, mild depression, cardiac arrhythmias. Aspiration causes severe lung irritation, coughing, pulmonary edema; excitement followed by depression.
Ingestion
Ingestion causes nausea, vomiting, swelling of abdomen, headache, and depression
Skin
Irritation to the eyes
Eyes
Irritation to the eyes

x x x x x Appropriate personnel protective clothing will be wear to prevent skin contact. Substance reported to cause eye irritation or damage; may require eye protection. Safety Goggles will be used to prevent eye contact. The worker will be instructed to wash the skin when it becomes contaminated. Work clothing that becomes wet will be immediately removed due to its flammability hazard(i.e. for liquids with flash point < 37.78 C ) Respirator Recommendations: Up to 500 ppm: (Assigned protection factor = 10) Any supplied-air respirator.
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Butanol
Chemical Profile
Colorless liquid, used in organic chemical synthesis, plasticizers, detergents, etc
Route of Entry
Level Concentration
TLV STEL IDLH 20 ppm; 8 hr Time Weighted Avg (TWA) NA; 15 min Short Term Exposure Limit (STEL) 1400 ppm

Anesthesia, nausea, headache, dizziness, irritation of respiratory passages. Acute Exposure causes pulmonary tract irritation and rarely pulmonary edema. Severe respiratory depression or death has not been reported after inhalation.
Ingestion
Harmful if swallowed
Skin
Mildly irritating to the skin
Eyes
Mildly irritating to the eyes
Proposed personnel Protective Equipment for Mitigation

x x x x x x Appropriate personnel protective clothing will be wear to prevent skin contact. Safety Goggles will be used to prevent eye contact. The worker will be instructed to wash the skin when it becomes contaminated. Work clothing that becomes wet will be immediately removed due to its flammability hazard(i.e. for liquids with flash point < 37.78 C ) Respirator Recommendations: Up to 500 ppm: (Assigned protection factor = 10) Any supplied-air respirator. Employees will be provided with and will be emphasis to use impervious clothing, gloves, face shields (eight-inch minimum), and other appropriate protective clothing necessary to prevent repeated or prolonged skin contact with liquid butyl alcohol.
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ADDITIONAL STUDIES
Methanol
Chemical Profile
Colorless fairly volatile liquid with a faintly sweet pungent odor like that of ethyl alcohol. Completely mixes with water. The vapors are slightly heavier than air and may travel some distance to a source of ignition and flash back. Any accumulation of vapors in confined spaces, such as buildings or sewers, may explode if ignited. Used to make chemicals, to remove water from automotive and aviation fuels, as a solvent for paints and plastics, and as an ingredient in a wide variety of products.
Route of Entry
Level Concentration
TLV STEL IDLH 250 ppm; 8 hr Time Weighted Avg (TWA): 200 ppm (Skin.); 15 min Short Term Exposure Limit (STEL): 6000 ppm
Health hazard Inhalation

Exposure to excessive vapor causes eye irritation, headache, fatigue and drowsiness. High concentrations can produce central nervous system depression and optic nerve damage. 50,000 ppm will probably cause death in 1 to 2 hrs.
Mild to moderate toxicity

Patients will initially have signs of acute intoxication, such as ataxia, sedation, and disinhibition. Patients may also complain of abdominal pain, nausea, vomiting, and headache. Acidosis or signs of visual impairment suggest a more severe poisoning.
Ingestion
Swallowing may cause death
Skin
Can be absorbed through skin
Eyes
Causes eye damage

x x x Approved canister mask will be used high vapour concentrations; Safety goggles; rubber gloves, safety boots will be used There is some data suggesting that the breakthrough times of methanol through natural rubber are approximately an hour or more.
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x x x
Breakthrough times of methanol through nitrile or Viton are greater than one hour reported by (normally) two or more testers. So we will use nitrile or viton gloves. Nitrile apron will be used to prevent skin contact. Safety Goggles will be used to prevent eye contact.
Toluene
Chemical profile
Clear colorless liquid with a characteristic aromatic odour, Flash point 40 F. Less dense than water and insoluble in water. Hence floats on water. Vapours are heavier than air. It may be toxic by inhalation, ingestion or skin contact. Used in aviation and automotive fuels, as a solvent, and to make other chemicals.
Route of Entry
Level Concentration
TLV STEL IDLH 20 ppm; 8 hr Time Weighted Avg (TWA) NA, 15 min Short Term Exposure Limit (STEL) 500 ppm

If aspirated, causes coughing, gagging, distress, and rapidly developing pulmonary edema. Vapors irritate upper respiratory tract; cause dizziness, headache, anesthesia, respiratory arrest.
Ingestion
If ingested causes vomiting, griping, diarrhea, depressed respiration.
Skin
Causes drying of skin
Eyes
Vapors & Liquid irritate eyes

x x x x Appropriate personnel protective clothing will be wear to prevent skin contact. Safety Goggles will be used to prevent eye contact. The worker will be instructed to wash the skin when it becomes contaminated. Work clothing that becomes wet will be immediately removed due to its flammability hazard (i.e. for liquids with flash point < 37.78 C)
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ADDITIONAL STUDIES
Ethylene Di Chloride
Chemical Profile
Clear colorless liquid with a chloroform-like odour. Flash point is 13.3 C. Denser than water and insoluble in water. Vapours are heavier than air. Density is 1.253.
Route of Entry
Level Concentration
TLV STEL IDLH 10 ppm; 8 hr Time Weighted Avg (TWA): NA, 15 min Short Term Exposure Limit (STEL): NA

Inhalation of vapors causes nausea, drunkenness, depression.
Skin
Prolonged contact with skin may cause a burn.
Eyes
Contact of liquid with eyes may produce corneal injury.
Ingestion
Initial effects seen after ethylene dichloride (EDC) ingestion are gastrointestinal; vomiting is common. Cyanosis, dyspnea, and coma may be delayed in onset.

x x x x Appropriate personnel protective clothing will be wear to prevent skin contact. Safety Goggles will be used to prevent eye contact. The worker will be instructed to wash the skin when it becomes contaminated. Work clothing that becomes wet will be immediately removed due to its flammability hazard(i.e. for liquids with flash point < 37.78 C)
Ethanol
Chemical profile
Clear colorless liquid with a characteristic vinous odor and pungent taste. Flash point is 12.8 F. Density 0.778. Vapors are heavier than air.
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ADDITIONAL STUDIES
Route of Entry
Level Concentration
TLV STEL IDLH 1100 ppm; 8 hr Time Weighted Avg (TWA) NA, 15 min Short Term Exposure Limit (STEL) 3300 ppm

x x Irritation on Throat. On Acute Exposure respiratory depression may occur. Respiratory failure may follow severe intoxication. Aspiration of vomitus may result in pneumonitis and pulmonary edema.
Ingestion
On Acute Exposure Nausea, vomiting, gastrointestinal bleeding and abdominal pain are common. Diarrhea may occur.
Skin
Ethanol can cause facial flushing, skin dryness and irritation. Allergic contact urticaria, possibly from impurities, may occur. Toxicity from dermal absorption through intact or damaged skin has occurred in pediatric cases.
Eyes
Irritating to eyes

x x x x x Appropriate personnel protective clothing of natural rubber, neoprene, nitrile, or vitron made will be wear to prevent skin contact. Safety Goggles will be used to prevent eye contact. Hand gloves of natural rubber, neoprene, nitrile, or vitron will be used The worker will be instructed to wash the skin when it becomes contaminated. Work clothing that becomes wet will be immediately removed due to its flammability hazard(i.e. for liquids with flash point < 37.78 C)
Xylene
Chemical profile
Clear colorless liquid with a characteristic aromatic odor is consisting of a mixture of the three isomers (ortho-, meta- and para-). The latter two predominate. Flash point is 27-46 C. Less dense (at 0.862) than water and insoluble in water. Hence floats on water. It may be toxic by ingestion. Vapors heavier than air and may be narcotic in high.
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ADDITIONAL STUDIES
Route of Entry
Level Concentration
TLV STEL IDLH 100 ppm; 8 hr Time Weighted Avg (TWA) 150 ppm, 15 min Short Term Exposure Limit (STEL) N.A.

Inhalation may cause reversible hepatic and renal toxicity. High vapor concentrations can cause CNS excitation followed by narcosis, olfactory changes, respiratory tract irritation, and noncardiogenic pulmonary edema. Severe exposure may result in death due to respiratory arrest and/or ventricular dysrhythmias.
Ingestion
Xylene ingestion can cause ventricular fibrillation, reversible hepatic and renal toxicity, CNS depression, a burning sensation in the oropharynx and stomach, and vomiting. Pulmonary aspiration can cause pneumonitis and noncardiogenic pulmonary edema
Skin
Defatting of the skin with irritation, dryness, erythema, and cracking commonly occur. Blistering may occur, particularly if exposure to concentrated xylene is prolonged and the exposed area of skin is occluded.
Eyes
Brief exposure to high vapor concentrations can cause a sensation of irritation. Vacuolar keratopathy has occurred in a few workers with prolonged exposure to high vapor concentrations. Splash accidents have produced transient, superficial injury in most cases. Older literature reports conjunctivitis and occasionally corneal burns following eye contact with liquid xylene.

x x x x x x Appropriate personnel protective clothing of natural rubber, neoprene, and polyvinyl chloride will be wear to prevent skin contact. Safety Goggles will be used to prevent eye contact. Hand gloves of natural rubber, neoprene, and polyvinyl chloride will be used The worker will be instructed to wash the skin when it becomes contaminated. Work clothing that becomes wet will be immediately removed due to its flammability hazard(i.e. for liquids with flash point < 37.78 C) Positive pressure self-contained breathing apparatus (SCBA) will be used.
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Solvent naphtha
Chemical profile
Clear colorless to dark brownish colored liquid with an aromatic odour. It is less dense 0.730-0.754) than water and insoluble in water. Hence floats on water. Vapours are heavier than air and used in cleaning preparations, as a solvent, and as a raw material for making various chemicals. Flash point above 37.78 C
Route of Entry
Level Concentration
TLV STEL IDLH 100 ppm; 8 hr Time Weighted Avg (TWA) NA, 15 min Short Term Exposure Limit (STEL) NA ppm

High concentration of vapours may cause intoxication, Coughing, choking, tachypnea, dyspnea, cyanosis, rales.
Ingestion
If liquid is swallowed, it may get into lungs by aspiration
Skin
Mild to moderate irritation
Eyes
Mild to moderate eye irritation

x x x Appropriate personnel protective clothing will be wear to prevent skin contact. Safety Goggles will be used to prevent eye contact. The worker will be instructed to wash the skin when it becomes contaminated.
Cyclohexanol
Chemical profile
It is colorless liquid with a camphor-like odour & soluble in most organic liquids. Flash point is 67.8 C. May be toxic by inhalation or skin exposure. Vapours are narcotic in high concentrations. Irritates skin, eyes and mucus membranes. Used in making soap, lacquers, and plastics
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Route of Entry
Inhalation, Skin & Eyes
Level Concentration
TLV STEL IDLH NA; 8 hr Time Weighted Avg (TWA) 50 ppm, 15 min Short Term Exposure Limit (STEL) 400 ppm

Irritation nose, throat; arcosis-depression of the central nervous system tending to produce sleep or unconsciousness
Skin
Irritation skin
Eyes
Irritation eyes

x x x Appropriate personnel protective clothing of nitrile rubber viton, barricade, chemrel, teflon , polyvinyl alcohol will be wear to prevent skin contact. Safety Goggles will be used to prevent eye contact. Hand gloves of natural rubber, neoprene, and polyvinyl chloride will be used
Cyclo Hexanone
Chemical Profile
Colorless to pale yellow liquid with a pleasant odour, less dense than water. Flash point is 43.8 C. Vapours heavier than air. Used to make nylon, as a chemical reaction medium, and as a solvent.
Route of Entry
Inhalation, Skin & Eyes
Level Concentration
TLV STEL IDLH NA; 8 hr Time Weighted Avg (TWA) 50 ppm, 15 min Short Term Exposure Limit (STEL) 700 ppm
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Inhalation of vapours from hot material can cause narcosis. Irritation, mucous membrane; headache; narcosis, coma;
Skin
The liquid may cause irritation to skin, dermatitis
Eyes
Irritation eyes

Nonane
Chemical profile
Clear colorless liquid with a sharp odour. Flash point is 30 C. Insoluble in water and less dense than water.
Route of Entry
Level Concentration
TLV STEL IDLH 200 ppm; 8 hr Time Weighted Avg (TWA) NA, 15 min Short Term Exposure Limit (STEL) NA

Vapor inhalation may cause irritation. Prolonged inhalation may lead to breathing difficulty.
Ingestion
Ingestion causes abdominal discomfort, nausea and diarrhea.
Skin
Contact may irritate eyes and possibly injury the cornea.
Eyes
May irritate skin
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Kerosene
Chemical profile
Clear colorless to light amber liquid with a petroleum odour. Flash point is 37.78C. It is less dense than water and insoluble in water. Vapours are heavier than air.
Route of Entry
Level Concentration
TLV STEL IDLH NA; 8 hr Time Weighted Avg (TWA) NA, 15 min Short Term Exposure Limit (STEL) NA

Vapor causes slight irritation of nose. if taken into lungs, causes coughing, distress, and rapidly developing pulmonary edema.
Ingestion
Liquid irritates stomach; Injection of kerosene, has resulted in febrile reactions, local tissue inflammation and systemic effects, including pulmonary edema, pneumonia, and mild CNS depression. Severe cases have resulted in multiorgan dysfunction syndrome. Injection of pressurized hydrocarbons has caused severe tissue damage.
Skin
Reversible ocular injury may occur after contact with most hydrocarbons.
Eyes
Vapor causes slight irritation of eyes

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7.3.3
Medical Examination of Workers
Medical Examination (Sec. 41-C- of the Factories Act-1948(1995) and Rule- 68-T of The Gujarat factories Rules-1963(2004)) The medical examination of the workers will be carried out by Factory Medical Officer as per following details; and records shall be maintained.
Before employment
x x Once before employment, to ascertain physical fitness of the person to do the particular job; No person will be employed for the first time without a certificate of fitness in Form No. 33.
During employment
x x 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 The details of pre-employment and periodical medical exam, carried out as aforesaid will be recorded in the Register in Form No. 32.
Workers engaged in handling of Benzene As per Schedule XX of Rule 102 of The Gujarat Factories Rules, Medical examination of workers engaged in handling of Benzene will be carried out as per following details; x x x A thorough pre-employment medical examination including a blood test for fitness for employment by medical officer will be carried out Periodically medical examination including blood test and other biological tests will be carried out at intervals of every 6 months by a laboratory. Certificates of pre-employment medical examination and periodical medical examination including tests, will be entered in a health register in Form No. 20.
Notifiable Disease As per the third schedule, (Sections 89 and 90) of the Factories Act, List of Notifiable Disease applicable to installation area; x x x x x x Benzene poisoning, including, poisoning by any of its homologues their nitro or amido derivatives or its sequelae Toxic anemia Toxic jaundice due to poisonous substances Occupational or contact dermatitis caused by direct contact with chemicals and paints. These are of two types, that is, primary irritants and allergic sensitizers Occupational cancer Toxic nephritis
Where any worker in a factory contracts any disease specified in the Third Schedule (as mentioned above), the manager of the factory will send notice thereof to the authorities, in Form No. 22.
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7.3.4
Work Area Monitoring
Work Area Monitoring (Section 41-F of the Factories act and Rule 12-B of the Gujarat Factories Rule) The installation will be using various hazardous chemicals for that Permissible level of certain hazardous chemicals as per Second Schedule under Section 41-F, of the Factories Act-1963(1995), are indicated in the Table 7-46.
Table 7-46: Permissible Limit of Hazardous Chemicals as per Factories Act

Permissible Limit S. No. 1 2 3 4 5 6 7 Chemical/ Substance Acetone Benzene (S.C.) n- Butyl Alcohol, Skin Ethyl Alcohol Methanol, Skin Toluene Xylene (o, m, pIsomers) S. No. At IInd Schedule 3 12 19 53 77 107 114 TWA (8 Hours) PPM 750 10 50 1000 200 100 100 mg/m 1780 30 150 1900 260 375 435
3
Short Term Expo. Limit (15 min) ppm 1000 250 150 150 mg/m3 2375 310 560 635
The Work area will be monitored for above mentioned chemicals and the report will be maintained in Form No. 37. 7.3.5 General Safety Measures
The purpose of proposed installation is to store liquid chemical in different tanks; located in tank-farm area of the Unit. The liquid chemicals will be received through pipelines from Kandla oil-jetty to storage-tanks. The stay of liquid chemicals in particular tanks will be uncertain period only, as storages of tanks will be on hire basis to the customers. The liquid chemicals will be dispatched to the said customer through gantry by filling the tankers/trucks. Thus, No specific liquid chemicals will stayed in any tank for longer period, and there will be no possibility of adverse effect to any person, surrounding atmosphere in ordinary circumstances. However, considering the various chemicals handled and stored at site; following safety measures will be provided at the site. General Safety Measures x x x x x x x Requisite personnel Protective Equipment shall be provided to the workers. Instruction/Notice to wear the same will be displayed. Further, it will be insisted to use the same while at work. Provision of water shower with Eye washer and display of Notice accordingly. MSDS of all hazardous chemicals will available at Office and responsible persons. Booklet on Disclosure of Information on Hazardous Chemicals to the workers will be prepared and educated them. Provisions of First Aid Box and trained person in first aid. Prohibition on eating or drinking at work-area. Any leakage/spillage of liquid chemical shall be immediately attended and provision of urgent cleaning.
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x x x x x x x x x
Work area will be monitored to maintain work environment free from any dust/chemicalsfumes/vapours and keep with in below permissible limit. Provision of adequate Fire Extinguishers at site and training will be imparted to the workers also. Maintaining the Fire-Protection System adequately. Availability of Self Breathing Apparatus at site. Provisions of immediate accident/incident reporting and investigation. Instructions on Emergency/Disaster will be displayed. Safety Posters and slogans will be exhibited at conspicuous places. Arrangement of Periodical Training to workers/operatives, supervisors. Safety Committee will be constituted and safety, health and environmental matters/issues will be discussed in the meeting and enlighten the participants in these respect.
7.4
7.4.1
On-site Emergency Plan

Introduction
The emergency is an undesirable occurrence of events of such magnitude and nature that adversely affect production, cause loss of human lives and property as well as damage to the environment. The emergency may be man-made or natural type. The production unit has to be prepared against such emergency/disaster and consequences. It is difficult to forecast the time and nature of emergency, which might strike the unit. In spite of the fact that every industry is expected to take steps to assess, minimize and wherever feasible eliminate risks, accidents may occur, as risk can only be minimized, it can never be totally eliminated. 7.4.2 Classification of Emergency/Disaster
Industrial units are vulnerable to various kinds of natural and man-made emergencies. Examples of Natural disasters are flood, Cyclone, earthquake, lightening etc. and man made disasters like major fire, explosion, sudden heavy leakage of toxic / flammable gases, civil work plant failure, human errors, vehicle crash, sabotage, Bomb-Threat, etc. Thus, the emergency can be divided in the following types, depending upon the nature:
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ADDITIONAL STUDIES
Figure 7-25: Nature of the Emergency
7.4.3
Nature of an Industrial Emergency / Disaster
Mode of emergency may depend upon the chemical property of the hazardous materials and maximum storage inventory. Fire emergency may arise due to flammable property of the Hazardous material. While explosive materials may create explosion emergency. Toxic gas dispersion in atmosphere creates Toxic release Emergency. Further, uncontrollable chemical reaction or dangerous occurrence may result into emergency. However, chemical incident can be following types; Toxic /flammable gas/vapour release as plume /puff from pipeline /fittings failures, tank ruptures etc. including flashing liquids stored above their atmospheric boiling point. x x x x x x x x x Spill of a toxic / flammable liquids Dispersal of toxic plumes and puffs Fire: Flash Fire, Fire Ball, Pool Fire, Heavy Fire, Fire with domino effect, etc. Evaporation and dispersal of toxic vapours from liquid spill pools Ignition of flammable gases, vapours and liquids leading to fires Ignition of flammable gases and vapours leading to Unconfined Vapour Cloud Explosion (UVCE) on site and/or offsite Boiling Liquid Evaporating Vapour Explosions (BLEVE) Mechanical / confined vapour explosion (CVE) including deflagrations (slow burning) and detonations (rapid burning) Dust explosions
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ADDITIONAL STUDIES
x x x x
Collapse of the structures / Buildings / Sheds Bursting of vessels/pressure plants/equipment, etc. Man made incident/Disaster Natural Calamity, etc. Industrial Emergency / Disaster Plan
7.4.4
While preparing the emergency plan, worst possible scenario of the accident or incident of the Unit should be considered. The worst effect of the maximum quantity of hazardous chemical, which create major accident must be calculated. Controlling the emergency will require prompt action by the operating staff, the staff of various agencies, emergency teams and outsiders when called for. Minimizing the effect on people may be achieved by prompt communication, rescue, evacuation etc., if the situation so warrants. However, an effective emergency plan helps to minimize the losses in terms of human lives, plant assets and environmental damage and to resume the working condition as soon as possible. In all these steps Speed is the Essence. 7.4.5 Stages of the Plan
The plan consists of the actual performance of duties & responsibilities by designated personnel and other agencies. Therefore, the plan is divided into three stages. The stage one is pre-emergency period i.e. Normal activities before emergency or preparedness, awareness and training parts. While stage second explains actions during emergency period i.e. during actual emergency period, specific duties are to be performed by designated personnel, using available resources & control measures in systematic ways. The third stage indicates post emergency period, which describes how to safe rehabilitation, restarting, to face inquiry, to preserve evidences and records for remedial measures etc; as required by various authorities. It also explains corrective steps from the incident and finding out the correct reason behind the emergency, so that such type of incident will not occur again. The chart of emergency plan, explaining how entire arrangement is required to manage, is produced below;
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ADDITIONAL STUDIES
Figure 7-26: Emergency Plan
7.4.6
Level of the Emergency
The level of Emergency can be classified according to the gravity of the situation at site. The command and control will follow as per the level of emergency. Level-I: On-Site Emergency The type of emergency, which can be handled and controlled by the management with own resources as per On-site emergency plan, is called as On-site or Level-I. Level-II: Mutual Aided / Local crisis (Off-site) If the Level-1, is uncontrollable by the management, further help is needed, the neighbouring units or mutual aided local units will provide their resources to tackle the situation. The emergency of the unit which is handled and controlled by the out side resources, is called as Mutual Aided local crisis or Level-II. Further, if this type of emergency is governed by Local Crisis Group then it is called as Local Crisis or Level-2.
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ADDITIONAL STUDIES
Level-III: District Crisis (Off-site) Even after putting efforts as explained in Level-II, the situation becomes uncontrollable and beyond the control of Local Crisis Management, than the District Crisis Group will take over the charge & handle the emergency situation. This is termed as Level-III or District Crisis. Level-IV: State Crisis / National Crisis (Off-Site) If gravity and situation of the emergency is beyond control of Local or District Crisis Group, The State/National Crisis Group has to command and control such crisis by utilizing all resources from the State or Nation, as prevailing circumstances, and then it is called as State Crisis or National Crisis. 7.4.7 Scope of Work
The activity of the installation is to receive, store and dispatch the liquid chemicals on behalf of customers. The liquid chemicals are received through pipelines; installed from jetty to the terminal and same chemicals are stored at the tank-farm. These liquid chemicals are termed as Hazardous Chemicals as per Rule 68-J of the GFR-2004 and the management has to prepare On-site Emergency Plan as per R-68-J(12) of the GFR-2004. 7.4.8 Assignment
The management has assigned the job of preparation of On-Site Emergency Plan-2012; vide their telephonic confirmation on Dated 03.09.2012 to HELPS, Vadodara; an ISO Certified Company. 7.4.9 Methodology
The following methodology is adopted in respect of preparation of On Site Emergency Plan, limited to scope of work. Initial Visit Our Team has visited the proposed area under scope of work and listed the physical, chemical & occupational hazards with respect to proposed maximum storage capacity of the hazardous Chemicals and operations. Details on hazardous Chemicals The information on proposed storage, Process, equipments, machinery etc in respect to hazardous Chemicals and operations, are collected as per check list. Documents, Maps, Facilities Information The Information on proposed layout plan, location plan, tank farm etc details, fire- protection layout, alarms systems, communication system, process and operations details, safety & monitoring details, weather condition, surroundings population, First Aid, etc. on system elements are collected. Preparedness Details Details on Occupier, Manager, Organisation structure, Safety Policy, No of person at site, proposed assigning specific role & responsibility, Emergency Control Room, resources etc are collected & discussed on the assignment of duties and preparedness details.
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Maximum Credible Scenarios Considering the proposed maximum storage/ inventories of hazardous Chemicals, and hazard involving operations, the maximum worst scenarios are considered by using mathematical formulae, Dispersion modules, Risk Assessment, data etc. Major Accident Response System Specific actions during actual emergency are systematically described for each designated person separately. Further, response actions for different scenarios are illustrated. 7.4.10 Emergency Management & Response Introduction The growing complexity of industrialization in our country, with the increasing use of hazardous chemicals with machineries, which put danger to human being as well as property, it is pertinent that industries plays a vital and responsible role to ensure occurrence of any such incident. Hence, it is absolutely essential that emergency procedures shall be success with effective control and enthusiastic management. There are two types of emergency control plans, (1) On site emergency plan and (2) Off site emergency plan/Disaster plan. On Site Emergency Plan is to be prepared by an industrial Unit under the guidance of the Government and local Authority, with compliance under statutory provisions. Off site Emergency Plan is to be prepared by the Local Authority and the Government itself with the help of the Government machineries and emergency resources including the concerned industrial units also. Type of Probable Emergency Considering the major storages of liquid hazardous chemicals at the installation, any type of emergency may strike out; as described below:
Flammable Liquid Leakage/spreading

Flammable Liquid Leakage/spreading from any Tank having storage capacity of minimum 866 KL to maximum 4069 KL (out of 85 Tanks), or Pipe Lines and if get any source of ignition, it may turn into FIRE or EXPLOSION. Due care shall be taken to avoid/prevent any source of ignition during leaking/spreading Flammable Liquid into surrounding atmosphere.
Toxic Liquid Leakage/spreading

Toxic Liquid leakages/spreading from any Tank, having storage capacity of minimum 866 KL to maximum 4069 KL ( out of 85 Tanks),or Pipe Lines, it will create toxic or corrosive or poisonous effect depending on the properties of chemicals to the surrounding area.
Fire
There are so many sources for fire i.e. x x During use, storage, supply, unloading of Liquid During movement or transportation of Truck/Tankers
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ADDITIONAL STUDIES
Boiler, D. G. Set, Electricity, etc.
Emergency Management The emergency management plan includes clearing stating the line of command, each persons specific responsibilities, and organizational set up available to tackle the emergency effectively. The command & control will be single structure, till emergency controlled. The personnel from the organization involved in emergency response management are identified as Designated Person. In order to effectively achieve the objectives of emergency planning, the critical elements that form the back bone of On Site emergency plan are; x x x x x x x x Reliable and early detection of an emergency & control planning The command, Co-ordination and response management structure along with efficient trained personnel The availability of resources for handling emergency Appropriate emergency response action Effective notification & communication facilities Regular review and updating of documents Proper training to the concerned personnel Periodical Mock-Drill/Exercise/Rehearsal
The participating persons as designated in the emergency management are in the following manner;
Figure 7-27: Emergency Set-up
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ADDITIONAL STUDIES
Role & Responsibilities of Designated Person The ultimate responsibility to manage the emergency rests with the occupier or site main controller of the unit for on-site emergency plan. The duties, functions and responsibilities of the designated persons, in respect of responding emergency are described in brief, in foregoing paras. However, specific action plan can be prepared in form of task force. The working group has to evaluate the situation and actions with rapid force should be activated as per pre-decided way. However, the maximum credible scenario for the unit shall be considered.
Site Main Controller (SMC)

Responsibilities of SMC include; x x x x x x x x x x x x x x x x x x On receiving information on emergency, he will reach at the scene / location & get details on incident from IC On consultation with IC, he will assess the situation and declare the emergency and activate the On Site Emergency Plan and inform to Head Office / Higher authorities Establish emergency control room Ensure the information to fire brigade, police, medical, experts, Director Industrial Safety & Health, GPCB, and other statutory authorities Ensure medical treatment to injured persons To ensure the accounting of personnel and search of missing persons and arrange hospitalization of victims and additional helps if required To ensure Control of traffic movement in factory premises & surrounding area If emergency is prolonged, arrange for the relief of personnel and to provide catering facility Direct the close down the plant and evacuation of the persons in consultation with the IC Ensure co-ordination among all and key personnel & essential workers are called in Ensure rehabilitation of affected areas and victims Continuous Review of developments of emergency & responding actions Ensure communication with Local or District Crisis Group for the further help if condition deteriorates To issue authorized statement to the news media and other authorities To ensure that proper consideration is given to the preservation of evidence. Arrange for photographs or video Withdrawal of emergency Order restarting the plant consulting with IC, after getting clearance from Director, Industrial Safety and Health or other authorities, as required To investigate the cause of accident & corrective measure.
Incident Controller (IC)

Responsibilities of IC include; x His primary duty is to take over the charge at the incident place immediately on getting information on the occurrence and assess the situation and start remedial measures from available resources He will work under the direction of SMC & keep informed of the development
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ADDITIONAL STUDIES
x x x x x x x x x x x
Try to minimize damage to property, environment and material loss by taking necessary actions within his control Start emergency action with the help of key personnel and essential workers Cordon incident / accident area and restrict unauthorized entry Ensure immediate starting of fire fighting system like fire hoses, monitors, sprinklers system, sprays, and neighboring equipments Ensure shut down of various plants in right sequence Search in affected area for casualties Call mutual aiders, if required Preserve evidence; arrange photographs, and logging of events Before ordering the re-entering checks that it is safe and gets permission from authority Do not restart till steps taken to prevent the returns of recurrence Dy. Incident controller will perform the role as incident control till the arrival of incident controller Immediate rush to the scene/place/site.
Action Plan for In-charge of Emergency Control Center i.e. Communication Officer
(On Hearing Alarm/ Emergency information) x x x x x x x x x x x x x x x x x x x Proceed to Emergency control centre and perform the duties Got the direction for the line of actions with IC/ SMC Ask key personnel & essential worker to report IC/SMC & perform their duties Inform fire brigade / police / mutual aiders, as required Inform all non-essential workers to reach the safe assembly point Inform neighboring factories, companies, units regarding emergency Communicate with statutory bodies like Factory Inspector, Boiler, Electrical, Explosive, Insurance Agency, Police Authority, District Magistrate etc Arrange to rescue of missing & trap persons Arrange to search affected area for causalities Ensure cordoning of affected area Instruction for movement for emergency vehicles, e.g. fire tender, etc. Inform surrounding population with the help of police Requisition vehicles, cars, buses, ambulance, if required and emergency equipments Additional ambulance and treatment for victim Reserve hospitalization for victim. (e.g. Burns, injuries, causalities) Inform relative of victims Evacuation of neighboring population, if required Check rehabilitation of victims Report each action to SMC/ IC time to time; with maintaining register.
Action Plan for Safety officer & Technical Persons

On receiving information on Incident/Accident x x x Immediate rush to the scene/place/site Assess the situation & ascertain the involved chemicals, quantities, storage details, type of hazard, leak, spread / dispersion rate, injured persons, etc On collecting details of involved chemicals, MSDS, Toxicological details, neutralizing agent, responding actions, special medical treatment, antidote, etc, Safety Officer/Technical Officer /EHS
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ADDITIONAL STUDIES
x x x
Officer shall provide and consult the related matters with SMC/IC and immediately provide necessary helps, assistance, guidance and technical details for responding actions and specific procedure for handling the emergency on urgent basis. On controlling the incident, procedure for monitoring environment, clean up, restarting and restoration, etc details shall be provided, advised and assisted to the SMC/ IC Assist, advice and guidance in preparation of investigation report and reporting various Authorities. Other duties as allotted/ required by SMC/IC
Action Plan for Factory Medical Officer (FMO)

On receiving information on Incident/Accident Factory Medical Officer has to arrange Casualty Receiving Centre with para-medical staff; necessary special medical treatment with medical equipment along with required antidotes. CRC should have sufficient space, capacity and located in a safe place, avoiding normal downwind direction. There shall be sufficient first-aiders; properly trained. FMO has to categorized the person as per injury and arrange the serious person for hospitalization immediately with necessary instruction indicating involved chemicals, special medical treatment and antidotes and toxicological details. He has to maintain the register for all people, containing the details, with respect to type of injury, treatment given, time of arrival, observations, further recommendation, discharge, etc. FMO has to carry out the work with consultation with SMC and IC
Action Plan for Key Personnel

x The key personnel shall be available at any time on duty or on call when off or on holiday. The Role of key personnel is to carry out the instruction as given by Site Main Controller / Incident Controller during the emergency. The key personnel shall be from the experienced and trained managerial staff. Generally, key personnel will be from senior levels, perform the major work on advise made by the site main Controller and pass on the messages. They will perform the work of conveying messages, Liaison, coordination, procuring materials, maintaining discipline amongst workers, assist, advice etc. as instructed by SMC / IC, and report actions taken and development of work to SMC/IC.
Action Plan for Essential Workers

It is the task force of trained workers or expert teams to carry out specific job or work at site at the time of emergency and perform the duty under guidance of Incident Controller/Site Main Controller. The Work includes fire fighting, repairing, helping, first Aid, instrumentation, pipe line control, Electrical, Mechanical, Water work, Weldon work, Shifting the materials and other helping hands to control the emergency on urgent basis. The different teams are formed to carry out specific works by responsible way such as, x x x x x Fire Team, First Aid Team Repair & maintenance Team Rescue Team Transportation & Evacuation Team
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ADDITIONAL STUDIES
Emergency Runners.
Such work shall include: x x x x x x x x x x Gas leak and spill control team takes the charge Shutting down plant and making it safe Emergency engineering work e.g. Isolating equipments, materials, process, providing temporary by-pass lines, safe transfer of substance, urgent repairing or replacement, electrical work etc. Provision of emergency power, water, lighting, instruments, equipments, materials etc. Movement of equipments, special vehicles and transport to or from the scene of the incident Search, evacuation, rescue and welfare First aid and medical help Inform to surrounding factories and neighboring public as directed by the site Main Controller Assistance at communication centre, casualties, reception centre, liaison with police etc. Any special help required.
Action Plan for Security Guards / Officer

x x x x x x x x x x x x x x Inform emergency in-charge by telephone on getting message On receipt of information in case siren is not actuated, sound / blow the siren, if directed by IC/SMC Depute security guards to control traffic around area of emergency and cordoning of incident area Keep visitors out & prevent unauthorized entry Control Traffic at gate / inside and outside Plant premises Await further instructions from in-charge of emergency centre Inform others as directed by in-charge of emergency centre Search affected areas for causalities Eliminating ignition sources Removal of tank, Lorries from unit Instruct non essential workers to go to the safe assembly point and Head Count Observe Evacuation of site (Partially or full) Guide the mutual aiders, fire brigade, govt. officers, emergency vehicles, etc. for safe way towards emergency incident and safe parking Other matters as instructed by SMC/IC.
Action Plan for Non- Essential Workers

Upon hearing emergency siren/alarm or message, the non-essential workers, who have no any duties allotted during emergency, they have to follow: x x x x x x x x Leave the site/place immediately by safest route to safe assembly point, as directed Proceed at right angels to wind direction or cross wind direction to safe place Do not re-enter site unless directed personally or via PA system Assist in head count at assembly point Inform contractor personnel to stop work upon hearing fire / gas alarm and ask to assemble at the Safe Assembly point or main security gate Do not go to incident place unless specifically instructed by Emergency in-charge Avoid Panic & do not spread any rumors Do not smoke
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ADDITIONAL STUDIES
x x
Extinguish any source of ignition, cigarette, bidi, lighter, gas, etc. Ask others to keep calm & discipline manner.
Procedure for Meeting Emergency The procedure for meeting the emergency, as described under GFR-2004 is given at Annexure 13. Preparation of Duty Lists of Designated Persons The role and responsibilities of designated persons shall be fixed by names, with contact phone numbers/Mobiles and seat, residential address, in all shifts of working days and on holidays. The designated persons shall be available during all shifts and holidays. Protective equipment, lifting gears, fire control points, fire-water, etc shall be sufficient in numbers and their locations shall be well informed. Necessary vehicles shall be kept ready to shift the persons in case of emergency. Reporting Incident There are possibilities of various types of accidents or mishaps occurring in the factory premises. Most are of minor type, while few cases may be major type. Some times there is no single incident during the life span. However, when any incident occurs, it cannot be distinguished immediately, the subsequent development or seriousness of such occurrence is required to handle safely. It should be general practice that any person noticing the accident / fire / explosion / mishap at the site, should shout FIRE, FIRE or HELP, HELP and such message should reach to Supervisor / Shift Engineer / Senior Person of the unit. This way first information will reach to responsible person. The information shall communicate regarding type of incident and type of help needed. It is said that root cause should be removed immediately. Similarly, if any incident takes place in the premises it should be tackled with available resources, and it should be so responded that it is contained immediately before spreading. If the incident looks severe and cannot be controlled by simple efforts, the Shift Engineer or Senior Man should rush to the place and try to control by using resources at the site. Main Response during Fire or Toxic Release
In Case of Fire
1. Persons working near the incident or who has seen the incident are responsible to report the details of the incident (Small, minor, major, etc) shift in-charge and shall act by all available means to prevent/ control it till it is possible. Time being, shift in-charge will work as Incident Controller, till IC (Designated Person) is arrived. IC shall x x 3. Assess the situation and report to SIC immediately and simultaneously, Order the Fire-Team to control it with all its available means.
2.
The SMC shall x x x Take all actions to extinguish/control the fire. Inform the surrounding industries/mutual aid services to be ready on demand. If incident could not controlled by use of own resources, ask to send & help the mutual aid services and emergency services, like local fire brigade, and others.
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ADDITIONAL STUDIES
Even, after putting such efforts, incident could not control, report to the Off-site fire fighting services for help and actions, police, Control Room, Authorities of LCG/DCG, etc; for necessary actions. Co-ordinate with Off-Site Fire Services and other emergency services and authorities to control and contain the incident of fire.
In Case of Toxic Liquid Release

1. Persons working near the incident of toxic liquid release or who has seen the incident are responsible to report the details of the incident (Small, minor, major, etc) shift in-charge and shall act to control or reduce it by all available means. Time being, shift in-charge will work as Incident Controller, till IC (Designated Person) is arrived. IC shall Assess the situation and immediately report to SIC about the type and possible cause and likely effect to the workers and property Order the Control-Team to control it with all it available means To take the precautionary measures to prevent to reduce its effect (Closed the valve, Isolation, use of proper neutralizing agent, ask the surrounding people to vacate the area and rush to self place/assembly point. etc). The SMC shall Order to al shift in-charge to control/reduce toxic release by all possible means Ask the teams (fire, toxic release) of the factory for necessary actions to control and evacuation in the plant Inform the surrounding industries/mutual aid services to be ready on demand Sound the siren to warn the surrounding people before it is likely to effect If incident could not controlled by use of own resources, ask to send & help the mutual aid services and emergency services, like local fire brigade, and others Even, after putting such efforts, incident could not control, report to the Off-site fire fighting services for help and actions, police, Control Room, Authorities of LCG/DCG, etc; for necessary actions Co-ordinate with Off-Site Fire Services and other emergency services and authorities to control and contain the incident of fire.
2. x x x
3. x x x x x x
Sequential Actions by Emergency Management It is not possible to include and discuss every action, which should be taken first during emergency. It is also not possible to describe entire actions on emergency situation. The basic principle of handling emergency is to rely upon person, who has the knowledge and experience to assess the situation and give direction as per the objectives as quickly as possible. However, the aim is to control the situation by safest way in limited time within available resources. Further, it should handle with care so that loss of life, property and environment is minimized. In short, the plan should be successfully complied with. Site Main Controller/ Responsible Person assesses the situation and declares On Site Emergency Plan to put in operation. The incident handles as site crisis and he starts responding actions to control the incident.
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ADDITIONAL STUDIES
He willx x x x x Call the essential workers, key personals to perform their duties immediately Activate the fire brigade, mutual aiders, police, medical services, expert persons etc. as per need Mobilize more resources from the neighboring industries and other available resources The messages regarding prevailing situation to concerned authorities, agencies, neighbors etc. will be communicated through the control room Non-essential workers, visitors, guest, contractor workers shall rush to safe assembly point and they will report to the nominated person. They have to stay there till emergency over or as instructed by responsible person Try to contain by using all available resources within his command & by use of outside resources and with help of expert persons advice On controlling the emergency, site main controller has to ascertain the risk and if he observes the safe position, then he can declare the emergency is over and ask to blow the siren declaring the withdrawal of emergency Only after declaration of withdrawal of emergency, the work by other people / workers should be restarted by resuming the duties The site main controller, after consulting the authorities, can carry out the clearing procedure to set the interrupted work and restart the process works The site main controller may constitute an engineers committee to investigate the incident and to suggest the corrective actions and to submit the report accordingly In case of the situation of emergency is turning into more serious and uncontrollable by site main controller even utilizing own all resources, than he should immediately ask and call the Local Crisis Group to handle the situation.
x x
x x x x
Recording of Emergency Information All details on the Incidence on emergency shall be recorded by responsible person of the installation and has to maintain all records and documents. A form for record of emergency information is given at Annexure 14. Infrastructure
Assembly Point
The Assembly Point will be marked at a conspicuous place, i.e. near security office and entry gate. The non-essential workers include employees, who have no any duties /responsibilities allotted, contractors person, vendors, visitors etc. have to rush at specified Safe Assembly Point, as announced, or they have to go at Assembly point as directed by IC/ Security/ Control Room, or rush to well away from areas of risk and least affected by the down wind direction. They have to report their presence to the person attending duty. Proposed safe Assembly Point is marked in Lay-out Plan at Annexure 15 and details are given below;
Table 7-47: Details of Safe Assembly Point

S. No. of the Assembly Point 1 2 Location Near Gate No. 1 Near Gate No. 2 Accommodation Capacity 100 100 In-charge Person Security Officer Security Officer
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ADDITIONAL STUDIES
Emergency Control Centre (ECC)

ECC is Communication Centre during the emergency. The senior and expert person shall be posted as In Charge of the ECC. ECC shall be safe & without risk. The particulars like On Site Emergency Plan, MSDS of hazardous chemicals, Plan layout of the Unit, maps, drawing, details of storages of chemicals, tank farm, operations, emergency telephone with contact person, Manual, Weather details, List of essential workers & key person etc. details shall be kept available at the ECC and in-charge shall ensure the availability of such documents while taking charge. The communication Team under the In-charge will carry out the all works. SMC will activate ECC by posting proper person, who obey and perform the emergency duties, in two folds, internal, like- sounding the siren, alert the workers/persons regarding type of emergency and response actions, direction to safe assembly point/shelter, by emergency communication system. Further, external to emergency communicate to the authorities, surrounding people and industries, type of helps/source required from out side, and other required matter for emergency purpose. Incharge of ECC will be constant touch with SMC/I.C. The details are given at Annexure 16.
Alarm & Siren

Workers and other persons are engaged in their work, they should be alerted to save life and rush to the safe area, in case of emergency arise. Thus, siren or public address system or any device is useful to alert the workers immediately and it is installed at the office building, where it can be heard to all the employees. The details on siren and code are given below;
Table 7-48: Details of Sirens & Siren Code

Type of Declaration 1 Emergency All Clear Siren Sound 2 Wailing Sound Continuous Sound Type of sound of siren 3 30 Second On 15 Second Off Two Times Continuous On for 2 Minutes Duration of Sounding 4 2 Minutes 2 Minutes
Wind Sock
Wind Sock shall be installed at the highest point, where any person can see and can observe the direction of wind.
Emergency Facility
The various types of equipments, appliances, facilities, etc. are to be utilized during the emergency, which depends upon type of emergency. Therefore, the emergency facilities shall be ascertained & listed according to the hazardous chemical being stored, handled or processed including quantities. Further, it should be ensured by the concerned person that the sufficient inventories should be maintained & keep in order to handle the emergency successful. Ensure the availability of PPEs, Safety equipment, Neutralizing Agents, D. G. Set., adequate supply of water, man power, etc. The emergency details are given as below:
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ADDITIONAL STUDIES
Table 7-49: Proposed Personnel Protective Equipments

S. No. 1. 2 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13 Name Helmet Safety Goggles Face Shield Gas Masks Dust Mask Self Contained Breathing Apparatus (45 Minutes) Spare Cylinder (45 Minutes) for SCBA Hand Gloves Gum Boots Safety Shoes Safety Belt PVC Chemical Suit Asbestos Fire Suit (3000 C) Self Contained Chemical Suits Other Equipment 14 15 16 Safety Torch Explosive meter First Aid Box 05 04 04 Quantity 30 42 10 10 15 04 04 10 30 30 04 03 06 03
Table 7-50: Proposed Fire Water Tank Details

Tank Size S. No. 1. 2. 3. 4. 5. 6. Tank No. Diameter In Meter Water Tank 1 Water Tank 2 Water Tank 3 Water Tank 4 Water Tank 5 Water Tank 6 17 17 14 14 14 16.50 TOTAL 11572 KL Height In Meter 14 14 14 14 14 16.50 Capacity In KL 3177 3217 2155 2155 2155 3528
Table 7-51: Detail of Proposed Fire Hydrant system

S. No. 1 2 3 4 5 Name Double Hydrant Point Monitor Point Hose Box Hose Pipe Jumbo Curtains Accessories 6 7 8 9 Short Branch T P Branch Foam Branch Fog Branch 210 As required Qty. in Nos. 138 14 138 138 04
AHIR SALT AND ALLIED PRODUCTS PVT. LTD. S. No. 10 11 12 13
ISOLATED LIQUID STORAGE TERMINAL AT VILLAGE MITHIROHAR, TALUKA GANDHIDHAM, DISTRICT KUTCH Name Landing Valve Spindle Rod Hydrant Valve Monitor Valve
ADDITIONAL STUDIES Qty. in Nos.
Table 7-52: Details of Proposed Fire Pumps

S. No. 1. 2. 3. Types of Pumps Fire Electric Pump 125 HP, 400 M /Hr Fire D. G. Pump 125 HP Jockey Pump Set 20 HP
3
Nos. 02 02 02
Table 7-53: Proposed Fire Extinguishers

S. No. 1 2 3 4 5 6 Type of Fire Extinguishers CO2 DCP Foam Extinguisher DCP Trolley Type Sand Bucket Foam AFFF Capacity 6 Kg 10 Kg 10 Kg 150 Kg Bucket Nos. 12 86 40 5 200 10 (9000 Liters)
Emergency Medical Services

Emergency Medical Treatment, medicines, antidotes, list of hospitals etc shall be kept ready. FMO shall arrange casualty receiving centre, para-medical staff, colour code-badges (injury wise identification of persons), Register to maintain attended patient, required antidotes, toxicological details on hazardous chemicals used at the Unit. etc.
Resources
The following resources shall be available in adequately, working condition & updated for the emergency purpose. x x x x x x x x x x x x Emergency Power Supply-D.G. Set Fire Protection Systems (as given in Emergency Facility) Emergency Communication System Storage of Fire-Water & Availability of source of water Personnel Protective Equipment & Safety Equipment Emergency Medical Treatment & Antidotes Weather details MSDS of certain chemicals proposed to, store at site List of trained person in fire fighting, first aid & expert person List of emergency equipment suppliers, medicines suppliers, hospitals, water resources, etc. Mutual Aiders list with contact person Emergency Telephone Numbers, etc.
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ADDITIONAL STUDIES
Table 7-54: Details of Emergency Telephone Numbers

S. No. Name / Organisation Office Resident / Mobile
M/S. Ahir Salt and Allied Products, (O) 02836-220421, 220112-220103, 222633. 1 2 Mr. Shamjibhai S. Kangad, M.D. Mr. Arjun S. Kangad Others, External 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 KPT Fire Brigade - Old Kandla KPT Fire Brigade- New Kandla IFFCO Fire Brigade Kandla Fire Station - Free Trade Zone Fire Station Municipality, Gandhidham Police Station Kandla Police Station - Gandhidham KPT Hospital (Govt.), Old Kandla KPT Dispensary, Old Kandla Govt. Hospital, Gandhidham Dasani Hospital, Gandhidham Govt. Hospital, Adipur D. S. P., Bhuj District Collector , Bhuj, Kutch District Government Hospital , Bhuj Dy. DISH, (Factory Inspector) Adipur Kutch Joint Director, Industrial Safety & Health, Rajkot Director Industrial Safety & Health Office, Ahmedabad IOCL, Fore Shore Terminal, Kandla Mr. K. S. Rao IOCL, Kandla Terminal, Kandla Mr. A. K. Khanna BPCL, Kandla Installation, Kandla Mr. D. R. Nade HPCL, Kandla Terminal, Kandla Mr. B. S. Baberwal GAIL (India) Ltd. LPG Despatch Terminal, Gandhidham, Mr. R. K. Garg IOCL, LPG Import Plant, Kandla Mr. S. K. Sinha 270176, 270178 270439, 270187 270352, 270382 252232 231610 270527, 270404 100 270205 270206 220262, 220263 220031 260263 250250, 250444 250020, 220340 220150 260020, 260262 0281-2442801 079-25502349/64 270628 233274, 220587 234313, 234341 230936 2206474 270805 0281-2273310 M. 94264 16108 229002 232808 260255 261826 220421 220421 98252 25712
Communication during Emergency

On declaration of On-Site Emergency by SMC/IC/Authorised Person, In-charge- person of Emergency Control Centre immediate communicate through emergency communication system (Emergency telephone, Mobile, e-mail, Messenger, wire-less, Megaphone, siren, hooter, inter-com-phone, etc.): x x By sounding siren/announcing according to the type of on-site emergency/ off-site emergency Inform to Fire-Services to rush with specific responding equipment
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x x x x x x x x x
Inform internally to the Designated Persons, Key Persons, Essential Workers, Officers, FMO, to report to SMC/IC immediately and start responding actions under intimation to SMC/IC Inform internally to workers, non-essential persons; directing to go to the Safe-Shelter, and report to authorised person their presence Inform to surrounding industries, mutual aiders, etc. to rush with required type of helps Intimate regarding emergency situation to Police, (DISH)/Factory-Inspector, Collector, DCG, LCG, other Govt. Authorities Inform the Govt./Pvt hospitals for making necessary arrangement Inform to the relatives of injured or death persons, if so Report to SMC/IC time to time and comply any pending or as directed by SMC/IC To maintain the records for all communications On withdrawal of emergency, it shall be communicated to all respective department/section, Key persons, Essential Workers, Assembly Point, Govt. Authorities, etc.
Liaison Arrangement with Organisation At the time of emergency, different types of help, services and cooperation from various emergency services like fire, police, medical, Govt. organizations/department, Private organizations, surrounding industries, out-side-experts, various suppliers, hospitals-authorities, medicines suppliers, special equipment suppliers, etc are be essentially utilized on urgent need base. Liaison with all type of organizations/person shall be made with their name of contact person with phone/ mobile numbers, residential address, etc and upto date record shall be maintained with ECC and responsible persons. Discipline The plan assumes certain discipline at site during emergency, as follows; x x x x x x x Do not get panicky Do not approach the site of incident, as a spectator Do not engage telephone unnecessarily Do not move about unnecessarily Do not approach unnecessarily for information or more inquiry Arrange medical / first aid care to the injured Do not allow unnecessary crowd nearby incident.
Check Schedule The following arrangements are to be maintained and up-dated for preparedness of emergency purpose during pre-emergency period.
Updating of Emergency Telephone Numbers with Contact Persons

The telephone or mobile numbers with name of contact persons shall be updated time to time and keep liaison with them for emergency purpose.
MSDS
MSDS for certain proposed Hazardous chemicals, which are handled and stored. Any updation or new information about hazardous chemicals shall be incorporated in MSDS.
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ADDITIONAL STUDIES
Weather Condition Data

The Meteorological data, which will be updated periodically and record shall be maintained accordingly.
Communication System
Emergency Telephone Nos. with name of contact person etc. modification shall be carried out for changes time to time.
Emergency Control Center

The Equipped Central Control Room shall be in working order. The plant layout maps, drawing, storage details, MSDS, emergency operations, manuals etc. documents shall be kept and shall be maintained up to date. List of Emergency telephone Nos. shall also be maintained up to date. The senior and expert person shall be posted as in charge of the control room.
Fire Protection
Check all the fire fighting equipments, units and machineries for their conditions, physical availability, workable and take necessary actions on replacement and maintenance, if required. Check resources of water and keep necessary telephone Nos. of suppliers for the same. Maintain the coordination with other fire services. The water showers should be checked periodically for working conditions.
Personnel Protective Equipments

Check all the personnel protective equipments provided at different places for their condition, working, maintenances and replacement, whenever required. Also keep sufficient stock of required personnel protective equipments. Also, maintain the relation with the mutual aiders for their supply of Personnel Protective Equipments at the time of emergency.
Safety Systems
Check the working of all safety devices; interlock systems, safety-guard, railing, and fencings, in position. The safety equipments shall be maintained in working condition. The safety motivation and safety training are continuous process and arrange such type of training, periodically. Check the monitoring instruments, if provided, for correct working. Check the alarm systems for its working condition. The care shall be taken in respect of wind sock/cock that it shall remain always in the position.
Medical Facilities
The First Aid Boxes provided at the plant area shall be adequately filled with requisite medicines and equipments. Arrangement shall be made that at least one trained person should be available during the working hours. The name and address with telephone No. of Doctors shall be displayed in the Control Room along with General Hospital & Ambulance facilities.
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Monitoring of Environment
A suitable type of flameproof and portable combustible gas indicator / sensor shall be provided and sample of various locations shall be measured & record shall be maintained in Form No.37,as prescribed under GFR.
Maintenance of Records
Keep the records of the monitoring conditions, safety systems, storage levels, process condition, etc. and maintain the log books, registers etc. Keep the MSDS and onsite emergency plan with required details at the emergency control centre.
Exercises / Mock Drill / Rehearsal

Organize the periodical mock drill/ rehearsal as per suggested format on emergency situation so as to keep up preparedness & awareness to over come shortcomings. Give prior information with reasonable time to the emergency services and public for proper response & training. Record the deficiencies of the system during the trial and take appropriate action to improve the effectiveness of the plan in terms of preparedness and response. A format on such mock drill is appended in following Table 7-55. Further, in this chapter illustrate the detail information on Mock Drill / rehearsal.
Table 7-55: Format for Exercise / Mock Drill / Rehearsal

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Date & Time Location Scenario Name of Participants with Designated role as per On Site Emergency Plan Name of observers, and location Start Time of Mock Drill Action By SMC Action By IC Action by Key Personnel Action by In Charge of Emergency Control Centre Action By Essential Workers Action by Assembly point officer Sequential action for Combat emergency Rime of withdrawal of mock drill Duration of Exercise Observation by observers De- briefing meeting Findings & Recommendation : : : : : : : : : : : : : : : : : :
Potentiality on Liaison
Keep constant liaison with mutual aiders, fire services, police department, medical services, statutory authorities, District administration, during pre-emergency situation. Keep liaison with local Crisis Group and District Crisis Group.
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Public Education
Efforts are to be made to educate the surrounding public about the existing hazards of the plant, the possible emergency actions and the precautions required to be taken in such condition. Leaflet containing such details can be distributed amongst the public. The training program can be arranged in the school, public institution. It can be circulated to news media, TV, Video- channels, newspapers etc. Disclosure of Information to the public can be issued as part of Statutory Compliance. A typical detail is given at Annexure 17.
Training (Internal) to Workers

The education & training to the workers, with the help of efficient plant supervisors, inspectors, and Sr. officials; are to be kept alive all the time and to ensure good housekeeping, discipline; by display of safety slogans, operative instructions and motivation on safety. Further, all the persons from the emergency services, organization is to be trained to respond the emergency.
Siren Testing
The siren shall be checked & tested periodically at certain intervals so that awareness & preparedness can be checked. Shut Down Procedure We cannot neglect the adverse effect of the running plant during emergency. Therefore, it is advisable and safe that the safe shut down procedure should be adopted, if running. First of all main electrical supply line should be cut-off. Similarly, the pipelines carrying flammable gas, liquid or chemicals are to be isolated immediately. If filling of the any tank is in operation, it should be stopped & safely shut down. Arrange to transfer or remove the flammable, toxic, dangerous, explosive, poisonous materials, goods, cylinders, drums etc. to safe place or try to isolate from the fire. Arrange the water shower on flammable storage tanks to keep it in cool conditions, if near the fire. The shut down procedure should be laid down in the process manual, which will be useful during such emergency. Post Emergency On controlling the emergency and ascertaining for no possibility of re-occurrence, the management will initiate the following actions. 1. 2. 3. 4. 5. 6. 7. Declare termination of Emergency & blow the siren accordingly. Disclose the authentic statement on incident to the authority & news media. Collect & preserve the documents, records, instruments, evidence etc. on incident. To set up the internal enquiry committee, appointing the internal or external expert person. Cleaning work after obtaining the permission from Authority. Preparation of restarting the process work. Detailed related work & procedure, as described below; x x Sound the emergency clear siren. The rehabilitation work will start in the affected area.
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x x x x x x x x x x x x x x
To ensure that all fires are extinguished and there is no risk of re-ignition, before starting work. To ensure that there is no chance of secondary explosion. Do not disturb wreckage and debris except to rescue the injured or recover bodies, until permitted to do so by statutory authority. All victims, dead or alive, are systematically identified and keep the records accordingly. Give information to their relatives, if asked. Record all relevant information. Take photograph / video or make suitable sketches of the incidence. Report the accident / incident, with details, to the statutory authorities, if not informed. Permission for restarting is required to be obtained from statutory authorities. Keep registers for recording the entries, details, inventory, list of persons etc. & preserve all the documents, log books, maps, registers & all records taken from the site. Keep the record of help; Co-operation, Mutual aiders sought from others & write thanks giving letters to them. Arrange the compensations to the affected persons, injured persons, dead etc. as per circumstance and if applicable, keep the records accordingly. Estimate the expenses incurred during the emergency. Estimate the various expenses under different head & prepare the total expenditures statement. Appoint the internal committee to investigate into the causes of the accident / incident, if necessary and get report.
7.4.11 Action Plan for Road Transportation Emergency Introduction The transportation of chemicals by road has got significant hazards. These need for precaution and actions during the Transport Emergency for mitigate the effect of the chemicals in the surroundings as well passers by on the road. When the tankers/trucks filled with hazardous chemicals are on the road and may trap with accident, which resulted into road transport emergency. The action plan is essential to handle and control such emergency. The provisions on road transportation are made under Central Motor Vehicle Act and Rules. These need on vehicles, display of correct technical name of the chemical, special signs or plates, Trem Card, Safe packing conditions, Particulars in transport documents, display of suppliers name, address, and phone number; including phone number from where specialist advice can be available. Further, transporters should carry Emergency Kit containing tool kit, emergency lighting, fire extinguisher, protective clothing, S. B. A. Set, and First Aid Kit, etc. Proper training to the drivers on hazardous chemicals is legally required. In case such emergency suddenly strikes then, prompt and proper responding actions shall be initiated and it will save the life and damage to property, and environment. Transportation of Hazardous Chemicals Following information are to be displayed on panel board on tanker / vehicles used for transporting Hazardous chemicals.
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x x x x x x
Correct Technical Name UN Nos. HAZCHEM CODE Emergency Contact Nos. Hazardous Class Label Specialist Advise/Instruction
UN classification of Hazardous Chemicals

Class 1 2 2.1 2.2 2.3 3 4 4.1 4.2 4.3 5 5.1 5.2 6 7 8 9 Flammable Gas Non Flammable Compressed Gas Toxic Gas Flammable Liquid Flammable Solids Substances liable to spontaneous combustion Substances which in contact with water emit flammable gases Oxidizing Substances Organic Peroxides Poisonous (Toxic) Substance Radioactive Substances Corrosives Miscellaneous Dangerous Substances Chemical Classification Explosives Substances
HAZCHEM Code
1 2 3 4 P R S S T T W X Y Y Z Z E V V V V : : : : Jet FOG Foam Dry Agent Full Body Protective Clothing with SBA SBA SBA for FIRE Only SBA SBA for FIRE Only FULL SBA SBA for FIRE Only SBA SBA for FIRE Only Consider Evacuation
Dilute
Contain
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AHIR SALT A AND ALLIED PRODUCTS PVT. LTD.
ISOLATED LIQUID STORAGE TERMINAL AT VILLA AGE MITHIROHAR, TALUKA GANDHIDHAM, DISTRIC CT KUTCH
ADDITIONAL D STUDIES
PANE EL-BOARD
1. 2. 3. 4. Name of Chemical C UN No os. HAZChem m Code Emergency Co ontact Nos. BENZENE 1114 3WE 100
5.
Class Label L
6.
Special Advise A
Benzene is co olorless, aromic odour and Flam mmable liquid. Non-Soluble N in water. Avoid co w ontact with liquid d & vapours. pr rotect the area from any source e o ignition; like heat, of h spark, flam me, static charg ge. Shut off engines, vehicles, or o electric supply y. Spray water on o the tank, if exposed e to fire. Warn that it is flashback along a vapour tra ail may occur fire e. leave and aw way from the c contaminated ar rea. Remove we etted cloths and d wash the affec cted area of bod dy p part with plenty y of water. Seek k medical Aid im mmediately. Inh halation: Remove the victim to fresh air area, and a give artificia al respiration. In ngestion: Get m medical treatme ent immediately Eyes : Flush with plenty of wat ter. Seek Medic cal a immediately aid y.
Safet ty Measures for f Chemicals during Tra ansportation n
Label eling
Containers like Barr rels, Carboys, and Drum etc. are marked/Labelled with the details, su uch as Name of o nt, quantity, Name N and address of manuf facturers, phys sical & Health hazards, prec caution during conten handli ing, personnel l protective eq quipments to be b used during g handling etc. The drivers / helpers are educated accordingly.
Safety ty Kit
Follow wing items are required with h the truck/tan nker carrying Hazardous H Goo ods/ Chemicals on the road. . x x x Sa afety equipme ents Se elf contained breathing b appa aratus in read dy to use condition 45 minut tes duration tw wo Nos and on ne spare cylind der Pe ersonnel prote ective equipme ents complete PVC Suit two NOs. PVC ha and gloves, chrome leather ha and gloves, fa ace shield, safe ety goggles tw wo pairs, gum boots two pairs. Tool Box with w required to ools. Non sparking Tools like e Hammer etc. Safety Torch h, First Aid Box x fully equippe ed, etc.
Respo ponsibility of f the Transpo orters or Own ner of the go oods carriage e/Tanker/Ve ehicle
Beside es valid registr ration and per rmit, it shall be e ensured that t the vehicle should be safe to transport such hazardous h goo ods and shall be b provided with adequate safety s equipments and devic ces such as PPE, Neutralizing N ag gent, Fire Extin nguishers, Spa ark Arrestor, Equipped E First Aid Box, Earth hing cable wit th the Cr rocodile attach hment, Tool Bo ox inclusive of f non sparking g tools, Stepne ey wheel, Caut tion Boards, etc.
KADAM ENVIRONMENTAL L CONSULTANTS | NOVEMBER 2012 2
21 19
ADDITIONAL STUDIES
It shall be also ensured that the driver being deputed for transportations is trained to handle and transport such hazardous materials and has been provided adequate and correct information, so as to enable him to comply with various safety rules and regulations as prescribed.
Responsibility of the Driver

x To keep all the information provided to him in writing i.e. TREM CARD (Transport Emergency Card).This is to be kept in the drivers cabin and is available all the times while transporting the Hazardous materials. He shall safely drive and satisfy the consignor. It is the duty of the driver to report about the occurrence of accident during transportation of hazardous goods to the nearest police station, fire-services, local authority, and also to the owner immediately. He has to park the vehicle at the safe area, if required.
x x
The driver has to keep following Important Document with him

x x x Valid Driving license. Safety Training Certificate for the Transportation of the Hazardous Goods from the Recognized Institution. First Aid Training Certificate, etc.
Document shall be available with Vehicle

x x x x x x x x x Registration papers of the tanker/truck and RC Book. R. T. O Passing certificate. Route permit Third party Insurance papers TREM CARD, MSDS of the chemicals. Invoice of the chemicals/ goods. Consignments Receipt Excise Gate Pass Weighment card, etc.
Following information should be well displayed & maintained on the shell of the Vehicle
x x x Emergency Information Panel. Hazard Class Label. Explosive license number detail with the validity.
Action Plan during transportation emergency for owner of the Company (FactoryOccupier)
Safe handling, control, mitigation, public disclosure and caution, etc during road transportation emergency are main activities. On receiving the information from driver or transporters regarding the Accident of the transport vehicle, the owner will form emergency team of three to four members; with consultation of the plant Manager and SHE Department, and ensure to reach immediately to the site. The team will rush to the
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site of the accident with all necessary PPE, tools, MSDS of the chemicals; Self contained Breathing Apparatus, First Aid Box, etc. The team members shall consist of following category: x x x x x Plant personnel as a Leader Supervisory level & Knowledgeable Plant Maintenance Personnel who has handle such type of Emergency in the plant Plant Safety Personnel with caution tape, Explosimeter, Dragger tubes etc for measuring the Hydrocarbon level, toxic gas and taking necessary safety precautions. Non Supervisory Level, plant operators, etc. On reaching to the site, the team will assess the situation; get the details on the mishap and to start responding actions to handle, control and mitigate the road emergency with carefully, keeping liaison with emergency services like, fire-services police, local authority, etc.
Emergency Actions
In case of Flammable Chemicals

x x x x x x x x x x Park vehicle on the safe road side immediately. Stop the engine, do not smoke and put away from any source of ignition Try to stop leak by closing the valve or shut off the source; to stop the further leak. Cordon off the area, stop traffic and keep people away from the vehicle Inform Police, Fire Brigade, and Manufacturer/owner Provide the Trem-Card, MSDS, etc to Police, if asked In case of fire, try to extinguish it with fire extinguisher Keep the tank cool by water sprays to prevent further fire or explosion Surrounding area shall be checked for extending fire incident or possibility of explosion. If so, then advice or request for evacuation Coordinate and help to the team deputed by occupier/manufacture; arrived for handling & controlling the road emergency.
In case of Toxic Release

x x x x x x x x Driver of hazardous cargo should be properly trained to handle& control small emergency on road. Cordon the area of leak. Stop traffic and keep people away from the vehicle. Leaking liquid can be contained in bunds of sand/earth. Small leak can be plugged by wooden peg. If a leak is from cylinder valve, it can be capped by yoke clamp. Inform the police, fire brigade, Manufacturer/occupier, and others. Provide Trem-Card, MSDS etc to the police, when ask. And coordinate and cooperate with them. If permits use water sprays, fogs to absorb leaking vapour/liquid, considering the property of the chemical, otherwise, do not use water at all and use neutralizing agent as suggested in MSDS/ Trem-Card. Advise to evacuate the downwind area in case of large toxic leakage. Coordinate, follow and help to the team deputed by occupier/manufacture; arrived for handling & controlling the road emergency.
x x
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ADDITIONAL STUDIES
The provision under Public Liability Insurance Act is applicable to handling (Transportation of Hazardous Substance by vehicle). DISCIPLINE The plan assumes certain discipline at site during emergency, as follows; x x x x x x x Do not get panicky Do not approach the site of incident, as a spectator Do not engage telephone unnecessarily Do not move about unnecessarily Do not approach unnecessarily for information or more inquiry Arrange medical / first aid care to the injured Do not allow unnecessary crowd nearby incident.
7.4.12 Action Plan to Respond Specific Emergency Introduction The natural or man-made emergency/disaster can be identified as like Bomb Threat (Terrorism), flood, Earthquake, Thunder Storm / Lightning Strike, Cyclone/Hurricane, Heavy Rain, Tsunami, etc. The Response Actions on each disaster are explained as below; Bomb Threat (Terrorism)
Response for Bomb Threat (Terrorism)

In the case of a threat being received at the site, the telephonist / security staff will record details of the threat using the Bomb Threat Checklist. Receiver of bomb threat information will then, immediately inform the control Room / Security In-charge. He will decide whether to alert the rest of the Emergency Response Team. The following factors are to be considered: 1. 2. 3. 4. 5. The seriousness of the threat. Resources available at the time. (e.g. For threats received out of normal working hours) communication with local authorities, i.e. Police / Fire Services Act on advice from local authorities. Decide on the following action: x x x x x To search and evacuate if anything suspicious is found Evacuate and then search. To evacuate immediately. In the event of a search, if an area was specified in the call, this would be searched first. At our site the most vulnerable areas to be searched first if no area is specified.
Action for Person working in an area where a suspect package, parcel or letter bomb is found x x Do not touch or tamper with the object. Report finding to Security/Emergency Control Room immediately.
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ADDITIONAL STUDIES
x x
Evacuate immediately the affected surrounding area for safety and security of working personnel. Do not create panic.
Suspect Vehicle
Actions x x x x Check persons car registration list (Security). Commercial vehicles currently on the site during an emergency will be documented in the security record book. Inform Security officer/Plant manager/HR manager. Inform Local authorities/Emergency control Centre.
Suspect Persons / Individuals

Actions x x x Inform Security/Human Resources. Do not approach, wait for security. Observe from a distance if possible and make notes.
Check List
A detailed Check list for identification is given at Annexure 18. Flood
Source
Following conditions are the sources of flooding inside the plant or buildings; x x x x x x Cloud bursting Heavy Rainfall Cyclone Tsunami High tide in River or Ocean Release of water from Dam or other nearby dam
Response
x x x x x x x Assess the situation through flood control room and inform Emergency Control Centre Go to the high level, if escape is not possible Shut off hazardous chemical supply valves. Close the other operations Remain calm, reassuring. Alert staff to potential hazards Look for loose or grounded / downed power lines. Avoid area. Report problems to Emergency Control Centre Look for electrical system damage: sparks, broken/frayed wires, smell of burning insulation. Turn off electricity at main switch, if you can without risk Do not re-enter the Building until declared safe by authority or emergency management officials
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ADDITIONAL STUDIES
x x
Stay well clear of any downed or damaged power lines. Establish a safe distance from the lines and report the incident to the responsible authority. Only adequately-trained authorised electrician will handle damaged power lines for corrective action Electrician will first assess the hazards present in order to minimize the chances of exaggerating the situation. Idle the lines involved will be de-energized When working on downed or damaged power lines, electrical workers must utilize proper electrical safe work practices and proper personnel protective equipment.
Dos & Donts

x x x x x x x x x x Remember flood-warning signs and alert signals. Go to the safest routes to shelters. Don't walk through flooded areas. As little as six inches of moving water can knock you off your feet. Snakes and other reptiles may be flowing through flooded water. Stay away from downed power lines and electrical wires. Electrocution is another major source of deaths in floods. Remember electric current passes easily through water If the water start to rise inside your plant/Building before you have evacuated, go to the higher levels. Take dry clothing, a flashlight and a portable radio with you. Then, wait for help. Don't try to swim; wait for resource to come to you. If outdoors, climb to high ground and stay there. There is a possibility of spread of water born diseases after flood, and hence medical treatment shall be taken immediately. Inspect plant/Building for any cracks or other damage. Check all the walls, floors, ceilings, doors and windows, so that any chance of house falling down can be ascertained and you will be aware about the imminent danger. Move to your process/plant only when instructed by the HOD. It is not safe to believe that the problems have ended after the floodwaters have receded. Check properly all the electric circuits, gas cylinders, or electric equipments like motor pump etc. Check whether any inflammable or explosive material has not entered along with the floodwater. Sewerage system will be checked and any damage shall be repaired immediately so as to curtail spread of diseases. Empty the water clogged in the basement with help of De-watering pump so that damage to infrastructure can be minimized. Rescue work will be undertaken immediately after flood situation as per the instruction. Do not follow any shortcut for rescue work. Do not try to leave the safe shelter to go back plant/home until the official declare normalcy after flood and instruction to return home/plant are not given.
x x x x x x
Earthquake
During Earthquake, if Indoors:

x x x x If possible escape to nearby open area away from electrical lines or other tall structures/ trees. Take cover under a piece of heavy furniture or against an inside wall and hold on. Stay inside. The most dangerous thing to do during the shaking of an earthquake is to try to leave the building because objects can fall on you.
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ADDITIONAL STUDIES
During Earthquake, if Outdoors:

x x Move into the open, away from buildings, street lights, and utility wires. Once in the open, stay there until the shaking stops.
During Earthquake, if in a moving vehicle:

x x Stop quickly, park the vehicle on left side of the road, and if possible escape to nearby open area away from electrical lines or other tall structures/ trees. Once the shaking has stopped, proceed with caution. Avoid bridges or ramps that might have been damaged by the quake.
After Earthquake
x Be prepared for aftershocks. Although smaller than the main shock, aftershocks cause additional damage and may bring weaken structures down. Aftershocks can occur in the first hours, days, weeks, or even months after the quake. Help injured or trapped persons. Give first aid where appropriate. Do not move seriously injured persons unless they are in immediate danger of further injury. Call for help. Listen to a battery-operated radio or television for the latest emergency information. Remember to help your neighbours who may require special assistance--infants, the elderly, and people with disabilities. Stay out of damaged buildings. Return home only when authorities say it is safe. Use the telephone only for emergency calls. Clean up spilled chemicals or other flammable liquids immediately. Leave the area if you smell gas or fumes.
x x x x x x x x x x
Thunderstorm & Lightning Strikes
Before
Thunderstorm is invariably accompanied by lightning A single stroke of lightning has 125,000,00 volts of electricity. Thats enough power to light a 100-watt light bulb for more than 3 months, or enough to seriously hurt or to skill someone. Know what steps to take in the event of an oncoming thunder storm & lightning. Lightning is something you should not be careless about, so seek a safe shelter immediately! Be warned, lightning can and does strike just about any object in its path. When you see lightning, follow these safety rules.
Indoors
x x x Stay or go indoors, If you hear thunder, dont go outside unless absolutely necessary. Stand clear from windows, doors, and electrical appliances. Stay away from anything that could conduct electricity. This includes electric lines, Electric Instruments, wires etc and phones. Unplug appliances well before a storm strikes. Dont use any plug-in electrical appliances like Cell phones, TV, music system, mixer, blender, iron press, hair dryer, or electric razor etc. If lightning strikes your house, these electrical / electronic gadgets can conduct the charge to you.
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ADDITIONAL STUDIES
Dont use the telephone during the storm. Lightning may strike telephone lines outside. Use the telephone quickly only for emergency purposes. Avoid contact with piping including sinks, baths and faucets.
Outdoors
x When outdoors, seek shelter from lightning! Buildings are best for shelter, but if no buildings are available, you can find protection in a cave, ditch, or a campus. Trees are not good cover. Tall trees attract lightning. Never use a tree as a shelter. Stay in your vehicle if you are travelling, vehicles gives you excellent lightning protection. Get in a hard topped car. If you cant find shelter avoid the tallest object in the area. If only isolated trees are nearly, your best protection is to crouch in the open, keeping the distance twice the height of isolated trees. Avoid areas that are higher than the surrounding landscape. Dont use metal objects outside. Keep away from metal objects including bikes, electric or telephone poles, fencing, machinery etc. Get out of the water. Immediately get out and away from pools, lakes, and other bodies of water. When you feel the electrical charge if your hair stands on end or your skin tingles- lightning may be about to strike near you. Immediately crouch down and cover your ears. Do not lie down or place your hands on the ground. Victims of lightning shock are administered Cardio pulmonary resuscitation (CPR) i.e. artificial respiration, if necessary. Seek medical aid.
x x
x x x
Cyclone/ Hurricane
General
The nature of a cyclone provides for more warning than other natural and weather disasters.
Preparation
x x x x x Stay calm and await instructions from the Emergency Coordinator or the designated officials. Continue to monitor local TV and radio stations for instructions. Move early out of low-lying areas, at the request of officials. If you are on high ground, plan to stay, secure the building, moving all loose items indoors and close windows and openings. Collect drinking water in appropriate containers.
Warning
Be ready to evacuate as directed by the Emergency Coordinator and/or the designated official.
During a Cyclone
Remain indoors and consider the following: x x x Small interior rooms on the lowest floor and without windows, Remain on the lowest floor away from doors and windows, and Rooms constructed with reinforced concrete, brick, or reinforced blocks with no windows. Stay away from outside walls and windows.
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ADDITIONAL STUDIES
x x
Use arms to protect head and neck. Remain sheltered until the cyclone threat is announced to be over.
Emergency Response for Heavy Rain x x x x x x x x x x x x x x x x Stay out of the basement. Stop all jobs outside. Heavy rain many times accompanies high-speed wind. Stop all work at height. Disconnection power supply to all electrical Machines in open yards. Cover all JBs\DBs where chances of water coming to it are there. Keep Gumboot, Raincoat and umbrellas ready. Keep all dewatering pumps ready in working order. Move valuable objects upstairs only if safe to do so, without straining yourself Keep yourself indoors and away from rivers and creeks Stay away from low/lying areas Avoid walking through a waterlogged area on foot; you can get swept away easily. Assemble everyone inside shelters or buildings. Close windows and blinds. Evacuate rooms that might bear the full force of the wind Avoid enclosures that have long roof spans. Keep the office radio tuned to a local station for current advisory information.
Response for Tsunami The phenomenon Tsunami is a series of travelling ocean waves of extremely long length generated primarily by earthquakes occurring below or near the ocean floor; occurrence of tsunami:
Before
Be familiar with the tsunami signals. People living along the coast should consider an earthquake or a sizable ground rumbling as a warning signal. A noticeable rapid rise or fall in coastal waters is also a sign that a tsunami is approaching.
During
x x x x x Listen to a radio or television to get the latest emergency information, and be ready to evacuate if asked to do so. If you hear a tsunami warning, move at one to higher ground and stay there until local authorities say it is safe to return home. Move in an orderly, clam and safe manner to the evacuation. Stay away from the beach. Never go down to the beach to watch a tsunami come in. Return home/plant only after authorities advise it is safe to do so.
After
x x x Stay tuned to a battery- operated radio for the latest emergency information. Help injured or trapped persons. Stay out of damaged buildings. Return plant/home only when authorities say it is safe.
227
ADDITIONAL STUDIES
x x x x
Enter your home with caution. Use a flashlight/ torch when entering damaged buildings. Check for electrical shorts and live wires. Do not use appliances or lights until an electrician has checked the electrical system. Open windows and doors to help dry the building. Shovel mud while it is still moist to give walls and floors an opportunity to dry. Check Accumulated mud & do not drink, drinking water retained in the pot or container. If Fresh food that has come in contact with floodwater may be contaminated and will be thrown out.
7.4.13 Action Plan during Off-Site Emergency Off Site Emergency When the industrial disaster can not be controlled by using units own resources, then, it is necessary to involve Govt. and other external resources to control such emergency. Even when Industrial disaster spread outside its premises and likely to affect / ought to be affected surrounding population, other industries, etc. then also Govt. resources etc needed to control it. This emergency called as Off Site Emergency & it will be controlled by either Local or District authority under District Crisis group (DCG)/ (Local crisis group (LCG). The emergency location will not change but the line of actions will be governed by crisis group instead of units authorities. The units own authority has to extend facilities, liaison, and coordination to the Local Crisis Group or District Crisis Group as per the requirement or situation. Probability for Off-Site Emergency The following incidents are identifying which may create Off Site Emergency from On Site Emergency.
S. No 1 2 3 Probable Scenario Fire & Explosion Flammable Liquid spreading, subsequent fire Toxic Liquid spreading with Toxic vapour
Outside Participation/ Government Body The emergency operations outside the factory premises are not different in character from those applicable to on sites. Hence the approach to and preparation for on-site emergency detailed in previous chapters will be applicable in case of Off-Site action also. However, the following points should be kept in mind: x x x x The groups involved are not as enlightened and responsible as those within the factory. In off-site actions, the local participants particularly the administration, fire & police play the dominant role. Industrial management has a limited and comparatively submissive role. The diversities of the problems and response are bigger. Humanitarian work assumes more importance.
The correct management strategy in this situation will be to involve the local participants fully in emergency operation and provide technical and financial support to them to manage the emergency. This task is more difficult than managing the on-site emergency operation in many ways and call for elaborate and consistent efforts.
ADDITIONAL STUDIES
Mutual Aid and Interaction The different industrial-units are operating surrounding K. K. Road, Old Kandla. The details on mutual aid with other Units is given following;
Figure 7-28: Initiation of Actions
Figure 7-29: Command & Control Level I & II
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AHIR SALT A AND ALLIED PRODUCTS PVT. LTD.
ISOLATED LIQUID STORAGE TERMINAL AT VILLA AGE MITHIROHAR, TALUKA GANDHIDHAM, DISTRIC CT KUTCH
ADDITIONAL D STUDIES
Prepa aredness for Off-Site If On site emergenc cy turns to off-site, the SMC C has to provid de the followin ng information/ /details to the e ority with expla aining the situa ation and to provide p the req quired resourc ces. Autho x x x x x x x x Ty ype of chemic cal Accident, in nvolved chemic cals, with quantities worst scenarios, s effe ect (which can es scalate in to off-site o emerge ency), probable duration, ca asualties, dama aged Lo ocation of Haz zardous chemicals with stock, and their MSDS Re esources can be spared by the t management of Affected Unit Av vailability of sp pecial Medical treatment and Antidotes Lo ocation of Safe e Assembly Po oints, Emergen ncy Control ce entre with In-c charge Person, , Parking Area an nd Approach route, r Medical centre, etc Li ist of required helps, resources (Type of Fire F Fighting materials, m Dam mage Control System, S Repair r It tems etc), Neu utralizing Agen nts, Type of em mergency equipment, etc M Matter to notify y to Public, Eva acuation arran ngement Arrangement of f disposal of waste, w clean up p, etc
Actio ons By Site Main M Controlle ler (SMC) & Incident I Con ntroller (IC)- During Off Site S Emerg rgency In Bri ief
The Units U Site Main n Controller, In ncident Contro oller and In-ch harge of ECC have h to perform m the duties and re esponsibility different from On O Site Emerg gency Plan. Th he Government Authority (Chairman of DCG/L LCG) will take charge of situ uation and they will be called d as Site Main n Controller or o Chairman fo or Off Sit te Emergency plan. Therefore, the Unit s Site Main Co ontroller will act Site Co-ord dinator, Incid dent Controller r will act as harge of ECC will w act as Liais son Man, whic ch is shown in chart as Incident Co-ordinator and In-ch w; below
KADAM ENVIRONMENTAL L CONSULTANTS | NOVEMBER 2012 2
23 30
ADDITIONAL STUDIES
Duties of Site Coordinator (SMC) (Now Site Coordinator) During Off Site Emergency, Units Site Main Controller becomes Co-ordinator and his duties are as follows: x x x x x x x x x x x x He has to extend liaison, co-ordination and facility to the Chairman of local crisis group or Chairman of district crisis group. He has to explain about disaster, his efforts and what type of help is needed in brief to Chairman of Local Crisis group (Govt. Authority) and Control Room. He has to communicate about available resources, fatality/injury to his own employees and probable affected surrounding area with maximum credible scenario. He has to keep ready with maps, layout of unit, records, documents, On Site Emergency Plan, MSDS, Details of Process Hazards, Safe Handling procedure on specific hazardous chemicals etc. He has to advise for special medical treatment and availability of antidotes. He has to divert Communication system for Off site emergency. He has to divert all available resource for Off site emergency. He has to provide aid and assistance for Off Site Emergency. Shutdown plant safely, if hazards is not involved. He has to reorganize the work of Key personal & essential worker. Arrangement of food, water, rest etc. for the person engaged in the duty. Arrangement of disposal of contaminated water, effluent, solid waste, etc.
Duties of Units Incident Controller (Now Incident Co-ordinator) x x x x x He has to show the actual incident place to off site action group. He has to provide proper information to all incoming off site action group. He has to also explain safe route for off site team members, fire crew members, etc. He has to describe available resources, other hazardous material near disaster, available PPEs, Neutralizing Media, etc. He has to show safe & proper parking arrangement for off site action group members.
Duties of In-charge of Emergency Control Centre (Now Liaison Man) The Units In-charge of Emergency Control Centre have to perform the duties as liaison man and to communicate massages to emergency services, outsiders and as instructed by authorities of DCG / LCG. Communication during Off-Site Emergency During off-site emergency, Emergency Control Centre will work as base communication centre and directives will be given by District Crisis Group and as instruction from Emergency Control Room. Duties of Other Officers during Off-Site Emergency Key persons, Safety Officer, FMO, Manager (HR), Security Officer and others have to co-operate, help & assist and coordinate with SMC and IC during Off-site Emergency till control and clean-up etc. Responding Actions As declaration of Off-site Emergency, the Authority of LCG/ DCG will take over the charge of situation and conduct the responding actions to handle and control the emergency by putting on line the
ADDITIONAL STUDIES
emergency services, pulling & acquiring the govt. /pvt. Resources; as per their own Emergency Plan, consulting other designated emergency officers with consultation of SMC/IC. Withdrawal of Emergency (Calling Off Emergency) The emergency declared both within the works and the community should be called off only after making sure that the incident is brought under control and that no further danger is possible to property or life. The authority will ask to GPCB/competent person to carry out the environment monitoring and report immediately. On getting all clear signal, The Govt. Authority in consultation with the Site Main controller, working groups concerned, should take a decision to this effect. The decision has to be based on prudence and actual information of assessment by work groups and should not be one based or hearsay or speculation. A system of documentation recording the recommendations of work groups, opinion of senior officers and endorsement by the works main controller will be a check against hurried decisions. Once the decision to call off the emergency is taken, the concerned persons should be informed. The co-ordinator of the off-site emergency operation and local participants has to be informed. The coordinator in turn will give information to the other local participants and members of the public. The declaration of the withdrawal of emergency will be announced by sounding of siren or by public address system by the authority. Even after calling off the emergency certain operations may need to continue. Hence the work groups should be released only after ensuring that the jobs attended to by them are over. The works main controller should take the decision. Also after the cessation of emergency the plant involved should not be left unmanned for quite some time and should be watched. Rehabilitation and Clean-Up On getting all clearance of the emergency from authority, SMC/IC along with Govt-Official will start clean-up-work of the affected area, take care of hospitalization persons and injured persons, informed their relatives, collection of evidence, etc. A report on incident shall be prepared. 7.4.14 Major Potential Hazards-Sources The operation and storages will be carried out in closed system. However, certain operations will have exposure to the chemicals, like during filling of tanker/truck, in case of failure of operating valve, collapse of tank, leakage from pipe lines or tank, etc. The major potential hazards and sources can be listed as per following: Jetty Terminal Handling of liquid chemicals may create certain hazards at Jetty terminal. Spillage of liquid chemicals during transfer either from Port Terminal or ships tank or transfer from tank farm to tanker ship. Spillage of liquid chemicals lends to fire hazard or generate toxic fumes according to the physical properties and prevailing atmospheric condition.
232
ADDITIONAL STUDIES
En-route Pipe Lines The pipe lines from jetty terminal through Port land, passing through roads, railway crossing, and pumping station to the tank farm. These transfer of chemical enroute 10 km pipelines will contribute following likely hazards; x x x x x x Failure of gasket Bursting of gasket Inadequate bolting Temporary of pipeline for pilferage Accidental damage due to forming holes in pipelines Median damages to pipelines
The result will be into any of the following: x x x x x Fire ball/BLEVE Flash fire Vapour cloud explosion Jet fire Pool fire
Liquid chemicals being transferred in to allocated tanks x x x Compatibility of chemical produced vigorous and hazardous chemical reaction. The generation of toxic gases, heating, overflows or rupture of storage tank or pipelines, subsequently fire or explosion. Pool fire if pump fails.
Effect of toxic released substance The effect of exposure to a toxic material can be divided into two categories according to the duration and concentration of exposure. x Acute toxic effect
These arise from short-term exposure at high concentration. x Chronic toxic effect
These arise from long-term exposure at law concentration. Hazard assessments are usually concerned with released of large quantities of substances, which disperse within/after an hour or so; therefore, hazard assessments consider acute effect only. The effects of acute exposure include:
Irritation
Irritation can be felt by the respiratory system by the skin or by the eyes. With some substance, irritation occurs at low concentrations and can be a warning to people to evacuate and seek for safe shelter.
233
ADDITIONAL STUDIES
Narcosis
Some material effect peoples responses, in such a way as to make them slow to seek shelter or to warn others (i.e. methanol).
Asphyxiation
Most gases can cause asphyxiation by displacing oxygen from the atmosphere; CO2 cause asphyxiation by displacing O2 from the blood and thus preventing O2 from reaching tissues.
Systemic damage
Some substances cause damage to the organs of the body. This damage could be temporary or permanent. The severity of the effect depends on the concentration and duration of exposure, and on the toxic properties of the materials. However, the toxic properties of many materials are not well established because the data about their effects on humans are very sparse. It is difficult to derive properties from real incidents are usually not known. Most toxicity data are based on experiments on animals, in which concentration and duration can be controlled. However, the applicability of the results of such experiments on humans in questionable, given the differences in body weight and physiology. One way of comparing the toxicity of substances is to use the LC (50) for a started duration of exposure; this is the lethal concentration which would be expected to cause fatal effect to 50% of the exposed population over the exposure period. Another way of comparing or expressing toxicity is to specify harmless level of exposure for a given period as the limiting exposure criterion. These levels are known as Threshold Limit Values (TLVs) and are specified for periods such as normal working life and short term periods for emergency exposure. Yet another criterion is the IDLH value for a 30 minute exposure, as described in NIOSH (1978). This is the dose which is immediately dangerous to life or health at that exposure duration. All of these criteria can be useful when choosing the lowest concentration of concern in dispersion calculation. However, we have used IDLH value to estimate the damage distance. 7.4.15 Mock Drill/ Exercise/ Rehearsal Subject Exercise / Rehearsal / Simulation on OnSite-Emergency Plan, Considering any one of the event related with hazardous chemical which may create maximum credible scenario. Aim It is necessary that all aspect of emergency plan is tested, often to ensure that they carry out their responsibility & function as specified and in particular to: x x x Test the response from workers, emergency services, and other responsible persons. Test and evaluate the interaction of various agencies / authorities involved and ensure that all components are properly coordinated. Evaluate the available resources, equipments, its effectiveness, accuracy etc.
234
ADDITIONAL STUDIES
x x
Gain experience to create the confidence to handle & control the emergency amongst the participating persons/ workers. The Mock drill of the on-site Emergency Plan is to be conducted at least once in every six months (Please see Rule 68 - J (12) (5) of Gujarat Factories Rules 1963 (2004).
Authority of Exercise / Rehearsal The Director / Occupier is required to assume responsibilities & make decisions as seen to be legitimate. Table Discussion The first part of exercise is Table Top exercise to test that emergency plan do not interrupt the dayto-day running of their concerns. This will identify the difficulties involved and practical approaches. The scenarios will be decided and consideration shall be given to live practical involving all concerned at suitable intervals, in addition to those of a theoretical nature. Blue Print A blue print is prepared as guideline to act, accordingly in a selected scenario. The details, maps, affected areas, role & responsibility will be specific and information will be supplied to all concerned persons. The scenario will be explained by co-ordinator. The On Site Emergency Plan will be helpful. Code-Name For Rehearsal The code name shall be give to identify the case of rehearsal not real incident. So that, on getting message there will be no panicky amongst the operative person. If real emergency arise, then there will be no code-name. Further, the code name will be announced to conveying the message to authority, operative persons, etc. Nature Origin, Date & time, location and Duration of exercise etc. will be pre-decided in particular manner. Affected Area It is the indication of the spread of disaster. This will be reflected in Blue print & give details of original place, units, surrounding identities, villages, roads, locations etc. Emergency Control Center An Emergency Control Centre will be established for exercise purpose where communication & other activities can be performed. The control centre will have emergency facilities. The required documents like On-Site Emergency Plan, Details on weather conditions, list of persons to participate, Emergency scenario, maps, affected areas, emergency telephone numbers, list of hospitals, list of emergency vehicle & equipment will be kept ready. An experienced & expert person will be posted in Control Room. Preparation Stage The responsibilities & duties will be allotted to each group, services and involving all personnel. Educative meeting will be arranged to explain the role of each participant. Blue print, scenarios and
ADDITIONAL STUDIES
arrangements will be discussed at large. Charts, maps, Posters, Banners etc. will be prepared for good performance. Resources and Facilities Certain essential facilities shall be provided to the participants as required during actual emergency period. Further, adequate resources shall be made available to handle the situation. The some dummy-person have to select as to play and act as dead, serious injured, minor injury for purpose of realization of scenario, and they will be identified by colour badges like, red indicates as dead, green indicates as immediate admission to the hospital for operation, yellow indicates first aid treatment, white indicates no physical injury. The experienced person shall be invited as observers and separate identity cards shall be issued to them. Sequential Actions The whole exercise /rehearsal will be arranged in sequential actions as per on-site emergency plan. Thus rehearsal will be conducted, as actual performance. Observations The outsiders / third party will perform the role of observers and they will submit their reports on various site- observations with shortcomings & good features. De-Brief Meeting On completion of exercise, de-brief meeting will convene to discuss the conducted exercise, give views on performance of each areas; explain difficulties, resources, limitation, planning etc. All these observations, with corrective steps will be noted & reports will be prepared. Photographs, Video & Press Coverage Photography, videography shall be carried out for the work performed, and that shall be used to educate companys employees, contract workers, etc. Format for rehearsal/exercise/mock drill A format for rehearsal / exercise / mock drill is given as below;
Table 7-56: Format for Exercise / Mock Drill / Rehearsal

1 2 3 4 5 6 7 8 9 10 Date & Time Location Scenario Name of Participants with Designated role as per On Site Emergency Plan name of observers, and location start Time of Mock Drill Action By SMC Action By IC Action by Key Personnel Action by In Charge of Emergency Control Centre : : : : : : : : : :
236
AHIR SALT AND ALLIED PRODUCTS PVT. LTD. 11 12 13 14 15 16 17 18
ISOLATED LIQUID STORAGE TERMINAL AT VILLAGE MITHIROHAR, TALUKA GANDHIDHAM, DISTRICT KUTCH : : : : : : : :
ADDITIONAL STUDIES
Action By Essential Workers Action by Assembly point officer sequential action for COMBAT emergency time of WITHDRAWAL of MOCK DRILL Duration of Exercise observation by observers de briefing meeting findings & RECOMMENDATION
7.5
7.5.1
Fire Hazard and Protection

Fire Hazard
The storage and usage of Acetone, Benzene, EDC, Ethyl alcohol, Hexane, IPA, Butanol, Methanol, Solvent Naptha, Toluene, N-Butanol, Cyclohexanone, Nonene, Para xylene , Cyclohexanol, LDO, Kerosene, FO are posing fire hazard apart from Electrical Fire Hazard. 7.5.2 Fire Prevention Aspect
Class-A Liquid Acetone, Benzene, EDC, Ethyl alcohol, Hexane, IPA, Butanol, Methanol, Solvent Naptha, Toluene etc are stored in 4069 (Maximum capacity) at separate tank farm area. Following safety precautions are provided at storage area; x x x x x x x x x x x x x x x x x Breather valve level indicators Remote operated valves Foam Pourer Electrical / instrument fittings are flameproof Earthing to Storage Tank Earthing and bonding to pipeline Fire extinguishers Fire Hydrant System Fire Monitors 2 nos. Fixed type foam generators for each tank dyke Medium Velocity Water Sprinkler system LEL detectors Loading & Unloading Procedure Mobile prohibited at area Spark Arrester at Trucks & Ignition off while Unloading No Smoking Display.
Class-B Liquid N-Butanol, Cyclohexanone, Nonene, Para xylene etc are stored in 4069 (Maximum capacity) at separate tank farm area. Following safety precautions are provided at storage area;
ADDITIONAL STUDIES
x x x x x x x x x x x x x x
Breather valve level indicators Remote operated valves Electrical / instrument fittings are flameproof Earthing to Storage Tank Earthing and bonding to pipeline Fire extinguishers Fire Hydrant System Fire Monitors Medium Velocity Water Sprinkler system Loading & Unloading Procedure Mobile prohibited at area Spark Arrester at Trucks & Ignition off while Unloading No Smoking Display.
Class-C Liquid Cyclohexanol, LDO, Kerosene, FO etc are stored in 3419 (Maximum capacity) at separate tank farm area. Following safety precautions are provided at storage area; x x x x x x x x x x x x x x Breather valve level indicators Remote operated valves Electrical / instrument fittings are flameproof Earthing to Storage Tank Earthing and bonding to pipeline Fire extinguishers Fire Hydrant System Fire Monitors Medium Velocity Water Sprinkler system Loading & Unloading Procedure Mobile prohibited at area Spark Arrester at Trucks & Ignition off while Unloading No Smoking Display.
No Smoking area Entire installation premise will be declared as no smoking zone. Flame proof fittings Flame proof type Electrical equipment, lightings, switches etc will be provided at storage & handling area. Earthing Earthing will be provided to all tanks, pipeline, motors, pump and equipments using flammable liquid. Continuity of earthing will be maintained for pipeline. Earth resistance will be checked periodically and record will be maintained.
238
ADDITIONAL STUDIES
Lightening Arrestor Lightening arrestors will be provided at various locations in Installation. Watch & Ward All entry to the installation will be under watch and ward of security. Unauthorized entry will be restricted inside the factory. Work Permit System All Work permit systems will be introduced including for Hot work inside the installation. Hot work will not permit without work permit system. License for Storage of Petroleum Products Necessary license for storage of petroleum products are obtained from Explosive Department (PESO). Periodical Inspection Inspection/testing of safety devices like safety valve, overheating protection, breather valve, flame arrestor etc. will be carried out periodically. Proposed Testing and Maintenance Procedure for Fire Prevention and Protection System is given as below;
Table 7-57: Testing and Maintenance Procedure for Fire Prevention and Protection System
S. No. 1 2 3 4 5 6 9 Description Fire Hydrant & Hose box inspection Fire Bucket inspection Siren Testing Fire Extinguisher inspection Fire Hydrant flushing & inspection Water cum Foam monitor inspection Fire Extinguisher Servicing Time Weekly Weekly Weekly Monthly Quarterly Quarterly Quarterly
7.5.3
Proposed Fire Protection Facilities
Fire protection system will be provided as per OISD 117 norms, details of details on proposed fire protection facility is given below: Source of Water Main source of water for installation is from outside water tanker. Fire Water Storage Tank Six dedicated Fire water storage tank of various capacities (3 X 2155 m3, 1 X 3177 m3, 1 X 3217 m3, 1 X 3528 m3, will be provided. Total water storage capacity will be 11572 KL.
239
ADDITIONAL STUDIES
Fire Pumps Company will provide fire hydrant networks to cater most of the area of the installation. Following Fire pumps will be provided on Fire hydrant system.
S. No. 1. 2. 3. Type of Pump Fire Electric Pump 125 HP, 400 m / Hr Fire Diesel Pump, 125 HP Jockey Pump Set 20 HP
3
Quantity 02 02 02
The diesel engines will be provided quick starting type with the help of push buttons located on or near the pumps. Each engine will be having an independent fuel tank adequately sized for 6 hours continuous running of the pump. The fire water network will be kept pressurized by jockey pump and one will be stand by pump. Fire water pumps will be exclusively used for fire fighting purpose only. Suction and discharge valves of fire water pumps will be kept full open all the times. Fire Hydrant Network Company will provide fire hydrant networks to cater different areas. Above ground Fire hydrant network will be provided at conspicuous location surrounding the storage area / Tanker Filling area/ Pump House/ buildings. Fire Hoses with Fire Hose box will be provided between two Fire Hydrant Points. Variable flow water-cum-foam monitors will be provided for suppression of pool fire in tank farm area. Hydrant/Monitors will be located along road side beams for easy accessibility. Double headed hydrants with two separate landing valves or monitor on suitably sized stand post will be used. All hydrant outlets/monitor isolation valves will be situated at workable height of 1.2 meter above ground or hydrant/monitor operating platform level. Monitors will be installed within 15 m of hazardous equipment. The location of the monitors will not exceed 45 m from the tank to be protected. Monitoring points are given below;
Table 7-58: Proposed Location of Monitoring Point

S. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Proposed Location On 6 meter Road, Near watchman cabin, W. B. Platform On 6 meter Road, Near Wheel wash Platform On 6 meter Road, Near Dust been On 6 meter Road, Near Tank No. 115 On 6 meter Road, Near Tank No. 115 On 6 meter Road, Near Tank No. 211 On 6 meter Road, Near Tank No. 212 On 6 meter Road, Near Boiler Room, Fire Fighting pump House On 6 meter Road, Near Tank No. 212 On 6 meter Road, Near Tank No. 411 On 6 meter Road, Near Tank No. 411 On 6 meter Road, Near Tank No. 411 On 6 meter Road, Fire Proof Elect. pump House
240
AHIR SALT AND ALLIED PRODUCTS PVT. LTD. S. No. 14
ISOLATED LIQUID STORAGE TERMINAL AT VILLAGE MITHIROHAR, TALUKA GANDHIDHAM, DISTRICT KUTCH Proposed Location On 6 meter Road, Fire Proof Elect. pump House
ADDITIONAL STUDIES
Fire Hoses & Hose Box The length and diameter of the hoses will be 15 m and 63 mm respectively fitted with instantaneous type male & female couplings. Fire Hose box will be provided between two hydrant points through out the installation. The proposed locations of fire hydrant/monitor point and Fire Hose Box are given as below;
Table 7-59: Proposed Location of Double Hydrant Point

S. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Hydrant Point No. DH- 1 DH- 2 DH- 3 DH- 4 DH- 5 DH- 6 DH- 7 DH- 8 DH- 9 DH- 10 DH- 11 DH- 12 DH- 13 DH- 14 DH- 15 DH- 16 DH- 17 DH- 18 DH- 19 DH- 20 DH- 21 DH- 22 DH- 23 DH- 24 DH- 25 DH- 26 DH- 27 DH- 28 DH- 29 DH- 30 DH- 31 DH- 32 Location On 6 meter Road, Near Manifold Chamber
On 6 meter Road, Near Tank No. 114 On 6 meter Road, Near Tank No. 113 On 6 meter Road, Near Tank No. 112 On 6 meter Road, Near Tank No. 111 On 6 meter Road, Near Tank No. 110 On 6 meter Road, Near Tank No. 109 On 6 meter Road, Near Tank No. 108 On 6 meter Road, Near Tank No. 107 On 6 meter Road, Near Tank No. 106 On 6 meter Road, Near Tank No. 105 On 6 meter Road, Near Tank No. 104 On 6 meter Road, Near Tank No. 103 On 6 meter Road, Near Tank No. 102 On 6 meter Road, Near Tank No. 101 & 102 On 6 meter Road, Near Tank No. 101
On 6 meter Road, Near Tank No. 126 On 6 meter Road, Near Tank No. 125 On 6 meter Road, Near Tank No. 125 & 201 On 6 meter Road, Near Tank No. 124 & 201 On 6 meter Road, Near Tank No. 124 & 202 On 6 meter Road, Near Tank No. 123 & 202 On 6 meter Road, Near Tank No. 123 & 203 On 6 meter Road, Near Tank No. 122 & 204 On 6 meter Road, Near Tank No. 121 & 204
241
AHIR SALT AND ALLIED PRODUCTS PVT. LTD. S. No. 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73
ISOLATED LIQUID STORAGE TERMINAL AT VILLAGE MITHIROHAR, TALUKA GANDHIDHAM, DISTRICT KUTCH Location
ADDITIONAL STUDIES
Hydrant Point No. DH- 33 DH- 34 DH- 35 DH- 36 DH- 37 DH- 38 DH- 39 DH- 40 DH- 41 DH- 42 DH- 43 DH- 44 DH- 45 DH- 46 DH- 47 DH- 48 DH- 49 DH- 50 DH- 51 DH- 52 DH- 53 DH- 54 DH- 55 DH- 56 DH- 57 DH- 58 DH- 59 DH- 60 DH- 61 DH- 62 DH- 63 DH- 64 DH- 65 DH- 66 DH- 67 DH- 68 DH- 69 DH- 70 DH- 71 DH- 72 DH- 73
On 6 meter Road, Near Tank No. 121 & 205 On 6 meter Road, Near Tank No. 120 & 205 On 6 meter Road, Near Tank No. 120 & 206 On 6 meter Road, Near Tank No. 119 & 206 On 6 meter Road, Near Tank No. 118 & 207 On 6 meter Road, Near Tank No. 118 & 208 On 6 meter Road, Near Tank No. 117 & 208 On 6 meter Road, Near Tank No. 117 & 209 On 6 meter Road, Near Tank No. 116 & 209 On 6 meter Road, Near Tank No. 116 & 210 On 6 meter Road, Near Tank No. 115 & 211
On 6 meter Road, Near Tank No .201
On 6 meter Road, Near Tank No. 225
On 6 meter Road, Near Tank No. 224 On 6 meter Road, Near Tank No. 223 On 6 meter Road, Near Tank No. 222 On 6 meter Road, Near Tank No. 221 On 6 meter Road, Near Tank No. 220 On 6 meter Road, Near Tank No. 219 On 6 meter Road, Near Tank No. 218 On 6 meter Road, Near Tank No. 217 On 6 meter Road, Near Tank No. 216 On 6 meter Road, Near Tank No. 215 On 6 meter Road, Near Tank No. 214 On 6 meter Road, Near Tank No. 213
On 6 meter Road, Near WT-1 On 6 meter Road, Near Flameproof Elect. Pole On 6 meter Road, Near Foam Tank On 6 meter Road, Near Tank No. 412
242
AHIR SALT AND ALLIED PRODUCTS PVT. LTD. S. No. 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114
ADDITIONAL STUDIES
Hydrant Point No. DH- 74 DH- 75 DH- 76 DH- 77 DH- 78 DH- 79 DH- 80 DH- 81 DH- 82 DH- 83 DH- 84 DH- 85 DH- 86 DH- 87 DH- 88 DH- 89 DH- 90 DH- 91 DH- 92 DH- 93 DH- 94 DH- 95 DH- 96 DH- 97 DH- 98 DH- 99 DH- 100 DH- 101 DH- 102 DH- 103 DH- 104 DH- 105 DH- 106 DH- 107 DH- 108 DH- 109 DH- 110 DH- 111 DH- 112 DH- 113 DH- 114
On 6 meter Road, Near Tank No. 413 On 6 meter Road, Near Tank No. 414 On 6 meter Road, Near Tank No. 415 On 6 meter Road, Near Tank No. 416 On 6 meter Road, Near Tank No. 417
On 6 meter Road, Near Tank No. 419 On 6 meter Road, Near Tank No. 420 On 6 meter Road, Near Tank No. 421 On 6 meter Road, Near Tank No. 422
On 6 meter Road, Near Tank No. 310 On 6 meter Road, Near Tank No. 309
On 6 meter Road, Near Tank No. 308 On 6 meter Road, Near Tank No. 307 On 6 meter Road, Near Tank No. 306 On 6 meter Road, Near Tank No. 305 On 6 meter Road, Near Tank No. 304
243
AHIR SALT AND ALLIED PRODUCTS PVT. LTD. S. No. 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138
ADDITIONAL STUDIES
Hydrant Point No. DH- 115 DH- 116 DH- 117 DH- 118 DH- 119 DH- 120 DH- 121 DH- 122 DH- 123 DH- 124 DH- 125 DH- 126 DH- 127 DH- 128 DH- 129 DH- 130 DH- 131 DH- 132 DH- 133 DH- 134 DH- 135 DH- 136 DH- 137 DH- 138
On 6 meter Road, Near Tank No. 302 On 6 meter Road, Near Tank No. 301
On 6 meter Road, Near Sand Bucket
On 6 meter Road, Near Tank No. 311 & 401 On 6 meter Road, Near Tank No. 310 & 402 On 6 meter Road, Near Tank No. 309 & 402 On 6 meter Road, Near Tank No. 308 & 403 On 6 meter Road, Near Tank No. 308 & 404 On 6 meter Road, Near Tank No. 307 & 404 On 6 meter Road, Near Tank No. 307 & 405 On 6 meter Road, Near Tank No. 306 & 405 On 6 meter Road, Near Tank No. 305 & 406
On 6 meter Road, Near Tank No. 304 & 407
On 6 meter Road, Near Tank No. 303 & 408 On 6 meter Road, Near Tank No. 302 & 409 On 6 meter Road, Near Tank No. 301 & 410 On 6 meter Road, Near Tank No. 411
Fire Water Network (material of construction)
Pipes
Carbon Steel as per IS: 3589/ IS: 1239/ IS: 1978 will be used as Fire Hydrant Pipes.
Isolation Valves
Gate or butterfly type isolation valves made of Cast Steel having open/close indication will be used.
Hydrants
Stand post will be of Carbon Steel and Outlet valves will be of Gunmetal/ Aluminum/ Stainless/ Steel/Al-Zn Alloy.
Monitors
As per UL/FM listed/approved
244
ADDITIONAL STUDIES
Fire Hoses
Reinforced Rubber Lined Hose as per IS: 636 (Type A)/Non-percolating Synthetic Hose (Type B)/UL or Equivalent Standard will be used.
Painting
Fire water mains, hydrant & monitor stand posts, risers of water spray system will be painted with Fire Red paint as per of IS: 5. Hose boxes, water monitors and hydrant outlets will be painted with Luminous Yellow paint as per IS: 5. Looping The fire water network will be laid in closed loops to ensure multi-directional flow in the system. Isolation valves will be provided in the network to enable isolation of any section of the network without affecting the flow in the rest. The isolation valves will be located normally near the loop junctions. Above Ground Network The fire water network steel piping will be laid above ground at a height of 300 mm above finished ground level. The fire hydrant pipe mains will be supported at regular intervals not exceeding 6 m. Header Pressure in Fire Hydrant System Fire water system will be designed for a minimum residual pressure of 7 kg/cm2 at hydraulically remotest point in the installation considering single largest risk scenario. Water spray system Fixed Water spray system will be provided on all tanks in Enclosure 1 & 2. Tanker loading gantry area will also cover with Fixed Water spray system. Tanker Loading Gantry Area Tanker Loading Gantry facilities will be provided with alternate hydrant and UL/FM listed/approved variable flow water-cum-foam monitors having multipurpose combination nozzles for jet, spray & fog arrangement and will be located at a spacing of 30 m on both sides of the gantry. The hydrants & monitors will be located at a minimum distance of 15 m from the hazard tanker loading facilities. Foam System For combating large hydrocarbon fires particularly in a contained area like storage tank, foam has proved useful for its inherent blanketing ability, heat resistance and security against burn-back. Aqueous Film Forming Foam (AFFF) compound is technically superior and compatible with other fire fighting agents. The system consists of an adequate water supply, supply of foam concentrate, suitable proportioning equipment, a proper piping system, foam makers and discharge devices designed to adequately distribute the foam over the hazard.
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ADDITIONAL STUDIES
Fixed foam conveying system will be provided which comprises of fixed piping for water supply at adequate pressure, foam concentrate tank, eductor, suitable proportioning equipment for drawing foam concentrate and making foam solution, fixed piping system for onward conveying to foam makers for making foam, vapor seal box and foam pourer. Foam Pourer Foam pourer will be provided on class A type tanks. Detection and Alarm System Hydrocarbon detectors with alarm system will be installed near all potential leak source of class-A like tank like dykes, tank manifolds, pump house manifold etc. Fire Extinguishers Different types of fire extinguishers will be provided at various locations, The details of proposed fire extinguishers are given as following;
Table 7-60: Proposed Numbers of Fire Extinguishers

S. No. 1 2 5 3 Type of Fire Extinguishers CO2 DCP Foam Extinguisher DCP Trolley Type Capacity 6 Kg 10 Kg 10 Kg 150 Kg Nos. 12 86 40 5
Table 7-61: Proposed Location of Fire Extinguishers

S. No. 1 2 3 Type of Area Pump House (Class A/B) Pump House (Class C) Tank Truck loading gantry Proposed Nos. & Type of Fire Extinguishers 2 Nos. of 10 kg for each pump. 2 nos. 10 Kg DCP for 4 pumps. 1 No. 10 Kg DCP extinguisher for each bay plus 1 No. 75 Kg DCP extinguisher for each gantry. 2 Nos. 10 Kg DCP extinguishers for each tank plus 4 Nos. 25 Kg DCP extinguishers for each Tank Farm positioned at four corners. In case of adjoining tank farms, the no. of 25 Kg extinguishers may be reduced by 2 nos. per tank farm. 1 No. 10 Kg DCP extinguisher for every 200 m2 or min. 2 Nos. 10 Kg DCP extinguishers for each floor of Building/Store whichever is higher. 2 Nos. each 10 Kg DCP & 4.5 Kg CO2 extinguishers for each DG room. 1 No. 4.5 Kg CO2 extinguisher for every 25 m2 plus 1 No. 9 Liter sand bucket per transformer bay. 2 Nos. of 2 Kg CO2 or 2 Nos. of 2.5 Kg Clean Agent extinguisher per Computer Room and 1 No. 2 Kg CO2 or 1 No. 1.0 Kg Clean Agent extinguisher per cabin. 1 No. 10 Kg DCP extinguisher per cabin. 1 No. 10 Kg. DCP extinguisher. 1 No. 2 Kg. CO2 extinguisher.
Tank Farm
5 6 7
Admin. Building DG Room Main switch Room /Sub-Station Computer Room/ Cabin Security Cabin Transformer UPS / Charger Room
8 9 10 11
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ADDITIONAL STUDIES
Fire Buckets 200 Nos. of fire buckets will be provided near Storage Tank farm area, Chemical Pump House, Tanker Filling area, etc. DG Set To get the power supply in case of emergency or in case of power failure, DG sets will be provided. Trained Persons in Fire Fighting Training on Fire fighting will be imparted to various employees. Further, all security persons with training in Fire Fighting will be selected for employment. Self Breathing Apparatus Sets 4 No. SCBA sets (45 Minutes) will be provided at conspicuous locations. Experienced person working Company will be employs experienced and qualified person. Wind Sock Company will provide wind sock at conspicuous locations. Communication & Warning System, Siren Details of communication & warning system are given in Table 7-62. Further following type of Siren will be available at premises; x x x x Hand operated sirens will be provided at trategic locations and clearly marked in the installation. Electric fire siren will be installed near security cabin at main gate. Electric fire siren will be audible to the farthest distance in the installation and also in the surrounding area up to 1 km from the periphery of the installation. Electric fire sirens will be connected to feeder to ensure continuous power supply during emergency shut down.
Table 7-62: Details of Communication & Warning System

S. No. 1 2 3 4 5 Description Siren Manual Siren PA System Internal Telephones Walkie-talkie system
Safety Shower with Eye Wash Fountain 15 Nos. of Safety Showers with eye wash fountain will be provided at various locations like near electric pump house, near tanker movement area, near TLF area (Phase-I & II), manifold chamber, etc.
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ADDITIONAL STUDIES
Medical Medical examination of workers will be carried out periodically. Employee will be trained person in First Aid. Mock Drill Fire Mock drill will be conducted periodically and record will be maintained. Fire Tender availability Fire Tender can be available from KPT Fire station (0.9 km from Installation) and Fire Station, Gandhidham (14 Km from Installation).
7.6
7.6.1
Disaster Management Plan

Impacts of Chemical Disasters
In addition to loss of life, the major consequences of chemical of chemical disasters include impact on livestock, flora/fauna, the environment (air, soil, water) and losses to industry as given below;
Chemical accidents may be categorized as a major accident or a disaster depending upon the number of casualties, injuries, damage to the property or environment. A major accident is defined in the Manufacture, Storage and Import of Hazardous chemicals (MSIHC) Rules, 1989, issued under the Environment (Protection) Act, 1986, whereas disaster is defined in the DM Act, 2005. 7.6.2 Major Accident- Definitions
Major Accident as defined under different Act/ Rules is given as below:

ADDITIONAL STUDIES
MSIHC Rules-1989(2000) Major Accident means an occurrence including any particular major emission, fire or explosion involving one or more hazardous chemicals and resulting from uncontrolled development in the course of an industrial activity or due to natural events leading to serious effects both immediate or delayed, inside or out side the installation likely to cause substantial loss of life and property including adverse effects on the environments. ---Rule-2(j). Gujarat Factories Rules-1963(2004) Major Accident means an incident involving loss of life inside or outside the site or ten or more injuries inside and /or one or more injuries out side or release of toxic chemical result in On-site or Off-site emergencies or damage to equipments leading to stoppage of process or adverse effects to the environment.--- Rule-68-J(1)(d). The DISASTER MANAGEMENT ACT-2005 Disaster means a catastrophic, mishap, calamity, or grave occurrence in any area, arising from natural or man made cause, or by accident or negligence; which results in substantial loss of life or human suffering or damage to, and destruction of, property, or damage to, or degradation of, environment, and is of such of magnitude as to be beyond the coping capacity of the community of the affected area. 7.6.3 Major Chemical Accidents in India
Following the Bhopal Gas Disaster in 1984, major incidences of Chemical disasters in India include a fire in an oil well in Andhra Pradesh (2003), a vapour cloud explosion in the Hindustan Petroleum Corporation Limited Refinery (HPCL), Vishakhapatnam (1997) and an explosion in the Indian Petrochemicals Corporation Limited (IPCL) Gas Cracker Complex, Nagothane, Maharastra (1990). Over 20 major chemical accidents have been reported in MAH units during 2002-06. Details of these accidents that involved chemicals like Chlorine, Ammonia, LPG and other HAZCHEMs are examples. 7.6.4 Statutory Regulations
The government has reinforced the legal framework on chemical safety and management of chemical accidents by enacting the rules and amending them time to time. The following major chemical class specific regulations are: x x x x x x x x x x x The The The The The The The The The The The Factories Act-1948(1986) Gujarat Factories Rules-1963(2004) Indian Boilers Act,-1923 Explosive Act 1884 Gas Cylinders Rules-1981, 2004 Static and Mobile Pressure Vessels (Unfired) Rules-1981 Insecticide Act 1968 Petroleum Act 1962 Environment (Protection) Act 1986 Disaster Management Act-2005 Central Motor Vehicles Act and Rules. (Transportation of hazardous goods)
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ADDITIONAL STUDIES
x x
The Building and other construction Workers (Regulation of Employment and Conditions of Service) Act,-1996 The Electricity Act,-2003. etc. Evaluation of Major Hazards
7.6.5
Various liquid materials having different chemical properties are handled & stored at the installation. The scales of possible fire, plume, spill, explosion, toxic release or dispersion, accident due to material handling & storages etc. have grown considerably. These factors have greatly increased the risk for major disasters involving loss of human lives, plants, Property and environment degradation. With the growing complexity of the installation, RISK ANALYSIS techniques have been developed over the years, involving more systematic and searching methods for risk identification and quantification. There are various methods adapted to carryout the risk assessment for Major Accident Hazardous Units. The selective methods are: x x x x x x x Primary Hazards Analysis Hazard Operability Study Fault Tree Analysis Event Tree Analysis FMECA MCAA PRORA, etc.
Details on Identification, Analysis and Assessment of Hazards and Risk will provide vital information for Risk Management. However, in absent of failure rate data, suitability of Industry for Indian environment, acceptable risk criteria to public & environment etc. the adequate Risk Assessment is not possible. 7.6.6 Initiators of Chemical Accidents
A number of factors including human errors could spark off chemical accidents with the potential to become chemical disasters. Failure of Containment may be caused by various reasons resulting in spillage / leakage of Liquids. It may be due to manmade, unsafe act, unsafe situation or natural. These are: Unsafe Act and Unsafe Situation x x x x x x x x x Inadequate design against internal pressure, external forces, corrosion and temperature. Mechanical failure of Pipes, Vessels, Elbows due to corrosion, erosion, impact, liquid expansion etc. Failure of manual and automatic control system and safe guard. Failure of safety systems. Weld failure, Gasket failure. Unsafe operation / maintenance. Fire / Emergency in neighboring units. Heating of electrical coils resulting into fire. Spillage, leakage of flammable material, if get any sources of ignition, result into fire.
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ADDITIONAL STUDIES
x x x x x x x x
Uncontrolled vehicle movement result into fire explosion or accident. Wrong operating valve & mixing or overflowing of chemicals from the tanks, result into fire or mishaps. Any source of Ignition to flammable liquid materials may be caused reaction of emergency. Process deviations Technical errors: design defects, fatigue, metal failure, corrosion etc. Lack of information: absence of emergency warning procedures, non- disclosure of line of treatment etc. Human errors: neglecting safety rules or instructions, deviating from specified procedures etc. Organizational errors: Poor planning and coordination, poor communication, lack on training.
Deliberate x x x x Sabotage Terrorism Commotion / Arm conflicts Plane crash / Air raid
Natural x x x x x x x x x Storm Cyclone Wind Flood Frost Earthquake Lightening Heavy rainfall High temperature
Stress & Strain Caused During Normal Operation Stress & Strain occur in manual and in mental work, yet its sensation is appreciated in the mind only. The result of Stress and Strain on worker generally inefficient and accident prone is a fairly recent one and not always appreciated. The muscular stress and Fatigue, mental and nervous fatigue, Boredom and Chronic fatigue, improper environment, climate, lighting, noise, vibration, ventilation, some effect of Insomnia (frequent sleep problem) etc are the stress & strain effects. There are nearly always potential accidental hazards. 7.6.7 Evaluation of Hazards
Process & Storages The major activity of the installation is to receive, store and dispatch the liquid chemicals and allied products. Tank Farm area of installation is well developed area with R. C. C. Dyke wall. There are total 85 Nos. of tanks to store classified liquid chemicals & petroleum products.
251
ADDITIONAL STUDIES
All the tanks are above ground and fixed roof/cone roof type. The liquid storage is preserved at atmospheric pressure and ambient temperature. Sprinkler system is provided on each tank. Firewater Storage tanks Nos-5 are provided at different locations in installation. Major Potential Hazards-Sources The major potential hazards and sources can be listed as per following: x x x x The main source of hazard is from storage of different chemicals at the tank farm with bulk quantities. During receiving of chemicals, from the supply point of Jetty Ship to receiving point i.e. at tankfarm by pipe-lines. Inter connected pipe network & operation valves. Truck loading / unloading facilities Area. Major Type of Possible Chemical Accidents
7.6.8
The leakage / spillage of liquid chemicals from storage-tank may spread out side and if get any source of ignition, then it catch fire and turn into disaster/emergency depending upon quantity and property of liquid chemical. Or if liquid have toxic property, then it may turn into toxic type of disaster/emergency. Thus, properties of chemicals, type of container, containers quantity, weather conditions etc are effective factors of the gravity of disaster/emergency. Chemical disasters may occur due to process deviations concerning the chemistry of the process, pressure, temperature and other identified parameters with regards to the state of the Substance i.e. solid, liquid or gas, proximity to other toxic substances and the probability of a runway reaction due to the incidental mixing of two or more HAZCHEMs with dissimilar properties. In addition, it may be due to hardware failure, resulting in large-scale spills of toxic substances (in any form) due to loss of containment, or an explosion (BLEVE) may occur due to sparks, shocks or frictional forces on the chemical during transportation. The effect can be further, compounded by the micro-meteorology of the area, wind speed and direction, rate of precipitation, toxicity / quantity of chemical released, population in the reach of release, probability of formation of lethal mixtures (fuel-air of other mixtures) and other industrial activities being performed in closer vicinity. It is very important to understand that the state of the chemical substance (solid, liquid or gas) contributes substantially to the gravity of the accident and affects control measures. Chemicals in solid form may have devastating effects if their properties are suddenly changed (e.g. sublimation) due to pressure and temperature conditions to which they are accidentally exposed. If solids continue to remain in solid form, the damage will be negligible. Any human / mechanical failure may cause large scale spills of liquids or of compressed gases like chlorine or Liquid Petroleum Gas (LPG) which can cause BLEVE and can directly affect human lives and the environment. The release of compressed gases gives rise to thermal and cryogenic structure or building, compounding the damage.
252
ADDITIONAL STUDIES
Process & Safety System Failure
Technical Errors:
Design defects, fatigue, metal failure, corrosion etc.
Human Errors:
Neglecting Safety instructions, deviating from specifies procedure etc.
Lack of Information:
Warning procedures, non-disclosure of line of treatment etc.
Organisation Errors:
Poor emergency planning and coordination, poor communication with public, non-compliance with mock drills / exercises etc; which are required for ensuring a state of quick response and preparedness. 7.6.9 Disaster Management
A disaster in industrial unit is one which has potential to cause serious injury or loss of life. It may cause extensive damage to property and severe disruption both, inside or may out side of installation. Whatever be the causative factors like human error, equipment failure, earthquake, lighting, Vehicle crush, Building collapse, fire in neighborhood, sabotage etc; they will normally happened, but it will be any of following forms: x x x x x Fire Explosion Liquid Release (Flammable or Toxic) Fumes/Gas Spreading/Dispersion (Toxic, Poisoning, Flammable, Reactive, Corrosive) Combinations of above.
Thus, Disaster is a situation, created by an accidental release or spill of bulk quantity of hazardous chemicals; which poses a threat to the safety of workers, residents, the environment or property. 7.6.10 Disaster Management Plan (DMP) Disaster Management means a continuous and integrated process of planning, organizing, coordinating and implementing measures which are necessary or expedient forx x x x x x x x Prevention of danger or threat of any disaster, Mitigation or reduction of risk of any disaster or its severity or consequences, Capacitybuilding, Preparedness to deal with any disaster, Assessing the severity or magnitude of effect of any disaster, Prompt response to any threatening disaster situation or disaster, Evacuation. Rescue, and relief, Rehabilitation and reconstruction.
253
ADDITIONAL STUDIES
Minor accidents on chemical do not much impact or damage, but major accidents involved large volume of inventories called as Disaster/Emergency cause extensive damage to person, property and environment. Emergency situation arises all of a sudden and contains high potential to cause havoc. Therefore, advance emergency planning and proper training of every employee in the emergency functions is very essential to make emergency control measures more effective. There are two types of emergency control plans for chemical accidents, 6. 7. On Site Emergency Plan Off Site Emergency Plan
The first is to be prepared by an industrial unit under the guidance of government & local authorities, while second one is to be prepared by the local authority or the government itself with the help of government machinery and resources including the concerned industrial units also. 7.6.11 Key Elements of DMP The Disaster is caused by an accident that takes place in the chemical installation and effects are confined to the factory premises involving the persons working in the factory. On-site Emergency Plan to deal with such eventualities is the responsibility of the occupier and is mandatory. The KeyElements of On-site Emergency Plan are: x x x x x x x x Internal & External contact numbers and addresses of all connected persons with emergency/disaster Site Plan, Lay out Plan, Entry & Exit Gates, Locations of various facilities, Fire Protection system, etc. Details of Hazardous chemicals, their storages, MSDS, locations, etc Manufacturing Process with flow chart, Critical Operations & Parameters. Role and responsibility of designated persons, their availability and response actions. Infrastructure, Communication &Warning system, Testing and Updating of the Plan. Other Details as required during disaster, like weather conditions, inventory, Requirement of PPE, safety equipment, emergency medical services, emergency vehicles, neutralizing agents, etc.
7.6.12 Disaster Management The experienced and senior persons are selected from the Unit and they will be responsible to handle and control the disaster over and above their general duties. The aforesaid person will called as Designated Person for disaster purpose. They have to perform their duty co-ordinately till the controlling the disaster. Further, every incident requires special treatment, because, it is difficult to predict type of situation will take place & how it turn and how person will react. The Disaster Set-Up is given in chart, as per below:
254
ADDITIONAL STUDIES
Figure 7-30: Disaster Management Cell
7.6.13 Hazardous Identification Hazard identification is a critical component for disaster plan, which is discussed above. 7.6.14 Response actions Various actions are required to be initiated according to the situation. However, some systematic codification is required to control such disaster; the following sequential actions will be helpful to contain disaster. Incident There are possibilities of various types of accidents or mishaps occurring in the factory premises. When any incident occurs, it should be distinguished immediately with the subsequent development or seriousness of such occurrence. So, subsequent response actions can be taken immediately to handle & control the situation. The person noticing (First Eye Witness) the Fire or Emergency condition shall shout " Fire, Fire, Fire " or Emergency and also manually sound the nearest bell kept in the field for attracting the attention of the personnel in the near vicinity.
ADDITIONAL STUDIES
Then, he will rush to the control room and inform Supervisor/ Officer. x x x Exact Location of Fire/ Occurrence Type of Fire/ Occurrence, and involved substances Time, when noticed,
In case of Fire, he shall immediately Attack the Fire with, appropriate type of first-aid fire fighting extinguishers available everywhere in the field and ask help of available trained persons at site. On receiving Message of Fire / Occurrence, one of the Supervisor will proceed to the trouble spot and Other may remain available in control room for guidance and coordination. The Supervisor will access the situation, consulting with technical persons then, he will hold the charge of Incident Controller and will inform immediately to Site Main Controller [Sr. Terminal Manager]. On consultation and accessing situation, Site Main Controller will order to operate Disaster Plan and declare emergency. To better deal with disaster coordination and co-operation among participants and members concerned are pivotal. Information sharing and awareness raising should also be incorporated in this network. Response actions shall be initiated immediately by the concerned Team-Heads with their members, by use of available resources as per instruction by SIC. Looking to the situation, information regarding development of incident, type & nature of incident, in case more help needed etc. shall be communicated to the Emergency Control Centre by SIC. Unit Head/ Manger / Shift In Charge will initiate following actions as Site Incident Controller. x x x x Inform the employees / persons working around to leave the area immediately & go to the safe assembly point. Continuous responding actions, with the use of Key Persons, Essential Workers and other helps, till control the incident. Constantly brief & inform the higher authority. On controlling the situation, he will communicate the CIC & Higher authority. On hearing, CIC will assure the safety of the area, & then declare withdrawal of Emergency and ask to sound the siren accordingly.
256
ADDITIONAL STUDIES
Figure 7-31: Chart of Emergency Communication
7.6.15 Designated Persons The role & responsibility of designated person are illustrated as below. However, response actions may differ according to the prevailing situation. Chief Incident Controller (CIC) On receiving information on Incident / Accident or emergency Chief Incident Controller [Managing Director / Director/Senior Officer] will be in overall In-charge of the Situation. x x x x Preparation, review and updating of the DMP; Assessment of situation and declaration of emergency; Mobilization of main coordinators and key personnel; Activation Emergency Control Centre;
257
ADDITIONAL STUDIES
x x x x x x
Taking decision on seeking assistance from mutual aid members and external agencies like Police, Fire Brigade, Hospitals etc.; Continuous review of situation and decide on appropriate response strategy; Taking stock of casualties and ensure timely medical attention; Ensuring correct accounting and position of personnel after the emergency; Ordering evacuation of personnel as and when necessary; Taking decision in consultation with District Authorities when an Off-site emergency to be declared.
Site Incident Controller (SIC) Manager / Shift In-Charge will work as Site Incident Controller. Further, He will hold the position of CIC, till CIC will take over. SIC has to perform the following duties, along with other duty as directed by CIC. x x x x The SIC shall maintain a workable emergency control plan, establish emergency control centers, organize and equip the organization with DMP and train the personnel; The SIC shall be capable of making quick decisions and taking full charge; The SIC shall communicate to the Emergency Control Centre; where it can coordinate activities among groups; The SIC shall be responsible for ensuring that appropriate local and national government authorities are notified, preparation of media statements, obtaining approval from the CIC and releasing such statements once approval received; The SIC shall also ensure the response to the incidents or the emergencies, as the case may be, is in line with entity procedures, coordinating business continuity or recovery plan from the incident. He must ensure next of kin are notified in a timely manner; The SIC shall also co-ordinate if any specialist support is required for the above purpose; and The SIC shall decide on seeking assistance of mutual aid members and external agencies like police, fire brigade, hospital etc.
x x
Coordinator (Administration & Communication) Responsibilities of the administration and communication controller shall include the following; x x x x x x x x x x x x To post senior & experienced person at emergency control centre To activate the medical centre and render first aid to the injured. arrange ambulance and coordination with hospitals for prompt medical attention to casualties; To ensure head counts at assembly points; To arrange procurement of spares for fire fighting and additional medicines and drugs; To mobilize transport to various teams for facilitating the response measures; To monitor entry and exit of personnel into and out of premises; To ensure only authorized personnel enter into the premises; To regulate the flow of traffic into and out of premises and control the mob outside, if any, with the assistance of the police. To provide administrative and logistics assistance to various teams; and To arrange evacuation as directed by the chief incident controller, and in coordination with the civil authorities like police, panchayat/municipal authorities etc. To coordinate with mutual aid members and other external agencies; To direct them on arrival of external agencies to respective coordinators at desired locations;
258
ADDITIONAL STUDIES
x x
To inform the emergency services and statutory authorities, crisis group, etc as instructed by CIC and SIC. To provide the information to news-media as directed by CIC.
Coordinator (Fire, Safety, Health & Environment Team) Responsibilities of the Fire and Safety Coordinator shall include the following; x x x x x x x x x x x x To activate emergency sirens as per the practiced codes; To take charge of all fire fighting and rescue operations and safety matters; To ensure that key personnel are called in and to release crew of fire fighting operations as per emergency procedure; Assess functioning of his team and communicate with the CIC and or administrative controller for any replenishment or, replacement of manpower or fire fighting equipment; Direct the fire brigade personnel and mutual aid members to their desired roles as also proper positioning of the manpower and equipment; To decide the requirement of mutual aid and instruct fire station, who, in turn will contact mutual aid members; To coordinate with outside fire brigades for properly coordinated fire fighting operation; To ensure that casualties are promptly sent to first aid centre / hospital; To arrange requirement of additional fire fighting resources including help from mutual aid partners; Ensure empty and loaded trucks are removed to safer area to the extent possible so as not to affect emergency handling operations; Continually liaise with the SIC and or CIC and implement the emergency combat strategies as communicated by him; and Ensure adequate hydrant pressure in the mains and monitor water level in the reservoir.
Note: Fire chief shall wear identification jackets at the site of disaster so that he is clearly
distinguished among fire fighting personnel and is visible from a distance. Safety personnel will guide and assist the CIC/SIC on chemical-safety, toxicological details, MSDS, neutralizing agent, type of PPE and safety equipment to be used, Health effect, environment effect, etc. Coordinator (Operational Team, Maintenance Workman, Helper, Essential Workers, others) x x x x To reach the incident place along with the necessary equipment To assess the situation and report the position to the In-Charge To take care of 2nd emergency, if it occurs simultaneously. To start the work as per urgency & report to the Team Leader and act according to the instructions given by the leader
They will be treated as Essential Workers in Disaster Plan. The List of Essential Workers shall be prepared and they shall be trained accordingly.
259
ADDITIONAL STUDIES
Coordinator (Support and auxiliary services for major installations) The following additional coordinators may be nominated and delegated the specific responsibilities falling under the basic functions of SIC and or CIC; x x x x x Additional Additional Additional Additional Additional Coordinator: Coordinator: Coordinator: Coordinator: Coordinator: Human Resources and Welfare Services Transport and Logistics Services Media and Public Relations Operations and Technical Security.
The Security Coordinator reports to the Chief / Site Incident Controller and is responsible for security of the installation during any incident or emergency situation and for implementing the actions below: x x x x x x x x x x x To stop the entry of all the unauthorized persons into the Terminal and control the traffic. To Guide the fire tenders etc. for the approach to Fire Spot & to Keep the route open to facilitate external help. To maintain discipline in the truck parking area. To control and disperse the crowd from the main gate. The team will insist all the persons other then the employees of ASAP to vacate the Terminal. Obtaining an approved visitor list from the security department or reception for ensuring that personnel on the list are escorted to reception by security staff; Maintaining security of the office in the event of an office evacuation; Providing office security and assisting authorities in the event of civil unrest or when required organizing additional security at the emergency scene; Obtaining initial briefing from Chief / Site Incident Controller and providing security information and or status reports to Site Incident Controller during the emergency; Assuming responsibility for any task delegated by Chief Incident Controller; and Assessing the emergency, identify security specific problems and recommend solutions to Chief Incident Controller.
Action by other officials The qualified, experienced, senior officers shall be selected to carry out liaison, communication, pool out resources, conveying messages etc emergency duties as per instruction by SMC/IC or situations and they have to perform their duties on urgent basis. Further, they have to ensure that proper messages along with statutory documents/formats/details should reach to the Factory Inspector/DISH and other authorities in time. They will also keep liaison with Explosive Department, GPCB, etc. They will perform liaison work with hospital Authorities for admitted injured person and inform their relatives. If emergency extend for prolong period, then they will arrange for water and food as per prevailing situation under consultation with SMC. Non-Essential Workers/Contractors Persons/ Visitors etc. The persons, who are not taking part/ allotted duties during emergency, they suppose to rush immediately at safe assembly point upon hearing emergency siren/alarm; x x x Leave site immediately by safest route to assembly point Proceed at right angels to wind direction Do not re-enter site unless all clear siren or directed personally or via PA system.
260
ADDITIONAL STUDIES
x x x x
Assist in head count at assembly point Inform contractor personnel to stop work upon hearing fire / gas/ emergency siren/ alarm and ask to assemble at the main security gate or Assembly Point. Do not go to incident place, unless specifically instructed by Emergency in-charge. Avoid Panic.
7.6.16 Infrastructures Emergency Control Centre 8. Each installation shall have the provision of ECC preferably with a back- up arrangement. x x x 9. The ECC shall be away from potential hazards and provide maximum safety to personnel and equipment. Preference should be given to a non-combustible building of either steel frame or reinforced concrete construction. The ECC should have at least two exits and adequate ventilation
Following certain basic supplies and dedicated equipment shall be made available at the ECC. x x A copy of the DMP. Maps and diagrams showing buildings, roads, underground fire mains, important hazardous material and process lines, drainage trenches, and utilities such as steam, water, natural gas and electricity are required. Aerial photographs, if possible, and maps showing the site, adjacent industries, the surrounding community, high-ways, rivers, etc., help determine how the disaster may affect the community so that the proper people can be notified, adequate roadblocks established, and the civil authorities advised. Names, addresses, and telephone numbers of employees. Names, addresses, and telephone numbers of off-site groups and organizations that might have to be contacted should be available. All telephone lists should be reviewed for accuracy on a scheduled basis and updated, as necessary. Dedicated and reliable communication equipment should be provided at the ECC. Enough telephones and one fax line to serve the organization for calls both on-and off-the-site. Twoway radio equipment shall be provided to maintain continuity of communications when other means fail and also provides an excellent way of keeping in contact with field activities. All ECC should have emergency lights so that operations can continue in the event of power failure. Facilities for recording the sequence of events should be provided to assist in investigating causes, evaluating performance, and preparing reports. This can range from a pan board, logbook to a tape recorder with a person assigned to record pertinent information. ECC should also have dedicated computer with LAN/ internet facility to access the installation data and also it should have the latest and updated soft copies of all standard operating practices (SOP) etc.
x x
x x
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ADDITIONAL STUDIES
Safe Assembly Point x There should be pre-designated areas in safe zone as per quantitative risk assessment, where the personnel like workers, staff, contractor workers etc. not involved in emergency operations shall assemble in case of an emergency. Depending on the location of the emergency, the assembly point can vary. For each potential hazardous zone, a specific assembly point shall be identified and clearly marked on the zones or maps. The assembly point should be clearly marked with directional display board along the route. Route should be well lighted with florescent marking. During an emergency, pre-designated persons would take charge of this point and take the roll call of the people reporting. Provisions should be made for assembly points, communication and headcount facilities at assembly points, and personnel to control the movement of assembled employees.
x x
Alarm & Siren x The Emergency siren/s should be located suitably to cover the whole area with the operational control within the installation. These should be tested at least once in a week to keep them in working condition. Emergency siren code should be as follows, namely; x x Emergency Level-I: A wailing siren for two minutes. Emergency Level-II and III: Same type of siren as in case of Level I and II but the same will be sounded for three times at the interval of one minutes i.e.( wailing siren 2 min + gap 1 min + wailing siren 2 min + gap 1 min + wailing siren 2 min) total duration of Disaster siren to be eight minutes.
x x x
All Clear: Straight run siren for two minutes. Test: Straight run siren for two minutes at frequency at least once a week Public address system should be provided with message.
Emergency Lighting & Power Back up One D. G. Set of 150 kVA will be provided for emergency purpose. Further, certain lightings fixtures will be connected with D. G. set. The DG set are to be utilized for fire fighting and emergency purpose. Signages Various signages will be displayed at conspicuous location like; x x x x x x x x Hazard Safe Escape Route Safe Assembly Point No Smoking Use of PPE Fire Extinguisher First Aid Box Caution
262
ADDITIONAL STUDIES
x x x
Siren Code Parking / No Parking Speed Limit
First Aid Arrangement Following facility will be provided; x x x x x x Occupational Health Centre with 2 Bed Facility, Oxygen Cylinder and other first aid medicine Part Time Factory Medical Officer Dresser cum Compounder First Aid Box Trained Person in First Aid Name, address and telephone nos. of specialized hospitals
Table 7-63: Special Medical Treatment and Antidots

S. No. Name of Chemicals Neutralizing Medical Treatment / Antidotes Immediate wash with plenty of water. 1 Acetone Provide artificial respirator. Seek medical attention. Skin is affected then washes with plenty of water. Administer Oxygen or shift to fresh air. Diazepam 0.1 mg/kg.(iv), bed rest. Ethyl Alcohol 2 gm of Sodium bicarbonate in 250 ml water, Diazepam 10 mg by intravenous. Skin or eye is affected then wash with plenty of water. Remove the victim to the fresh air. Induce vomiting. 4 E.D.C. Flush the affected area with large quantity of water. Seek medical aid immediately. 10 Not Soluble 750 / Inactivating Media TLV ppm LD50 mg/kg Not Listed Solubility in Water
Mixible
Benzene
Incineration
10
3400
Poor
1000
7060
Soluble
Toluene
Wash Completely with. Remove exposed Person to Fresh Air, Artificial Respiration.
100
1640
Poor
Hexane
Flush with plenty of water. Do not Induce vomiting. Maintain respiration, be oxygen if required Ethanol (30% solution from inside, 5% solution from out side i.e. by intravenous injection), Epicake Syrup. In case of acidosis give Sodium bicarbonate. In case of delirium give Diazepam 10 mg.
50
28710
Not Soluble
Methanol
200
4100
Good
263
ISOLATED LIQUID STORAGE TERMINAL AT VILLAGE MITHIROHAR, TALUKA GANDHIDHAM, DISTRICT KUTCH Neutralizing
ADDITIONAL STUDIES
S. No.
Name of Chemicals
Medical Treatment / Antidotes by intravenous injection. Folinic acid (Leucovorin), 1 mg/kg, iv, 4 hourly.
/ Inactivating Media
TLV ppm
LD50 mg/kg
Solubility in Water
Naphtha
Flush with plenty of water. Do not Induce vomiting. Maintain respiration, be oxygen if required
300 ppm
Insoluble
Emergency Exits The emergency exit route shall be pre-decided and the boards shall be displayed accordingly; so person can come out safely from the site during disaster. Fire Protection Fire Protection System will be proposed as per mention in Table 7-51 & Table 7-52. PPE Personnel Protective Equipment and safety equipment will be proposed as mention in Table 7-49. 7.6.17 Evacuation x Planning and training on evacuation techniques are important in preventing injuries. Evacuation of local communities or people near the site may be prudent depending on the situation and downwind dispersion information etc. Although this action will normally be initiated and handled by district authorities, the affected installation shall help to implement such evacuation. This evacuation plan shall also consider: x x x x x x x x x x Basis for recommending on-site or off-site actions Authorize person for area or site evacuation Mode of communication Training in locating exits from buildings, areas and the site Location of escape equipment Provisions for flashlights or other supplemental lighting Which areas can function as safe area Moving crosswind from gas or fume releases, etc. Provision of food and drinking water at assembly point and transfer point.
If evacuation takes place after initial head counts are reported, means for recounting may be necessary. Where it is safe to do so, areas being evacuated should be thoroughly searched to ensure everyone has departed safely. Portable mobile vehicle for announcement should be available in the emergency.
7.6.18 Information to the Public The safety measures to be taken in the event of an emergency shall be made known to the general public who are likely to be affected.
264
ADDITIONAL STUDIES
For the purpose, use of Dos' and Donts' shall be prepared and furnished to the Crisis management Group. Display boards carrying dos and donts should be located outside the gate as well as in the neighboring colonies and other habitat areas in the immediate vicinity. 7.6.19 Shut Down Procedure It is already described in On-site Emergency Plan. 7.6.20 Discipline It is already described in On-site Emergency Plan. 7.6.21 Termination of Emergency x Termination activities should concentrate on giving accurate information to people who need it most especially employees, neighborhood, District Authorities engaged in offsite emergencies, and should begin as soon as the emergency phase of the operation is completed. The termination of emergency shall be declared through siren as per the Siren Code defined by industry in case of Level- I and II. For Level-III termination of emergency shall be declared by District Authority through appropriate mode of information transfer so as to reach each and everyone.
7.6.22 Capacity Building Capacity in terms of adequate skilled man power, material logistics and infrastructural facilities etc are to be required in managing of chemical disasters. 7.6.23 Training, & AWARENESS, & Skill Development Employees need to be aware of the disaster plan available at the site. They will need to clearly understand their roles and responsibilities during disaster. The success of disaster plan depends largely on the level of awareness of the plan by the employees, for, their response directly is based on the awareness level. Employees need to be aware of the basic contents of the plan, the evacuation procedures, the site assembly points, handling of the fire fighting equipment and also administering first aid. Sites will need to have a clear training plan for their employees and also check their level of understanding. Training Employees Contractors Visitor - Emergency Plan & Drill - Evacuation procedure, Assembly point - Evacuation procedure, Assembly point
Emergency Control Team - Role Play Skill Development Fire Fighters & First Aiders per shift will be trained for any emergency.
265
ADDITIONAL STUDIES
7.6.24 Emergency Recovery Procedures After the emergency, the following activities need to be carried out in detail. x x x x x x Information to statutory authorities. Incident investigation. Damage assessment. Salvage of products, de-contamination, clean-up and restoration. a detailed report shall be prepared based on the entire experience of the incident, including restorations, limitations and lessons learnt. Ambient air monitoring at the site as well as 5 km radius of the installation by State Pollution Control Board to determine the contamination level affecting health.
7.6.25 Incident Preventing Measures The check-points for incident preventing measures are given as per following;
Table 7-64: Check List for Incident Prevention

S. No. 1 2 3 4 5 8 9 10 11 13 14 15 16 17 18 Check-point Whether Safety, Health and Environment Policy of the location is displayed Whether the Safety Policy is documented and duly approved by the top management Whether the Safety Policy is well structured to cover all elements of Safety, Health and Environment protection Whether the layout is convenient from operation and safety aspects and meets minimum distance norms as per OISD-118 Whether a duly constituted Safety Committee is functioning in the location with representation from workmen/staff Whether all unsafe developments and likely risks are deliberated in the meetings and appropriate steps are recommended for eliminating such risks Whether compliance status of recommendations of earlier Safety Committee meetings are discussed before taking up new issues. Whether performance and shortcomings observed during recent mock disaster drills form part of the discussions in safety committee meetings Is the safety committee minutes are recorded and signed by all the attending members Whether periodical safety audits and inspections by internal and external audit teams are conducted in defined intervals Whether a system of regular monitoring of such audit compliances by controlling offices / HO are in place What is the composition of external audit teams to ensure impartiality of audit findings Whether Work Permit System in line with OISD-105 have been implemented Whether work permits are issued for hot work, cold work, electrical work and vessel entry jobs Whether the location-in-charge or his authorized nominee remains the issuer for all hot work and vessel entry permits for enhanced safety and control. Yes No Remarks
266
AHIR SALT AND ALLIED PRODUCTS PVT. LTD. S. No. 19 20 21
ISOLATED LIQUID STORAGE TERMINAL AT VILLAGE MITHIROHAR, TALUKA GANDHIDHAM, DISTRICT KUTCH Check-point
ADDITIONAL STUDIES Yes No Remarks
Whether work permits are duly closed at completion of the stipulated jobs, duly certified by the supervising officer Whether heat detectors in tank sprinkler systems, high level alarms of tank farm management system are provided and checked for regular functioning Whether in-built safety interlocks provided in the design of the terminal are adequately specified and checked for regular functioning
7.6.26 FORMAT FOR MOCK-DRILL Format for mock-drill and Mutual Aid is given as below;
Table 7-65: Format Mutual Aid/ Mock drills

S. No. 1 2 3 4 5 6 Check-point Whether mock fire / emergency response drills are held If yes, periodicity of emergency response drills Mock drills cover all types of probable emergencies Does the location have Mutual Aid Plan If yes, the details of other members including names and contact nos. of concerned officials List of fire fighting equipments available with each Mutual Aid members including District Fire Service Compatibility of safety equipment of all Mutual Aid members including District Fire Services with said location has been tested and documented in the DMP Details of water storage available with Mutual Aid member including District Fire Service and mechanism to utilize the same in the said location well documented in the DMP Details of fire fighting foams concentrate/chemicals available with Mutual Aid members including nearest Fire Service has been incorporated Details of lead time for response of Mutual Aid members including District Fire Service has been documented in the DMP Periodicity of safety training for officers, staff, contractor workers, TT crew and security personnel mentioned in the ERDMP. Mutual Aid Plans Does the location have established Mutual Aid Plans Which are the Mutual Aid Team members and the assistance offered Does the plan clearly indicate types of possible hazards and fire fighting measures required? Does the plan include expected assistance from each members Does the Plan spell out the communication protocol and the channels in times of emergency Periodic joint exercise and meetings for practice, familiarization and identifying and resolving compatibility issues. Yes No Remarks
9 10 11 12 13 14 15 16 17
267
ADDITIONAL STUDIES
7.6.27 Action Plan for Road Transportation Emergency It is already described in On-site Emergency Plan. 7.6.28 Action Plan for Specific Natural Disaster It is already described in On-site Emergency Plan. 7.6.29 Action Plan for Off-Site Emergency It is already described in On-site Emergency Plan. 7.6.30 Disclosure of Information to the General Public It is already described in On-site Emergency Plan. 7.6.31 Mock Drill It is already described in On-site Emergency Plan.
7.7
Recommendations for OSHMS Procedure Manual
Recommendations are made for different aspects of the project and are given in subsequent paragraphs. 7.7.1 x Storage of Hazardous Chemicals in Bulk
x x
x x x x x x
Attempt should be made to find suitable less hazardous alternate chemicals, to replace the hazardous chemical. The inventory of all hazardous chemicals for that matter must be kept as minimum as possible. The tanks should be located so as not to pose safety problems due to leakage and reaction with other chemicals stored nearby. The storage area should be declared as a prohibited area and should be provided with fencing having at least two exits / No Smoking and/or Prohibited Area display boards, as applicable should be provided at site. The storage tank and foundation should be of suitable material of construction to prevent corrosion. The connections and openings to the tank should be as less as possible so that the possibility of leakage and maintenance hazards is minimized. Each storage tank should have necessary instruments to monitor its level, pressure and temperature. The storage tanks / area should have suitable fire protection and fire fighting facility. The name of chemical, type of hazard, emergency operational instructions, antidote first aid etc. should be displayed near each tank. All cables and electric fittings shall be constructed, installed, protected, operated and maintained in such a manner so as to prevent risk of open sparking. Storage of Hazardous Chemicals in Drums and other Containers
7.7.2 x
The drums should never be filled full with the liquid chemical. There should be sufficient space to take care of thermal expansion.
268
ADDITIONAL STUDIES
x x
The drums should preferably be stored in a well ventilated shed (preferably away from process units) with impermeable floor sloping away from drums. Periodic site inspection should be carried out to ensure that there is no leakage from any of the drums. Unloading of Tank Trucks
7.7.3 x
x x x x x x x
Before the tanker enters the industry premises, the tanker is to be inspected for authorized entry and safe & sound condition of the tanker, its contents and that of the prime mover. Tankers entering plant are to be fitted with flare arresters on their exhaust. Static charge neutralizing The quality of the chemical in the tanker should be ascertained before unloading to avoid contamination of chemical already at storage. Coupling used for connecting hose to tanker must be leak proof. For flammable chemicals, the tanker and the hose are to be properly earthed before starting unloading operation. Unloading should be done under personal supervision of responsible staff authorized by the management. Provision of sample quantity of water / neutralizing medium to take care of leakage / spillage must be made. Also steam and inert gas hose stations must be available at unloading point. Fire alarm and fire fighting facility commensurate with the chemical should be provided at the unloading point. Hazardous Waste Transport
7.7.4
The occupier of hazardous substance shall prepare six copies of the manifest (transporting documents) in Form 9 comprising of colour code indicated below (all six copies to be signed by the transporter): x x x x x x Copy 1 (white): to be forwarded by the occupier to the State Pollution Control Board or Committee Copy 2 (yellow): to be retained by the occupier after taking signature on it from the transporter and rest of the four copies to be carried by the transporter Copy 3 (pink): to be retained by the operator of the facility after signature Copy 4 (orange): to be returned to the transporter by the operator of facility after accepting waste Copy 5 (green): to be returned by the operator of the facility to State Pollution Control Board / Committee after treatment and disposal of wastes. Copy 6 (blue): to be returned by the operator of the facility to the occupier after treatment and disposal of wastes
The occupier shall forward copy number 1 (white) to the State Pollution Control Board or Committee and in case the hazardous waste is likely to be transported through any transit State, the occupier shall prepare an additional copy each for such State and forward the same to the concerned State Pollution Control Board or Committee before he hands over the hazardous waste to the transporter. No transporter shall accept hazardous wastes from an occupier for transport unless it is accompanied by copy numbers 2 to 5 of the manifest. The transporter shall return copy number 2 (yellow) of the manifest signed with date to the occupier as token of receipt of the other four copies of the manifest
ADDITIONAL STUDIES
and retain the remaining four copies to be carried and handed over to respective agencies as specified in sub-rule (4). 7.7.5 General Safety Practices
Work Permit System x It is recommended that plot plans of the installation and the operating blocks should be displayed in the fire and concerned unit control rooms respectively and site of hot jobs under progress should be indicated on these plot plans with red pins. No hot/cold work shall be undertaken without a work permit except in the areas pre-determined and designated by the owner-in-charge. Permit should be issued only for a single shift and its validity should expire at the termination of the shift. However, where the work has to be continued, the same permit may be revalidated in the succeeding shift, by authorized person after satisfying the normal checks. Equipment or area where work is to be conducted should be inspected to ensure that it is safe to carry out the work and assess other safety requirements / stipulations. Unsafe conditions for performance of work may arise from surrounding area. It should be cleaned-up to remove flammable material such as oil, rags, grass etc. Other activities (routine / non-routine) being carried out near-by which can create conditions unsafe for performance of the permit work, should be taken into consideration and the concerned persons should be alerted accordingly. Running water hose and portable fire extinguisher are required respectively to flush / dilute in case of release of any hazardous chemical or to quench sparks and to put out small fires immediately. In order to meet any contingency, it should be ensured that the fire water system including fire water pumps, storage, network etc. is checked and kept ready for immediate use Equipment / Vessel, on which the work permit is being issued, should be completely isolated from the rest of the plant with which it is connected during normal operation, in order to ensure that there is no change in the work environment with respect to presence of toxic / flammable gases, liquids, hazardous chemicals etc. in the course of the work. Equipment under pressure should be depressurized after isolation. This will be followed by draining / purging / water flushing etc. as the case may be. Proper means of exit is required in case of emergencies developed on account of the work or otherwise. Availability of an alternate route of escape should be considered.
x x
x x x
x x
x x
Contractor Safety Duties & responsibilities of the contractor should include the following: x x x x To implement safe methods and practices, deploy appropriate machinery, tools & tackles, experienced supervisory personnel and skilled work force etc. required for execution. To prepare a comprehensive and documented plan for implementation, monitoring and reporting of Health, Safety and Environment (HSE) and implement the same after its approval. To nominate qualified & trained Safety Engineers / Officers reporting to the Site in charge, for supervision, co-ordination and, liaison for the implementation of the safety plan To arrange for fire protection equipment as per the advice of owner
270
ADDITIONAL STUDIES
x x x x x
x x x x
To ensure that its employees have completed appropriate health and safety training as required by the statute / regulation and also as per requirements of the Owner / Consultant To comply with all the security arrangements of owner. To ensure availability of First Aid boxes and First Aid trained attendant. To ensure that all incidents including near misses are reported to all concerned immediately. To ensure strict compliance with work permit system by carrying out work only with appropriate work permits and after ensuring that all safety precautions / conditions in the permit are complied with and closing the same after job completion. To ensure that the workers likely to be exposed to hazardous chemicals/materials have access to appropriate Material Safety Data Sheets (MSDS), wherever applicable, and provide necessary mitigation measures. To ensure that appropriate warning signboards or tags are displayed. To ensure that workers have proper training for their job assignments, including use of appropriate PPE and first aid fire fighting equipment. To comply with all applicable safety and health standards, rules, regulations and orders issued by competent authority pertaining to the assigned activities. To conduct daily inspections to ensure compliance with safety standards, codes, regulations, rules and orders applicable to the work concerned.
Static Electricity x x x x x Ensure no metal objects/appurtenances projecting from roof/shell plates, which will attract highly charged spots in fuel for dissipation. Ensure reduced rate of flow initially into tank/vessel until fill point/nozzle is completely submerged in fluid. Ensure periodic checking and recording of earthing test for tanks and piping systems are maintained. Agitation with air, steam gas, jet nozzle or mechanical mixtures should be avoided. Ensure no personnel is allowed on tank roof for gauging / sampling during product transfer unless dip pipes extend to bottom of tanks. Use only mechanical gauges for ascertaining product transferred during transfer operations otherwise. Protective bonding is required when fill open containers where the product to be handled has a flash point below 54.5 C (130 F) or, in the case of a higher flash point product, when it is heated to within 6.0 C (15 F) of its flash point. The purpose is to keep the nozzle and container at the same electrical potential, thus avoiding a possible static spark in the area of a flammable mixture. Small containers made up of plastic or other non-conductive materials should not be used for filling of fuels. Water washing is safe from a static electricity stand-point. However, there should be no insulated conductive objects within the tank.
x x
Lightning Protection x x Measures to control fugitive emission from storage tanks should be given special consideration. Structures of exceptional vulnerability by reason of explosive or highly flammable contents need special consideration and every possible protection need to be provided even against the rare occurrence of a lightning discharge.
271
ADDITIONAL STUDIES
x x
x x x x x x x
A lightning protection system (Conventional Air Terminal System) consists of the following three basic components - Air terminal, Down conductor and Earth connection Non-conducting chimneys whose overall width or diameter at top is upto 1.5 m shall be provided with one down conductor, and chimneys with overall width or diameter at top more than 1.5 m shall be provided with 2 no. down conductors Metal stacks shall be properly earthed at the bottom. Flammable liquids shall be stored in essentially gastight structures. Openings where flammable concentrations of vapour or gas can escape to the atmosphere shall be closed or otherwise protected against the entrance of flame. Structures and all accessories e.g. dip-gauge hatches, vent valves shall be maintained in good and sound operating conditions. Flammable air-vapour mixtures shall be prevented to the greatest possible extent from accumulating outside storage tanks. Potential spark-gaps between metallic conductors shall be avoided at points where flammable vapours may escape or accumulate. A properly designed / constructed gas tight storage tanks considered to be self-protected against lightning, provided it is properly earthed and bonded. Such a structure may not require any additional means of lightning protection. Personnel Safety
7.7.6
Personnel Protective Equipment x x x x x x Special clothing and personnel protective equipment necessary for entry. All pesticides processing equipment and pipes shall be properly identified by such means as labeling or color coding to indicate that pesticides are contained therein. Protective equipment should be inspected frequently to ensure that it is in good condition. Frequency of checking can be decided depending upon the usage. After the use of protective equipment, it should be cleaned and disinfected before being issued to another person Glove materials must resist the products active ingredients and its solvents. it should allow adequate grip so that applicators can safely carry out their jobs(e.g. change nozzles and screens) For protection of eyes always use goggles, polycarbonate lenses are preferred to protect eyes from flying objects. Face shields are secondary means of eye protection and are designed to be worn over safety spectacles or goggles for full face protection. When purchasing eye protection, make sure it complies with ANSI Z87 for occupational and educational eye and face protection. Sleeve guards should be use when handling hazardous materials to avoid the splashing effect of material. Wash contaminated clothing and other PPE daily, as soon as possible after wearing. Delay in laundering will reduce the likelihood of total residual removal Follow the work instruction/checklist. Know about MSDS of hazardous chemicals used. A person not-familiar with MSDS and trained in use of appropriate shall not commence any work with hazardous chemicals. Frequently refer to the MSDS and use of appropriate PPE Display prominently requisite information on MSDS and use of PPE through illustrations
272
x x x x x x x x
ADDITIONAL STUDIES
x x x x
It is essential that right type of PPE and in sound condition be used. All stocks of PPEs should be periodically inspected, serviced and maintained and unusable ones removed from stock of usable PPEs and sent for disposal. All PPEs should be cleaned for personnel hygiene and kept packed in poly bags. All PPEs should be inspected before and after each use.
Training x x Participants reaction should be obtained in respect of the course content; training methods/techniques used by the faculty, quality of course material etc. Before employees are exposed to any solvent, they should be fully apprised of the following. x x x x x x x Identification by name, characteristics (smell, appearance, etc) and physical properties. Hazards of toxicity. Signs and symptoms of overexposure Fire and explosion hazards. Precaution of safe handling Emergency first aid treatment for over exposure.
x x x x
It should be ascertained whether participants are learning in terms of knowledge and skills in specific areas or activities e.g. safe operating and maintenance procedures, fire prevention and control etc. have improved after the training. It should be checked in what ways and to what degree/extent the attitude of the participants (values or beliefs) have been influenced by the training programme. An evaluation of their behavior on the job is necessary for this purpose. Change in participants performance at their place of work as a result of the training, should be evaluated. The effectiveness of faculty in each training programme should be evaluated and necessary changes if need be, should be made in subsequent training programme. The impact of the training programme on the performance standards of the organization and attainment of tangible results with respect to safety should be evaluated. Records of training should be maintained in respect of every employee indicating the types and the period of training programme attended, performance evaluation and the need for future training. The impact of training programme should be evaluated in terms of overall safety objectives achieved. Safety of Plant Equipment
7.7.7
Thermal Insulation x Frequency of Visual Inspection shall be once a year for plants and mobile equipment. This visual inspection shall be preferably carried out before monsoon, to check for any damage/deterioration, and record the same. Like equipment, insulation also shall be checked and maintained at regular intervals. Preventive maintenance of insulation is very much necessary for safe and economic operation.
273
ADDITIONAL STUDIES
Electrical Equipment x Before initiating the inspection of electrical equipment and associated circuits, Inspector should familiarize himself with the complete previous history of the equipment/circuits, design parameters, service, and likely areas of concern, manufacturers recommendations and such other pertinent data to arrive at the appropriate inspection procedure. The field inspection of electrical equipment in an operating unit is classified into following three types as follows:
On Stream Inspection
This covers audio visual inspection items (instrument aided or otherwise) for checking of general equipment conditions, while the equipment is in operation. (e.g. an abnormal nose or vibration of motor, leakage of transformer oil or overheating of equipment etc., can be assessed through such inspections).
Shutdown Inspection
This covers those inspection items for checking conditions of equipment and systems which cannot be revealed through on-stream inspection (such as internal condition of equipment). This inspection shall be carried out after taking the shutdown of the related equipment after obtaining the Electrical Line Clearance and Work Permit requirements
Inspection of Standby Equipment and Spare Parts

The standby electrical equipment electrical equipment shall be inspected on the same basis and schedule applicable under shutdown inspection, so that changeover from normal to standby equipment shall be possible without any downtime of unit operation. Equipment Safety
Pumps
Pre-starting procedure x x x x x x Equipment: Pump shall be thoroughly cleaned. Piping: Assembly of all piping shall be checked to ensure that they are as per the design drawing. Piping shall be thoroughly flushed to remove rust preventive/foreign material. Support: Relevant pipe supports shall be checked to ensure that they are as per design drawing. Alignment: Alignment of pump and prime mover shall be carried out. Bearing: Bearings shall be lubricated with correct lubricant wherever applicable. Prime mover: The prime mover shall be prepared for operation as manufacturers instruction. In case of Electric Drive correct direction of rotation shall be ensured in decoupled condition. Insulation value of motor and cable shall be checked and recorded. Packing: For gland packing and mechanical seal, cooling and flushing shall be ensured. Mechanical Seals (if applicable) shall be installed as per manufacturers recommendations. Heating up before startup: Pumps on high temperature service shall be heated up gradually to an even temperature before putting on service. Balancing drum leakage: For pumps equipped with balancing drums, any valve in the line shall be locked open for ensuring leakage return to pump suction or to the vessel.
274
x x x
ADDITIONAL STUDIES
Start-up Procedure x x x x x x x The free rotation of the pump shall be checked. Ensure all instruments are installed as per P&I diagram. Ensure that strainer is provided in the suction line. Discharge valve shall be closed (if not already closed). On pumps having externally sealed stuffing boxes, the injection line valves shall be opened and sealing fluid allowed to flow to the seal cages. Pump shall be properly primed. Prime mover shall be started as per prescribed recommendation.
Post-start Checks x x x x x x All instrument readings shall be checked and recorded periodically. Vibration readings shall be checked and signature shall be taken as necessary. Stuffing box packing shall be checked for overheating. Temperature rise, vibration and any abnormal sound from bearings shall be checked. Cooling water flow shall be checked frequently. Suction and discharge pressure shall be monitored to ensure proper operating condition.
Diesel Engines
x x x x Fuel, oil, water and exhaust shall be checked for leaks. Air cleaner oil level shall be checked. Oil level in hydraulic governor shall be checked, if provided. The following checks shall be carried out after every 250 hours - condition of entire oil, the filter elements for metal particles and oil sludging, element holes and tears, oil in aneroid control, if provided, belts, fan hub and drives.
Mechanical Seals
Inspection of Seal Components Prior to Installation: x x x x It should be ensured that all parts are kept clean; especially the running faces of the seal ring and insert. The seal rotary unit should be checked to ensure that the drive pins and/or spring pins are free in the holes or slots. The set screws in the rotary unit collar should be checked to ensure that they are free in the threads. The thickness of all gaskets should be checked against the dimensions shown on the assemble drawing. Improper gasket thickness will affect the seal setting and the spring load imposed on the seal. The fit of the gland ring to the equipment should be checked to ensure that the gland ring pilot enters the bore with a reasonable guiding fit for proper seal alignment. It should be ensured that there is no interference or binding on the studs or bolts or other obstructions. It should be ensured that all rotary unit parts of the seal fit over the shaft. V ring should be placed on the shaft individually, and never be installed on the shaft while they are seated in the seal ring or rotating assembly. Both running faces of the seal should be checked to ensure that there are no nicks or scratches. Imperfections of any kind on either of these faces will cause seal leakage.
275
ADDITIONAL STUDIES
Fixing of mechanical seal x x x x x x x x x x The complete seal assembly drawings and instructions should be carefully studied before starting installation. All burrs and sharp edges should be removed from the shaft or shaft sleeve including sharp edges on key-ways and threads. Worn shaft or sleeves should be replaced. The stuffings box bore and stuffing box face should be checked to ensure that they are clean and free of burrs. The shaft or shaft sleeve should be marked with various reference marks required for installation of seal as per assembly drawings. The shaft or sleeve should be oiled lightly prior to seal assembly to allow the seal parts to move freely over it. The rotary units should be installed on the shaft or sleeve in proper sequence. The back of the collar should be set at the proper distance from the original reference mark on the shaft or sleeve. Tighten all set screws firmly and evenly. The seal faces should be wiped clean and a thin oil film applied prior to completing the equipment assembly. The gland ring should be inserted with insert over the shaft carefully. Complete the equipment assembly taking care when compressing the seal into the stuffing box. The gland ring and gland ring gasket should be seated to the faces of the stuffing box by tightening the nuts or bolts evenly and firmly enough to affect a seal at the gland ring gasket.
Rotating Equipment
x x Maintenance work on any rotating equipment should be started only after obtaining the work permit from the concerned department. Ensure that the equipment is electrically isolated. During opening of equipment such as pumps and compressors, it is a good practice to treat the equipment as if it were under considerable pressure even though all steps have been taken to relieve the pressure. Vehicle entry permit should be obtained from the concerned authority before bringing any crane or any other equipment for removing the pump.
Inspection of Storage Tanks

x Inspection of tanks during fabrication shall be carried out as per the requirements of the applicable codes, specifications, drawings etc. This inspection requires regular checks on the work at various stages as it progresses. During fabrication, a thorough visual check should be undertaken and the tank should be checked for foundation pad and slope, slope of the bottom plates, proper welding sequence and external & Internal surfaces etc. Roof plates shall be inspected for defects like pin holes, weld cracks, pitting etc., at water accumulation locations Tanks pads shall be visually checked for settlement, sinking, tilting, spalling, cracking and general deterioration Anchor bolts wherever provided shall be checked for tightness, and integrity by hammer testing. All open vents, flame arrestors and breather valves shall be examined to ensure that the wire mesh and screens are neither torn nor clogged by foreign matter or insects. If a tank is insulated, the insulation and weather proof sealing shall be visually inspected for damage
276
x x x x x
ADDITIONAL STUDIES
x x x
Grounding connections shall be visually checked for corrosion at the points where they enter earth and at the connection to the tank. The tanks shall be inspected for any obvious leakage of the product. Valves and fittings shall be checked for tightness and free operations. The tanks shell shall be visually examined for external corrosion, seepage, cracks, bulging and deviation from the vertical.
Pipes, Valves and Fittings

x The inspection of piping during fabrication shall be carried our as per the requirement of applicable codes, specifications, drawings, etc. This inspection requires regular checks on the work at various stages as it progresses. The inspection shall include Identification and inspection of material, approval of welding procedures in accordance with code and tender requirement, carrying out of performance qualification test and hydrostatic testing. Visual inspection shall be made to locate leaks. Particular attention should be given to pipe connections, the packing glands of valves and expansion joints. Pipe supports shall be visually inspected for condition of protective coating or fire proofing if any. If fireproofing is found defective, sufficient fireproofing should be removed to determine extent of corrosion. If vibrations or swaying is observed, inspection shall be made for cracks in welds, particularly at points of restraint such as where piping is attached to equipment and in the vicinity of anchors. Line shall be checked for bulging, bowing and sagging in between the supports. Conditions of paint and protective coating shall be checked. Pipelines shall be inspected for cracks. Particular attention should be given to areas near the weld joints. Externally coverts lined piping shall be visually inspected for cracking and dislodging of concrete. All piping, which cannot be checked on the run, shall be inspected during shutdown. These are mostly high temperature piping. During shutdown inspection, hammer-testing and hydrotesting as applicable should be carried out in addition to visual, ultrasonic and radiographic inspections. Pipelines in some of the services like water, phenol and steam are prone to pitting corrosion. Neither ultrasonic nor radiographic testing will reveal the actual internal condition of the pipes in such service. In such cases samples shall be cut for thorough internal examination, at scheduled comprehensive inspections. The samples shall be spilt open in two halves and internal surfaces inspected for pitting, grooving, etc. Piping shall be opened at various locations by removing valves at flanged locations to permit visual inspection. When erratic corrosion or erosion conditions are noted in areas accessible for visual examination, radiographic examination or ultrasonic testing shall be performed to determine thickness. The gasket faces of flange joints, which have been opened, shall be inspected visually for corrosion and for defects such as scratches, cuts and grooving which might cause leakage. Ring gaskets and joints shall be checked for defects like dents, cuts, pitting and grooving. Inspection shall be made for hot spots on internally insulated piping. Any bulging or scaling shall be noted for further inspection when the equipment is shut down.
x x
x x x x x x
Pressure Relieving Devices

x All pressure relieving devices shall be bench tested for set pressure, blow down and leakage as applicable prior to installation.
277
ADDITIONAL STUDIES
The following inspection checks shall be carried out once in every six months for breather valves on storage tanks - discharge opening should be checked for obstruction, flame arrestor wherever provided shall be inspected for fouling, bird nests or clogging, element shall be inspected for mechanical damage, deposits, scaling etc. and cleaned before onset of monsoon, oil filled type liquid seal valve shall be inspected for oil level, fouling, bird nests, foreign material etc. and free movement of pallet shall be checked. Visual inspection of different parts of safety valve shall be done after dismantling to check the condition of flanges for pitting, roughening, decrease in width of seating surface etc. Tank Farm Safety
7.7.8
Inspection of Storage Tanks x x x x All vents storages and reactors and safety relief valve vents to be taken above the roof- top if inside the building or taken above the nearest roof of the building and fitted with flame arrestors. All electrical equipments should be flame proof. Smoke/heat sensors with fore alarm should be installed. Electrical bonding and earthing of flanges/piping and vessels must be carried out. Emergency Management
7.7.9
Emergency Prevention x Preparation of a Preventive Maintenance Schedule Programme covering maintenance schedules for all critical equipments and instruments as per recommendations of the manufacturers user manuals, Establishment of a computerized Failure Modes Effects and Criticality Analysis (FMECA) or similar procedure to generate data on failures of critical equipments and instruments based on mode wise failures and their criticality. This requires codification of equipments, instruments and their modes of failure and their criticality. Consideration may be given to the use of appropriate software for processing FMECA data for review of the Preventive Maintenance Schedule and for improvement of the same to ensure critical failures, Establishment of a Non Destructive Testing (NDT) system as necessary. This may not be feasible in-house but there are specialized organizations who undertake the work, and the same may be used. Importantly, it is of great importance to collect and analyse information pertaining to minor incidents and accidents at the site, as well as for recording near-misses or emergencies that were averted. This information gives an indication of how likely or unlikely it is for the site to face actual emergencies and what should be further done to prevent them from occurring. Establishment of an ongoing training and evaluation programme, incorporating the development of capabilities amongst employees about potential emergencies and ways and means of identifying and averting the same. Most emergencies do not occur without some incident or an abnormal situation. So there is always some time of few seconds to few minutes to arrest an incident of abnormal situation from turning in to an emergency. This is the role of the shift incharge who is the incident controller (IC) along with his shift team. Material Safety Data Sheets (MSDS) or chemical information sheets (CIS) should be kept handy. Fire and emergency alarms should be provided; alarm recognition training should be given to every employee.
278
x x
ADDITIONAL STUDIES
x x x x
x x x
Regular mock drills should be conducted on a specific potential disaster scenario as determined through risk assessment study Safe operating procedures including safe emergency and normal shut down procedures and safe maintenance procedures should be adopted. The roles and responsibilities of all responsible for the control of emergency should be clearly defined. List of key personnel and authorities (including police, factory inspector, district magistrate, state and central level authorities, experts, doctors, village leaders) along with their location should be kept handy. Personnel Protective Equipments (PPEs) and safety torches should be made available. Sufficient antidotes and first aid facilities like stretchers, beds, wheel chairs etc should be made available in the factory dispensary/hospital to cope with emergency. Liaison with outside agencies, home guards and civic authorities for co-operation in mitigating the emergency consequences.
Emergency Response
Onsite Emergency Response

x x Shut down and Isolation: Raising the alarm, followed by immediate safe shut down of the power supply, and isolation of affected areas. Escape, Evacuation and Rescue: Safeguarding human lives at site by commencement of the Emergency Evacuation and Rescue Plan. Ensuring that all personnel are accounted for and carrying out a head count of persons evacuated. Notification and commencement of offsite emergency plan in case offsite impacts are possible. Stopping the development of the emergency: Control or response to the emergency depending upon its nature (fire, toxic release or explosion). Fire can be somewhat better controlled through fire fighting, while toxic release impacts can be partially controlled through proper communication with affected persons. Impacts of explosions impacts can not be controlled once they occur, hence efforts will require focusing on provision of relief or control of secondary impacts (such as property damage or fires) resulting from explosions. Treatment of injured: First aid and hospitalization of injured persons. Protection of environment and property: During mitigation, efforts should be made to prevent impacts on environment and property to the extent possible. Welfare of the personnel managing the emergency: Changeover, first aid and refreshments for the persons managing the emergency. Informing and collaborating with statutory, mutual aid and other authorities including those covered in the Local Crisis Group. Informing and assisting relatives of the victims. Informing the news and electronic media. Preserving all evidences and records: This should be done to enable a through investigation of the true causes of the emergency. Investigation and follow up: This requires to be carried out to establish preventive measures for the future and a review of the DMP & its annexures to fill up the deficiencies in the emergency planning procedures. Ensuring safety of personnel prior to restarting of operations: Efforts require to be made to ensure that work environment is safe prior to restarting the work.
279
x x x x x x x x
ADDITIONAL STUDIES
Off-site Emergency Response Plan

An emergency may affect areas offsite of the works as for example, an explosion can scatter debris over wide areas and the effects of blast can cover considerable distances, wind can spread burning brands of gases. In some cases e.g. as the result of an explosion, outside damage will be immediate and part of the available resources of the emergency services may need to be deployed in the affected areas. In any case, the possibility of further damage may remain, e.g. as the result of further explosion or by the effect of wind spreading burning brands of hazardous material. It will be necessary to prepare in advance simple charts or tables relating the likely spread of the vapours cloud taking into account its expected buoyancy, the local topography and all possible weather conditions during the time of release. It may also be desirable to install instruments indicating wind speed and direction, which could be done jointly with surrounding industries. Inspection of Fire Fighting Equipment and Systems x x x x x The internal and external surfaces of the cylinder body shall be coated with Zinc or lead-tin alloy Material used for the cylinder shell shall be identified to ensure conformity with manufacturing standard. Extinguisher (DCP Vessel) is prone to internal corrosion at the interface between the dry powder top level and empty space; periodic inspection should therefore be undertaken. The shell of the DCP extinguisher shall be visually inspected externally once a month and internally once every three months to check for any mechanical damage or corrosion. A DCP extinguisher body shall be removed from service and destroyed when it is corroded or damaged to such an extent beyond repair is required, when the shell threads are damaged, when it has failed in hydro testing or when the extinguisher has been exposed to high temperatures due to proximity of fire. The internal coating and external painting shall be checked for damage/deterioration once in three months. The safety valve shall be visually inspected for corrosion or damage once every three months. The safety valve shall be bench tested at rated test pressure once every three years. All DCP extinguishers shall be permanently punched at the bottom ring with Manufacturers name, year of manufacture, manufacturers Sr. No. and Inspectors stamp. Equipment, which will automatically detect heat, flame, smoke, flammable gases, or other conditions likely to produce fire or explosion and cause automatic actuation of alarm and protection equipment should be provided.
x x x x
Recommendations on Individual Accident Risks x Fall of persons from height: Training, use of life harness for working at height, providing platforms with railing at height, barricading pits and eliminating piping and other trips in passages are needed to prevent fall accidents of individuals. Fall of objects from overhead work: Helmet use is essential for all project personnel, irrespective of their job nature; use of proper tools properly and handling non-greasy tools is important in preventing falls of objects; use of MS plates on overhead platforms to help restrict the fall of objects since even nuts and bolts can cause injuries. Object hits on the body causing injuries: These accidents are prevented by providing appropriate guards and barricades for all moving parts and in-running nips.
280
ADDITIONAL STUDIES
x x
Hand and foot injuries: Training may be given to workers pertaining to these techniques. Use of safety shoes with toe protection cup and use of appropriate hand gloves for specific activities are required in addition to use of correct tools and correct methods. Flying objects and splinters causing face injuries: Use of face shields is required wherever such hazards exist. Falls, vehicle accidents, flying objects and falling objects causing head injury: Head injury is a very serious injury. Use of helmet should be mandatory. Helmet should be worn with snugly fitting chin belt. This is very important, as the chin belts are never used in India. Non-use of chin belt, leads to the helmet flying off before the head hits during falls exposing the head for injuries. Collisions of vehicles with other vehicles, other structures and human beings: Vehicular movement restrictions and routes need to be displayed. Backing of vehicles has high risk of accidents. Backing alarm signal (Not musical one) be made mandatory on all vehicles. For fork lift trucks now they come fitted with infra red sensors to detect objects behind about one meter away are available. All such measures be ensured to prevent collisions.
281
PROJECT BENEFITS
PROJECT BENEFITS
M/s. Ahir Salt and Allied Products Pvt. Ltd. are proposing for Isolated Liquid Storage Facility of 2,42,182 KL Capacity at Survey No. 573, Village Mithirohar, Taluka Gandhidham. The Proposed project has indirect positive impact on surrounding area which is mentioned below: x x x x Plant will be set up on State Governments land; hence no displacement of people is required. Substantial Socio-economic benefits Good Techno-commercial viability Around the project site semi-skilled and unskilled workmen are expected to be available from local population in these areas to meet the manpower requirement during construction and Operational phase. There will be employment opportunity for local people during construction and operation phase. Infrastructural facilities will be improved due to the project.
x x
Critical analyses of the existing socio-economic profile of the area indicate that the impacts of the project are expected to be of varying nature. The following are the impacts predicted: x x x x No displacement of people will be required. Around the project site semi-skilled and unskilled workmen are expected to be available from local population in these areas to meet the manpower requirement. Secondary employment will be generated thereby benefiting locals. Thus a significant benefit to the socio-economic environment is likely to be created due to the project.
282
ENVIRONMENTAL MANAGEMENT AND MONITORING PLAN

Environmental Management Plans
9.1
Introduction Chapter 5 has identified a number of impacts that are likely to arise. Where adverse impacts have been identified, the EIA has examined the extent to which these impacts would be mitigated through the adoption of industry standard practice and guidelines and following legislative requirements of the Gujarat Pollution Control Board (GPCB). The Environmental Management Plan (EMP) describes both generic good practice measures and site specific measures, the implementation of which is aimed at mitigating potential impacts associated with the proposed activities. Purpose of the Environmental Management Plan The environment management plan is prepared with a view to facilitate effective environmental management of the project, in general and implementation of the mitigation measures in particular. The EMP provides a delivery mechanism to address potential adverse impacts and to introduce standards of good practice to be adopted for all project works. For each stage of the programme, the EMP lists all the requirements to ensure effective mitigation of every potential biophysical and socioeconomic impact identified in the EIA. For each impact or operation, which could otherwise give rise to impact, the following information is presented: x x x x Role of ASAP and its contractors; A comprehensive listing of the mitigation measures (actions) that ASAP shall implement; The parameters that shall be monitored to ensure effective implementation of the action; The timing for implementation of the action to ensure that the objectives of mitigation are fully met. Air Quality
9.1.1
Environment Management Plan for Air is shown below;
Table 9-1: Environment Management Plan for Air

S. No. 1. Activity Storage of Various Products Management Action to be Taken Stacks of adequate height will be provided to limit the ground level concentration of pollutants. The management will ensure proper usage of PPE's by workers and explore methods for reducing the fugitive emission. 2 Transportation of all the Hazardous materials, finished products & hazardous wastes. Ensure provision of PPEs to truck drivers during transportation. Ensure availability of Hazardous Waste characteristics.
283
9.1.2
Water Quality
Environment Management Plan for Water is shown below;
Table 9-2: Environment Management Plan for Water

S. No. 1. Activity Storage of Various Products Management Action to be Taken For the purpose of wastewater treatment, ETP will be provided and the treated effluent will meet on-land disposal norms. The effluent will be used for the green belt development. Monitoring data of ETP will be analyzed and reviewed at regular intervals and compared with the operating standards so that any necessary corrective actions can be taken. There will be no disposal of untreated water on land. 2. 3. Operation of Effluent Treatment Plant Transportation of all the Hazardous materials, finished products & hazardous wastes. ETP sludge will be sent to authorize TSDF. Ensure provision of PPEs to truck drivers during transportation. Ensure availability of Hazardous Waste characteristics.
9.1.3
Land and Soil
Environment Management Plan for Land & Soil is shown in Table 9-3.
Table 9-3: Environment Management Plan for Land & Soil

S. No. 1. Activity Storage of Various Products Management Action to be Taken Also all necessary precautions will be taken to make its solid waste and effluent treatment areas impervious to prevent leachate migration. Hazardous waste generated at site (ETP sludge, used/spent oil) will be sent to authorize TSDF. Provision for temporary storage of waste will be made by providing a storage area with proper top covering and impervious flooring within the premises. 2. 3. Operation of Effluent Treatment Plant Storage of all the hazardous materials Ensure only decontaminated drums, bags (used for solid waste storage) for sale/ recycling and maintain records of same. Proper facilities will be provided to prevent runoff contamination. Ensure disposal of used drums, bags for sale/reuse, only after decontamination. Ensure proper training to drivers for transportation of hazardous chemicals, spill control and emergency actions. Ensure availability of MSDS of all the Hazardous materials to the Off-site Emergency team, whenever required. 4. Transportation of all the Hazardous materials, finished products & hazardous wastes. Ensure provision of PPEs to truck drivers during transportation. Ensure availability of Hazardous Waste characteristics.
9.1.4
Noise
Environment Management Plan for Noise is shown in Table 9-4.
284
Table 9-4: Environment Management Plan for Noise

S. No. 1. Activity Storage of Various Products Management Action to be Taken Proper precaution will be taken to keep the noise levels within prescribed limits. Acoustic enclosure on all major equipment in the plant will be provided for noise attenuation. Workers deployed in high noise areas will be provided with suitable personnel Protective Equipment such as ear muffs and ear plugs.
9.1.5
Ecology and Biodiversity
Green Belt Plan The company has decided to propose the plantation at the peripheral boundary of the proposed plant premises. During survey of the proposed site and study area it has been recorded that project site is located in an area where the land use is mainly industrial. It is an area of raised mudflats and can be described as coastal saline wetlands. The area adjacent to the coast is used for local fishing and salt making. Salinity of the soil in that area is very high so for greenbelt Plantation, Company can grow the plants which can survive in saline atmosphere. However, company has decided proposed green belt in the area of 1283.57 m2. General Principles in Greenbelt Design Plants grown in such a way so as to function as pollutant sinks are collectively referred as greenbelts5. These plants should also provide an aesthetic backdrop for persons using the site and for the surrounding community. General principles in greenbelt design considered for this study are: x x x x Type of pollution (air, noise, water and land pollution) likely from the activities at the site. Agro-climatic zone and sub-zone where the greenbelt is located (and hence the plant species which can be planted in the area). Water quantity and quality available in the area. Soil quality in the area.
Greenbelt is designed to minimize the predicted levels of the possible air and noise pollutants.
Table 9-5: Species Suggested for Green Belt Development

S. No. Botanical Name Common Name Usage Coconut is a plant that has uses from its roots to its tops. Its give delicious fruit. Coconut roots can be used for medicinal purpose. Coconut leaves can produce good quality of paper pulp Its a rich source of Starch, it can tolerate heat quite well
Cocos nucifera
Coconut
Phoenix sp.
Palm Tree
1
5
Central Pollution Control Board, 2000, Guidelines for Developing Greenbelts pp 2
285
AHIR SALT AND ALLIED PRODUCTS PVT. LTD. S. No. 3 Botanical Name
ENVIRONMENTAL MANAGEMENT AND MONITORING PLAN Usage
Common Name Bougainvillea
Bougainvillea spectabilis
Reduce air pollution
Note: Actual species planted at site will be decided in consultation with horticulturalists and native species (as far as possible) will be planted. In order to maintain bio-diversity, a mixture of species will be selected for green belt. Green Belt Management This section mentions about the source of water and soil requirements, their procurement and the general maintenance required with respect to water requirement. It also summarizes the name of plant species to be used at each area, their characteristics and their advantages. It is presumed that the selected plants will be grown as per normal horticultural practice and the authorities responsible for the plantation will make adequate provisions for water and protection of the spillages. A budgetary cost prepared for green belt development as shown in Table 9-6.
Table 9-6: Presenting Budgetary Expenditure for Greenbelt development

S. No. Items Estimated Rate (Rs) Quantity Approximate Cost (Rs) Cost for green belt development 1 2 3 4 Soil filling Soil dressing Tree plantation Shrubs (assuming 10% of total green belt area) Ground cover (assuming 90% of total green belt area) Irrigation Capital Cost 800/truck 14/m
3
1077.625 8621 1915 1724
862,100 120,694 134,050 148,281
70/tree 86/sq m
5 6
70/sq m 172/m
15,518 202
1,086,246 34744 2,386,115
Cost for running/maintenance of green belt (manure, pesticide, herbicide and other maintenance costs) 1 2 3 Trees Ground cover and shrubs Irrigation 21/tree 35/sq m 1915 17242 40,215 603,470 60,000 703,685
Total recurring cost per annum
Table 9-7: Five Year plantation Program

Year 2012-13 2013-14 2014-15 2015-16 Number of Saplings to be Planted 383 383 383 383 Area in m2 3448 3448 3448 3448
286
AHIR SALT AND ALLIED PRODUCTS PVT. LTD. Year 2016-17
ENVIRONMENTAL MANAGEMENT AND MONITORING PLAN Area in m2 3448
Number of Saplings to be Planted 383
9.1.6
Socio-Economic Environment Management Plan (SEEMP)
The various CSR activities being carried out by Ahir Salt & Allied products Pvt. Ltd under the Neelkanth Group Trust are as mentioned below: x x x x x x x Runs management & computer education college in rural area of Kutch (Supeda) Support Girls Child education in Adipur Support various govt. hospital for welfare of poor people Runs various water conservation and harvesting scheme of 6 villages. The Neelkanth group is looking after environment protection and awareness activities Supports various Gaushala Arrange various Blood Donations camp in various parts of Kutch
Commitment of the Project proponent: x x x x The project proponent is committed to spend INR 50,000 every year for medical activities in the surrounding villages of the proposed project site. Proponent will also donate INR 30,000 to Gaw Shala for treatment and food of cattle. Proponent will encourage tree plantation activities by spending INR 50,000. In addition the project proponent will spend INR 1.5 Lacs for Girl Child Education Programme and also spend INR 2 Lacs for Samuh Vivah for Girls.
9.2
9.2.1
Environmental Monitoring Programme

Environment Monitoring Plan
Environment monitoring plan is given in Table 9-8.
Table 9-8: Environment Monitoring Plan

S. No. Activity Air Pollution Monitoring 1. Ambient air monitoring of parameters specified by GPCB in their air consents from time to time within the ASAPs premises Ambient air monitoring of parameters specified by GPCB in their air consents from time to time at four stations outside the project site Stack monitoring of DG set and Oil Fired Boiler, as given in air consent from time to time Water Pollution Monitoring 4. Monitoring of wastewater inlet and outlet at ETP plant for the parameters specified by GPCB in their water consent from time to time Monitoring of one sample of ground water at plant / Daily when in operation Once every Quarter Schedule
2.
Once every season at each station
3.
Once every Quarter for each stack
5.
Once every season
287
AHIR SALT AND ALLIED PRODUCTS PVT. LTD. S. No.
ENVIRONMENTAL MANAGEMENT AND MONITORING PLAN Schedule
Activity nearby location. Parameters are essential parameters as per IS: 10500:1991.
Solid Waste Generation Monitoring / Record Keeping 6. 7. 8. Records of generation of used drums, bags and records of their dispatch to suppliers for refilling Records of generation of waste oils and their treatment Records of generation, handling, storage, transportation and disposal of other solid, aqueous and organic hazardous wastes as required by hazardous waste authorization Environmental Audit 9. Environmental statement under the EP (Act) 1986 Once in a year Daily Daily To be updated daily
9.3
Environmental Management Cell
An environment management cell shall be created which shall perform the following functions: x x x x x x x x Achieve objectives of the Environment Protection Policy of the management. Collect information from regular monitoring and create a database. Analyze the data and decide thrust area. Based on the data collected, decide target for each thrust area. Carry out Projects in each thrust area to arrive at practical solutions to environmental problems. Discuss the reports of study on environment and disseminate the information. Work out Action plan for implementation of the recommendations made in the reports. Prepare Management Information System (MIS) reports and budget for environment management program.
The Plant Manager will be responsible for environmental issues at plant. The responsibilities of the various members of the environment management cell are given in Table 9-9.
Table 9-9: Environment Management Cell

S. No. 1. 2. 3. Designation MD/CEO Vice President General Manager x x Proposed Responsibility Environmental policy and directions Overall responsibility for environmental management and decision making for all environmental issues Overall in-charge of operation of environmental management facilities. Ensuring legal compliance by properly undertaking activities as laid down by various regulatory agencies from time to time and interacting with the same
4. 5.
EHS Manager Manager (Utilities) Secondary responsibility for environmental management and decision making for all environmental issues
288
AHIR SALT AND ALLIED PRODUCTS PVT. LTD. S. No. 6. Designation
Proposed Responsibility x x x Ensure environmental monitoring as per appropriate procedures Ensure scrubber efficiency for effective control of emissions Ensure correct records of generation, handling, storage, transportation and disposal of solid hazardous wastes.
Asst. Manager Plant In-charge
9.4
Expenditure on Environmental Matters
The expenditure will be incurred by ASAP on environmental Matters is given in Table 9-10.
Table 9-10: Expenditure on Environmental Matters

Approximate recurring cost per annum (Rs. in lacs) Approximate Capital cost (Rs. In Lacs)
S. No.
Head
Basis for cost estimates
1.
Air pollution control
0.3
3.5
The capital cost would include cost of providing adequate height of the stack, ladder and platform and recurring cost would include cost of monitoring of air environment. Capital cost would include cost of oil water separator. In capital cost civil work, mechanical work, electrical work and piping work is included. Recurring cost is cost of treatment of wastewater at site Additional DG sets used will have acoustic enclosures. Capital cost would include cost of providing storage space for hazardous waste and membership of TSDF Fee. Recurring cost would include cost of land filling and transportation. The recurring cost would be incurred on hiring of consultants and payment of various statutory fees to regulatory agencies. Greenbelt will developed
2.
Water pollution control
1.2
24.5
3.
Noise pollution monitoring Solid and hazardous waste management Environment monitoring and management Green belt Total
0.18
4.
0.05
2.1
5.
19
6.
1.70 6.39
1.0 50.1
It is expected that ASAP shall incur approximate capital expenditure of about INR 50.1 lacs and an annual recurring expenditure of about INR 6.39 lacs, at current price on environmental matters.
289
SUMMARY AND CONCLUSION
10
SUMMARY AND CONCLUSIONS
The saltpans of M/s Ahir Salt & Allied Products Private Limited are located in Kandla Port area. Out of 1357.56 acres of saltpan areas, M/s Ahir Salt & Allied Products Private Limited proposes to convert its 40 acres of area into liquid storage terminal. The total number of tanks to be installed are 85, and the maximum total capacity will be 2, 42, 182 KL. The landward distance of the proposed storage terminal is approximate 1.2 km from the Old Kandla Oil Jetty. The proposed liquid storage terminal will receive the liquid chemicals from oil jetty through the KPT (Kandla Port Trust) laid pipelines and will transfer these chemicals to end users by Road Tankers.
10.1
Salient Features of the Project
The salient features of the proposed project are given in Table 10-1.
Table 10-1: Salient Features of the Proposed Project

S. No. 1 2 3 4 5 6 7 8 9 10 Features Location Details Proposed Capacity Total Plot area and greenbelt area Capital cost of project Total water consumption Total wastewater generation Effluent Treatment Plant Mode of Disposal for Treated Effluent Fuel used Hazardous waste Disposal Details M/s. Ahir Salt and Allied Products Pvt. Ltd. is geographically located in Survey No. 573, Village Mithirohar in Gandhidham Taluka in Kutch District. 2,42,182 KL Capacity of Isolated Liquid Storage Total plot area is 161881 m2 and 2907.94 m2 i.e. 1.8 % of the total plot area will be developed as greenbelt. 9894.26 Lacs, approximate capital expenditure of about INR 50.1 lacs and an annual recurring expenditure of about INR 6.39 lacs 39.1 KLD in peak (winter season) consumption & 14.8 KLD in average (non- winter season) consumption 5.9 KLD in peak (winter season) effluent generation & 4.6 KLD in average (non- winter season) effluent generation Oil and Water Separator for 34.2 m3 for each (7 Nos.) will be provide Treated effluent will be used for onland irrigation 8 kg/hr Furnace Oil/ LDO for Boiler 2 lit/hr HSD for DG Set Hazardous waste disposed at GPCB approved TSDF. During constructional phase 30 kW and during operational phase around 347 kW it will be sourced from PGVNL (Paschim Gujarat Vij Nigam Limited). Stand by electricity source: D. G. Set of 150 kVA capacity 12 Employment During Construction phase ~ 50-100 persons will be employed for a few 9 months and during operation phase ~30 job opportunities will envisaged. Some of the area around proposed site falls under Coastal Regulation Zone. Demarcation of CRZ mapping had already done and it is found that proposed site for Liquid Storage Terminal falls under Non- CRZ area.
11
Power Requirement
13
Sensitive area
290
SUMMARY AND CONCLUSION
10.2
Conclusions
It can be concluded on a positive note that after the implementation of the mitigation measures and environmental management plans, the project activities during the construction and operation phase would have manageable & largely reversible impacts on the environment, and on balance, the project would be beneficial to surrounding communities and the region. Further, the management of the isolated storage terminal facility will be done in accordance with rules and regulations as stipulated in the relevant statutes, codes and orders.
291
DISCLOSURE OF CONSULTANTS
11
11.1
Brief Resume and Nature of Consultancy Rendered by Kadam Environmental Consultants
Kadam Environmental Consultant (KEC) was established in 1981 and has more than 3 decades of varied experience in the field of environment. The mission of company is providing sustainable solutions on Environment for Development. The company has a dedicated and experienced team of more than 200 technical staff. The team comprise of environmental planners and engineers, chemical and civil engineers, geologist, socioeconomic experts, microbiologists, zoologists, botanists and industrial/analytical chemists. The companys strength lies in project management, performing risk assessment, formulating environmental disaster plans, use of satellite imagery in impact assessment, use of mathematical models for air, water and soil assessment and expertise in public consultation. The company has three sister concerns namely : Kadam Pollution Control Pvt. Ltd dealing in operation and maintenance contracts of sewage, effluent and water treatment plants, Kadam projects dealing in supply of effluent and sewage treatment plants on turnkey basis and Kadam Enviro International Consultancy headquartered in UAE, offering environmental and safety consultancy services in the middle east region. Customer services are mainly categorized into: x Consultancy services(since more than 20 years) in the field of environmental impact assessment, environmental site assessment and due diligence, Enviro legal services, statutory environmental audits/ statements, risk assessments and HAZOP, energy audit, environmental health and safety management systems and waste management systems. Engineering Services (since almost 30 years) for collection and conveyance of liquid and solid wastes, designing and executing effluent and sewage treatment plants, municipal solid waste studies and solid waste management systems, bio gas plants , rain water harvesting systems and deep sea marine disposal systems. Laboratory services (since more than 25 years) in chemical and waste testing, microbiology, soil testing and Field sampling (we have amongst the highest number of environmental field sampling equipments amongst environmental companies in the country). The company has a well equipped laboratory with modern instruments and experienced staff catering to the need of statutory and advisory environmental testing for air, water and wastewater and hazardous solid waste.
The group has a varied industrial clientele encompassing Indian and Multinational Companies covering the industrial and services spectrum viz. Bulk Drugs and Pharmaceuticals, Paints, Chemicals, Oil and Gas, Real Estate, Hospitality and Infrastructure sectors. Whilst the heart of our clientele encompasses the top 50/Blue Chip Indian companies ( reliance Industries, ONGC, Infosys, ITC, ICICI, Indian Oil, GAIL, GSPC/GSPL, Sun Pharma, NTPC, Reliance Energy/Reliance Power, Welspun and many others) who have placed implicit trust in us over the decades. We are increasingly working with several multinationals (such as : ABB, Alstom , Areva , GM, Hindustan Lever, Honeywell, Kohler, Sabic and Tyco amongst others) who value our deep rooted general domain and India centric functional knowledge, reasonable costs and comparable services as those offered by our multinational competitors. Their continued patronage is our biggest testimonial.
The Group has branch offices at Delhi and other places in Gujarat and an overseas office in the UAE. KEC has received ISO 9001:2008 certification for its Quality Management System. The company is accredited EIA Consultant organization by NABET, Quality Council of India under EIA accreditation scheme as per mandatory requirement of the MOEF, Govt. of India for carrying out Environmental Clearance studies. It has approved EIA coordinators and Field Area Experts for undertaking Environmental and related studies in eleven approved sectors.
11.2
EIA Team Members
Work presented in this report was carried out by KEC with active co-operation from M/s. Ahir Salt and Allied Products Pvt. Ltd. KEC team members (along with their role in the project and educational qualifications) include:
Functional Areas Name of the Team Member Dhara Patel Air Pollution Monitoring & Control (AP) Bijal Kothari Involvement /Task Site visit, study for locating monitoring locations, checking air quality data, evaluation of results of Ambient Air Quality Monitoring (AAQM) and contribution to EIA documentation Site visit, finalization of monitoring locations, checking air quality data, evaluation of results of Ambient Air Quality Monitoring (AAQM) Supervision of air quality modeling and prediction Helping in air quality modeling and prediction Help in development of landuse maps of study area using GIS / related tools, finalization of landuse maps Site visit, collection of baseline data with the consultation with the villagers, help for data compilation Site visit, Finalization of sampling locations for surface water sampling, water balance for the project and contribution to EIA documentation Water balance for the project, evaluation of water pollution control management, identification of impacts Site visit, Supervision of noise sampling programme, analysis of data and contribution to EIA documentation Site visit, Identification of modeling scenarios, consequence modeling using PHAST, finalization of DMP, contribution to RA / DMP Documentation and contribution to EIA documentation contribution to the EIA documentation, identification of impacts, finalization of DMP, contribution to RA / DMP Documentation Identification of waste generated from the industry, studying adequacy of mitigation measures for management of hazardous waste Understanding and representing groundwater conditions, contaminants, finalization of survey findings Geology and geomorphologic analysis based on secondary data 293
Mahendra Jadhav Air Quality Modeling and Prediction (AQ) Landuse (LU) Socio-economic (SE) Mahendra Jadhav Maulik Suthar Sheetal Kadam Maria Jessica Sharma Dhara Patel Water Pollution (WP) Maulik Suthar Bijal Kothari Noise and Vibration (NV) Neelam Sharma
Dhara Patel Risk and Hazards (RH) Maulik Suthar Bijal Kothari Solid and Hazardous Waste Management (SHW) Hydrogeology and Water Conservation (HG) Geology (G) Bijal Kothari
Mehul Petkar/ Neelam Sharma Mehul Petkar
Functional Areas
Name of the Team Member
Involvement /Task and in co-operation with FAE, HG
Laboratory Drafts Man
Arpana Patel Krunal Kharva
Sample analysis of water, soil and air collected from the study area as per MoEF requirements. Preparation of landuse maps of study area using GIS / related tools
294
ANNEXURE
Annexure 1: Application Letter for EC
295
ANNEXURE
Annexure 2: Terms of Reference Letter from SEIAA
296
ANNEXURE
297
ANNEXURE
298
ANNEXURE
299
ANNEXURE
300
ISOLATED LIQUID STORAGE TERMINAL AT VILLAGE MITHIROHAR, TALUKA GANDHIDHAM, DISTRICT KUTCH ANNEXURE
Annexure 3: Landuse showing Separate Entry & Exit for Emergency Vehicle Movement
301

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AHIR SALT AND ALLIED PRODUCTS PVT. LTD.

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2012

AHIR SALT AND ALLIED PRODUCTS PVT. LTD.

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2012

AHIR SALT AND ALLIED PRODUCTS PVT. LTD.

Occupational Health Hazard and Mitigations

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2012

AHIR SALT AND ALLIED PRODUCTS PVT. LTD.

AHIR SALT AND ALLIED PRODUCTS PVT. LTD.

Health Hazard Toxicology

AHIR SALT AND ALLIED PRODUCTS PVT. LTD.

Mild to Moderate Intoxication

Proposed Personnel Protective Equipments for Mitigation

Health Hazard Inhalation

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2012

AHIR SALT AND ALLIED PRODUCTS PVT. LTD.

Proposed Personnel Protective Equipments for Mitigation

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2012

AHIR SALT AND ALLIED PRODUCTS PVT. LTD.

Iso Propyl Alcohol

Health Hazard Inhalation

Proposed Personnel Protective Equipment for Mitigation

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2012

AHIR SALT AND ALLIED PRODUCTS PVT. LTD.

Health Hazard Inhalation

Proposed Personnel Protective Equipment for Mitigation

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2012

AHIR SALT AND ALLIED PRODUCTS PVT. LTD.

Health Hazard Inhalation

Proposed personnel Protective Equipment for Mitigation

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2012

AHIR SALT AND ALLIED PRODUCTS PVT. LTD.

Health hazard Inhalation

Mild to moderate toxicity

Proposed Personnel Protective Equipment for Mitigation

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2012

AHIR SALT AND ALLIED PRODUCTS PVT. LTD.

Health Hazard Inhalation

Proposed Personnel Protective Equipment for Mitigation

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2012

AHIR SALT AND ALLIED PRODUCTS PVT. LTD.

Health hazard Inhalation

Proposed Personnel Protective Equipment for Mitigation

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2012

AHIR SALT AND ALLIED PRODUCTS PVT. LTD.

Health hazard Inhalation

Proposed personnel Protective Equipment for Mitigation

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2012

AHIR SALT AND ALLIED PRODUCTS PVT. LTD.

Health hazard Inhalation

Proposed Personnel Protective Equipment for Mitigation

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2012

AHIR SALT AND ALLIED PRODUCTS PVT. LTD.

Health hazard Inhalation

Proposed Personnel Protective Equipment for Mitigation

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2012

AHIR SALT AND ALLIED PRODUCTS PVT. LTD.

Health hazard Inhalation

Proposed personnel Protective Equipment for Mitigation

Health hazard Inhalation

KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2012

AHIR SALT AND ALLIED PRODUCTS PVT. LTD.

Proposed personnel Protective Equipment for Mitigation