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ENVIRONMENTAL CONSULTANT
ENKAY ENVIRO SERVICES PVT. LTD., JAIPUR(At S. No. 43, as per NABET list of Accredited Consultant Organization)
Corporate Office: - L-G-6, Lower Ground Floor, Corporate Park, Gopal Bari, Ajmer Road, Jaipur 01
Phone: - 01414013996, 4016996, Fax No.:- 0141 4026996
Email info@enkayenviro.com, web site: - www.enkayenviro.com
Form - 1(Extension of validity of Environmental Clearance)
ForEstablishment of Integrated Project of
2.0 mio TPA Capacity Greenfield Cement Plant,27 MW Captive Power Plant at Salang under Sutnga Elaka
and2.3 mio tpa Limestone Mines covering 230 ha area
atSutanga-Nongkhlieh Ridge, Khliehriat,
Jaintia Hills District, Meghalaya
Environmental Clearance Granted VideLetter No. - J-11011/417/2008- IA II (I) dated 25th 2009
August 2014
Cosmos Cements Limited
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FORM 1(As per New Notification of M.O.E.F dated 1-12-2009 vide SO 3067 (E)
BASIC INFORMATION
S. No. Item Details
1. Name of the Project/s Cosmos Cements Ltd.
2. S. No. in the schedule As per EIA Notification 14th and
its subsequent amendments thereof, this project
Project.
Cement: S. No. 3 (b); Category A
Mine: S. No. 1 (a); Category A
Captive Thermal Power Plant: S. No. 1 (d);
Category B
3. Proposed capacity/ area/ length/ tonnage to
be handled/ command area/ lease area/
number of wells to be drilled
PlantArea - 160 ha.
Cement Plant: 2.0 MMTPA (Cement) & 1.44
MMTPA (Clinker)
Captive Thermal Power Plant: 27 MW
MineArea - 230 ha.
Captive Mine: 2.3 MMTPA of ROM
4. New/ expansion/ modernization New
Extension of Validity of Environmental Clearance granted vide MoEF F. No. J-11011/417/2008-IA.II(I) dated 25th August 2009.Enclosed as Annexure - I.
5. Existing capacity/ Area etc. Not applicable as it is a Greenfield Project.
6. Category of
7. Does it attract the general condition? If yes
please specify.
No
8. Does it attract the specific condition? If yes
please specify.
No
9. Location The project area is situated near Village
Salang Area under Sutnga Elaka, Tehsil -
Khliehriat and District - Jaintia Hills, Meghalaya.
The proposed project falls within toposheet no.
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83C/7 & 83C/11. The location of the project area
with respect to latitude and longitude is given
below:-
PlantLatitude (N): 250 250
Longitude (E): 920 920
Mine LeaseLatitude (N): 250 250
Longitude (E): 920 920
Plot/ Survey/ Khasra No Not Available as whole Meghalaya is a Non-
cadastral State.
Village Salang Area under Sutnga Elaka
Tehsil Khliehriat
District East Jaintia Hills - The district was carved out of
Jaintia Hills district on 31st 2012.
State Meghalaya
10. Nearest railway station/ airport along with
distance in Kms.
Railway Station: Badarpur (Assam) ~ 125 km,
SSE by road
Airport: Shillong ~ 135 km, NW by road
11. Nearest town, city, district headquarters
along with distance in kms.
Town: Khliehriat ~ 21.0 km, WNW by road
City: Shillong ~ 119.0 km, WNW by road
District HQ: Jowai ~ 33.0 km, WNW by road
12. Village panchayaths, Zilla parishad, Municipal
Corporation, Local body (Complete postal
addresses with telephone nos to be given)
Village Panchayat: Sutunga
Zila Parishad: Earlier Jowai Now Khliehriat
Plant: Salang Area Under Sutnga Elaka,
Khliehriat, East Jaintia Hills District, Meghalaya.
Mine: Sutanga-Nongkhlieh Ridge Under Sutnga
Elaka, Khliehriat, East Jaintia Hills District,
Meghalaya.
13. Name of the applicant Cosmos Cements Ltd.
14. Registered address Ferndale Complex, Block III, Keating Road,
Shilong-793001, Meghalaya.
15. Address for correspondence
Name Mr. U.R. Raju
Designation (Owner /Partner/ CEO) Director
(Authorized Signatory)
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Address Project ProponentCosmos Cements Limited
11th - 12th Floor, Hansalaya Building, 15,
Barakhamba Road, New Delhi
ConsultantEnkay Enviro Services Pvt. Ltd.
L-G-6, Lower Ground Floor, Corporate Park,
Gopal Bari, Ajmer Road, Jaipur 302 001
Pincode Project Proponent:- 110 001
Consultant:- 302 001
E- mail Project Proponent:- ur.raju@dalmiabharat.com
Consultant:- info@enkayenviro.com
Telephone no. Project Proponent:- 011- 23457268
Consultant:- 0141 - 4013996, 4016996
Fax no. Project Proponent:- 011 - 23324136
Consultant:- 0141 - 4026996
16. Details of Alternative sites examined, if any
location of these sites should be shown on a
topo sheet.
Limestone is the raw material for the Integrated
cement plant. The area is mineral specific. Thus,
plant is proposed at optimum location and no
alternative site has been taken into
consideration.
17. Interlinked projects No
The proposed project is an Integrated Cement
Plant (2.0 MTPA Cement Plant (25% OPC, &
75% PPC) and 1.44 MTPA of Clinker), Captive
Power Plant (27 MW) at Sutunga Elaka with
Captive Limestone Mine (2.30 MTPA of ROM;
230 ha.) at Sutnga Nongkhlieh Ridge, Khlierit,
Jaintia Hills district, Meghalaya.
18. Whether separate application of interlinked
project has been submitted?
No
Environmental Clearance has been granted for
Integrated Project (25.08.2009) prior to MoE&F
Office Memorandum no. J-11013/ 41/2006-IA.II
(I) dated 24.12.2010. Hence, no separate
application was submitted.
19. If yes, date of submission Not Applicable
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20. If no, reason It is an integrated project and EC has been
granted by MoEF.
The proposed project is submitted for the extension of the validity of EnvironmentalClearance issued by MoEF vide letter No. J-11011/417/2008- IA II (I) dated. 25th August 2009.
21. Whether the proposal involves approval/
clearance under: if yes, details of the same
and their status to be given.
(a) The Forest (Conservation)Act, 1980
(b) The Wild Life (Protection)Act, 1972
(c) The CRZ Notification, 1991
NAa) NOC has been obtained from Office of the
Jaintia Hills Autonomous District Council:
Jowai for establishment/ setting up of Cement
plant and CPP vide letter no.
JHADC/FOR/1/2009/ 3322-3324 dated 11th
Sept. 2009, stating entire area of Cement
Plant and ML area as non-forest Area
(Enclosed as Annexure-II A).
A Letter has also been obtained from
Divisional Forest Officer, Jaintia Hills Division,
Jowai, vide letter no. JH/VFR/CP/2010-
11/563/B/1895 dated 5th March, 2013
(Enclosed as Annexure-II B) stating that the
project as well as mine area falls in non -
forest area; supported by Joint Inspection
Team (JIT) Report.
b) Not Applicable
c) NA Applicable
22. Whether there is any Government Order/
Policy relevant/ relating to the site?
Yes
Mining lease area of 230 ha. was granted by
Govt. of Meghalaya, vide order no.
MG.113/2007/92 dated 09.06.2010 for a period
of 30 years.
23. Forest land involved (hectares) No, forest land is involved.
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24. Whether there is any litigation pending
against the project and/or land in which the
project is propose to be set up?
(a) Name of the court
(b) Case No
(c) Orders/ directions of the court, if any and
its relevance with the proposed project.
No litigation is pending against the project in the
court of law to the best of our knowledge.
25. Expected cost of the project Estimated Cost at the time of grant of EC: Rs
1009.15 crores.
Revised Estimated Cost of project: Rs. 1500
crores.
(II) Activity
Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)
S. No. Information/Checklist confirmation Yes/No
Details thereof (with approximate quantities /rates, wherever possible) with source of information data
1.1 Permanent or temporary change in
land use, land cover or topography
including increase in intensity of
land use (with respect to local land
use plan)
Yes Land UseThe total Mining area of 230 ha is classified as
community land. Existing land use of plant site (160
ha.) is fallow land and mining area (230 ha.) is
community land. There will be permanent change in
land use which will be confined in acquired area.
Land use will be changed to industrial, residential
and greenbelt.
Land CoverAt places, rocks are exposed and available soil is
very thin giving appearance of an eroded land.
Impact will be significant but confined to project site
only.
TopographyIt is hilly area with 1210 MSL to 960 MSL (i.e. 250
m). Impact on topography will be significant and
confined to the project area.
Water BodiesThere are no water bodies existing within the project
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site except some seasonal nallahs. Kwai River flows
in the west of the project site which will be one of
the sources of water supply.
VegetationThe area is basically an open grass land
interspersed with small patches of artificial grove
like pure pine plantation of varying density. At
present the mine area covered mostly with seasonal
invasive weeds, herbs, small and big shrubs.
However, some tree species are also coming out
from crevices of Karsts topography of limestone
localized in small patches mixed with few bamboo
clumps and saplings of local tree species.
Afforestation / greenbelt development will be done
during and after mining. As per the green belt
development program 1,29,000 saplings are
proposed to be planted in 38 ha. of mine area, 53
ha. of plant area and 38 ha. of additional area
outside the project site.
1.2 Clearance of existing land, vegetation
and buildings?
Yes Not so significant at the plant site. The layout is
planned in such a way that there is minimal clearing
of vegetation. Pine clusters, existing in the area, will
be maintained.
In the ML area, there will be clearing of bushes,
shrubs and few trees as per the Mining Schedule
approved by IBM. Therefore, any significant impact
on the physical environment from the proposed
project is not envisaged. It will be compensated with
proposed green belt within the ML area and plant
area.
There is no structure or building existing in the
project area.
1.3 Creation of new land uses? Yes Industrially productive land;
Plantation & green belt.
Total Project Area 390 ha.
Plant Area 160 ha. [65 ha. (Plant Area and
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Roads) + 30 ha. (Colony with infrastructure) + 12
ha. (Parking Area) + 53 ha. (Greenbelt)]
Mine Area 230 ha [183 ha. (Excavated Area) + 1
ha. (Built up Area) + 8 ha. (Roads) + 38 ha.
(Greenbelt)].
At the end of mining, 180 ha of land shall be
developed for community use/grassland.
1.4 Pre-construction investigations e.g.
bore houses, soil testing?
Yes Done
1.5 Construction works? Yes New Set up; No construction work has been taken
over yet. Partial ground leveling works carried out.
The construction activities will have permanent
localized change in the physical environment of the
site.
Total Area Under Construction 116 ha.
Plant Area 107 ha. [65 ha. (Plant Area and
Roads) + 30 ha. (Colony) + 12 ha. (Parking Area)]
Mine Area 9 ha [1 ha. (Built up Area) + 8 ha.
(Roads)]
1.6 Demolition works? No No existing construction in the plant/ mining area.
Therefore, no demolition work will be carried out.
1.7 Temporary sites used for construction
works or housing of construction
workers?
Yes As far as practicable local people will be employed
as construction workers.
Temporary sites/ housing of construction workers
will be provided on-site with amenities like - power,
water, road, medical, RO Water for Drinking,
Sanitary, Canteen and Shops, if required.
1.8 Above ground buildings, structures or
earthworks including linear structures,
cut and fill or excavations
Yes New set up. No construction work has been taken
over yet. Only partial ground leveling work has been
carried out.
Construction of plant, CPP, Township and allied
infrastructure facilities will be developed over an
area of 160 ha.
Mining Lease is granted over an area of 230 ha out
of which 183 Ha area is proposed to be under
mining activity up to the conceptual phase.
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1.9 Underground works including mining
or tunneling?
No There will be no underground mining activities.
The mining will be carried out by opencast fully
mechanized method.
1.10 Reclamation works? Yes At the end of life of mine, the excavated area (183
ha.) will be leveled and developed as grassland and
left for community purpose.
1.11 Dredging? No Not applicable
1.12 Offshore structures? No Not applicable
1.13 Production and manufacturing
processes?
Yes Cement Plant:
Cement @ 2.0 million tonnes per annum will be
produced with state-of-art dry process technology.
CPP:
A coal based captive Power Plant of 27 MW
capacity.
Limestone Mining:
Conventional, Fully mechanized open cast mining is
proposed.
1.14 Facilities for storage of goods or
materials?
Yes The details of storage facility required for the plant
is given below:-.
a. Limestone Pre blending Stockpile - 50 kT for 7
days
b. Correctives
i. Shale / Clay 7 kT for 15 days
ii. Mill Scale - 2 kT for 15 days
iii. Sandstone - 10 kT for 15 days
c. Raw Meal - 15 kT for 2 days
d. Coal 2 X 16 kT for 60 days
e. Clinker - 50 kT for 10 days
f. Gypsum - 10 kT for 30 days
g. Fly Ash - 5 kT for 3 days
h. Cement Silos 3 X 7.5 kT for 4 days
The waste to be generated during mining includes
clay & shale, which is present in the form of a thin to
thick layer over limestone. The limestone to waste
(Shale) recovery ratio 1:0.80 during plan period.
Considering shale as a corrective, about 15-20 mio t
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shale shall be utilized for manufacturing clinker
during the mine life. The remaining reject shall be
stacked separately or utilized for preparing road,
ramp and filling of non-mineralized portion for ease
of mining. Ultimately the rejects dump shall be
converted into an elevated plain ground and
developed into community use/ grassland.
1.15 Facilities for treatment or disposal of
solid waste or liquid effluents?
Yes Facilities for treatment of solid waste and liquid
effluents will be provided.
Cement Kiln Dust and cement dust collected in
all pollution control devices will be recycled.
Municipal Solid waste from plant & colony will
be collected, segregated and organic fraction
will be composted and the inorganic fraction will
be compacted and stacked suitably at
earmarked place.
Effluent treatment plant will be provided to treat
the process water and treated water shall be
used for green belt development and dust
suppression.
Sewage treatment Plant will be provided to treat
the sewage generated from plant & colony and
treated water shall be used for green belt
development and dust suppression.
Fly ash from CPP will be utilized in cement
manufacturing.
Refractory bricks lining in the kiln have high
recycling values and will be disposed off to
external vendors for their use in other
industries.
Mining:
Solid waste generated during mining shall be
stacked in dump yard or utilized for preparing
road, ramp and filling of non-mineralized portion
for ease of mining. Ultimately the rejects dump
shall be converted into an elevated plain ground
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and developed into of community
use/grassland.
1.16 Facilities for long term housing of
operational workers?
Yes A separate residential township is planned with
modern amenities.
However, for wastewater treatment, STP is
proposed. Proper disposal of Municipal Solid waste
will be carried out. Green belt development will
further enhance the air quality of the area. Hence,
extent of impact will be minimum and confined
within project area only.
1.17 New road, rail or sea traffic during
construction or operation?
Yes Increase in road/rail traffic during construction &
operation phases is envisaged due to movement of
man, machinery during construction phase and
transport of raw materials and finished product
during operation phase.
Not major, except Plant and township internal
roads. The roads will be properly maintained. Water
sprinkling and plantation along the haul and paved
road will be done to minimize the dust dispersion.
Hence, the impact on physical environment will be
insignificant.
1.18 New road, rail, air waterborne or other
transport infrastructure including new
or altered routes and stations, ports,
airports etc?
No Not Applicable
1.19 Closure or diversion of existing
transport routes or infrastructure
leading to changes in traffic
movements?
No Not Applicable
1.20 New or diverted transmission lines or
pipe lines?
Yes Although the proposed power plant will have a CPP
of 27 MW, arrangements will be made to source
power through 132 KV grid substation of Meghalaya
State Electricity Board (MSEB) at Khliehriat sub-
station which is approx. 8 km (crow fly distance)
away from the proposed site.
1.21 Impoundment, damming, culverting, Yes The run-off from the lease area will be suitably
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realignment or other changes to the
hydrology of watercourses or
aquifers?
collected through garland drains and will be stored in
sedimentation pond for further utilization in mine.
However, all measures will be taken not to disturb
the natural drainage system of the surrounding
area.
1.22 Stream crossings? No Not Applicable
1.23 Abstraction or transfers of water form
ground or surface waters?
Yes The total water consumption of the project is about
2125 m3/day, which can be met from ground
water/Kwai River, which is close to the plant site or
by the natural water springs in the region.
Detail of water consumption is given below:-
I. Cement Plant - 1,500 KLD
II. CPP 275 KLD
III. Mine 100 KLD
IV. Residential Colony 250 KLD
CCL obtained GW NOC for abstraction of ground
water from CGWA vide letter no 21-4(41)/NER/CGWA/2012-217 dated 5th Feb 2013 to
the tune of 1955 KLD considering reuse of 170 KLD
treated water for greenbelt development. Enclosed as Annexure- III
1.24 Changes in water bodies or the land
surface affecting drainage or run-off?
Yes There are no water bodies at the project site.
Changes in water bodies: NoNo major surface water body in the project area.
Land surface affecting drainage: YesMineral excavation will lead to the change in
topography of the area, and the present landform.
Establishment of the project will affect the surface
drainage pattern; however, the drainage will be
channelized to the nearest stream/ sump.
Land surface affecting run-off: YesThe run-off from the lease area will be collected
through garland drains. The changes in land runoff
pattern will not be significant; however, slight
changes are anticipated due to mineral excavation.
Run-off water in the project area will be channelized
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to the nearest stream/ sump.
1.25 Transport of personnel or materials
for construction, operation or
decommissioning?
Yes Construction phase: - As far as possible, local
people will be deployed, however for people coming
from far off places, temporary housing will be
provided along with other necessary infrastructure
facilities and services. As far as possible locally
available construction materials will be used.
Operation Phase: - As far as possible, local people
will be employed. However, there is a provision of a
colony with modern facilities for the employees.
Limestone (major raw material) will be sourced from
the adjacent captive mines.
1.26 Long-term dismantling or
decommissioning or restoration
works?
No At the conceptual phase 183 ha. area will be leveled
and developed as grassland for community
purpose.
However, for cement plant no long term dismantling/
decommissioning is proposed.
1.27 Ongoing activity during
decommissioning which could have
an impact on the environment?
No Not Applicable
1.28 Influx of people to an area in either
temporarily or permanently?
Yes Temporary influx of the people from the surrounding
areas will be observed during the construction and
operation of the project till the life of project. The
project presents vast opportunity of employment
under various cadres viz. Management,
supervisory, skilled workmen, semi-skilled workmen
and unskilled workmen. The estimated direct
employment in the plant & CPP will be around 447
persons. The mining operations will employ about
75 people. As far as possible local people will be
given priority in employment
1.29 Introduction of alien species? No No alien species will be introduced.
The plant species used for plantation will be native
and selected in consultation with the Forest
Department and local people.
1.30 Loss of native species or genetic Yes There may be a temporary loss of diversity as large
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diversity? scale construction activity will take place, but it will
be compensated/ restored by green belt
development once the plant is commissioned. The
density of species will increase to a large extent.
1.31 Any other actions? No --
2. Use of Natural resources for construction or operation of the Project (such as land, water, materials or energy, especially any resources which are non-renewable or in short supply):
S. No. Information/checklist confirmation Yes/No
Details thereof (with approximate quantities /rates, wherever possible) with source of information data
2.1 Land especially undeveloped or
agricultural land (ha)
Yes 160 Ha of land for plant & Colony is fallow land, and
230 ha land of mining is community land. No
agricultural land is involved in the project activities.
2.2 Water (expected source & competing
users) unit: KLD
Yes The total water consumption of the project is about
2125 m3/day, which can be met from ground water/
Kwai river, which is close to the plant site or by the
natural water springs in the region.
CCL obtained GW NOC for abstraction of ground
water from CGWA vide letter no 21-
4(41)/NER/CGWA/2012-217 dated 5th Feb 2013.
Enclosed as Annexure III.
2.3 Minerals (MT) Yes Limestone (5,850 TPD), Shale/ Clay (405 TPD) and
sandstone (650 TPD) will be obtained from
proposed captive Mine, and adjacent to the cement
plant. Mill scale (125 TPD), Gypsum (335 TPD),
Coal (900 TPD) and Fly ash (1535 TPD) will be
procured from outside the plant area and will be
transported by road.
2.4 Construction material stone,
aggregates, sand / soil (expected
source MT)
Yes The project site will have concrete work for
administrative building, office, security room etc.
Timber will be avoided in construction. The building
materials required will be coarse aggregate, fine
aggregate, structural steel, bricks etc. Sand will be
procured from local vendors.
2.5 Forests and timber (source MT) No Not Applicable
2.6 Energy including electricity and fuels Yes The power demand for the proposed plant has been
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(source, competing users) Unit: fuel
(MT), energy (MW)
estimated as 25 MW. The power requirement will be
met by a proposed 27 MW Coal based Captive
Power Plant, generating power at 11 KV.
Arrangement shall also be made for sourcing power
through 132 kV grid substation of Meghalaya State
Electricity Board at Khliehriat, through a single
circuit line, which is approx. 8 km (crow fly distance)
away from the proposed site.
Total fuel consumption (Coal) for plant will be 900
TPD. Fuel required for mining will be 3000 ltrs/day.
2.7 Any other natural resources (use
appropriate standard units)
No --
3. Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health.
S. No. Information/ Checklist confirmation
Yes/No
Details thereof (with approximate quantities/ rates, wherever possible) with source of information data
3.1 Use of substances or materials, which
are hazardous (as per MSIHC rules) to
human health or the environment
(flora, fauna, and water supplies)
Yes PlantUsed oil and grease, fuel oil, HSD will be generated
which will be stored properly in a separate labeled
area in leak proof containers and finally it will be
sent to the CPCB authorized vendors for its proper
disposal.
Hazardous Waste Management & Transboundary
Rules 2008 and Batteries (Management &
Handling) Rule, 2001 will be followed.
MineANFO for blasting operation. Blasting will be done
under supervision of certified blaster.
3.2 Changes in occurrence of disease or
affect disease vectors (e.g. insect or
water borne diseases)
No --
3.3 Affect the welfare of people e.g. by
changing living conditions?
Yes The proposed project will directly/ indirectly develop
the area by providing employment opportunities.
With the proposed development in and around the
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area, there will be many supporting facilities/
infrastructure eventually leading to the development
of the area.
The estimated direct employment in the plant & CPP
will be around 447 persons. The mining operations
will employ about 75 people. In addition to it,
company will also undertake CSR activities in the
affected area for welfare of locals.
Apart from direct employment, the indirect
employment generated by way of transportation,
workshops, petty contractors, shopkeepers and
other casual employment allied activities is expected
to be about 1000 which will have a greater beneficial
impact on the living conditions and socio-economic
conditions of the local people living therein.
3.4 Vulnerable groups of people who
could be affected by the project e.g.
hospital patients, children, the elderly
etc.,
No There are no vulnerable groups nearby the Project
site, which could get affected due to project
operations. Under its CSR plans the local people will
be benefitted at large in terms of enhanced medical
facilities/ frequent health check-up camps and allied
activities.
3.5 Any other causes No Nothing is significant
4. Production of solid wastes during construction or operation or decommissioning (MT/month)
S. No. Information/Checklist confirmation Yes/No
Details thereof (with approximate quantities/ rates, wherever possible) with source of information data
4.1 Spoil, overburden or mine wastes Yes Shale will be used as corrective and about 15-20
mio t shale shall be utilized for manufacturing
clinker during the mine life. The remaining reject
shall be stacked separately or utilized for preparing
road, ramp and filling of non-mineralized portion for
ease of mining. Ultimately the rejects dump shall be
converted into an elevated plain ground and
developed into community use/ grassland.
4.2 Municipal waste (domestic and or
commercial wastes)
Yes Municipal solid waste will be generated @ 0.5
Metric ton per day. Daily House-to-House collection
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system in township and canteen will be employed.
Collected waste will be segregated into
biodegradable and non-biodegradable waste.
Biodegradable waste will be composted and used
as manure. Non-degradable waste will be stacked
suitably at earmarked place.
4.3 Hazardous wastes (as per Hazardous
Waste Management Rules)
Yes Waste oil & grease drained out of gearboxes and
other equipment, and scrapped automobile batteries
shall be disposed off by selling to CPCB authorized
recycler/ vendors.
4.4 Other industrial process wastes Yes Ash from CPP will be used in cement manufacturing
process
Cement PlantDust collected from air pollution control equipment
will be recycled in the cement manufacturing.
Power PlantFly ash (48 TPD) and Bed ash (8 TPD) will be
generated from the power plant. Generated fly ash
will be used in PPC manufacturing whereas bed ash
will be used as boiler bed material.
4.5 Surplus product No No surplus product will be generated.
4.6 Sewage sludge or other sludge from
effluent treatment
Yes ETP Sludge @ 5 MT per annum- stacked suitably at
identified place.
STP Sludge @ 10 MT per Month- utilized as
manure in greenbelt development
4.7 Construction or demolition wastes Yes PlantWaste will be generated during construction
activities. The wastes will be utilized for filling low
lying area in the plant premises and making internal
roads.
MineNo significant waste will be generated.
4.8 Redundant machinery or equipment Yes Occasional- after 20-25 years
4.9 Contaminated soils or other materials Yes Top soil was not found in the lease area except the
thin layer of soil at few places. The top soil will be
stored in 2.0 ha. area outside the lease and proper
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care will be taken. As the mineral is nontoxic in
nature, it will not contaminate the soil.
4.10 Agricultural wastes Yes No agricultural waste will be generated. However
Horticultural Waste from Lawns/Garden.
4.11 Other solid wastes Yes Dust/ Cement Dust (770 TPD ) will be generated
from the cement manufacturing process which will
be collected through air pollution control devices
and recycled back to the cement manufacturing
process.
Refractory Bricks (720 TPA) will be replaced due to
wear and tear, once in year. These have high
recycling values, hence will be sold to outside
agencies.
Solid waste @ 1 TPD generated from-Regular Road
Sweeping collection comprises of a mixture of
limestone dust, clay and soil. Civil and construction
debris/ rubbish (Occasionally). These wastes will be
collected and transported through tractor/ lorry and
will be dumped in the low lying area, which are
devoid of mineable reserves. The area thus filled
up/ reclaimed shall be used for plantation purpose.
5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)
S. No. Information/Checklist confirmation Yes/No
Details thereof (with approximate quantities/rates, wherever possible) with source of information data
5.1 Emissions from combustion of fossil
fuels from stationary or mobile
sources
Yes There will be emission from combustion of fossil
fuels from stationary or mobile sources which are:-
CPP boiler- SPM 1.87 g/s, SO2 28.4 g/s, NOx
11.52 g/s
DG sets- SPM 0.54 g/s, SO2 9.0 g/s, NOx 0.59 g/s
Kiln/Vertical Roller Mill- SPM 7.36 g/s, SO2 65.2
g/s, NOx 23.14 g/s
There will also be gaseous emission from
transportation.
All measures will be taken to restrict the emission
within MoEF/CPCB/SPCB norms.
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5.2 Emissions from production processes Yes Details of the emission from industrial process of
cement plant and mining are as below:-
PlantCPP boiler- SPM 1.87 g/s, SO2 28.4 g/s, NOx
11.52 g/s
DG sets- SPM 0.54 g/s, SO2 9.0 g/s, NOx 0.59 g/s
Kiln/Vertical Roller Mill- SPM 7.36 g/s, SO2 65.2
g/s, NOx 23.14 g/s
Crusher- SPM 0.28 g/s
Cooler- SPM 2.78 g/s
Cement Vertical Roller Mill- SPM 5.13 g/s
Packer (2 nos.)- SPM 0.26 g/s
Coal mill- SPM 1.01 g/s
ESP and bag filters will be used to control the
emissions.
MineDrilling- SPM 0.151 g/s
Blasting- SPM 1.167 g/s
Hauling- SPM 71.39 g/s
Limestone Handling & Loading- SPM 0.068 g/s
The different measures taken to control the dust
emissions are:-
Water sprinkling on haul roads
Wet drilling
Limiting the speed of the vehicles
Regular maintenance of vehicles/ equipment.
Materials will be covered with tarpaulin sheets
during transportation.
Plantation along the road as green barrier.
5.3 Emissions from materials handling
including storage or transport
Yes Fugitive emissions will be generated from handling
of materials:-
Plant-Packer (2 nos.)- SPM 0.26 g/s
MineHauling- SPM 71.39 g/s
Limestone Handling & Loading- SPM 0.068 g/s
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Mineral from the crusher to the plant will be
transported via conveyer belt. Thus, fugitive
emission due to internal transportation of raw
materials will not be significant. While, there will be
fugitive emissions generated during loading,
unloading and storage etc. Movement of vehicles
like dumpers, trucks, tankers etc. will also generate
dust. Bag filters and regular water sprinkling on haul
road, will suppress the dust particles and prevent
them from getting air-borne. Covered silo will be
used for storage of material.
5.4 Emissions from construction activities
including plant and equipment
Yes There will be fugitive emission during construction
phase but that will be temporary in nature and
mitigating measures suggested shall be followed.
5.5 Dust or odours from handling of
materials including construction
materials, sewage and waste
Yes Included in Section 5.2
No odor is envisaged from the project activities
5.6 Emissions from incineration of waste No No waste material will be incinerated in the proposed project.
5.7 Emissions from burning of waste in
open air (e.g. slash materials,
construction debris)
No Not Applicable
5.8 Emissions from any other sources No No other source is significant.
6. Generation of Noise and Vibration, and Emissions of Light and Heat:
S. No. Information/ Checklist confirmation
Yes/No
Details thereof (with approximate quantities/rates, wherever possible) with source of information data with source of information data
6.1 From operation of equipment e.g.
engines, ventilation plant, crushers
Yes PlantVarious equipment like mills, pumps, draft fans,
compressor, Boiler feed pump, generator, air
compressor, cooling tower, coal mill etc are the
sources of noise in the cement plant. Generally, the
generated noise level varies from 77 to 100 dB(A).
MineOperation of heavy earth moving machines and
allied mining operations such as transport,
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workshop activities, etc. shall produce noise in the
mining area. Noise is produced due to mining
equipment such as compressors, shovels, dozers,
etc. and by mining produced due to movement by
different equipment deployed in mines are given
below:.
Wheel Loader- 95 (Max), 80 (Min), 85 (Mean) at
Trailer- 80 (Max), 75 (Min), 77 (Mean) at 10m away
from truck on up gradient
Dozer- 90 (Max), 80 (Min), 85 (Mean) at 5m away
Drill-
cabin
Proper Maintenance of the equipment & machines,
green belt development and personal protective
measures will be used to minimize the harmful
effect of the noise.
6.2 From industrial or similar processes Yes There will be generation of noise due to running of
various equipment like mills, pumps, draft fans,
compressor, Boiler feed pump, generator, air
compressor, cooling tower, coal mill etc for
industrial process in the range of 77 to 100 dB(A).
Resultant noise level will mingle with the
background noise levels (assumed to be 75 dB (A)
at 30 m during day time and 70 dB (A) at 100 m
during night time). The above noise levels worked
out are without mitigative measures. With the
mitigative measures, the noise levels will be further
restricted within very short distance from the source.
The operators/ personnel working near the noise
sources in the plant will be provided with earmuffs
and earplugs.
6.3 From construction or demolition Yes The general noise levels due to construction
activities such as working of heavy earth moving
equipment and machinery installation may
sometimes go up to 90 dB(A) at the work sites in
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daytime during construction phase. The workers in
general shall be likely to be exposed to an
equivalent noise level of 80-90 dB (A) in 8-hour shift
for which all statutory precautions as per the law will
be implemented. Use of proper personal protective
equipment shall further mitigate any adverse impact
of noise to the workers.
By using standard practice of operation, these
impacts can be minimized and made insignificant.
Impacts on the noise levels will be temporary for
short duration and reversible in nature.
6.4 From blasting or piling Yes Instantaneous noise is generated from blasting.
Noise of blast is site specific and depends on the
type and quantity of explosive, dimension of drill
hole, degree of compaction in the hole and rock
type. Blasting shall be carried out in accordance
with MMR 1961 and the Indian Explosive Act, 1984.
Blasting shall be done with the use of delay
detonators in the day light. Vibration and noise shall
be kept within the required limits by proper blasting
system with use of optimal charges, control of
delay, and resorting to muffled blasting. Peak
particle velocity will not exceed as provided in
circular (Tech) (S&T) circular no. 7 of 29.08.1997.
noise level should not exceed 85 dB(A) as per
DGMS norms.
6.5 From construction or operational
traffic
Yes Noise will be generated due to operation of
machineries and equipments used in the mining &
cement manufacturing process. However, the
expected noise levels will be maintained within the
DGMS norms
6.6 From lighting or cooling systems No Not envisaged
6.7 From any other sources No Not Applicable
7. Risks of contamination of land or water from releases of pollutants into the ground or into sewers, surface waters, groundwater, coastal waters or the sea:
S. No. Information/Checklist confirmation Yes/ Details thereof (with approximate quantities/
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No rates, wherever possible) with source of information data
7.1 From handling, storage, use or
spillage of hazardous materialsYes In the project, there is no generation of hazardous
material except the used oil from various
machineries. This used oil and ETP Sludge will be
handled properly. Used oil will be stored in the
closed containers and ultimately sent to the CPCB
authorized vendor or may be used in kiln after
obtaining necessary permission. The ETP sludge
will be suitably stacked at identified site.
ANFO Mixture is proposed to be used for blasting
purpose. Due care will be taken to avoid risk during
handling, storage, use or spillage of explosives.
Explosives will be stored in magazine in compliance
with Explosives Act. Blasting will be done under the
supervision of certified blaster
7.2 From discharge of sewage or other
effluents to water or the land
(expected mode and place of
discharge)
No The industrial as well as domestic waste water will
be treated by ETP and STP respectively and the
treated water will be used in green belt development
and dust suppression etc. Zero discharge will be
maintained.
7.3 By deposition of pollutants emitted to
air into the land or into water
No Air pollutants emitted from different activities can
cause contamination of soil. But, following
measures will be adopted to minimize pollutant
deposition.
PlantDuring various industrial activities like Material
handling & transfer, Vehicle traffic at site, Gypsum
storage, Clinker storage, Product storage, Clinker
Hopper, Clinker Silo, Fly ash Silo, Ball Mill,
Packaging Plant fugitive dust will be generated.
Following measures will be adopted to minimize the
same:
High efficiency ESP and bag house will be
installed to control the emission within the
prescribed limits.
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Enclosed belt and bucket conveyors, bag filters
will be provided at the transfer points.
Concreting roads.
Covered unloading hoppers with atomized water
spray system.
Silo for storage of raw materials and products.
Green belt development (33%) shall be
maintained.
Proper maintenance of vehicles will be done
regularly.
Periodic air quality monitoring within & outside
premises will be carried out to check and comply
within the prescribed norms / limits from time to
time.
MineDuring operation phase there will be emissions
generated from excavation, loading and unloading
and mineral handling and transportation. Measures
like controlled blasting, wet drilling, water sprinkling,
green belt development etc. will be adopted to
minimize the same.
7.4 From any other sources No No other sources are involved
7.5 Is there a risk of long term build up of
pollutants in the environment from
these sources?
No There will be no long-term buildup of pollutants in
the environment, however periodic monitoring will
be carried out for continuous improvement.
8. Risk of accidents during construction or operation of the Project, which could affect human health or the environment
S. No. Information/Checklist confirmation Yes/No
Details thereof (with approximate quantities/rates, wherever possible) with source of information data
8.1 From explosions, spillages, fires etc
from storage, handling, use or
production of hazardous substances
Yes Risk of fire due to leakage/spillage from oil storage
tanks and risk of explosion of CPP boiler.
Risk assessment study report attached as
Annexure-IV.
Risk due to storage of explosives at the magazine
proposed for mining activities. Risk due to blasting
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activities in mines.
Explosives will be handled with utmost care in
compliance of conditions imposed by Chief
Controller of Explosive & Metalliferous Mines
Regulation, 1961. Only competent and authorized
persons will be allowed to handle the explosives as
per MMDR, 1961 and permission
8.2 From any other causes No MineThe risks of accident are anticipated from operation
of equipments, land sliding etc. No loose stone or
debris will be allowed to remain near the edges of
excavation and along the sides of haul road.
However, good safety practices will be applied at
the mine site. All precautionary measures will be
adopted and use of protective equipments will be
mandatory. However, to deal the minor incidences
and accidents, first aid measures at site will be
provided.
PlantThe following measures will be implemented:-
Fire detection alarm will be installed.
Auto power off system will be installed.
Personal protective equipment (spats, boots,
gloves, helmets with face shield or goggles
against flying sparks) will be provided.
Health surveillance will be conducted as per
Factory Act.
8.3 Could the project be affected by
natural disasters causing
environmental damage (e.g. floods,
earthquakes, landslides, cloudburst
etc)?
No The study area is located in Seismic Zone-V as per
IS 1893 (Part-I)-2002. All the plant structures will be
designed accordingly in compliance of same.
9. Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality
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S. No.Information/Checklistconfirmation
Yes/NoDetails thereof (with approximate quantities/ rates, wherever possible) with source of information data
9.1 Lead to development of
supporting facilities, ancillary
development or
development stimulated by the
project which could have
impact on the environment
e.g.:
(roads, power supply, waste
or waste water treatment,
etc.)
Yes Township is proposed for about 400 families.
The project will generate direct employment for
about 522 persons. The indirect employment for
about 1000 persons will be generated by the way
of transportation, workshops, petty contractors,
shopkeepers and other casual.
Ancillary Development (transportation,
workshops, petty contractors, shopkeepers.
The livestock-rearing pattern is likely to change in
the vicinity of the plant from holding of goats and
sheep to an increase in cows and buffalo rearing.
A moderate increase in poultry farming is also
likely to meet the increased demand for eggs and
poultry items.
Development of cement based industries such as
Hume pipes, cement concrete poles, cement
concrete prefab structures etc. because of regular
availability of cement from the plant within the
state.
Development of HDPE/Jute bags manufacturing
units.
9.2 Lead to after-use of the site,
which could have an impact
on the environment
No --
9.3 Set a precedent for later
developments
No --
9.4 Have cumulative effects due
to proximity to other existing
or planned projects with
similar effects
No There is no likelihood of cumulative effect due to
transportation of minerals.
(III) Environmental Sensitivity
S.No. AreasName/Identity
Aerial distance (within 15 km.) Proposed project location boundary
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1 Areas protected under
international conventions,
national or local legislation for
their ecological, landscape,
cultural or other related value
None None within the 15 km radius
2 Areas which are important or
sensitive for ecological reasons
- Wetlands, watercourses or
other water bodies, coastal
zone, biospheres, mountains,
forests
Saipung RF~ 10 km, E
Kwai River ~ 4.3 km, SW
Nallah near plant site ~ 0.67 km, W
3 Areas used by protected,
important or sensitive species
of flora or fauna for breeding,
nesting, foraging, resting, over
wintering, migration
None None within the 15 km radius
4 Inland, coastal, marine or
underground waters
Kwai River ~ 4.3 km, SW
5 State, National boundaries None None within the 15 km radius
6 Routes or facilities used by the
public for access to recreation
or other tourist, pilgrim areas
National Highway (NH) no 44
8.5 km, W from site (aerial distance)
21 km from plant site (by road)
18 km from mine lease (by road)
7 Defense installations None None within the 15 km radius
8 Densely populated or built-up
area
None Nearest densely habituated village is Latyrke (1120
population as per 2011 census) which is 5 km
towards NW from the proposed project site
9 Areas occupied by sensitive
man-made land uses
(hospitals, schools, places of
worship, community facilities)
None Nearest Medical FacilitiesKhliehriat PHC ~ 12.4 km, WNW.
Jowai Civil Hospital ~ 31.80 km, NW.
Nearest Educational FacilitiesJaintia Eastern College, Khliehriat ~ 12.5 km, NW.
10 Areas containing important,
high quality or scarce
resources (ground water
resources, surface resources,
None Mineral: limestone: Available in abundance around
the lease & study area
Entire Jaintia hills is classified as safe zone by
CGWA, New Delhi
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forestry, agriculture, fisheries,
tourism, minerals)
11 Areas already subjected to
pollution or environmental
damage. (those where existing
legal environmental standards
are exceeded)
None None within the 15 km radius
12 Areas susceptible to natural
hazard which could cause
the project to present
environmental problems
(earthquakes, subsidence,
landslides, erosion, flooding or
extreme or adverse climatic
conditions)
Seismic
Zone V
The study area is located in Seismic Zone - V as
per IS 1893 (Part-I)-2002. All the plant structures
will be designed accordingly in compliance of the
same.
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RISK ASSESSMENT
1.2 RISK ASSESSMENT
The main objective of risk analysis study is to identify the potential hazards, assess the impact of all probable accidental hazards and mitigating measures to reduce hazards from the coal based captive thermal plant. The objective of Risk Assessment includes:
Identification of hazards at proposed coal based captive power plant
Assessment of the impact of accidental hazards from the facilities to men and material at and around proposed coal based captive power plant
Recommendations necessary for mitigating measures based on risk analysis.
1.2.1 APPROACH & ANALYTICAL TECHNIQUES USED
Risk Analysis broadly comprises of the following steps:
Identification of Hazards and Selection of Scenarios
Effects and Consequence Calculations
Likelihood Estimation Risk Summation
Measures for Risk Mitigation
Hazard Identification is the essential first step in Risk Analysis. It is also an important step in various safety studies and many techniques are available for hazard identification. The most relevant to risk analysis is the review of release sources. For each release scenario a set of consequences chain is developed showing escalation of events.
Effects & Consequence Estimation is done to determine the potential for damage or injury from selected scenarios. The incidents outcomes are analyzed using release rate, pool fire and dispersion and explosion models. Software EFFECTS developed by TNO, The Netherlands, based on Yellow Book has been used for physical effects calculation. For estimation of consequences Green Book has been referred to.
Likelihood Estimation is required to estimate the frequency or probability of occurrence of an incident. Estimates have been obtained from historical incident data on failure frequencies.
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Risk summation is done by combining the consequences and likelihood of all incident outcomes from all selected incidents to provide a measure of risk. The Risk to people from existing and proposed facilities is presented in the form of Individual Risk of fatality. The risk to environment is presented in terms of cumulative frequency versus released quantity and annual oil spill rate.
Figure 1.1: Risk Analysis Scheme
Major risk contributors have been identified and recommendations are made for risk reduction.
1.2.2 IDENTIFICATION OF HAZARDS
The starting point of a risk analysis study is the identification of hazards and selection of scenarios that are then addressed for further analysis.
Hazard is defined as a chemical or physical condition that has the potential for causing damage to people, property or the environment. A number of techniques are available for hazard identification depending upon the depth and objective of study.
Accidental release of flammable liquids or toxic gas can result in severe consequences like fire, vapour cloud explosion (VCE) or toxic vapour cloud. Delayed ignition of flammable vapours can result in blast overpressures covering large area. Toxic clouds may cover yet larger distances; due to the lower concentration threshold value for potentially lethal situations in relation to those in case of explosive clouds.
In contrast, fires have localized consequences. The extent of damage to people depends on the heat flux and duration of exposure. Fires can be put out or contained in most cases, but there are few mitigating actions one can take once a vapour cloud gets released. Major accident hazards arise, therefore, consequent upon the release of flammable or toxic vapours.
In general, proposed coal based captive thermal plant does not involve any hazardous chemical process, which can create potential risk to personnel and property at site and
Identification of Accident Scenarios
Frequency of Accident Scenarios
Calculation of Physical Effects
Probability of Physical Effects
Calculation of Overall Frequency
Calculation of Damage Probability of Damage
Risk Quantification
Risk Evaluation
Risk Reduction
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surroundings. However, few hazardous materials, like, fuel oil and gases, like, chlorine and hydrogen will be handled at coal based power plant, that can create potential hazardous situations in the unlikely event of accidental release.
1.2.2.1 Hazards Handled at Coal Based Power Plant
It is essential to have comprehensive information on the hazardous process and chemicals handled at the proposed captive power plant. For risk assessment, hazard identification is first step. Various hazardous activities at the proposed captive power plant are described below:
Oil Handling System
Light Diesel Oil (LDO) /Furnace Oil (FO) will be used to light up boilers and may be used for supporting combustion at low loads and during short falls of solid fuel. LDO and FO will be stored in tanks with capacity of 5 kl and 1 kl, respectively.
Release of LDO/FO from storage tank can create pool fire hazard, if an ignition source is available.
Chlorination
At coal based power plant, chlorine is used for controlling the microbiological growth in circulation water system and stored in standard size of toner cylinders. Chlorine toners will be stored at isolated place in the plant with adequate safety provisions as per Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 and amendments thereafter.
On an accidental release, chlorine can create a hazardous situation in the form of toxic vapour cloud. Chlorine gas is a toxic gas and about 2.5 times heavier than air hence, tends to spread at floor levels, drains, pits, etc.
Hydrogen Gas
In thermal power plant, hydrogen gas is used for generator (turbine) cooling and is generated in the power stations by electrolysis method using sodium hydroxide solution as electrolyte in a separate plant. Hydrogen gas with oxygen can create explosion hazard, if it gets ignition sources.
Boilers and Ash Handling System
At coal based thermal plant, boiler can create explosion hazard and subsequently pressure wave. Explosion in boiler is possible due to accumulation of an explosion mixture caused by:
Improper sequence of operation,
Insufficient ignition energy supplied, when compared to actual requirement,
Firing with improper fuel-air ratio,
Almost all the inter locks and protections for boiler are generally converted under combustion control system, though which the master fuel-trip relay is actuated.
1.2.2.2 Characteristics of Hazard Substances at Coal based Thermal Power Plant
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Chlorine Gas
Chlorine is a toxic gas (B. P. is -34 oC). In liquefied form chlorine is a clear amber dense liquid. The gas is greenish-yellow, about 2.5 times as dense as air, and non-flammable. Liquid chlorine causes severe irritation and blistering of skin. The gas has a pungent suffocating odour and is an irritant to the nose and throat. It is an extremely powerful vesicant and respiratory irritant.
Typically exposure to chlorine concentrations of 3 - 6 ppm results in a stinging and burning sensation in the eyes. Exposures for 0.5 -1 hour to concentrations of 14 - 21 ppm cause pulmonary oedema, pneumonitis emphysema and bronchitis. This is usually associated with marked bronchospasm, muscular soreness and headache. Whilst there is inevitably a variation in individual susceptibility, typically 4 ppm is the maximum concentration that can be breathed for one hour without damage, 40-60 ppm is dangerous for a 30-minute exposure and a concentration of 1000 ppm is likely to be fatal after a few breaths.
Hydrogen Gas
Hydrogen is a colorless and odorless gas. It is a flammable and explosive gas and results in violent reaction with air. It forms sensitive explosive mixers with bromine and chlorine. Lower and upper explosive limits of hydrogen gas area (LEL & UEL) are 4.1 % and 74.2 %, respectively.
Hydrogen gas is a chemically stable gas and incompatible with water. No chemical reaction occurs with common materials but low temperature causes most materials to become very brittle.
Hydrogen gas can enter the human body though skin and inhalation. If atmosphere does not contain enough oxygen, inhalation can cause dizziness, unconsciousness or even death. Contact of liquid with eyes or skin causes freezing similar to burns.
Liquid Petroleum (LDO)
The liquid hydrocarbons (LDO) are not pure components and are mixtures of a large number of hydrocarbons of varying carbon number. Therefore, no stream has a definite boiling point but instead each has a boiling range. A particular stream may be defined in terms of the various carbon number cuts it contains as specified by its initial and final boiling points.
The hazard posed by these hydrocarbons is largely that of fire. These liquid hydrocarbon streams give rise to only pool fires upon ignition, with the heat radiation hazard. From experience it may be concluded that releases of these hydrocarbons will not give rise to off-site consequences.
1.2.2.3 Scenarios for Consequence Analysis
Various hazardous scenarios are described below:
For consequence analysis following scenarios has been considered for risk assessment:
Leakage of Chlorine from Ton Cylinder
Pool fire in Dyke of LDO Tank Scenario No. Description Outcomes Consequence
1 Catastrophic Failure in Largest Connection (1/4”) of Toner Cylinder
Release of Chlorine
Toxic Cloud
2 Rupture followed by ignition in LDO Pool fire Thermal
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Tank Radiation
1.2.3 EFFECTS AND CONSEQUENCE ANALYSIS
The released quantity will depend on failure size and the duration of release. On release of chlorine from toner, toxic cloud will be formed and dispersed towards wind direction. While release of petroleum oil (LDO), a fixed or spreading pool may be formed, which may or may not ignite. If immediate ignition takes place a pool fire will take result. Delayed ignition may also lead to vapour cloud explosion / flash fire, if release quantities/surface area are significant.
1.2.3.1 Dispersion of Toxic Clouds
The IDLH (Immediately Dangerous to Life and Health) and Time Weighted Average (TWA) concentration values have been taken as the criteria for chlorine release.
1.2.3.2 Pool Fire
Fixed Pool: A leak or spill of sufficient size of flammable liquid from tanks will result in an accumulation of liquid in dyke area.
Spreading Pool: Leak or spill of flammable liquid from piping will result in spreading pool.
If immediately ignited, the resulting fire is known as fixed or spreading pool fire. Objects coming in contact with the flame, fixed or spreading pool will be severely damaged or destroyed and personnel exposed to flame will suffer extensive burn injuries. Objects and personnel outside the actual flame volume may also be affected or injured by radiant heat. The extent of damage or injury depends on the heat flux and duration of fire and exposure. If a large area of the body receives second and third degree burns, it can result in fatalities.
If the over ground tanks leak and the discharged petroleum products are contained within the dykes of the tank farms, these could result in a fixed pool fire, if they are not transferred into another empty tank or are ignited before any emergency action occurs. Hazards associated with a burning pool fire will be localised.
The extent of injury to people depends on the heat flux and duration of exposure. The extent of damage to property or environment depends on the size of the pool and the duration of fire.
Spreading Pool Fire
Thermal Radiation from Pool Fire
Thermal radiation hazards result from the ignition and subsequent burning of flammable liquid. The severity of the hazard is a function of the flame size, heat flux and exposure time. There are two concerns with thermal radiation, namely its impact on humans and the potential for the development of secondary fires.
Thermal effect data relates to bare skin. People wearing heavy clothes or protected by buildings would be much less likely to be injured. Also, in hot sunny climates, it may be necessary to add solar radiation intensity to that estimated by consequence models to determine total radiation exposure from an incident. In general, error in thermal effects is likely to be less than errors in estimating explosion and toxic effects.
The following damage criteria for 1% fatality distances has been used:
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Fires: heat radiation 12.7 kW/m2 during 20 sec
Following effect – distances have also been calculated:
10 kW/m2 - high damage risk 3 kW/m2 - low damage risk 1 kW/ m2 - no damage risk (safe)
Scenario 1: Largest Connection (Catastrophic Failure) Failure of Chlorine Toner Cylinder
Outcome: Toxic Vapour cloud of Chlorine
Scenario Description
Catastrophic failure (¼” connection) of the chlorine toner cylinder results in a release of chlorine gas. The released chlorine will flash vigorously. A toxic vapour cloud will be formed which will be dispersed in the prevailing wind direction.
TNO software EFFECT 2.1 has been used to calculate the release rate and atmospheric dispersion of chlorine. Release of pressurized liquefied Cl2 gas through hole was considered to calculate the release rate.
a. Release Rate (Release of Pressurized Liquefied Gas from Vessel)
Parameters Input: input parameters are given in Table 1.1.
Temperature 25oCPressure Equilibrium Vapour Pressure Volume of ton cylinder 0.72 m3
Leak size ¼” Outcome of Release RateAverage flow rate 0.69 kg/s Duration of release 600 s Total mass released 433.2 kg
Table 1.1: Input Parameters Release of Chlorine
b. Atmospheric Dispersion
For dispersion calculation of released chlorine, heavy gas dispersion (horizontal jet) model of TNO, EFFECT 2.1 software was used. Dispersion calculations were carried out for 1 PPM (time weighted average) and 10 PPM (IDLH-immediately dangerous for life & health) at various stability classes. Dispersion results are given in following paragraphs:
Chlorine Cloud Size and Location for 1-PPM (TWA) Concentration in Extremely Unstable Atmospheric Conditions
Scenario Description
Catastrophic failure (¼” connection) of the chlorine ton cylinder results in a release of Cl2.To calculate the release rate “vapour release from vessel through pipe” has been considered. The released Cl2 will flash vigorously or entrained. A toxic vapour cloud will be formed which will be dispersed in the prevailing wind direction. For atmospheric dispersion of chlorine “heavy gas dispersion-horizontal jet model” has been used.
Chlorine Leakage Source Information
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Cl2 in ton Cylinder : 930 kg
Leak Size : (1/4”) 0.00635 m
Initial Cl2 Temperature : 30oC
Cl2 release time : 600 s
Cl2 release rate at 600 s : 0.04 kg/s
Total Cl2 release in 600 s : 29.44 kg
Diameter of expended Jet : 0.0099 m
Atmospheric Conditions
Temperature : 30oC
Average Wind speed : 1 m/s
Stability Conditions : A
Model Output Information
Size of Cl2 cloud and its location with Cl2 concentration of 1 PPM (TWA) at cloud boundary.
Time t After Start
of Cl2Release
Maximum Width of Vapour Cloud
(m)
Maximum Length of
Vapour Cloud (m)
Minimum Distance to Threshold
Concentration (m)
Minimum Distance to Threshold
Concentration (m)
100 74 88 1 89 200 94 213 1 214 400 94 319 1 320 600 94 319 1 320 601 No 1 ppm concentration contour found
Note: 1. All distance are from the location of release source of chlorine. 2. Threshold concentration of Cl2 is 1 ppm at cloud boundary
Chlorine Cloud Size and Location for 1-PPM (TWA) Concentration in Neutral Atmospheric Conditions
Scenario Description
Catastrophic failure (¼” connection) of the chlorine ton cylinder results in a release of Cl2.To calculate the release rate “vapour release from vessel through pipe” has been considered. The released Cl2 will flash vigorously or entrained. A toxic vapour cloud will be formed which will be dispersed in the prevailing wind direction. For atmospheric dispersion of chlorine “heavy gas dispersion-horizontal jet model” has been used.
Chlorine Leakage Source Information
Cl2 in ton Cylinder : 930 kg
Leak Size : (1/4”) 0.00635 m
Initial Cl2 Temperature : 30 oC
Cl2 release time : 600 s
Cl2 release rate at 600 s : 0.04 kg/s
Total Cl2 release in 600 s : 29.44 kg
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Diameter of expended Jet : 0.0099 m
Atmospheric Conditions
Temperature : 30oC
Average Wind speed : 1 m/s
Stability Conditions : D
Model Output Information
Size of Cl2 cloud and its location with Cl2 concentration of 1 PPM (TWA) at cloud boundary.
Time t After Start of Cl2
Release
Maximum Width of
Vapour Cloud (m)
Maximum Length of
Vapour Cloud (m)
Minimum Distance to Threshold
Concentration (m)
Minimum Distance to Threshold
Concentration (m)
600 125 427 1 428 800 125 859 1 860
1000 138 898 215 1113 1500 81 461 1119 1580 1589 11 63 1449 1512 1590 No 1 ppm concentration contour found
Note: 1. All distance are from the location of release source of chlorine. 2. Threshold concentration of Cl2 is 1 ppm at cloud boundary
Chlorine Cloud Size and Location for 1 - PPM (TWA) Concentration in Extremely Stable Atmospheric Conditions
Scenario Description
Catastrophic failure (¼” connection) of the chlorine ton cylinder results in a release of Cl2.To calculate the release rate “vapour release from vessel through pipe” has been considered. The released Cl2 will flash vigorously or entrained. A toxic vapour cloud will be formed which will be dispersed in the prevailing wind direction. For atmospheric dispersion of chlorine “heavy gas dispersion-horizontal jet model” has been used.
Chlorine Leakage Source Information
Cl2 in ton Cylinder : 930 kg
Leak Size : (1/4”) 0.00635 m
Initial Cl2 Temperature : 20 oC
Cl2 release time : 600 s
Cl2 release rate at 600 s : 0.03 kg/s
Total Cl2 release in 600 s : 23.23 kg
Diameter of expended Jet : 0.0074 m
Atmospheric Conditions
Temperature : 20oC
Average Wind speed : 1 m/s
Stability Conditions : F
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Model Output Information
Size of Cl2 cloud and its location with Cl2 concentration of 1 PPM (TWA) at cloud boundary.
Time t After Start of Cl2
Release
Maximum Width of
Vapour Cloud (m)
Maximum Length of
Vapour Cloud (m)
Minimum Distance to Threshold
Concentration (m)
Minimum Distance to Threshold
Concentration (m) 600 147 178 1 179 800 146 435 1 436
1000 157 630 1 631 1500 169 1035 113 1148 2000 167 1247 477 1669 2500 149 1261 894 2155 3000 105 965 1551 2516 3318 15 149 2301 2451 3319 No 1 ppm concentration contour found
Note: 1. All distance are from the location of release source of chlorine. 2. Threshold concentration of Cl2 is 1 ppm at cloud boundary
Chlorine Cloud Size and Location for 10-PPM (IDLH) Concentration in Extremely Unstable Atmospheric Conditions
Scenario Description
Catastrophic failure (¼” connection) of the chlorine ton cylinder results in a release of Cl2.To calculate the release rate “vapour release from vessel through pipe” has been considered. The released Cl2 will flash vigorously or entrained. A toxic vapour cloud will be formed which will be dispersed in the prevailing wind direction. For atmospheric dispersion of chlorine “heavy gas dispersion-horizontal jet model” has been used.
Chlorine Leakage Source Information
Cl2 in ton Cylinder : 930 kg
Leak Size : (1/4”) 0.00635 m
Initial Cl2 Temperature : 30 oC
Cl2 release time : 600 s
Cl2 release rate at 600 s : 0.04 kg/s
Total Cl2 release in 600 s : 29.44 kg
Diameter of expended Jet : 0.0099 m
Atmospheric Conditions
Temperature : 30oC
Average Wind speed : 1 m/s
Stability Conditions : A
Model Output Information
Size of Cl2 cloud and its location with Cl2 concentration of 10 PPM (IDLH) at cloud boundary.
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Time t After Start of Cl2
Release
Maximum Width of Vapour Cloud
(m)
Maximum Length of
Vapour Cloud (m)
Minimum Distance to Threshold
Concentration (m)
Minimum Distance to Threshold
Concentration (m)
100 22 62 1 63 200 22 62 1 63 400 22 62 1 63 600 22 62 1 63 601 No 10 ppm concentration contour found
Note: 1. All distances are from the location of release source of chlorine. 2. Threshold concentration of Cl2 is 10 ppm at cloud boundary
Chlorine Cloud Size and Location for 10-PPM (IDLH) Concentration in Neutral Atmospheric Conditions
Scenario Description
Catastrophic failure (¼” connection) of the chlorine ton cylinder results in a release of Cl2.To calculate the release rate “vapour release from vessel through pipe” has been considered. The released Cl2 will flash vigorously or entrained. A toxic vapour cloud will be formed which will be dispersed in the prevailing wind direction. For atmospheric dispersion of chlorine “heavy gas dispersion-horizontal jet model” has been used.
Chlorine Leakage Sources Information
Cl2 in ton Cylinder : 930 kg
Leak Size : (1/4”) 0.00635 m
Initial Cl2 Temperature : 30 oC
Cl2 release time : 600 s
Cl2 release rate at 600 s : 0.04 kg/s
Total Cl2 release in 600 s : 29.44 kg
Diameter of expended Jet : 0.0099 m
Atmospheric Conditions
Temperature : 30oC
Average Wind speed : 1 m/s
Stability Conditions : D
Model Output Information
Size of Cl2 cloud and its location with Cl2 concentration of 10 PPM (IDLH) at cloud boundary.
Time t After Start of Cl2
Release
Maximum Width of Vapour Cloud
(m)
Maximum Length of
Vapour Cloud (m)
Minimum Distance to Threshold
Concentration (m)
Minimum Distance to Threshold
Concentration (m)
100 35 42 1 43 400 52 338 1 339
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Time t After Start of Cl2
Release
Maximum Width of Vapour Cloud
(m)
Maximum Length of
Vapour Cloud (m)
Minimum Distance to Threshold
Concentration (m)
Minimum Distance to Threshold
Concentration (m)
600 52 393 1 394 700 41 452 80 532 780 6 70 358 428 781 No 10 ppm concentration contour found
Note: 1. All distance are from the location of release source of chlorine. 2. Threshold concentration of Cl2 is 10 ppm at cloud boundary
Chlorine Cloud Size and Location for 10-PPM (IDLH) Concentration in Extremely Stable Atmospheric Conditions
Scenario Description
Catastrophic failure (¼” connection) of the chlorine ton cylinder results in a release of Cl2.To calculate the release rate “vapour release from vessel through pipe” has been considered. The released Cl2 will flash vigorously or entrained. A toxic vapour cloud will be formed which will be dispersed in the prevailing wind direction. For atmospheric dispersion of chlorine “heavy gas dispersion-horizontal jet model” has been used.
Chlorine Leakage Source Information
Cl2 in ton Cylinder : 930 kg
Leak Size : (1/4”) 0.00635 m
Initial Cl2 Temperature : 20 oC
Cl2 release time : 600 s
Cl2 release rate at 600 s : 0.03 kg/s
Total Cl2 release in 600 s : 23.23 kg
Diameter of expended Jet : 0.0074 m
Atmospheric Conditions
Temperature : 20oC
Average Wind speed : 1 m/s
Stability Conditions : F
Model Output Information
Size of Cl2 cloud and its location with Cl2 concentration of 30 PPM (IDLH) at cloud boundary.
Time t After Start of Cl2
Release
Maximum Width of
Vapour Cloud (m)
Maximum Length of
Vapour Cloud (m)
Minimum Distance to Threshold
Concentration (m)
Minimum Distance to Threshold
Concentration (m)
600 114 172 1 173 800 114 382 1 383
1000 110 456 66 522
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Time t After Start of Cl2
Release
Maximum Width of
Vapour Cloud (m)
Maximum Length of
Vapour Cloud (m)
Minimum Distance to Threshold
Concentration (m)
Minimum Distance to Threshold
Concentration (m)
1200 95 460 195 655 1500 52 299 497 796 1593 5 32 703 735 1594 No 10 ppm concentration contour found
Note: 1. All distance are from the location of release source of chlorine. 2.Threshold concentration of Cl2 is 10 ppm at cloud boundary
c. Rupture followed by ignition in LDO (Pool fire)
In this scenario, rupture of nozzle (dia 2“) with 5 kl tank has been considered. It is assumed that the pool will spread within the bund area and filled with released liquid. If ignition source is available, only pool fire is possible. The consequence calculations in this scenario include:
Effective Pool Area, Combustion Rate on immediate ignition of pool,
Heat radiation distance to 15 kW/m2, 12.7 kW/m2, 10 kW/m2, 3 kW/m2 and 1 kW/m2.
The consequence results are tabulated below.
Parameters LDO Tank Release Rate (k/s) 4.63 Pool Diameter (m) 2.8 Combustion Rate (kg/s) 0.66 Heat Radiation DistanceFor (12.7 kW/m2) 3.9 For 10 kW/m2) 4.8 For (3 kW/m2) 11.0 For safe distance (1 kW/m2) 17.9
On release LDO from over ground tanks, fixed pool will be formed in bund area. The safe distance from tanks, defined as the distance to 1 kW/m2 heat flux level, extends from 17.9 m.
1.2.4 OCCUPATIONAL RISK INVOLVED IN COAL BASED POWER PLANT
Coal based thermal power plant deals with various hazards, which have potential to pose occupational risk. These hazards can pose threat to occupational health risk of personnel engaged in the hazardous operations. Some major occupational risk involved in operation of power plants with necessary safety and preventive measures are described below:
1.2.4.1 Coal Dust Emissions from Coal Handling System
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Coal handling systems are major sources of coal dust emissions and can create occupational risk to personnel engaged in coal handling activities. Inhalation of coal dust by personnel engaged coal handling could pose occupational health problems.
Pneumoconiosis results from the inhalation of coal dust from coal handling plant. The two forms of coal pneumoconiosis and complicated pneumoconiosis of progressive massive fibrous (PMF) are common. In simple pneumoconiosis, nodules are produced in the upper part of the lungs, particularly around bronchioles. Dyspnoea and chronic bronchitis are symptoms associated with forms of the disease although they may not occur until the nodules are well advances. In PMF, which may occur together with simpler pneumoconiosis, the nodules are larger and more fibrotic.
1.2.4.2 Occupational Risk due to Chlorine Gas from Chlorination Process
Chlorine is toxic gas and 2.5 heavier then air. It does not immediately disperse in atmosphere. As per NIOSH, 10 ppm concentration is immediately dangerous to life and health (IDLH). Chlorine can cause occupational risk in the form of burning of eyes, nose, mouth; lacrimation (discharge of tears), rhinorrhea (discharge of thin mucus); cough, choking, substernal (occurring beneath the sternum) pain; nausea, vomiting; headache, dizziness; syncope; pulmonary edema; pneumonitis and hypoxemia (reduced oxygen in the blood).
1.2.4.3 Occupational Risk due to Hydrogen Gas used in Generator Cooling
Hydrogen is used in cooling of generators and considered as explosion hazard. Hydrogen gas can enter in human body by skin and inhalation. If atmosphere does not contain enough Oxygen, inhalation of hydrogen can cause dizziness, unconsciousness or even death. Contact of hydrogen with eyes or skin cause freezing similar to burn.
1.2.4.4 Occupational Risk Due to High Noise Generation
At coal based thermal power plant, many operations such as generators, turbine, blowers, ID fans, etc generate high noise levels, which can pose occupational risk to personnel working in high noise areas. High noise affects human beings in a number of ways disturbing works, rest, sleep and communication. It can damage hearing and can cause physiological and psychological conditions.
Interference with the Communication
In high noise area, speech interference is a major source of annoyance. The annoyance may range from simple interference with speech in the home to communication interference in the work place causing inefficiency and potential danger from accidents, e.g. inability to hear a fire alarm because of noise.
Disturbance of Sleep
Noise may cause personnel to experience difficulty in falling asleep and may awaken people already asleep or affect their sleep patterns. Studies have shown that disturbance of sleep becomes apparent as ambient noise levels exceed about 35 dB(A) equivalent continuous sound level (leq).
Stress
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Constriction of the blood vessels can be produced by noise and high level disturbances including hypertension have been found in noise exposed workers. Personnel exposed to noisy environments have higher prevalence to peptic ulcers and other stress induced conditions.
Damage to Hearing
The main physiological effect of high noise is that the inner ear becomes damaged either acutely, due to sounds of very high intensity such as explosions or gradually as result of long term exposure to high noise levels. A person exposed to a noise level of over 80 dB (A) for up to eight hours will experience a hearing loss for several hours. Within few hours, the hearing will be back to normal. People exposed to high noise levels in excess of 100 dB(A) for an eight hour period can show a temporary threshold shift of up to 40 dB(A).
1.2.5 FREQUENCY OF OCCURRENCE
Frequency of occurrence of incident is important in risk analysis. Failure frequencies may be classified as generic and those synthesised for a particular situation, especially, more complex systems, by drawing Fault Trees which make use of generic failure frequencies of components of a system or its subsystems. Generic failure frequencies are preferred, wherever these are available, as these reduce variances arising out of analyst judgement in the failure frequency estimation.
The classical method of calculating the failure rate of an isolatable section of equipment or a chosen set of equipment items is to count the different items and associated line lengths. The failure rate for a certain item is then broken down into the correct proportions for required release rate bands. The overall frequency for a particular set of equipment is then:
Ft = F N Where: Ft = total failure frequency/per year/per unit F = individual item frequency/per year N = number of items or length of piping unit
Scenarios selected for Risk Summation have been discussed and listed above.
Safe operating procedures, proper maintenance and safety precaution reduced the frequency of occurrence of such incident.
Frequency of leakage of chlorine from ton cylinder 2.0 x 10 –5 per year. Safety precaution taken in storage and handling of chlorine ton cylinders will further reduce the probability of occurrence of leakage of chlorine gas.
The data sources referred for failure frequency is E & P Forum (Oil Industry International Exploration & Production Forum) Frequency database from TNO and Failure frequency data from the Rijmond Report (COVO Study). Frequency of rupture in storage tank is 1 x 10 -6 /yr. Probabilities of ignition are 0.065, 0.065 and 0.87 for immediate ignition, delayed ignition and no ignition, respectively.
1.2.6 RISK ESTIMATION
Risk is defined as the unwanted consequence of a particular activity in relation to the likelihood that this may occur. Risk thus comprises of two variables: magnitude of consequences & the probability of occurrence.
A risk analysis provides a measure of the risks resulting from a particular facility or activity. It thus finds application as a decision making tool in situations where judgment has to be
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made about the tolerability of the risk posed by an existing/proposed activity. However, risk analysis produces only numbers, which themselves provide no inherent use. It is the assessment of those numbers that allows conclusions to be drawn and recommendations to be developed. The normal approach adopted is to relate the risk measures obtained to risk acceptance criteria.
Risk criteria, if they are to be workable, recognize the following:
There is a level of risk that is so high that it is considered unacceptable or intolerable regardless of the benefits derived from an activity.
There is also a level of risk that is low enough as to be considered negligible. Levels of risk in between are to be considered tolerable subject to their being reduced As Low As is Reasonably Practicable (ALARP). (The meaning of ALARP is explained in the following sub-section.)
The above is the formulation of the, now well-established, three tier structure of risk criteria and risk control.
The risk criteria simply attempt to establish whether is risk is “tolerable”. Below is a list of words generally in use and their meaning.
ACCEPTABLE RISKS: Since risks in general are unwelcome no risk should be called “acceptable”. It might be better to say that the activity may be acceptable generally, but the risks can only ever be tolerable.
TOLERABLE RISKS: are risks the exposed people are expected to bear without undue concern. A subtle difference is made out here between Acceptable Risks and Tolerable Risks though these terms are sometimes used interchangeably.
NEGLIGIBLE RISKS: are risks so small that there is no cause for concern and there is no reason to reduce them.
The ALARP Principle
The ALARP (As Low As is Reasonably Practicable) principle seeks to answer the question “What is an acceptable risk?” The definition may be found in the basis for judgment used in British law that one should be as safe as is reasonably practicable. Reasonably practicable is defined as implying “that a computation must be made in which the quantum of risk is placed on scale and the sacrifice involved in the measures necessary for averting the risk (whether in money, time, or trouble) is placed on the other, and that, if it be shown that there is a gross disproportion between them – risk being insignificant in relation to the sacrifice – the defendants discharge the onus upon them”.
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Intolerable level
The ALARP region
Negligible risk
Tolerable if cost of reduction would exceed the improvement gained
Broadly acceptable region
(No need for detailed working to demnstarate ALARP)
(Risk is undertaken only if a benefit is desired)
Tolerable only if risk reduction in impracticable or if its cost is grossly disproportionate to the improvement gained
Intolerable Region
Risk cannot be justified on any grounds
Figure 1.2: ALARP Criteria In this chapter results of Risk Summation are presented as following:
Risk of fatality in terms of Individual Risk levels
Risk to environment in terms of cumulative frequency versus released quantity and annual release rate.
Individual Risk
Individual risk (IR) is the probability of death occurring as a result of loss of containment at an installation or a transport route expressed as a function of the location from such activity. Such a risk actually exists only when a person is permanently at that spot.
For a pool fire, the individual risk from a given scenarios at a given location can be completed as shown below:
Individual Risk = Accident probability x release probability x ignition probability x response faction
Response fraction is defined as the fraction of people at that location who are likely to suffer fatality. The individual risk from all scenarios considered at the same given relation need to be sunned up to arrive at the over all individual risk.
The individual risk at a certain location inside a plant is result of the accumulation of risks connected with all possible scenarios. The calculation of individual risk assumes that the contributors of all incident out come cases are additive. Thus, the total individual risk at a point is equal to the sum of the individual risks, at that point, of all incident outcome cases associated with the plant.
IR x, y = I =1 n IR x, y, I IR x, y = the total individual risk of fatality at geographical location x, y (changes of fatality) IR x, y, i = the total individual risk of fatality at geographical location x, y from incident outcome case I (changes of fatality per year)
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n = the total no. of incident outcome cases considered in the analysis. Now the individual risk of fatality at particular geographical location is calculated by the following equation,
IR x, y, I = Pa. Ps. Pw.fr Where
Pa = accident probability (per year) Ps = Weather stability probability Pw = Wind direction probability Fr = response fraction
The individual risk may also present by using the results of these equations at very geographical locations surrounding the facility in the form of ISO Risk Contour.
TNO software model RISKCURVES has been used for computation of individual risk and plotting of FN curve for Societal Risk. The RISKCURVES program package is a very powerful tool to combine the probabilities and consequences of all the release scenarios into and then add them.
All of the information required for individual risk calculation is also required for societal risk estimation. Additionally information on the population surrounding the terminal is also required.
The results of Risk Analysis are often reproduced as Individual Risk. Individual Risk is the probability of death occurring as a result of accidents at a fixed installation or a transport route expressed as a function of the distance from such an activity.
There are as yet no specified risk acceptance criteria in our country for Individual Risk levels. A review of risk acceptance criteria in use in other countries indicates the following:
For fixed installations Official Individual Risk Criteria have been developed by various countries and the review indicates that Individual Risk of fatality to the members of the public outside the installation boundaries may be adopted as higher 10-5 per year (in populated areas) for intolerable risk and lower than 10-6 per year for negligible risk. The region in between is the so-called ALARP region where risk is acceptable subject to its being As Low As Reasonably Practicable (the ALARP principle).
The individual risks from an activity are the result of the cumulative of risks connected with all possible scenarios.
The individual risk level of 10-6 /yr to public from the proposed coal based power plant will be tolerable limits.
In case of transfer pipelines jetty to IOCL PLT, the Individual Risk Contours run parallel and close to the pipelines. Individual Risk of 10-6 per year from release scenarios will approximately 100 m from the pipeline and it runs away from populated area. Therefore, the individual risk from transfer pipelines system is tolerable as it lies within ALARP region.
Societal Risk
For societal risk, the risk can be calculated per segment (where all of the basic variables such as population density remain constant and then summed. The number of people affected by each incident outcome case in given segment is given by:
Ni = Cai x PD x PDi
Where
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Ni = Number of fatalities resulting from incident outcome case.
Cai = Consequence area associated with incident out come case
PD = Population density for segment PFi = Probability of fatality for incident outcome case
The individual risk values for each location when combined with population at that location gives the group risk at that location i.e. the probability of certain number of victims per year. For an identifiable community, total group risk can be obtained by adding the values for all the locations comprising that community. The group risk can be obtained by adding the values for all the locations comprising that community. The group risk is represented as F-N curve, which plots the cumulative frequency per year (F) of a given number of fatalities (N) or less.
1.2.6.1 Findings of Risk Summation
The individual risk from proposed coal based captive power plant is tolerable as it lies within ALARP region as it is below the criterion of individual risk not to exceed 10-6 per year in populated areas.
Societal Risk Contours
The off site societal risk level (out side the plant boundary) lies in the broadly acceptable region and can be considered as negligible.
1.2.7 RISK MITIGATION MEASURES
1.2.7.1 Handling of Chlorine
Safety provisions to be made in storage of Chlorine toners, to prevent/control the minor leakage are as follows:
Provide paper type or ammonia torch chlorine gas detectors
Leak detectors should be provided in tonner storage area. Emergency repair kits for rectifying leaks in different part of tank.
Chlorine absorption system to neutralize chlorine, as the valve mounted Cl2 sensors should be provided to activate the blowers. The blowers will blow out the chlorine to absorber where 20 % w/v caustic soda solution (NaOH) will convert the chlorine to NaCl.
Canister type gas masks should be available.
Provide Self-Contained Breathing Apparatus (SCBA) should be provided and personnel should be trained about the use and maintenance of SCBAs
Siren should be ready to warn people in case emergency.
Eye washers should be provided near the storage of chlorine and strategic location to wash eyes in case of irritation due to leakage of chlorine.
Phensedyl syrup and throat lozenges for oral application should be provided. On-site and off-site emergency management plans should be developed to take the action in the event of leakage of chlorine.
Safe operating procedures should be formulated specific to chlorine gas handling and distributed to concerned plant personnel.
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An edited version of on-site management plan may be published in the form of pocket booklet and circulated to the all personnel of the plant.
The plant should explore the possibilities for mutual aid agreement with near by industry (if any).
1.2.7.2 Control Measures to reduce the Occupational Risk Due to High Noise
Following control measures/ safe guards are suggested, to reduce the occupational risk from high noise generation:
By selecting equipment, machines and technology generating low noise levels.
Use of ear muffs and plugs by the personnel engaged in high noise areas Providing acoustic enclosures to the high noise generating machine and equipment wherever is possible.
Wherever acoustic enclosures are not possible, soundproof cabin should be provided for personnel engaged in high noise area.
Provide silencers on engines wherever is possible. Provide barrier (wall, curtain, etc.) around the noise generation source wherever is possible.
1.2.7.3 Major Safeguards for Hydrogen Generation and Handling System
Major safeguards for hydrogen handling system should include safety arrangement as described below:
Hydrogen gas is normally filled in 45 litres capacity cylinders at a pressure of 150 kg/cm2 by using compressors. The compressors should have safety valves at each stage of compression. If pressure rises the gas will be released to the atmosphere through flame arrestor.
Flameproof light fittings and power sockets should be provided to avoid arcing.
No smoking caution board should be exhibited in all areas on hydrogen area. No welding or gas cutting work should be permitted to a distance of 50 feet on all sides of the plant.
1.2.7.4 Safe Guard to Control Dust Emissions
Major safeguards, which shall be followed to control, the coal dust emissions in coal handling system are as follows:
Installation of appropriate dust collection system to capture the coal dust particles from coal handling system.
Scrubbing of coal dust emissions before discharging into the atmosphere.
Provision relevant Personal Protective Equipment (PPE) like face shield to the personnel engaged in coal handling activities.
1.3 DISASTER MANAGEMENT PLAN
The objective of onsite and offsite Disaster Management Plan (DMP), for the proposed cement plant, coal based captive power plant and mines is:
To ensure safety of people, protect the environment and safeguard commercial considerations.
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Immediate response to emergency scene with effective communication network and organized procedures.
Obtain early warning of emergency conditions so as to prevent damage to personnel, assets and environment.
Safeguard personnel to prevent injuries or loss of life by: o Protecting personnel from hazard. o Evacuating personnel from an installation when necessary and minimize the
impact of the event on the installation and the environment by: Minimizing the hazard as much as possible Minimizing the potential for escalation Containing any release
1.3.1 DEFINITIONS
Disaster
Disaster is a sudden calamitous event, bringing great damage, loss or destruction.
Disaster Management
It is the most comprehensive plan which states who does what, when and how before, during and after a disaster.
Incident
Incident may be defined as an emergency situation of any critical deviation in the process control or otherwise that may lead to a major accident /potential emergency and disaster.
Emergency
Emergency may be defined as any incident of process deviation that if uncontrolled may lead to a major accident /disaster with potential short term and/or long term risk damage consequence to life and property in and /or around the factory and where the situation has arisen that the control of which requires external help and controls.
Hazard
Hazard may be defined as “the potential of an accident ”. Hazard exists in man and the system of materials and machines.
Accident
An accident may be defined as “ an undesirable and unplanned event with or without or major damage consequence of life and /or property”.
Risk
Risk of an accident may be defined as the chance or probability or likelihood of an accident being caused in a given man-material –machine system.
1.3.2 MAIN COMPONENT OF THE ON – SITE DISASTER MANAGEMENT PLAN
Disaster Management Plan does not cover the natural disasters and sabotage activities. However, duties and responsibilities given in this DMP may be followed to deal with
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emergencies, arising out of natural disasters and subrogate activities. The main components of Disaster Management Plan are as follows:
1.3.2.1 Emergency Response Organization
Following officers of the plant will be responsible for coordination, in case of emergency situation in any section of the cement plant and CPP:
Chairman - Safety : Site Controller Head - Operation : Incident Controller Employee who gives the first information about the incident/ accident
: Primary Controller
Head - Personnel : Liaison Officer In - Charge of Security Personnel : Emergency/Communication Officer Medical Officer
1.3.2.2 Responsibility of Key Personnel
Site Controller
Chairman (Safety) or his deputy will assume overall responsibility. As soon as he is informed of the emergency, he shall proceed to the Emergency Control Center (ECC) and his duties shall be:
To assess the magnitude of the incident and decide if employees need to be evacuated from assembly points.
To maintain continuous review of possible development and to assess in consultation with Incident Controller as to whether the shutting down of plant or part of plant and evacuation of persons is required.
To exercise direct operational control over the areas other than affected.
To give necessary instructions to Liaison Officer and Emergency Officer regarding the help to be obtained from outside agencies like fire brigade, police and medical. To advice Liaison Officer to pass necessary information about the incident to news media and ensure that the evidences are preserved for inquiries to be conducted by statutory authorities.
To liaison with senior officials of Police, Fire, Medical, MSPCB and Factory Inspectorate
To issue authorized statement to news media.
Incident Controller
The HOD of affected department shall have overall responsibility for controlling the incident and directing the personnel. Section-in-charge of the affected department shall assume the responsibility of Incident Controller in the absence of HOD of the affected department. His duties during emergencies shall be:
Immediately rush to the ECC and report to the Site Controller and take overall charge and rush to scene.
To act as Site Controller till the latter arrives.
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To direct all operations within the affected area.
To inform Emergency Officer about the emergency, Control Center and assembly point. To direct all operators within the affected areas with priorities for safety of personnel, to minimize damage to the plant and environment and to minimize loss of material.
To ensure safety of personnel and minimize damage to the plant/properties etc.
To inform In-charge (Electrical) to switch off the supply and ask for the alternate supply if necessary.
To ensure that the workers of the affected areas are evacuated to the appropriate assembly point.
To provide advice and information to fire squad, security officer and local fire services when they arrive
To ensure that all non-essential persons are sent to the assembly point.
To report all significant developments to the Liaison Officer. To arrange for preservation of evidence to facilitate any enquiry regarding the causes etc.
Primary Controller
The Primary Controller is the employee who gives the first information about the incident/ accident. He will be responsible:
To inform the Security Office (main gate) /Sr. Engineers/ Shift In Charges / HOD of section of the Department/Section from the nearest available telephone about the location and the nature of incident.
To assist fire brigade in their operation and assist in clearing any obstruction coming in way of fire extinguishers.
To carry out all instructions from Incident Controller.
Emergency /Communication Officer
Section-in-charge (Security & Safety) shall act as Emergency/Communication Officer. He shall work from Emergency Control Center (ECC) and maintain communication between relevant personnel. On receipt of the information he will immediately rush up to the scene and his responsibility will be:
To apprise the Site Controller of the situation, based on the information received and to suggest the evacuation of personnel from assembly points, if needed.
To arrange for suitable persons to act as runners/messengers in case of failure to communication system.
To carry out any other works as assigned by Site Controller/Incident Controller.
Assuming full responsibility in organizing fire fighting and security measures. Providing latest information to the Incident Controller.
Deputing one Sr. Security for assisting the Site Controller.
Co-ordinate with the external fire service as and when they arrive and direct them as required.
To give instructions to security guards to cordon off area as required by Incident Controller.
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To handle unauthorized persons inside the affected area and inside the plant during emergency.
Liaison Officer
The Head (Personnel) will act as a Liaison Officer. On hearing the fire siren/alarm, he will rush to the ECC and will act as per the instruction of the Site Controller. His responsibilities shall be:
To arrange additional help if required and inform relatives.
To control traffic inside factory and arrange alternate transport if need arises.
To arrange for relief of personnel and organize refreshment /catering facility, in case the duration of emergency is prolonged.
To inform relatives of affected employees at the earliest.
To issue authorized statements to news media and ensure that evidence is preserved for enquires to be conducted.
Medical Officer
On hearing the emergency siren/alarm or phone message, the Medical Officer with first aid team will report to the Incident Controller. His responsibility will be:
To ensure that ambulance will be made available at the ECC.
If the ambulance leaves the ECC, it should be informed to Incident Controller. If the ambulance leaves with patient, the name and other particulars, hospital, destination etc. should be informed to the Incident Controller. To inform the Chief at the hospital about the casualty reaching hospital for treatment.
To keep necessary first aid medicines and artificial respiration equipment ready.
To inform doctors at other places to be ready, for attending serious injury and burns cases, if required.
Shift-in-Charge (Security)
Shift-in-Charge shall be responsible:
To arrange the necessary help as requested by Incident Controller/ Primary Controller.
To inform Section-in-Charge (Security).
To switch on the Emergency Siren, if instructed by Incident Controller/Primary Controller.
To rush ambulance to the accident site with fire brigade along with available trained security persons.
Departmental Heads
The Departmental Heads of the nearby areas of the incident will report to the Incident Controller and provide assistance as required.
1.3.2.3 Emergency Procedures
Based on the QRA study, procedures are defined as per guidelines to be followed in case of any emergency as given below:
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1.3.2.4 In Case of Fire/Explosion
Noticing Person
Immediately on noticing the incident, the noticing person should:
Identify himself and location of incident.
Inform shift-in-charge about the nature of incident.
Inform the Security & Time office about the incident.
Hold on until the message is repeated to ensure proper communication.
Switch off the electrical main in the nearby area.
Stop all the machinery that is running in the storage area, if possible. Inject fire extinguishers to extinguish the fire.
Be on or near the incident site till the fire service personnel arrive to guide them
In case of fire in electrical equipment or installations, inform electrical Shift-in-charge about the nature and place of fire.
Shift-in-Charge/ Operator
On receipt of the message / noticing the incident the Operator should:
Switch on the emergency siren for few minutes (If not already switched on by the noticing person)
Inform over phone to fire/security and Central Control Room (CCR)
Give the location and brief description of fire
Close down all out going line of HSD/LSHS/Sludge oil or Coal. Keep vigil/ watch over the fire
Try to extinguish or prevent it from the further spreading with available resources, in case of fire.
Move out the LSHS/HSD/Sludge oil tankers/Coal Lorry/Wagon placed for unloading by informing Stores. Do not allow unauthorized persons at scene.
Security Personnel
On receipt of message over phone about the incident the security personnel should:
Note down the location/ details of incident.
Inform Senior Personnel Officer/ Duty Officer.
Stop the visitors/ contractors/ customers to enter inside the plant. Be at telephone for receiving any message.
Organize the workers to assemble at the safe assembly point.
Security Officer
On hearing the emergency siren/alarm or on receiving the message over phone, he will:
Proceed to the emergency assembly point along with sufficient security personnel. Act as per the instruction of Site Controller.
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Cordon off the area.
Not allow the unauthorized person in to the oil storage area/Coal yard.
Prevent crowding of the people around the scene of incident. Inform:
o Duty Officer o Head (Production) o Head (Maintenance) o Head (Personnel)
Keep ambulance ready.
Inform nearby fire service as required by Site Controller or Emergency Officer.
Head (Civil)
On hearing the emergency siren/alarm/message over phone he should rush to the emergency assembly point and report to the Incident Controller. He should
Ensure continuous water supply for fire fighting.
Depute responsible person for continuous water flow for fire fighting.
Rush to the Control Center for further activity if any as per the instruction of the Site Controller.
Maintain continuous water supply for fire fighting till further instruction from Emergency Officer.
In-charge – Transport
On hearing the emergency siren/alarm or on receipt of the message, the Transport In-charge should
Contact the Emergency Control Center (ECC). Depute a representative to ECC.
Plan for deployment of vehicles whenever / wherever necessary.
Head (Material/Store)
On hearing the emergency siren/ alarm/ message over phone, he will rush to the emergency assembly point and report to the Incident Controller. He will
Move away the tanker / wagon / lorry, if any. Stop the incoming vehicles.
Give the quantity of the oil stored, coal stored etc.
Head (Electrical)
On hearing the emergency siren/alarm/message over phone, he should rush to the emergency assembly point and report to the Incident Controller. He will:
Check the electrical connections in the affected area.
Ensure the availability of the electrical supply if the lines are affected.
Arrange for alternate supply.
Tele-Communication In Charge
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On hearing the emergency siren/alarm/message he will
Rush to the Emergency Control Center and report.
Ensure proper working condition of the entire communication systems such as PA system, local and P&T phone and wireless sets.
1.3.3.5 In Case of Accident
During the time of any accident or emergency condition, the person present has to inform the Shift-in-Charge immediately which shall be followed by:
Shift-in-Charge will inform the responsible Department Head, Time Office and Security Personnel. According to the seriousness of the accident the Department Head will arrange duty doctors, ambulance and inform the Personnel department.
The department head will immediately report to the spot and collect the cause of accident.
The department head will make a final report. The cause of accident shall be analyzed and rehabilitation measures shall be implemented.
The workmen shall be advised to work with more safety measures.
1.3.3.6 Emergency Shutdown Procedure
If necessary, full or partial shut down of the plant should be followed under the judgment of the Incident Controller or the Site Controller. On hearing the emergency siren/message over phone, the following procedure will be followed to shutdown the plant.
The Operation/Maintenance department will stop incoming and outgoing HSD/ LSHS/ Gas/ Sludge oil supply or coal supply.
If the unloading of HSD/ LSHS/ Gas/ Coal is in progress that will be stopped and vehicle/ wagon, will be sent out of the area. Head (Operations) will stop all the production/maintenance activity if necessary.
Loading of cement will be stopped and the vehicles will be sent out.
The individuals designated for the emergency preparedness will carry out the work as assigned to him as per the checklist.
1.3.3.7 Declaring the Major Emergency
The declaration of major emergency puts all personnel/agencies on action and the running system may be disturbed which may be very costly at times or the consequences may be serious, therefore such declaration should not be decided on whims or immature judgment or without proper thought. Because of scale of activity, which will be activated after the declaration of major emergency, it is advisable to restrict the authority to declare it. However, it is not necessary, to limit this authority to the Incident Controller and his appointed deputy.
It may be advisable, therefore, to invest the authority to declare a major emergency in a number of nominated people. They should be selected on the basis of their knowledge and experience. Nominated person/persons will advise the Incident Controller or the Site Controller to declare the emergency.
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The joint decision to declare major emergency may be taken but it should be as early as possible and without wasting any time.
1.3.3.8 Evacuation Procedure
Personnel not required will usually be evacuated from the incident site and also from adjacent areas. Evacuation should be to predetermined assembly points in a safe part of the plant. Assembly points need to be clearly marked. The plan should designate someone to record all personnel arriving at assembly point so that the information can be passed to the ECC.
Personnel required to be transported for the purpose of medical care or for better shelter should be transported with care and facilities.
On hearing the emergency siren / alarm, the employees of the connected area, where they are working should stop their work and rush to the safe assembly point.
Head (Operation) is responsible for stoppage of production and evacuation of employees if necessary. He will also, ensure the stoppage of production and the evacuation of employees from the area with the help of all production heads.
1.3.3.9 Communication System
Any person noticing an emergency should be able to raise or cause to be raised the first Floor Level Emergency Alarm (FLEA). All employees must be trained to operate such emergency alarms. Siren shall be provided to indicate the emergency. This siren is different from regular sirens in use with hauling arrangement and is audible throughout the plant.
1.3.3.10 Telephone Message
After hearing the emergency alarm and emergency declaration or even while first receiving the emergency message on phone, a telephone operator (or Communication Officer) has to play an important role. He should be precise, sharp, attentive and quick in receiving and noting the message and then for immediate subsequent action of further communication.
1.3.3.11 Communication of Emergency
There should be an effective system to communicate emergency (a) inside the plant i.e. to the workers including key personnel and essential workers, on duty and inside during normal working hours (b) to the key personnel and essential workers not on duty and outside during normal working hours. (c) to the outside emergency services and to the government authorities (d) to the neighboring firms and the general public in the vicinity.
Communication to the Outside Emergency Services and Authorities
Once the declaration is made, it is essential that the outside emergency services if they have not already been called in, be informed in the shortest possible time.
The emergency must be immediately communicated to the Government Authorities such as local Factory Inspectorate, Collectorate, Police and District Emergency Authority.
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The statutory information to above authorities must be supplied beforehand so that they can be well prepared to operate their off-site emergency control (contingent) plan. As per their advice to consultation the onsite plan should be modified and updated.
Internal telephone numbers should be listed as per format given in Table 1.2.
Department Designation Telephone Number Office Residence
Plant President Operation Head Process HOD (P&QC) In-charge (Production) In-charge (Quality Control) Packing Plant HOD (Packing) In-charge (Sales) Section In-charge (Sales accounting) Power Plant HOD (TPP) Stores HOD Material In-charge (Stores) Electrical HOD (Electrical) In-charge (Electrical) Mechanical HOD (Mech.) In-charge (Mech.) Infrastructure HOD (Inst.) In-charge (Inst.) P&A HOD (P&A) In-charge (P&A) Section In-charge (Security) Section In-charge (Safety) Fire Service/ Ambulance Main gate/ Security office Section In-charge (Medical)/ Doctor Nurse Nurse Nurse
Table 1.2: Emergency Internal Telephone Numbers
Statutory Communications
Under the statutory provisions, information is required to be given to the following:
The workers
The general public and neighboring firms
District Emergency Authority Factory Inspectorate
Meghalaya State Pollution Control Board
1.3.4 ASSEMBLY POINTS
Emergency assembly point shall be identified in case of fire in the oil storage area/ coal yard in the proposed plant. The key personnel and the responsible personnel will report to
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the Incident Controller at this point, after getting suitable instruction from the Site Controller and act as per instructions of Incident Controller.
The maintenance personnel will directly report here, information will be passed on to the Site Controller and Liaison Officer from here over phone and through special messenger. This area will be under the control of Incident Controller.
A safe assembly point, which is located near the main entrance of the plant, which is far away from the probable hazardous location shall be identified. On hearing the emergency siren all employees connected with the hazardous location will be assembled in this location and act as per the instruction of the Site Controller. During emergency no one will be allowed to go to the hazardous location.
1.3.4.1 Roll Call
The employees attending duty will be known through the punch card and the records (on daily basis) of other employees (contractors and others) will be available at the gate with security. At the time of emergency the attendance will be verified with the people assembled in the safe assembly and emergency assembly point.
Contractors should maintain a similar list of personnel on site. Record is also maintained of the arrival and departure of visitors, together with the names of those they have called to see which will prove useful in establishing their whereabouts in the emergency. Visitors should wherever practicable, be accompanied on site by a responsible member of the work staff.
In the immediately affected area, the Incident Controller should arrange for a search to be made for any casualty by fire brigade. Nominated work personnel should record the names and other details of casualties taken to respective reception areas and the location, e.g. hospital.
At the Emergency Control Center, a nominated person should be posted to collate the lists, check them against the nominal role of these believed to be missing. Where missing people could have had cause to be at the affected area, the Incident Controller should be informed and arrangement shall be made for further search.
1.3.4.2 All Clear Siren / Alarm
If the indication of the emergency is over and on hearing all clear signal, all employees will report back to their jobs excepting personnel who are instructed to stay back for necessary jobs at the scene of incident. The Incident Controller is responsible for giving all clear signal after assessing the entire area conditions.
1.3.4.3 Restarting
The Incident Controller with his team of operation and Head (Engg), will inspect the area thoroughly and give instruction to start the plant as per restarting procedure in consultation with Site Controller and the Emergency Officer.
1.3.5 ACTION ON THE SITE
Though the scope of the on site plan is to prepare for and activate the emergency –time-activities so that the emergency, arisen as a result of the failure of the pre emergency control measure, can be controlled and contained within the shortest time. Following three
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stage activities are suggested as they are co-related and provide better plan for emergency preparedness, emergency actions and subsequent actions and subsequent follow up.
1.3.5.1 Pre-Emergency Activities
The following are the details of pre-emergency activities.
Internal Safety Survey
It is to be conducted to identify various hazards in plant premises as per details given below:
To check protective equipment for workability.
To check various safety installation / facility available at site for workability. To check fire system, fire water pumps, sprinkler from an ejectors, spray system, etc.
To suggest extra requirement / modification to make system more reliable.
Third Party Survey
The survey is to be conducted by a ‘Third Party” i.e experts /consultants from outside:
To study and identify various hazards. To conduct survey on available safety equipment/ appliances.
To check in built safety system for its adequacy.
To suggest modifications/ additions in the system, if necessary.
Prepare Vessel Testing
Following testing are recommended and records of the same should be maintained:
The mandatory testing of the boiler once in a year under the Boiler Act. Testing various equipment under statutory obligations.
Non-Destructive Testing (NDT)
NDT is recommended to draw an action plan for replacements/ repairs as per the past record and to maintain plan/section-wise record to compare with the past period.
Safety/ Relief Valves Testing
It is necessary:
To prepare the list of safety/ relief valves in plant.
To prepare a periodic schedule for their testing and to maintain records.
To draw action on replacement /repairs and to implement it.
Fire System testing
To prepare list of fire hydrants, fire applications, fire pumps, water monitors, automatic fire alarms, smoke detectors and other available appliances and maintain the record.
To draw testing schedules and record the findings.
To replace /modify defective equipment / accessories.
To check fire pumps capacities, delivery, pressure and auto-start /stop systems periodically.
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To draw schedule on running, standby equipment etc. for workability/ and appliances under fire service for operability.
Mutual Aid Scheme
Mutual aid scheme will be available for:
Fire Fighting:
Medical Help: from Govt. Hospital
External Technical Support
Dy. Chief Controller of Explosive
Dy. Chief Inspector of Factories Specialist / Consultant
Mock Drill
Minor mock drills to be conducted for training the persons internally. Major mock drills to be conducted after informing State Authority, Press, and Police for handling the situation effectively. The objective of the mock drill is:
To conduct periodic drills as to check the performance of man and equipment.
To know the drawbacks in the system for its corrective action.
Mock Fire Response drill will be conducted inside the plant once in six months to ensure awareness about “FIRE MISHAP” among employees.
Training
Security staff shall be trained on fire fighting. Fire fighting refresher course shall be conducted. Fire demonstration and drills shall be conducted. The Fire extinguishers shall be maintained by the Security Staff. Periodical inspection shall be carried out for the working condition of the extinguishers. The workers will be trained for using extinguishers.
Some of the employees and the security staff shall be trained in first aid, in the in-house First Aid Training Programme. Selective employees will be given intensive training on first aid by reputed organization and will act as first aid team in emergency situation.
Emergency/Protective Equipment
Personal protective equipments such as helmets, asbestos apron, leather apron, asbestos suit, asbestos gloves, leather gloves, asbestos shoes, safety shoe, gum boots, safety belts, safety goggles, ear muff, respirator etc. shall be made available to the workers as per requirements.
First Aid Kit with medicine, resuscitator, Self breathing apparatus and Torch light shall be provided at different locations as per requirements.
Recommended list of Personal Protective Equipments (PPEs) for the proposed plant is given in Table 1.3.
Sn Personal Protective Equipment Numbers 1 Self Containing Breathing Apparatus 6 2 Gas Mask 10 3 Fire Suits 2
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Table 1.3: Recommended List of Personal Protective Equipment (PPEs)
Communication System
It is necessary:
To maintain internal / external communication system in good working order.
To maintain telephone system between fire station and off sites in working conditions.
To modify the siren sound for emergency
To install wind cocks/wind recorders inside the plant area at prominent locations to record wind direction and velocity.
Emergency Lights
These are necessary:
To check and maintain the emergency lights in control rooms and selected plant areas.
To keep sufficient number of torches /batteries available in control rooms.
To keep mobile diesel operated power generating set standby in case of failure of normal power supply during emergency.
Emergency Control Room
An administrative building like the Security Office may be identified as Emergency Control Center (ECC). Approach to the Control Center from any part of the factory should be very easy. Any assistance required to the emergency area should be able to reach fast from the Control Center. In case of any emergency all key personnel and other responsible personnel will assemble here and act as per directives of the Site Controller.
Since the Control Center is proposed to be located near the main entrance, it will also be helpful to guide the external agencies like fire service etc., Monitoring the employees’ movement during emergency shall also be easy. ECC shall be equipped with the following:
Site Plan List of key person and their Telephone no.
List of Govt. Officials / external agencies and their Telephone no.
Communication system
Personal Protective equipments
First Aid Kit
Emergency Plan Paper pad and pencil
Site plan indicates the following:
Work Center
Fire hydrant System
Update Road System Emergency assembly Point
Safe assembly point
Control Center
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First Aid Center
Fire Zone
The Control center shall be well equipped with the communication system such as:
PA system
Telephone Auto and P & T
Wireless sets
Hospital Facilities
Equip the hospital/health center with necessary equipment/medicines
To keep the blood group record of all the employees. To train the Doctors for handling emergency situation/ casualties.
To keep liaison with city hospitals and other hospitals in the area.
To keep the list of the blood donors ready.
The Security office shall be provided with a first aid kit. First aid boxes shall be made available in all departments. The employees and security staff shall be trained in first aid. A team of first aiders will provide first aid during emergency.
Fire Fighting Facilities Available
Foam extinguishers and fire hydrant shall be made available to meet any fire incident in the plant.
1.3.5.2 Post Emergency Activities
Post emergency activities comprise of steps taken after the emergency is over so as to establish the reasons of the causation of the emergency and preventive measures. The steps involved are:
Collection of records.
Conducting inquiry and concluding preventive measures.
Making insurance claims. Preparation of inquiry reports with recommendations.
Rehabilitate the affected persons within the plant and outside the plant.
To restart the plant.
1.3.5.3 Off – Site Emergency Plan
As per risk assessment studies, the possibility of “offsite” emergency situation are ruled out as the project is not likely to pose any off site emergency and hence this plant does not call for any preparation of an off site emergency plan.
However, considering extreme situation, District Authorities including police (Address and telephone numbers of external Authorities are given below will be informed about any “Off-Site” emergency situation arises. Address and telephone numbers of external authorities are given in Table 1.3.
Sn External Authorities Address Telephone
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Sn External Authorities Address Telephone 1 District Collector Collector Office, Jowai 2 Superintendent of Police S.P. Office, Jowai 3 Chief Medical Officer CMO Office, Jowai 4 Inspector of Factories & Boilers I.F.B. Office, Shillong 5 District Transport Office D.T.O. Office, Jowai 6 Tahsildar Tahsil Office, Jowai 7 Fire Brigade Shillong 8 In charge-Fire Brigade Fire Brigade, Shillong 9 SHO - Police Station Police Station
Table 1.4: Address And Telephone Numbers of External Authorities
1.4 DISASTER MANAGEMENT PLAN - MINES
The mining operation shall be carried out under the management control and direction of a qualified Mines Manager holding a first class manager’s certificate of competency to manage a metalliferous mine granted by Director General of Mines (DGMS), Dhanbad. DGMS has been issuing a number of standing orders, model standing orders and circulars to be followed by the mines management for management of risks associated with mine operations. However, the following hazards may be possible during normal operation of mines:
Slope failure at the mine faces
Accident due to explosives
Accident due to sabotage in the magazine
In order to avoid the above said hazards, the following precautions/ measures would be implemented:
All safety precautions and provisions of Metalliferous Mine Regulation, 1961 shall be strictly followed during all mining operations
Working of mine as per approved mining plan and regular review and update of the mining plan, if needed Cleaning of mine faces on regular basis
Provision of magazine at a safe place with fencing and necessary security arrangements
Handling of explosives, charging and blasting shall be done by competent persons only Preventive maintenance and regular testing of all mining equipment as per the manufacturer’s guidelines
Proper handling of the hazardous chemicals and Material Safety Data Sheet (MSDS) shall be made available to ensure safety within the mine
Entry of unauthorized persons shall be prohibited
Provision of fire fighting and first-aid in the mining office
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Provision of all safety appliances such as safety boots, helmets, goggles, etc. to workers and regular inspection of the same
Training and refresher courses for all employees on regular basis as per Mines Vocational Training Rules
Awareness of safety and disaster through competitions, posters and other similar drives
The following facilities, which are proposed at the plant shall also be available at the mines
Public address system
Telephones/ Mobile handsets Runners/ messengers
Emergency alarm
Fire fighting equipments & accessories with trained manpower
Ambulance at plant
Full fledged dispensary at plant site Training center
1.4.1 CARE AND MAINTENANCE DURING TEMPORARY DISCONTINUANCE
When the mine is temporarily discontinued due to any unforeseen circumstances the following care and maintenance shall be undertaken:
Notice to be served to all the concerned authorities
The mining pit area shall be covered by temporary fencing All access roads / openings to the pit/face shall be closed by parapet wall as per rule.
Warning shall be display on “Notice Board” at appropriate places Security personnel shall be posted at every danger point.
No unauthorized person shall be allowed to enter into the mine without prior permission of the management. All men and machinery shall be withdrawn from the mine and shall be kept in a compact and safe place.
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