by m/s leayan global pvt. ltd.environmentclearance.nic.in/writereaddata/online/risk... · 2016. 5....

Environment Impact Assessment Report for Proposed Leather Processing Unit (Raw hide to Finished Leather) at District Kanpur Dehat, U.P. By M/s Leayan Global Pvt. Ltd.

Environmental Consultant: M/s Perfact Enviro Solutions Pvt. Ltd. 1

1.1 RISK ASSESSMENT

Risk is a potential that a chosen action or activity may lead to a loss of human or property.

Risk assessment is a step for Risk Management. Risk assessment is determination of qualitative and

quantitative value of risk related to a situation or hazard.

Hazard is a situation that poses a level of threat to life health or environment.

Disaster is a natural or man-made hazard resulting in an event of substantial extent causing significant

physical damage or destruction or loss of life or drastic change in environment.

Risk assessment involves the following:

Hazard Identification

Vulnerability Analysis

Risk Analysis

Emergency Plan

1.2 HAZARD IDENTIFICATION

The Project is a proposed leather processing unit & there may be following types of hazards:

1.2.1 NATURAL HAZARD:

1. Earthquake

2. Flooding

a. Heavy rainfall

b. Rind river

c. Nearby distributaries or drains

1.2.2 MAN MADE HAZARD:

1. Fire & explosion

Explosive material



Chemicals

Short circuiting

Boilers

2. Chemical

Chemical storage

Fuel storage

leakage from process

3. Electrical

Electrical room

Non insulated wires

4. Mechanical/ Accident

Raw material Handling

Equipment’s area

Process area

Transportation

5. Thermal

Boilers

Chemical Storage area

1.3 HAZARD & VULNERABILITY ANALYSIS

The vulnerable analysis is done on all the hazards as below:

HAZARD IDENTIFICATION

Severity (1-5)

likelihood (1-5)

Severity x likelihood (1-25) (Hazards scoring 1-12 are less serious hazards & 13-25 are very serious hazards &

During Construction/Installation

During Operation



need prior attention)

Natural hazard

Earthquake 5 1 5 For immediate areas of construction

For the complete leather processing Unit

Flood 5 1 5 For immediate areas of construction

For the complete leather processing Unit

Man-made hazard

Fire & explosion 5 3 15 For all working areas

Chemical storage area Oil storage area Area for keeping Packaged material &product storage area Office area Boiler area Electrical Room

Chemical 4 4 16 Storage area Chemical leakage area Process area DG set area

Electrical 3 2 6 For all working areas

For all the machinery used in process. Electrical room

Mechanical/ Accident

3 3 9 Cranes & Machineries

Equipment’s area Process area Material handling area Transportation

Thermal 3 2 6 Overall area Chemical Storage area Boiler area

TABLE ERROR! NO TEXT OF SPECIFIED STYLE IN DOCUMENT.-1; HAZARD ANALYSIS FOR THE PROPOSED PROJECT

1.4 RISK ANALYSIS

The risk is likelihood of harmful effect big or small due to hazard, together with severity of harm suffered.

Risk also depends on number of people exposed to hazard.



Risk analysis provides severity of harm from particular type of hazard.

1.4.1 EARTHQUAKE:

The project is located in Seismic Zone IV where earthquake can occur in the range of 4.0-7.0 Richter scale.

No earthquake history has been found in past 10 years in U.P. or any other nearby area.

1.4.2 FLOODING:

The project site is located in area where Rind River which lies at 4.8 Km E. Flooding can occur due to

excess of rain, so proper drainage shall be maintained.

1.4.3 FIRE & EXPLOSION:

Fire is mainly caused due to carelessness or accident. Since it is a leather processing Unit, fire can occur

due to exposure of chemicals/ flammable substances or electrical spark. The fire can also occur in the

boiler area and electrical room.

1.4.4 CHEMICAL:

All the chemicals used in the process have risk of leakage during handling, storage and transportation.

1.4.5 MECHANICAL/ ACCIDENT:

Mechanical hazard or Accident can occur during the material handling, processing & transportation.

Mechanical hazards are created by powered operation of equipments or tools.

1.4.6 ELECTRICAL:

The electrical current can pass to the floor & metals due to inadequate insulation or accidently. Electric

spark can generate due to short circuiting in the electrical room.

1.4.7 THERMAL:

Thermal heat can be generated from the process machinery, D.G sets and the vehicles in the area.

Thermal hazards are objects or substances that transfer energy as heat.



1.5 ON-SITE EMERGENCY PLAN

An onsite emergency is caused by an accident or hazard that takes place within the plan area and the

effects are confined to the plant area.

The onsite emergency plan consists of following key elements:

Planning as per hazard analysis

Preventive measures

Emergency response procedure

Recovery procedure

1.5.1 PLANNING

1. Mapping of hazard vulnerable area.

2. There shall be Disaster Management Cell in place.

3. The disaster management cell have following members to share the responsibility

Site Controller (Administrator of complex)

Incident Controller (Asstt. Administrator)

Personal Manager

Communication Officer

Fire Officer

Security Officer

Engineering In-charge

Fire pump attendant

First Aid Team

1.5.2 PREVENTIVE MEASURES

1.5.2.1 EARTHQUAKE:

The project is situated at Seismic zone-IV area. Special attention shall be given to the structural design of

foundation, elements of masonry, timber, plain concrete, reinforced concrete, pre-stressed concrete,

and structural steel. All applicable guidelines will also be followed in this regard to ensure safety of the

building.



1.5.2.2 FLOODING:

To avoid flooding or water logging in the area due to the existing nearby river, the site shall be raised

above the existing road level.

Proper designing of drainage system for domestic as well as storm water shall be done. All the rain water

will be diverted to rain water harvesting pits & recharge the ground water and extra water will be

diverted in sewer line of area.

1.5.2.3 FIRE AND LIFE SAFETY

Safety Precautions

1. Smoking must be prohibited.

2. Vehicle access should be strictly controlled.

3. Chemicals, oil tanks, packaged materials shall be kept in separate rooms.

4. Ventilation must be sufficient to cope with the maximum expected vapor levels in building.

5. Storage tank vents to atmosphere should be sized for fire-heated emergency vapor release.

6. Electrical equipment must be explosion-proof to meet national electrical code requirements.

7. Dry chemical extinguishers should be accessible for small fires. An adequate supply of hand-held and

wheeled types should be available.

8. Hydrants should be strategically placed with adequate hoses.

9. Small spills should be remediated with sand, earth, or other non-combustible absorbent material, and

the area then flushed with water. Larger spills should be diluted with water and diked for later disposal

10. Lighting should be grounded. Tall vessels and structures should be fitted with lightning

conductors that are securely grounded

Precaution In Case Of Fire

For leather processing unit, all practicable measures shall be taken to prevent outbreak of fire and its

spreads, both internally and externally, to provide and maintain :-

a) Safe means of escape for all person in the event of a fire, and

b) The necessary equipment and facilities for extinguishing fire.

Effective measures shall be taken to ensure that all the workers are familiar with the means of escape

in case of fire and have been adequately trained in the routine to be followed in such cases.



Fire Fighting Personal Protective Equipment

Due consideration must be given to hazards from chemical and heat exposure. Therefore, fire-fighters

should wear full-face, positive pressure, self-contained breathing apparatus or an air-line. Chemical

protection may be provided with impervious clothing, gloves and footwear. Suitable materials include

polyvinyl plastic, neoprene or rubber.

1.5.2.4 CHEMICAL:

Vapour Pressure, Flash Point, Boiling Point, Melting Point & Ignition Temperature value of some of the

chemicals used in the process is given below:

S.No. Chemicals Vapour Pressure

Flash Point

Boiling Point

Melting Point

Ignition Temperature

1 Sodium sulphide NA NA NA 950 °C The substance or mixture is classified as self-heating with the category 1

2 Ammonium sulphate NA NA NA > 280°C NA

3 Sodium bi sulphite

4 Sodium formate NA NA NA 259 - 262 °C

NA

5 Formic acid 42.00 hPa at 20 °C

49.5 °C 100 -

101 °C 8.2 – 8.4 °C

NA

6. Sulphuric acid 1.33 hPa at 145.8 °C

NA 290 °C 3 °C NA

7 Acitic acid 15.2 hPa at 20 °C

40.0 °C 117 - 118 °C

16.2 °C 485.0 °C

8 Basic chromium sulphate NA NA NA NA NA

9 Sodium bi carbonate NA NA NA 300 °C NA

10 Acrylic acid 5 hPa at 20 °C

46 °C 139 °C 13 °C NA

TABLE ERROR! NO TEXT OF SPECIFIED STYLE IN DOCUMENT.-2; CHEMICAL REQUIREMENT FOR THE PROPOSED PROJECT

Chemical Handling:

Workers shall wash their hands thoroughly after handling.



Chemicals shall be used only in a well-ventilated area.

Workers shall use spark-proof tools and explosion proof equipment.

Workers shall avoid contact with eyes, skin, and clothing.

Container shall be kept tightly closed.

Workers shall avoid contact with heat, sparks and flame.

Do not pressurize, cut, weld, braze, solder, drill, grind, or expose empty containers to heat, sparks

or open flames.

Operator training as well as written operating instructions, safety rules and check lists shall be

provided.

Protective protection:

Sources of Exposure

Human exposure to chemicals can occur via absorption, contact with the eyes, inhalation or ingestion.

First Aid Measures

1. In case of chemicals come in contact with the skin, remove contaminated clothing. Wash with soap

and water for 15 minutes. Seek medical attention if irritation occurs.

2. In case of chemicals contact with the eyes, flush immediately with gently running water for a minimum

of 15 minutes, ensuring all surfaces and crevices are flushed by lifting lower and upper lids. Obtain

medical attention.

3. In case of inhalation of chemical’s vapours, remove the individual to fresh air, but only if it is safe to

do so. Asphyxiation from vapours may require artificial respiration. Due to the possibility of delayed onset

of more serious illness, it is important to obtain medical attention.

4. Ingestion of chemicals is life threatening. Onset of symptoms may be delayed for 18 to 24 hours after

ingestion. Do not induce vomiting. Transport to medical attention. The individual should remain under

close medical care and observation for several days.

Chemical Storage:

Chemicals shall be kept away from heat, sparks, and flame. Keep away from sources of ignition.

Store in a tightly closed container.



Chemicals shall be stored in a cool, dry, well-ventilated area away from incompatible substances.

Storage & handling area shall be readily accessible with safety showers, fire extinguishers and

other fire fighting equipment, water hydrants with spray nozzle and other emergency equipment

such as chemical proof suits and respiratory apparatus.

The flammable materials shall be stored in a separate safety storage room. Keep away from heat.

Keep away from sources of ignition. Keep container tightly closed. Keep in a cool, well-ventilated

place.

Spills / Leaks: Spills will be absorbed with inert material (e.g. vermiculite, sand or earth), they will be

placed in suitable container. All sources of ignition shall be removed and a spark-proof tool shall be

used. Ventilation shall be provided and a vapour suppressing foam shall be used to reduce vapours.

List of chemicals involved in Process & Storage facilities of chemicals

S. No.

Name of raw material Daily Consum

ption (In Kg)

Max. Quantity to be stored

in plant (Capacity in Kg)

In 10 Days

Number of stora

ge

Weight of each

storage unit

category

1 Lime 813.75 8137.5 204 Bags 40kg\Bag Non hazardous

2 Sodium sulphide 697.5 6975 140 Bags 50 kg\Bag hazardous

3 China clay 232.5 2325 47Bags 50 kg\Bag Non hazardous

4 Dispersing agent (Tergolix-A-IN) 30.0 300 3 Carbuoy

120 Kg/Carbuoy

Non hazardous

5 Hair removal agent 38.75 387.5 16Bags 25 Kg\Bag Non hazardous

6 Deliming agent 161.25 1612.5 54Bags 30 Kg\Bag Non hazardous

7 Ammonium sulphate 967.5 9675 194Bags 50 kg\Bag Non hazardous

8 Bate 86 860 17Bags 50 kg\Bag Non hazardous

9 Sodium bi sulphite 129 1290 26Bags 50 kg\Bag hazardous

10 Enzyme bate ( Basozym-A {Alkali Bate}

&

TLP-HP-10 {Acid Bate} )

50.0 500 5 Bags

5 Carbuoy

50 Kg/Bag

50 Kg/

Carbuoy

Non hazardous

Non hazardous



11 Degreasing agent 193.5 1935 20Drums 100 Kg\ Drum

Non hazardous

12 Salt 1397.5 13975 280Bags 50 kg\Bag Non hazardous

13 Sodium formate 215 2150 43Bags 50 kg\Bag Non hazardous

14 Formic acid 107.5 1075 31Drums 35 kg\Drum hazardous

15 Sulphuric acid 279.5 2795 47Drums 60 kg\Drum hazardous

16 BCS 1290 12900 258 Bags 50 kg\Bag hazardous

17 Fungicide 32.25 322.5 6Drums 60 kg\Drum hazardous

18 Chrome exhaustion agent (Sodium

Formate & Sodium

Bi Carbonate )

160.0 1600 16 bags 16 bags

50 kg\Bag 50 kg\Bag

Non hazardous Non hazardous

19 hypo 161.25 1612.5 33Bags 50 kg\Bag Non hazardous

20 Tergolix 148 1480 13Drums 120 kg\Drum

Non hazardous

21 Acetic acid 40.0 400 8 Carbuoy

50 Kg/ Carbuoy

Hazardous

22 Wetting agent 31 310 3Drums 100 Kg\ Drum

Non hazardous

23 Basic chromium sulphate 310.0 3100 62 bags 50 Kg\Bag Non hazardous

24 Chrome syntan ( Balsyn-CR) 310.0 3100 124 bags 25 Kg\Bag Non hazardous

25 Sodium bi carbonate 279.5 2795 56Bags 50 kg\Bag Non hazardous

26 Synthetic tanning agent 1536 15360 154Drums

100 Kg\ Drum

Hazardous

27 Acrylic system 350 3500 70 Drums

50 Kg\ Drum

Hazardous

28 Filling syntan 144 1440 58Bags 25 Kg\Bag Hazardous

29 Dyes 240 2400 96Drums 25 Kg\Drum Hazardous

30 Synthetic fatliquor 288 2880 19Drums 120 Kg\ Drum

Hazardous

31 Vegetable oil 96 960 10Drums 100 Kg\ Drum

Hazardous

32 Mineral oil 72 720 7Drums 100 Kg\ Drum

Hazardous

Listed as hazardous chemicals involved in Process & listed in “The manufacture, storage and import of hazardous chemical rules, 1989” in:

Name of chemical

Chemical Formula

Schedule-1, Part II Sulphuric acid

H2SO4

Schedule-1, Part II Sodium Sulphide

NA2S

TABLE ERROR! NO TEXT OF SPECIFIED STYLE IN DOCUMENT.-3; LIST OF THE CHEMICALS AND THEIR DETAILS FOR THE USE



Sulphuric acid- As per the MSDS sheets, the LD50 value of Sulphuric acid is 2140 mg/ kg (oral- rat) & LC50

value is 510 mg/ m3 (inhalation- rat). Strong inorganic acid mists containing sulphuric acid are

carcinogenic. The permissible exposure limit of sulphuric acid is 1 mg/ m3.

Sodium sulphide- As per the MSDS sheets, the LD50 value is 246 mg/ kg (oral-rat). The LC50in guppy fish

is found to be 15mg/l. This chemical is not identified as carcinogenic.

Major accidental Release measures & measures for storage & handling

The hazardous materials shall be stored in a separate safety storage room, shall be kept away

from sources of ignition.

Proper ventilation should be maintained.

In case of fire outbreak due to sodium sulphide use flooding quantities of water, foam or dry

powder as extinguishing agents.

Sulphuric acid is not flammable or combustible. However, fires may result from the heat

generated by contact of concentrated sulphuric acid with combustible materials. In case of fire

outbreak use dry chemical or carbon dioxide extinguishers or water spray to cool fire-exposed

containers. Do not use water directly on acid as a violent reaction may occur resulting in

spattering of the acid.

Proper medical facility arrangement shall be provided in case of any accidental release.

In case of leak or spill, ventilate area of leak or spill. Keep unnecessary and unprotected people

away from area of spill. Wear appropriate personal protective equipment. Pick up and place in a

suitable container for reclamation or disposal, using a method that does not generate dust. Do

not contact with acids. Do not handle with bare hands.

Collection, development and dissemination of information

Material Safety Data Sheet (MSDS) shall be provided.

Prior to working with these chemicals, workers should be trained on its proper handling &

storage.

Label Hazard Warning on container.

Label Precautions and First Aid.



Emergency plan shall be prepared and mock drill of the on-site emergency should be conducted

Inspection of the industrial activity shall be done at least once in year and annually status report

on the compliance with the Rules shall be submitted.

1.5.2.5 MECHANICAL:

Mechanical hazards are created by powered operation of equipments or tools.

Mechanical hazards can occur at:

1. Process machinery

2. DG set room

3. Vehicular Movement

Following preventive measures shall be taken:

1. Periodic replacement of critical components of machine.

2. Proper training to operators of machines.

3. There will be safe distance demarcation on heavy machines like cranes (during construction)

4. Sign of danger at the hazard places.

1.5.2.6 ELECTRICAL:

The electrical current can pass to the floor & metals due to inadequate insulation or accidently. Electric

spark can generate due to short circuiting in the electrical room

1.5.2.7 THERMAL:

Thermal hazards are objects or substances that transfer energy as heat.

Leather processing Unit can have following points of thermal hazard.

Boilers

Chemical storage Area

The thermal hazard can cause burn of skin; following preventive measures can be taken:

1. The open flame area like canteen shall be restricted.

2. Boiler section shall be properly insulated and safe distance & guard will be installed.



3. D.G set room; etc will have restricted entry.

4. Operators in the thermal hazard area shall be provided with protective gears like gloves, goggles

etc.

5. For emergency first aid room will be maintained.

1.5.3 EMERGENCY RESPONSE PROCEDURE

Even after all the preventive measures for any emergency, following infrastructure shall be provided:

1. There will be an Emergency Control Room.

2. Assembly area shall be demarked for Industry.

3. Communication system shall be installed which includes intercom and public address system.

4. Fire alarm shall be installed at vulnerable place.

5. The safe zones (at the time of emergency) shall be displayed at different locations.

6. First Aid facility shall be made available at Control room.

In case of emergency following action shall be taken:

1. The emergency shall be declared in case of following:

i) Fire alarm buzzing (Fire hazard)

ii) Vibration/Earthquake feeling (Earthquake)

iii) Water logging above 30 cm from ground level (Flood)

iv) Any unusual smell of gas or suffocating feeling (Chemical leakage)

v) Security alarm from main gate. (Security risk/Terrorism)

2. On declaration of emergency, communication shall be made to residents for any type of

emergency

3. All the workers of the affected area shall be moved to safe zone

4. The control measures shall be done as per the emergency action plan for each type of hazard.

5. All the members of disaster management cell shall take charge of their respective duties.

6. Outside help like fire tender, police, ambulance etc. shall be called by site controller or Incident

controller.

1.5.4 RECOVERY PROCEDURE



The recovery procedure will depend on the type of emergency. Recovery procedure shall be followed by

engineering section to restore the essential services. The PLI (Public Liability Insurance) shall be done as

a part of off/on site emergency plan.

1.6 OFF-SITE MANAGEMENT PLAN:

If an accident takes place in an industry/ unit & its impacts are felt outside its premises, the situation is

called an “Off-site Emergency”. To meet such Emergencies, an Off-site Emergency Plan is required to be

prepared.

Cause of off-site emergency

In a Leather Processing industry, the chemical storage room, chemical handling area & transportation of

the chemicals may cause off- site emergency to occur.

The proposed project involves use of Sulphuric acid & Sodium Sulphide which is the hazardous chemical

which shall be used in the process.

Areas in vicinity (Vulnerable areas)

The areas in extreme vicinity to the industrial unit which may have an impact of Off- site Emergency are

given in the table below:

Facility in the East of Project Boundary Industries

Facility in the North of Project Boundary Highway and further industries

Facility in the West of Project Boundary Industries

Facility in the South of Project Boundary Agricultural land

List of Running Industries Nearby site:

S.No. Name of Industry Type of Production Distance & Direction

1. RSPL at Parsidhpur Xpert soap 1 NW

2. RSPL Logistic at Ranian Transport Unit 0.51km,WSW



3. Mayur Refinery (P) Ltd. Dalda & soyabean refined 0.32 km, NNE

4. Kamdhenu Kettle feeds Pvt. Ltd.

Leather Industry 2.47km , ENE

5. K.P.I. Industries Plastic Fiber 0.67 km, ENE

6. Kushal food maida Ltd. Maida Mill 0.87 km, ENE

7. GanpatiAidmill (P) Ltd. Soyabean Oil(Refined) 0.13 km , ENE

8. Agmotex Fabrics Ltd. Clothes 2 Km

9. Frontier Spring Ltd. Aloy Steel 0.3 km , WSW

10. SNG Solvent Ltd - 0.68 km ,ENE

11. Agro Food Industry Suji, Maida &Aata 1.5 Km ENE

12. M/S. Ruch Organics Ltd.(Modi Bond)

- 1.86 km , ENE

13. Mantoora Solvent Soiabeen Oil 0.70 km, WSW

14. RSPL Packaging Material Unit 1.12 km , ENE

15. OM Plex (P) Ltd. Plastic Balti, Small Container 1.53 km , ENE

As per the details given above, it is observed that there is no residential habitat near the proposed

industrial unit.

VULNERABILITY ANALYSIS

The vulnerable analysis is done for all the hazards that may cause offsite emergency as given below:

Activity Hazard Severity (1-3)

likelihood (1-3)

Severity x likelihood (1-6) (1 – Hazard With Least Concern & 9 - Hazard With Highest Concern)

Vulnerability

Chemical Transportation

Spillage/ leakage

2 1 3 Approximately 50 m But dangerous if enters any water body, as it may travel distances.

Fire/ Explosion

3 1 3 Approximately 250 m



Accident 2 1 2 Approximately 20 m

Chemical Storage & Handling

Spillage/ leakage

2 1 2 Within the storage room.

Fire/ Explosion

3 1 3 Approximately 250 m

Accident 2 1 2 Storage area of chemicals. Process Area Nearby Areas

PREVENTIVE MEASURES

DURING TRANSPORTATION Following measures shall be adopted to ensure safe transportation:

• The transportation of the raw material, chemicals & products shall be done in Leak Proof MS

Tanks while transporting through trucks & tempo.

• Cushion shall be provided to the materials to prevent chemical container breakage.

• Safety data sheets shall be kept & Labelling shall be done on the tanks used for transportation of

the chemicals.

• A sheet listing the materials being transported shall be available in the vehicle and the emergency

phone numbers shall also be listed.

• Workers/ driver shall be trained for MSDS & handling of these chemicals.

• Proper First Aid facility shall be provided within the transportation vehicle in case of any

accidental release.

• The shipping paper of vehicles used for transportation of hazardous chemicals should be proper

& vehicles shall not be overloaded.

The mode of transportation for chemicals used in process are described below:

S. No.

Name of raw material Mode of transportation

1 Hides By Truck

2 Lime By Truck

3 Sodium sulphide By Loader

4 China clay By Truck

5 Dispersing agent By Loader

6 Hair removal agent By Loader



7 Deliming agent By Loader

8 Ammonium sulphate By Loader

9 Bate By Loader

10 Sodium bi sulphite By Loader

11 Enzyme bate By Loader

12 Degreasing agent By Loader

13 Salt By Loader

14 Sodium formate By Loader

15 Formic acid By Loader

16 Sulphuric acid By Loader

17 BCS By Loader

18 Fungicide By Loader

19 Chrome exhaution agent By Loader

20 hypo By Loader

21 Tergolix By Loader

22 Acitic acid By Loader

23 Wetting agent By Loader

24 Basic chromium sulphate By Loader

25 Chrome syntan By Loader

26 Sodium bi carbonate By Loader

27 Synthetic tanning agent By Loader

28 Acrylic system By Loader

29 Filling syntan By Loader

30 Dyes By Loader

31 Synthetic fatliquor By Loader

32 Vegetable oil By Loader

33 Mineral oil By Loader

DURING STORAGE & HANDLING

Based on the physical, thermal, chemical and biological properties available from the material safety

data sheets (MSDS) of the various substances handled in the proposed project, the hazardous

substances are identified.

The threshold limit for the storage of the chemicals at any point of time shall not exceed.

To prevent and control risk and damage, all the raw material are stored in leak proof MS/SS tanks at

a secured and contained location with proper safety measures. MSDS is displayed at all the prominent

sites



Handling is shall be done as per NIOSH guidelines

There shall be no drainage lines or water bodies near the chemical storage room to avoid

contamination of water upto long distances.

The chemical used in the project & their storage facilities has already been discussed under section

7.5.2.4 of chemicals.

EMERGENCY RESPONSE PROCEDURE

Under the ‘Manufacture, Storage and Import of Hazardous Chemicals Rules‘ preparation of ‘Off-site

Emergency Plan’ is covered in Rule No.14. The duty of preparing and keeping up to date the ‘Off-site

Emergency Plan’ as per this rule is placed on the District Emergency Authority. Already so, occupiers are

charged with the responsibility of providing the above authority with such information, relating to the

industrial activity under their control, as they may require for preparing the off-site emergency plan.

As per the rules, the main component of the Off-Site Emergency Plan is coordination with the District

Authority. The District Authority (i.e. District Collector, Factory Inspector etc.) in conjunction with the

company & nearby industries under mutual aid scheme and relevant emergency services should have an

off-site emergency plan considering the following:

Incidents at the site including fires and/or explosions would likely cause concern among local

population. Although, the unit does not fall in residential area & does not have any residential

premises in the vicinity, the people will be advised to stay away from the area, and relevant actions

shall be followed.

In addition to company’s own Emergency control center, the "local" external agencies will also be

involved in the formulation of procedures for off-site incidents and in response to any incident;

Other external agencies that will also be involved in response to any incident are:

o Traffic Police;

o Fire services available with nearby industries;

o Civil Authority;

o Factory Inspector;

o State Pollution Control Board; etc.

The following aspects shall be addressed in any detailed response to an off-site incident:



o Organization: details of command structure, coordination arrangement, implementation

procedures, emergency control centers. The organizational chart to deal with the emergencies

(onsite & off site) is given ahead.

o Communication: identification of personnel involved, communication centre, lists of telephone

numbers (as given above) etc.

o Specialist Emergency Equipment; details of availability & location of heavy lifting gear bulldozers,

specialized fire fighting equipment;

o Specialist Technical Knowledge; details of organization or individuals whom it may be necessary

to call e.g. for specialized chemical knowledge, impact knowledge etc;

o Mutual Aid Scheme: details of companies in this scheme and available facilities with them & their

phone nos.;

o Meteorological Information Sources; arrangements for obtaining details of weather conditions

prevailing and weather forecast on regular basis;

o Humanitarian Arrangements; details of provisions for transport, evacuation routes and centers,

food, treatment of injured etc;

o Public Information; arrangements for dealing with the media, informing relatives of employees

and local population;

o Incident Assessment; arrangements for collecting information on incident causes and reviewing

the efficiency and effectiveness of all aspects of the emergency plan;

Efficient off-site incident planning also involves interaction on regular basis among various

organizations. To ensure that every procedure put in place will run efficiently and effectively, exercise

(mock drills) involving all the relevant organizations will be carried out. These will be monitored and

assessed with procedures updated to reflect knowledge gained;

ROLES & RESPONSIBILITIES OF EXTERNAL AGENCIES

The roles of the various parties that may be involved in the implementation of an off-site plan are

described below:

A) ROLE OF THE POLICE

Protecting life and property and controlling traffic movements.

Controlling bystanders, evacuating the public, identifying the dead and dealing with casualties and

informing relatives of dead or injured.



B) ROLE OF THE FIRE AUTHORITIES

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

over the handling of the fire from the site incident controller on arrival at the site.

Fire authorities having major hazard works in their area should have familiarized themselves with

the location on site of all stores of flammable materials, water and foam supply points and fire-

fighting equipments.

C) ROLE OF THE HEALTH AUTHORITIES

Health authorities, including doctors, surgeons, hospitals, ambulances and so on, have a vital part

to play following a major accident and they should form an integral part of any emergency plan.

D) ROLES OF THE GOVERNMENT SAFETY AUTHORITY

In the event of an accident, local arrangements regarding the role of the factory inspector will

apply.

In the aftermath, factory inspectors may wish to ensure that the affected areas are rehabilitated

safety.

Chemical Accidents (Emergency Planning, Preparedness and Response) Rules, 1996 prescribes for the

constitution of the State Crisis Group as apex body at the State Level to deal with major chemical

accidents and to provide expert guidance for handling major chemical accidents and for the constitution

of District and Local Crisis Groups.

A. Functions of the State Crisis Group

i. Review all district off-site emergency plans in the State with a view to examine its adequacy in

accordance with the Manufacture, Storage and Import of Hazardous Chemical, Rules and forward

a report to the Central Crisis Group once in three months;

ii. Assist the State Government in the planning, preparedness and mitigation of major chemical

accidents at a site in the State;

iii. Continuously monitor the post accident situation arising out of a major chemical accident in the

State and forward a report to the Central Crisis Group;

iv. Review the progress report submitted by the District Crisis Groups;

B. Functions of the District Crisis Group

i. Assist the preparation of the district off-site emergency plan;

ii. Review all the on-site emergency plans prepared by the occupier of Major Accident Hazards

installation for the preparation of the district off-site emergency plan;



iii. Assist the district administration in the management of chemical accidents at a site lying within the

district;

iv. Ensure continuous information flow from the district to the Centre and State Crisis Group regarding

accident situation and mitigation efforts;

v. Forward a report of the chemical accident to the State Crisis Group; and Conduct mock-drill of a

chemical accident at a site each year.

C. Functions of the Local Crisis Group

i. Prepare local emergency plan for the industrial pocket;

ii. Ensure dovetailing of the local emergency plan with the district off-site emergency plan;

iii. Train personnel involved in chemical accident management;

iv. Conduct at least one full scale mock-drill of a chemical accident at a site every six months and

forward a report to the District Crisis Group; and

v. Respond to all public inquiries on the subject.

RECOVERY PROCEDURE

The recovery procedure will depend on the type of emergency. Recovery procedure shall be followed by

engineering section to restore the essential services. The PLI (Public Liability Insurance) shall be done as

a part of off/on site emergency plan.

EMERGENCY CONTROL TEAM

KEY PERSONNEL

The key Personnel involved in Emergency (Onsite & Offsite) are given below:

1. Emergency Controller – Plant Head

2. Incident Controller

3. Security Supervisor

4. HOD – Utility & EHS

5. Safety Officer

6. Fire fighter

7. Evacuation members [Emergency Response Team (ERT) Members]

8. First Aid provider



9. Rescue members

CHAIN OF COMMAND DURING EMERGENCY:

The organizational chart for coordination within the industry as well as the external agencies is given

below:

1.7 OCCUPATIONAL HEALTH & SAFETY

Action plan for the implementation of OHS standards as per OSHAS/USEPA/NIOSH/ACGIH shall be

followed as given below:

• Occupational health surveillance programme shall be done six monthly & and their records are

being maintained.

• At project site in case of emergency First Aid facility shall be provided. A room shall be provided

separately with provision of bed and experienced doctor shall be provided.

Anybody who sees

emergency requirement/

Emergency Controller

Area In-charge Incident Controller

Gate SecurityDepartment HODSafety Officers

Plant Head

ERT Members

HR Head

Safety

head (EHS

HOD)Engineering

Head

Fire Fighting

Head

Business Head

Managing

Director

Electrical HOD

Utility HOD

Emergency Coordinating

Officer & Its Team

Police &

Traffic Police

Fire Services

Electricity

Authority

Hospital/

Ambulance

Factory

Inspector

District

Administratio

n

OFF SITE EMERGENCY

PLANNING

ON SITE EMERGENCY PLANNING



• Health check-up camps shall be organized on regular basis at company dispensary / nearby

locations for nearby peoples to evaluate exposure of the workers to chemicals during pre-

placement and periodical medical monitoring.

• Prior to working with chemicals, workers shall be trained on its proper handling & storage.

• The workers shall be educated/ trained for MSDS & handling of these chemicals.

• Proper medical facility arrangements shall be provided in case of any accidental release.

• Label Precautions and First Aid facility shall be provided.

• Emergency plan shall be prepared and mock drill of the on-site emergency is being conducted.

• Employers and employees shall be made aware of the hazardous properties of materials in their

workplaces, and the degree of hazard each poses.

• Inspection of the industrial activity shall be done at least once in year and annually status report

on the compliance with the Rules shall be submitted.

• A safety officer / environmental officer shall be recruited and lead all the safety issues related to

man, machine & materials.

• Exterior refuge or safe areas include parking lots, open fields or streets which is located away

from the site of the emergency and which provides sufficient space to accommodate the

employees shall be provided.

• The company will spent approximately Rs. 15 lacs on Occupational Health Safety & Environment

Facility related activities and proposed budget for Public Health & safety will be Rs. 5 Lacs.

Personal Protective Equipment

The level of risk of exposure to particular chemical will dictate the appropriate level of personal

protective equipment (PPE) required, Provide wearing side shielded safety spectacles and appropriate

gloves, footwear, face shields, respiratory protection, fire-resistant clothing, or chemical suits.

Respirators: A complete respiratory protection program has been instituted. It includes

evaluations of workers’ abilities to perform tasks while wearing CPC, Regular training of



personnel, Fit testing, Periodic environmental monitoring, Regular maintenance, inspection, and

cleaning.

Clothing: Workers wear appropriate protective clothing to prevent skin exposure.

Skin Protection: Workers wear solvent resistant gloves and clothing.

Eye Protection: Workers wear splash proof chemical goggles and face shield when working with

liquid, unless full face piece respiratory protection is worn.

Eyewash facility and a safety shower: Common work places are equipped with Eyewash facility

and a safety shower.



SAFETY IN WORK ENVIRONMENT FOR WORKER HEALTH

Sr. No. Name of Chemical Permissible Exposure

Level (PEL)as per

OSHA (Occupational

Safety and Health

Administration)

Recommended Exposure

Level (REL) as per NIOSH

(National Institute of

Occupational Health and

Safety)

Threshold Limit Value

(TLV) as per American

Conference of

Governmental

Industrial Hygienists

Hazards Related to the Substance

(Category)(Category 1 – most

hazardous and Cat. 5 is least

Hazardous)

Mitigation Measure Proposed in

the EMP

1 Sodium sulphide - - - Self-heating substances and mixtures (Category 1), H251 Corrosive to metals (Category 1), H290 Acute toxicity, Oral (Category 3), H301 Acute toxicity, Dermal (Category 3), H311 Skin corrosion (Category 1B), H314 Acute aquatic toxicity (Category 1),

H400

1. Isolated Storage Tanks

2. Handling as per NIOSH guidelines

3. Minimisation of worker exposure

by restricting access

4. Providing proper ventilation in

the storage and reaction areas

5. All workers are required to wear

all PPE (masks, goggles, helmets) at

all times in the plant

2 Ammonium sulphate - - - Not a hazardous substance or mixture according to Regulation (EC) No. 1272/2008.



3 Sodium bi sulphite 5 mg/m3 5 mg/m3 5 mg/m3 Acute toxicity: No data available Skin corrosion/irritation: No data available Respiratory or skin sensitisation: No data available Carcinogenicity: IARC: 3 - Group 3: Not classifiable as to its carcinogenicity to humans (Sodium hydrogensulphite)





4 Sodium formate 5 mg/m3 - 3 mg/m3 Not a hazardous substance or

mixture according to Regulation

(EC) No. 1272/2008



5 Formic acid 5 ppm (ST) 10 ppm

5 ppm 5 ppm (ST) 10 ppm

Flammable liquids (Category 3), H226 Skin corrosion (Category 1A), H314










6 Sulphuric acid 0.1 mg/m3 (ST) 3 mg/m3

1 mg/m3 0.2 mg/m3

Corrosive to metals (Category 1), H290 Skin corrosion (Category 1A), H314










7 Acitic acid 10 ppm (ST) 15 ppm (C) 40 ppm

10 ppm (ST) 15 ppm

10 ppm (ST) 15 ppm

Flammable liquids (Category 3), H226 Skin corrosion (Category 1A), H314












8

Basic chromium sulphate

0.5 mg/m3 - - Skin corrosion (Category 1B)










9 Sodium bi carbonate

- - - Not a hazardous substance or

mixture.



10

Acrylic acid

30 mg/m3 6 mg/m3 5.9 mg/m3 Flammable liquids (Category 3), H226 Acute toxicity, Oral (Category 4), H302 Acute toxicity, Inhalation (Category 4), H332 Acute toxicity, Dermal (Category 4), H312 Skin corrosion (Category 1A), H314 Specific target organ toxicity - single exposure (Category 3), Respiratory system, H335 Acute aquatic toxicity (Category 1),

H400












WORKER HEALTH CHECKUP PLAN

Company shall conduct pre-employment and post-employment medical tests for its

employees besides various educative and awareness programs on health and safety. A full

time medical assistance centre will be made available to its employees to carry out any first

aids.

Following is the list of Medical Tests / occupational health surveillance program for the

employees.

LIST OF MEDICAL TESTS

Health Parameter Proposed Practice

Lung Function Test Shall be done Annually

Chest X-Ray Shall be done Annually

Haemoglobin Shall be done Annually

ECG Shall be done Annually

Urine Tests Shall be done Annually

Blood Sugar, Cholesterols Shall be done Annually

Liver and Kidney Function Tests Shall be done Annually

Audiometry Shall be done Annually

Spirometry Shall be done Annually

Vision Testing (Far, near, color and ocular defects)

Shall be done Annually

Complete Blood Count (CBC) Shall be done Annually

BUDGET FOR OCCUPATIONAL HEALTH & SAFETY

S.No Description Amount

(Rupees In Lacs)

1 Workers will be subjected to primary health check-

up before they are employed to ascertain their

health conditions. Thereafter, Regular Medical

check-up & First Aid facility will be organized for

workers to evaluate the adverse impact if any on

4



these persons due to proposed activity.

Occupational health surveillance programme shall

be done six monthly. A safety officer /

environmental officer shall be recruited.

2 Infrastructure facilities such as sanitation, fuel,

restroom, canteen etc. shall be provided to the

labour force during construction as well as to the

casual workers including truck drivers during

operation phase.

4

3 Workers will be provided with masks, gloves,

goggles & ear muffs will be provided.

1

4. Covered transportation of vehicles. 2

5. Insurance for worker & Tie up with ESI Hospital 4

Total Rs. 15 lacs

BUDGET FOR PUBLIC HEALTH AND SAFETY

Sr. .No. Impact Mitigation Amount (In Lacs)

1. Health and

Safety • Health Check-up camps shall be

organized. • Support to primary Health centre. • Public addressing system

5

Total Rs. 5 lacs

SAFETY, HEALTH AND ENVIRONMENTAL (SHE) MANAGEMENT PLAN

The company has a written policy for the safety, Health and Environment Management.

Through this policy, the company management commits itself to the following objectives.

Meet all the relevant laws, regulations and international agreements



Conduct its activities safely, protecting the health of all employees and the products users

Reduce the adverse environmental impacts to a practicable minimum at an acceptable

cost to the company and society

Encourage continuous improvement in safety, health and environment performance

by m/s leayan global pvt. ltd.environmentclearance.nic.in/writereaddata/online/risk... · 2016. 5....

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