CHAPTER-IV

(RISK ASSESSMENT & MANAGEMENT PLAN)

4.0 DISASTER MANAGEMENT PLAN – IRON ORE MINE

It is presumed that the proposed mining process would be designed and engineered with all

possible safety measures and standard code of practices. In spite of this, there may be some

design deficiency or due to operation and maintenance faults which may lead to accidental

events causing damage to life and property. This chapter presents an over view of

environmental risk associated with various mining operations, suggested remedial measures

and on outline of the emergency preparedness plan.

4.1 Risk assessment

The objectives of environmental risk assessment are governed by the following, which excludes

natural calamites.

a. To identify the potential hazardous areas so that necessary design safety measures can

be adopted to minimize the probability of accidental events.

b. To identify the potential areas of environmental disaster, which can be prevented by

proper design of the installations and their control operations.

c. To manage emergency situation or a disastrous event, if any from the mining operation.

4.2 Identification of hazards

During the proposed operation of the open-cast mine, the following risks have been expected.

1. Filling up the mine pit due to excessive rains. 2. Failure of slope in the pit. 3. Failure of slope of external dump. 4. Fly Rock Fragment from Blasting Operations. 5. Accidents of heavy machinery. 6. Surface fire (Electrical and Oil). 7. Possible Danger due to Storage of Explosives.

4.2.1 Filling up the mine pit due to excessive rains

Filling up the mine pit due to excessive rains in the worked out area is a remote possibility.

Normally there will be sufficient warning time before such an incident takes place, harming

equipment and human life. However, as a precautionary measure, interceptor ditches along the

outer boundary of the pit area constructed to control inflow of runoff into the mine pits. Water

that collects in the mine pit from rainfall will be pumped out from the pits, using centrifugal

pumps.

4.2.2 Failure of slope in the pit

In order to allay dangers due to open cast slope failure, slope stability estimations have been

made of the existing quarries after determining various physical parameters of the ground mass

like uniaxial compressive strength, triaxial compressive strength, cohesion, angle of friction,

specific gravity of the rock, water pressure etc. Besides, all the discontinuities have been plotted

in stereo plots, which indicate that there is no chance of any planer failure or wedge failure.

Even then, factor of safety has been determined against overall slope failure as well as against

individual bench slope by circular failure, planer failure, wedge failure. Besides determining

factor of safety the slopes are monitored at regular intervals to check for any possible failure.

The well-developed drainage system over the lease area ensures that storm water does not

accumulate in the lease area and therefore hydrostatic pressure remains at a low level.

Thus all types of measurements and inspections will be carried out. The mine has been

designed based on the above considerations with sufficient safety margins to eliminate any

chances of slope failure in the pit.

4.2.3 Failure of slope of external dump

The slopes of external dumps have been initially planned at the angle of repose of dump

material. However, as the edge attain final position, the slopes will be terraced and proper

vegetation will be laid which will cause lowering of the slopes as well as binding of the soil,

preventing any slope failure.

4.2.4 Fly rock fragments and vibrations due to blasting

Trial blasting results from nearby mines have been used to arrive at the field empirical equations

based on which the charge per delay has been regulated to protect the nearby structures. All

precautions related to control of fly rock will be taken during the blasting operations. Safety zone

of 500 m as per statute shall be maintained. The nearest habitation is too far to be affected by

fly rock.

4.2.5 Accidents of heavy machinery

Most of the accidents during transfer of dumpers, trucks and other vehicles are often attributed

to mechanical failures, in which the factor of human errors cannot be ruled out. The subject

mine is a manual mine and the machinery is very less and hence the cause of accidents,

4.2.6 Surface fire

Spillage of HSD and resultant fire constitutes a potential risk. The quantity of the maximum oil,

which can spill, is not much and can be easily controlled. Sufficient numbers of portable fire

extinguishers has been provided at strategic locations to take care of any eventuality.

As soon as any fire is reported the shift-in-charge shall assume the function of disaster

controller. In case of serious fire and depending on the gravity of the situation, the Mines

Manager may be summoned to assume charge. Personnel trained in dealing with fires will be

summoned. Meanwhile the hospital will be informed to handle causalities. The fire area will be

cordoned off till the fire is fully extinguished and remain so until all wreckage and debris is

cleared away.

4.2.7 Danger due to storage of explosives

An explosive magazine exists in the mine. Adequate safety zone has been provided as per

statutory requirements while locating the magazine. The magazine has been constructed as per

plan approved by Department of Explosives. The following have been considered in the design

of the magazine.

All dry vegetation within a 15 m radius cleared.

Lighting arrestor installed on the magazine roof.

A safety zone around the magazine created.

In summer, the temperature inside the magazine is monitored to guard against

spontaneous fire.

The manufacturing dates of all explosives stored in the magazine are carefully recorded

so that no explosive whose shelf life has expired is kept in stock.

In case of any fire, whosoever notices the fire will sound the alarm and inform the shift-in-

charge. The shift-in-charge will inform security personnel and arrange to evacuate all personnel,

except those who are required for fire fighting, from the area. The fire brigade shall be

summoned to deal with the emergency. Concerned district officials will be informed. Nearby

hospitals will be informed to standby to handle casualties.

4.3 Preparedness Plan In order to take care of above hazards/disasters the following measures have been envisaged.

• Checking and regular maintenance of garland drains will be taken to avoid any in flow of surface water into the mine pit.

• Provision of suitable capacity pumps for pumping out water from mining pit. • Regulation 1961 will be strictly followed during all mine operations. • Entry to unauthorized persons will be prohibited. • Provision of all safety appliances such as safety boots, helmets Goggles etc. to the

employees and regular check for their use. • Training and refresher courses for all employees working in hazardous places. • Working of mine, as per approved plans and regularly updated. • Cleaning of mine faces will be regularly done. • Competent persons will carry out handling of explosives, charging and blasting only. • A blasting SIREN is used at the time of blasting for audio signal. • Before blasting and after blasting, red and green flags are displayed as visual signals. • Warning notice boards indicating the time of blasting and NOT TO TRESS PASS are

displayed prominently. • An approved explosive van is also available for transporting explosives to the blasting

site. • Provision of magazine at a safe place when fencing and necessary security

arrangement. • Regular maintenance and testing of all mining equipment as per manufacturer's

guidelines. • Suppression of dust on haulage roads. • Increasing the awareness of safety and disaster through competitions, posters and other

similar drives. As a part of disaster management, a rescue team is formed by imparting specialized training to

select mining staff.

4.4 TRAINING

The training of mine personnel is conducted regularly with respect to environmental protection.

Training facilities are also extended to equipment maintenance and operation also to the

operators. Training will cover the following fields.

Awareness regarding pollution control and environmental protection.

Operation and maintenance of pollution control equipment. Afforestation / plantation and post care of plants. Field monitoring, maintenance and calibration of pollution monitoring instruments. Chemical analysis of various environmental parameters at laboratory. Repair of pollution monitoring instruments. Knowledge of norms, regulations and procedures. Occupational health and safety. Risk assessment and disaster management plan.

4.5 IMPLEMENTATION OF EMP AND MONITORING SYSTEM

4.5.1 General

Various measures have been proposed to implement for mitigating the adverse impacts due to

mining on the environment in the area. A separate wing “Environmental Management Cell

(EMC)” will be formed to look after the inspection / monitoring requirements. The mine

management will undertake the control measures in coordination with the State Forest

Department, Regional APPCB and Environmental consultant. The management of environment

shall be made an integral part of the major activities of mining.

Fig.4.1 Organisational setup

of EMC

Important records to

be maintaine

d by EMC are:

Fiel

d monitoring results for air, water, meteorology

Inspection records of slope failure, land erosion, drainage, socioeconomic development.

Mines Manager

Geologist (Incharge of monitoring and

supervision)

Mining Engineer / Asst. Manager

Foreman

Dust Suppression Mate

Helpers

Format to record / monitor plantation measures.

Environmental and related standards / norms.

Records pertaining to statutory consents, approvals

Code of actions for population control in identified areas.

Periodic medical examination (PME) records.

Complaint register (environmental pollution)

Records on water and electricity consumption

Periodic progress records

Environmental audit records

Records of annual budgetary requirement and allocation for pollution control.

4.6 IMPLEMENTATION

The following system shall be followed to see that the environmental scheme is implemented as

per schedule.

a) A separate wing will be created to see that the engineering measures such as

construction of check dams and retention walls are taken up, wherever necessary.

b) A crew attends for afforestation measures on a regular basis for culturing, manuring and

watering.

c) On an quarterly basis, the quality of air, water, noise and soil will be monitored to

understand the status vis-à-vis the baseline data. This will enable the management for

taking up any corrective measures, if required. The frequency of sampling will be as

prescribed by the MOEF guidelines issued in this regard.

4.7 ACTIVITIES TO BE MONITORED / INSPECTED BY EMC

4.7.1 Slope failure

Regular examination will be carried out to look after for slope failure on open cast mine faces,

ore and over burden benches etc. Any abnormal condition, if observed will be brought to the

notice of concerned department. Survey team shall also monitor mine face with precision level

instruments.

4.7.2 Land erosion

Regular observations during the rainy season for checking land erosion will be made in back

filled areas / hill slopes.

4.7.3 Drainage

The effectiveness of drainage system depends upon proper cleaning of all drains and sumps.

Any blockage due to silting or accumulation of loose materials will be checked on a regular

basis. Stone pitching, brick mounds etc on drains shall also be monitored.

4.7.4 Blasting effects

Regular testing and inspection of blasting operations in work zone will be done with respect to

noise, fly rock fragments, vibration, dust and fume generation. These tests will also be

conducted whenever new pattern of blasting are adopted as per mine working.

4.7.5 Revegetation and green belt development

Planned schedule for green belt development will be checked after every year and improvement

required will be implemented. Post plantation status will be regularly checked in every season.

Phase wise development in the areas of plantation including rate of growth, survival rate etc. will

be recorded systematically.

4.7.6 Air quality monitoring

SPM, RPM, NOx and SO2 will be monitored every month in both core and buffer zones as per

the APPCB directions.

4.7.7 Water quality monitoring

Surface runoff during rainy season will be monitored for pH, TDS, SS and 24−SO contents.

Ground water quality is monitored seasonally for the above parameters also.

4.7.8 Occupational health

Each group of mine workers undergo regular medical checkup at regular intervals by specialist

doctors.

4.7.9 Socio-economic development

As a part of the social responsibilities, the project proponent will take up the following peripheral

developmental works.

Encouraging entrepreneurship among locals by vocational training.

Upgrading one primary school.

Health camps

Distribution of school uniforms and books to needy students Cultural activities in the villages Provision or free Transportation of patients Preferential employment to the local people depending upon their qualification and

suitability of post.

4.8 RISK ASSESSMENT – PROPOSED BENEFICIATION PLANT

Hazard analysis involved the identification and quantification of the various hazards (unsafe

conditions) that exist in the plant. On the other hand, risk analysis deals with the identification

and quantification of risks. The workers are exposed to, accidents resulting from the hazards

due to accident occur in the plant area.

Risk analysis follows an extensive hazard analysis. It involves the identification and assessment

of risks the neighbouring populations are exposed to as a result of hazards present. This

requires a thorough knowledge of failure probability, maximum credible accident scenario,

vulnerability of population etc. Consequently, the risk analysis is often confined to maximum

credible accident studies.

In the sections below, the identification of various hazards, probable risks in the proposed plant,

maximum credible accident analysis, consequence analysis are addressed which gives a broad

identification of risks involved in the plant. Based on the risk estimation for fuel and chemical

storage Disaster Management Plan (DMP) has been prepared.

4.8.1 Approaches to the Study

Risk involved the occurrence or potential occurrence of some accidents consisting of an event

or sequence of events. The risk assessment study covers the following:

Identification of potential hazard areas.

Identification of representative failure cases.

Visualization of the resulting scenarios in terms of fire (thermal radiation) and explosion.

Assess the overall damage potential of the identified hazardous events and the impact

zones from the accidental scenarios.

Assess the overall suitability of the site for hazard minimization and disaster mitigation

points of view.

Furnish specific recommendations on the minimization of the worst accident possibilities.

Preparation of board Disaster Management Plan (DMP), On-site and Off-site Emergency

Plan, which includes Occupational and Health Safety Plan.

4.8.2 Hazard Identification Risk analysis and possible hazards details

S.No.

Operation Process

Equipment

/areas

Possible

Hazardous

Precautionary

Measures

Measures to be taken if any hazard occurs

1 Rotary Kiln

Heat of the kiln

1. Fire fighting equipments powder / foam type extinguishers on vehicles and mounted on walls are kept readily available.

2. Hydrant systems provided at conspicuous places.

3. Water hose is provided.

4. No smoking zone – declared.

1. To switch off the system.

2. Fire extinguishers shall immediately be used.

3. Water hose will be operated to set out the fire.

4. Emergency alarm to be put on to signal the accident.

5. First aid shall be rushed to the site by the security staff.

6. Inform the manager present in the factory.

7. Immediate First Aid should be given to the victims and sent to hospital for further treatment.

2 Charging of coal No 1. Fire fighting equipments 1. If any worker is

and Iron Ore to crusher and dryer.

Hazardous due to automatic system

like extinguisher and water hydrogen with sufficient number of points easily available.

2. only trained and qualified people shall be appointed.

hurt/burnt in plant, immediate first aid should be given to the victim by trained person and refer to the doctor/hospital for further treatment.

2. Inform the In-charge Officer present in that shift.

3. Information should be given to the Plant Manager/CIF.

3 Control Rooms

Electrical Shock possible due to short-circuit.

Earth leakage circuit breaker is installed

In an event of electric leakage main supply should be immediately shut off.

4

Welding Gas Oxygen LPG and /Acetylene cylinders

Fire hazards caused by flames and leakage.

1. Emergency kit is kept readily available in store and working place.

2. Fire fighting equipments powder / Foam type extinguishers on vehicle and mounting on walls are kept readily available.

3. Hydrant system provided at conspicuous place.

4. Fire fighting trained man is employed.

5. Cylinders are handled carefully without dropping or rolling.

6. Precaution to ensure that cylinders are not allowed to dash with each other.

7. Sand bed cushion available for the purpose of

1. Installation of inert gas Nitrogen, Carbon dioxide. Equipments to take care of fire hazards in the factory are being installed.

2. Hydrant point will be for gas cylinders stores and point where welding operation is done.

unloading cylinders.

8. Periodic inspection done to avoid accident of any kind.

5 Electrical transformer

Electrical power

Shock proof insulted PCC Platform.

Immediate Cut off the power supply, treat the injured for electrical shock

Fire I

Fire fighting equipment

(i) Sand buckets.

(ii) Fire extinguisher.

Immediately fight fire with available resources, summon outside help if necessary.

6 Diesel Oil/ Transformer Oil etc. storage.

Fire hazard may be possible if directly comes in contact.

1. Fire proof system made available and fighting equipment like Foam, extinguishers and hydrant system, etc., are kept.

Proper care is to be taken while storing and keeping the oil drums.

7 Lab Chemicals

In case of bottle breakage, causes burns and damage to respirator systems due to inhalation.

1. Proper care should be taken while handling the chemicals.

2. First Aid Box should be available at Site with all necessary and required medicines.

3. Fire fighting equipment like Extinguishers, sand buckets should be available always.

Instruction Boards to be displaced for knowledge of other workers to take care of the situation in the event of occurrence.

4.9 DISASTER MANAGEMENT PLAN – PROPOSED BENEFICIATION PLANT

The word ‘disaster” is synonymous with ‘emergency” as defined by the Ministry of Environment

and Forests (MoEF). An emergency occurring in the proposed Iron Ore Beneficiation Plant is

one that may affect several sections within it and /or may cause serious injuries, loss of lives,

extensive damage to environment or property or serious disruption outside the plant. It will

require the best use of internal resources and the use of outside resources to handle it

effectively. It may happen usually as the result of a malfunction of the normal operating

procedures.

The project is in its formative stage and detail engineering is yet to be done, so the element of

the DMP are based on concepts.

Capability of DMP

The emergency plan envisaged will be designed to intercept full range of hazards

Specific to proposed plant such as fire, explosion, major spill etc. In particular, the DMP will be

designed and conducted to mitigate those losses of containment situations, which have

potentials to escalate into major perils.

Another measure of the DMP’s capability will be to combat small and large fires due to ignition,

of flammable materials either from storage or from process streams and evacuate people from

the affected areas speedily to safe locations to prevent irreversible injury.

Emergency medical aids to those who might be affected by incident heat radiation flux, shock

wave overpressures and toxic exposure will be inherent in the basic capabilities.

The most important capability of this DMP will be the required speed of response to intercept a

developing emergency in good time so that disasters such as explosion, major fire etc. are

never allowed to happen.

Disaster Contorl Philosophy

The principa l strategy of DMP is “prevention” of identified major hazards. The “Identification” of

the hazards will employ one or more of the techniques {e.g.Hazard and Operability Study

(HAZOP), accident consequence analysis etc}. Since these hazards can occur only in the event

of loss of containment, one of the key objectives of technology selection, project engineering,

construction, commissioning and operation is “Total and Consistent Quality Assurance”. The

Project Authority will be committed to this strategy right from the conceptual stage of the plant

so that the objective of prevention can have ample opportunities to mature and be realized in

practice.

The DMP or Emergency Preparedness Plan (EPP) will consist of

On-site Emergency plan

Off-site Emergency plan

Disaster Management Plan preparation under the headlines of On-site Emergency plan and Off-

site Emergency plan is in consonance with the guidelines laid y the Ministry of Environment and

Forests (MoEF) which states that the “Occupier” of the facility is responsible for the

development of the On-site Emergency plan.

The Off-site Emergency Plan should be developed by the Government (District Authorities)

4.9.1 On-Site Emergency Plan Objectives

The Objective of the On-site Emergency plan should be to make maximum use of the combined

resources of the plant and the outside services to

1. Effect the rescue and treatment of casualties.

2. Safeguard other personnel in the premises.

3. Minimize damage to property and environment.

4. Initially contain and ultimately bring the incident under control.

5. Identify any dead

6. Provide for the needs of relatives.

7. Provide authoritative information to the news media

8. Secure relevant records and equipment for the subsequent enquiry into the

cause and circumstances of emergency.

Action plans

The Action Plan should consist of:

1. Identification of Key Personnel

2. Defining Responsibilities of Key personnel

3. Designating Emergency Control Centers and Assembly points.

4. Declaration of Emergency

5. Sending All Clear Signal

6. Defining actions to be taken by non-key personnel during Emergency.

Key Personnel

The actions necessary in an emergency will clearly depend upon the prevailing circumstances,

Nevertheless, it is imerative that the required actions are initiated and directed by nominated

people, each having specified responsibilities as part of co-ordinated plan. Such nominated

personnel are known as Key Personnel.

The Key Personnel are:

1. Site Controller (SC)

2. Incidental Controller(IC)

3. Liaison and Communication Officer (LCO

4. Fire and Security Officer (FSO)

5. Team Leaders(TL)

Site Controller (SC)

In the emergency situation, decisions have to be taken which may affect the whole or a

substantial part of the plant and surrounding area. Many of these decisions will be taken in

collaboration with the other officers at the plant and the staff. It is essential that the authority to

make decision be invested in one individual. In this plan, he is referred to as the ‘Site Controller’.

The Plant Manager (however called) or his nominated deputy will assume responsibility as SC.

Incident Controller (IC)

In the emergency situation, someone has to direct the operations in the plant area and co-

ordinate the actions of outside emergency services at the scene of incident. The one who will

shoulder this responsibility is known as ‘Incident Controller’ in this plan.

A Senior Operations Officer or an officer of similar rank of the unit may be nominated to act as

the IC.

Liaison and Communication officer (LCO)

Operations Officer or any other officer of deputy rank will work as LCO and will be stationed at

the main entrance during emergency to handle police, Press and other enquiries. He will

maintain communication with the IC

Fire and Safety officer (FSO)

The Fire and Safety Officer will be responsible for fire fighting. On hearing the fire alarm he shall

contact the fire station immediately and advise the security staff in the plant and cancel the

alarm. He will also announce on PAS(Public Address System) or convey through telephones or

messengers to the SC, IC and LCO about the incident zone. He will open the gates nearest to

the incident and stand by to direct the emergency services. He will also be responsible for

isolation of equipment from the affected zone.

Team Leader (TL)

A number of special activities may have to be carried out by specified personnel to control as

well as minimize the damage and loss. For this purpose designated teams would be available.

Each team will be headed by a Team Leader (TL)

Following teams are suggested:

1. Repair Team

2. Fire Fighting Team

3. Communication Team

4. Security Team

5. Safety Team

6. Medical Team

Responsibilities of Key Personnel

Site Controller (SC)

1. On getting information about emergency, proceed to Main Control Centre

2. Call in outside emergency services

3. Take control of areas outside the plant, which are affected

4. Maintain continuous communication, review situation and assess possible course

of events.

5. Direct evacuation of nearby settlements, if necessary

6. Ensure that casualties are getting enough help

7. Arrange for additional medical help and inform relatives

8. Liaison with Fire and Police services and provide advice on possible

9. Effects on outside areas

10. Arrange for chronological recording of the emergency

11. where emergency is prolonged, arrange for relieving personnel, their catering

needs etc.

12. Inform higher officials in head office

13. Ensure preservation of evidence

14. Direct rehabilitation work on termination of emergency

Incident Controller (IC)

1. On getting emergency information, proceed to Main Control Centre.

2. Activate emergency procedure such as calling in various teams

3. Direct all operations within plant with following priorities:

a) Control and contain emergency

b) Secure safety of personnel

c) Minimize damage to plant, property and the environment

d) Minimize loss of material

e) Direct rescue and repair activities

f) Guide fire-fighting teams

g) Arrange to search affected area and rescue trapped persons

h) Arrange to evacuate non-essebtuak oersibbek ti safe area/assembly

point.

i) Set up communications network and establish communication with SC

j) Arrange for additional help/equipment to key personnel of various teams

k) Consider need for preserving all records, information for subsequent

enquiries

Liaison and Communication Officer

1. To ensure that casualties receive adequate attention, arrange additional help if

required and inform relatives

2. To control traffic movements into the plant and ensure that alternative transport is

available when need arises

3. When emergency is prolonged, arrange for the relief of personnel and organize

refreshments/catering facility

4. Advise the Site Controller of the situation, recommending (if necessary) evacuation

of staff from assembly points.

5. Recruit suitable staff to act as runners between the Incident Controller and himself if

the telephone and other system of communication fail. Maintain contact with

congregation points

6. Maintain prior agreed inventory in the control room

7. Maintain a log of the incident on tape

8. In case of a prolonged emergency involving risk to outside areas by wind blown

materials- contact local meteorological office to receive early notification of changes

in weather conditions.

Fire and Safety Officer

1. Announces over the PAS in which zone the incident has occurred and on the advice of

the Shift Officer informs the staff to evacuate the assembly

2. Inform the Shift Officer In-charge, if there is any large escape of products.

3. Call out in the following order:

a) Incident Controller or his nominated deputy

b) Maintenance Officer

c) Personnel and Administrative Officer

d) Departmental Head in whose area the incident occurred

e) Team Leaders(TL)

Emergency Control Centre

The Emergency Control Centre will be the focal point in case of an emergency from where the

operations to handle the emergency are directed and coordinated. It will control site activities.

Emergency management measures in this case have been proposed to be carried from single

control centre designated as Main Control Centre (MCC)

MCC is the place from which messages to outside agencies will be sent and mutual aids and

other helps for the management of emergency will be arranged. It will be located in the sage

area. It will be equipped with every facility for external and internal communication, with relevant

data, personal protective equipments to assist hose manning the centre to enable them to co-

ordinate emergency control activities. CC will be attended by SC.

Following facilities would be available in the MCC:

• P &T phones, mobile phones, intercoms, and wireless

• Fax and telex

• Emergency manuals

• Blown up area maps

• Internal telephone directories

• District telephone directories

• Emergency lights

• wind direction and speed indicator

• Requisite sets of personal protective equipment such as gloves, gumboots and aprons

MCC will be furnished with call out list of key persons, fire, safety, first aid, medical, security,

police and district administrative authorities. MCC will also contain safety data pertaining to all

hazardous materials likely to cause emergency and well-defined procedures of fire fighting,

rescue operations, first aid etc.

Assembly point

In an emergency, it will certainly be necessary to evacuate personnel from affected areas and

as precautionary measure, to further evacuate non-essential workers, in the first instance, from

areas likely to be affected, should the emergency escalate. The evacuation will be effected on

getting necessary message from i.e. on evacuation, employees would be directed to a

predetermined safe place called Assembly Point.

Proposed Location: Area opposite to service building will be the Assembly Point where all non-

key personnel would assemble on getting direction over Public-Address System.

Outdoor assembly points, predetermined and premarked, will also be provided to accommodate

evacuees from affected plant area(s). Roll call of personnel collected at these assembly points,

indoor and outdoor will be carried out by roll call crew of safety team to account for any missing

person(s) and to initiate search and rescue operations if necessary.

Declaration of Emergency

An emergency may arise in the terminal due to major leakage of oil or major outbreak of

fire/explosion. In case of major leak or major outbreak of fire the state of emergency has to be

declared by the concerned by sounding Emergency Siren.

Upon manual or sensor detection of a major loss of containment of volatile hazardous

substance, the DMP is activated by raising an audible and visual alarm through a network of

geographically dispersed gas/vapour and heat detectors and also “break glass” type fire alarm

call points with telephone hand sets to inform the Central Control Room.

A separate siren audible to a distance of 5 km range will be available for this purpose. The

alarm is coded such that the nature of emergency can be distinguished as a leakage or major

fire.

The Control Centre and Assembly point will be located at an area of the minimum risk or

vulnerability in the premises concerned, taking into account the wind direction, areas which

might be affected by fire/explosion, leakage etc.

After cessation of emergency, FSO will communicate to IC. After verification of status, IC will

communicate with SC and then announce the “All Clear” by instructing the Time Office to sound

the “All Clear Signal”.

Alarms would be followed by an announcement over Public Address System (PAS). In case of

failure of alarm system, communication would be’ by telephone operator who will make

announcement in the complex through PAS. Walkie-talkie system is very useful for

communication during emergency with predetermined codes of communication. If everything

fails, a messenger could be used for sending the information. Two 5 km, range variable pitch

electric sirens (one in service and the other standby) will generate the main alarm for the entire

site as well as for the district fire brigade. The alarm is coded such that the nature of emergency

can be distinguished as a leakage of major fire. Fire and Gas alarm matrices are provided at the

Central Control room, security gate, on-site fire station and main administrative office corridor to

indicate location of the site of emergency and its nature.

Mutual Aid

Procedure

All factories may not be equipped with an exhaustive stock of equipment/materials required

during an emergency. Further, there may be a need to augment supplies if an emergency is

prolonged.

It would be ideal to pool all resources available in the and nearby outside agencies especially

factories during an emergency, for which a formal Mutual Aid scheme should be made among

industries in the region.

Essential Elements

Essential elements of this scheme are given below:

• Mutual aid must be a written document, signed by Location In-charge of all the industries

concerned

• It should specify available quantity of materials/ equipment that can be spared (not that

which is in stock)

• Mode of requisition during an emergency.

• It should authorize the shift-in-charge to quickly deploy available material/equipment

without waiting for formalities like gate pass etc.

• It should spell out mode of payment/replacement of material given during an emergency

• It should specify key personnel who are authorized to requisition materials from other

industries or who can send materials to other industries

• It should state clearly mode of receipt of materials at the affected unit without waiting for

quantity/quality verification etc.

• Revision number and validity of agreement should be mentioned

• This may be updated from time to time based on experience gained

Emergency Management Training

• The Key Personnel would undergo special courses on disaster management. This may

preferably be in-plant training. The Managers, Senior Officers and Staff would undergo a

course on the use of personal protective equipment.

• The Key Personnel belonging to various Teams would undergo special courses as per

their expected nature of work at the time of emergency.

• The plant management should conduct special courses to outside agencies like district

fire services to make them familiar with the plant layout and other aspects, which will be

helpful to them during an emergency.

Mock Drills

• It is imperative that the procedures laid in this Plan are put to the test by conducting

Mock Drills. To avoid any lethality, the emergency response time would be clocked

below 2 minutes during the mock drill.

• 1st Step: Test the effectiveness of communication system

• 2nd Step: Test the speed of mobilization of the plant emergency teams

• 3rd Step: Test the effectiveness of search, rescue and treatment of casualties

• 4th Step: Test emergency isolation and shut down and remedial measures taken on the

system

• 5th Step: Conduct a full rehearsal of all the actions to be taken during an emergency

The Disaster Management Plan would be periodically revised based on experiences gained

from the mock drills.

Proposed Communication System

The instrument and control system will take care of the following operating philosophy of the

plant

• The project will be provided with a control system located in a central control room.

• The shift engineer will operate the plant from his console panel.

• All operations will be represented in a graphic panel on the console and every operation

will be depicted as operating sequences.

• All operating parameters will be displayed in digital format.

• Alarms will be provided for all parameters, when they exceed set values.

• High-High/Low-Low alarms and trip functions will be provided to trip

• Pumps/compressors to bring the entire system to a safe shutdown.

Proposed Fire Fighting System

Elaborate fire fighting system will be available for fighting fires in any corner of the plant. A

comprehensive fire detection and protection system is envisaged

• Fire water storage tanks of adequate capacity.

• Fire water pump house containing combination of diesel and electrically driven pumps.

• Hydrant system complete with suitable size piping, valves, instrumentation, houses,

nozzles, hose boxes/stations, monitors etc.

• Foam injection system for fuel oil/storage tanks consisting of foam concentrate tanks,

foam pumps, in-line inductors, valves, piping and instrumentation etc.

• Automatic high velocity water spray system consisting of detectors, deluge valves

projectors, valves, piping and instrumentation.

• Automatic high velocity water spray system consisting of QB

• Detectors/smoke detectors, linear heat sensing cable detectors, deluge valves, isolation

valves, nozzles, piping instrumentation etc.

• Suitable “Halon Substitutes” such as INERGEN or FM..200 or AGGONITE for protection

of control room, equipment room, computer room and other electric and electronic

equipment rooms.

• Computerized analogue, addressable, early warning type fire detection and alarm

system consisting various types of fire detection such as ionization type smoke detection

system, photo electric type smoke detection system, linear heat sensing cable detector,

quartzoid bulb (QB) heat detection system, infrared heat detectors and spot type

electrical heat detectors.

• Portable and mobile extinguishers, such as pressurized water type, carbondioxide type,

foam type, dry chemical powder (DCP) type located at strategic locations throughout the

plant.]

• Fire tenders/engines of water type, DCP type/foam type, trailer pump with fire jeep

etc.provided in the fire station.

• Complete instrumentation and control system for the entire fire detection and protection

system for safe operation of the complete system.

Other safety Measures

Considering that fire and explosion is the most likely hazard in such installations, the plant is

being provided with systems to guard against such hazards. Salient among these are:

• A proper layout to prevent and minimize the effects of any hazardous situation

• Design of storage vessels and all components to codes and standards to withstand the

rigorous duty

• Provision of operating systems to conduct the process through well established safe

operating procedures

• A control system, which monitors all, plant parameters and give alarms

• Control system, which has trip provisions to prevent hazard conditions escalating

• A gas detection system which will provide early warning of any leaks

• Provision of a fire protection system to control fire

• Provision of flame-proof lighting system in the fire prone areas

Proposed First Aid and Medical Facilities

The First Aid Medical Centre has been proposed. It will be fully equipped with emergency

facilities. It will be open round the clock. A Medical Officer with Compounder will always be

available in the centre. Emergency cars will be available in all the shifts. Adequate number of

first aid boxes will be kept at strategic locations. Required stock of first aid medicines will be

maintained. Trained first aiders will be available in all departments.

Facilities to be kept in the Medical Room along with others will include: Oxygen Cylinders,

Injection Coramine, Glucose Saline, LV. Sets, Syringes, Injection Needles, Stretchers and

medicines.

Proposed Emergency Power Supply

Strategic areas will be provided with emergency lights fed through stationed battery system.

Portable emergency lamps will be also available at required points. A Diesel Driven Generator

of adequate capacity will be available to keep the operations running in case of power failure.

Diesel Engine operated fire pumps will be available.

4.9.2 Off Site Emergency Plan

Objective

If the effects of the accident or disaster inside the plant are felt outside of its premises, it calls for

an off-site emergency plan, which should be prepared and documented in advance in

consultation with the District Authorities.

Key Personnel

The ultimate responsibility for the management of the off-site emergencies rests on the

Collector / District Magistrate / Deputy Commissioner. He will be assisted by representatives

from all concerned organizations, departments and services at the District level. This core group

of officers would be called the District Crisis Management Group (CMG). The members of the

group will include:

1) Collector/District Magistrate Deputy Commissioner

2) Commissioner of Police

3) Municipal Commissioner, if municipalities are involved

4) Deputy Director, Health

5) Pollution Control Board Representative

An Operation Response Group (ORG) will then be constituted to implement the directives of the

CMG.

The various government departments, some or all of which will be concerned, depending on the

nature of the emergency, could include:

• Police • Animal Husbandry

• Health & Fami Welfare • Agriculture

• Medical • Civil Defense

• Revenue • PWD

• Fire Service • Civil Supplies

• Transport • Panchayats

• Electricity

The SC and IC, of the on-site emergency team, will also be responsible for communications with

the CMG during the off-site emergency.

Education to Public

People living within the influence zone should be educated on the emergency in a suitable

manner. This can be achieved only through the Local and District Authorities. However, the

Project Authority can extend necessary information to the Authorities.

4.9.3 Disaster Management Plan for the Beneficiation Plant

The main objectives of this disaster management plan are to:

• To identify type of major disaster which may occur in the plant

• To prepare an action plan to handle disaster.

Identified Areas where disasters can occur

• Rotary kiln

• Bucket elevator

• Auto Loading & Unloading Section

• Electrical premises

Electrical room

Transformer area

Cable tunnel

• Other premises

All operating facilities and storage facilities for raw materials like coal, fuel oil etc

Severity of accidents have been categorized as Category I – Operator Level and Category II

– Local / Community Level

Category–I

In category-I, disasters may occur due to fire, explosion, oil spillage, mall function of the

machines and spontaneous ignition of inflammable materials. The severity of this category

depends upon the disaster type and nature of it. It may affect the work force health that involves

the operation at that facility and even may be on the facilities of the plant.

Category–II

In case of complete failure of all automatic control / warning systems of the different units then it

may leads to disaster which may have the high severity on inside work force and facilities of its

own and even may effects on the others facilities surrounding plant. Probability of these

disasters occurrences will be very less because of the plant alternative systems and well

qualified and trained work force which will be placed in respective areas.

Disaster Preventive Measures

• Design, construction of all facilities and machineries will be as per national and

international codes as applicable in specific cases and lay down by statutory authorities

• The operations of the plant will be as per applicable standards laid by the statutory

authorities

• Provision of adequate access ways for the movement of equipment and work force will

provide

• Minimum two numbers of gates for escape during disaster will take place

• All the storage facilities will be marked properly and protected by providing the fencing

around to the storage systems

• Water spraying in coal storage facility

• Well established fire fighting system

Safety and Training

In the plant all the workforce will be provided with necessary safety protective equipments.

Instrument the like safety valves, safety controls system. Safety department will look after the

safety awareness programs by different means like posters, messages on the notice boards, etc

and safety trainings in the plant as per requirement of the criticality. Safety training and practical

demos to the selected individuals in each department will provided.

Functions of Disaster Controller

• To declare “Disaster Emergency” after consulting the Sr. Officer available and inform

Fire Station Control Room to sound the sirens accordingly and arrange to convey the

message in public addresses system

• To report to DCR immediately

• To receive message from the communication centre

• To take decision in consultation with the commanding Officer of different services and

convey them to the disaster point

• To be responsible for planning and provision of assistance from township and from local

authorities

• Decision of the Disaster Controller on any matter will be final to met the objective of

disaster control plan.

• To assist Disaster Controller for provision of material and man power concerning his

services

• To convey message to his services team through communication centre after consulting

Disaster Controller

• To consult between themselves on matters related to more than one services and to

decide on the action to be taken

Repair Services

This section will look after mainly for the following areas after disaster takes place.

• To take up quick repairs of the damaged machinery

• To take up repair of damaged building roads and culverts.

• To maintain essential public utility services viz. water, electricity and sewages system.

Traffic Control

During the disaster, the movement of the safety vehicles and fire fighting vehicles will be

monitored and make the emergency ways to be free from vehicles to attend the disaster works

by the security of the plant. Persons arriving by motor transport at the location of fire /

emergency must not park their vehicle within 100 meters of fire, near fire hydrants, at road

junction and at access roads. The ignition key should be left in the vehicles.

Security Services

In the plant security department will be responsible for the plant security by keeping security

checks at different locations based on the sensitivity of the area. During the disasters the

functions of security will be follows:

• Alter the all workforce about the disaster and its location

• Update the developments and status of the disaster to the higher officials to take

necessary actions

• Co-ordinate the disaster status to the local authorities to get necessary support for them

• Control the vehicular traffic inside the plant to get way to the safety and fire fighting

vehicles to attend the disaster works immediately

• Assist the different divisions like fire fighting, safety, local authorities etc. to make the

process easy to handle the disaster works