chapter 7. risk assessment

EIA of Greenfield Facility SSP Manufacturing Unit at Village - Harjiana,

Tehsil - Garhshankar, District –Hoshiarpur(Punjab)

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CHAPTER 7. RISK ASSESSMENT

7.1. Introduction

GAFPL would be handling all materials (including some hazardous chemicals) at the

proposed plant. The storage of these materials is planned at the site location itself, so, in

an unlikely event of uncontrolled release of hazardous materials, there would be a

potential risk to life and property. The risk assessment study has been conducted for

various parameters that include identification of hazards, to calculate consequence

distances, to evaluate safety at the plant and to spell out risk mitigation measures to

enhance safety at the plant.

7.2. Hazard Identification

Hazard is defined as a chemical or physical conditions those have the

potential for causing damage to people, property or the environment. In this

chapter the hazards associated have been discussed.

The primary step of the Hazard identification is the risk analysis and entails the

process of collecting information on:

The types and quantities of hazardous substances stored and handled at the

plant,

The location of storage tanks & other facilities, and

Potential hazards associated with the spillage and release of hazardous

chemicals.

7.3. Hazardous Materials to be Stored at the Plant

Only major hazardous chemical to be stored at the project site is Sulphuric

Acid 98% with specific gravity 1.84. Spent sulphuric acid may be considered

for use based on availability and project viability.

The acid will be stored in two separate tanks; with each tank capacity of 1000

MT. Total acid storage capacity will be 2000 MT.

7.4. Characteristics of Hazardous Materials

This chapter details risks associated with the project activities and storage of

hazardous chemicals



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Important characteristics of the hazardous material (i.e. sulphuric acid) has been

presented below:

Associated Hazards

Hazards associated with the use and storage of sulphuric acid has been presented in the

following table:

CAS number 7664-93-9

ChemSpider 1086

UNII O40UQP6WCF

EC number 231-639-5

UN number 1830

RTECS number WS5600000

Properties

Molecular formula H2SO4

Molar mass 98.086 g/mol

Appearance Clear, colorless, odorless liquid

Density 1.84 g/cm3, liquid

Melting point 10 °C, 283 K, 50 °F

Boiling point 337 °C, 610 K, 639 °F

Solubility in water Miscible

Acidity (pKa) −3

Viscosity 26.7 P (20 °C)

Hazards

MSDS External MSDS

EU Index 016-020-00-8

EU classification Toxic (T)



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Corrosive (C)

Dangerous for the environment (N)

R-phrases R35

S-phrases (S1/2) S26 S30 S45

NFPA 704

Flammability (0)

Health (3)

Reactivity (2)

Flash point Non-flammable

Related compounds

Related strong acids

Selenic acid

Hydrochloric acid

Nitric acid

Related compounds

Sulfurous acid

Peroxymonosulfuric acid

Oleum

Types of

Hazard / Exposure

Acute Hazards / Symptoms

Prevention First Aid/ Fire Fighting

Fire Not combustible. Many

reactions may cause fire

or explosion. Gives off

irritating or toxic fumes (or

gases) in a fire.

No contact with

flammable

substances. No

contact with

combustibles.

No use of water. In case

of fire in the

surroundings: powder,

foam, carbon dioxide

may be used

Explosion Risk of fire and explosion

on contact with base(s), combustible substances,

oxidants, reducing agents

In case of fire: keep

drums, etc., cool by

spraying with water but



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Types of

Hazard / Exposure

Acute Hazards / Symptoms

Prevention First Aid/ Fire Fighting

or water. No direct contact with

water.

Actions required in case of Exposure

Exposure Effect

Prevent generation

of mists! Avoid all

contact!

In all cases consult a

doctor!

Inhalation Corrosive. Burning

sensation. Sore throat. Cough. Laboured

breathing. Shortness of

breath. Symptoms may be

delayed (see Notes).

Ventilation, local

exhaust, or

breathing

protection.

Fresh air, rest. Half-upright position. Artificial

respiration may be

needed. Refer for

medical attention.

Skin Corrosive. Redness. Pain. Blisters. Serious

skin burns.

Protective gloves. Protective clothing.

Remove contaminated

clothes. Rinse skin with

plenty of water or

shower. Refer for

medical attention.

Eyes Corrosive. Redness. Pain. Severe deep burns.

Face shield or eye

protection in

combination with

breathing

protection.

First rinse with plenty of

water for several minutes

(remove contact lenses if

easily possible), then

take to a doctor.

Ingestion Corrosive. Abdominal

pain. Burning sensation.

Do not eat, drink, or

smoke during work.

Rinse mouth. Do not

induce vomiting. Refer



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Exposure Effect

Prevent generation

of mists! Avoid all

contact!

In all cases consult a

doctor!

Shock or collapse. for medical attention.

7.5. Consequence Analysis

Scenario: Spill pool evaporation through sulphuric acid storage tank catastrophic failures: Sulphuric acid has high BP / low vapour pressure, the vapours generation will be limited

and spillage occurred will be contained within the dyke wall. It will be recovered. The

dangerous situation will arise due to any contact with metal giving rise to Hydrogen

generation.

7.6. Recommendations

Based on the outcome of the risk assessment, following recommendation has been made

to avoid any risk associated with the storage and use of sulphuric acid in the plant:

Double drain valve will be provided to sulphuric acid storage tank.

Full body protection PVC suit will be provided to operator during handling of

acid system.

Caution note and emergency first aid will be displayed

All employees will be trained for use of emergency first aid.

Safety shower and eye wash will be provided in storage tank area and plant

area.

Total close process will be adopted for Sulphuric acid handling.

Dyke wall will be provided to storage tank. Acid resistant tiling in dyke flooring

and inside dyke walls and acid resistant painting on tank foundation will be

provided

Tanker unloading procedure will be prepared.

SOP will be prepared for sulphuric acid handling.



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Training programme will be conducted for safe handling and emergency

handling of Sulphuric Acid to all concerned personnel including tanker drivers

and security

In Storage Tank Area, caution board with safety message for ‘acid on reaction

with water generates fumes and avoid such practice’ should be displayed

Suitable extinguishing media-Extinguish with dry powder / sand will be

provided. Do not use water. Fire and explosion hazards-Not flammable.

Personal protective equipment- Emergency Responders must use fresh-air

supplied breathing apparatus, eye protection, acid resistant hand gloves,

helmet and chemical protection suit.

Use acid neutralizing Diphoterine for personnel exposed to acid to protect

against burns.

Spillage protection: Do not let this chemical enter the environment. Collect

the acid from dyke in tank.

Evacuate danger area! Do not absorb in saw-dust or other combustible

absorbents.

Use lime for neutralizing the acid spillages/ leakages.

7.7. Occupational Exposure Mitigation Planning

To control any occupational health and safety impact a detailed planning for mitigation

measures has been done in the design stage of the project. Apart from the occupational

exposure mitigation plans for various activities and work areas of hazards, following

administrative control measures are will be followed site

GAFPL shall have a well-defined safety and occupational health programme conforming

to all international standards. The Company's integrated EHS Management System shall

include an onsite disaster management plan, mock-drills, safety audits and workshops,

an onsite medical centre, health awareness programmes and regular health assessment

of employees. A corporate EHS (Environment, Health and Safety) Policy and a site EHS

Policy shall provide the framework and guidelines for environment, health and safety.

GAFPL believes in building and maintaining excellent safety culture among its employees

and contractor workforce. The aim is to prevent/ minimize all incidents and injuries,



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investigate all incidents including first aid injuries and near misses followed by

implementation of 'Corrective and Preventive actions'. The Company ensures that all

jobs are adequately supervised, using necessary 'Personnel Protective Equipment' and

strictly follow safety precautions. Detail planning will be done during finalisation of

contracts.

EHS for construction Workers: GAFPL will also ensure that similar system of EHS

including occupational health, safety, environment, canteen, sanitary etc. ( as per

PunjabBuilding Construction Rules and National Building Code 2005 and Factories Act in

case of an industry) are followed by its construction group including contractors. As a

principal employer Geminiknows its responsibility.

7.8. Other Recommended Measures for Safe Operation of the Plant

In addition to the specific recommendations made in the above section for storage and

handling of sulphuric acid within the plant premises, for safe operation of the plant and

risk reduction, following suggestions and recommendations are made:

Personnel especially contractor workers at the plant should be made aware about the

hazardous substance stored at the plant and risk associated with them.

A written process safety information document may be compiled for general use.

The document compilation should include an assessment of the hazards presented

including (i) toxicity information (ii) permissible exposure limits. ( iii) Physical data (iv) thermal and chemical stability data (v) reactivity data (vi) corrosively data (vii) information on process and mechanical design.

The process design information in the process safety information compilation must

include P&IDs/ PFDs; process chemistry; maximum intended inventory; acceptable

upper and lower limits, pressures, flows and compositions and process design and

energy balances.

The adequate numbers of heat, smoke, detectors may be provided at strategic locations

in the plant and indication of detectors/sensors should be provided in main control room.

Predictive and preventive maintenance schedule should be prepared for

equipment, piping, pumps, etc. and thickness survey should be done

periodically as per standard practices.



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Safe work practices should be developed to provide for the control of hazards during

operation and maintenance.

Personnel engaged in handling of hazardous chemicals should be trained to

respond in an unlikely event of emergencies.

The plant should check and ensure that all instruments provided in the plant

are in good condition and documented.

Safety measures in the form of DO and Don’t Do should be displayed at

strategic locations especially in Hindi and English language.

Electrical Hazards: Proper guidelines and safety measures should be framed

for all electrical installations as per electricity rules. All major installations to

have proper earthing and if required (as per norms) lightening arrestors.

7.9. Personal Protective Equipment

Personal protective equipment (PPEs) is devices that are fitted and issued to each

worker personally for his or her exclusive use. They are intended for temporary use and

emergency response action only. If a worker must enter a confined space / contaminated area, he must wear adequate protective equipment. Employees should be

taught when and how to use respiratory apparatus (SCBA) provided, and how to

recognize defects in the equipment. Without SCBA entry into the confined space / contaminated area should not be attempted.

Keep personal protective equipment where it can be accessed quickly, outside

the hazardous material storage area and away from areas of likely

contamination.

Each employee should maintain his personal protective equipment in clean,

working condition at all times.

All equipment should be used and maintained in accordance with the

manufacturer’s instructions.

Equipment installed for body and eye wash should be checked properly for

round the clock operation.

7.10. Handling of Hazards



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Some of the measures employed in handling of hazards:

Personal protective equipment used by the workers during handling of hazardous

chemicals, should be replaced after getting defective.

If any spillage of hazardous chemicals, it should be cleaned and disposed as

per standard practiced.

Empty drums of hazardous chemicals should neutralize immediate.

Workers engaged in handling of hazardous chemicals should be made aware

of properties of hazardous chemicals.

7.11. General Working Conditions at the Proposed Plant

7.11.1. House Keeping

The House Keeping practices employed would be:

All the passages, floors and stairways should be maintained in good

conditions.

The system should be available to deal with any spillage of dry or liquid

chemical at the plant.

Walkways should be always kept free from obstructions.

In the plant, precaution and instructions should be displayed at strategic

locations in Hindi and English Languages.

All pits, sumps should be properly covered or securely fenced.

7.11.2. Ventilation

The Ventilation measures that would be employed:

Adequate ventilation would be provided in the work floor environment.

The work environment would be assessed and monitored regularly as local

ventilation is most effective method for controlling dust and gaseous emissions

at work floor.

7.12. Safe Operating Procedures

Other operation procedures followed would be:



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Safe operating procedures will be available for mostly all materials, operations

and equipment.

The workers will be informed of consequences of failure and strongly

emphasized to observe the safe operating procedures.

7.13. Work Permit System

Work permit system will be followed at the plant during maintenance.

7.14. Fire Protection

For fire protection the measures taken are:

The firefighting system and equipment will be tested and maintained as per

relevant standards.

Smoke detectors will be provided at the plant and shall be calibrated and

maintained properly.

Smoking and carry ignitable material, match boxes are not allowed inside

factory premises

Static Electricity

The general instructions for working with static electric are:

All equipment and storage tanks/containers of flammable chemicals shall be

bounded and earthed properly.

Electrical pits shall be maintained clean and covered.

Electrical continuity for earthing circuits shall be maintained.

Periodic inspections shall be done for earth pits and record shall be

maintained.

Material Handling

For material handling the regulatory measures that are taken for workers handling various

materials would include:

The workers shall be made aware about the hazards associated with manual

material handling.

The workers shall be made aware and trained about the use of personal

protective equipment (PPE) while handling hazardous chemicals.



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Communication System

Communication facilities such as PA system, landlines extension and

emergency numbers and walkie-talkie shall be checked periodically for its

proper functioning.

Safety Inspections

The system shall be initiated for checklist based routine safety inspection and

internal audit of the plant. Safety inspection team shall be formed from various

disciplines and departments.

Safe Operating Procedures

Safe operating procedures should be formulated and updated, specific to

process & equipment and distributed to concerned plant personnel.

Predictive and Preventive Maintenance

Predictive and preventive maintenance schedule shall be followed in religious

manner.

Electrical Safety

For electric safety provisions to be taken care of are:

Insulation pad at HT panels shall be replaced at regular interval.

Housekeeping in MCC room shall be kept proper for safe working conditions.

First Aid training and First Aid charts will be provided at all electrical control

centres

Colour Coding System

Colour coding for piping and utility lines shall be followed in accordance with IS: 2379:1990.

7.15. Emergency Management Plan

The organizational set-up necessary for chain of commands during emergency situation

in the plant is as given below.

Works Manager of the GAFPL is the Overall Site In charge and he shall be the main

guiding person directing the emergency operations. Works Manager will select two

rooms as Emergency Control Centres (ECC). Both these ECC rooms will be strategically



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(considering wind direction, safe location, approach etc.) located and furnished. ECC will

have adequate:

Multiple communication facilities (both within and Outside plant); telephone no’s. of all

essential personnel, mutual aid group organisations, district and other statutory

authorities, fire and safety and medical personnel no’s., will be highlighted, emergency

vehicle etc.

Plant Data [personnel working in different plants, Plant’s Manuals, Specific safety

features, hazardous locations etc.] and documents [Statutory clearances copies, Layout

drawings, Hazardous locations and safety features, Fire circuit, Safety manual, Anti dotes

for hazardous material, MSDS etc.] as may be required during emergencies.

Works Manager shall be assisted by:

Site Coordinator Manager- Production

Coordinate and direct all the activities from Emergency site.

In absence of Manager-Production, Dy. Manager (Prod) will

act as Site Coordinator.

Maintenance

Coordinator Manager-Maintenance

Coordinate all the maintenance activities from the Emergency

Control Centre.

In absence of Manager (Maint.), Dy. Manager-Maintenance

will act as Maintenance Coordinator.

Technical Coordinator Manager-QC

Coordinate for all the Environment Monitoring, support for

Safety & Fire Fighting.

In absence of Manager-QC, Dy Manager Safety will act as

Technical Coordinator.

Service Coordinator Manager-Admn.

Coordinate with local administration take care of transport,



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medical, canteen arrangements, and evacuation of people if

required.

In absence of Manager-Admn., Officer will act as Service

Coordinator.

GAFPL will select some areas and mark these areas as “Assembly Points” for collection

of the staff / personnel who will not be required to take part in the emergency operation. Attendance of these personnel will be taken and recorded.

Service Coordinator shall contact the following senior officers stationed at taluka and

district authorities at as may be required.

Table 7.1 : Telephone Numbers of the Authorities

DISASTER MANAGEMENT

KEY PERSONNEL - OFFSITE EMERGENCY RESPONSE

OFFICERS PLACE OFFICE RES.

COLLECTOR & DISTRICT MAGISTRATE

CITY MAGISTRATE (Taluka)

HSIDC Official

POLICE CONTROL ROOM

DY CHIEF INSPECTOR OF FACTORIES

PUNJABSTATE POLLUTION CONTROL BOARD

FIRE BRIGADE

CIVIL SURGEON

Local Hospital

NEAR BY INDUSTRIES (If any/ Mutual aid group

members)

NEAR BY INDUSTRIES (If any/Mutual aid group members)

7.16. Responsibilities & Role of Key Personnel



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7.16.1. Over all Site In-charge –Works Manager

On getting the information about emergency from Manager-Production rush to incident

site/ECC. Assess the overall situation and provide guidance in critical decision-making.

Site Coordinator-Manager-Production

On getting the information about emergency from plant, inform Works

Manager.

Rush to the emergency site to assess the situation and decide to:

Declare emergency based on amount/extent of hazards and water/air analysis

(toxic / flammable material release) and advise dy. Manager Safety for

sounding emergency siren.

Review if plant shutting down is required to contain / control the hazard.

Review, evacuation from affected areas and sending the affected person to a

safe place.

Advise Incident Controller and other key personnel to take necessary action.

He will interact with Service Coordinator and advise him on possible effects on

areas inside and outside the factory to initiate Off- Site Emergency Response

Plan.

Remain in touch with Overall in-charge (Works Manager) and inform about

the situation & actions being taken and seek his advice for the critical

decisions.

Maintenance Coordinator- Manager-Maintenance

After getting information about emergency from Plant. Inform other

Maintenance Supervisors to rush to site.

Rush to the ECC, assess the situation and facilitate with Site Coordinator- for

maintenance support needed to tackle the emergency.

Facilitate earth-moving equipment like Cranes, Dozers etc. required for

handling the emergency through civil coordinator.



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Facilitate elect. isolation of the affected area, if required through Supervisor-Electrical

Facilitate lighting arrangements at (a) affected locations and (b) Assembly

points if required

Facilitate work-shop facilities with adequate manpower if required.

Remain in touch with Site Coordinator.

Technical Controller & Environment Coordinator- Manager-QC

Rush to the site of emergency on getting the information from Plant, informs

other supervisors to rush to site to identify the hazards.

Facilitate monitoring /analysis of the area inside and outside the factory if

required and keep informed Site Coordinator about the results.

Remain in touch with Site Coordinator and shift in charge for taking samples

and rendering help to the plant personnel.

Facilitate laboratory equipment for sampling analysis within plant and outside

plant for accurate assessment with reference to offsite disaster if required.

Inform concentration of toxic gases to Site coordinator, Incident controller,

Service Coordinator.

Remain in touch with overall In charge – Works Manager and inform for any

foreseen Dangers in plant operations and suggest remedial measures.

Service Coordinator – Manager-Admin.

On getting information from site inform the administrative authorities and seek

help from District Admn., Police and Medical Centre. Rush to the Emergency

Control Centre.

Assess the situation in consultation with Site Coordinator and Incident

Controller and ensure that casualties get adequate transport / medical help.

Make arrangement to shift all the persons to the safest place if called for.

Assess 'Law and Order' situation.



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Inform press, TV / Radio, local authorities on the severity of situation in close

co-ordination with Site Coordinator and in consultation with Overall In-charge –Works Manager.

Arrange to close the school and shift all the persons to the safest place.

Inform the District Authority / local police station in case their help is required

for evacuation of personnel / preserving law and order.

Evacuation of adjoining areas and villages, if required.

Arrange help from mutual aid group neighbouring industrial units as per the

requirement of Site Coordinator.

Shift In charge:

Immediately proceed to the site of emergency and assess the situation: Inform:

Emergency Control Room (with name and location of emergency)

Manager -Production

Supervisor-QC

Inform Safety Officer for control of fire incidence.

Initiate the shutting down operations for controlling the hazard if unavoidable.

Cordon off the area and do not allow any body to enter the affected area

without respiratory protection (In case of toxic gas leakage).

Direct rescue operations with the help of fire and safety staff.

Open safety Almirah for the use of plant personnel.

Have regard to the need for preserving evidence that could facilitate

subsequent inquiry.

Advise one senior person of the plant to take roll call and account for missing

personnel.



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Hand over charge of the operation and assist the Manager Plant when he

arrives at site.

During emergency involving total failure of power and telephone system, the

concerned Shift In-charge will inform the Security Person on duty will organize

transport for sending messages (as per guidelines of Shift In-charge) through

messengers / Security guards on duty.

Ensure service agencies like Electrical, mechanical, instrumentation are

mobilized to handle the emergencies.

Fire & Safety Controller- Dy Mgr. Safety

Rush to the spot of emergency after getting information from ECC and inform

to other safety staff.

Direct rescue operations under the guidance of Site Coordinator/ Incident

controller if required

Ask additional help from shift in charge for cordoning off the area and advise

fire personnel for rescue / firefighting if required

Arrange to provide water curtains, water monitors, at affected locations if

required.

Organize and supervise fire-fighting operations if called .

Provide necessary respiratory equipment to plant personnel for emergency

use.

Advise Site Coordinator to arrange additional help from mutual aid group

members if required.

Give safety precautions to the personnel at rescue work.

Post Emergency Recovery

The post-emergency procedures discussed briefly below are designed to successfully

manage the damage / losses of an emergency event. The focus of these procedures is

to move the plant back into normal operating mode as quickly and efficiently as possible.

Immediately after the “ALL CLEAR” an emergency meeting will be held in emergency

control centre to assess the loss both for men & materials, where in following will be



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present with attendance records, details of injured, outside situation and preparation of

press release (if felt necessary)

Overall In charge

Site Coordinator

Maintenance Coordinator

Technical & Environment Coordinator

Service Coordinator

Accident Investigation

a. As soon as possible after the emergency is over and plant operation has

become normal, the investigation and analysis is to be carried out to determine

the cause of the event.

b. Representatives from various disciplines will be members of the investigation

and analysis team.

c. The areas of the events are to be sealed off so that tempering or alterations of

the physical evidence are not likely to occur.

d. Key components are to be photographed and logged with time, place, direction

etc.

e. Statements are to be taken from those who were involved with the operation or

who witnessed the event.

Damage Assessment

This phase of recovery establishes the quantum of replacement machinery considered

necessary for bringing back plant to normal operation; property and personnel losses

accounted and culminates in a list of necessary repair, replacement and construction

work.

Insurance companies will be informed of the damage and requested to pay the

compensation as per claim.

Clean-up and Restoration

This phase will only begin once the investigation is complete. Reporting documentations

are to be prepared and forwarded to appropriate authorities. Repair, clean up and

restoration work to begin.

chapter 7. risk assessment

Documents