risk assessment and disaster management...

RISK ASSESSMENT AND DISASTER RISK ASSESSMENT AND DISASTER RISK ASSESSMENT AND DISASTER RISK ASSESSMENT AND DISASTER

MANAGEMENT PLANMANAGEMENT PLANMANAGEMENT PLANMANAGEMENT PLAN

ForForForFor

Proposed Expansion of Cement Plant (Clinker Proposed Expansion of Cement Plant (Clinker Proposed Expansion of Cement Plant (Clinker Proposed Expansion of Cement Plant (Clinker

from 3.3 to 4.5 MTPA and Cement from 4.48 to from 3.3 to 4.5 MTPA and Cement from 4.48 to from 3.3 to 4.5 MTPA and Cement from 4.48 to from 3.3 to 4.5 MTPA and Cement from 4.48 to

6.0 MTPA)6.0 MTPA)6.0 MTPA)6.0 MTPA)

At Awarpur Cement Works, Village - Awarpur,

Taluka - Korpana, District - Chandrapur

(Maharashtra)

CONTENTS

S. NO. PARTICULARS PAGE NO.

1.1 RISK ASSESSMENT & DISASTER MANAGEMENT PLAN 1

1.1.1 RISK ASSESSMENT & DAMAGE CONTROL 1

1.1.2 HAZARD IDENTIFICATION & RISK ASSESSMENT (HIRA) FOR THE INTEGRATED CEMENT PROJECT 1

1.1.2.1 EXPOSURE TO HIGH TEMPERATURE 2

1.1.2.2 PHYSICAL HAZARDS 2

1.1.2.3 EVENTS PERTAINING TO THE MANUFACTURING PROCESS 3

1.1.2.4 FIRE 4

1.1.2.5 EXPLOSION 4

1.1.2.6 ELECTROCUTION 4

1.1.2.7 NATURAL AND MANMADE CALAMITIES WHICH CAN LEAD TO EMERGENCY 4

1.1.2.8 MANAGEMENT MEASURES TO PREVENT THE PHYSICAL HAZARDS IN THE PLANT 8

1.1.2.8.1 HIGH RISK CATEGORIES AND PREVENTIVE MEASURES 9

1.1.2.8.2 MEASURES FOR OCCUPATIONAL HEALTH HAZARDS 9

1.1.3 DISASTER MANAGEMENT PLAN 10

1.1.3.1 DEFINITION 10

1.1.3.2 SCOPE 10

1.1.3.3 OBJECTIVE 10

1.1.3.4 ONSITE EMERGENCY PLAN 11

1.1.3.4.1 DISASTER CONTROL MANAGEMENT SYSTEM 11

1.1.3.4.2 EMERGENCY CONTROL CENTRE 12

1.1.3.4.3 ROLES AND RESPONSIBILITY 14

1.1.3.4.4 EMERGENCY COMMUNICATION 21

1.1.3.4.5 ON SITE EMERGENCY PLANNING FOR CEMENT PLANT 21

1.1.4 OFF-SITE EMERGENCY PLANNING 26

1.1.4.1 ORGANIZATION 27

1.1.4.2 COMMUNICATIONS 27

1.1.4.3 SPECIAL EMERGENCY EQUIPMENT 27

1.1.4.4 VOLUNTARY ORGANIZATIONS 27

1.1.4.5 NON-GOVERNMENT ORGANIZATIONS (NGO) 27

1.1.4.6 CHEMICAL INFORMATION 28

1.1.4.7 METEOROLOGICAL INFORMATION 28

1.1.4.8 HUMANITARIAN ARRANGEMENTS 28

1.1.4.9 PUBLIC INFORMATION 28

1.1.4.10 ASSESSMENT 28

1.1.4.11 ROLE OF LOCAL AUTHORITY 28

1.1.4.12 ROLE OF POLICE 28

1.1.4.13 ROLE OF FIRE BRIGADE 28

1.1.4.14 MEDIA 29

1.1.4.15 ROLE OF HEALTH CARE AUTHORITES 29

1.1.5 CONCLUSION 29

LIST OF TABLES

LIST OF FIGURES

FIGURE NO. PARTICULARS PAGE NO.

1 VARIOUS ORGANIZATIONS INVOLVED DURING EMERGENCY 11

2 SCHEMATIC REPRESENTATION OF VARIOUS ORGANIZATION 27

TABLE NO. PARTICULARS PAGE NO.

1 POSSIBLE HAZARDOUS LOCATIONS ON SITE 2

2 LIST OF DAMAGES ENVISAGED AT VARIOUS HEAT LOADS 4

3 HIGH RISK CATEGORIES AND PREVENTIVE MEASURES 9

4 RESPONSE LEVEL MATRIX DURING EMERGENCY 13

5 LIST OF EXTINGUISHERS TO BE USED AS CASE SPECIFIC 23

6 LIST OF EXTINGUISHERS TO BE USED AS SITE SPECIFIC 23

7 SUMMARY OF RECOMMENDED PERSONAL PROTECTIVE EQUIPMENT

ACCORDING TO HAZARD ONSITE 25

1

1.1 RISK ASSESSMENT AND DISASTER MANAGEMENT PLAN

1.1.1 Risk Assessment & Damage Control

Risk assessment is the determination of quantitative or qualitative value of risk related

to a concrete situation and a recognized threat.

Activities requiring assessment of risk due to occurrence of most probable instances

of hazard and accident are both onsite and off-site.

1.1.2 Hazard Identification & Risk Assessment (HIRA) for the Integrated Cement

Project

The cement manufacturing industry is labor intensive and uses large scale and

potentially hazardous manufacturing processes. The industry experiences accident

rates that are high compared with some other manufacturing industries. Cement

industries experiences risk of a number of hazards inherent to the cement production

process. Following hazards may occur:

� Exposure to High temperatures;

� Physical Hazards;

� Events pertaining to Manufacturing Process;

� Fire;

� Explosion;

� Electrocution;

� Natural & Manmade hazards.

These mainly impact on those working within the industry, although health hazards

can also impact on local communities. The potential hazardous areas and the likely

accidents with the concerned area have been enlisted below in Table - 1.

2

TABLE - 1

Possible Hazardous Locations on site

S. No. Hazardous Area Likely Accident

1. Boiler Area Explosion

2. Electrical rooms Fire and electrocution

3. Transformer area Fire and electrocution

4. Cable tunnel Fire and electrocution

5. Storage yard Sliding

6. Crushing and grinding unit Fatal accident

7. Chimney Air pollution

8 Coal / fuel storage area Fire and spillage

9. Turbine room Explosion

1.1.2.1 Exposure to High Temperature

The principal exposures to heat in this sector occur during handling of hot raw meal

(Powdered limestone, laterite additives etc. heated in a pre-heater cyclone), hot

clinker and operation & maintenance of kilns or other hot equipment. Recommended

prevention and control techniques include the following:

� Shielding surfaces where workers proximity and close contact with hot

equipment is expected,

� Using personal protective equipment (PPE), as needed (e.g. insulated gloves

and shoes);

� Minimizing the work time required in high temperature environments by

implementing shorter shifts at these locations.

1.1.2.2 Physical Hazards

Injuries during Project operation are typically related to slips, trips, and falls; contact

with falling / moving objects; and lifting / over-exertion. Other injuries may occur due

to contact with, or capture in, moving machinery (e.g. dump trucks, front loaders,

forklifts). Activities related to maintenance of equipment, including crushers, mills, mill

separators, fans, coolers, and belt conveyors, represent a significant source of

exposure to physical hazards. Such hazards may include the following:

3

� Falling / impact with objects

� Hot surface burns

� Transportation

� Contact with allergic substances.

1.1.2.3 Events pertaining to the manufacturing process

The following areas are identified as hazard prone incase of Integrated Cement Plant

where Disaster management plan is required.

(i) Handling Of Coal

1. The coal will be received and stored in Stockpile. The possible hazards are envisaged

due to the slipping of wagon during unloading.

2. During summer season, there is chance of coal catching fire due to spontaneous

heating.

3. Effective sprinkling systems should be provided all round the coal storage yards.

(ii) Handling of fine dust

The hot raw meal (Powdered limestone, laterite additives etc will be heated in a multi -

stage pre heater cyclone) will be stored in the raw meal silos. It is very common that

the hot raw meal gets jammed in the chute and screw conveyers. During the

maintenance process, the operator generally works in the pre-heater cyclone and

other areas. Always there is a possibility of hazard that the jammed material falls on

the workers and due to hot temperature of the material, possibility of injury may

occur to the worker, sufficient care should be taken in the maintenance operations.

(iii) Handling of Hot Clinker

The hot clinker will be transported by chain conveyors to the top of the silo or closed

stock pile for storage. During this operation, there is a possibility of spill out of hot

clinker. Proper care for the conveyor system and the bund wall for the clinker stock

pile should be provided.

(iv) Handling of Cement

Cement is the fine dust which requires proper care in handling, storage and packing to

avoid any health hazards.

4

1.1.2.4 Fire

Fire can be observed in the boiler area, Coal storage yard, Fuel spillage, Electrical

rooms, Transformer area etc. due to accidental failure scenario.

1.1.2.5 Explosion

Explosion may lead to release of heat energy & Pressure waves. Table below shows

tentative list of Damages envisaged due to different heat loads.

TABLE: 2

List of Damages Envisaged at Various Heat Loads

Sr.

No.

Heat loads

(kW/m²)

Type of Damage Intensity

Damage to Equipment Damage to People

1 37.5 Damage to process equipment 100% lethality in 1 min. 1% lethality

in 10 sec

2 25.0 Minimum energy required to ignite

wood

50% Lethality in 1 min. Significant

injury in 10 sec

3 19.0 Maximum thermal radiation intensity

allowed on thermally unprotected

equipment

--

4 12.5 Minimum energy required to melt

plastic tubing

1% lethality in 1 min

5 4.0 -- First degree burns, causes pain for

exposure longer than 10 sec

6 1.6 -- Causes no discomfort on long

exposures

Source: World Bank (1988). Technical Report No. 55: Techniques for Assessing Industrial Hazards. ,

Washington, D.C: The World Bank.

1.1.2.6 Electrocution

Fatal Accident due to carelessness during working hours may lead to electrocution.

Probable areas where chances prevail are enlisted in Table - 2.

1.1.2.7 Natural and Manmade Calamities which can lead to Emergency

(a) Earthquake

The Chandrapur District area falls under the seismic zone-III, which is the moderate

risk quake up to magnitude 6.9 and may trigger into a technological disaster, includes

collapse of old structures, buildings leading to fire and explosion. Earthquake cannot

usually be forecasted and therefore precautions immediately prior to such event are

5

not usually possible. Apart from some of the counter-measures to be taken in

foreseeable cases, emergency recovery plan has been considered by the emergency

management team as per the situation and site conditions as follows:

Step Activity Action By

Preparedness • Identify and constitute Emergency Response Team

• Identify ECC, if the identified ones are damaged

• Control centers to be equipped with � Communication facilities � Emergency vehicles/ equipment � List of emergency contacts & suppliers � Medical facilities

Plant Key Person

Action during

effective period

• Do not panic. Raise alarm

• Avoid standing near to windows, external walls

• Stand near the columns or duck under sturdy furniture.

• Assemble at emergency assembly point as there may be aftershocks

Individual(s)

Action after

effective

Period (Establish

Emergency

Control

Center. Site Main

Controller to

direct

all activities)

• Take head count

• Activate emergency plan as situation demands

• Assess situation and initiate shut down of plants (if required)

• Initiate search & rescue (if required)

• Provide first aid to victims. Remove casualties

• Key persons to report to site

• Assess damage

• Undertake

Site Incident

Controller Site Main

Controller

Coordinators – Fire &

Security, Safety,

Material, Medical,

and Plant Key Person

(b) Storm

The contingency actions during storm shall be based on the weather forecasts

obtained from meteorological stations and the local meteorological department.

Some of the important actions to be carried out are as follows:

Prior to Storm

� Establish regular contact with the local meteorological department.

� Establish distances from storm in order to execute preparatory actions in a

shorter time.

� Appraise the factory operations / installations and consider the consequences that

the emergency might have on operations and personnel.

� Check the availability of tools, batteries, non-perishable foods and other materials

that might be required.

6

� Review all operations carefully to ensure that systems in jeopardy are taken care

of or shut down.

� Ensure the readiness of first aiders, emergency vehicles, medical centre, medicines

etc.

� Metallic sheets, loose materials, empty drums and other light objects shall be

properly secured.

� Flush the drainage systems.

During Storm

� Remain calm.

� Do not go outdoors.

� Do not seal the office completely as the suction created by the difference in

atmospheric pressure inside and outside can rip open a window or door by

breaking window glass panes.

After the Storm

� Do not touch electric lines.

� Stay away from the disaster area.

� Take special precautions in driving vehicles since the under-pavement could cave

in due to the weight of automobile.

(c) Flood

Though flood in this region is rare by virtue of its location from rivers and dams. ACW

and Captive Power Plants are out of danger from flood. However, the mine area will

affect during heavy rainfall as there is a nallah in between A-Block and B-Block mines.

The HFL alarm is provided at mine and during rainy season nallah is monitored by the

supervisors in all shifts. Two dewatering pumps are provided in case of flood in the

mine.

(d) Air Raid

Air raid warning would be obtained from the District Emergency Authority or Defense

Authorities, during which total blackout of the entire complex should be considered.

Some of the contingency actions to be considered during an air raid are as follows:

� The Aviation Lights installed on highest point inside the factory shall be

switched off.

� All the lighting on the Streets shall be put off.

7

� All the plant lighting shall be put off.

� Brown curtains shall be provided for all windows inside the building.

� Other emergency actions shall be followed in addition as per the general

procedure.

(e) Bomb Threat

In view of the probable acts of terrorism, the possibility of receiving bomb threats or

the sabotage cannot be ruled out. Therefore, consider all bomb threats as genuine

and act accordingly keeping in mind the safety of the people in the factory and the

property. For such situation, the security people will take action under the guidance of

the Section Head (Security). The Bomb threats may be received in writing or may be

received on phone. The expected actions by telephone receiver are as follows:

� Keep the caller on the line as long as possible. Request him to repeat the

message, listen carefully as every word spoken by the person has to be

recorded mentally or penned down.

� If the caller does not indicate the location of the bomb or the time of possible

detonation, it is advisable to try to ask him for this information.

� Pay particular attention to peculiar background noises such as motors running,

background music and any other noise, which may give a clue as to from where

the call is being made.

� Listen closely to the voice (male, female), voice quality (calm, excited), accents

and speech impediments. Immediately after the caller hangs up, report should

be made to the immediate senior manager or security officer on duty about all

the above details.

� In consultation with SMC, the Legal-Coordinator can immediately inform the

nearest Police station at Gadchandur and Police Chowaki at Nandaphatha over

phone and also Bomb diffusion squad.

� If the location is identified, cordon-off the area and ask people to leave the area

and assemble at designated assembly point.

� During strikes police will be informed by the Legal-Coordinator in advance and

taken their help to maintain law and order.

(f) Food and Water Poisoning

Food and water poisoning to a no of persons, due to canteen food or other means, is

another scenario which can leads to major emergency. In this case Medical Officer

8

would be informed immediately by the Sr. most person available at site and then to

incident Controller(IC) and Site Main Controller (SMC). In such situation doctors will

act and if situation demands additional help such as ambulances, doctors and

medicine would be arranged from nearby factories and hospitals. For such situations

SMC may decide whether siren is required to blow or not and arrange to inform key

persons in the factory and if required set up Emergency Control Centre (ECC) at

Hospital. Functional Head (FH) of HR would rush to ECC and assist SMC for informing

nearby hospitals, doctors and govt. authorities in consultation with the doctor. Plan to

deal with food & water poisoning can be divided in following stages:

Step Activity Action By

Planning & Preparedness • Maintain adequate inventory/ supply of medicines, saline water etc. and identify resources to obtain during emergency

• Impart awareness training regarding food/ water poisoning

Medical

Coordinator

Action during effective

Period (Establish Emergency

Control Center. Site Main

Controller to direct all

activities)

• Identify the contaminant source

• Seize contaminated material and keep out of circulation

• Take preventive measures for avoiding recurrence

• Inform all concerned

• Arrange to analyze samples

• Arrange alternate supplies

• Arrange medical assistance to the victims

• Mobilize assistance from outside (if necessary)

Site Main

Controller, Medical

coordinator and QC

person

Action after effective period • Conduct detailed epidemiological investigation to identify the cause of contamination

• Take appropriate preventive measures to avoid recurrence

• Follow up on causalities

Site Main Controller

Medical

coordinator, and FH

(HR)

1.1.2.8 Management measures to prevent the physical hazards in the plant

� Any person working on equipment with moving parts will personally ensure the

equipment is de-energized, isolated and locked/tagged out.

� Any person working from a position with the potential risk for a fall from height

will use fall protection.

� Any person doing flame welding, cutting or brazing in the proximity of any

flammable material will obtain PPE.

� Safety helmets to be used to protect workers below against falling material.

� Barriers like a toe boards or mesh guards is to be provided to prevent items

from slipping or being knocked off the edge of a structure.

� An exclusion zone is to be created beneath areas where work is taking place.

9

� Danger areas are to be clearly marked with suitable safety signs indicating that

access is restricted to essential personnel wearing hard hats while the work is in

progress.

� In case of any accident immediate & proper medical care shall be provided at

the plant site.

1.1.2.8.1 High Risk Categories and Preventive Measures

High Risk Categories and Preventive Measures are given in Table - 7.5.

TABLE: 3

High Risk Categories and Preventive Measures

High Risk Categories Prevention

Contractors Contractor Safety Management

Young/Temporary Employees Special Safety Induction Training

Direct Causes

Traffic & Mobile Plant Driver Training

Falls from Heights, Objects falling from

Heights

Safety Procedures for Work at Heights,

Overhead Protection

Caught in Starting/Moving Equipment Plant Isolation Procedures

1.1.2.8.2 Measures for occupational Health Hazards

� Dust Exposure level of shop floor workers is to be appropriately monitored.

� Check of the effectiveness of preventive and control measures on regular basis.

� Adequate supplies of potable drinking water is to be provided .Water supplied to

areas of Plant food preparation or for the purpose of personal hygiene (washing

or bathing) are to according to drinking water quality standards.

� Where there is potential for exposure to harmful dusts by ingestion arrangements

are to be made for clean eating areas, where workers are not exposed to the

hazardous or noxious substances

� Periodic medical hearing checks are to be performed on workers exposed to high

noise levels

� Provisions are to be made to provide OHS orientation training to all new

employees to ensure they are apprised of the basic site rules of work at / on the

site and of personal protection and preventing injury to fellow employees

10

� Contractors that have the technical capability to manage the occupational health

and safety issues of their employees are to be hired, extending the application of

the hazard management activities through formal procurement agreements

� Ambulances and First aid treatment facilities are made available for any

emergency situation.

1.1.3 Disaster Management Plan

1.1.3.1 Definition

A major emergency in a work is one, which has the potential to cause serious injury or

loss of life. It may cause extensive damage to property and serious disruption both

inside and outside the work. It would normally require the assistance of emergency

services to handle it effectively.

1.1.3.2 Scope

The aim of hazard control and disaster management is concerned with preventing

accidents through good design, operation, maintenance and inspection, by which it is

possible to reduce the risk of an accident, but it is not possible to eliminate it. Since,

absolute safety is not achievable; an essential part of major hazard control must also

include mitigating the effects of a major accident.

An important element of mitigation is emergency planning, i.e. recognizing accidents

as soon as possible, assessing the consequences of such accidents and deciding on the

emergency procedures, both on-site and off-site, that would need to be implemented

in the event of an emergency.

1.1.3.3 Objective

The overall objectives of the emergency plan will be:

a) To localize the emergency and, if possible eliminate it; and

b) To minimize the effects of the accident on people and property.

Elimination will require prompt action by operations and works emergency staff using,

for example, fire-fighting equipment, water sprays etc. Minimizing the effects may

include rescue, first aid, evacuation, rehabilitation and giving information promptly to

people living nearby.

To deal with the above emergencies, the Emergency Plan is prepared.

1.1.3.4 Onsite Emergency Plan

The onsite emergency management of Awarpur

same will be applied in case of proposed expansion.

1.1.3.4.1 Disaster control Management system

Disaster Management group plays an important role in combating emergency in a

systematic manner. Schematic representatio

during emergency is shown below in the figure

of an Emergency Response Plan relies on a number of response functions, which deal

with different aspects of emergency, with the most

� Communication and Co

� Fire and Rescue (Emergency Mitigation) Emergency Control Team at Incident

Site

� Medical Services

� Security

� Administration (Logistics and Welfare)

� Co-ordination with external agencies

Figure – 1: Various Organizations Involved During Emergency

11

Onsite Emergency Plan

The onsite emergency management of Awarpur Cement Works is given here, as the

same will be applied in case of proposed expansion.

Disaster control Management system


Schematic representation of Emergency Control Team involved

during emergency is shown below in the figure - 7.6. In addition; the implementation


with different aspects of emergency, with the most important ones being:

Communication and Co-ordination

Fire and Rescue (Emergency Mitigation) Emergency Control Team at Incident

Administration (Logistics and Welfare)

ordination with external agencies

Various Organizations Involved During Emergency

Cement Works is given here, as the


n of Emergency Control Team involved

In addition; the implementation


Fire and Rescue (Emergency Mitigation) Emergency Control Team at Incident

12

1.1.3.4.2 Emergency Control Centre (ECC)

An Emergency Control Centre (ECC) is established from which emergency operations

are directed and co-ordinated. Centre will be activated as soon as on-site emergency is

declared. The ECC will consist of one room, located in an area that offers minimal risk

being directly exposed to possible accidents. During an emergency, the Emergency

Management Staff, including the main controller will gather in the ECC. Therefore, the

ECC will be equipped with adequate communication systems in the form of

telephones and other equipments to allow unhampered organization and other

nearby facility personnel. The ECC is located at the following two locations:

� Security Office located at Main Gate (marked as “ECC-1” on the plant layout

drawing)

� Alternate ECC at CCR (marked as “ECC-2” in the plant layout drawing).

Manning of ECC during Emergency is as follows:

� Site Main Controller and his alternate

� Assistant to SMC

� Telephone Attendant

� Three Messengers

� Key Personnel as per the matrix.

The ECC will provide shelter to its occupants against the most common accidents; in

addition, the ECC’s communication systems will be protected from possible shutdown.

The ECC will have its own emergency lighting arrangement and electric communication

systems operation. The ECC will always be ready for operation and provided with the

equipment and supplies necessary during the emergency such as:

� Hazard identification chart, All Emergency response plans

� Population around factory

� Internal telephone connections and External telephone connections

� A list of key personnel, with addresses, telephone numbers, etc.

� Hotline connection to district collector, police control room, fire brigade, Hospital

etc.

� Public address system (PAS)

� MSDS of all the materials used in Plant site

13

� List of dispensaries and registered medical practitioners around factory

� Area map of surrounding villages

� Note pads and ball pens to record message received and instructions

� The blown up copy of Layout plan showing areas where accident has Occurred

� Undated copies of the On-site Disaster Management Plan

� Emergency telephone numbers

� The names, phone number, and address of external agencies, response

organizations and neighbouring facilities

� The adequate number of telephone

� Emergency lights

� List of fire extinguishers with their type no. and location, capacity, etc

� Personal protective equipment(PPE)

� Safety helmets

� Clock

� Material safety data sheets for chemicals handled at the facility

� Several maps of the facility including drainage system for surrounding area

showing:

� Areas where hazardous materials are stored

� Plant layout

� Plot plans of storage tanks, routes of pipelines, all water permanent lines etc.

� The locations where personal protective equipment are stored

� The position of pumping stations and other water sources

� Roads and plant entrances

� Assembly areas

� Lay out of Hydrant lines

TABLE - 4

Response Level Matrix during Emergency

S. No. During Normal Operation During Emergency

Designation Location Designation Location

1. Unit Head Admin Block Site Main Controller (SMC)* ECC

CCR - ACW Alternate – FH (Technical)

CPP – FH (CPP)

Mines Office – FH (Mines)

2. HOD ( Process) – ACW CCR Incident Controller Site

Alternate – SH (Process Kiln)

14

HOD (Packing) – ACW

Packing

Plant

Incident Controller Site

Alternate – SH (PP Oprs.)

3.

HOD (Operations) – CPP CCR-CPP

Incident Controller Site

Alternate – SH (TPP Oprs.)

4. HOD (Operations) – Mines

Mines Office Incident Controller Site

Alternate – SH (Oprs.)

5. FH (HR) Admin Block

Liaison Officer ECC

Alternate – HOD (Admin)

6. FH (F&C) Admin Block

Material Coordinator Site

Alternate – HOD (Materials)

7. CMO Hospital Medical Coordinator Hospital

Alternate – MO

8. HOD (Safety) Safety Dept Safety Coordinator ECC

Alternate – SH (Safety)

9.

SH (Security) Security

Dept

Fire & Rescue Coordinator Site

Alternate – Security Officer

* Site Main Controller for three plants. In his absence respective plant functional head would act as

Site Main Controller. In emergency functional head should rush to the Emergency Control Centre.

* Shift In-charge of the incident area will work as Incident Controller till arrival of designated incident

controller as indicated above.

1.1.3.4.3 Roles and Responsibility

Site Main Controller (SMC)

The Site Main Controller (SMC) has an overall responsibility for directing operations

and calling outside help. The Unit Head assumes the role of SMC. The alternate would

be as per the response level matrix indicated above. Depending on the location of the

emergency site and the prevailing wind direction, the SMC will decide and use one of

the two Emergency Control Centres, the main is at the Security Department at Main

Gate as ECC-1 and alternate is CCR as ECC-2 for handling and controlling the

emergency. He will then proceed to that Emergency Control Centre and take overall

control of the emergency and provide guidance in critical decision making. Specific

Responsibilities / duties of the SMC are as under:

� Continually review and assess existing and possible developments to determine

the

� Most probable course of events and effective methods to deal with them.

� Direct a safe shut down and evacuation of plants, if required, in consultation

with the IC and key personnel.

15

� Ensure that casualties are receiving adequate attention.

� Decide in consultation with Incident Controller and key persons whether an off-

site emergency exists or is likely to take place. If an off-site emergency exists or

it is imminent then arrange to or instruct the concern–

o To alert evacuate the public living in the vicinity of the Plant and, if

necessary, advise their evacuation.

o Call the outside emergency services.

o Inform district emergency authorities.

o Co-ordinate with district emergency authorities to mitigate the

consequences

o Outside the factory.

o Co-ordinate with district emergency authorities for evacuation, shelter,

rescue.

o Rehabilitation of general public in the vicinity of affected area.

� Issue authorised statements to the press or the media in consultation with

media contact person.

� Inform company senior officials.

� Declare cessation / termination of emergency after having full control on

emergency event.

� Rehabilitate the affected area after the emergency is over.

� In case of Strike by the Plant Personnel, identify critical areas of the Plant in

advance. If emergency occurs during the strike, following arrangements are

required to be made in advance to meet the crisis.

o Keep the list of Technical and Administrative Records needed to run the

factory in an emergency and train the team.

o Keep the record of Personnel (Non-executive) likely to be available during

the strike and keep the same in safe custody.

o Identify alternate arrangements for meeting any emergency in the

factory, i.e. by mutual aid with other factories, etc.

Incident Controller(IC)

The Incident Controller (IC) operates from the nearest accident site. The ICs are

identified location wise and mentioned in Table - 7.6 (Response Level Matrix during

emergency). The identified ICs are:

16

� HOD (Process) – ACW : Process Area

� HOD (Packing) – ACW : Packing Areas

� HOD (Operations) – CPP : Captive Power Plant

� HOD (Operations) – Mines : Mines

For silent hours, i.e. shifts or on holidays the senior most available or shift in-charge,

for that shift would work as IC until the arrival of the seniors. The responsibilities of

the IC are enumerated below:

After getting the emergency call from site, rush to the emergency site to assess the

situation and look into the following:

� Check other responders are arrived at site.

� Set up communication network with the Emergency Control Centre (ECC-1 or

ECC-2, as the case may be), using Intercom and walkie-talkie.

� Take stock of the situation at site and found uncontrollable inform SMC. After

taking the stock of the situation decide in consultation with SMC for declaring

the emergency and inform the security guard at CCR for sounding the

emergency siren.

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

inform SMC and if required shut down the plant in consultation with SMC. If

required evacuate the persons from affected areas by sending them to the

assembly points. Guide response teams i.e. fire & rescue and first aid and other

personnel to take necessary action.

� Interact with SMC and brief him on possible effects on areas inside and outside

the factory to initiate Off- Site Emergency Response Plan.

� Remain in touch with SMC and inform him about the situation & actions being

taken and seek his advice for the critical decisions.

� Ensure that the essential personnel have been called in at site

� Direct all operations within the affected area with following priorities –

o Secure safety of personnel, giving priority to saving life and preventing

further injury.

o Minimize damage to plant, property and the environment.

o Minimize loss of material.

17

o Advice and inform as required by the emergency responders, i.e., Fire and

Security personnel or emergency services.

Preserve evidences, which would be necessary for subsequent investigation to find

out the immediate and underlying causes of the emergency and for concluding

preventive measures.

Legal Coordinator

Functional Head (HR) would be the liaison officer. On hearing the emergency siren or

getting the information about emergency he shall immediately come to Emergency

Control Room and provide necessary instructions to his team members. The team

comprises HOD-HR, HOD-ER, HOD-Security/Admin and Medical Services. His duties are:

� Arrange to send time keepers to the Assembly points for counting the persons

assembled at the assembly points through HOD-ER

� To ensure the casualties receive adequate attention for immediate medical

treatment.

� To arrange additional medical help if so required.

� Arrange to inform the relatives of the injured persons after taking permission

from Main Site Controller.

� Arrange to keep ready alternative arrangements for transport to carry out the

necessary work related to emergency.

� If emergency prolongs arrange relief for the personnel who are engaged in

controlling emergency and organize refreshment or other canteen facilities.

Materials Coordinator

Functional Head (F&C) would be the Materials Coordinator. On hearing the emergency

siren or getting the information about emergency he shall immediately come to

Emergency Control Room and provide necessary instructions to his team members.

The team comprises HOD-Materials, SH-Raw Materials and SH-Stores. His Duties are:

� Get the stores opened for requirement of the Fire fighting/safety and other

materials, which may be required during emergency.

� Assess the situation in consultation with SMC and IC for any material

requirement help at the affected site.

� Ensure free movement of trucks of bulk material, if required.

18

Medical Coordinator

Chief Medical Officer would be the Medical Coordinator. On hearing the emergency

siren or getting the information about emergency he shall immediately perform

following duties.

� Rush to the hospital on getting information about emergency by siren or

telephone.

� Depute one Medical Assistant for spot first aid.

� Remain in touch with SMC for any help required.

� If required he shall send the seriously injured persons to the pre-identified

hospitals

Fire & Rescue Coordinator

Section Head (Security & Fire) would be the Fire & Rescue Coordinator. On getting

message on telephone or by other means about emergency he shall immediately rush

to the affected site with his and work under the command of Incident Controller.

� The Fire Team members shall immediately start fire-fighting operation by

connecting the hoses to the fire hydrant system or by operating deluge

system.

� The Rescue Team members shall search for any missing person/casualty and

carry out rescue operation and brought to the nearest first aid centre, where

ambulance available.

� Ask additional help for cordoning off the area and advise fire personnel for

rescue/fire fighting if required

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

required. Organize and supervise fire-fighting operations if called for.

� Provide necessary respiratory equipments to plant personnel for emergency

use.

� Advise IC to arrange additional help from nearby by industries, if required.

� Give safety precautions to the personnel at rescue work.

Safety Coordinator

HOD (Safety) would be the Safety Coordinator. On hearing the emergency siren or

getting the information about emergency he shall immediately come to Emergency

19

Control Room and provide necessary instructions to his team members and advise

them to report at emergency site. His duties are:

� His main role is to advise SMC on Occupational Health and Safety matters.

� Make arrangements for all necessary safety equipment, breathing apparatus,

fire entry suit, etc.

Security Coordinator

HOD (Security/Admin) would be the Security Coordinator. On getting message on

telephone or by other means about emergency they shall immediately rush to the

main security gate and arrange as follows:

� Advise the security person at security department to activate the barrack alarm

to call additional security personnel at colony

� Arrange to send the Security Guards/Firemen to the affected site for providing

the help to Emergency teams.

� Arrange to close all the Security gates except Main Gate for any kind of

unauthorized entry in the plant.

� Arrange for all necessary fire fighting t, foam making and rescue equipments.

� Guide the Outside helping agencies such as Fire Brigade, ambulances, etc to

the emergency site.

� Arrange for traffic and mob control.

� Arrange to take the transporter trucks/vehicles outside the main gate.

Engineering Activities Controller

The person form the section /department from where emergency situation raised, is

lead as the controller. He would be assisted by maintenance and electrical people. On

hearing the emergency siren or getting information of the emergency he shalli)

Arrange to send the Electrician and Mech. Fitter to the Pump House to ensure the

pumps are operating with uninterrupted electrical supply and without any problem.

� To arrange electrical shut down of the affected plant or portion thereof after

getting information by the Main Site Controller/Incident Controller.

� Make arrangements for necessary tools, forklift, etc for carrying out salvage

operation to save the unaffected material from the affected site.

� Make arrangements for emergency illumination/ lighting in case of power

failure during night time.

20

Other functions

� Transport In-charge

On hearing the emergency siren or getting the information about emergency he

shall immediately rush to the Emergency Control Room for providing vehicles for

emergency duties and shifting casualties to Medical Centre.

� Communication Coordinator

Shift Security Supervisor at CCR would work as communication coordinator.On

getting the information about the onsite emergency from on duty process Shift

Engineer of affected area only, he shall perform following duties.

o Send one security to ECC to operate.

o Inform immediately all the key personnel about the Incident individually on

telephones.

� ETP Officer

o Arrange all available resources for efficient housekeeping and cleanliness work

of affected site after the emergency is over.

o Make necessary arrangement for treatment of effluent/fire water/fire fighting

foam/chemical spillage satisfactory at the Effluent Treatment Plant to avoid

the pollution control problem.

� Person who notices the Emergency

The initial response by individual to an emergency situation will make the difference,

as seconds count. The people in the departments are trained for using of the fire

extinguishers. If anybody notices the fire or any other emergency they should act as

follows:

o Inform immediately about the fire to the concerned process control room and to

the Security Department (dial 339). Also make the announcement about the fire

on PA system, if available.

o Try to extinguish the fire with the help of fire extinguisher/ fire hydrant system/

CO2 total flooding valve/deluge valve. Take the help from others if required.

o If the fire is extinguished at its initial stage inform Safety Department and Security

Department.

21

1.1.3.4.4 Emergency Communication

The views of the possible hazards that can arise out of the daily operations in the plant

various measures are adopted to prevent the occurrence of a major accident. This

comprises of:

a) Built in safety measures, alarms, trips and interlocks etc.

b) Standard safe operating and maintenance procedures permit system etc.

c) Training of all the involved staff in normal and emergency operating procedures.

d) Training of all employees in safety, fire fighting and first aid.

However, in spite of these precautions, it is required to foresee situation of major

accident and plan for taking timely action to minimize the effects of such incident on

the safety and health of persons working in the plant as well as those situated around

the premises. Hence the present plant is drawn up to serve as the manual of handling

major emergencies.

Internal telephone systems are provided at work places. Shift In charge at site and

other In charge also given on call handset (Walkie Talkie) for immediate

communication to all concerned. The shift in charge /Site in charge will immediately

inform department Head / in-charge, security and dispensary (if required). The

department head in charge will inform Vice president and factory manager who

according to severity of emergency will inform about the emergency to Senior

President.

In case of devastating fire / major accident or hazard, immediate information will be

given as per need to following through telephone operators who will be available

round the clock over phone.

1.1.3.4.5 On site emergency planning for cement plant

Following onsite measures is being/will be taken to avoid/ minimize the risk of

accidents & other hazards in cement plant and power plant:

(i) Alarm and Communication Systems

Communication is crucial factor in handling an emergency. It is the practice at many

plants that any employee can raise an emergency alarm, so allowing the earliest

possible action to be taken to control the situation.

Alarm systems vary and will depend on the size of the plant. There should be an

adequate number of points from an audible warning, or indirectly, viz. a signal or

message to a permanently manned location. The alarm should alert the people to

22

implement appropriate emergency procedures. In areas where a high level of noise; it

may be necessary to install more than one audible alarm transmitter or flashing lights.

Automatic alarms may be appropriate on some sites.

There should be a reliable system for informing the emergency services as soon as the

alarm is raised on site. The details of the communication arrangements should be

agreed locally; in some cases it may be advisable to have a direct line to the fire bridge.

Predetermined code works to indicate the scale and type of the emergency may be

valuable.

(ii) Fire-fighting System

In view of vulnerability to fire, effective measures will be taken to minimize fire

hazard. Fire protection is envisaged through hydrant and sprinkler system, designed

as per the recommendation of Tariff Advisory Committee of Insurance Association of

India. The following areas in the power station are mainly susceptible to fire:

� Cable galleries

� Electrical switchgear/ MCC room

� Coal handling areas: Conveyors, transfer points, tunnels and storage yard.

� Transformers and turbine oil tank

For containment of fire and preventing it from spreading in cable galleries, section

wise fire barriers with self - closing fire resistant doors will be provided. The ventilation

systems, if any, provided in cable galleries will be interlocked with the fire alarm

system, so that in event of a fire, the ventilation system will be automatically switched

off. In order to avoid spreading of fire all cable entries opening in cable galleries,

tunnels, channels, floors, barriers etc will be sealed with non-inflammable/Fire

resistant sealing materials.

For detection and protection of the plant against fire hazard, any one or a

combination of the following systems will protect susceptible areas:

� Hydrant system.

� Automatic high velocity spray system

� Medium velocity spray system

� Portable fire extinguishers

� Fire alarm systems

Fire hydrant points will be provided throughout the premises. Automatic high velocity

spray system will be provided for protection of transformers and cable galleries.

23

Manual medium velocity spray system will be provided for protection of fuel oil and

turbine oil storage tanks and coal conveyor galleries.

Water for hydrant, spray and sprinkler system will be supplied from the firewater

pumps located in firewater pump house adjacent to Raw Water Reservoir. Adequate

number of portable and mobile chemical fire extinguishers will be provided at

strategic locations throughout the plant. Fire detection and alarm system will be

provided at strategic locations throughout the plant. Fire detection and alarm system

will be provided to detect fire/ smoke in vulnerable areas of the plant through smoke

/heat detectors. Table - 5 & Table - 6 enlist case & Site specific Fire extinguishers

respectively.

TABLE - 5

List of Extinguisher to be used as case specific

Sl No. Chemical Name Type of Extinguisher

1 Coke Use: Water fog, CO2, Foam, Dry Chemical

2 Fuel Oil Use: Water spray, foam, dry powder or carbon

dioxide

Do Not Use: water jet as an extinguisher, as this

will spread the fire

3 HSD Use: Foam, Carbon dioxide, Dry Chemical Powder.

Water may be used to cool fire-exposed containers

4 LDO Use: water fog, foam, dry chemical or carbon

dioxide (CO2) to extinguish flames

5 Fly Ash Non Flammable

6 Gypsum Non Flammable

7 Laterite Non Flammable

8 Metal dust Certified class D Extinguishing agent

TABLE - 6

List of Extinguisher to be used as Site specific

Sl No. Name of site Type of Extinguisher

1 Cable galleries CO2 & Foam type, Dry chemical powder

2 High voltage panel CO2 & Foam type, Dry chemical powder

3 Control rooms CO2 & Foam type, Dry chemical powder

4 MCC rooms CO2 & Foam type, Dry chemical powder

5 Pump Houses CO2 & Foam type, Dry chemical powder

6 Guest houses and offices Dry chemical powder, foam type

7 Godowns Foam type

8 Bunkers, Silo, enclosed dust

collector

CO2 type, N2 type, automatic sprinkler, fixed spray

nozzle(unless water reactive)

24

(iii) Evacuation Procedure

As the major hazard is only due to fire, which has more or less localized impact no

mass evacuation, procedures are required. Evacuation would involve only the people

working very close to the fire area.

(iv) First Aid

A first aid center with adequate facilities shall be provided. It shall be maintained

round the clock by a compounder cum dresser and a doctor. An auxiliary first aid

squad shall be identified, the members of which shall be spread in each shift in

different departments. In the event of an emergency this squad will augment medical

services. An Ambulance which is available with plant shall also be used at site to carry

affected people to hospital. Assistance of these hospitals will be taken in case of any

necessity.

(v) Safety

The safety wing led by a Safety officer will meet the requirement of emergencies

round the clock. The required safety appliances shall be distributed at different

locations of the plant to meet any eventualities. Poster/placards reflecting safety

awareness will be placed at different locations in the plant area.

(vi) Emergency Drills

The emergency response plans and emergency preparedness level would be tested

through the following drills:

a. Table-top exercise (TTE)

b. Functional exercise (FE)

c. Full-scale exercise (FSE)

All elements/procedures of the On-Site Emergency Plan would be first tested through

TTE and perfected to the extent possible. The Plan then would be modified/ updated.

Functional Exercises basically to ensure proper functioning of various equipment such

as the fire-fighting equipment and the fire hydrant system. The Full-Scale Drill would

be conducted to know the level of preparedness of all teams. Initially, TTE and FE

would be conducted periodically.

The following drills are conducted periodically:

a) Plant Emergency Drill for fire

b) Fire Drills at offices and admin building

c) Plant Emergency Drills (fire scenario involving evacuation)

25

(vii) Personal Protective Equipments (PPEs)

Personal protective equipments play a vital role in overcoming major disastrous

situation saving life during onsite emergency. List of recommended Personal

Protective equipment (PPE) is given below in Table - 7.

TABLE - 7

Summary of Recommended Personal Protective Equipment according to hazard onsite

Objective Workplace Hazards Suggested PPE

Eye and face

protection

Flying particles, molten metal,

liquid chemicals, gases or

vapors, light radiation

Safety glasses with side-shields, protective

shades, etc.

Head protection Falling objects, inadequate

height clearance, and overhead

power cords

Plastic helmets with top and side impact

protection

Hearing

protection

Noise, ultra-sound Hearing protectors (ear plugs or ear muffs)

Foot protection Failing or rolling objects, points

objects. Corrosive or hot

liquids

Safety shoes and boots for protection against

moving and failing objects, liquids and

chemicals

Hand protection Hazardous materials, cuts or

lacerations, vibrations, extreme

temperatures

Gloves made of rubber or synthetic material

(Neoprene), leather, steel, insulation

materials, etc.

Respiratory

protection

Dust, fogs, fumes, mists, gases,

smokes, vapors

Facemasks with appropriate filters for dust

removal and air purification (chemical, mists,

vapors and gases). Single or multi-gas

personal monitors, if available

Oxygen deficiency Portable or supplied air (fixed lines).

Onsite rescue equipment

Body / leg

protection

Extreme temperatures,

hazardous materials, biological

agents, cutting and laceration

Insulating clothing, body suits, aprons etc. of

appropriate materials

Fly Ash Fly ash handling and storage Wear dust-proof goggles and rubber or PVC

gloves.

When using large quantities or where heavy

contamination is likely, wear: coveralls.

At high dust levels, wear: a Full-face Class P3

(Particulate) or an Air-line respirator where an

inhalation risk exists, wear: a Class P1

(Particulate) respirator.

26

Apart from this, all the employees are provided with helmets and safety shoes. It is

statutory on the part of the company employees to wear the appropriate safety gear

given while attending duty in the factory.

1.1.4 Off-Site Emergency Planning

The off-site emergency plan is an integral part of any hazard control system. It is based

on those accidents identified by the works management, which could affect people

and the environment outside the works. Thus, the off-site plan follows logically from

the analysis that took place to provide the basis for the on-site plan and the two plans

therefore complement each other. The roles of the various parties that may be

involved in the implementation of an off-site plan are described below. The

responsibility for the off-site plan will be likely to rest either with the works

management or with the local authority. Schematic representation of various

organisation involved during emergency is shown below in Figure - 2.

Either way, the plan must identify an emergency coordinating officer who would take

overall command of the off-site activities. Consideration of evacuation may include the

following factors:

� In the case of a major fire but without explosion risk (e.g. an oil storage tank), only

houses close to the fire are likely to need evacuation

� If fire is escalating very fast it is necessary to evacuate people nearby as soon as

possible.

� In acute emergency people are advised to stay indoors and shield themselves

from the fire.

Figure - 2:

1.1.4.1 Organization

Organizational details of command structure, warning systems, implementation

procedures, emergency control centres include name and appointments of incident

controller, site main controller, their deputies and o

emergency.

1.1.4.2 Communications

Identification of personnel involved, communication centre, call signs, network, list of

telephone numbers.

1.1.4.3 Special Emergency Equipment

Details of availability and location of

equipment, fireboats etc.

1.1.4.4 Voluntary Organizations

Details of Voluntary organizations, telephone numbers nearby of hospitals,

Emergency helpline, resources etc are to be available with chief

1.1.4.5 Non-government Organizations (NGO)

NGO’s could provide a valuable source of expertise and information to support

emergency response efforts. Members of NGOs could assist response personnel by

performing specified tasks, as planned d

� Evacuation of personnel from the affected area

27

: Schematic Representation of Various Organizations



controller, site main controller, their deputies and other key personnel involved during


Special Emergency Equipment

Details of availability and location of heavy lifting gear, specified fire

equipment, fireboats etc.

Voluntary Organizations


Emergency helpline, resources etc are to be available with chief authorities.

government Organizations (NGO)



performing specified tasks, as planned during the emergency planning process.

Evacuation of personnel from the affected area

Various Organizations



ther key personnel involved during


heavy lifting gear, specified fire-fighting


authorities.



uring the emergency planning process.

28

� Arrangements at rallying posts and parking yards

� Rehabilitation of evacuated persons.

1.1.4.6 Chemical information

Details of the hazardous substances (MSDS information) and a summary of the risks

associated with them are to be made available at respective site.

1.1.4.7 Meteorological information

There is to be arrangements for obtaining details of weather conditions prevailing at r

before the time of accident and weather forecasts updates.

1.1.4.8 Humanitarian Arrangements

Transport, evacuation centres, emergency feeding, treatment of injured, first aid,

ambulances, temporary mortuaries.

1.1.4.9 Public Information

� Dealing with the media-press office

� Informing relatives, etc.

1.1.4.10 Assessment

� Collecting information on the causes of the emergency

� Reviewing the efficiency and effectiveness of all aspects of the emergency plan.

1.1.4.11 Role of local authority

Local Authorities like Panchayat, Sabha, Samity, municipalities can help in combating

emergency situation after assessing the impact scenario in rescue phase.

1.1.4.12 Role of police

The police is to assist in controlling of the accident site, organizing evacuation and

removing of any seriously injured people to hospitals.

� Co-ordination with the transport authorities, civil defence and home guards

� Co-ordination with army, navy, air force and state fire services

� Arrange for post mortem of dead bodies

� Establish communication centre with easy contact with ECC.

1.1.4.13 Role of Fire Brigade

The fire brigade is to be organized to put out fires and provide assistance as required

during emergency.

29

1.1.4.14 Media

� The media is to have ready and continuous access to designated officials with

relevant information, as well as to other sources in order to provide essential and

accurate information to public throughout the emergency and to avoid

commotion and confusion.

� Efforts are made to check the clarity and reliability of information as it becomes

available, and before it is communicated to public.

� Public health authorities are consulted when issuing statements to the media

concerning health aspects of chemical accidents.

� Members of the media are to facilitate response efforts by providing means for

informing the public with credible information about accidents involving

hazardous substances.

1.1.4.15 Role of health care authorities

� Hospitals and doctors must be ready to treat all type of injuries to causalities

during emergency.

� Co-ordinate the activities of Primary Health Centres and Municipal Dispensaries to

ensure required quantities of drugs and equipments.

� Securing assistance of medical and paramedical personnel from nearby

hospitals/institutions.

� Temporary mortuary and identification of dead bodies.

1.1.5 Conclusion

It has concluded that there will be no major risk involved due to proposed project

activity. Proper precaution will be taken so risk can be minimized. Personal Protective

Equipments (PPEs) will help to minimize the health hazards and accidental casualties.

So it is safe to say that there will be no major risk involved due to the proposed project

activity.

risk assessment and disaster management...

Documents