risk assessment and disaster management...

M/s. Century Rayon

(A Division of Century Textiles

and Industries Limited)

Risk Assessment and

Disaster Management Plan

Proposed Expansion of Viscose Filament Yarn

(25,000 TPA to 30,000 TPA)

At

P.B. No. 22, Murbad, Shahad, Ulhasnagar, District -Thane (Maharashtra)

Proposed Expansion of Viscose Filament Yarn (25,000 TPA to 30,000 TPA)

At P.B. No. 22, Murbad, Shahad, Ulhasnagar, District -Thane (Maharashtra)

Risk Assessment & Disaster Management Plan

Century Rayon 1 (A Division of Century Textiles and Industries Limited)

1.1 RISK ASSESSMENT

Accidental risk involves the occurrence or potential occurrence of some accident consisting of an

event or sequence of events resulting into fire, explosion or toxic hazards to human health and

environment.

MCA stands for Maximum Credible Accident or in other words, an accident with maximum damage

distance, which is believed to be probable. MCA analysis does not include quantification of the

probability of occurrence of an accident. In practice, the selection of accident scenarios for MCA

analysis is carried out on the basis of engineering judgement and expertise in the field of risk

analysis especially in accident analysis.

A disastrous situation is the outcome of fire, explosion or toxic hazards in addition to other natural

causes that eventually lead to loss of life, property and ecological imbalances.

1.1.1 Methodology of MCA Analysis

The MCA analysis involves ordering and ranking of various sections in terms of potential

vulnerability. The data requirements for MCA analysis are:

o Operating manual

o Flow diagram and P&I diagrams

o Detailed design parameters

o Physical and chemical properties of all the chemicals

o Detailed plant layout

o Detailed area layout

o Past accident data

Following steps are involved in the MCA analysis:

o Identification of potential hazardous sections and representative failure cases

o Visualization of release scenarios considering type and the quantity of the hazardous

material

o Damage distance computations for the released cases at different wind velocities and

atmospheric stability classes for heat radiations and pressure waves.

1.1.2 Hazard Identification

Identification of hazards is an important step in Risk Assessment as it leads to the generation of

accidental scenarios. The merits of including the hazard for further investigation are subsequently

determined by its significance, normally using a cut-off or threshold quantity.

o Fire

o Explosion

o Accidental Spillage or Leak of Hazardous (Flammable, Toxic) Chemicals & Gases

o Contact with Flammable Toxic Chemicals and Gases

o Loading/ Unloading /Packaging Operations failures

o Electrocution/ Electrical Hazards.





Table - 1.1

Possible Hazardous Locations Onsite

S. No. Hazardous Area Likely Accident

1. Churn Room / Simplex Flammable

2. After Treatment Dryer Corrosive

3. Sulphur Pit Flammable

4. CS2 Plant Flammable

5. Sulphuric Acid Plant Flammable

6. Coal Handling Yard Fire

1.1.2.1 Fire and Explosion Index (FEI)

Fire and Explosion Index (FEI) is useful in identification of areas in which the potential risk reaches a

certain level. It estimates the global risk associated with a process unit and classifies the units

according to their general level of risk. FEI covers aspects related to the intrinsic hazard of

materials, the quantities handled and operating conditions. This factor gives index value for the

area which could be affected by an accident, the damage to property within the area and the

working days lost due to accidents.

Fire and explosion index is then calculated as the product of Material Factor (MF) and Unit Hazard

Factor. Degree of hazards based on FEI and TI is given in the following Tables 1.2 and 1.3,

respectively.

Preventive and protective control measures are recommended based on degree of hazard.

Therefore, FEI indicates the efforts to be taken to reduce risks for a particular unit. FEI and TI

computed for various process equipment are presented in Table 1.4.

Table - 1.2

Degree of Hazards Based On FEI

FEI Range Degree of Hazard

0 - 60 Light

61 - 96 Moderate

97 - 127 Intermediate

128 - 158 Heavy

159 and Above Severe

Source: Dow’s Fire and Explosion Index Hazard Classification Guide,

Seventh Edition, AIChE Technical Manual (1994)

Table - 1.3

Degree of Hazards Based On TI

TI Range Degree of Hazard

0 - 5 Light

5 - 10 Moderate

Above 10 High





Table - 1.4

Fire and Explosion Index and Toxicity Index for Process Units

S. No. Unit Name FEI Category

Fire and Explosion Index

1. Furnace Oil Storage Tank (Diesel Power House) 18 Light

2. Carbon Disulphide Storage Tank (CAS No. 75-15-0) 53.13 Light

Toxicity index

1. Carbon Disulphide Storage Tank 14.72 High

1.1.3 Results & Conclusion from MCA Analysis

Risk has been quantified in terms of individual and societal risk contours for process equipment and

storage tanks for partial and full rupture scenarios. The maximum individual risk generated in the

plant site is of 10-6 level. Risk acceptance criteria provided by UK Guidelines are used. The risk is

acceptable according to the international standards.

The necessary risk mitigation measures for these equipments have been recommended in following

sections. The societal risk from other process equipment and storage tanks is within the acceptable

region.

1.1.4 Risk Mitigation Measures

Risk mitigation measures have been recommended based on computation of indices and MCA

analysis. General as well as specific recommendations are presented in the subsequent sections.

Following are some of the anticipated Hazards in the plant premises of Century Rayon along with

the preventive measures to be undertaken for the same:

1. Fire Hazard

a. Fire In Churn / Simplex

Hazardous Chemical CS2

Hazard Fire and explosion

May arise due to Exhaust system not working and CS2 Comes into contact with air

Areas effected Rayon and Tyrecord Plant Churn Room / Simplex

Preventive Measures

� Fresh air is supplied through a fan from one end and the same is vented out through

induced draft from the other end.

� Only non-sparking tools are permitted.

� Mobile phones are strictly prohibited.

� Light fitting in churn / simplex room are imported Class II - C flame proof fittings and

so also the motors driving the churn.

� There are double fire proof steel doors. The walls for isolating the churn / simplex

from other sections are 18” thick as per insurance regulations.

� The CS2 measuring vessels are ultrasonically tested for their thickness every year.

(Churn to Stain Steel).





In case of fire occurs in churn / simplex, action to be taken is as follows:

� Actuate the fire alarm.

� Inform the fire fighting dept. And all concerned as per plan.

� Drain all the CS2 in measuring vessels.

� Flush the area with hydrant water.

� Only minimum number of people should be allowed to go near the area.

� In case the fire is heavy evacuate the people from the adjoining section.

� Extinguish the fire and investigate the reasons for the Fire.

� Do not take CS2 in the vessels till the problem is solved.

� Anybody affected should be immediately shifted for medical help.

b. Fire Hazard in After-Treatment Dryer

Nature of Fire

� Fire can be localized inside the dryer tunnel.

� Can engulf full tunnel or entire dryer.

� Can have cascading effect on the adjacent dryer.

� Dried yarn is vulnerable to fire hazard.

Causes of Fire

� Electrical spark.

� Welding spark while carrying out maintenance job.

� Spark out of mechanical friction.

Remedial Measures

� Hydrant system to be operated by fire fighting dept.

� While carrying out any maintenance job inside or outside the dryer:

i) Area to be barricaded.

ii) Work permit to be taken;

ii) Trained personnel to operate the hydrant system.

Immediate action to be Taken

� Inform incident controller

� Shut off the steam supply to the dryers.

� Put off the electrical supply to the dryer.

� Identify the location of fire.

� Put fire fighting team into action.

� Evacuate Rayon Yarn from dryers.

To avoid cascading Effect

� Keep the adjacent / neighboring dryer under low temp & heat.





c. Fire in Sulfur Melting Pits

Sulfur which is the raw material for the manufacture of sulfuric acid and carbon-di-sulfide is

melted in common melting unit by steam coils. This molten sulfur is then used. This sulfur in

melting units can catch fire and thus cause toxic release in the form of SO2 gas. The melting

point of sulfur is 1210C and sulfur requires a temperature of about 130 - 140 0C to remain in the

molten state. Steam pressure of about 3.5 kgs / cm2 is used for this purpose.

Preventive Measures

� All the pits are covered with MS plates to avoid sparks etc. from coming in contact

with molten sulfur.

� No smoking boards are put up.

� Care is being taken to see that all the steam coils are submerged in sulfur to cut off

atmospheric oxygen.

� CO2 cylinders are kept to extinguish fire.

� Hydrant hose pipe arrangement is kept near the melting area.

� Hot work is allowed only after proper covering & issuance of hot work permit.

Consequences of Fire in Sulphur Melter

The entire area is affected by SO2 gas. These SO2 gases cause irritation in the throat. In case

of heavy fire in the melting area the duties are mentioned below :-

� The fire is reported to the Shift Incharge.

� Shift Incharge rushes to the site and informs the fire fighting officer.

� The fire fighting officer arrives with his team to extinguish the fire.

� The telephone operator is also informed who, in turn, passes on the information of fire

to the medical team, to the senior plant officer. Transport arrangement is also made to

shift gas affected people, if any, to the hospital.

� After the fire is extinguished, all clear signal is given notifying the end of emergency.

2. Measures for Chemical Hazard

a. Rayon Plant

� In simplex, after Xanthation process is completed any excess CS2 in it is exhausted

before the simplex door is opened for removal of the orange crumbs.

� Each spinning machine is provided with a forced exhaust arrangement to take away

the gases.

� Process requirement for spinning of yarn is to maintain 75% R.H. inside the hall. Also

spinbath at a temperature of 55oC evaporates and gives off hot gases. Workers,

electric motors, tube lights, PIV gear boxes add up to the heat load. Hence, cooled

humidified air from air washer system is fed under pressure by AW fans into the

spinning halls.





b. Sulphuric Acid plant

� Plants have been provided with DCDA system in order to avoid gas nuisance.

� Gas Scrubbing system has been provided to reduce any gas nuisance in the

atmosphere.

� Tripping arrangements have been provided with the circulation pumps. Air blowers

and sulphur pumps so that in case of failure of any one of them, the equipment

preceding that will be automatically stopped.

� Pressure release valves are provided for waste heat boiler and air blowers.

c. Carbon-di-sulphide

� Carbon-di-sulphide furnaces have been provided with water seal which will blow off in

case of any pressure build up in the furnace.

� Two numbers of rapture discs are provided as an additional safety measure which will

get ruptured in case of any excessive pressure build up in the furnace.

� During deashing a scrubbing system has been provided so that the gases get scrubbed

before going to the atmosphere.

� Carbon-di-sulphide storage tanks have been earthed to discharge any static electric

charges, if produced.

Collecting tanks, dump tanks

� A catch tank of a capacity of 450 m3 has been constructed to contain any loss of

spinbath in case of emergency in spinbath department.

� Acid storage tanks in sulphuric acid plant and spinbath department have been

provided with dyke walls, so that any acid spillage is collected in that area.

� Carbon-di-sulphide is stored in storage tanks under water and these tanks are kept

immersed in water in a water pond. Any CS2 leaking out of the storage tank is

collected under water, at the bottom of the water pond. The overflow of this water

pond is again connected to a catch pit having a level of water in it at all times. Even all

the wash water in this plant is diverted to this catch pit. Hence, the exposure of CS2 to

atmosphere is avoided and all chances of a possible fire is totally eliminated in this

area.

� Caustic received from Century Chemicals is stored in tanks, which are in open area.

These tanks are provided with dyke walls.

d. Heavy Leakage of Sulfuric Acid from Pipelines

Anyone noticing the emergency should:-

� Inform the shift incharge.

� Also inform telephone operator, in turn, to inform the controlling structure.

� Actuate the siren (emergency siren).

� Should inform the security who will ensure that no unauthorized persons, enter the

area.





� In case of acid burns make arrangement for medical aid. Wash with copious quantity

of water till medical aid arrives.

� Go to emergency control center.

Duties & Responsibilities of Shift Incharge

The Shift Incharge should

� Arrange for the shutdown of the plant and inform other dept.

� Cut off acid supply to the leakage pipeline.

� Switch on water spray and operate the water hydrant. Flush off the spillage into the

drain.

� Cordon off the entire area.

� Monitor the effluent for pH control. Make necessary alkali addition.

� Inform the Dept. Head, who, in turn, inform the Plant Manager who, on arrival,

becomes the site controller and emergency leader.

� The Plant Manager informs the top management.

� Maintenance is also informed to carry out the necessary repairs after issuing Work

Permit Slip.

All other persons on site

� All the persons not involved in the emergency should assemble at the ASSEMBLY

POINT

� They should avoid panic.

After the emergency is over, information should be communicated to all that the emergency

is over and normalcy should be restored.

Steps to Avoid / Reduce Leakage - Regular replacement of the pipelines.

e. Leakage from Storage Tanks

� Reduce the level of storage tank leaking by transferring the acid to a standby storage

tank.

� The entire area is cordoned off.

� Maintenance dept is informed for repairing the jobs to be done.

� Work Permit Slip is given to maintenance after total isolation of the tank. Blank the

line.

� In case of any person suffering from burns, the burns should be washed continuously

for 15 - 20 minutes and then in the meantime arrangement is to be made to get the

affected persons to the hospital.

� The storage tanks are located in a dyke so that the acid spillage collects in the dyke.

This acid has to be pumped to a tank to reduce the level in the dike. After pumping off

as much acid as possible, the acid in the dyke is neutralized and flushed with an

adequate quantity of water. This water then goes to the effluent stream.

� In the case of the above, the controlling structure is to be informed through the

telephone operator.





Preventive Measures

Thickness testing of the storage tanks to be done once in a year and record of their tests to

be maintained and corrective steps should be taken at the earliest.

F. Leakage from Vehicles carrying Sulfuric Acid

Leakage can occur from vehicles transporting conc. Sulfuric acid. Leakage from these tankers

can create an emergency.

Action Plan

� Cordon off the area around the tanker.

� Make arrangements for transferring the acid from the tanker to a storage tank or

other tanker if it is available.

� Cordon off that road and warn the public nearby.

� Make sure that the engine is stopped.

� Call fire fighting personnel to ensure that the acid does not cause a fire and explosion

emergency which occurs when acid comes in contact with liberation of hydrogen.

� Also ensure that this acid does not come in contact with saw dust load etc.

� Make sure that the driver and cleaner are away from the site.

� Make sure that public stays away from the area.

G. Toxic Release of Gases in Sulfuric Acid Plant

SULFUR TRIOXIDE

Chemical Sulfur trioxide (vapour)

Hazard Health hazard affecting respiratory tract.

May arise due to

Leakage from pipelines, failure acid circulation pumps, circulating acid

being dilute.

Area affected Acid plant and surrounding when SO3 goes to the atmosphere via the

chimney.

Sulfur trioxide vapours react with moisture in the air to form sulfuric acid. Inhalation of

sulfur trioxide causes damage to tooth enamel and also respiratory tract. The vapours are

misty white and appear as fumes.

Sulfur trioxide vapours condense at temperatures of about 210C. They react with moisture to

form sulfuric acid. When the acid plant is kept stopped for a very long duration, then gases

condense due to low temperature, forming SO3 fumes which are noticed from pipelines

during start up after long shut down.

In case of heavy leakage of SO3 from pipelines:

� Sulphur pump is stopped first. Then the blower is run for about 5 – 7 mts to blow

through the gases so that the leakage can be attended. Thus SO3 emission to the

atmosphere is stopped.

� All the fuses are removed.





� The blower is then stopped (the line is made gas free).

� The area is cordoned off as acid may fall from the leaking pipeline.

� Shift incharge informs other people in the dept. about the leakage.

� Personal protective equipment is kept ready in such circumstances.

� Maintenance dept. is informed to carry out the necessary repair work.

� Water should not be sprayed on the source of leakage as otherwise the leakage can

increase and water can enter the pipeline.

� Scaffolding arrangement also is made if necessary.

� Work permit slip is issued to maintenance to carry out the jobs.

� After completion of the job work permit slip is returned back.

Preventive Measures

� Pipelines to be replaced regularly.

� Acid concentration to be maintained at about 98.5 %.

� Pumps to be periodically overhauled and replaced.

H. Measures FOR Sulfur Dioxide Plant

SULFUR DIOXIDE

Hazard Sulfur dioxide.

Nature of Hazard Toxic release.

Area Around sulfuric acid plant.

Period of toxic

release

During starting of plant after overhauling or any

long stoppage.

Precautions Taken During Startup of the Plant:-

� Communication is sent to all departments before starting of plants after annual

inspection.

� The scrubbing system is to be properly tested and fresh caustic is added to minimse

SO2 going to the atmosphere.

� The plant initially runs on low load and concentration of H2SO4 is maintained at 98 –

98.5% so as to reduce the SO3 emission.

In case of SO2 Gases Release, Emergency is Combated as follows:-

� Persons affected are to be immediately shifted for medical aid.

� They are made to drink water and stimulants.

� If there is too much gas then the plant is shutdown and the reason for the toxic

release is identified and necessary steps are to be taken.

� The scrubbing system is very effective as a result of which the SO2 gases conc to

atmosphere is in quantities which will not seriously affect people. Also initially on

plant start-up by running the plant on a low load, conc. of SO2 gases are reduced.





I. Release of Toxic or Flammable Gases in CS2 Plant

Gas Line Leakage

The gases coming out of the furnace are a mixture of CS2 and H2S gases. H2S gases are

produced in the furnace because of moisture in charcoal and sulfur. Any leakage in the gas

line is attended with safety precaution because of the presence of H2S and CS2 vapour.

Regular maintenance schedule is followed to avoid gas leakage.

In the Event of any Leakage

Anyone noticing any leakage shall inform the Shift Incharge or any other responsible person

in the department clearly indicating the location of the emergency site and a brief detail of

the incident.

Duties and Responsibilities of Shift Incharge:

- Cordon off the area near leakage.

- Using proper respiratory apparatus identify the source of leakage.

- Never allow a single person to go near the source of leakage. Someone must

accompany at all times.

- Isolate or de-pressurize the line so that the severity of leakage is reduced. Proper

breathing apparatus to be used by all involved.

J. Toxic Release of Liquid CS2

Toxic release of liquid CS2 can happen due to following reasons:

CS2 LEAK FROM STORAGE TANK

CS2 is stored under water in storage tanks. There are 14 storage tanks for storing CS2 . CS2

can leak from these storage tanks. Storage tanks are located in cooling ponds and they are

submerged in water so that even if there is a leak, there is a continuous water blanket over

the CS2 not allowing the CS2 to vaporize and form explosive and flammable substances. The

overflow and drain of the dykes (cooling ponds) lead to catchment pond where CS2 is

collected. This ensures that CS2 does not go to effluent stream even if there is leak.

However, 2 storage tanks are always kept empty for emergency transfer of CS2 if needed and

the inventory in each storage tank has been reduced to 23.0 tons from 28.0 tons (as per

recommendations from Tata Risk Management Services) to reduce the maximum credible

loss scenario to within 5 Km area.

Even this risk also has been nullified by submerging each and every storage tank under water.

Preventive Measure

� Thickness testing is done regularly and records are maintained and hydraulic test done

every alternate year.

� The storage tanks are located in the dyke with sufficient quantity of water in it.

� The overflow of the cooling pond to catch pond should be clear so that cooling pond

does not overflow from top.

� Aluminium rod is used for taking level to avoid sparking.





3. Measures for Coal handling yard

Coal is Flammable and will be easily ignited by heat, sparks or flames:

� Coal handling facility is stored 500 meters away from the ecological sensitive area and

forests area.

� Coal handling facility is ensured for adequate water supply through pipe/water

sprinklers to avoid fugitive dust emission.

� Coal handling facility is ensured for stacking of coal in heaps does not get higher than

the compound wall of premises.

� During loading/unloading, fixed pipe network with sufficient water storage and pump

are installed. Coal handling facility is /will ensure maximum sprinkling of water at each

and every stage of transportation to avoid generation of coal dust or other dust.

� The ignition sources, which are traceable to routine operations or worker habits such

as smoking, open flames, open light (bulbs), welding, cutting, and grinding, are

eliminated by sufficient staff training and enforcement of discipline.

� Coal handling facility is ensured that all transportation vehicles before leaving the

storage yard are covered with tarpaulin and also that they are not over loaded as well

as there is no spillage during transportation.

� Coal handling facility is ensured of regular sweeping of coal from internal and main

road and also ensures that there is adequate space for free movement of vehicles at

the surrounded area.

� Coal handling facility is storing coal in such a way that coal heap is not higher than 15

feet and clear distance between two adjoining heap at G.L. is 5 meters ,so that in case

of fire ,approach is available.

� Coal handling facility is taking measures to control the air pollution while

loading/handling coal. Specific measures are under-taken to avoid fugitive emission at

the time of loading/unloading of coal by coal yard unit.

� Coal handling facility is provided with adequate fire fighting measure to avoid any fire

and is ensured that there is no explosive or chemical reaction in storage yard.

1.1.4.1 Preventive Measures for Electrical Hazard

� All electrical equipments are provided with proper earthing. Earthed electrode are calibrated,

periodically tested and maintained.

� Emergency lighting are available at all critical locations including the operator’s room to carry

out safe shut down of the plant, ready identification of fire fighting facilities such as fire

water pumps and fire alarm stations.

� All electrical equipments are free from carbon dust, oil deposits, and grease.

� Use of approved insulated tools, rubber mats, shockproof gloves and boots, tester, fuse

tongs, discharge rod, safety belt, hand lamp, wooden or insulated ladder and not wearing

metal ring and chain is insured.





� Flame and shock detectors and central fire annunciation system for fire safety are provided.

� Temperature sensitive alarm and protective relays to make alert and disconnect equipment

before overheating are provided.

� Dangers from excess current due to overload or short circuit are prevented by providing

fuses, circuit breakers, thermal protection.

� Carbon dioxide or dry chemical fire extinguishers are for electrical fires.

1.1.4.2 Fire Protection Systems

Each plant is provided with a hydrant system and portable fire extinguishers and sand buckets to

fight fire.

We have the following types of fire extinguishers all over the plant.

1. Water Type 191 Nos.

2. Foam type 111 Nos.

3. Dry Chemical powder 154 Nos.

4. CO2 type 935 Nos.

Apart from this, well equipped (with hoses and nozzles) 15 Central Fire station is strategically

located. 9 Nos. in Rayon / Auxiliary Divisions and 6 Nos. in Tyrecord Division.

The points at which these fire stations are located are as follows:

S. No. Location

1. Near Time Office

2. Rayon Viscose Corner Near main substation

3. Rayon Godown No.4

4. Rayon Viscose (Near B/H)

5. Boiler House (Near Material Gate)

6. Acid Plant, Road side

7. Acid Plant Near Temple

8. CS2 Plant, Near Loading Point

9. CS2 Road side

10. Rayon Warehouse

11. Tyrecord, Near Engine Room

12. Tyrecord pulp godown

13. Tyrecord, Near Civil Office

14. BTC

Water & Sand buckets are provided in sufficient numbers in all the departments.

In addition to the above, we have hydrant system to fight the fire. Even in the event of power

failure, the arrangement is such that we can get uninterrupted water supply to the hydrant system

for at least 2 hours.

Specification of the fighting pumps:

There are 3 fire fighting pumps, one of kirloskar make and the other two of Mather & Platt Make. All

the three pumps are interconnected. The capacity of the pumps is 1000 gpm while the head is 200

ft. One additional Jockey pump is also provided for emergency.





Specification of fire hydrant pumps:

Service condition : Centrifugal

Liquids : Water

Capacity : 1000 gpm

Differential Head : 200 ft

Description

Model : 1. Kirloskar .. 1 No.

2. Mather & Platt : 2 Nos.

(England)

Suction : 200 mm dia

Discharge : 150 mm dia

Speed : 1450 rpm

Capacity : 76 1/s

Total Head : 76 mtrs

Motor HP / KW : 120 / 90

Qty for Hydrant : 2 Nos. (1 Kirloskar, 1 Mather & Platt)

Qty for Sprinkler : 1 No. (Mather & Platt)

Quantity and location of water storage or sources which can be used for firefighting purposes: The

total water storage that could be at the disposal for firefighting in a major emergency is about 3 lac

gallons.

The typical fire fighting system for the various facilities described under this project is outlined in

this section. Fire protection system are designed in accordance with the requirements of OISD,

Tariff Advisory Committee (TAC) of India, NFPA standards, design requirements and safe

engineering practices and have full capability for early detection and suppression of fire. The

system primarily consists of:

o Hydrant system

o Portable fire extinguisher

o Fire detection and alarm system

1.1.4.3 Personnel Protective Equipment (PPE)

Personnel Protective Equipment (PPE) provides additional protection to workers exposed to

workplace hazards in conjunction with other facility controls and safety systems.

PPE is considered to be a last resort that is above and beyond the other facility controls and

provides the worker with an extra level of Personnel protection. Table 1.5 presents general

examples of occupational hazards and types of PPE available for different purposes.

Recommended measures for use of PPE in the workplace include:

Proper maintenance of PPEs, including cleaning, when dirty and replacement when damaged or

worn out. Proper use of PPE is a part of the recurrent training programs for Employees.

Selection of PPE is based on the hazard and risk ranking described earlier in this section, and

selected according to criteria on performance and testing established.





Table - 1.5

Summary of Personnel Protective Equipment According to Hazard

Objective Workplace Hazards PPE

Eye and face

protection

Flying particles, molten metal, liquid

chemicals, gases or vapours, 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, vapours

Facemasks with appropriate filters for dust removal and

air purification (chemical, mists, vapours 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

1.1.4.4 Measures for Occupational Health Hazards

o To detect the possible onset of an occupational disease regular monitoring of health status is

done/will be done.

o To check the effectiveness of preventive and control measures are done on regular basis.

o Adequate supply of potable drinking water is provided from a fountain with an upward jet or

with a sanitary means of collecting the water for the purposes of drinking.

o Pre-Employment Medical Examination is being carried out for all new employees and

Contract labours.

o Periodic medical hearing checks are performed on workers exposed to high noise levels

o OHS orientation training is provided to all new employees to ensure they are appraised of the

basic site rules of work at / on the site and of Personnel protection and preventing injury to

fellow employees

o Contractors that have the technical capability to manage the occupational health and safety

issues of their employees are hired, extending the application of the hazard management

activities through formal procurement agreements.

o Two nos. ambulance and fully fledged First aid treatment facilities are provided with OHC.





1.1.5 Need for Disaster Management Plan

Extreme care is essential in handling such chemicals in any form and at all stages of manufacture,

processing, treatment, package, storage, transportation, use, collection, destruction, conversion or

sale.

Several agencies of the Government, both at the Central and State levels, such as the Directorate of

Explosives, the Inspectorate of Factories and Port and Transport Authorities are entrusted with the

responsibility of ensuring safe handling and management of hazardous chemicals under acts and

rules made for the purpose. In spite of these measures, the possibility of accidents cannot be ruled

out. Human errors and mechanical, electrical, instrumental or system failures have, on occasions,

led to severe disasters. Occurrence of fatal accidents makes it essential that the Central and State

Governments as well as the local authorities are fully prepared to mitigate the sufferings and meet

the eventualities resulting from any unfortunate occurrence of chemical accidents in our country.

Following are the general types of Emergency /Disaster which lead to preparation of disaster

management plan:

o Fire in tank area

o Large oil spillage which may escape outside the boundary.

o Major fire / explosion in unit area

o Toxic gas release.

1.1.5.1 Objectives of Disaster Management Plan

“Disaster Management Plan“ means a well coordinated, comprehensive response plan to contain

loss of life, property, environment and provide speedy and effective recovery by making the most

effective use of available resources in case of a disaster. The purpose of DMP is to give an approach

to detail organizational responsibilities, actions, reporting requirements and support resources

available to ensure effective and timely management of emergencies associated to production and

operations in the site.

Onsite and offsite emergency plans have been defined, documented and implemented in the industry.

They follow these emergency preparedness plans and carryout periodic mock-drills and onsite

mock drill at regular intervals.

The overall objectives of DMP are to:

o Ensure safety of people, protect the environment and safeguard commercial considerations.

o Immediate response to emergency scene with effective communication network and

organized procedures.

o Obtain early warning of emergency conditions so as to prevent impact on personnel, assets

and environment.

o Safeguard personnel to prevent injuries or loss of life by protecting personnel from the

hazard and evacuating personnel from an installation when necessary

o Minimize the impact of the event on the installation and the environment, by:

� Minimizing the hazard as far as possible





� Minimizing the potential for escalation

� Containing any release.

1.1.5.2 Key Elements

Following are the key elements of Disaster Management Plan:

o Basis of the plan

o Pre-Emergency Planning

o Accident/emergency response planning procedures

o On-site Disaster Management Plan

o Off-site Disaster Management Plan

1.1.5.3 Basis of the Plan

Identification and assessment of hazards is crucial for on-site emergency planning and it is

therefore necessary to identify what emergencies could arise in production of various products and

their storage. Hazard analysis or consequence analysis gives the following results.

o Hazards from spread of fire or release of flammable and toxic chemicals from storage and

production units.

o Hazards due to formation of pressure waves due to vapour cloud explosion of flammable

gases and oil spill hazards.

1.1.5.4 Emergency Planning and Response Procedures

Emergency rarely occur, therefore activities during emergencies require coordination of higher

order than for planned activities carried out according to fixed time schedule or on a routine day-to-

day basis. To effectively coordinate emergency response activities, an organizational approach to

planning is required. The emergency planning includes anticipatory action for emergency,

maintenance and streamlining of emergency preparedness and ability for sudden mobilization of all

forces to meet any calamity.

1.1.6 Onsite Disaster Management Plan

Onsite Emergency/disaster is an unpleasant event of such magnitude which may cause extensive

damage to life and property due to plant emergencies resulting from deficiencies in Operation,

Maintenance, Design and Human error, Natural Calamities like Flood, Cyclone and Earthquake; and

deliberate and other acts of man like Sabotage, Riot and War etc. An Onsite Disaster may occur all

of a sudden or proceeded by a Major Fire.

In order to handle disaster / emergency situations, an organizational chart entrusting responsibility

to various personnel of Century Rayon showing their specific roles are available as shown below:





EMERGENCY ORGANISATION

EMERGENCY LEADER

H.O.D. (Rayon ) / H.O.D.(T.C) / H.O.D. (Aux)

Communication Team Advisory Team

Telephone Operator Sr. President

Ex. President (Engg , Aux & Inst.)

Jt. President (Rayon)

Jt. President (T/C ,CSY & TQM)

Jt. President ( P&A )

Jt. President ( CC & SHE.)

Action Team A

Action Team B

Action Team C

Action Team D

Action Team E

• H.O.D. of the affected area

• Shift Incharges of the effected Dept.

• Shift Incharge other plant / Dept.

• Sr. Supdts. / Dept. Heads / other plants

• Manager /Sr. Supt. (Maintenance)

• Manager / Sr. Supt. (Electrical) Fire Team

• Security Officer – Rayon

• Security Officer / Fire Officer

• Fire Team

• Safety Officer

• Stores Incharge

• Medical Officer

• Nurses

• Transport Incharge

• First Aiders

• All staff not listed in Emergency Action Teams including all Contractor workmen

• Rescue teams

INCIDENT CONTROLLER H.O.D. (Department)





Following fire protection facilities are available to combat the emergencies and depending upon

the type of emergencies any one or combination of the facilities are applied.

o Fire Water System

o Carbon Dioxide System

o Foam System

o First Aid Fire Fighting Equipment

o Mobile Fire Fighting Equipment

o Gas / Fire Detection and Alarm System

1.1.6.1 Emergency Organization Structure& their Roles and Responsibilities

o Overall objectives of an emergency control organization are:

� To promptly control problems as they develop at the scene.

� To prevent or limit the impact on other areas and off-site.

� To provide emergency personnel, selecting them for duties compatible with their

normal work functions wherever feasible. The duties and functions assigned to various

people, including full use of existing organizations and service groups such as fire,

safety, occupational health, medical, transportation, personnel, maintenance, and

security.

Employees must assume additional responsibilities as per laid down procedure of DMP whenever

an emergency alarm sounds.

Following are the key personnel and the units in the plant which are responsible to take

appropriate actions during emergencies.

EMERGENCY LEADER / MAIN CONTROLER

H.O.D. (Division) will resume the role of the Main Controller and will be the overall Incharge of the

situation. He will coordinate all the internal and external activities from the Emergency Control

Room at the Main Gate from where all operation will be decided. He will relieve the Incident

Controller of the responsibility of the Main Controller.

1. Investigate extent and nature of Emergency.

2. Consults with the advisory Team, Action Team A and Communication Team.

3. To decide further action such as :-

a) Immediate fire-fighting system like water sprays, fixed monitors, cooling neighboring

equipments.

b) Shutdown of various plants in right sequences.

c) Communication with top management.

d) Additional ambulances and treatment of affected persons.

e) Calling mutual aid fire brigade, city fire brigade, if required.

f) Special hospitalization of victims.

g) Evacuation of site – partial / full.





4. Enquire about Head-count at assembly point.

5. Rescue of missing persons.

6. Controlling traffic inside and outside.

7. Evaluation of neighboring population, if necessary.

8. Inform authorities; arrange photograph / logging of events.

9. Preserve evidence.

10. Before ordering re-entering, check that it is safe (Toxic release, fire potential,

structural stability, etc.).

11. Do not restart plant unless cleared by authorities.

12. Deal with media.

13. Organize investigation team.

14. Check rehabilitation of victims.

15. Do not restart till steps are taken to prevent occurrence.

A. RESPONSIBILITIES OF INCIDENT CONTROLLER & TEAM – A

Upon hearing the emergency alarm, the H.O.D. (Production) / Shift Incharge will assume the

role of incident controller and take charge of the situation at the site of the emergency. He

will keep the Main Controller /Emergency Leader informed of the situation from time to

time.

He Shall :-

1. Immediately proceed to the scene of emergency and assess the situation.

2. Inform Emergency Leader and Security Officer about the location and nature of

emergency.

3. Immediately eliminate all sources of ignition, gas cutting, welding etc.

4. Isolate area of emergency by closing valves, etc.

5. Transport toxic products to other empty storage facilities.

6. Switch on water sprays if required.

7. Switch on caustic spray if required.

8. Arrange emergency shutdown of plant (or part thereof).

9. Stop loadings of further lorries, trollies, etc.

10. Co-ordinate with the Fire Controller and Local Fire Services in case of Fire Emergency.

11. Check for casualties.

12. Get all non-essential workers / staff evacuated.

13. Set up a communication system with the emergency control center.

Call outside emergency services and help, if necessary. Allot jobs to the Emergency Squad.

1. Report all developments to the Main Controller.

2. Preserve all evidence for use in subsequent inquiry.





B. ACTION TEAM – B (ACTION ON HEARING FIRE / GAS ALARM )

Shift Incharge of other plants :-

1. Ensure that fire pumps are operating normally.

2. Shut off feed / chemicals to affected area.

H.O.D. Maintenance/ Maintenance Engineer

1. Provide engineering assistance to Incident Controller.

2. Ensure the fire pumps and ambulances are in good working order.

They will be ready with the rescue equipment and be ready to extricate trapped personnel

by cutting structures.

H.O.D. Electrical

Manager – (Electrical)

1. Ensure that adequate power supply is made available for sensitive plant operations

and for emergency lighting.

2. He will make available an electrician to be at the disposal of the Incident Controller.

C. ACTION TEAM – C ( ACTION ON HEARING FIRE OR GAS ALARM )

H.O.D. SECURITY / SECURITY OFFICER

1. Proceed to the scene of emergency in case of fire.

2. Control traffic.

3. Arrange guard at gate inform essential personnel.

4. Depute guard at firefighting station.

5. Prevent unauthorized entry at gate.

6. Get additional help if necessary.

7. Liaison with the City Fire Brigade.

8. Arrange firefighting squad to fight fire.

H.O.D. SAFETY / SAFETY OFFICER

1. Will ensure adequate supply of Safety Appliances

2. Inform DISH / M. P. C. B.

3. Offer any help expected advice and with First Aider render First Aid to the injured.

4. Coordinate with Emergency Leader and Medical Officer.

STORES INCHARGE

1. Arrange additional supplies of foam compound and other fire-fighting /safety

equipment as required.

D. ACTION TEAM - D (ACTION ON HEARING FIRE OR GAS ALARM)

MEDICAL OFFICER / NURSE

1. Keep ambulance ready to proceed to scene of emergency at short notice.

2. Prioritize casualties for treatment.





3. Call First Aiders.

4. Consider sending casualties for specialist treatment.

5. Arrange hospitalization, additional ambulances.

6. Alert outside hospitals to be ready with necessary antidotes / treatment as case may

be to call additional doctors.

7. Prepare documentations.

8. Inform District Health Authorities, Medical Inspector of Factories.

9. Maintain a list of blood group of all employees with special reference to group.

FIRST AIDERS

1. Proceed to medical center as requested and render all assistance.

TRANSPORT INCHARGE

1. Be in close contact with Control Room.

2. Arrange transport as required.

3. Requisition cars, buses, drivers as necessary for evacuation.

E. ACTION TEAM – E (ALL OTHER PERSONS ON - SITE )

Upon hearing Fire / Gas Alarm

1. Avoid panic.

2. Do not go to scene of emergency unless specifically instructed by Emergency Leader.

3. Leave site immediately by safest route to assembly point suggested.

4. Proceed at right angles to wind direction.

5. Do not re-enter site unless directed personally or via Public Address System.

6. Assist in Head – count at assembly point.

Assembly Point Coordinator

1. Rush to the assembly point.

2. Maintain time logging of persons reaching assembly point.

3. Arrange head count.

4. Maintain liaison with Emergency Controller.

5. Avoid panic amongst the assembled persons.

6. When emergency is over, send the people back to their respective work area.

1.1.6.2 FIRST AID FACILITIES & HOSPITAL SERVICES

�� First Aid Boxes are made available in the entire department. First Aid Boxes are maintained by

all the department

�� First Aid trained persons are available in all the plant

�� Occupational Health center at the Main gate is provided

�� Safety Showers are provided as a first aid of chemical splashes

�� Century Rayon Hospital with 66 bed capacity is available near the site with qualified doctors &

nurses.





First Aid

Chlorine affects the mucous lining of breathing system. General symptoms are sneezing,

coughing, irritation, watering of eyes and breathlessness. People affected by this gas are

removed from the contaminated area and sent to hospital for further treatment

FIRST AID

General

1. Be cautious, do not become casualty yourself.

2. Remove exposed persons to fresh area.

3. Send for medical treatment.

1.1.7 Offsite Disaster Management Plan

Emergency is a sudden unexpected event, which can cause serious damage to personnel life,

property and environment outside the boundary wall of the refinery as a whole, which necessitate

evolving Off-site Emergency Plan to combat any such eventuality. In Offsite disaster management

plan, many agencies like Revenue, Public Health, Fire Services, Police, Civil Defence, Home Guards,

Medical Services and other Voluntary organization are involved. Thus, handling of such

emergencies requires an organized multidisciplinary approach.

Evacuation of people, if required, can be done in orderly way. The different agencies involved in

evacuation of people are Civil Administration (both state and central), non Govt. organizations,

factory Inspectorate and Police authorities.

Various organizations involved during emergencies are shown below:

Figure 1.1: Various Organizations Involved During Emergency

1.1.7.1 Mock Drills

As per the Industrial Major Accident Hazard Rules, the occupier has to ensure that a mock drill of

the on-site emergency plan is conducted every six months. A detail report of the mock drill

conducted under sub-rule (4) is made immediately available to the concerned authority.

Accordingly, Fire mock drills are conducted once in three months.





1.1.7.2 All Clear / Re-entry Procedures

Chief Emergency Controller (CEC) will ask incident controller to declare “All Clear” after control of

the Incident and checking the site.

After incident normalization, CEC would ask Unit in-charge to visit and check the incident site

along with representatives of Inspection and F&S and also Maintenance (Electrical / Mechanical /

Civil/ Instrumentation/ Rotary) as needed. Standard Checks particular to a unit will be provided by

respective Area Managers.

Based on feedback of the team, CEC would allow re-entry / resumption of operations at the

incident site.

1.1.7.3 Evacuation Plan

To establish method of systematic, safe and orderly evacuation of all the occupants in case of fire

or any emergency, in the least possible time, to a safe assembly point through nearest safe means

of escape. Additionally to use available fire appliances provided for controlling or extinguishing

fire and safeguarding of human life.

1.1.7.4 Training

On job training to the engineers on various facets of risk analysis would go a long way in

improving their horizon which in turn is expected to reflect in the operation of plant, especially

from the safety stand point. In order to combat with emergency situations arising out of accident

release of hazardous chemicals, it is necessary for industries to prepare an exhaustive offsite and

onsite emergency preparedness plan. The fire crew belonging to the firefighting department is

given intensive training for the use of all equipment and in various firefighting methods for

handling different types of fires.

1.1.7.5 Voluntary Organizations

Details of Voluntary organizations, telephone numbers nearby of hospitals, Emergency helpline,

resources etc are to be available with chief authorities. In case of major fires, Fire Brigade from

Ulhasnagar Municipal Corporation and Kalyan Dombivali Municipal Corporation are called. They

help in fighting the fires.

In case of chlorine leakage police of KDMC are summoned for rendering help. The police

personnel cordon off the area and control the traffic at the entrance gate.

Liaison is established between our Factory and Kalyan Ambernath Manufacturers Association (

KAMA) of which our Factory is also main member. Mutual Aid Response Group is formed between

KAMA member companies. Regularly MARG meetings are conducted.

Following are some MARG members in the vicinity of our company;

1. NPL, Mohone

2. Gharda Chemicals, Dombivali

3. BalKrishna Paper Mill, Mohane





Local Crisis group is formed as per Chemical Accidents (Emergency Planning , preparedness &

response) Rules 1996, framed By MoEF as Follows;

Muncipal Commissioner , Kalyan : Chairman, Local Crisis group

Dy.Director, DISH : Secretary, Local Crisis group

Century Chemical, Shahad : Member, Local Crisis group

NPL, Mohone : Member, Local Crisis group

Gharda Chemicals Dombivali : Member, Local Crisis group

Other Members are all MAH industries in Kalyan Ambernath area, Two Transporters, Police, Home

Guards, Fire Brigade officers, Health Officer & two Social Servant, Local Newspapers.

This group will help to control & minimize the losses in case of any emergency in KAMA area.

1.1.7.6 Non-governmental 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 during the emergency planning process.

o Evacuation of personnel from the affected area.

o Arrangements at rallying posts and parking yards.

o Rehabilitation of evacuated persons.

1.1.7.7 Chemical information

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

with them are made available at respective site.

1.1.7.8 Meteorological information

There are arrangements for obtaining details of weather conditions prevailing at before the time

of accident and weather forecasts updates.

1.1.7.9 Humanitarian Arrangements

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

temporary mortuaries are made available at plant site.

1.1.7.10 Public Information

It includes dealing with the media-press office&Informing relatives, etc.

1.1.7.11 Assessment

o Collecting information on the causes of the emergency.

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

1.1.7.12 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.

1.1.7.13 Role of police

o The police will assist in controlling of the accident site, organizing evacuation and removing

of any seriously injured people to hospitals.





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

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

o Arrange for post mortem of dead bodies.

o Establish communication centre with easy contact with ECC.

1.1.7.14 Role of Fire Brigade

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

emergency.

1.1.7.15 Role of 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.

1.1.7.16 Role of health care authorities

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

emergency.

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

required quantities of drugs and equipments.

o Securing assistance of medical and paramedical personnel from nearby

hospitals/institutions.

o Temporary mortuary and identification of dead bodies.

1.1.8 CONCLUSION

As discussed in above sections, adequate risk mitigation measures for process are considered for

to say that the Existing project is not likely to cause any significant risk to onsite, offsite &

environment. In the event of disaster onsite, offsite and all the emergency planning procedures

are to be followed so as to minimise the impact on working personnel, plant surrounding and

environment. Company has the Risk Management Matrix developed on each aspect covering the

Safety, Environment, Health & Business Continuity Aspects and Report on monthly / Quarterly

basis to Business Review Council. Du Pont safety system is implemented for plant safety.

risk assessment and disaster management...

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