CHAPTER-6 RISK ASSESSMENT ADDITIONAL STUDIES 6.1 SCOPE OF THIS STUDY:

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1 RISK ASSESSMENT ADDITIONAL STUDIES CHAPTER-6 In order to support the Environment Impact Assessment and Environment Management Plan, following additional studies have been included in this report. Risk Assessment On-Site / Off-Site Emergency Plan Occupational Health Programme 6.1 SCOPE OF THIS STUDY: The QRA study in this report has been conducted considering the Terms of References (TORs) given by Expert Appraisal Committee of SEAC for Environment Clearance (EC). The study has been carried out with a view to comply the following TOR points: TOR No. 39: Occupational health impacts on the workers and mitigation measures proposed to avoid the human health hazards along with the personal protective equipment to be provided. Provision of industrial hygienist and monitoring of the occupational injury to workers as well as impact on the workers. Plan for periodic medical checkup of the workers exposed. Details of workplace ambient air quality monitoring plan as per Gujarat Factories Rules. TOR No.41: Risk assessment including prediction of the worst-case scenario and maximum credible accident scenarios should be carried out. The worst-case scenario should take into account the maximum inventory of storage at site at any point of time. The risk contours should be plotted on the plant layout map clearly showing which of the facilities would be affected in case of an accident taking place. Based on the same, proposed safeguard measures including On-Site / Off-Site Emergency Plan should be provided. TOR No. 43: Details of hazardous characteristics and toxicity of raw materials and products to be handled and the control measures proposed to ensure safety and avoid the human health impacts. This shall include the details of Antidotes also. TOR No. 44: Details of quantity of each hazardous chemical (including solvents) to be stored, Material of Construction of major hazardous chemical storage tanks, dyke details, threshold storage quantity as per schedules of the Manufacture, Storage & Import of Hazardous Chemicals Rules of major hazardous chemicals, size of the biggest storage JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD. 6. 1

2 tank to be provided for each raw material & product etc. How the manual handling of the hazardous chemicals will be minimized? TOR No. 45: Details of the separate isolated storage area for flammable chemicals. Details of flame proof electrical fittings, DCP extinguishers and other safety measures proposed. Detailed fire control plan for flammable substances and processes showing hydrant pipeline network, provision of DG Sets, fire pumps, jockey pump, toxic gas detectors etc. TOR No. 46: Submit checklist in the form of Do s & Don ts of preventive maintenance, strengthening of HSE, manufacturing utility staff for safety related measures. 6.2 INTRODUCTION TO RISK ASSESSMENT M/s. Camlin Fine Sciences Ltd., for its upcoming new unit in Dahej shall handle chemicals, some of which are hazardous in nature by virtue of their intrinsic chemical properties or their operating temperatures or pressures or a combination of them. Fire, toxic release or combinations of them are the hazards associated with industrial plants using hazardous chemicals. More comprehensive, systematic and sophisticated methods of Safety Engineering, such as, Hazard Analysis and Qualitative/Quantitative Risk Assessment have been developed to improve upon the integrity, reliability and safety of industrial plants, the same has been discussed in detail under their respective headings OBJECTIVES OF RISK ASSESSMENT Risk analysis follows an extensive hazard analysis. It involves the identification and assessment of risks the neighboring populations are exposed to as a result of hazards present. This requires a thorough knowledge of failure probability, credible accident scenario, vulnerability of population etc. Much of this information is difficult to get or generate. Consequently, the risk analysis is often confined to maximum credible accident studies. It provides basis for: Risk assessment is carried out for the following objectives: 1. To identify hazard and risk resulting from the hazards 2. To identify the potential scenarios that could occur within the facility. 3. To carry out Consequences Analysis of maximum credible scenarios to determine the vulnerable zones for each probable accident scenario. 4. To study and foresee the effects of such risks on the workers, public, property and environment and to find out necessary control measures to prevent or minimize risk. 5. To comply the legal requirement by various safety and environment laws of the country like JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD. 6. 2

3 The Factories Act, 1948 The Gujarat Factories Act, 1963 The Environment Protection Act and Rules, 1986 Hazardous waste (Management & Handling) Rules, 1989 Public Liability Insurance Act & Rules,1991 Chemical Accident, (Emergency, planning, preparedness and response) Rules, To get the necessary information for Emergency planning and evacuation. 7. To decide the recommendation to mitigate measures to reduce the hazard / risks. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD. 6. 3

4 6.2.2 DETAILS OF STORAGE FACILITIES The storage facilities for the hazardous chemicals have been marked on the company layout given below: FIGURE: 6.1 PLAN LAYOUT SHOWING STORAGE FACILITIES Plasma Gasification Plant Fire Hydrant Network. As shown here in the fig., the hydrant network is made available for all facilities (all round the periphery). Class A Tank farm (Storage of Toluene, Ethanol, Methanol & IPA) Fire Water Tank Double Entry** ** Provision of double entry and adequate margin all round the periphery for unobstructed easy movement of the emergency vehicle / fire Tenders, etc. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD. 6. 4

5 TABLE: 6.1 A: STORAGE DETAILS OF HAZARDOUS CHEMICALS Sr. No. Raw Materials Mode of Storage MOC of Storage Container Capacity of Containers Dyke Details 1. Toluene Tank M.S. 50 KL Dyke of sufficient capacity i.e. 10% extra than tank capacity will be provided. 2. Ethanol Tank M.S. 10 KL Dyke of sufficient capacity i.e. 10% extra than tank capacity will be provided. 3. Methanol Tank M.S. 80 KL Dyke of sufficient capacity i.e. 10% extra than tank capacity will be provided. 4. Phenol Tank M.S. 430 KL Dyke of (215 x 2) sufficient Possible Type of Hazards Flammable liquid in presence of open flames and sparks, of heat. Flammable liquid in presence of open flames and sparks, of heat. Flammable liquid in presence of open flames and sparks, of heat. Flammable liquid in Control Measures Proposed To Ensure Safety And Avoid The Human Health Impacts Proper storage area shall be provided. PPEs like Splash goggles, Full suit, Vapor respirator or self contained breathing apparatus, Boots, Gloves etc, will be used while handling this chemical. Specialist will be consult, if required. Proper storage area shall be provided. PPEs like Splash goggles, Full suit, Vapor respirator or self contained breathing apparatus, Boots, Gloves etc, will be used while handling this chemical. Specialist will be consult, if required. Same as above. Proper storage area shall be provided. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD. 6. 5

6 Sr. No. Raw Materials 5. Isopropyl Alcohol 6. Hydrogen Peroxide Mode of Storage MOC of Storage Container Capacity of Containers Dyke Details capacity i.e. 10% extra than tank capacity will be provided. Tank MS 25 KL Dyke of sufficient capacity i.e. 10% extra than tank capacity will be provided. Tank Aluminiu 10 MT Dyke of m sufficient capacity i.e. 10% extra than tank capacity will be provided Possible Type of Hazards presence of open flames and sparks, of heat. Flammable liquid in presence of open flames and sparks, of heat. Flammable liquid in presence of open flames and sparks, of heat Control Measures Proposed To Ensure Safety And Avoid The Human Health Impacts PPEs like Splash goggles, Full suit, Vapor respirator or self contained breathing apparatus, Boots, Gloves etc, will be used while handling this chemical. Specialist will be consult, if required. Proper storage area shall be provided. PPEs like Splash goggles, Full suit, Vapor respirator or self contained breathing apparatus, Boots, Gloves etc, will be used while handling this chemical. Specialist will be consult, if required. Adequate ventilation and ample water supply (Safety shower, eye wash station, etc.) for thorough flushing of accidental spillage on personnel and property shall be provided. PPEs like safety glasses or, preferably, goggles shall be worn, in addition to eye protection, rubber gloves and suitable protective clothing such as aprons or coveralls made of polyester acrylic fiber, polyvinyl chloride, polyethylene, or neoprene shall be worn when handling JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD. 6. 6

7 Sr. No. Raw Materials Mode of Storage MOC of Storage Container Capacity of Containers Dyke Details Possible Type of Hazards Control Measures Proposed To Ensure Safety And Avoid The Human Health Impacts hydrogen peroxide. Safety shower, eye wash fountain, and one additional source of water shall be made readily accessible in the unloading area, hydrogen peroxide storage and pumping area. System shall be made such that an activation of the shower or eyewash station shall trigger an alarm to summon help. In case of fire, only water shall be used. Foam is not effective because oxygen and heat continues to generate under the foam blanket. 7. Carbon Transfer Compatibl - NA Fire & Toxic. Monoxide line (500 e material Please refer the section no.: Hydrogen mm dia.) from with 3 mm thk rubber - NA Explosive. Please refer the section no.: Plasma lining / reactor to Storage tank. FRP Lining NOTES: The quantity of these chemicals being stored within the factory premises, are well below the threshold storage quantity as per schedules of Manufacture, Storage & Import of Hazardous Chemicals (MSIHC) Rules of major hazardous chemicals. 1. The size of the biggest storage tank provided is 215 KL for Phenol. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD. 6. 7

8 Physical State EIA REPORT OF M/S. CAMLIN FINE SCIENCES LTD., DAHEJ SEZ PART-II, GUJARAT. TABLE: 6.2 B: PROPERTIES OF HAZARDOUS CHEMICALS Sr. No. CHEMI CAL 1 Toluene Liq. FP o C BP o C SP. 20 o C Vap. Den. Vs air Vap. Pr. Mm 20 o C kpa LE L % U EL % LD 50 ORAL mg/kgs LD 50 DERM AL mg/kgs LC 50 mg/l IDLH Value by ACGIH/NI OSH STEL by OSHA (PPM) TLV- TWA by OSHA (PPM) Isopropyl alcohol Liq kpa mg/kg (Mouse) mg/kg (Rabbit) ppm 500 ppm 400 ppm 3 Ethanol Liq kpa mg/kg [Rat] ppm 8 hours [Rat] Methanol Liq kpa mg/kg [Rat]. 20 mg/kg (Rabbit) ppm (Rat) ppm 5 Phenol Liq mm Hg mg/kg [Rat] 669 mg/kg [Rat] 81 ppm (rat) 250 ppm 5 ppm 5 ppm JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD. 6. 8

9 6 Carbon Monoxid e Gas NA mmh C ppm (Rat) 4H Hydroge n Gas NA NA 4 75 NA NA 3124p pm 1 hrs.(ra t) NA NA NA JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD. 6. 9

10 6.3 RISK ASSESSMENT Identification of hazards in the proposed project activity is of primary significance. Hazard states the characteristics of system/plant/process that presents potential for an accident. All the components of a system or plant or process need to be thoroughly examined to assess their potential for initiating or propagating an unplanned event/sequence of events, which can be termed as an accident HAZARDS IDENTIFICATION AND DETAILS OF PROPOSED SAFETY SYSTEMS At M/s. Camlin Fine Sciences Ltd., major risks have been identified for the following areas: Plasma Gasification Plant Class A Tank Farm In this study: Storage & Handling of Methanol, Toluene, Isopropyl Alcohol, Carbon Monoxide & Hydrogen have been considered for Consequence Analysis. Their storage location has been shown in Figure-6.1. Hazardous properties of these chemicals have been summarized in Table QUALITATIVE RISK ASSESSMENT Quantitative Risk Assessment (QRA) is a structured approach to identifying and understanding the risks associated with hazardous activities such as the operation of a plant. The assessment starts by taking an inventory of potential hazards, their likelihood and consequences. It involves the steps of identifying the hazards associated with the operations/storage/unloading activity and selecting the worst case scenario for consequence estimation. Finally, suggesting the measures to minimize or mitigate risks to meet appropriate acceptability criteria. The planning for emergency evacuation shall be borne in mind whilst interpreting the results METHODOLOGY TO CONDUCT QUANTITATIVE RISK ASSESSMENT: Consequences of loss of containment can lead to hazardous situation in any industry handling potentially hazardous materials. Following factors govern the severity of consequence of the loss of containment. Intrinsic properties; flammability, instability and toxicity, Dispersive energy; pressure, temperature and state of matter, Quantity present, JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

11 Environmental factors; topography and weather. Consequence analysis and calculations are effectively performed by computer software using models validated over a number of applications. Consequence modeling is carried out by PHAST of DNV Software or by ALOHA. PHAST contains data for a large number of chemicals and allows definition of mixtures of any of these chemicals in the required proportion. The calculations by software involve following steps for each modeled failure case: Run discharge calculations based on physical conditions and leak size. Model first stage of release (for each weather category). Dispersion modeling takes into account weather conditions. In case of flammable gas release, calculate size of effect zone for fire and explosion. The hazardous chemicals considered in this study are Hydrogen and Carbon Monoxide CONSEQUENCE ANALYSIS In a plant handling hazardous chemicals, the main hazard arises due to storage and handling of hazardous chemicals as mentioned above. If these chemicals are released into the atmosphere, it may cause damage due to resulting fires or vapour clouds. Blast Overpressures depend upon the reactivity class of material between two explosive limits DAMAGE CRITERIA In Consequence Analysis studies, in principle three types of exposure to hazardous effects are distinguished: 1. Heat radiation, from a jet, pool fire, a flash fire or a BLEVE. 2. Explosion 3. Toxic effects, from toxic materials or toxic combustion products. In the next three paragraphs, the chosen damage criteria are given and explained. Heat Radiation The consequence caused by exposure to heat radiation is a function of: The radiation energy onto the human body [kw/m 2 ]; The exposure duration [sec]; The protection of the skin tissue (clothed or naked body). In this report following damage criteria has been considered for the effects due to fire/ explosion. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

12 TABLE: 6.3 EFFECTS DUE TO INCIDENT RADIATION INTENSITY INCIDENT RADIATION TYPE OF DAMAGE kw/m Immediate ignition of wood (without flame Contact). 100 % fatal. 25 Minimum Energy required for igniting wood (Without flame contact). 100 % fatal in 1 min. Significant injury in 10 sec Minimum heat required to ignite wood (With flame contact). 1 % fatal in 1 min. First degree burn in 10 sec. 4 Pain after 20 sec. Blistering unlikely. 2 No discomfort for long exposure. Explosion In case of vapour cloud explosion, two physical effects may occur: a flash fire over the whole length of the explosive gas cloud; A blast wave, with typical peak overpressures circular around ignition source. As explained above, 100% lethality is assumed for all people who are present within the cloud proper. The following damage criteria may be distinguished with respect to the peak overpressures resulting from a blast wave: TABLE: 6.4 DAMAGE DUE TO OVERPRESSURES Peak Overpressure Damage Type 0.40 bar Ear Drum Rupture to humans 50 % probability of fatality inside 15% probability of fatality in open 0.21 bar Structural Damage to buildings 20% probability of fatality to personnel inside 0% probability of fatality in the open 0.13 bar Minor Structural Damage to near by structures 0.02 bar Glass Damage 0.01 bar Minor Damage 10% probability of fatality to personnel inside 0% probability of fatality in the open JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

13 Intoxication In this report, LC 50 concentration and IDLH concentrations have been considered for Consequence Analysis ASSUMPTIONS FOR CONSEQUENCE ANALYSIS For Consequence Analysis, assumptions regarding Meteorological, Pasquil Stability Classes, Wind velocity, Ambient Temperature, Relative Humidity, Inventory, Ground Roughness, Model used etc. are very important. In this report, the following assumptions have been considered. I. Meteorological Paste other tables Atmospheric Conditions: No Inversion Ambient Temperature: 35 0 C has been considered as MCA approach. Relative Humidity: As the site is not in rainy zone RH of 50% has been considered. II. Pasquil Stability Classes Pasquil Stability category E/F is considered as conservative approach. III. Other assumptions: Ground Roughness: Ground Roughness has been considered as 0.3 M. Dispersion model of both Heavy Model and also Gaussian distribution have been used as applicable/appropriate. Inventory: Release of 100% of the inventory has been considered. For this, failure of the container has been considered from the bottom. Storage conditions: Storage conditions have been considered as they are practically stored at site. Following Weather data has been used for the study: TABLE: 6.5 WEATHER DATA USED FOR THE STUDY Wind Speed (m/s) Pasquill Stability 1.5 F 1.5 D 5 D SOFTWARE USED FOR CALCULATIONS 1. PHAST MICRO SCENARIOS CONSIDERED FOR CONSEQUENCE ANALYSIS 1. In this study, the scenarios for consequence analysis have been selected considering: JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

14 The physical and chemical properties of hazardous materials Storage conditions & Modes of Storage (Underground & Above ground storage tanks). Hazards ranking by NFPA Guidelines by OSHA (29 CFR) Operating and storage conditions of handling and storage of hazardous chemical 2. This report considers the worst case scenario which is possible during any set of operation variable and production methodologies. The objective of the study is emergency planning, hence only holistic & conservative assumptions are used for obvious reasons. Hence though the outcomes may look pessimistic, the planning for emergency concept should be borne in mind whilst interpreting the results. In this regard, the failure cases which may lead to release of hazardous chemicals are as under: Failure of Unloading Arm of the ISO tanker during unloading of solvents, Full bore rupture from Transfer lines, Catastrophic Rupture of storage tank Partial Leakage from Transfer line. 3. The scenarios of flammable solvent storage tanks have been considered assuming unavailability of bunds. Practically a bund shall be provided as per OISD guidelines. 4. In this study, results of consequence analysis shall be used for; a. Emergency Planning b. Deciding Evacuation Routes c. Deciding Location of Assembly Points and ECC d. Resource Allocation for mitigation TABLE: 6.6 SCENARIOS IDENTIFIED FOR CONSEQUENCE ANALYSIS Scenarios Description of Scenario FIRE/EXPLOSION SCENARIOS Storage Pressure & Temp. Scenarios considered 1. Release of Methanol Ambient Flash Fire, UVCE, Late Pool Fire, 2. Release of Toluene Ambient Flash Fire, UVCE, Late Pool Fire 3. Release of Isopropyl Ambient Flash Fire, UVCE, Late Pool JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

15 Alcohol 4. Release of Hydrogen Gas Catastrophic Rupture of tank TOXIC GAS RELEASE SCENARIOS 5. Release of Carbon Monoxide- Catastrophic Rupture of tank 6. Release of Carbon Monoxide- Full Bore Rupture of Transfer line (500 mm) Press: 0.01 Bar Temp.: 50 degc Ambient Ambient Fire Flash Fire, UVCE, Jet Fire Dispersion Dispersion Considerations Made: In Case of Solvents (i.e. Methanol/Toluene & IPA) we have considered the failure case of unloading line (2 i.e. 50 mm pipe dia.) during the unloading of these chemicals from their respective tankers for a period of 10 mins. As the solvent tankers are compartmentalized, the maximum release quantity equals the storage quantity of a single compartment. Selection Criteria of Scenarios: As per the relevant guidelines for consequence analysis, we have considered the maximum credible scenarios for all the above mentioned chemicals, which is the representative of all kinds of minor/major leakages for the respective chemicals. Modeling has been carried out for dispersion up to LC 50 concentration and IDLH concentration, in case of toxic chemicals. Evacuation should be carried out in less than 30 min from the areas covered under IDLH in case of relevant leakage scenario. The purpose is to avoid irreversible health effects to persons inside the area of IDLH concentration. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

16 TABLE: 6.7 SCENARIO#1 RELEASE OF METHANOL (FULL BORE RUPTURE OF UNLOADING HOSE 2 ) Basis: Possible Release/Leakage due to failure of Unloading Arm of Tanker. Input Data Stored quantity in one compartment 5 m 3 Leak Duration Considered 600 secs Leak Size considered 50 mm Release Rate 1066 gms/sec Pressure Ambient Temperature 35 deg C Weather Condition 1.5/F, 1.5/D, 5/D LFL ppm UFL ppm CASE:1 FLASH FIRE CASE:2 VAPOUR CLOUD EXPLOSION (OVERPRESSURE RESULTS) CASE:3 LATE POOL FIRE (EFFECTS OF RADIATION LEVEL) JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

17 FIGURE: 6.2 RISK CONTOURS FOR FLASH FIRE: JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

18 FIGURE: 6.3 RISK CONTOURS FOR VAPOUR CLOUD EXPLOSION (OVERPRESSURE RESULTS): JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

19 FIGURE: 6.4 RISK CONTOURS FOR LATE POOL FIRE: JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

20 TABLE: 6.8 SCENARIO#2 RELEASE OF TOLUENE (FULL BORE RUPTURE OF UNLOADING HOSE 2 ) Basis: Possible Release/Leakage due to failure of Unloading Arm of Tanker. Input Data Stored quantity in one compartment 5 m 3 Leak Duration Considered 600 secs Leak Size considered 50 mm Release Rate 1091 gms/sec Pressure Ambient Temperature 35 deg C Weather Condition 1.5/F, 1.5/D, 5/D LFL ppm UFL ppm CASE:1 FLASH FIRE CASE:2 VAPOUR CLOUD EXPLOSION (OVERPRESSURE RESULTS) CASE:3 LATE POOL FIRE (EFFECTS OF RADIATION LEVEL) JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

21 FIGURE: 6.5 RISK CONTOURS FOR FLASH FIRE: JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

22 FIGURE: 6.6 RISK CONTOURS FOR LATE EXPLOSION (OVERPRESSURE): JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

23 FIGURE: 6.7 RISK CONTOURS FOR LATE POOL FIRE: JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

24 TABLE: 6.9 SCENARIO#3 RELEASE OF ISOPROPYL ALCOHOL Basis: Possible Release/Leakage due to failure of Unloading Arm of Tanker. Input Data Stored Considered 5 m 3 Leak Duration Considered 600 secs Leak Size Considered 50 mm Release Rate 997 gms/sec Pressure Ambient Temperature 35 deg C Weather Condition 1.5/F, 1.5/D, 5/D LFL UFL ppm ppm CASE:1 FLASH FIRE CASE:2 VAPOUR CLOUD EXPLOSION (OVERPRESSURE RESULTS) CASE:3 LATE POOL FIRE (EFFECTS OF RADIATION LEVEL) JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

25 FIGURE: 6.8 RISK CONTOURS FOR FLASH FIRE: JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

26 FIGURE: 6.9 RISK CONTOURS FOR LATE EXPLOSION (OVERPRESSURE): JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

27 FIGURE: 6.10 RISK CONTOURS FOR LATE POOL FIRE: JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

28 CATASTROPHIC RUPTURE OF SYNGAS STORAGE TANK TABLE: 6.10 SCENARIO#4.1 RELEASE OF CARBON MONOXIDE GAS Basis: Catastrophic Rupture of Syn Gas Storage Tank. Input Data Quantity considered Total volume of tank i.e lit. Pressure 100 mm WC Temperature 50 deg. C Weather Condition 1.5/F, 1.5/D, 5/D LC ppm IDLH 1200 ppm CASE:1 FLASH FIRE CASE:2 JET FIRE Not Applicable TABLE: 6.11 RESULTS FOR DISPERSION: Sr. Concentration Downwind Distance (meters) No. Category 1.5/F Category 1.5/D Category 5/D 1. LC 50 : 1807 ppm IDLH : 1200 ppm meters in downwind direction is considered as evacuation area. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

29 FIGURE: 6.11 RISK CONTOURS FOR DISPERSION OF CARBON MONOXIDE FOR LC 50 CONCENTRATION: JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

30 FIGURE: 6.12 RISK CONTOURS FOR DISPERSION OF CARBON MONOXIDE FOR IDLH CONCENTRATION: JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

31 FIGURE: 6.13 RISK CONTOURS FOR FLASH FIRE: JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

32 TABLE: 6.12 SCENARIO#4.2 RELEASE OF HYDROGEN GAS Basis: Catastrophic Rupture of Syn Gas Storage Tank. Input Data Quantity considered Total volume of tank i.e lit. Pressure 100 mm WC Temperature 50 deg. C Weather Condition 1.5/F, 1.5/D, 5/D LFL UFL ppm ppm CASE:1 FLASH FIRE (Dispersion) CASE:2 VAPOR CLOUD EXPLOSION (UVCE Overpressure Results) No Hazards CASE:3 JET FIRE (Effects of Radiation Level) No Hazards Note: For Syn. Gas, we have considered the 2 most vulnerable cases: Catastrophic Rupture of SYN Gas Storage Tank, and Full bore rupture of SYN gas transfer line. We have considered the individual gas scenarios (considering the total volume of tank for each individual gas) for the catastrophic rupture of syn. Gas storage tank. But from the scenarios shown above, it is summarized that the scenario for Carbon monoxide is the most vulnerable one than the Hydrogen case. Also, CO alone consumes the % in total SYN gas volume. Thus, as a conservative approach we can consider the total storage of syn. Gas as carbon monoxide only. Considering all above points, for the scenario of full bore rupture of gas transfer line, we have considered the scenario for CO only as the total SYN gas flow rate. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

33 FIGURE: 6.14 RISK CONTOURS FOR FLASH FIRE: JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

34 FULL BORE RUPTURE OF SYN GAS TRANSFER LINE TABLE: 6.13 SCENARIO#5.1 RELEASE OF CARBON MONOXIDE GAS Basis: Full Bore Rupture of Syn Gas Transfer Line. Input Data Release rate of Carbon Monoxide 2556 kgs/hr (considered total rate of syn gas as CO) Release Duration 10 mins Pressure 0.01 bar Temperature 50 deg. C Weather Condition 1.5/F, 1.5/D, 5/D LC ppm IDLH 1200 ppm CASE:1 FLASH FIRE (Dispersion) CASE:2 JET FIRE (Effects of Radiation Level) CASE:3 VAPOR CLOUD EXPLOSION (UVCE Overpressure Results) TABLE: 6.14 RESULTS: Sr. Concentration Downwind Distance (meters) No. Category 1.5/F Category 1.5/D Category 5/D 1. LC 50 : 1807 ppm IDLH : 1200 ppm meters in downwind direction is considered as evacuation area. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

35 FIGURE: 6.15 RISK CONTOURS FOR DISPERSION OF CARBON MONOXIDE FOR LC 50 CONCENTRATION: JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

36 FIGURE: 6.16 RISK CONTOURS FOR DISPERSION OF CARBON MONOXIDE FOR IDLH CONCENTRATION: JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

37 FIGURE: 6.17 RISK CONTOURS FOR FLASH FIRE: JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

38 FIGURE: 6.18 RISK CONTOURS FOR JET FIRE: JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

39 FIGURE: 6.19 RISK CONTOURS FOR UVCE OVERPRESSURE: JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

40 CONSEQUENCE ANALYSIS SUMMARY TABLE: 6.15 FLASH FIRE SCENARIOS: Sr. No. Scenario Concentration (ppm) 1. Release of Methanol 2. Release of Toluene 3. Release of Iso Propanol 4. Release of CO (Catastrophic Rupture of 5. St. Hydrogen Tank) Gas(Catastro phic Rupture 6. of Release St. Tank) of CO (Full bore Rupture of Transfer line) TABLE: 6.16 Distance (meters) Category Category 1.5/F 1.5/D LFL Frac LFL LFL Frac LFL LFL Frac LFL LFL Frac LFL Category 5/D LFL Frac LFL LFL Frac LFL EXPLOSION OVERPRESSURE SCENARIOS: Sr. No. Scenario Overpressure (Bar) Downwind Distance (meters) 1. Release of Methanol 2. Release of Toluene 3. Release of Iso Propanol Category 1.5/F Category 1.5/D Category 5/D JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

41 Sr. No. Scenario 4. Release of CO (Full bore Rupture of Transfer line) TABLE: 6.17 Overpressure (Bar) LATE POOL FIRE SCENARIOS: Sr. No. Scenario Radiation Level 1. Release of Methanol 2. Release of Toluene 3. Release of Iso Propanol Downwind Distance (meters) Category 1.5/F Category 1.5/D Category 5/D Downwind Distance (meters) (KW/m2) Category 1.5/F Category 1.5/D Category 5/D TABLE: 6.18 JET FIRE: Sr. Scenario No. 1. Release of CO (Full bore Rupture of Transfer line) Radiation Level (KW/m2) Distance (meters) Category 1.5/F Category 1.5/D Category 5/D NR JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

42 TOXIC SCENARIOS: TABLE: 6.19 CATASTROPHIC RUPTURE OF SYN GAS STORAGE: Sr. Concentration Downwind Distance (meters) No. Category 1.5/F Category 1.5/D Category 5/D 1. LC 50 : 1807 ppm IDLH : 1200 ppm TABLE: 6.20 FULL BORE RUPTURE OF GAS TRANSFER LINE: Sr. No. Concentration Downwind Distance (meters) Category 1.5/F Category 1.5/D Category 5/D 1. LC 50 : 1807 ppm IDLH : 1200 ppm COMMENTS / RECOMMENDATIONS BASED ON CONSEQUENCE ANALYSIS FLASH FIRE AND UVCE SCENARIOS: Of all the Scenarios considered above, vapor travels to distance (17.09 m) in case of Release of CO (Full bore Rupture of Transfer line) in 1.5/F weather condition. If it gets a source of ignition within this radius, it will create UVCE (Unconfined vapor cloud explosion) and effects of overpressure ( bar) would be felt up to m. Also, in case of IPA vapor travels to distance (9.41 m) in case of release of Methanol in 1.5/F weather condition, If it gets a source of ignition within this radius, it will create UVCE (Unconfined vapor cloud explosion) and effects of overpressure ( bar) would be felt up to 55 m. Scenario for Release of Methanol & Hydrogen in all weather conditions, poses least danger of flash fire/uvce. It can be seen from the summery table above that 5/D weather condition is safer compared to other weather conditions. Evacuation plan to be designed considering the worst case scenario of IPA & CO as mentioned above. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

43 6.4.2 LATE POOL FIRE SCENARIOS: The risk of late pool fire is highest in case of release of IPA in 5/D weather condition for 4 KW/m 2 radiation level. Scenario for Release of Toluene, poses least danger of radiation as compared to other chemical scenarios TOXIC RELEASE SCENARIOS: Dispersion of Release of CO (Full bore Rupture of Transfer line) for IDLH concentration covers highest distance in case of in 1.5/F weather condition. Evacuation plan to be designed considering the worst case scenario of Carbon Monoxide as mentioned above RECOMMENDATIONS: 1. Evacuation routes shall be planned such that alternate route is available from any corner in more than one direction. 2. Extra precautions to be taken in unloading of flammable solvents. The details of precautions during storage handling and transportation of solvents have been given in separate paragraph. 3. Fire fighting arrangements shall be provided as per the guidelines of OISD. 4. In case of release of flammable chemicals, evacuation plan shall be designed considering the worst case of all scenarios for Carbon Monoxide & Isopropyl Alcohol. 5. All sources of ignition shall be avoided near plasma reactor as well as Syngas carrying pipeline. 6. Hazardous Area Classification shall be carried out to decide the type of electric fitting to be installed. 7. Tanker Storage: OISD guidelines shall be followed in design, installation and maintenance of UG storage tanks. HAC shall be carried out to decide the type of electric installation. 6.5 OTHER SAFETY PRECAUTIONS PROPOSED SAFETY/CONTROL MEASURES TO REDUCE THE RISK OF FIRE, EXPLOSION AND TOXIC RELEASE: Following Safety Precautions shall be followed/ practiced during transportation, unloading and handling of flammable & toxic chemicals in order to ensure safety and avoid the human health impacts. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

44 TABLE: 6.21 SAFETY PRECAUTIONS Sr. Activity No. 1. Transportation of Solvents by road tanker. 2. Unloading of Solvents from tanker. 3. Solvents Storage Area (Tank Farm). Safety Precautions Training will be provided to driver and cleaner regarding the safe driving, hazards of Flammable chemicals, emergency handling, and use of SCBA sets. TREM card will be kept with TL. SCBA set will be kept with TL. Fire extinguishers will be kept with TL. Flame arrestor will be provided to TL exhaust. Instructions will be given not to stop road tanker in populated area. Hazard Identification symbol and emergency telephone number will be displayed as per HAZCHEM CODE. Appropriate PPEs will be kept with TL. In case of leak or spill: Area will be isolated. Container shall be isolated. Source of leakage will be checked. Damaged containers or spilled material shall not be attended without wearing appropriate protective clothing. Leak will be stopped, if possible to do so without risk. Water spray shall be used to reduce vapors (but do not put water directly on leak, spill area or inside container). Combustibles (wood, paper, oil, etc.) shall be kept away from spilled material. Priority will be given to Tanker to immediately enter the storage premises at site and will not be kept waiting near the gate or the main road. Security person will check License, TREM CARD, Fire extinguisher condition; SCBA set condition, Antidote Kit, required PPEs as per SOP laid down. Store officer will take sample as per sampling SOP from sampling point. After approval of QC department unloading procedure will be allowed be started, as per rules & guidelines. Following precautions will be taken during unloading: Wheel stopper will be provided to TL at unloading platform. Static earthing will be provided to road tanker. Tanker unloading procedure will be followed according to check list and implemented. Flexible SS hose connection will be done at TL outlet line. All TL valves will be closed in TL. Only day time unloading will be permitted. Separate Isolated Storage Area will be constructed as per explosive department requirement for flammable chemical (will be marked at Class A Tank Farm) and separation distance will be maintained, accordingly. Pipes and equipment shall be inspected at regular intervals. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

45 Sr. No. Activity 4. Solvents transfer from storage tank to Process Plant. Safety Precautions All storage areas shall be isolated from all sources of open flame and well posted with NO SMOKING signs and will provided with adequate fire fighting/extinguishing system. Entry of unauthorized persons is prohibited. Transfer through rigid piping only. Spark-resistant tools will be used. Water spray shall be used to reduce vapors (but do not put water directly on leak, spill area or inside container). Combustibles (wood, paper, oil, etc.) shall be kept away from spilled material. Dyke wall will be provided to storage tanks. Level transmitter will be provided with low level/high level auto cut-off provision. Vent will be connected to water trap and vent of water trap will be provided with flame arrestor. Fire hydrant monitor with foam attachment facility will be provided. Suitably eye-wash, showers and water showers to body is provided nearby acid and Caustic Storage area. Dumping /Drain vessel/alternate vessel will be provided to collect the spillage material inside the dyke wall. No hot work shall be carried out nearby. Ignition sources shall be avoided in such areas. Area shall be covered with fire hydrant network. Appropriate PPEs like Safety Goggles, Butyl or Nitrile rubber gloves, gumboot, plastic apron etc. shall be used. Only trained operators shall be allowed to work in this area. Inspection (for pumps, flange joints etc) shall be carried out on regular basis. FLP type pump & electrical fittings will be provided. Flame arrestor with breather valve will be provided on vent line. NFPA label (hazard identification) capacity and content will be displayed on storage tank. Lightening arrestor will be provided on the top of tallest structure. Material Safety Data Sheets (MSDSs) shall be kept available for all such flammable solvents in language understandable by operators. Double static earthing will be provided to storage tank, as per the requirement. Double Jumper clip shall be provided to all solvent handling pipeline flanges. Double mechanical seal type FLP type pump shall be provided. Double on / off switch shall be provided at tank farm and process area near day tank. Pump auto cut off with day tank high level shall be provided. Flame arrestor shall be provided on day tank vent. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

46 Sr. No. Activity Safety Precautions Over flow shall be provided for additional safety and it shall be connected to main storage tank. NRV shall be provided on pump discharge line. Double Jumper clip shall be provided to all solvent handling pipelines. Color coding will be provided for solvents handling pipelines. Double static earthing shall be provided to day tank RECOMMENDATIONS TO REDUCE FUGITIVE EMISSIONS: CONTROL TECHNIQUES FOR FUGITIVE EMISSIONS ARE IN THE FOLLOWING ORDER: (1) First preference: Engineering Controls (2) Second preference: Administrative / Management Controls (3) Last resort: Personal Protective Equipment (PPE) FUGITIVE EMISSIONS OCCURS OR MAY OCCUR DURING (1) Charging of Raw Materials. (2) Leakage from Flanges, joints etc (3) Tanker loading & unloading MITIGATION MEASURES Regular monitoring of plant area to be conducted and records to be maintained. At strategic point of the plants, online detectors shall be provided for detection of such emissions. Lines of such hazardous chemicals will be tested periodically and such tests will be recorded. All lines carrying toxic liquid shall be continuous welded and must be provided with proper slopes and special tongue and groove joints to avoid liquid stagnation and leakage. In the process area, all the strategic pumps must be of submerged type so as to eliminate leakages from glands. Safe Operating Procedures and EMERGENCY RESPONSE PROCEDURES are followed strictly FIRE CONTROL PLAN M/s. Camlin Fine Sciences Ltd. has considered fire prevention measures at the project planning stage for its upcoming new facility to avoid any outbreak of fire. By looking to the hazardous nature of process and the chemicals that are handled and processed, the chances of outbreak of fire cannot be totally ignored. Hence to tackle such a situation, company shall JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

47 develop a well-resourced and adequate fire protection system/fire fighting network (the same is being shown in the company layout fig. 6.2). The company has planned to keep the following types of fire extinguishers at various conspicuous locations: TABLE: 6.22 FIRE EXTINGUSHERS Sr. Type Capacity Total Quantity No. 1. Dry Chemical Powder 5 Kgs 11 Nos. 10 Kgs 25 Nos Kgs 10 Nos. 25 Kgs 4 Nos. 2. Carbon dioxide 2 Kgs 2 Nos. 3.2 Kgs 2 Nos. 4.5 Kgs 15 Nos. 3. Water Type Extinguishers 9 Litre 7 Nos. 4. ABC 5/10 Kgs 3 Nos. 5. Foam Type Extinguishers 9 Lits 12 Nos. 9 Kgs 6 Nos. 6. Mechanical Foam type Extinguisher 50 Kgs 2 Nos OTHER FIRE FIGHTING MEASURES PROPOSED FOR THE NEW FACILITIES: Fire load calculation will be carried out and accordingly fire fighting facilities comprising of main pump, stand by pump, jockey pump, diesel driven pump, Hydrant Network, under ground water reservoir, Hose Box, Hose reels, Manual call points, fire alarms, fire buckets, smoke / heat detectors etc. will be provided as per the GFR and TAC guidelines. Working staff will be given training to operate DCP and CO 2 extinguishers. DG set shall be made available to be use as power back, in case of power failure. Factory Layout has been designed in such a way that there is a provision for double entry which can be used as a separate entry and exist with adequate margin all around the periphery for unobstructed easy movement of the emergency vehicle / fire tenders without reversing back. Same has been marked in plant layout also. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

48 6.5.4ANTIDOTES DETAILS: Following Antidotes for major hazardous chemicals shall be kept available at site. TABLE: 6.23 ANTIDOTES FOR MAJOR HAZARDOUS CHEMICALS Chemical Antidote / Medical Treatment Methanol Ethanol (30% solution from inside, 5% solution from outside i.e. by intravenous injection), Epicake Syrup. In case of acidosis give Sodium bicarbonate. In case of delirium, give Diazepam 10 mg. by intravenous injection. Folinic acid (Leucovorin), 1 mg/kg, (I v), 4 hourly. Toluene Wash affected skin with plenty of water. Administer Oxygen or shift to Fresh air, Don t apply Epinefrin, Ifridin etc. Don t apply milk, vegetable oil or alcohol. Give Diazepam 0.1 mg/kg (I v) slowly through injection, bed rest. Administer Diazem 1 mg/kg. (Intravenous). Ethanol 2 gm. Of Sodium bicarbonate in 250 ml water, Diazepam 10 mg. by intravenous. Wash affected area of skin/eye with plenty of water. Phenol Immediately wash the affected skin with copious amounts of water followed by undiluted polyethylene glycol. Wash the area thoroughly with soap and water after treatment. Immediately decontaminate the eyes with copious amounts of tepid water for at least 15 minutes. If phenol is ingested, avoid emesis, alcohol and oral mineral oil and dilution, because they may increase absorption. Gastric lavage is usually not recommended. Immediate administration of olive oil and activated charcoal by small bore nasogastric tube is necessary. Carbon Monoxide Pure oxygen through mask. 20% mennytole (1gm/ kg) prednisolone 1 mg/kg through injection. Hydrogen Contact with eyes: - Shall be flushed immediately with plenty of Peroxide water for at least 15 minutes, while holding the eyelids apart. Medical attention shall be obtained immediately. Contact with the skin: - Shall be flushed immediately with plenty of water for at least 15 minutes. Obtain medical attention after contact with hydrogen peroxide at above 50% concentration. Remove contaminated clothing and shoes quickly after commencing water flush. After first aid measures are complete, contaminated clothing shall be washed thoroughly in order to eliminate a delayed potential fire hazard. Ingestion: - Do not induce vomiting. Give large volumes of water. Do not give anything by mouth to an unconscious person. Obtain medical attention immediately. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

49 6.5.5 WAYS TO MINIMIZE THE MANUAL HANDLING OF THE HAZARDOUS CHEMICALS: 1. Fork lifts shall be used for handling bulk chemical bags, drums, carboys, etc. 2. Cranes, hoists, pallet trucks, conveyors, etc. shall be used as per the requirement, to eliminate manual handling. 3. Lifting tools & tackles will be used, wherever required. 4. SOPs, work instructions will be prepared and followed. 5. Trainings will be provided to relevant staff, operators, workers for the risk associated with manual handling of hazardous chemicals, ways to overcome those risk, etc INBUILT SAFETY MEASURES IN PLASMA PLANT FOR PREVENTING ACCIDENTS. 1. Plasma reactor shall operate under negative pressure (-10 to -15 mmwcg) thus avoiding possibility of SYN gas coming out from reactor in case of leakage. 2. Emergency vent shall be provided on plasma reactor which immediately opens on sensing pressure of plasma reactor. Emergency vent valve shall get activated at +2 mmwcg pressure of reactor and reduces pressure to 0 mm wcg immediately. This design does not allow plasma reactor to get pressurized. 3. Plasma reactor shall operate under oxygen starved atmosphere. So, even flammable waste gets gasified in controlled condition. There shall be no adequate oxygen in reactor for fire, explosion or any runaway reactor to take place. 4. The entire system except gas holder shall operate under negative pressure by ID fan. So, even if there is leakage in the duct or rupture of duct, SYN gas will remain contained in the system and does not come out to cause fire or explosion. In case of power failure ID fan shall be backed up by UPS system with 15 min. backup to keep SYN gas contained within the system. 5. Gas holder is not a storage tank for SYN gas but shall be provided to damper pulsation in SYN gas flow rate generated due to waste feeding into the reactor. The volume of gas holder is 1000 lit. The gas holder shall be provided with emergency vent activated through pressure transmitter. In case of failure of booster fan or excess pressure in gas holder beyond 250 mmwcg, emergency valve on gas holder shall gets activated & SYN gas shall be vented to flare system. 6. Pressurized nitrogen injection system shall be provided for any power failure occasion or failure of mechanical equipment. Plasma reactor, ducts & scrubbing system shall be flooded with nitrogen to present any fire & explosion incidence. Nitrogen purging shall be initiated in auto, in case of. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

50 Power failure Reaction pressure increase. Nitrogen purging shall be initiated manually, in case of. In case of ID fan failure Any equipment failure Any abnormal condition 7. Automatic trip sequence shall be configured which trips the plant in case of any of the abnormal process deviations like reactor pressurization, scrubber pump trip, ID fan trip, booster fan trip, boiler flame failure, etc OTHER RECOMMANDATIONS TO REDUCE THE RISK OF FIRE, EXPLOSION AND TOXIC RELEASE 1. Carbon Monoxide Detectors shall be installed. The detectors shall be installed in diagonally opposite directions. The detectors shall be linked with alarm and process control system. 2. Hydrogen LEL detectors shall also be installed. The alarms to be configured at different concentrations. Process control to be given such that the supply is cut off on detection of leakage. 3. Pressure drop in SYN gas carrying pipeline shall be monitored on line. 4. Flame proof electrical equipments shall be provided. 5. All required permits shall be secured prior to starting work (hot work permit, lockout/tag-out, and vessel entry if applicable). 6. Buildings shall be well ventilated (typically 10 air changes per hour), 7. Appropriate protection measures shall be designed for containment and explosion venting. 8. Welded connections, instead of flanged connections shall be used to improve reliability. 9. Automated Plant Emergency Shutdown system (ESS) shall be incorporated. 10. Overhead piping of SYN gas shall be coded or identified. 11. Corrosion of SYN gas piping shall be avoided by paint or cathodic protection. 12. Fire detection and suppression equipment shall be used. 13. Procedures shall be developed for start-up and schedules shall be made for regular inspection of plant machinery. 14. Fire load calculation will be carried out and fire fighting system shall be installed accordingly. 15. Loading and unloading of wastes in storage sheds shall only be done under the supervision of the well trained and experienced staff. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

51 6.5.7 DO S & DON TS Management has listed some of the Do's & Don'ts activities to strengthen the SAFETY AT WORK, which will be followed strictly: FOR PREVENTIVE MAINTENANCE Do's: Inspection of Storage Area, Earthing & Bonding system. Inspection of all Fire Fighting Facilities /Check Alarms operation. Ensuring that operators/workers etc. follows the SOPs, Safety procedures & standards, work permit system etc. Checking the availability of Spill Containment Kit. Make sure existing fire extinguishers are fully charged and ready for action. Inspections of plant, machinery, tools, equipment, premises, work practices, processes, procedures and general environment must be carried out for the health and safety of plant, people and surrounding. On-site and Offsite Emergency Plans shall be reviewed and updated, as per the requirement. Don ts: Don't allow anyone who hasn't received specific safety and operational training to get indulge in any site activity. Don't perform your own maintenance. Don t compromise on Design and Engineering part. Don't perform any activity without proper permit. Don't panic if you are in a risky situation. Don't allow spilled chemicals to drain to sewers/gutters etc. STRENGTHENING OF HSE (APPLICABLE FOR MANUFACTURING UTILITY STAFF) Do's: Follow instructions. Do not take chances. If you don t know, ask. Correct or report unsafe conditions. Include a timeline for completion of each recommendation. Make recommendations that are measurable and track able. Ensure that each recommendation is assigned to an individual to oversee implementation. Help keep things clean & orderly. Keep gangways clear. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

52 Do not Horseplay. Do not run. Avoid distracting others. Avoid throwing things. Report all injuries. Get first aid promptly. Use, adjust and repair equipment only, when authorized. Use right tools &equipments for the job, use them safely. Do not smoke in restricted areas. Do not flick cigarette / beedi in company. Use prescribed protective equipment; keep them in good working conditions. Respect signs / warnings. Abide by rules laid down for your safety. Don ts: 1) No worker in a factory- Shall willfully interfere with or misuse any appliance, convenience or other thing Provided in the factory for the purpose of securing the Health, Safety or Welfare of The workers therein: Shall willfully and without reasonable cause do anything likely to endanger himself or others; and Shall willfully neglect to make use of any appliance or other thing provided in the factory for the purposes of securing the Health or Safety of the workers therein. Do not make vague statements, do not overrule supervisor, and do not adopt shortcuts. 6.6 ON-SITE / OFF-SITE EMERGENCY PLAN M/s. Camlin Fine Sciences Ltd. has prepared the Proposed On-Site / Off-Site Emergency Plan which shall be followed from the project construction & erection phase. This plan has been prepared based on the risk contours plotted on the plant layout map clearly showing the facilities that would be affected, in case an accident takes place. The purpose of this plan is to provide M/s. Camlin Fine Sciences Ltd. with the means to effectively utilize all the resources at its disposal for the protection of life, environment and property. The details of the same are discussed in the following sections DEFINING THE NATURE/LEVEL OF EMERGENCY THE LEVEL OF EMERGENCY CAN BE CLASSIFIED IN THREE CATEGORIES: LEVEL - 1: The leakage or emergency, which is confinable within the plant or area. It may be due to: a) Small pipe/valve rupture or similar leakages that do not affect outside premises. b) Release of toxic chemicals for short duration. c) Small fire in the plant. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

53 LEVEL - 2: The emergency, which is confinable within the factory premises. It may arise due to - a) Leakage of toxic chemicals for long duration. b) Medium scale explosion confined to the factory premises. c) Medium scale fire inside the factory premises. LEVEL - 3: The emergency, which is not confinable within the factory premises and general public in the vicinity are likely to be affected. It may arise due to - a) Heavy / Profuse leakage of toxic / flammable gases for a long duration. b) Explosion of high magnitude affecting the adjacent area. c) Major fire inside the factory premises OBJECTIVES OF EMERGENCY MANAGEMENT SYSTEM The objectives of the emergency management system are summarized as under. To identify and assess types of emergencies due to different types of hazards. To work out plan with all provisions to handle emergencies and safeguard employees and people in the vicinity of the factory. To provide for emergency preparedness and the periodical rehearsal of the plan. To plan mode of proper communication & actions to be followed in the event of emergency. To keep all necessary information with respect to hazard/accident control and emergency contacts in one document for easy and speedy reference. To inform employees, general public and the authorities about the hazards/risk if any and the role to be played by them in the event of emergency. To control and contain the accident. To effect rescue and treatment of casualties. To inform and help relatives of casualties. To secure rehabilitation of affected area and restore normalcy. To provide information to media and government agencies. To preserve record, equipment etc. for investigating cause of emergency. To be ready for mutual aid if need arises to help neighboring units STRUCTURE OF EMERGENCY MANAGEMENT SYSTEM M/s. Camlin Fine Sciences Ltd. shall develop an Emergency Management Team. The management structure shall include the following personnel s; JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

54 Site Main Controllers Incident Controllers and Deputy Incident Controllers Key Personnel s Essential Workers The other elements of Emergency Plan shall be: Assembly points Emergency control center Fire control arrangements Medical arrangements Other arrangements SITE MAIN CONTROLLER Senior most Executives of the company shall be nominated as SMC. His task will be to coordinate all internal and external activities from the Emergency Control Centre at Main Security Gate, from where all operations will be directed. He shall: Immediately on being informed of the emergency and its location, will arrive at the site, review the situation and control further actions. Direct all Emergency Operations within the approved area with the following priorities: a. Personnel Safety, b. Plant, Property and Environment Safety and c. Minimum loss of production. Co-ordinate to avail services from external agencies like fire brigade, hospitals etc, if called for, following the declaration of major emergency. If necessary, major installations in the vicinity may also be informed of the situation. Exercise direct operational control of the unaffected section of the plant. In consultation with the advisory team, expedite the shutting down of loading / unloading operations of tankers and if necessary, instruct the supervisor / security personnel to evacuate tankers. Ensure that all employees are evacuated from the affected area and the casualties, if any, are given necessary medical attention. Instruct P & A Assistant / Security for rushing casualties to hospitals if required. Liaise with fire and police officials, pollution control board officials and other statutory bodies and advise them of all possible consequence effects outside the premises. Arrange for relief of personnel when emergency is prolonged. Issue authorized statement or press release to the news media. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

55 Ensure preservation of evidence for enquiries to be conducted by statutory authorities. Authorize the sounding of All Clear and Evacuation Siren. Arrange for obtaining the head count of all personnel within the premises and crosschecking with the data from records available for no. of persons within the premises. Nominate a person from advisory team, to maintain chronological log of event during the entire period of emergency ROLE OF INCIDENT CONTROLLER AND DEPUTY INCIDENT CONTROLLER His primary duties shall be to take charge at the scene of the incident. In the initial stage he may be required to take decisions involving the operation of the other plants or to stop or continue any process and to take technical decisions to control the incident. The deputy incident controller will take the charge of incident controller, if he is not available due to any reason. They will be always available in each shift and can take charge of the incident RESPONSIBILITIES/DUTIES OF INCIDENT CONTROLLER AND DEPUTY INCIDENT CONTROLLER: Managers connected with Plants/ the respective Plant-In-Charge has been indicated as I.C. Two Production officers in each shift will be identified as Deputy Incident Controllers. Shift-In-Charge (Maintenance) will act as Deputy Incident Controller for Area-III. He shall take charge at the scene of incident. He shall immediately assess the gravity of risk and alert panel and field operators to start controlling their respective section. He will work under the direction of the SMC, but till his arrival he may have to execute following responsibilities. He will ensure that all the Key Personnel are called. Direct for evacuation of plant and areas likely to be affected by the emergency. He shall communicate to the SMC the type of outside help needed. He shall direct all emergency operations within the affected area with the following priorities. Personnel safety, including of surrounding community. Minimum damage to Plant, Property and Environment. Appropriate actions to minimize loss of Production and Material. Give information to the head of fire fighting and rescue team and other emergency services. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

56 Depending on the incident, instruct partial or total shut down, isolations, depressurization, Nitrogen purging, fire fighting, rescue operations. Instruct upstream/downstream units to take emergency shutdown /cutting off supply and other appropriate actions and emergency evacuation help etc. Direct for search of casualties. Evacuate non-essential workers/visitors/contractors to safe assembly points. Brief site main controller and keep him informed about the developments. Preserve evidences. This will be necessary for investigation for cause and concluding preventive measures KEY PERSONNELS Senior officers of various departments like Fire, Security, Safety, Administration, Engineering, Project, Production and Stores shall be nominated as Key Personnel in their respective fields. As necessary, they will decide the actions needed to shutdown plants, evacuate personnel, carryout emergency engineering work, arrange for supplies of equipments, utilities, carryout environment monitoring, provide catering facilities, liaise with police, fire brigade and other local authorities, relative of casualties, hospital, press & neighboring industries, action at assembly points, outside shelters and mutual aid center under the direction of the SMC. All the key personnel and other called in so to assist shall report to the ECC. They shall be available at any time on duty or on call or on holidays ESSENTIAL WORKERS Essential Workers are those who are trained in Fire Fighting and First Aid. Identified E.W. s are supposed to report at EMERGENCY SITE to take instructions from I.C. or Dy. I.C. Such work instructions will include: Fire fighting and spill control till a Fire Brigade takes the charge. To help the Fire Brigade and mutual aid teams, if it is so required. Shutting down plant and making it safe. Emergency engineering work e.g. isolating equipment, material process, providing temporary by-pass lines, safe transfer of materials, urgent repairing or replacement, electrical work, etc. Provision of emergency power, water, lighting, instruments, equipments, materials, etc. Movement of equipment, special vehicle and transport to or from the scene of the accident. Search, evacuation, rescue and welfare. The injured is given First Aid. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

57 Moving tankers or other vehicles from area of risk. Carrying out atmospheric test and pollution control. Manning of assembly points to record the arrival of evacuated personnel. Manning for outside shelters and welfare of evacuated persons there. Assistance at causalities reception areas to record details of causalities. Assistance at communication centers to handle out going and in coming calls and to act as messengers if necessary. Manning of works entrances in liaison with the police to direct emergency vehicles entering the work, to control traffic leaving the works and to turn away or make alternative safe arrangements for visitors, contractors and other traffic arriving at the works. Informing surrounding factories and the public as well as directed by the Site Main Controller. Any special help required. OTHER ELEMENTS OF DMP: ASSEMBLY POINT Inaffected & vulnerable plants, all nonessential workers (who are not assigned any emergency duty) will be evacuated from the area & they shall report to specified Assembly Points. Assembly Points will be located at a safe place, well away from area of risk and least affected by the down wind direction. To ensure that workers do not have to approach the affected area to reach the Assembly Point, proper location and numbers have been marked at Assembly Points. Each Assembly Point will be manned by a nominated person to record the names and dept. At each Assembly Point, duties of Assembly Point In-charge will be displayed in brief. Before reaching an Assembly Point or subsequently, if it is required to pass through an affected area or due to presence of toxic substances, suitable PPE's including respirators, helmet etc., will be issued & made available with workers EMERGENCY CONTROL CENTER Security cabin or other room which is located besides the Main Security Gate and is also close to the assembly point will be decided as Emergency Control Center. Telephone and other facilities required with necessary documents shall be displayed in ECC for ready reference. In case of Major Emergency, the Site Main Controller will operate from ECC. The ECC center shall be equipped with the following facilities. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

58 1. Internal and external telephone including STD facility 2. Telephone directory 3. Telephone nos. of mutual aid centers 4. Factory layout plan 5. Map of the area 6. Employee blood group and their address 7. Messengers / Runners for sending messages 8. Adequate numbers of PPEs FIRE CONTROL ARRANGEMENTS (FIRE FIGHTING, GAS LEAK CONTROL AND RESCUE OPERATION) A) Role of Manager (Fire and Safety) / Shift In-Charge (Fire & Safety) 1. Incident Controller will be the only person to direct the fire fighting and Emergency operation. His duties include 2. Keep the constant touch with the SMC / in charge - EHS. 3. Direct the crew members to the scene of emergency and arrange replenishment of Manpower / equipment / extinguishing media etc. B) Role of EHS Representative: 1. On being notified about the location of fire/ gas leakage immediately proceed to the help. 2. Decide his line of action in consultation with Incident controller and take appropriate measures to handle the emergency. 3. Assessing the severity of the incident immediately report to emergency controller about the gravity of the situation. 4. He will assess the extra requirement required if any from the neighboring industry. C) Fire crew members 1. On hearing fire alarm, emergency siren they shall immediately report to control room and proceed to the scene of emergency and work under the direction of IC/ Dy IC. 2. The personal availability at the scene of incident to be made optimize. D) Emergency Squad Members 1. On hearing Emergency Siren, they shall immediately report to site main controller, safety in charge or incident controller. 2. They shall combat the emergency situation as per the direction of site main controller, safety in charge or incident controller. 3. They shall help for safe evacuation. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

59 MEDICAL SERVICES The roles of Medical officers are as follows; (a) He will report immediately to the SMC/IC. (b) He will render necessary treatment, at Occupational Health Center. (c) He will arrange for Hospitalization and Treatment at outside hospitals, if required. (d) He will mobilize in getting the services of External medical agencies, other Para medical services etc. and transportation services etc. (e) He will arrange for extra medical assistance/antidotes, from out, if required. (f) He will arrange for first-aid trained volunteers for necessary help. (g) He will liaise with the Government Health Authorities for treatment of the affected persons nearby ROLE OF SECURITY IN-CHARGE (SECURITY OFFICER) On hearing the emergency siren, he shall find out the location of the incident (fire / gas leak / spill / explosion) and inform the location of the same to the key personnel coming to the plant. He will depute the security guards for managing gates and traffic control at the incident site & send remaining guards to the site of incident. He will prevent unauthorized entry in to the site He will render assistance as demanded by the safety in-charge. He will mobilize additional security force for help, if required. He will direct ambulance(s) and emergency vehicle(s) to the scene of incident. He will help evacuate persons within the scene of incident. As directed by the site main controller, he may be required to address the public of surrounding villages for warning / evacuation ROLE OF MUTUAL-AID MEMBERS On receiving the call, they shall proceed immediately with fire squad & fire tenders. They will be guided to the place of the incident by the main gate security guard. The fire squad in-charge will report to the safety in-charge of the unit in which the incident has occurred OTHER ARRANGEMENTS Other arrangements include external transport, cranes, generator sets to supply emergency power, environment monitoring equipment, rescue items etc. when available resources do not meet the requirement. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

60 6.6.4 STANDARD OPERATING PROCEDURE (EMERGENCY) As soon as emergency alarm is heard, all essential workers shall report to IC or SMC. They shall carefully listen to the instructions given by IC or SMC According to the type of emergency/accident, they shall get equipped with PPE/Fire fighting equipment and devices. The runner among the workers shall inform SMC/IC and key personnel if they are not at site. The messenger amongst the workers shall deliver messages to nearby units as per the instructions of SMC/IC. The in-charge of medical arrangements shall prepare first-aid and other required facilities for the injured. The other essential workers shall try to control the emergency as per the instructions given to IC. IC would keep SMC informed about the status of control measures being taken at the site and ask for other requirements eg. Mutual aid, equipment etc. If he find necessary. SMC would co-ordinate with outside agencies regarding control measures being taken, need for external help, evacuation, medical treatment etc COMMMUNICATION SYSTEM Communication System is a Crucial Factor while handling emergency. Company have quick & effective Communication System through which, any situation, which can lead to emergency, can be informed or known to i. All persons working inside the plant. ii. Key Personnel outside during normal working hours & during off-duty hours. iii. Outside emergency services, Statutory and Local Authorities and 1. Neighboring facilities and public leaving in vicinity. Each and every section, Plant & Department of the Factory shall be connected by internal telephones. External Phone at Office and Residence and Mobile shall also be made available with Key Personnel and top executive of the factory. The Communication System shall begin with raising the alarm declaring the emergency, Telephone messages and Procedure to communicate the emergency to other persons & General Public RAISING THE ALARM As soon as incident takes place inside the factory and is noticed by someone, the first step shall be to raise the nearest manual emergency bell to alert the nearby people. Next, he/she JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

61 shall inform the security persons to raise the emergency siren located at the factory gate. The security personnel sound the siren. The alarm sound shall inform the I.C and the S.M.C that an emergency has been created and emergency organization is to be activated. The I.C. rushes to the site and shall take charge of the scene DECLARING THE MAJOR EMERGENCY Major emergency has to be declared after sufficient and thorough check because the declaration of major emergency puts many agencies on action and it may disturb the running system, which may be Costly at, time or its Consequence may be Serious. Therefore, major emergency must not be decided on whims or immature judgment or without proper thought. Looking to all the above, we will have taken care to nominate the persons who can declare the emergency; we will have selected them on the basis of their knowledge & experience. These persons will be technically qualified and experienced. They shall advice the Incident Controller or Site Main Controller regarding the type of emergency. On being convinced, the Site Main Controller or Incident Controller shall declare an ON-SITE emergency. The decision about major emergency shall be taken as early as possible and without wasting time so that control action can be started immediately TELEPHONE MESSAGES A Telephone operator who is precise, sharp, attentive and quick in receiving and noting the message and subsequently effective in further Communication, shall be appointed. A form to record emergency telephone calls shall be available with telephone operator or Person available in Emergency Control Center, who will record such calls during emergency. Telephonic messages shall be given out by the telephone operator to Site main Controller and key personnel as per the instructions of the Incident Controller. Telephonic messages shall also be given to authorities and external agencies to describe the type of emergency. All details of emergency shall be collected/delivered according to this format shall available with the telephone operator COMMUNICATION OF EMERGENCY & STATUTORY INFORMATION COMMUNICATION OF EMERGENCY An effective system to communicate emergency shall be made to communicate about the emergency situation as mentioned below: Inside the factory i.e. workers including key personnel and essential workers, on duty & inside during normal working hours. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

62 To key personnel and essential workers not on duty and outside during normal working hours. To the outside emergency services and the Government authorities. To the neighboring factory & the General Public in the vicinity STATUTORY INFORMATION a) Information to Workers Set of Statutory information regarding types of hazards and their prevention and control as directed in the Factories Act shall be prepared by the unit. This information shall be printed in the local language and given in the form of booklet to all workers including contract workers. b) To the outside emergency services and authorities Statutory information in the form of booklet shall be given to outside emergency services and authorities. c) To neighboring firms and the general public Statutory information in the form of booklet will be given to neighboring units and the general public of the villages in the vicinity of the unit ACTION ON SITE The activities related to Emergency Time Activities shall be divided into two parts. These are Pre-Emergency Activities Post-Emergency Activities PRE-EMERGENCY ACTIVITIES These activities are part of safe run of the plant and avoid emergency situation. They are considered as the preparatory part of the Disaster Management. The details of such activities shall be as follows: 1. INTERNAL SAFETY SURVEY A safety committee shall be constituted as per Factories Act. The nominated members of the committee will be assigned the responsibility to conduct safety survey once in a month before safety meeting. The internal safety survey includes Identify various hazards in the factory Check whether protective equipments are in sound working condition Check various safety installations located at various plants for proper working JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

63 Check sprinklers, showers, etc. in all plants Suggest extra modifications/ requirements to make systems more reliable Check presence of toxic gases by the help of dragger tube 2. THIRD PARTY SURVEY A safety survey shall be carried out by an external agency. It includes Inspection of building, structures for strength and stability Identify and study the hazards inside individual plants and within the factory premises. Check safety system for its adequacy. Suggest modifications or additions in the operating practices and safety system, if necessary. Frequency of Third Party Safety Survey: Once in two years. 3. PRESSURE VESSEL TESTING/ EXAMINATION A list of pressure vessels in the plant with details of operating conditions and manufacturing details shall be prepared. Preventive maintenance of valves & fittings on all pressure vessels (valves, pipelines, pressure gauge, temperature recorders and emergency vent lines) shall be carried out. Testing and examination of all pressure vessels shall be done as per the rules of Factories Act by govt. certified competent person on due date. Records of testing and certificates issued by competent person shall be maintained and made available to Factory Inspector at the time of inspection. 4. NON-DESTRUCTIVE TESTING (NDT) A list of equipment and pipelines in the plant shall be prepared which require NDT as per the rules of Factories Act. Non-Destructive Testing (NDT) shall be conducted as per the rules under Factories Act by govt. certified competent person on due dates. Records of testing and certificates issued by competent person will be maintained. Frequency of Non-Destructive Testing : Once in a year 5. SAFETY RELIEF VALVES TESTING A list of Safety Relief Valves installed on will be prepared. A schedule for testing and calibration as per the rules under Factories Act by govt. certified agencies on due dates will be made. Records of testing and certificates issued by competent person will be maintained. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

64 Frequency : Twice in a year 6. FIRE SYSTEM TESTING To prepare list of various fire-fighting equipment (Fire Extinguishers, etc.) installed at various locations in the unit along with detailed specifications. To prepare schedule for testing of all these equipment and check operability To maintain record of testing and mark dates of testing on the equipment. To carry out repairs/replacement of defective equipment 7. MUTUAL AID SCHEME To prepare Mutual Aid Scheme and enter into agreement with the neighboring units for getting or extending help during emergency To appoint coordinator for follow-up under mutual Aid Scheme To review the scheme once in a year with coordinators of neighboring unit w.r.t. scope of help, type of aid, contacts persons, etc. To include the scheme in mock drills 8. MOCK-DRILLS To conduct minor mock drills, to train employees about their role / duties during emergency. To refresh training to the employees for fire fighting, spill control, use of personal Protective equipments etc. To check whether various members of emergency control committee remember their role / duties properly and to find out the faults and points of improvement in their performance. To check whether the various equipment for emergency control are operating Satisfactorily and rectify the draw-backs if any. To conduct major mock-drills with permission from the authorities Mock drills are regularly conducted in our unit by our Emergency Control Organization and the findings are compiled to analyze whether employees are familiarized with the emergency control procedures and what sort of training is required to be given. 9. SAFETY TRAINING Regular training shall be organized for the employees for handling of safety equipment, use of personal protective equipment, first-aid, etc. by internal/external faculty, as well as by sending persons outside to attend safety programs etc. The topics covered in safety training shall be as JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

65 Training on fire fighting Training on spill control Training on toxic release control Training on good housekeeping Training on use of PPE The records of the training programs shall be maintained. 10. PERSONAL PROTECTIVE EQUIPMENT Adequate number of personal protective equipment (aprons, hand gloves, safety goggles, helmets, nose masks, safety belts, gas cartridges, self-breathing apparatus, safety shoes etc.) suitable for plant operations shall be issued to concerned employees and workers. Workers shall be trained for proper use of PPEs. 11. COMMUNICATION Following means of communication shall be made available: Telephones Mobiles Public announcement system Emergency Siren 12. EMERGENCY LIGHTS Emergency lights shall be provided at appropriate areas. Sufficient number of emergency torch/ batteries shall be kept in ECC as well as at the production site. For emergency purpose DG sets shall be made available in the factory as stand-by in case of power failure. The D.G. sets shall be set to start functioning within two minutes of failure of electricity. 13. EMERGENCY CONTROL ROOM & ASSEMBLY POINTS The same has been discussed in earlier sections. 14. LIAISON WITH STATE AUTHORITIES: The procedure for liaison with state authorities shall be prepared and responsibilities shall be assigned to concerned persons to serve the following purposes: To liaison with civil authorities, local hospitals, Fire-Brigade, Collector, factories Inspector, Police, etc regarding emergency activities and need for external aid. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

66 To keep the details regarding name, address & telephone numbers of various government authorities and neighboring units available and update the details from time to time. To inform about Mock-drill in advance and if required conduct mock-drill in presence of any of these authorities. To submit report of Mock-drill conducted and the out comings with photograph to Factories Inspector. 16. HOSPITAL FACILITIES Company will be equipped with First-Aid facilities and medicines. Company shall do tie up with Nearby Hospitals. Health records (esp. blood-group records) of all employees shall be maintained. List of blood donors will be kept for reference. 17. STATUTORY INFORMATION As discussed earlier, Statutory Information shall be shared as per the necessity POST EMERGENCY ACTIVITIES These activities are to be carried out after an emergency is over so as to establish the cause of the emergency and decide the measures to be taken to prevent its re-occurrence. These activities are 1. Collection of records of accident, injury, damage to property, buildings, equipment, material and loss of production 2. Conducting enquiries and concluding preventive measures 3. Making insurance claim for the materialistic loss / damage 4. Implementation of enquiry report s recommendations 5. Rehabilitation of affected persons within and outside the plant 6. Restarting the plant and normalizing the operations. 6.7 OCCUPATIONAL HEALTH & SAFETY PROGRAMME M/s. Camlin Fine Sciences Ltd. has prepared the Proposed Occupational Health Surveillance Programme which shall be followed right from the project construction & erection phase. The details of the same are described in the following sections OCCUPATIONAL HEALTH Occupational health needs attention both during construction & erection and operation & maintenance phases. However, the problem varies both in magnitude and variety in the above phases. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

67 6.7.2 HOSPITAL FACILITIES & FACTORY MEDICAL OFFICER Company will made formal agreements with nearby hospital having facilities to attend fire and toxic effect cases for attending the affected persons in the emergency arising out of accidents, if any. A qualified doctor will be appointed as FMO on retainer ship basis. Apart from him, required medical facilities applicable as per Gujarat Factories Rules and Factories Act shall also be made available FACILITIES AVAILABLE AT OHC A Room will be provided to be operated as OHC. The centre shall be equipped with the following medical equipments: 1. Beds: 2 Nos. 2. Green curtain : 01 No 3. A.C.: 01 No & Ceiling Fan: 03 Nos. 4. Weight & Height measurement scale: 01 No. 5. Various types of biomedical disposal bags. 6. Stethoscope : 01 No 7. Blood Pressure apparatus : 01 No 8. Amu bag : 01 No 9. Electronic Thermometer: 01 No. 10. Medicines & Antidotes as prescribed by FMO. 11. All types First aid related accessories AMBULANCE VAN & FIRST AID BOX An Emergency Vehicle will be made available round the clock to be used as an Ambulance. First Aid Boxes will be made available at the different location in the plant. Training shall be given to employees for First Aid PERIODIC MEDICAL EXAMINATION Periodic Medical Examination shall be being conducted as per the following schedule; Workers employed will be examined by a Qualified Medical Practitioner/ Factory Medical Officer, in the following manner: (a) Before employment, to ascertain physical fitness of the person; (b) During employment, once in a YEAR, to ascertain physical fitness of the person to do the particular job; JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

68 6.7.6 DETAILS OF OCCUPATIONAL HEALTH IMPACTS AND SAFETY HAZARDS Exposure to Toxic Chemicals. Exposure to Flammable solvents. Exposure to corrosive chemicals. Impacts of the above mentioned Occupational Health Impacts on workers are: Body Injury, Suffocation, Accident, Irritation, Toxicities, etc. For the details of: Mitigation measures proposed to avoid the human health hazards along with the personal protective equipment please refer Section: 6.5 Other Precautions DETAILS OF WORK PLACE AMBIENT AIR QUALITY MONITORING PLAN Work zone monitoring will be carried out by independent competent third party every month. Records will be kept in Form No. 37 as per Gujarat Factories Rules. Location for samplings shall be identified. Following information will be incorporated in the format for maintaining records of work zone monitoring: Location/Operation monitored Identified contaminant Sampling instrument used Number of Samples Range of contaminant concentration as measured in sample Average concentration TWA concentration of contaminant (As given in Second Schedule of Factories Act) Reference method used for analysis Number of workers exposed at the location being monitored Signature of the person taking samples Other relevant details MONITORING OF THE OCCUPATIONAL INJURY & IT S IMPACT ON WORKERS The action plan will be prepared to monitor the occupational injury to workers: Each workplace will be evaluated for the existing work conditions. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD

69 Unsafe Act & Unsafe Practices will be identified. Unsafe equipments, unsafe areas, etc., will be identified. Area will be checked for proper Ventilation and Illumination. Air-borne concentration of toxic chemicals will be measured and records will be kept. Impact of the above mentioned unsafe conditions on workers will be studied and remedial measures for the same will be adopted PROVISION OF INDUSTRIAL HYGIENIST & HEALTH EVALUATION OF WORKERS 1. It is proposed that management will device a plan to check and evaluate the exposure specific health status evaluation of workers. 2. Workers will be checked for physical fitness with special reference to the possible health hazards likely to be present, where he/she is being expected to work before being employed for that purpose. Complete medical examinations including PFT, Urine and Blood examination, Liver Function tests, chest X-ray, Audiometry, Spirometry Vision testing, ECG, etc. shall be carried out. However, the parameters and frequency of such examination will be decided in consultation with Factory Medical Officer and Industrial Hygienists. 3. While in work also, all the workers will be periodically examined for the health with specific reference to the hazards which they are likely to be exposed to during work. Again, the parameters and frequency of such examination will be decided in consultation with Factory Medical Officer and Industrial Hygienists. Plan of monthly and yearly report of the health status of workers with special reference to Occupational Health and Safety, will be maintained. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD