Chapter 7 Environmental Risk Assessment (ERA) And Disaster

EIA-EMP Report of M/s Rosvar & Power Private Limited., Haruvanahalli Village, Hospet Taluk, District Bellary, Karnataka.

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Chapter – 7

Environmental Risk Assessment (ERA)

And

Disaster Management Plan (DMP)

7.1 Public Consultation

The details of Public Consultation have been conducted and the details of which have been

enclosed as AnnexureVII.

7.2 Risk Assessment

Risk Assessment, on site Emergency Preparedness & Disaster Management Plan It is presumed

that the proposed facilities for expansion would be designed and engineered with all possible

safety measure and standard code of practices of engineering. In spite of this, there may be

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

accidental events causing damage to life and property. This Chapter presents an overview of

environmental risk associated with various production facilities, suggested remedial measures

and an outline of the emergency preparedness plan.

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

natural calamities.

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

be adopted to minimize the probability or accidental event.

To identify the potential areas of environmental disaster this can be prevented by proper

design of the installations and its controlled operation.

To manage the emergency situation or a disastrous event, if any, from the plant

operation.

Managing a disastrous event will obviously require prompt action by the operators and the crisis

management personnel using al their available resources like alerting the people and other plant


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personnel remaining inside, deployment of the fighting equipment, operation of emergency shut

off valves, opening of the escape doors, rescue etc.

Minimizing the immediate consequences include cordoning off, evacuation, medical assistance

and giving correct information to the families of the affected persons and local public for

avoiding rumors and panic.

Lastly, an expert committee is required to probe the cause of such events and the losses

encountered, and suggested remedial measures for implementation, so that if future such

events or similar events do not reoccur.

7.3 Identification of hazards

The hazards are attributable due to processing of raw materials and chemicals used in

steelmaking and the other plant operations. A list of major raw materials used in the plant and

the process units with their hazard potential is presented below.

Group Item Hazard Potential

Remarks

Raw materials & Products

Iron ore None -

Coal Moderate Fire

Other fluxing minerals

None -

Product steel None -

Lube oil Moderate Flammable

Processing

Iron making in Rotary kiln

Coal reduction fuel gas

Major Flammable and CO pollution

Hot Metal Major Personnel injury & fire

Burning coal Major Personnel injury & fire Rolling Mills Hot metal Major Fire Utilities

Fuel gas Distribution Gas leaks Major Fire and CO pollution

Electric power supply Short circuit Major Fire

Transformer Small Explosion & fire

Power Plant


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From the above table, it may be observed that major on-site emergency situation may occur

from the organic coal, and handling, fuel gas handling, molten metal and slag handling, and

electrical short-circuits. The off-site environmental disaster may occur if large scale fire and

explosion occurs, the effect of which extends beyond the plant boundary. The off-site

environmental disaster may occur due to significant environmental degradation prolonged

for a sustained period.

7.4 HAZOP Study

It is suggested to have HAZOP study for the fuel gas distribution network handling facilities prior

to commissioning, for last minute corrections in the design of the systems from fail safe angle.

The HAZOP analysis for the gasholder has been carried out for safe operations.

The degree of Hazard is identified based on FEI and TI range as per the criteria given below.

Steam turbine generator building

Moderate Fires in Lube oil system, Short circuit in control room/switch gear, cable galleries & oil drum storage.

Boilers Heat recovery boilers

Moderate Fire/steam explosion

Coal Handling plant Normal weather condition with shed

Moderate Fire or dust explosion

Coal Storage Normal weather condition with shed

Moderate Spontaneous combustion

FEI Range Degree of Hazard

0-60 Light

61-96 Moderate

97-127 Moderately High

128-158 Heavy

159 & above Severe

TI Range Degree of Hazard

0-5 Light

5-10 Moderate

>10 Severe


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The storage of fuel oil/HSD is of a small quantity & may have light degree of hazard.

7.5 Electrical safety

Adequately rated and quick response circuit breakers, aided by reliable and selective digital or

microprocessor based electromagnetic protective relays would be incorporated in the electrical

system design for the proposed activities. The metering and instruments would be of proper

accuracy class and scale dimensions.

7.6 Risk Management measures

The risk management measures for the proposed activities require adoption of best safety

practice at the respective construction zones within the works boundary. In addition, the design

and engineering of the proposed facilities would take into consideration of the proposed

protection measures for air and water environmental as outlined in earlier Chapter. The detailed

risk management measures are listed below.

7.6.1 Coal Handling Plant

Coal dust when dispersed in air and ignited will explode. Crusher houses and conveyor are most

susceptible to this hazard. The minimum of explosive concentration of coal dust (33% volatiles)

is 50 grams/M3. Failure of dust extraction & suppression systems may lead to abnormal

conditions and increasing the concentration of coal dust to the explosive limits. The sources of

ignition are incandescent bulbs, electric equipments & cable, friction & spontaneous combustion

in accumulated dust. Dust explosion may occur without warning with maximum explosion

pressure upto 6.4 bars. Another dangerous characteristic of dust explosions is that it sets off

secondary after of initial dust explosion. Stack pile area shall be provided with automatic garden

type sprinklers as well as to reduce spontaneous ignition of coal stocks piles, necessary water

distribution net work will be provided for distributing water at all transfer points, crusher

houses, control room, etc.

A centralized control room has been envisaged for operation of the coal handling plant. Except

locally controlled equipment like traveling tripper, dust extraction/dust suppression/ventilation


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equipment, sump pumps, water distribution system all other in line equipment will be provided

for safe and reliable operation of the coal handling plant.

7.6.2 Control measures for coal yard

The entire quantity of coal will be stored in separate stack piles, with proper drains around to

collect washouts during the monsoon. Water sprinkling system will be installed on stocks of pile

to prevent spontaneous combustion and consequent fire hazards. The stack geometry will be

adopted to maintain minimum exposure of stock pile areas towards predominant wind

direction. Temperature will be monitored in the stock piles regularly to detect any abnormal

change in temperature inside the stock pile to be enable to control the same.

7.6.3 Induction Furnace

Preventive Measures

If any job is to be undertaken in furnace areas where the gas is toxic, the following procedure

has to be laid down to ensure safety of men and the equipment.

Gas safety man would accompany the team and would test the atmosphere for the

presence of CO, before starting the work.

If CO, concentration is found exceeding the sage limit, the job would be undertaken using

necessary safety appliances viz., Oxygen Breathing Apparatus/Blower type Gas mask.

Any gas cutting /welding job would be undertaken with the clearance from Gas safety

man.

7.6.4 Gas Explosion, Prevention & Preventive Measure

The following actions would be taken to prevent any gas explosions in case of gas leakage.

For jobs on gas lines/equipment, non-sparkling copper tools will used. If such tools are

not available, grease coated steel tools would be used. Electrical drill & other electrical

equipment will not be used as these can give rise to sparks.


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The gas line would be thoroughly purged with steam before undertaking the job on the

same.

Naked lights will not be used near any de-pressurized gas main or equipment unless the

same has been thoroughly purged.

In case of profuse leakage of gas, action would be taken for water sealing and isolating

that portion.

The approach road to the gas line complex would be kept free from any obstructions.

If gas catches fire due to some leakage, it will be extinguished with plastic clay, steam or

water. The portion of gas main affected would be cooled down with water. The valve will

not be closed when fire is still there and the pressure in the main will be maintained at

minimum 100mm (WC).

Gas tapping points of flow or pressure measurement will be cleaned with wooden stick

or grease coated wire.

If lighting is necessary near gas line, portable spark, proof electrical lamps of low voltage

or explosion proof torchlight will be used for enclosed areas.

7.6.5 Hot Metal

Sudden break out of molten metal result in heavy explosions, due to their coming in contact

with water, thereby causing serious burn injuries to persons and damage to equipment. These

breakouts may take place from weak portions of the health, tuyeres & monkely.

Preventive Measures

Any accumulation of water will be prevented in such vulnerable areas.

In case of minor leakages, the flow of molten metal & slag will be controlled.

If there is major breakout, the area would be cut off and cordoned.

Vital connections e.g. water, gas, compressed air, oxygen etc., would be cut off or regulated as

per requirement.


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7.6.6 Steel Melting Shop

The main hazards arise out of the use of hot metal and oxygen at the spillage of hot metal cause

serious burn injuries and fires. Severe explosions are also caused due to hot metal /slag falling

over a pool of water, resulting in injuries to persons, fire and damage to equipment due to flying

of hot splinters & splashing of liquid metal/slag.

7.7 Objective of the Plan

The emergency plan has been prepared to ensure the smooth working of the steel plant

complex. The main objectives of the plan are to take immediate actions to meet any emergency

situation making maximum use of combined in plant and allied resources for the most effective,

speedy and efficient rescue and relief operations. These are briefly enumerated below.

Cordon and isolate the affected are for smooth rescue operation.

Rescue and treat causalities and safeguard the rest.

Minimize damage to persons, property and surroundings

Contain and ultimately bring the situation under control

Secure and safe rehabilitation of the affected area

Provide necessary information to statutory agencies

Provide authoritative information to statutory agencies

Ward off unsocial elements and plying onlookers.

Counter rumor mongering and panic by relevant accurate information.

7.8 Methodology

Keeping in mind the detailed information on the proposed steel plant, the plan is formed on the

following basis:

Identification of possible hazards in various units and their impact on the surroundings.

Detailed information on the available resources and control measures.


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7.9 Industrial Safety and Fire Fighting

As detailed above, many working premises of the plant have hazardous and fire — prone

environment. To protect the working personnel and equipment from any damage or loss and to

ensure uninterrupted production, adequate safety and fire fighting measures have been

proposed for the project.

7.10 Safety plan during Construction & Erection Phase of Expansion

A highly qualified and experience Safety Officer will be appointed. The responsibilities of the

safety officers include identification of the hazardous conditions and unsafe acts of workers and

advice on corrective actions, conduct safety audit, organize training programmes and provide

professional expert advice on various issues related to occupational safety and health.

7.10.1 Safety Personnel

All workmen employed in hazardous working conditions will be provided with adequate

personal safety appliance as applicable to the work like:

Industrial helmets

Industrial safety boots

Hand gloves

Ear muffs

Welder's screen and aprons

Gas masks

Respirators

Resuscitators

7.10.2 Fire Protection facilities

Keeping in view the nature of fire and vulnerability of the equipment and the premises, the

following fire protection facilities have been proposed for the plant.


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7.10.3 Portable Fire Extinguishers

All plant units, office buildings, stores, Laboratories, MCCs etc. will be provided with adequate

number of portable fire extinguishers. The distribution and selection of extinguishers will be

done in accordance with the requirement of fire protection manual of Tariff Advisory Committee

(TAC).

7.10.4 Hydrant System

Hydrants will be provided in the coal handling plants at suitable locations and in different levels

inside the plant buildings. Yard hydrants will be provided in the vicinity to meet the additional

requirement of water to extinguish fire.

7.10.5 Automatic Fire Detection System

Unattended vulnerable premises like electrical control rooms, cable tunnels, MCC, oil cellars,

etc. will be provided with automatic fire detection and alarm systems.

7.10.6 Manual Call Point Systems

All major units and welfare/administrative building will be provide with manual call points for

summoning the fire fighting crew from the fire station for necessary assistance.

7.10.7 Fire Station

The Rosvar is going to provide elaborate arrangements for managing any incidents of fire with

adequate communication facilities. There will be sufficient fire tenders to extend the necessary

assistance required for fighting fire in any of the plant units and associate premises with

requisite augmentation. The following equipment will be provided in the fire posts.

Water tender

Foam tender

Portable pump

Wireless set

Hoses

Hot line telephone, etc.


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7.10.8 Plant Disaster Control

The Onsite emergency plan is prepared considering all the different units of the proposed steel

plant complex.

7.10.9 Organization

A Central Disaster Control Cell will be set up under the direct charge of the General Manager of

the project. He will be the person nominated to declare any major emergency and would be in-

charge of all operations in such situations. In his absence, Manager Works would be the in

charge. He will be supported by the other nominated members of cell, Engineer„ SMS & Mill.

Personnel, Security, Fire and safety, Administration. In case of any major emergency, the

Disaster Control Cell would operate from Disaster Control Room. At the shop level, Shift in

charge will be nominated as controller who will be assisted by trained key workers to deal with

any minor emergencies arising at the shop.

7.10.10 Information flow

The following guidelines will be observed by any person after noticing a gas leak, fire etc. till help

is made available from Central Disaster Control Cell.

Raise alarm

Communicate to the control room about the incident/emergency.

Communicate to fire station for relief in case telephone is available otherwise try to

attract attention by any available means.

Attempts to close doors, windows or ventilators of the room to prevent any

contaminated air getting in.

7.10.11 Central Disaster Control Room

Upon receiving information from any site regarding emergency, the person operating from the

Disaster Control room will.

Depute a person to rush to site and assess the situation.


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Inform fire transport, safety, and concerned control room.

Organize operating personnel and arrange for control over the situation.

Keep the management informed about the gravity of the situation from time to time.

On receiving the call, the Disaster Control room would immediately direct the different

supporting service agencies as enumerated below.

Security and Administration Service: responsible for safety of the plant against

trespassers, saboteurs, any crowd, information to Government authorities and in the

neighborhood (if required), provision of transport facilities, telecommunication facilities

and fire service facilities.

Safety service: responsible for implementation of safety measures at work place and

occupational safety.

Medical service: responsible for providing medical care to the injured or the affected in

an event of emergency. The visiting Doctor will be surrounded to the site to take charge

of medical care to employees.

Stores: responsible for providing adequate number of tools, tackles and accessories for

proper emergency control.

Preservation of evidence and taking of photographs, if necessary, for future enquiries to

determine the cause and taking further preventive actions.

Welfare: Provide food, clothes, shelter etc., as per requirement.

Power and water supply: to ensure supply of fire fighting water requirement and

provisions of power supply.

7.10.12 Shop Level Disaster Control Cell

The controller at the shop level would take immediate charge of any emergent situation and

would assume full responsibility regarding mobilization of resources, guide and help service

agencies in properly carrying out their assigned duties. Being from the operations side of the

plant, he has full knowledge of the process aspects and he would decide whether to stop the

plant/process. He will be responsible for overall co-ordination. In his absence, his Deputy would

be Controller of the operations. The duties of the Shop level Controller are enumerated below:


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Assess the scale of emergency and decide, if any possibility of major emergency exists

and inform the Central Control Room, if necessary.

Direct safe close down of plant or any operation, if necessary.

Direct evacuation of areas in the vicinity, which may be endangered.

Ensure key personnel are called in immediately and they start carrying out their assigned

duties.

Direct rescue and fire fighting operations from safe operation point of view.

Direct the shop personnel to the designated places for safe assembly.

Control rehabilitation of affected areas and any victim on emergency.

Ensure complete safety before restating the plant/operation.

At shop floor, teams of workers will be trained, who will be present at the incident site for doing

the needful; they will assist and extend help.

in controlling fire.

In shutting down plant to make it safe.

Search, evacuation, rescue team.

Movement of vehicles for emergency control.

Plant pollution monitoring staff for carrying out atmospheric tests. Medical team for

providing necessary help.

Any other special operation.

7.10.13 Contingency Plan

It has been based on the following considerations:

The plant general layout.

The available resources.

The analysis of hazards.

And is aimed at the

Pre-emergency activities.


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Emergency time activities.

Post emergency activities.

In the event of an emergency, the people from affected pockets would be directed to move to

safe assemble places nearby the units.

The following facilities will be provided.

Security service

Fire fighting service

Medical service

Pollution control service

Public relation service

Telecommunication service

Transport service

Evacuation service

Welfare service

An alarm system will be provided with a wailing type siren at a centralized place and actuators at

the strategic locations in the plant. Adequate number of telephones will be provided in each unit

at shop floor so that a person can either directly raise the alarm or ring up disaster control room

from where the alarm can be raised directly. The wailing siren will mark the beginning of the

emergency while a continuous note will mark the end meaning all clear signal.

All firefighting equipment like ,valves, fire hydrants, pumps, monitors, etc., will be checked

periodically to detect defective parts and such parts would be immediately replaced. Mock drills

will be conducted for training the persons and to check the performance of men and equipment

and also to keep them fir for any emergency. The plant will be equipped with a separate medical

centre with necessary instrument/appliances, medicines and manpower. The medical officer will

maintain close liaison with different hospital in the nearby city.


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7.10.14 Rescue and Repair Services

The responsibility of effective working of Rescue and Repair service will be with the incident

controller.

Rescue Services

To extricate persons from the debris of collapsed building / structure and safe human

lives.

To hand over the extricated persons to first aid parties.

To take immediate steps as may be necessary for the temporary supports or demolition

of buildings and structures, the collapse of which is likely to endanger life or obstruct

traffic.

To cut off supplies of water, gas, electricity to damaged buildings.

Trained Rescue parties shall be formed at Shop levels, who will be provided with the following

equipment:

Self contained oxygen breathing apparatus

Blower type gas mask

Resuscitators

Petromax lamp/Torches

Axe/hand saw

Bamboo ladder

Necessary Safety appliances

First aid box

Blankets

On-site emergency planning rehearsals will carried out from time to time. It requires monitoring

by experience persons from other similar factories or by senior officials from the State

inspectorate of Factories and /or the

Directorate of Fire Services, who can help in updating the emergency plan procedure.


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7.11 Off-site emergency planning

Off-site emergency planning is normally under the jurisdiction of the district administration. The

designated official of the Steel Plant is required to have co-ordination with the district

administration for responsive action in off-site emergency planning.

7.12 Fire Fighting organization and Procedure

There will be trained fire fighting personnel and a Fire officer under the Fire & safety

department. The following important instructions will be given for fire prevention and tackling of

any fire in the plant.

Overall control of the Fire fighting operations will rest with the senior most officers

present at the scene of fire, who will be assisted by the operational and fire staff. Close

co-ordination and planning for fire protection will be done between plant operations and

fire services.

While turning out for fire calls, the staff will be guided to the correct location

immediately on their arrival.

In-charge of the section at shop floor will explain special risks involved and guide the in

charge of the fire fighting crew. He will, however, not interfere in the method of fire

fighting operations.

No one would tamper with the sources of water supply/fire hydrants or misuse them in

any manner. The passages/approach to /from hydrants to the fire appliance would

always be kept clear.

Fire drills would be held in each, zone periodically under the direction of the Fire Officer.

The organization and brief procedure for fighting small, major and simultaneous fire is given

below:

Degree of fire emergency

Fire chief

Siren code

Persons attending

Small fire Functional head in charge of affected area

No siren First and second line fire-fighting team

Major fire Head of the production Wailings two minutes First, second and third


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department fire fighting teams

Simultaneous fire In-charge of affected area

No siren except for major fire

Persons already present at the scence of fire, operators.

7.13 Definitions:

Small fire: A fire in its incipient stage which is controlled by the first line fire fighting team.

Major fire: The fire is spreading to other equipment or areas and which threatens to go beyond

the control of first line and second line fire fighting teams.

Simultaneous fire: More than one fire occurring at the same time.

Fire Control Office: The Fire Control Officer will be in-charge at the scene of fire. In case of small

fire, Section Head/Functional Head of affected area will be Fire Officer.

In major fire, Head of Production Department will be Fire Control Officer.

In simultaneous fires, in-charge of the respective affected areas will be Fire Control Officers.

Fire call: Fire call will be received at the fire station regarding occurrence of fire and its location.

The message will be conveyed either by telephone or fire alarm or in person.

While giving Fire call message on telephone, the person will

Give his name, Section & Department.

Exact location of Fire and if possible, nature of fire.

Confirm that the fire call message is repeated by the Control room attendant.

When the cal message is Oven by the Fire alarm, the person would stand rear the fire alarm to

guide the fire fighting team to the location of the fire.

7.14 Fire siren code

For small fire No siren will be sounded.

For Major fire Wailing type continuously for two minutes.


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For all clear Straight sound for two signal minutes.

7.15 Testing of the Fire Sirens

Fire sirens may be tested by sounding straight for one minute on every Monday at 9 AM for coke

oven plant and every Wednesday at 9 AM for cogeneration power plant.

7.16 Fire Fighting for small fire

The small fire will be tackled by the first team which would comprise of the persons already

present at the scene of fire. However, the second line fire fighting team whose composition is

given below will also report at the scene of fire immediately after receiving the Fire call of

affected area at the time of fire. The team will consist of the following

7.17 Fire Control Officer

7.17.1 First line Fire Fighting team

Operational / maintenance staff and / or other plant personnel workings in the area.

7.17.2 Second line Fire fighting team

Fire station shift in charge and trained fire fighting personnel.

Ambulance driver with ambulance.

Functional head of affected area.

Shift Officer production.

Security personnel.

7.17.3 Third line Fire fighting team

Fire Officer & Auxiliary Fire Fighting personnel.

All Departmental & Functional Head.

Local Fire Brigade from Government if necessary.


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7.17.4 Responsibilities of Security personnel at the manned gate

To prevent entry unauthorized persons.

To keep the gate open for emergency vehicles and officers and staff concerned with fire

fighting and allied operations.

7.17.5 Responsibilities of Telephone Operator

To receive fire call messages.

To inform Shift Officer for all fires.

7.17.6 Responsibilities of Medical Officer during major fire

To be available at the first aid centre for necessary medical advice.

To depute one of the medical staff to the scene of fire to render any medical assistance,

required at site.

7.17.7 Responsibilities of Head of the Personnel and Welfare Department during major fire

To arrange the transport of the fire fighting personnel with minimum loss of time in

consultation with the Fire Control / Fire Officer.

To make arrangements for the refreshment/meals for persons engaged in fire fighting.

To inform the Fire Officer regarding the actions taken.

7.17.8 Responsibilities of Head of the Maintenance Department during major fire.

To report to Fire Chief and render all help that may be required from Maintenance Department.

7.10.9 Responsibilities of Head of the Electrical Maintenance Department during major fire

To report to Fire Officer and render assistance to be required from Electrical Department such as

installation of equipment, provision of temporary lighting etc.


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7.17.10 Responsibilities of Head of the Materials Procurement Department during major fire

To arrange to man the stores for emergency issue of materials. If the materials are not available

in the stores or are likely to be exhausted during fire fighting operations, he would arrange for

the same from other sources.

7.18 Cloud Burst / Lighting

Cloud burst / lighting may at times lead to minor to major emergency. In such an emergency,

actions indicated under fire and explosion will be undertaken.

7.19 Food Poisoning

In case of food poisoning in plant canteens, the following will be done;

Disaster Controller will inform Medical Officer for immediate first aid.

Medical Officer will contact other hospitals and seek their help, if necessary.

Security will help in evacuating the affected people to various hospitals, in co-ordination

with the Medical Officer.

7.20 Mutual-aid System

At times the possibility of a major emergency (a situation out of control of plant authority )

cannot be ruled out. In such a case, the plant authority would declare it to be a major

emergency and total control would be transferred to the district level officer of contingency plan

committee.

Necessary help would also be sought from Government sources having necessary infrastructure

for dealing with disaster.

Documents

Chapter 7 Environmental Risk Assessment (ERA) And Disaster