ON SITE EMERGENCY PLAN REPORT - Gujarat Pollution …gpcb.gov.in/pdf/Godrej_Boyce_Mfg_Annexure_Part_III.pdf · ON SITE EMERGENCY PLAN REPORT ... Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00

Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00

ON SITE EMERGENCY PLAN

REPORT

PREPARED FOR

M/S. GODREJ & BOYCE MFG. CO. LTD.

DAHEJ, BHARUCH

CONDUCTED & PREPARED BY

GREEN CIRCLE CONSULTANTS (I) PVT LTD. Environmental, Health, Hygiene, Safety, Risk, & Quality

Consulting Engineers & Trainers

(An ISO 9001: 2008 Certified Company)

ALSO AT NEW DELHI MUMBAI PUNE BANGALORE HYDERABAD

OVERSEAS: AUSTRALIA OMAN QATAR DUBAI NIGERIA

M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in

CRZ area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00

Green Circle Consultants (I) Pvt. Ltd.

QUALITY CONTROL SHEET

Rev. Date Reason History Prepared

By

Reviewed

By

Approved

By

00 24/05/2010 Draft Report of On Site

Emergency Plan AT DD NP

AT : Apexa Thaker DD : Dipali Desai NP : Narendra Parmar Prepared by Apexa Thaker, Executive-EHS

Signature

Reviewed by Dipali Desai, Asst. Manager

Signature

Approved by Narendra Parmar, Asst. General Manager

Signature

Released by Nachiket Joshi, Group Manager-A & F

Signature




ACKNOWLEDGEMENT

WE EXPRESS OUR SINCERE THANKS TO MANAGEMENT & EMPLOYEES OF

GODREJ & BOYCE LTD., DAHEJ, BHARUCH, FOR THEIR CO-OPERATION &

UNSTINTED HELP WITHOUT WHICH THE ’ON SITE EMERGENCY PLAN’ COULD

NOT HAVE BEEN POSSIBLE. THE COURTESY EXTENDED TO OUR TEAM IS

HIGHLY APPRECIATED.

For: GREEN CIRCLE CONSULTANTS (I) PVT.LTD.

AUTHORISED SIGNATORY




INDEX

CHAPTER CONTENTS PAGE NO.

Introduction to On Site Emergency Plan 1.1 General

1.2 Statutory requirement for Onsite plan 1.

1.3 Scope of the plan

Overview of the Unit

2.1 Introduction

2.2 Location

2.3 Details of factory

2.

2.4 Organization structure

Unit Hazard & Control

3.1 Evaluation of Hazards

3.2 Storage Hazards

3.3 Hazards

3.4 Process description

3.5 Safety measures for LPG storage

3.6 Safety measures for Compressed Gas

Cylinders

3.7 Utility

3.8 Other safety measures

3.9 Safety measures for solvents storage and

handling

3.

3.10 Safety and Mitigating measures

Environment Impact Assessment

4.1 Introduction

4.2 Layout of the Unit

4.3 Effluent Treatment Plant

4.

4.4 Noise Level




4.5 Solid Waste

4.6 Consents from GPCB

Accident History

5.1 Introduction

5.2 Accident Reporting System

5.3 First Aid Box

5.

5.4 Medical Examination

Organization Plan

6.1 Introduction

6.2 Identification of Hazards and Control

Measures

6.3 Planning for Emergency

6.4 Command & Control

6.5 Incident Controller

6.6 Site Main Controller

6.7 Key Personnel

6.8 Essential Workers

6.9 Safe Assembly Point

6.

6.10 Check Schedule

Emergency Procedure

7.1 Actions during Emergency

7.2 Sequential Actions during Emergency

7.3 Emergency Actions (General)

7.4 Emergency Communication

7.5 Action Plan for Emergency In-Charge

(IC/SMC)

7.

7.6 Action Plan for In-Charge of Emergency

Control Center i.e. Communication

Officer




7.7 Action plan for Key Personnel and

Essential Workers

7.8 Action plan for Security Guards/ Officer

7.9 Action Plan for Workers/Officers

/Contractor

7.10 Discipline

7.11 Shut down Procedure

7.12 Post Emergency

7.13 Corrective Actions

Annexure Section

Appendix Section



Green Circle Consultants (I) Pvt. Ltd. 1

CHAPTER – 1

INTRODUCTION OF ON-SITE EMERGENCY PLAN




ON SITE EMERGENCY RESPONSE & MANAGEMENT 1.1 General

It is impossible to forecast the time and nature of emergency, which might

strike the unit. In spite of the fact that every industry is expected to take steps

to assess, minimize and wherever feasible eliminate risks, accidents may

occur, as risk can only be minimized, it can never be totally eliminated.

Industrial units are vulnerable to various kinds of natural and man-made

emergencies. Examples of Natural disasters are flood, Cyclone, earthquake,

lightening etc. and man made disasters like major fire, explosion, sudden

heavy leakage of toxic / flammable gases, civil work plant failure, human

errors, vehicle crash, sabotage etc.

The emergency is an undesirable occurrence of events of such magnitude

and nature that adversely affect production, cause loss of human lives and

property as well as damage to the environment.

Controlling the emergency will require prompt action by the operating staff,

the staff of various agencies, emergency teams and outsiders when called

for. Minimizing the effect on people may be achieved by prompt

communication, rescue, evacuation etc., if the situation so warrants.

However, an effective emergency plan helps to minimize the losses in terms

of human lives, plant assets and environmental damage and to resume the

working condition as soon as possible. In all these steps SPEED IS THE ESSENCE.

As a part of emergency preparedness, keeping in the view the potential

hazards prevailing in the factory and effect of such hazards, the On-Site

Emergency Action Plan has been prepared.




1.2 Statutory Requirement for Preparation of On-site Emergency Plan

The unit, which is covered under chemical hazardous factory, has to

prepare the On-Site Emergency Plan with indicating what preventive

measure has been taken against hazards and how to fight emergency. This

plan has to be submitted to the specified authorities. It is also provided that

the periodical rehearsals / exercises are also required to be conducted.

The provisions for preparing the on-site emergency plan are explained on

next page:

1.2.1 The Factories Act, 1948 (1987) & Gujarat Factory Rules 1963 (1995)

Section 7 A (2) & 41 (B) of The Factories Act 1948 (1987) and Rules 68-J (12)

of the Gujarat Factories Rules 1963 (1995) providing that the every

occupier, who has control of an industrial activity pertaining to hazardous

chemical shall furnish the On-Site Emergency Plan detailing how major

accidents shall be dealt with along with explaining specific responsibilities

and actions by various persons.

1.2.2 The Environment (Protection) Act- 1986 (2001)

Rule 13 (1) under the Manufacture, Storage and Import of Hazardous

Chemicals Rule 1989 (Amended 2000), rules framed under The

Environment (Protection) Act -1986 (2001), indicates that the occupier

shall prepare and keep up-to-date as On-Site Emergency Plan containing

details specified in schedule II and detailing responsibilities and actions by

different person and agencies.




1.2.3 Chemical Accidents (Emergency Planning, Preparedness and

Response) Rule 1996 (2000)

Under this rules, framed under The Environment (Protection) Act 1986, the

state government has constituted local crisis group & District Crisis Group

to deal with major chemical accidents and to provide expert guidance

for handling chemical accidents. Further provision is made that the Major

Accident Hazard units have to prepare the on-site emergency plan &

submit the plan to the crisis groups. The local emergency plan will dovetail

with the District off-site emergency plan.

1.2.4 Off-Site Emergency Plan

The emergency planning for on-site and off-site are different but they

should be dovetailed with each other. On-site emergency planning is the

responsibility of the site management, while offsite planning is for the

whole district having responsibility casts to district authorities like District

Magistrate & Collector, Factory Inspector, Police Department, Fire

Brigade, Health & Medical Services, Pollution Control Board, Explosive

Department etc.

1.3 Scope of the Plan

The emergency procedure as outlined herein is designed with the primary

aim of protecting, to the greatest extent possible, all employees, persons, in

the vicinity and company property against fire, explosion, spills, or other

major accident of disastrous proportion, which might arise as a result of our

own operations, processes, storage, adjacent operations, or any other

circumstances.




This plan is prepared basically to cope with any emergency, which could

occur during storage or process, at any time of the day or night or

weekends.

The success of this plan in accomplishing its purpose depends largely upon

each individual carrying out his designated duties effectively and promptly.

This plan is in three sections. The first section provides basic requirements,

which explains essential elements of the plan.

The second section is Annexure Section, which is designed to give specific

information needed during emergency.

The third section is Appendix Sections, which gives additional useful

information and details for preparation & handling of emergency.

An emergency cannot be always prevented, but it can be controlled within

limits and its effects can be minimized by using the best available resources,

at the time.

The emergency planning is a management function and it should not be

considered in isolation. The Management should evaluate the activities,

operations and processes carried out within the works before starting to

plan an emergency operation. A check must be kept to ensure that all

necessary steps are taken which are included in emergency planning.

Considering the number of employees, material and process, availability of

resources, location of site, size and complexity of the works, we have

prepared this plan. This plan may be updated in case any new material is

added, revision of process or change of method etc.




CHAPTER – 2

OVERVIEW OF THE UNIT




2.1 Introduction

Godrej & Boyce Mfg. Co. Ltd. is a private limited company. Godrej & Boyce

Mfg. Co. Ltd., is today one of the largest Engineering and Consumer products

company in the country having varied interests from engineering to personal

care products. It has its manufacturing two units located at Mumbai

(Maharashtra).

Company is intending to put their new engineering unit for “Fabrication of

Heat Exchanger, Pressure Vessels & Columns” along with Jetty in CRZ area at

SEZ – Dahej, Gujarat to cater the global market demand.

2.2 Location:

The Project is planned in Plot no. Z – 90, SEZ - Dahej, Village - Luvara, Taluka -

Vagra, District – Bharuch, Gujarat State, India. Total Plot area for Project shall

be 235030 m2.The project site is located on 210 39’ 36.02” North latitude and

720 33’ 22.92” East longitude. The average mean sea level is 4 mtr.

In the immediate vicinity the site is bounded on four sides by:

East: IPCL (RIL) Jetty

West: Gulf of Khambhat

North: Petronet LNG Terminal

South: Narmada River

LAYOUT OF FACTORY: The topography of the proposed plot is not flat in shape. There is no dense

natural vegetation around the site. Construction of new Industrial engineering

unit for “Fabrication of Heat Exchanger, Pressure Vessels & Columns” along with

Jetty is proposed. The existing land use pattern is Industrial Zone and out of




235030 m2 areas only 41028.90 m2 shall be used for the proposed unit of

fabrication of process related equipments. The area allotted for jetty will be

3960m2. Green belt area shall be 49207 m2. The remaining plot shall be

developed in future.

The Project Land Use Plan describes two categories of land uses: Unit for

fabrication of Heat Exchanger, Pressure Vessel & Columns is proposed in the

processing area. The unused land will be used for captive consumption in future

for further plant expansion. The space will be spare for future electrical substation

and other infrastructure facilities like internal roads, lights, STP / ETP. Design for the

same will be created at the time of actual planning for expansion of the units.

The Factory is mainly divided into following sections or Blocks as:

PROCESSING ZONE

Administrative building

Open fabrication yard (Phase I)

Common open Plot (Phase II)

Future expansion (Phase III)

LPG bullet area

Parking area

Green Belt area

UTILITY

The Utility block encloses Fabrication Air Compressor, Heat exchanger, Thermic

Fluid System, DG set etc.

ETP

Effluent Treatment Plant design for 300 m3 / day for M/s. Godrej & Boyce Mfg.

Co. Ltd., Dahej.




The ETP consists of Receiving Sump, Aeration Tank, Secondary clarifier, Flash

mixer, flocculator cum clarifier, Treated Effluent Sump, Pressure Filter, Activate

carbon Filter, Filter Press, Equalization Tank & all rest primary and secondary

treatment units.

NON PROCESSING ZONE

Corporate office

Pantry / Canteen

Security Cabin

Car Parking (11502.86 m2)

Truck Parking

Over Head Water Tank

Water Harvesting System

Temple

Labor Welfare Office

The layout of unit is given in Annexure-3.

2.3 Details of the Factory:

Sr.

No. Descriptions Details

1 Name & Address of Unit

A Unit for fabrication of heat exchanger,

pressure vessels & columns at Godrej & Boyce

Mfg. Co. Ltd Taluka - Vagra, District-Bharuch,

State-Gujarat

2 Regd. Office Address

Godrej & Boyce Mfg. Co. Ltd.

Pirojshanagar, Vikhroli,

Mumbai – 400 021.

Mobile: 98205 22010




3 Telephone No. (022) 67962051

4 Fax No. (022) 67961501

5 TELEX -

6 E-mail [email protected]

7 Name & Address of Occupier

of Factory

Mr. Anil G Verma

Executive Director cum - Head ( P&A )

Godrej & Boyce Company Ltd.

Plant-12,Corporate Personnel Department


Mumbai - 400 079, MS, India

8 General Manager of Factory Mr. Nitin S Palan

9 Finished Products Fabrication of various process equipments like

heat exchangers, pressure vessels & columns.

10 Process involved

1. Inspection & Marking

2. Machine cutting & gas cutting

3. Cold rolling

4. Welding

5. Fabrication

11

Hazardous Chemicals

Hydrogen

Acetylene

Liquefied Petroleum Gas

a) As per listed under schedule-1 of Rule 68-

J of GFR 1963 (1995).

b) The quantities of the identified hazardous

chemicals under MSIHC Schedule-I are

much below the applicable / permitted

threshold quantities as per Schedule-II.

12

Factory License from Factory

inspection Department, Gujarat

State

Under Process

13 License from Department of

Explosives -




2.3 Details of Units (Continue…)

Sr.


14 GPCB Consent

NOC application is done. CC&A application will

be done well in advance before

commencement of operation.

15 Facility/System

(1) All electrical equipments, wiring &

fitting shall be flameproof type.

(2) Provision of D.G. Set to meet

emergency.

(3) Provision of water storage.

(4) Water sprinkler system shall be installed

in the plant.

(5) Provision of portable fire extinguishers &

fire buckets.

(6) Well ventilated storage area.

(7) Provision of Earthing

(8) Smoking is prohibited

(9) Trained & Experienced persons.

(10) Arrangement of Siren/Bell/Messages

(11) Auto control, Control Room, Internal

Phone.

(12) Communicator system, Mobile phone,

Fax, E-mails, etc.

(13) Displayment of Notices

(14) Color Code system for Pipe Lines.

(15) First Aid Trained Person.




2.4 Organization Structure: The detail of Organization Structure is given in the Appendix-B.

CHAPTER – 3

UNIT HAZARD & CONTROL




3.1 Evaluation of Hazards:

Hazard is a physical situation which may cause human injury, damage to

property or the environment or combination of these criteria. Hazard

identification provides vital information to risk management.

The unit is engaged in fabrication of heat exchanger, pressure vessels &

columns. Main components of the unit are as follows:-

1) Storage

2) Process

3) Utility

3.2 Storage Hazards The following substances are stored at various places of the premises:

TABLE 1 STORAGE FACILITY FOR RAW MATERIALS

Sr.No Raw Material

No. of container &

size (MT)

Pres--sure

Kg/cm2

Temp (˚C )

Total Quantity

(MT)

Type of Hazard

Consumption MT/

annum No. Size

1 Carbon Steel

N.A N.A N.A N.A 810 MT Non-combustible

9720

2 Stainless Steel

N.A N.A N.A N.A 40 MT Fumes / gases

produced from

welding or burning

operations

480

3 Mild Steel – 410

N.A N.A N.A N.A 365 MT Fumes / gases

produced from

welding or burning

operations

4380

4 Other N.A N.A N.A N.A 135 MT May be 1620




metals Flammable 5 Oxygen 145 7 m3 150

kg/cm2 Ambient 1015 m3 Non

flammable 181200

6 Argon 40 7 m3 150 kg/cm2

Ambient 280 m3 Non Flammable

68760

7 Hydrogen 3 5.5m3 150 kg/cm2

Ambient 15.6 m3 Flammable gas &

Asphyxiant

600

8 Nitrogen 50 7 m3 150 kg/cm2

Ambient 350 m3 Non Flammable

4380

9 Acetylene 50 7 m3 16-18 kg/cm2

Ambient 350 m3 Explosion 24876

10 Carbon dioxide

30 30 Kg 150 kg/cm2

Ambient 900 Kg Non Flammable

38880

11 Thinner 30 20 L N.A Ambient 600 L Flammable 21600 12 Hydro

Fluoric Acid

10 35 Kg N.A Ambient 350 Kg Corrosive in nature

600

13 Nitric Acid 17 35 Kg N.A Ambient 595 Kg Health hazard

5160

14 M3 Degreaser

100 5 Kg N.A Ambient 500 Kg Slightly pungent

240

15 Primer 10 20 Lit N.A Ambient 200 L Fire & health hazard

2160

16 Other paints

100 20 Kg N.A Ambient 2000 Kg

Health hazard

37740

17 Hydraulic oil

10 210 L N.A Ambient 2100 L NA 24300

18 Grease 1 5 Kg N.A Ambient 5 Kg NA 18 19 Turpentine 5 20 L N.A Ambient 100 L Flammable 3240

Refer Annexure – 4 Storage Hazards

Refer Annexure – 5 Material Safety Data Sheet




STORAGE FACILITY FOR HAZARDOUS CHEMICALS

Sr. No.

Name Of Chemical Type of Storage

Storage Quantity

Type of Hazard

Hydrogen Cylinder 110 CMT Flammable gas & Asphyxiant

Acetylene Cylinder 110 CMT Explosion

1 Flammable Gases

LPG Bullet/Cylinder 6 Ton Flammable

HSD Tank 1250 ltrs Flammable liquid

Nitric Acid Carboys(35 lit) 300 kg Health hazard Primer Tin Container 300 ltrs Fire & health

hazard Other paints

Tin Container 300 ltrs Health hazard

Thinner Tin Container 920 kg Flammable

2 Flammable Liquids

Turpentine Tin Container 300 ltrs Flammable

Note: The quantities of the identified hazardous chemicals under MSIHC

Schedule-I are much below the applicable / permitted threshold quantities as

per Schedule-II.

Details of Fuel Consumption

SR. NO. NAME OF FUEL QUANTITY / MONTH

1 LPG 60700 KG 2 CNG 28000 SCM 3 HSD 7500 LTR




3.2. Storage All storage tanks, bullets, cylinders are above ground, located safe distance

away from the plant and the storage tanks will be under strict safety conditions.

The storage facilities includes the storage of flammable gases like LPG,

Acetylene, Hydrogen and flammable liquids like HSD, Nitric acid and Turpentine

tin containers.

3.3 Hazards As far as storage hazards concerned, the following probable emergency

situations may arise, while handling, transporting and using the types of

materials.

(1) FIRE: 1. Generation of Static Electricity

2. Electrical Short Circuit

3. Transformer area

4. Diesel Oil

5. Solvents Storage

6. Tank farm area

7. Electrical Sub Station

8. Fabrication Yard

9. Compressed gas Storage Unit.

(2) EXPLOSION:

1. Bullet of LPG,

2. Cylinder of Hydrogen & Acetylene

(3) LEAKAGE & SPILLAGE OF:-

1. Nitric acid




2. Hydrogen

3. Acetylene

4. Primer

5. HSD

6. Thinner

7. Other paints (Solvents)

8. Turpentine

3.4 PROCESS DESCRIPTION The company is engaged in fabrication of heat exchanger, pressure vessels &

columns at Godrej & Boyce Mfg. Co. Ltd Taluka - Vagra, District-Bharuch, State-

Gujarat.

Brief Description of Manufacturing Process of Process Equipment Division The manufacturing process of Process Equipment Division comprises of following sub-processes:

1. The raw material is received in the form of heavy thickness plates and stored for the manufacturing process.

2. The material received from Raw materials stores is first inspected and

marking is done on the raw material as per drawing of item to be fabricated. Also the cutting is done in accordance top the marking.

3. The plates cut to size are cold rolled to the required diameter of shell.

After the plate is rolled its two ends are joined to form a shell of a diameter raging from 600 mm to 6 meters by welding. Longitudinal shell welding and circumferential seam welding is done.

4. The machining work for various fabricated components required for the

fabrication of Heat Exchangers, Pressure Vessels, Column jobs etc is carried out.

5. Fabricated Nozzles required for the fabrication of Reactors, Vessels, Heat

Exchangers & Columns are prepared.




6. All the components and subassemblies are assembled to make the final fabricated product.

7. The final fabricated product is tested, inspected, treated, cleaned and

painted as per the requirements specified in the drawings.

8. The final fabricated product is dispatched. 3.5 Safety Measures for LPG storage

LPG, being highly volatile and inflammable liquid, poses the greatest

potential for fire and explosion. The following Safety measures shall be

installed for the storage facilities.

1. Fire Hydrant System

2. Automatic fire detection system

3. Fire extinguishers & trained personnel

4. Electrical lockouts, gas tests and hot work permit

5. Ventilation and air pollution control

6. Gas monitoring system

7. Leak & fault detection sensors

8. “No Smoking Signs”

9. Bunding

10. Minimum separation distance as per the applicable rules

11. Emergency control valve (in plant storage area)

12. Shut-up valve

13. Safety valves – 2 no.

14. Level switch (High and low)

15. Pressure Measuring Switch

16. Remote control fittings & valves (fire-safe & fail-safe)

17. Electrical installations flameproof

18. Vapor recovery compressors

19. CCOE Approvals




3.6 Specific safety details / provisions for handling and management

of Compressed Gas Cylinders such as hydrogen, Acetylene,

LPG, etc to be used in the process:

1. All the Compressed gas cylinders are stored properly in a dry, well

ventilated room and away from flammable substances.

2. Proper inspections of all the cylinders.

3. Empty and full cylinders are stored separately.

4. Store room should be fire proof and electrical installations

completely flameproof.

5. Acetylene cylinders are always stored upright.

3.7 Utility

The Utility block encloses Fabrication Air Compressor, Heat exchanger,

Thermic Fluid System, DG set etc.

3.8 Other Safety measures shall be provided as follow: a. Level Indication & transmitters to all storage tanks interlocked with

respective unloading and loading pumps

b. Temp transmitters with control interlock in reaction section.

c. Nitrogen inlet lines to reactors for purging with interlocked On/Off

valves

d. High/Low level alarms switches to storage tanks and interlocked with

respective pumps

e. PSV in transferring lines wherever needed.

f. Flow control valves in raw material/Product transferring lines, wherever

needed.

g. Electrical tracing wherever required with proper insulation.

h. Detection System with Alarm in plant.

i. Oxygen Analyzer in Nitrogen Line

j. Safety Vent System




k. Safety inert lock for reactor

l. Personnel will be provided all PPE’s during working

3.9. Solvents Storage & handling

Following are the general guideline for emergency action:-

1. All storage tanks will be equipped with contact DP/non-contact radar type

level transmitters with feedback to main PLC/SCADA.

2. All storage tanks will be equipped with level switch which will stop the

respective transfer pump on activation at high level.

3. Local temperature and pressure gauges will be provided wherever

applicable.

4. Leakage or spillage of this solvent may lead to health hazards or fire /

Explosion or toxic release. So proper PPE (Personal Protective Equipments)

are provided.

3.10 Safety and Mitigating Measures SAFETY CONSIDERATIONS IN THE DESIGN Safety Considerations in the design of M/s. Godrej & Boyce Mfg. Co. Ltd, &

important mitigating measures will be provided to contain and control the

emergency are outlined below:-

General Safety Considerations:- • Adherence of international engineering standards in the design,

Construction and testing of the storage tanks, equipments and other

hardware.

• Statutory approvals of hazardous storage, waste treatment and disposal

stack emission etc.

• Storage tanks containing hazardous materials are located away form the

plant.




• Full fledge fire protection system.

• All Storage tanks shall be located in Dykes and equipped with high and low

level indicator wherever indicated.

• Spillages and leaks from the storage tanks can be collected and transferred

out and treated for safe disposal.

• Local temperature and pressure gauges shall be provided wherever

applicable.

• The hazardous reactors are provided with seal arrangements, which will

prevent leakage of fugitive emission in case of seal failure.

FIRE PROTECTION & FIRE FIGHTING SYSTEM: - The plant will be equipped with a comprehensive fire protection system. The

fire fighting equipments will be provided as per the requirements of Gujarat

Factories Rules, 1963. Following facilities will be provided for the fire

protection.

• Fire Water Supply

• Fire Hydrant system

• Portable Fire Extinguishers

• Sand buckets, Water buckets

• Sprinkler System




CHAPTER – 4

ENVIRONMENT IMPACT ASSESSMENT




4.1 Introduction:

The environment elements (attributes) that are likely to be affected are

identified and categorized as air, water, land, sound, ecology, human

aspect, economics and resources.

The environment includes human being, other living creature, plants and

properties.

Amongst, these, the human beings are the most important and need

protection from any adverse impact. We have to consider two Groups:

(1) Those at work on site, and

(2) Those living and/or working in the vicinity.

The necessary instruction, training and precaution shall be taken to protect

these people against the anticipated situation by the management.

Consent from GPCB shall be obtained and necessary GPCB norms shall be

maintained.

In case of unexpected happening like collapse of tank, puncture in tank or

in pipeline etc., if not controlled, it may spread in the vicinity, may result into

its effect on human beings, other living organism, plants, properties,

depending upon the type of chemicals which contained in the tank and

gravity of incident.

4.2 Layout of the Unit The topography of the proposed plot is not flat in shape. There are no dense

natural vegetation around the site. Construction of new Industrial engineering




unit for “Fabrication of Heat Exchanger, Pressure Vessels & Columns” along with

Jetty is proposed. The existing land use pattern is Industrial Zone and out of

235030 m2 area only 41028.90 m2 shall be used for the proposed unit of

fabrication of process related equipments. The area allotted for jetty will be

3960m2. Green belt area shall be 49207 m2. The remaining plot shall be

developed in future.

The Project Land Use Plan describes two categories of land uses: Unit for

fabrication of Heat Exchanger, Pressure Vessel & Columns is proposed in the

processing area. The unused land will be used for captive consumption in future

for further plant expansion. The space will be spare for future electrical substation

and other infrastructure facilities like internal roads, lights, STP / ETP. Design for the

same will be created at the time of actual planning for expansion of the units.

4.3 Effluent Treatment Plant

The management has provided Receiving Sump which is followed by Aeration

tank. Then the sludge developed in Aeration tank 1 will be settled in secondary

settling tank and from there it will be settled in Aeration tank II. Excess sludge shall

be dewatered by pumping to the filter press. Then further it gets transferred in

clariflocculator and then to treated effluent sump. The treated effluent pumped

from the Treated Effluent Sump through the filters (Pressure filter & activated

carbon filter) shall be used for hydraulic testing of vessels.

4.4 Noise Level

The green belt area will be developed within industrial premises and around the

periphery to prevent the noise pollution in surrounding area. Development of

green belt with carefully selected native plant species is of prime importance

due to their capacity to reduce noise and air pollution impacts by attenuation /




assimilation.

4.5 Solid Waste Waste is an unavoidable byproduct of human activity. Economic development,

rapid urbanization & improved living standards have led to the increase in

quantity & complexity of the waste generated. Proper disposal of waste is

essential for preservation and improvement of public health.

Solid waste management: Solid waste management is one of the most essential services for maintaining the

quality of life in the plant and for ensuring better standards of health and

sanitation. Solid waste generated in the plant area can be handled under two

main categories, namely domestic wastes and industrial wastes. Effective

measures shall be taken to effectively implement the solid waste management

systems in the plant. During operation phase, generation of the solid waste shall

be around 450-500 kg/day, which shall be segregated as organic and inorganic

and handed over authorized vendor for disposal. The hazardous waste shall be

handed over to authority (BEAIL) for further disposal as per Solid Waste

Management Rules (2000) and MSIHC (Hazardous waste and Management rules

(Amended till 2008)).

4.6 Consents from GPCB:

NOC application is done. CC&A application will be done well in advance

before commencement of operations.




CHAPTER – 5

ACCIDENT HISTORY




5.1 Introduction

It is an engineering based unit which is going to manufacture process

equipments. The proposed industry will include infrastructure development of

the proposed area for fabrication of heat exchanger, pressure vessel &

column.

Thus, the Potential Risk can be divided in to two parts: (1) Mechanical Hazard

(2) Potential Risk of FIRE & EXPLOSION. (3) Health hazard. The handling and

use of the LPG, Nitric acid, and other compressed gas cylinders require due

precautions.

5.2 Accident Reporting System

The statutory requirements shall be fulfilled by maintaining accident register

in Form No.29, as prescribed under Gujarat Factories Rules 1963 and form

NO.21 shall also be kept for reporting to the Factory Inspectorate, as

required.

5.3 First Aid Box

The first Aid Box shall be maintained at Security cabin and all other

departments. The security staffs and operative personnel shall be trained in

First Aid.

5.4 Medical Examination

The medical examination of employees shall be carried out and records in

Form NO.32 as prescribed format shall be maintained.




CHAPTER – 6

ORGANIZATION PLAN




6.1 Introduction Pre - Emergency means the preparatory stage. It is the planning period and

it should come out to ensure that the plan should contain required

provisions and facilities to handle and contain the emergency successfully.

The unit has to consider worst possible scenario for emergency while

planning. Further, the unit has to develop and maintain the essential

facilities, so that emergency can be controlled & minimized the damages in

shortest period by use of existing resources.

The unit has to be ready for any possible emergency, whether it may strike

or not. Being an Engineering unit along with Chemical handling & storage

i.e. unit and knowing the hazards of the chemicals stored and handled in

the unit, response actions must be created within unit.

The structure of the plan may vary depending on the number of

employees, materials, process, and availability of recourses, location of site,

size and complexity of the unit. It should work out a plan with possibilities of

various emergencies likely to arise within unit. Further periodical rehearsal is

also to be carried out to check and examine the effectiveness, awareness

and preparedness of the plan as well as services. The emergency planning

is not a substitute for good design, operating and maintenance practices.

Therefore, these must always be followed to avoid emergency.

No plan will succeed without effective emergency organization. The

organization plan has been described the role and function of various

categories, as explained in previous Chapter. It also provides a list of

facilities with the units.

6.2 Identification of Hazards and Control Measures LPG, Acetylene, Hydrogen, Nitrogen, Nitric Acid, turpentine, HSD, Hydraulic

oil, Primer are the materials stored, handled and processed at the safe




distance from the Transformer area. For the handling and storing of LPG,

Nitric acid, Acetylene and other hazardous materials, proper care shall be

taken.

The management shall take ample safety measures against the potential

threat of risks. However, the possibility which may lead to emergency has

been explained in previous chapters. The management is keen to maintain

highest level of safety at the unit. The various control measures on safety

have been provided in the plant.

6.3 Planning for Emergency The management shall identify the maximum credible scenario and has

planned to tackle the emergency which may strike at any time. The

following specific details in respect to create the emergency Preparedness

& awareness are listed as required into Annexure Section and Appendix

Sections.

These details shall be updated time-to-time.

(1) Participants shall be fully conversant and trained in their function or

role (As explained in for going paras)

(2) To keep and update the emergency equipments, communication

system, neutralizing agents, medicines, antidotes etc.

(3) Up-dated emergency telephone Nos. with contact persons.

(Appendix - A)

(4) Emergency control center.

(5) Emergency alarm / siren system.

(6) Marking of safe assembly point.

(7) M.S.D.S. of each hazardous chemicals (Annexure - 5)

(8) Storage, process, vessels, utility, trade waste disposal, Pollution control




arrangements.

(9) Fire & Toxicity - Details, Gas Dispersion, Evacuation Details, Transport

and Evacuation Arrangement

(10) Medical arrangement

(11) Meteorological details

(12) Personal Protective Equipments Details

(13) Charts, Maps (Annexure 2, 3)

(14) Maintenance of Records

(15) Updation of On-site Emergency Plan to Conduct Mock Drill (Format

given in Appendix-G) and Training.

(16) Liaison with emergency services, Govt. Authorities, Voluntary

organizations, suppliers etc.

The arrangement of communication system should be foolproof so that

correct message reaches to the proper person in shortest time. The chart at

Appendix-C indicates initiation of actions and where to report.

The role and responsibilities of each acting person shall be explained in brief

with Command & Control Appendix-D during emergency period. All the

persons involved in Emergency management shall be aware of the roles &

responsibility.

The Emergency Control Room shall be fully equipped with the facilities. A

safe assembly point shall be marked with alternate safe assembly point in

case of sudden change of wind direction.

6.4 Command & Control Organization chart is given in Appendix - B, which gives organizational

structure. Chart of Initiation of Actions for the emergency plan has been

given at Appendix - C, which explains the order of command, Channel of

information flow, and actions as required during the emergency. The single




organization structure has been created and the same shall be continued

till the emergency is over. The Safety Officer shall take the initial charge, as

Incident Controller, and he will coordinate with various agencies effectively

to combat the situation. The Office room will be used as emergency control

Room. The Assembly point shall be marked and people shall be informed to

reach at the assembly point during emergency. The Director/General

Manager will act as site main controller for the unit. On arrival, he will

supervise all activities with the help of Incident Controller (Safety Officer).

The duties & responsibilities have been defined as per below:

6.5 Incident Controller

His responsibilities include:

(1) His primary duty is to take charge at the scene.

(2) Direct all operations within the affected area giving priority to safety of

personnel.

(3) Minimize damage to property, environment and material loss by

taking necessary actions within his control.

(4) Pending arrival of site main controller, incident controller takes the

responsibility of his post and directs shut down of plant and evacuates

people, if necessary. Further, he will intimate and request to the fire,

police and medical services for required helps by giving details of

incident/accident/emergency.

(5) Ensure that all non-essential workers/staff of the affected area are

instructed to go to respective assembly point / shelter and areas are

searched for casualties.

(6) Safety Officer (Production) will perform the role of "Incident controller"

at the time of emergency period.

(7) Dy. Incident controller will perform the role as incident control till the

arrival of incident controller.




6.6 Site Main Controller His responsibilities include:

(1) Immediately on being informed of the emergency and its location, he

will arrive at the scene & handle the situation.

(2) He will access the magnitude of the situation and decide if persons

need to be evacuated from the assembly / shelter.

(3) On his decision, he will activate the on-site emergency plan as well as

local crisis. Further, he will intimate to District Crisis Group for the further

help if condition deteriorates.

(4) To maintain continuous review of developments and access in

consultation with incident controller and other key personnel.

(5) To give information to head office and to fire bridge, police, medical,

experts, Factory inspector, GPCB and other statutory authorities.

(6) To provide advice on possible effect on areas surrounding factory

premises.

(7) To ensure that the casualties are receiving adequate attention.

Arrange for hospitalization of victims and additional help if required.

Ensure that the relatives are authorize advised.

(8) To ensure the accounting of personnel and search of missing persons.

(9) To Control traffic movement for factory premises & surrounding area.

(10) If emergency is prolonged, arrange for the relief of personnel and to

provide catering facility.

(11) To issue authorized statement to the news media and other authorities.

(12) To ensure that proper consideration is given to the preservation of

evidence. Arrange for photographs or video.

(13) To Control rehabilitation of affected areas and victims.

(14) Do not restart the plant unless, clearance or approval received from

the authorities.




6.7 Key Personnel The key personnel shall be available at any time on duty or on call when off

or on holiday. The Role of key personnel is to perform the following

functions:

(1) Take the charge of managerial activity and support to Site Main

Controller and Incident Controller.

(2) Immediate communicate to various authority with specific details and

request for helps.

(3) Supervise and execute the work as instructed by Site Main Controller

and Incident Controller.

(4) Handle the situation & cope up the work by fair dealing.

(5) Report time to time to the Site Main Controller and Incident Controller

about your work status.

(6) Advice, Counsel, Guide, Suggest, or Caution in respect to the

handling of emergency to the SMC/IC as per your knowledge.

The List of Key Personnel & their contact numbers shall be displayed &

updated on regular bases. (Appendix A)

6.8 Essential Workers They are a task force of trained workers or expert teams to carry out specific

job or work at the time of emergency and perform the duty under

guidance of Incident Controller/Site Main Controller. The list shall be

updated from time to time.

Such work will include:

(1) Fire fighting, gas leak and spill control till a Fire Brigade takes the

charge.

(2) Shutting down plant and making it safe.




(3) Emergency engineering work e.g. Isolating equipments, materials,

process, providing temporary by-pass lines, safe transfer of substance,

urgent repairing or replacement, electrical work etc.

(4) Provision of emergency power, water, lighting, instruments,

equipments, materials etc.

(5) Movement of equipments, special vehicles and transport to or from

the scene of the incident.

(6) Search, evacuation, rescue and welfare.

(7) First - aid and medical help.

(8) Information to surrounding factories and the public as directed by the

site Main Controller.

(9) Assistance at communication centre, casualties, reception centre,

liaison with police etc.

(10) Any special help required.

6.9 Safe Assembly Point In affected and vulnerable plant, all non - essential workers (who are not

assigned any emergency duty) shall evacuate the area and report to a

specified assembly point.

The assembly point should be clearly marked at a conspicuous place.

Assembly point must be sited in a safe place, well away from areas of risk

and least affected by the down wind direction. It may be in the open or in

a building depending on the hazard involved. The nominated person for

recording the names and departments of those reporting should be posted

there. He should have a means of communication with the site main

controller in case it is necessary to establish the where abouts of people

and to receive further instructions concerning the deployment of the

evacuated personnel.

Further, an alternative Safe Assembly point shall be marked considering the




prevailing wind direction, incase of sudden change of wind direction.

6.10 Check Schedule The following arrangements are to be maintained and up-dated for

preparedness, of emergency purpose during pre-emergency period.

6.10.1 M.S.D.S. M.S.D.S. for Hazardous materials, which are handled and stored are given in

Annexures-5. Any updation or new information about hazardous materials

should be incorporated in M.S.D.S.

6.10.2 Weather Condition Data The Meteorological data will be updated periodically and record should be

maintain accordingly.

6.10.3 Communication System Emergency Telephone Nos. with name of contact person etc. are given in

Appendix - A. Time to time modification should be carried out for changes.

6.10.4 Emergency Control Center The Equipped Central Control Room should be in working order. The plant

layout maps, drawing, storage details" M.S.D.S, emergency operations,

manuals etc. should be kept and should be up to date. List of Emergency

telephone Nos. is also maintained up to date. The senior and expert person

shall be posted as in charge of the control room.

6.10.5 Fire Protection: To fight the fire, Systems like Fire Hydrant system, Fire extinguishers shall be

provided.

Check all the fire - fighting equipments, units and machineries for their

conditions, physical availability, workable and take necessary actions on




replacement and maintenance, if required. Check resources of water and

keep necessary telephone Nos. of suppliers for the same. Maintain the co-

ordination with other fire - services. The water showers should be checked

periodically for working conditions. As per K-5 of schedule XXI under Rule-2

of GFR-1963, an automatic water spray / sprinkler system shall be provided.

Refer Annexure – 6

6.10.6 Personnel Protective Equipments Check all the personnel protective equipments provided at different places

for their condition, working, maintenances and replacement, whenever

required. Also keep sufficient stock of required personnel protective

equipments. Also, maintain the relation with the mutual aiders for their

supply of Personnel Protective Equipments at the time of emergency.

6.10.7 Safety Systems Check the working of all safety devices; interlock systems, safety-guard,

railing, and fencings, in position. The safety equipments should be kept

available with working condition. The safety motivation and safety training is

a continuous process and arrange such type of training, periodically.

Check the monitoring instruments, if provided, for correct working. Check

the alarm systems for its working condition. The details shall be up-dated.

6.10.8 The Medical Facilities The First Aid Boxes shall be provided at the plant area shall be adequately

filled with requisite medicines and equipments. Arrangement should be

made that at least one trained person should be available during the

working hours. The name and address with telephone No. of Doctors shall

be displayed in the Control Room along with General Hospital &

Ambulance Van facilities.




6.10.9 Monitoring the Environment A suitable type of flameproof and portable combustible gas indicator /

sensor shall be provided and sample of various locations shall be measured

& record shall be maintained.

6.10.10 Precaution against Power Failure Provisions shall be made for the in the event of power failure, DG sets shall

be provided.

6.10.11 Maintenance of Records Keep the records of the monitoring conditions, safety systems, storage

levels, process condition, etc. and maintain the log - books, registers etc.

keep the M.S.D.S. and onsite emergency plan with required details.

6.10.12 Exercises/Mock Drill/Rehearsal Organize the periodical mock drill/ rehearsal as per suggested format on

emergency situation so as to keep up preparedness & awareness to over

come shortcomings. Give prior information with reasonable time to the

emergency services and public for proper response & training. Record the

deficiencies of the system during the trial and take appropriate action to

improve the effectiveness of the plan in terms of preparedness and

response. A format on such mock drill is appended in Appendix-G.

6.10.13 Potentiality on Liaison Keep constant liaison with mutual aiders, fire services, police department,

medical services, statutory authorities, District administration, during pre-

emergency situation. Keep liaison with local Crisis Group and District Crisis

Group.

6.10.14 Public Education




Efforts to be made to educate the surrounding public about the existing

hazards of the plant, the possible emergency actions and the precautions

required to be taken in such condition. Leaflet containing such details can

be distributed amongst the public. The training program can be arranged

in the school, public institution. It can be circulated to news media, TV,

Video- channels, newspapers etc.

6.10.15 Training (Internal) With the help of efficient plant supervisors, inspectors, the education &

training of the workers to be kept alive all the time to ensure good

housekeeping, discipline and display of safety slogans, operative

instructions and motivation on safety. All the persons from the emergency

services, organization is to be trained to response the emergency.

6.10.16 Siren Testing The siren shall be checked & tested periodically at certain intervals so that

awareness & preparedness can be checked.




CHAPTER – 7

EMERGENCY PROCEDURE




7.1 Actions during Emergency It is not possible to include and discuss every action, which should be taken

during emergency; It is also not possible to describe entire actions on

emergency situation. The basic principle of handling emergency is to rely

upon person, who has the knowledge and experience to assess the

situation and give direction as per the objectives as quickly as possible.

However, the aim is to control the situation by safest way in limited time

within available resources. Further, it should handle with care so that loss of

life, property and environment is minimized. In short, the plan should be

successfully complied with.

7.2 Sequential Actions during Emergency

Various actions are required to be initiated according to the situation.

However, some systematic codification is required to control such

emergency, the following sequential actions may be helpful to contain

emergency.

7.2.1 Incident

There are possibilities of various types of accidents or mishaps occurring in

the factory/premises. Most are of minor type, while few cases may be major

type. Some times there is no single incident during the life span. However,

when any incident occurs, it cannot be distinguished immediately, the

subsequent development or seriousness of such occurrence is required to

handle safely.

It should be general practice that any person noticing the




accident/fire/explosion/mishap at the site, should shout "FIRE", "FIRE" or

"HELP", "HELP" and such message should reach to Supervisor/Shift Engineer/

Senior Person of the unit. This way first information will reach to responsible

person.

7.2.2 Responding Actions

It is said that root cause should be removed immediately. Similarly, if any

incident takes place in the premises it should be tackled with available

resources, it should be so responded that it is contained immediately before

spreading. If the incident looks severe and cannot be controlled by simple

efforts, the Shift Engineer or senior person should rush to the place and try to

control by using resources at the site.

Further, if it is uncontrollable even after using own resources, immediately

call for further help from outside e.g. mutual aiders, fire-brigade etc. He

takes over as incident controller & initiate following actions.

Sound the siren or ring the emergency bell.

Continuous responding actions, with the use of other helps.

Call the higher authority / Site main controller.

7.2.3 On-Site Emergency On arrival, of Incident Controller/Site Main Controller, he assesses the

situation and handles the incident as site crisis. The incident can be said as

On Site-Emergency.

He will,

Activate the fire brigade, police, mutual aiders and essential workers,

expert persons.

Mobilize more resources from the neighboring industries and other




available resources.

The messages regarding prevailing situation to concerned authorities,

agencies, neighbors etc. will be communicated through the control

room.

Non-essential person will rush to safe shelter and their roll call to be

taken.

Try to contain by using all available resources within his command.

Now, if situation is uncontrollable by the management of the unit, he should

immediately call the local crisis group to handle the situation.

7.2.4 Off-Site Emergency:

a) Local Crisis Group: The Chairman of Local Crisis Group with committee members handles the

situation by responding actions. The Chairman of the Committee pools the

entire local resources at site and tries to mitigate the situation. However, if it is

presumed that the magnitude of the event is such high that it is

uncontrollable by the Local Crisis' Group, than The District Crisis Group will be

intimated to handle the emergency.

b) District Crisis Group: The Chairman, along with members of District Crisis Group takes over the

charge of escalating situation. After, assessing the situation, he declares the

"District Crisis" in action. To combat the emergency, he mobilizes the

emergency services; and handles the situation as off-site emergency.

The Central Control Room will activate and communicate the messages to

the various District resources. Thus, all the resources from entire District will be

called on and diverted to the scene and mobilize to control the incident in a




efficient & coordinated way.

7.2.5 Messages: While conveying the messages regarding the incident, the following details

should be incorporated.

Brief description of incident.

Type of help required & direction.

Chemical involved & quantity.

Action immediately taken.

Development of the incident.

The Appendix - F indicates the format for emergency call/meeting.

7.3 Emergency Actions (General) 1. On receiving information, the control room activates and establishes

the contact with Key Personnel, Essential workers, services, agencies &

authorities, urgently.

2. The essential workers, who are responsible to carry out certain specific

functions, have to work immediately.

3. The non-essential workers should go to the assembly center.

4. Ensure the cordoning of the incident area.

5. Spray the water on the flammable storage tank, even if not caught

under fire.

6. Consult the experts for responding the emergency, if required.

7. Give authorized information to Press / Public.

8. Arrange to remove the flammable, dangerous materials, cylinders etc.

at safe places and try to isolate from fire.

9. Provide all assistants to fire brigade to control spreading of fire.

10. Rescue the trapped personnel.




11. Eliminate possibility of re-ignition or Explosion.

7.4 Emergency Communication:

Anyone from Factory, if notice or observe any type of fire, explosion, gas cloud,

leak, toxic release,

He has to -

Inform security officer, who will then actuate fire Siren or emergency

alarm after consultation with authorized person

In case of injury, inform Assistant Manager.

Get back to your normal work station if safe or else report to the

nearest emergency control point.

7.5 Action Plan for Emergency in Charge (IC/SMC)

(On receiving information on incident/Accident)

Immediate rush to the scene/place

Assess the situation & start remedial measures

If situation is more severe than activate emergency control center, initiate

following action;

o Communications with top management ~ Start responding

actions

o Preserve evidence.

o Organize investigation team

If necessary set up of forward control centre and start following

immediate actions;

1. Inform security person to sound fire siren or emergency alarm.

2. Start emergency action with the help of key personnel and




essential workers.

3. Cordon incident/accident area and restrict unauthorized entry.

4. Ensure immediate starting of fire fighting system like fire hoses,

monitors, sprinklers system, sprays, and neighboring equipments.

5. Ensure shut down of various plants in right sequence.

6. Communicate with top management / head office.

7. Communicate with statutory bodies like Factory Inspector,

Insurance, and District Magistrate etc.

8. Issue authorized statement to news media.

9. Search of affected area for casualties.

10. Call mutual aiders and inform local crisis group.

11. Preserve evidence; arrange photographs, and logging of

events.

12. Before ordering the re-entering check that it is safe for.

13. Do not restart till steps taken to prevent the returns recurrence.

7.6 Action Plan for In-Charge of Emergency Control Center i.e.

Communication Officer

(On Hearing Alarm Emergency information)

Proceed to Emergency control central and perform the duties.

Follow the line of action with IC/ SMC.

Inform fire brigade / police / mutual aiders.

Ask key personnel & essential worker to report IC/SMC.

Inform all non-essential workers to reach the assembly point.

Inform neighboring factories, companies, units.

Communicate with statutory bodies like Factory Inspector, Insurance

Agency, Police Authority, Magistrate etc.

Arrange to rescue of missing & trap persons.

Arrange to search affected area for causalities.




Ensure cordoning of affected area.

Instruction to emergency vehicle, e.g. fire tender, etc.

Inform surrounding population with the help of police.

Requisition cars, buses, ambulance, if required.

Additional ambulance and treatment for victim.

Reserve injuries, hospitalization for victim. (e.g. Burns, causalities)

Inform relatives of victims

Evacuation of neighboring population, if required.

Check rehabilitation of victims.

7.7 Action plan for Key Personnel and Essential Workers

(On Hearing Fire/Emergency Alarm)

Inform security officer of location and nature of emergency.

Minimize consequence by :

o Eliminating ignition source

o Shutting down plants as quickly as possible

o Transferring flammable material to safer places

o Switch on water sprays / sprinklers

o Stopping of loading unloading operations

o Removal of tanker lorries from the unit

o Cordoning of area / incident place .

o Monitoring atmosphere water channels for further action.

o Operation of fire fighting equipments, foam type extinguishers.

o Ensure that fire pumps are in working order.

o Provide engineering assistance to emergency in charge

o Other duties as allocated by IC/SMC.

7.8 Action plan for Security Guards/ Officer




Inform emergency in-charge by telephone

On receipt of information in case siren is not actuated, sound/blow the

siren, if directed by IC/SMC

Depute security guards to control traffic around area of emergency

and cordoning of incident area.

Keep visitors out & prevent unauthorized entry

Control Traffic of gate / inside and outside

Await further instructions from emergency center/in charge

Inform others as directed by emergency center/ in charge

Evacuation of site - Partially or full

Search affected areas for causalities

Eliminating ignition sources

Removal of tank lorries from unit

Evacuation all non essential workers to the assembly point and Head

Count.

Guide the mutual aiders, fire brigade, govt. officers, emergency

vehicles, etc. for safe way towards emergency incident and safe

parking.

7.9 Action Plan for Workers/Officers /Contractor

Upon hearing emergency siren/alarm

Leave site immediately by safest route to assembly point.

Proceed at right angels to wind direction.

Do not re-enter site unless directed personally or via PA system.

Assist in head count at assembly point

Inform contractor personnel to stop work upon hearing fire / gas alarm

and ask to assemble at the main security, gate.

Do not go to incident place unless specifically instructed by

Emergency in-charge.




Avoid Panic

7.10. Discipline

The plan assumes certain discipline at site during emergency, as follows;

Do not get panicky.

Do not approach the site of incident, as a spectator.

Do not Engaged telephone unnecessary;

Do not move about unnecessary.

Do not approach unnecessarily for information or more inquiry.

Arrange medical first aid care to the injured.

Do not allow unnecessary crowd nearby incident.

7.11 Shut down Procedure

We cannot neglect the adverse effect of the running plant during emergency.

Therefore, it is advisable and safe that the safe shut down procedure should be

adopted, if running. First of all main electrical supply line should be cut-off.

Similarly, the pipelines carrying flammable gas, liquid or chemicals are to be

isolated immediately. If reaction in the any vessel is in process, it should be

stopped & safely shut down.

Arrange to transfer or remove the flammable, toxic, dangerous, explosive,

poisonous materials, goods, cylinders, drums etc. to safe place or try to isolate

from the fire.

Arrange the water shower on flammable storage tanks to keep it in cool

conditions, if near the fire.




The shut down procedure should be laid down in the process manual, which will

be useful during such emergency.

7.12. Post Emergency

The following actions are suggested as per prevailing situation depending upon

the level of emergency.

1. In Case of On-Site Emergency

After controlling the emergency and ascertained for no possibility of re-

occurrence, the management will indicate the following actions.

1. Declare termination of Emergency & blow the siren accordingly.

2. Disclose the authentic statement on incident to the authority &

news media.

3. Collect & preserve the documents, records, instruments, evidence

etc. on incident.

4. To set up the internal enquiry committee, appearing the internal or

external expert person.

5. Cleaning work after obtaining the permission from Authority.

6. Preparation of restarting the process work.

7. Detailed related work & procedure, as described below;

o Sound the emergency clear siren.

o The rehabilitation work will start in the affected area.

o To ensure that all fires are extinguished and there is no risk of

re-ignition, before starting work.

o To ensure that there is no chance of secondary explosion.

o Do not disturb wreckage and debris except to rescue the

injured or recover bodies, until permitted to do so by




statutory authority.

o All victims, dead or alive, are' systematically identified and

keep the records accordingly. Give information to their

relatives, if asked.

o Record all relevant information.

o Take photograph / video or make suitable sketches of the

incidence.

o Report the accident / incident, with details, to the statutory,

authorities, if not informed.

o Permission for restarting is required to be obtained from

statutory authorities.

o Keep registers for recording the entries, details, inventory, list

of persons etc. & preserve the all the documents, log books,

maps, registers all records taken from the site.

o Keep the record of help; Co-operation, Mutual aiders sought

from others & write thanks giving letters to them.

o Arrange the compensations to the affected persons, injured

persons, dead etc. as per circumstance and if applicable,

keep the records accordingly.

o Estimate the expenses incurred during the emergency.

o Estimate the various expenses under different head &

prepare the total expenditures statement.

o Appoint the internal committee to investigate into the causes

of the accident / incident, if necessary and get report.

2. In Case of Off-Site Emergency Plan: Being apex body during the Off-Site Emergency Period, the Crisis Group will

get the report from emergency services for safe rehabilitation and Pollution

Control Authority for safe environment condition and then decide the

declaration of termination of emergency. The authority may constitute the




enquiry committee, by appointing inclusive of expert persons and ask to

submit the said report within specified period. Then, Crisis Group will ask the

explanation from management on the said report. On winding up the

actions, the Crisis Groups will permit the management to clean and re-

starting the work for process and other related work as mentioned in above

Para 7.12.1- point No. (7).

7.13 Corrective Actions

The accident is eye opening toward the irregularities. Similarly, the occurrence of

major emergency directly indicates the shortcomings or weaknesses of the plant,

handling method, transportation, working procedure, storage procedure, unsafe

condition or unsafe actions etc. It may reveal from the investigation or

recommendations of the committee.

Necessary corrective steps / actions in light of the investigation report or findings

are required to be taken to ensure that such emergency accident does not

repeat. Therefore, modification, alterations, changes in operation, instruction,

process, and handling are suggested, should be implemented accordingly to

make working safe.




ANNEXURE SECTION




ANNEXURE SECTION

ANNEXURE NO. CONTENTS PAGE NO.

1. Identification of factory

2. Location Map

3. Plant Layout

4. Storage Hazards & Controls

5. List of M.S.D.S

6. Fire Hydrant Layout

7. External phones

8. Emergency Instruction Booklet

M/s. Godrej & Boyce Ltd. On Site Emergency Plan for Proposed Engineering unit along with Jetty in CRZ

area at SEZ - Dahej Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00


55

ANNEXURE -1

IDENTIFICATION OF THE FACTORY

Sr.


1 Name & Address of Unit

A Unit for fabrication of heat exchanger,

pressure vessels & columns at Godrej & Boyce

Mfg. Co. Ltd Taluka - Vagra, District-Bharuch,

State-Gujarat

2 Regd. Office Address

Godrej & Boyce Mfg. Co. Ltd.


Mumbai – 400 021.

Mobile: 98205 22010

3 Telephone No. (022) 67962051

4 Fax No. (022) 67961501

5 TELEX -

6 E-mail [email protected]

7 Name & Address of Occupier

of Factory

Mr. Anil G Verma

Executive Director cum - Head ( P&A )

Godrej & Boyce Company Ltd.

Plant-12,Corporate Personnel Department


Mumbai - 400 079, MS, India

8 General Manager of Factory Mr. Nitin S Palan

9 Finished Products Fabrication of various process equipments like

heat exchangers, pressure vessels & columns.

10 Process involved

1. Inspection & Marking

2. Machine cutting & gas cutting

3. Cold rolling

4. Welding




56

5. Fabrication

11

Hazardous Chemicals

Hydrogen

Acetylene

Liquefied Petroleum Gas

a) As per listed under schedule-1 of Rule 68-

J of GFR 1963 (1995).

b) The quantities of the identified hazardous

chemicals under MSIHC Schedule-I are

much below the applicable / permitted

threshold quantities as per Schedule-II.

12

Factory License from Factory

inspection Department, Gujarat

State

Under Process

13 License from Department of

Explosives -

3.3 Details of Units (Continue…)

Sr.


14 GPCB Consent

Sr.

No.

Consent Consent

No.

Validity

1 CC&A -- --

15 Facility/System

(1) All electrical equipments, writing &

fitting shall be flameproof type.

(2) Provision of D.G. Set to meet

emergency.

(3) Provision of water storage.

(4) Water sprinkler system shall be installed

in the plant.

(5) Provision of portable fire extinguishers &

fire buckets.

(6) Well ventilated storage area.

(7) Provision of Earthing

(8) Smoking is prohibited




57

(9) Trained & Experienced persons.

(10) Arrangement of Siren/Bell/Messages

(11) Auto control, Control Room, Internal

Phone.

(12) Communicator system, Mobile phone,

Fax, E-mails, etc.

(13) Displayment of Notices

(14) Color Code system for Pipe Lines.

(15) First Aid Trained Person.




58

ANNEXURE – 2

LOCATION MAP




59

ANNEXURE – 3

PLANT LAYOUT

M/s. Godrej & Boyce Ltd.

On Site Emergency Plan for Proposed Engineering unit along with Jetty in CRZ area at SEZ - Dahej



60

Annexure -4 STORAGE HAZARDS & CONTROL

TABLE 1 STORAGE FACILITY FOR RAW MATERIALS

Sr.No Raw Material No. of container & size (MT)

Pres--sure Kg/cm2

Temp (˚C )

Total Quantity

(MT)

Type of Hazard Consumption MT/

annum No. Size

1 Carbon Steel N.A N.A N.A N.A 810 MT Non-combustible 9720 2 Stainless Steel N.A N.A N.A N.A 40 MT Fumes / gases produced from

welding or burning operations 480

3 Mild Steel – 410

N.A N.A N.A N.A 365 MT Fumes / gases produced from welding or burning operations

4380

4 Other metals N.A N.A N.A N.A 135 MT May be Flammable 1620 5 Oxygen 145 7 m3 150

kg/cm2 Ambient 1015 m3 Non flammable 181200

6 Argon 40 7 m3 150 kg/cm2

Ambient 280 m3 Non Flammable 68760

7 Hydrogen 3 5.5m3 150 kg/cm2

Ambient 15.6 m3 Flammable gas & Asphyxiant

600

8 Nitrogen 50 7 m3 150 kg/cm2

Ambient 350 m3 Non Flammable 4380

9 Acetylene 50 7 m3 16-18 kg/cm2

Ambient 350 m3 Explosion 24876

10 Carbon dioxide

30 30 Kg 150 kg/cm2

Ambient 900 Kg Non Flammable

38880

11 Thinner 30 20 L N.A Ambient 600 L Flammable 21600 12 Hydro Fluoric

Acid 10 35 Kg N.A Ambient 350 Kg Corrosive in nature 600

13 Nitric Acid 17 35 Kg N.A Ambient 595 Kg Health hazard 5160





61

14 M3 Degreaser 100 5 Kg N.A Ambient 500 Kg Slightly pungent 240 15 Primer 10 20 Lit N.A Ambient 200 L Fire & health hazard 2160 16 Other paints 100 20 Kg N.A Ambient 2000

Kg Health hazard 37740

17 Hydraulic oil 10 210 L N.A Ambient 2100 L NA 24300 18 Grease 1 5 Kg N.A Ambient 5 Kg NA 18 19 Turpentine 5 20 L N.A Ambient 100 L Flammable 3240

Details of Fuel Consumption

SR. NO. NAME OF FUEL QUANTITY / MONTH

1 LPG 60700 KG 2 CNG 28000 SCM 3 HSD 7500 LTR





62

STORAGE FACILITY FOR HAZARDOUS CHEMICALS

Sr. No. Name Of Chemical Type of Storage Storage Quantity Type of Hazard Hydrogen Cylinder 110 CMT Flammable gas & Asphyxiant

Acetylene Cylinder 110 CMT Explosion

1 Flammable Gases

LPG Bullet/Cylinder 6 Ton Flammable

HSD Tank 1250 ltrs Flammable liquid Nitric Acid Carboys(35 lit) 300 kg Health hazard

Primer Tin Container 300 ltrs Fire & health hazard Other paints Tin Container 300 ltrs Health hazard

Thinner Tin Container 920 kg Flammable

2 Flammable Liquids

Turpentine Tin Container 300 ltrs Flammable

Note: The quantities of the identified hazardous chemicals under MSIHC Schedule-I are much below the

applicable / permitted threshold quantities as per Schedule-II.

Material Safety Data Sheet given in Annexure – 5.





63

Annexure- 5 LIST OF MSDS

Sr. No. Hazardous Chemicals

1 Hydrogen

2 Acetylene

3 LPG

4 Nitric Acid

5 Thinner

Note:- MSDS will be attached in the final copy of onsite plan




64

Annexure - 6

FIRE HYDRANT LAYOUT




66




67

ANNEXURE -7

EXTERNAL PHONES

Person available on this Phone Phone No.

Residence

Sr.

No.

Name &

Address of the

dept/Service/

Person

(including

external

emergency

services)

External Internal

Name Designation Services

expected

under On-

site/Off-

site

emergency

plan

Phone No.

(External)

Address

1 2 3 4 5 6 7 8 9

Please See Appendix – A





ANNEXURE -8 (1 OF 2) EMERGENCY INSTRUCTION BOOKLET

Sr. No.

Role to be Played as (Name emergency

designation)

His emergency duties /Function Also refer (other relevant document

of the factory)

He should report at (the incident place or

control room) 1 2 3 4 5 1. Rush to accident site

1. Ask the field operators to close the required values & operation/process at accident site.

2. Assess the scale of emergency. 3. Take necessary actions to activated the emergency procedure 4. Ensure safety of personnel and arrange to issue all required personal

protective equipments 5. Alert the hospital authorities and arrange for necessary antidotes 6. Direct key personnel & Essential workers to carry out their duties to control

the situations 7. Ensure that out side emergency services have been called in. 8. Decide for continuing the operation of the plant 9. Ensure affected area is cordoned off 10. Ensure that all non-essential workers in the affected area evacuate and

assemble to safe assembly point/ shelter and arrange for roll call. 11. Brief site main controller and intimation to local crisis Group 12. Preserve all evidence for subsequent fact finding investigating the matters

1 Incident Controller (I.C.)

13. Provide necessary information to authorities who investigating the matters

M.S.D.S On-Site E-Plan,

Operational Mutual

Emergency Control Center, Site Main

controller, Local Crisis Group

1. Immediately rush to the scene on knowing about the emergency. Consult incident controller, get details from emergency control centre and assessing situation declare emergency

2. Ensure for mutual aid & outside help and intimation to District Crisis Group 3. Ensure availability of all the important personnel, key person 4. Shut down and evacuate 5. Ensure that the injured or casualities are receiving adequate attention and

relatives are advised /informed 6. Ensure accounting of personnel 7. Intimate to Local/District Crisis Group, and other statutory authorities 8. Continuously review possible developments

2 Site Main Controller

(SMC)

9. Direct for Vehicle, transportation, medical, fire fighting, leak-control, traffic

M.S.D.S On-Site E-Plan,

Operational Mutual

Emergency Control Center, Central Main

controller, District Crisis Group





control 10. Arrange for relief of personnel 11. Issue authorized statement to news and media 12. In Case of escalation arrange to warn & necessary information to nearby

population. 13. Take action for rehabilitation of victims at Hospitals 14. Arrange for chronological records on emergency to be maintained.





ANNEXURE -8 (2 OF 2) EMERGENCY INSTRUCTION BOOKLET

Sr. No.

Role to be Played as (Name emergency

designation)

His emergency duties /Function Also refer (other relevant document

of the factory)

He should report at (the incident place or

control room) 1 2 3 4 5

1. Rush to the site, with required equipments & gadgets and act as assigned their respective duties for handling emergency in consultation with IC & SMC

2. Will take other directives form IC & SMC 3. Direct and help the mutual aiders, outside agencies, traffic vehicles etc.

according to the instruction 4. Do not leave the place of incident unless permitted. 5. Do not take any decision on your own. If any self generated idea for control

measures first consult with IC/SMC then put in action, as per discussion.

3. Key Personnel

(K.P.)

6. Keep proper and exact all records of relevant matters pertaining to emergency/incident

On-site E-Plan M.S.D.S.

Incident Place Emergency Control

Center Incident Controller, Site Main Controller

1. On hearing siren, immediately rush to the scene of incident and act according to directives given by IC/SMC or assigned duties role of emergency plans.

2. Assist & help fire gighting, leak control, first aid, closing valves or supply or other work

3. Do not take any decision on your own. However, any good idea pertaining to handle emergency effective, get consulted with IC/SMC & do accordingly.

4. Do not act which will duplicate the same work & without wasting of tiem & delay, carryout your assigned function with personal protective equipments.

5. Do not leave the place of incident without permission.

4 Essential Workers (E.W.)

6. Report all matters pertaining to emergency to IC/SMC




1. On hearing emergency siren take instructions form shift in charge or supervisor and act accordingly.

2. Assessment at safe assemble points if situation demand or check wind direction and rush to the safe place.

3. Do not get panicky. 4. Do not obstruct any activity being done for controlling emergency. 5. Do not engage any phone to know about emergency 6. Be alert to hear clear instruction from authority

5 Non-Essential Workers

7. Ensure your presence and help to count numbers








71

APPENDIX SECTION





72

APPENDIX SECTION

APPENDIX CONTENTS PAGE NO.

A Emergency Telephone No.

B Organizational Chart

C Chart of Initiation of Actions

D Command & Controller Level – I & II (Onsite)

E Disclosure of Information to the Public

F Procedure for Meeting Emergency

G Rehearsal/Simulation/Mock Drill





73

Appendix - A

EMERGENCY PHONE Nos.

Sr. No. Service Phone no.

1 Police Control Room 100

2 Fire station – Control room 101

3 Ambulance room, Bharuch 102

4 Civil Hospital , Bharuch 243523

5 D.S.P., Police Dept. 243320

6 Fire station, Bharuch 240093

KEY PERSONNELS TO BE CONTACTED DURING EMERGENCY

Sr. No. Name of Key Personnels Contact no

1. Mr Nitin Palan (M)09820444897

LAN 0226796 5566 2. Virendrasinh Bhadola

(M) 09819959618

LAN: 0226796 5530

3. Cyrus Shroff

(M) 09820550459

LAN: 022 6796 2041

M/s. Godrej & Boyce Ltd..




74

Appendix – B ORGANIZATIONAL CHART

ORGANIZATIONAL STRUCTURE

Dahej ROLE General Alternative

Chief Emergency Controller Plant incharge

Site Controller Safety officer

Shift In-charge

Team - A (Fire fighting) Shift Production Team

Team- B (Support Team) All Maintenance

Team - C (Rescue Team) All Trained First Aiders

Advisory Team All QA staff

Communication Team Logistics / Security Team

EMERGENCY MANAGEMENT CHART

CHIEF CONTROLLER PLANT INCHARGE / SHIFT

SITE CONTROLLER SAFETY OFFICER. / SHIFT

SUPERVISOR

COMMUNICATION TEAM

ILE – DLE /

ADVISARY TEAM CP - QA

Team-A Fire Fighting

All plant

Team-B Supporting Team

Maintenance

Team-C Rescue Team Trained first-

Task completion

Report to ECC

Investigation &

Report preparation





APPENDIX – C

CHART OF INITIATION OF ACTIONS





APPENDIX – D

COMMAND & CONTROLLER LEVEL – I &II (ON SITE)





Appendix – E

Disclosure of Information to the Public The arrangement to disclose the following instruction is to be made by the management to educate the surrounding public about the hazards existed at site and explain the precautionary measures and actions to be taken during an emergency if arises. SUMMARY: The management has taken ample step to run the installation safely. However, the emergency may strike at any time due to unavoidable circumstances and beyond control of management. Fire would be major emergency, which may affect people and property outside the installation/unit. The declaration of emergency will indicate by Siren. It will sound differently depends upon the type of emergency arises. The public in vicinity shall be take prompt action to protect themselves as instructed. The following suggestions/ actions have to be implemented immediately, in case of major fire or any emergency arise in the unit. Follows the do’s and don’ts instructions s given below:

• Shut down open flame, gas, electrical instruments etc in the emergency area. • Do not smoke. Do not light Bidi/Cigarate/Lighter etc. • Do not go near the incident and don’t allow others. • Be calm, don’t get panic. • Shut down the windows, doors etc. and seat open ground or terrace. • Rush to the safe shelter as instructed by authority • Ascertain the emergency and hear the correct instruction. • Do not approach unnecessarily to the incident for information or any inquiries. • Do not allow unnecessarily crowd nearby incident place. • Do not believe in rumors. • Follow the instructions and convey to others accordingly during an emergency. • Once emergency is clear, all clear sirens will blow and, then you can start your routine

work. • During an inquiry, give your statement on emergency as experienced by you when you are

asked by higher authority. • Co-operate, help and assist the person/authority handling the emergency and rescue

operation.





Appendix – F

Procedure for Meeting Emergency _____________________________________________________________________

ABSTRACT Abstract of procedure for meeting emergencies as prescribed under Gujarat Factories

Rules, 1963 (95)

Para 23 of Part – I – of Schedule XIX of G.F.R. 1963 (95)

1. Act, shall arrange to identify all types of possible emergencies that could occur in

the Unit. The occupier of every factory carrying out the works covered in the first schedule of the processes during the course of work or while carrying out maintenance work or repair work. The emergencies so identified shall be reviewed yearly;

2. The occupier shall formulate a detailed plan to meet all such identified

emergencies including arrangements for summoning outside help for rescue and fire fighting and arrangements for.; making available urgent medical facilities.

3. The occupier shall send the list of emergencies and the details of procedures and

plans formulated to meet the emergencies, to the Chief Inspector, of Factories. 4. The Occupier shall arrange to install distinctive and recognizable warning

arrangements to caution all persons inside the plant as well as the neighboring community, if necessary, to enable evacuation of persons and to enable the observance of emergency procedures by the persons who are assigned emergency duties. All concerned must be well informed about the warning arrangements and their meaning. The arrangements must be checked for its effectiveness every month.

5. Alternate power supply arrangements shall be made and inter-locked with the

normal power supply system so as to ensure constant supply of power to the facilities and equipment.

6. The occupier shall arrange to suspend the further process work in a place where

emergency is established and shall forthwith evacuate all persons in that area except workers who have been assigned emergency duties.

7. All the employees of the factory shall be trained about the action to be taken by

them including evacuation procedure during emergencies.





8. All emergency procedures must be rehearsed every three months and deficiencies, if any, in the achievement of the objectives shall suitably be corrected.

9. The occupier shall arrange to have ten per cent of the workers trained in the use

of First Aid, Fire-fighting appliances and in the rendering of specific First Aid measures taking into consideration the special hazards of the particular process.

10. The occupier shall furnish immediately, on request the specific chemical identity of the hazardous substance to the treating physician' when the information is needed to administer proper emergency of first-aid treatment to exposed person.





Appendix – G Rehearsal/Simulation/Mock Drill

1. SUBJECT:

Exercise / Rehearsal/Simulation on ON-SITE-EMERGENCY PLAN 2. AIM:

It is necessary that all aspect of emergency plan be tested often to ensure that they carry out their responsibility & function as specified and in particular to: Test the response from workers, emergency services, and other responsible persons. Test and evaluate the interaction of various agencies / authorities involved and ensure that all components are properly coordinated. Evaluate the available resources, equipments, its effectiveness, accuracy etc. Gain experience.

3. AUTHORITY OF EXERCISE I REHEARSAL:

The Director / Occupier is required to assume responsibilities & make decisions as seen to be legitimate.

4. TABLE DISCUSSION:

The first part of exercise is 'Table Top' exercise to test that emergency. Plan does not interrupt the day-to-day running of their concerns. This will identify the difficulties involved and practical approaches. The Scenarios will be decided and consideration should be given to live practical involving all concerned at suitable intervals, in addition to those of a theoretical nature.

5. BLUE PRINT:

A blue print is prepared as guideline to act, accordingly in a selected scenario. It is advised to give CODE NAME for identification of each emergency exercise. Further, Identification mark should be given to each emergency services, observers, inviters, connected persons etc.

6. NATURE:

Origin, Date & time, location and Duration of exercise etc. will be predecided in particular manner.

7. AFFECTED AREA:

It is the indication of the spread of disaster. This will be reflected in Blue print & give details of original place, units, surrounding identities, villages, roads, locations etc.





8. CONTROL ROOM:

A control room will be established for exercise, where communication & other activities can be performed.

9. PREPARATION STAGE:

The responsibilities & duties will be allotted to each group, services and involving all personnel. Educative meeting will be arranged to explain the role of each participant. Blue print, scenarios and arrangements will be discussed at large. Charts, maps, Posters, Banners etc. will be prepared for good performance.

10. SEQUENTIAL ACTIONS:

The whole exercise /rehearsal will be arranged in sequential actions as per on-site emergency plan. Thus actual exercise will be conducted, as rehearsal.

11. OBSERVATIONS:

The outsiders / third party will perform the role of observers and they will submit their reports on various site- observations with shortcomings & good features.

12. DE-BRIEF MEETING:

On completion of exercise, a de-brief meeting will convene to discuss the conducted exercise, give views on performance of each areas; explain difficulties, resources, limitation, planning etc. All these observations, with corrective steps will be noted & reports will be prepared.

13. PHOTOGRAPHS, VIDEO & PRESS COVERAGE:

Photography, vediography will be carried out for the work performed. The reports of such exercise will be sent to press for coverage. Leaflets and Pamphlets will be issued to the public to educate them for the emergency.

M/s. Godrej & Boyce Mfg. Co. Ltd. (PED) TOR compliance for Proposed Engineering unit along with Jetty in CRZ

area at SEZ – Dahej

Report No: GCI/V/Godrej/TOR Compliance/2010-11/May/EMS-008/R00

Green Circle, Inc. Annexure XIX 1

Annexure XIX

Odor Management Plan– Issues related to Treatment Plant Performance

The potential release of odors is a major concern of the public relative to

construction new facilities. Thus, the control of odors has become a major

consideration in the design and operation of waste water collection,

treatment, and disposal facilities, especially with respect to the public

acceptance of these facilities. The importance of the odors in the field of ETP

can view by following means,

1. The types of the odors encountered

2. The sources of odors

3. The movements of odorous gases

4. Strategies for odor control

5. Odor control methods

6. The design of odor – control facilities

Types of odors

The Principal types of odors encountered in waste water management

facilities are Ammonia (NH3), Chlorine (Cl2), Hydrogen sulfide (H2S), Sulfur

dioxide (SO2), and Methyl Amine (CH3NH2) etc. with few exceptions,

odorous compounds typically contain either sulfur or Nitrogen. The

characteristic odor of organic compounds containing sulfur is that of

decayed organic material. Gas chromatography has been used

successfully for the identification of specific compounds responsible for

odors. Unfortunately, this technique has not proved as successful in the

detection of odor because of many compounds that may be involved.





Sources of odors:

Table 19.1: Sources of odors

Location Source/Cause Odor

Potential

Waste Water –Collection System

Air release Valves

Cleanouts

Access Part (man holes

Accumulation of odorous gases

released from wastewater

High

Industrial waste water

discharges

Odorous compounds may be

discharged to waste water collection

system

Variable

Raw Wastewater

pumping station

Wet well/Septic raw wastewater , solids

and scum deposits

High

ETP facilities

Head works Release odors gases generated in the

waste water collection system due to

turbulence in hydraulic channels and

transfer basins

Screening facilities Putrescible matter removed by

screening

Preaeration Release odors gases generated in the

waste water collection system

Grit removal Organic matter removed with grit

Flow – equalization basins Basin surfaces/septic conditions due to

accumulation of scum and solids

deposits

Septage receiving and

handling facilities

Odorous compounds can be released

at septage receiving stations, especially

when septage is being transferred

Side stream returns Return flows from bio solids processing

facilities

High





Location Source/Cause Odor

Potential

Primary clarifiers Effluent weirs and troughs/turbulence

that releases odorous gases. Scum-

either floating of accumulated on weirs

and baffles/putrescible matter. Floating

sludge/septic conditions

High

/Moderate

Fixed film processes (TF or

RBCs)

Biological film due to insufficient

oxygen, high organic loading or

plugging ; turbulence causing release

of odorous material

Moderate/Hi

gh

Aeration basins Poor Mixing, Inadequate DO, solids

deposits

Secondary clarifiers Floating solid/excessive solids retention

Low

/Moderate

Sludge and bio solids facilities

Thickener, solids holding

tanks

Solids deposits, odor release by

turbulence

Aerobic digestion Incomplete Mixing

Anaerobic digestion High sulfate content, leakage of H2S

Sludge storage basins Lack of mixing, formation of scum layer

Mechanical dewatering

by belt-filter press,

recessed plate-filter

press, or Centrifuge

Cake solids; chemical addition,

ammonia release

Moderate/Hi

gh

Sludge load out facilities During transfer of bio solids from storage

to transfer facilities

Composting facilities Insufficient aeration and ventilation

High

Alkaline stabilization Reaction with lime Moderate

Sludge drying beds Drying solids/excess putrescible matter

due to insufficient stabilization

Moderate/Hi

gh





The movements of odorous gases

Odorous gases are denser than air so it tends to transfer at the point of

generation (e.g. sludge thickening facilities, sludge storage lagoons). In some

cases odors have been detected at distances of up to 25 km from their

source.

Strategies for odor management

1. Control of odor causing wastewaters discharged to the collection

system and treatment plant that creates odor problems

2. Control of odors generated in the waste water collection system

3. Control of odors generated in the waste water treatment facilities

4. Installation of odor containment and treatment facilities

5. Application of chemicals to the liquid phase

6. Use of odor masking and neutralizing agents

7. Use of gas-phase turbulence inducing structures and facilities

8. Establishment of buffer zones





Odor – Treatment Methods

Fig 19.1: Odor – Treatment Methods

Typical Odor containment facilities at ETP

1. covered primary sedimentation tank

2. Covered Trickling Filter

3. Covered Sludge tank

4. Sand bed - sludge

5. Sludge removal facility

Physical Methods Chemical Methods Biological Methods

Adsorption on activated carbon

Adsorption on Sand, Soil or compost bed

Dilution with odor – free air

Masking Agent

Oxygen Injection

Scrubbing Tower

Turbulence Inducing Facilities

Odor Treatment Methods

Chemical Oxidation

Chemical Precipitation

Neutralizing Agent

Scrubbing with various alkalies

Thermal Oxidation

Activated sludge aeration tanks

Bio trickling filter

Compost filters

Sand and soil filters

Trickling filter




Green Circle, Inc. Annexure XX 1

Annexure XX

Energy Efficient measures

• Total street lighting load-25.6 KW Out of which 2.5 KW is replenished through Solar panels

• Hot water for canteen will be provided through solar water heaters • Furnace & chiller will be run through Variable Frequency Drive(VFD) • Energy efficient compressor will be installed • Energy efficient & Eco friendly lighting fixtures in office Building. • Energy efficient Bus Bar system for plant power distribution




Green Circle, Inc. Annexure XXI 1

Annexure XXI

Checklist in the form of Do’s & Don’ts

Do’s for Preventive maintenance

Do follow SOP for all the operations.

Do ensure that methods of access for work at height have been

properly assessed, and the safest method reasonably practicable has

been chosen

Do ensure that all materials are secure before lifting/craning above a

safety net

Do ensure that a handover certificate is completed prior to allowing

works above a safety net

DO provide and use proper rubbish bins, preferably those made of

non-combustible material like metal.

DO dispose of unwanted items at regular intervals to ensure good

housekeeping at your workplace.

DO keep corridors, walkways and passageways free of obstructions.

DO discuss project and procedures with station manager/operator

before performing service on dispenser.

DO follow lockout/tag out procedures.

DO position service vehicle to protect work area; use safety cones and

barricades to isolate your work area.

DO wear appropriate safety attire, including brightly colored vests

made of cotton, goggles and gloves.

DO properly dispose of absorbent materials and filters in an approved

container.

DO watch for sharp edges.

DO remove both doors and store in a safe place when working on

hydraulic components to ensure that the vapors can escape from

dispenser cabinet. Evacuate vapors from immediate work area if

necessary.





DO close impact valve when working on hydraulic components.

DO use antistatic grounding techniques when servicing electronic

dispensing equipment.

DO follow manufacturer’s service and trouble shooting guidelines.

DO reopen impact valve when work is complete.

DO wear proper safety equipment.

DO know where you can get first aid.

DO keep your job site uncluttered.

DO communicate with others about safety on job site.

DO look over your job site for hazards.

DO maintain your tools for safety and effectiveness.

DO wear your seat belt at all times.

DO report all unsafe conditions to your supervisor immediately.

DO review MSDS sheets before using hazardous materials.

DO barricade work site.

DO use appropriate covers and/or barricades over open holes and

trenches.

DO be aware of what is going on around you.

DO obey all speed limits and traffic laws.

Do inspect and clean machinery and tools regularly.

Don’ts for Preventive maintenance:

DON’T assume station manager/operator knows what you are doing.

DON’T smoke around dispenser.

DON’T wear jewelry or loose clothing while servicing electrical

components and moving parts.

DON’T perform service work on a remote dispensing pump while

dispensers of the same product are operating unless the impact valve

is closed and/or electrical power to the entire system is shut down.





DON’T use electric/spark producing tools when vapors could be

present.

DON’T allow a unit to be placed back into operation with a

“temporary fix.” Repair the unit completely.

DON’T use plastic containers to transport fuel between dispenser and

tank.

DON’T leave fuel in the sumps.

DON’T tolerate horseplay at any job site.

DON’T operate equipment under the influence of controlled

substances.

DON’T attempt to use power tools before receiving proper training.

DON’T allow safety devices to remain inoperative or in disrepair.

DON’T wear loose clothing or jewelry that could get caught in

machinery.

DON’T use substances from unmarked containers.

DON’T allow visitors to enter your work area without taking the same

safety precautions as workers.

DON’T leave open holes or trenches unattended.

DO NOT use cardboard boxes, wooden crates or other receptacles

that are made of combustible material as makeshift rubbish bins at

your workplace.

DO NOT accumulate unwanted items at your workplace.

DO NOT use corridors, walkways, or passageways that form parts of the

emergency escape route at your workplace for storage.

DO NOT accumulate unwanted items at your workplace.

DO NOT use corridors, walkways, or passageways that form parts of the

emergency escape route at your workplace for storage.

DO NOT paint over smoke / heat detectors and sprinkler heads or

hang objects on them.

DO NOT smoke in "No Smoking" areas.

DO NOT leave heavy machinery operating or running unattended.





DO NOT leave electrical appliances or equipment continued to be

energized when they are not in use, especially after office / working

hours.

DO NOT put any liquid or thing that is flammable or combustible near

an electrical switchboard or an enclosure containing electrical

components.

Do’s & don’ts for Strengthening HSE:

DO’s: Do aware the employees about the HSE policy.

Do keep HSE manual or some instruction book let available for all

employees.

Do follow work permit system.

Do keep permit-to-work system fully documented.

Do specify the jobs & authorized person in the work permit system.

Do make staff and contractors fully understand the importance of the

permit-to-work system and trained.

Do fill inspection check list regularly.

Do keep floors clean and clear of waste.

Do prepare SOP for all the processes & operations.

Do follow the SOP for each operation.

Do keep available MSDS for all chemicals.

Do all storage areas clearly marked.

All combustible and flammable material must be present only in the

quantities needed for the job and kept in safety cans during use. Oily

or greasy rags should be placed in a metal container and disposed of

regularly.

Do keep workplaces adequately lighted.

Do keep light fixtures clean.

All the areas to be clearly marked with signage.





DO wear proper personal protective equipment, including safety

glasses, safety shoes with slip-resistant soles, a bump cap for your head,

gloves where there is hot or sharp material, ear protection for noise,

and respiratory protection for hazardous dusts, mists, vapors or fumes.

Do ensure that the PPE is used for which it is designed.

Do give proper training to all employees for HSE awareness.

Do celebrate the programs like Safety day, Environment day to bring

the awareness among the employees.

Do carry out the cultural programs to motivate the workers.

Do report all the unsafe accidents & Incidents to the HSE dept.

Don’ts for strengthening HSE: Don’t misuse the Personal Protective Equipments.

Don’t allow the workers without PPE for the Hazardous processes.

Don’t store waste in hallways or in other public areas

Don’t use aisles and stairways as storage areas.

Don’t allow materials to build up on floors.

Don’t block emergency exits, fire equipment or first aid stations with

stored materials.

Don’t store compressed gases near heat sources.

Don’t use aisles and stairways as storage areas.

Don’t allow materials to build up on floors.

Don’t block emergency exits, fire equipment or first aid stations with

stored materials.

Don’t store the PPE at isolated place.

Don’t keep the PPE box lock.

Don’t allow the unauthorized person near machinery.

Don’t allow unauthorized entry near hazardous processes.

Don’t break the rules of HSE system.

Don’t ignore the near miss or unsafe actions or unsafe conditions.

FOR MANUFACTURING & UTILITY:





DO mark underground electric lines.

DO turn power off while working on electrical wiring.

DO ensure breakers are off before servicing.

DO have your tester and its attachments checked regularly.

DO test the circuit with a voltage tester before beginning work.

DO lockout the breaker for the system being used.

DO lockout/tag out the circuit.

DO follow manufacturer’s trouble shooting recommendations.

DO maintain tools in good condition.

DO be aware of vapors and other hazardous conditions.

DO know the associated hazardous location classifications.

DO use the proper fire extinguisher in case of electrical fire.

DO use the correct size wire for the run length and service

requirements.

DO verify that all work meets applicable electrical codes.

DO ensure all equipment is properly grounded.

DO verify that seal-offs are properly installed and poured.

DO assume all wiring is “hot.”

DO place barricades and caution tape around work area.

DO check jobs periodically that have been postponed to ensure

that barricades are still on site and erected.

DO escort visitors around job site.

DO post signs detailing dangers present, such as gasoline vapors,

flammable liquids, excavation work, etc.

DO have visitors leave site when vapor freeing tanks or when

hazardous conditions exist.

DO use fencing or other barriers to form a safe walk-through

corridor when performing construction work at an operating facility.

DO review scope of work, “as-built drawings,” safety concerns and

visitor control with customer.

Make sure personal protective equipment is required.

DO keep a log of visitors.





DO communicate safety and coordinate work with subcontractors.

DO use barricade fence and lights to identify hazardous areas.

DO assign a person to secure the site and check regulatory

compliance.

DO use ‘Danger’ — ‘Do not enter’ signs around the work area.

DO advise the site manager to warn employees about the dangers

of entering work area.

DO park visitors’ vehicles away from excavation and operating

machinery.

DO designate a smoking area, if necessary.

DO train all employees on the correct use of fire extinguishers.

DO check and maintain extinguishers properly.

DO post the telephone number of your local fire department and

burn center.

DO have regular fire drills for all personnel.

DO post fire exits and escape routes.

DO check location of fire extinguishers and fire exits when arriving

on a new job site.

DO know and review proper first aid for fire accidents.

DO ensure the detectors and sprinkler heads are not painted over

or obstructed with objects.

DO store flammable liquids in proper, unbreakable containers and

keep flammable substances in well-ventilated places and away

from any ignition source.

DO ensure ventilation openings are not sealed up and have

defective ventilation fan repaired quickly.

DO make available battery operated portable torches as a back

up.

DO observe "No Smoking" rule strictly in your premises.

DO have the equipment / machinery cleaned and serviced

regularly.





DO ensure that machines that are in use are tended at all times by

qualified operators

DO switch off at the mains all electrical appliances or equipment

that are not in use, especially after office / working hours.

DO ensure that the electrical switchboards and the enclosures of

electrical components are kept clear of flammable or combustible

substances and liquids.

DO dispose of oil-soaked rags in self-closing metal bins.

DO ensure the wiring is in good condition and for any defect, get a

licensed electrician to check and rectify it immediately.

DO engage licensed electricians for all electrical fitting works.

DO keep staircases free of obstructions at all times.

DO ensure fire doors are kept closed but unlocked at all times.

DO keep the hose reel cabinets and fire extinguishers free from any

obstruction.

DON’TS

DON’T work on any equipment or components unless the power is off.

DON’T assume anything.

DON’T rely on others to ensure the power is off. Check it yourself.

DON’T trust anyone else.

DON’T let wires hang.

DON’T use metal ladders near the electrical source.

DON’T use non-insulated tools for cutting wire.

DON’T lift tools by the electrical cord.

DON’T pull too many wires through a conduit.

DON’T turn the power on until work is completed and the area is safe.

DON’T assume visitors are aware of hazards at job site.

DON’T allow unauthorized visitors in the area.

DON’T allow visitors into barricaded areas unless they are essential to

the work being performed.





DON’T allow visitors to be near moving machinery, or operate any

equipment on site.

DON’T allow smoking or flame- or spark producing devices in

hazardous work areas.

DON’T depart job site without first making sure the site is secure.

DON’T continue to work when unauthorized visitors have entered the

area.

DON’T start work until area is secure and the owner has been advised

of the work plan.

DON’T allow visitors to enter work area without safety equipments.

DON’T allow subcontractors to enter site without proper safety training.

DON’T allow children to play around dirt piles or excavations.

DON’T leave visitors unattended.

DON’T leave site open and unmanned.

DON’T return an extinguisher after use without recharging it.

DON’T leave trash or flammable materials in workplace.

DON’T smoke in any potentially hazardous area.

DON’T store combustible materials near an open flame or heat.

DON’T obstruct path to a fire extinguisher or hydrant.

M/s. Godrej & Boyce Mfg. Co. Ltd. (PED) TOR compliance for Proposed Engineering unit along with Jetty in CRZ area

at SEZ – Dahej


Green Circle, Inc. Annexure XXII 1

Annexure XXII

Traffic Survey

The traffic survey, to ascertain the traffic density in the study area was

conducted on the four lane road from Dahej to Jageshwar. The hourly counts

were carried out for the different type/category of vehicles. The variations in the

traffic flow at all the places along the number of vehicles are presented in the

following table.

UP Direction – From Dahej to Jageshwar

DOWN Direction – From Jageshwar to Dahej

Table 22.1: Traffic Survey

UP Direction DOWN Direction

SL.

No. Vehicle Type

During Lean

Hrs

(Nos./hr)

During Peak

Hrs

(Nos./hr)

During

Lean Hrs

(Nos./hr)

During Peak

Hrs

(Nos./hr)

1. Two Wheelers 12 25 10 19

2. Three Wheelers 18 22 22 31

3. Cars 4 15 5 12

4. Buses/Mini Buses 1 3 1 2

5. Trucks/ Lorries 28 36 14 41

6. Heavy vehicles 21 27 27 31

7. Slow moving vehicles 15 22 18 26

TOTAL 99 150 97 162

Note: PCU’s as per IRC-106:1990

Peak Hrs: After 8 hrs & 5 to 9 hrs in the evening

Lean Hrs: Before 8 hrs & After 9 hrs in the evening (also afternoon hrs 1 to 5 hrs)


at SEZ – Dahej



Fig 22.1: Trafic Flow – Dahej to Jageshwar

Traffic flow chart : Jageshwar to Dahej

Traffic Flow - Dahej to Jageshwar

05

10152025303540

Lean Hrs Peak Hrs

Vehi

cles

/Hr.

Two Wheelers Three Wheelers CarsBuses/Mini Buses Trucks/ Lorries Heavy vehicles

Slow moving vehicles


at SEZ – Dahej



Table 22.2: Traffic Survey

UP Direction DOWN Direction

SL.

No. Vehicle Type

No. of

Vehicles in

PCU’s -

Lean Hrs

No. of

Vehicles in

PCU’s -

Peak Hrs

No. of

Vehicles

in PCU’s -

Lean Hrs

No. of

Vehicles in

PCU’s - Peak

Hrs

1. Two Wheelers 9 19 8 9

2. Three Wheelers 36 44 44 62

3. Cars 4 15 5 12

4. Buses/Mini Buses 7 7 2 4

5. Trucks/ Lorries 104 133 114 152

6. Heavy vehicles 105 135 135 155

7. Slow moving vehicles 8 11 9 13

TOTAL 273 364 317 407


at SEZ – Dahej



Existing Traffic Scenario & Level of Services

All types of vehicles move on the road. As per IRC, subject road is a four lane

road of capacity 4000 PCU’s/hr.

Up Direction

Total Volume during Peak Hours = 364

Existing Volume/Capacity ratio = 364 / 4000 = 0.09

The level of service is “A” that is Excellent.

Down Direction

Total Volume during Peak Hours = 407

Existing Volume/Capacity ratio = 407 / 4000 = 0.10

The level of service is “A” that is Excellent.

Level of Service:

Table 22.3: Level of Service

SL.

No.

Existing

Volume/Capacity

Ratio

Level of Services

1 0.0 to 0.2 “A” (Excellent)

2 0.2 to 0.4 “B”(Very Good)

3 0.4 to 0.6 “C” (Good)

4 0.6 to 0.8 “D” (Fair)

5 0.8 to 1.0 “E” (Poor)


at SEZ – Dahej



Modified Traffic Scenario & LOS (After completion of the project):

367 vehicles (in PCU’s) assume to enter during 3 hrs and exit during 3 hrs

Additional volume in PCU’s/hr will be 367/3 = 122 PCU’s/hr during peak hours.

Up Direction

Total volume during peak hours (V) = 364 + 122 = 486

Modified Existing Volume/Capacity ratio (V/C) = 486/4000 = 0.123

The level of service will be “B” that is Very Good after construction.

Down Direction

Total volume during peak hours (V) = 407 + 122 = 529

Modified Existing Volume/Capacity ratio (V/C) = 529/4000 = 0.132

The level of service will be “A” that is Excellent after construction.

Parking Statement

Table 22.4: Parking Statement

No. Type of Vehicles No. of Parking required No. of Parking

Provided

1 Two wheeler 296 296

2 Car 94 94

3 Truck 23 23




Green Circle, Inc. Annexure XXIII 1

Annexure XXIII

The main building materials used for the project are cement, aggregates, steel,

fly ash blocks, aluminum, glass, iron and china mosaic. These materials are

manufactured integrating the recycled component to the allowable extent as

mentioned here below:

• Steel : 20-25%

• Cement : 25-30%

• Fly-ash Blocks : 30-40%

• Glass : 10-15%

• Ceramic tiles : 20-30%

• MDF Wood : 15%

• Roofing Tiles : 25-30%

Copper slag (70%) and Fly-ash (30%) mix will be used as the filling material for

the road and flooring works.

Apart from the materials mentioned above other preferred materials to be used

within the scope of this project shall have recycled content. The prospective

users of the area will be emphasized to integrate recycle materials in their interior

design.

___________________________________________________________________________ M/S Godrej & Boyce Page 1 of 5 May-10

FIRE PROTECTION SYSTEM FOR M/S GODREJ & BOYCE MANUFACTURING CO.LTD.

DAHEJ-GUJARAT

DESIGN PHILOSOPHY FOR FIRE PROTECTION SYSTEM

INDEX

1 INTRODUCTION………………………………………………………2

1.1 Codes and Standards………………………………………………………2 1.2 Protection against Freezing……………………………………………… .2 1.3 Design Conditions ………………………………………………………….2

2 HAZARD CLASSIFICATION …………………………………………………...3

2.1 Total Hydrant Load……………… ………………………………………....3 2.2 Hazard and Pumping Requirement as per Standards ………………….3 2.3 Reservoir …………………………………………………………………….3

3 BASIC SYSTEMS DESIGN & OPERATION ……………………………………4

3.1 External Fire Hydrant System………………………………………………4 3.2 Hydrant system Operation ………………………………………………….4

3.3 Sprinkler System Operation ………………………………………………..4 3.4 Fire Extinguisher …………………………………………………………….4

3.4.1 Reference Standards …………………………………………………...5 3.4.2 System Description ……………………………………………………..5

DESIGN PHILOSOPHY ___________________________________________________________________________


1 INTRODUCTION This specification covers the design basis and the design requirements of fire fighting system for M/S GODREJ & BOYCE MANUFACTURING CO.LTD. DAHEJ-GUJARAT (referred to as “Plant” hereafter). The term, Fire Fighting System, used in this specification are measures to be taken to minimize, control and extinguish fires already burning, for the purpose of life safety and properly protection. The fire fighting system is provided for the purpose of fire extinguishing, fire intensity control, and /or fire exposure protection. The fire protection system is being designed to meet the largest fire water demand in the plant. The system is proposed to have common above ground pressurized mains for sprinkler and hydrant system.

Codes and Standards Local and government requirements and international regulation like NBC-2005 and corresponding IS codes shall be applied for the fire fighting system. Equipment, material and devices used for the fire fighting system shall be designed, manufactured, tested and inspected in accordance with the requirements of Indian Standards (IS) for Indian manufacture’s practice may be applied for design and manufacturing of equipment unless specified in the codes or standards of manufacturing country, this specification or IS/NFPA. The Specifications shall comply with following standards : National Building Code – 2005 Indian Standards (IS) – 3844 – Fire Fighting system Indian Standards (IS) – 2190 – Portable Fire Extinguishers Indian Standards (IS) – 15105- IS Standard for Sprinkler Systems 1.2 Protection against Freezing The firewater piping shall be designed for non-freezing condition as there are no freezing conditions at site. 1.3 Design Condition Design Pressure Design pressure of the equipment and materials used in the fire water network and the water fire fighting system shall not be less than the sum of maximum suction pressure and shut off pressure of the fire water pump. Design temperature The design temperature for the equipment and material shall be; 55 oC for those subject to direct sun 45 oC for those not subject to direct sun 2.1.1 Total Hydrant Load

Table 1.

Description Qty Equivalent hydrants

Single hydrant SH 31 31 Fire Escape Hydrants FEH 02 02 Monitor WM 02 06 Total Load 39



Legend: SH - Single Headed Hydrant WM - Water Monitor 2.2 Hazard and Pumping Requirement as per Standards SPRINKLER SYSTEM: For Admin Area only and any other Future expansion area.

As per NBC/IS CLAUSE Hazard Hazard Moderate Table 23 Storage Capacity

Storage Capacity

NR Table 23 (Clauses 4.18.2,6.1.2,6.2.3,6.3.2,6.4.3,6.5.2,6.5.2.1,6.5.2.2,6.5.2.3,6.5.2.4,6.5.2.5,6.6.2,6.7.2,6.7.2,6.8.2 and 6.9.2)

Pump Capacity Pump Capacity

137 m3/hr @ 70 MWC

All Above and as per note 20

HYDRANT SYSTEM: Coutryard along the perimeter.

As per NBC/IS Hazard Hazard Low Storage Capacity Storage

Capacity 100000 Liters Table 1 (Clauses

4.1.1,4.1.2,5.1.1,5.2.1 ,5.3.1,5.4.1 AND 7.2) Pump Capacity Pump

Capacity 137 m3/hr @ 70 MWC

The fire water pump system shall be provided for the plant as follows: Pumping Capacity for Hydrant : 137 Cubic Mtr @ 70 MWC Pumping Capacity for Sprinkler : 137 Cubic Mtr @ 70 MWC Standby Diesel Engine Pump : 137 Cubic Mtr @ 70 MWC Common Jockey Pump set : 10.8 Cubic Mtr @ 70 MWC Tapping for Spray System for LPG Bullets shall be provided from Hydrant Ring Main. Design of Spray system is not part of this scope. 2.3 Reservoir 2.3.1 Fire Water Source Raw water shall be used as fire water. Fire water shall be stored in the two Fire water tanks with a minimum effective storage capacity of 100 m3 in 2 compartments. 3 BASIC SYSTEMS DESIGN & OPERATION The entire plant is provided with the following type of fire protection systems.

• External Fire Hydrant system • Internal Hose Reel Connection • Pumping system • Fire extinguishers



3.1 External Fire Hydrant System The hydrants are spaced as per Light hazard at 45 m spacing. The entire plant is being protected with hydrants and the distribution of the hydrants is as per Table 1. The quantity of hydrants is tentative and the exact quantity shall be worked out during details engineering by the fire fighting vendor as per NBC/IS guidelines. The vetting of the entire fire fighting system from NBC/IS (Local CFO) accredited professional agency and getting approval shall be the responsibility of the fire fighting vendor. The hydrant system is designed to protect the buildings and equipments by providing hydrants around the area as mentioned above. The system mains run above ground and shall be provided with required number of tees with blind flanged joints to facilitate future expansion. The installation is to provide with adequate number of isolation valves at suitable locations for the purpose of isolation during the event of fire or during emergencies. 3.2 Hydrant system Operation Maximum operating pressure required at the remotest point as per NBC/IS – 3.5 kg/cm2 All above pump sets are to be installed in the Fire Water pump house. The fire water pump system shall be operated as follows: The jockey pumps shall be activated/ de-activated through a pressure switch mounted on the pumps discharge header so as to maintain the network pressure around 7.0 kg/cm2. At normal static condition of the network, the charged pressure of 7.0kg/cm2 shall be maintained. When pressure falls below 7.0 kg/ cm2 due to minor leakage any where in the network and it reaches to 6.0 kg/ cm2g, the jockey pump automatically will come in to operation and thus maintains the network pressure of 7.0 kg/ cm2 and stops automatically. Jockey pumps shall be inter-linked with main pumps, so that in the event of starting of main pump, jockey pump shall stop automatically, if jockey pump is running. In the event of more fire water demand at required pressure the jockey pump can not fulfill, the main electric pumps fire water pumps shall kick-in automatically in sequence at 5.0 kg/ cm2 and incase Electric pump fails to start and the pressure drops below 4.0 kg/cm2 the Diesel Engine starts automatically. The fire water pump suction shall be sized such that with pump operating at 150% of rated capacity, the velocity in the suction pipe does not exceed 4.50 m/s. All pumps shall be preferably centrifugal type pumps. The fire water pumps shall have relatively flat characteristic curves furnishing not less than 150% of the rated capacity at not less than 65% of rated head. The fire water pump shut-off head shall not exceed 120% of the rated head. 3.3 Sprinkler System Operation Maximum operating pressure required at the remotest point as per NBC/IS – 0.5 kg/cm2 A sprinkler has two functions to perform. It must first detect a fire and must then provide an adequate distribution of water to control / extinguish it. The classic use of the sprinkler is in the hot gas layer which forms beneath the ceiling of an enclosure in which a fire is developing. The sprinkler operate at pre-determined temperatures to discharge water over the affected part of the area below, the flow of water through the alarm valve initiating a fire alarm. The operating temperature is generally selected to suit ambient temperature conditions. only sprinkler in the vicinity of the fire.i.e those which become sufficiently heated operated. The hydrant mains are hydraulically designed & checked so that when maximum sprinklers demand is discharged at one end and simultaneously the assumed hose stream is discharged at the other farthest / hydraulically remote point in the most vulnerable area reroute, a minimum pressure of 5.2 kg/cm2 is available at the former points and the velocity is generally restricted to 4.5 m/sec and in any case does exceed 5m/sec. The sprinkler system is considered in Warehouse area only.



3.4 FIRE EXTINGUISHER Portable fire extinguisher shall be provided for the Plant as a first aid safety measure. The objective is to protect the entire premises with suitable Fire Extinguishers approved and certified for particular application. The extinguishers shall form as a first aid action against small and incipient fire so as to extinguishing of the fire even before it develops into a major hazard. 3.3.1. REFERENCE STANDARD The requirement of the extinguishers shall meet the IS 2190 guidelines. 3.3.2. SYSTEM DESCRIPTION The Extinguishers proposed is to protect the all equipments, areas with relevant type of suitable Fire Extinguishers. Carbon-di-oxide Extinguishers are proposed as it is an inert gas with no residue, is electrically non-conductive and ideal for all electronic and electric protection application. ABC type Extinguishers are proposed for Type ‘A’ class fire, which is stored, pressured type and used to protect against fires causing from tables, furniture’s, curtains etc. Water/ Foam Type Extinguishers are proposed for protect against fire causing from liquid (kitchen oil) fires caused in pantry areas. Portable fire extinguishers of water (Gas pressure) type of 9 liters capacity, Carbon-di-oxide of 4.5 kg and ABC Type 5 Kg capacity shall be provided as first aid fire extinguishing appliances. The appliances shall be so distributed over the entire floor area so that a person has to travel not more than 25 m to reach the nearest appliance. These shall be placed or hanged on wall in a group on several suitable places. The number of extinguishers shall be calculated as per IS 2190 ------------------------------------ END OF DOCUMENT ------------------------------




Green Circle, Inc. Annexure XXV

Annexure XXV

Details of the debris management plan along with the use/disposal of

excavated soil during construction phase and top soil conservation plan.

• Proper barricading and enclosures (minimum 20 ft) will be provided at

the construction site to avoid escape of fugitive dust into atmosphere

as well as its deposition and spreading on streets / footpaths / drains

etc.

• Debris / construction waste generated will be stored in proper

container before it is transported.

• Debris or other construction material required during the construction

will be stored within working area and not on the roads.

• The vehicles deployed shall be properly covered with tarpaulin or other

suitable materials firmly fixed on the vehicles to ensure that neither any

dust escapes nor any debris is allowed to fall on the roads during

transportation.

• It will be ensured that arrangements to clean / wash vehicles carting

dust / debris before they move on the streets. Water will be sprinkled

on the earth filled vehicles to prevent dust while transporting.

• Noise levels during construction will be restricted within permissible

limits.

• The excavated earth, debris, construction waste generated will be

absorbed with in the site or transported to places within our own site.

• Excavated earth / debris / construction waste will not be dumped into

any dumping site.

• Surrounding vicinity of the site will be maintained aesthetically abutting

the road and utilization of debris within the site will not cause any

obstruction or stagnation.

• No building material used, unused, waste, all type of debris or its

residues will be scattered on portions of footpath / roads outside the

plot.




Green Circle, Inc. Annexure XXVI 1

Annexure XXVI

Details of the basic amenities and welfare facilities to be provided to the

construction workers to ensure that they do not damage the existing

environment.

• Adequate on-site sanitation facilities will be provided for the construction

laborers so as to avoid defecation in and around project site.

• Few numbers of toilets comprising latrine, bath and hand wash facilities

will be constructed in the labour camp.

• Septic tank will also be constructed for collection and treatment of

domestic wastewater generated from the construction laborers use.

• Adequate water supply for drinking and other domestic uses will also be

provided during the construction stage of the project.

• There will not be any unsanitary conditions created around the project site

due to deployment of construction labour during the construction stage

of the project.




Green Circle, Inc. Annexure XXVIII 1

Annexure XXVIII

Details of Corporate Social Responsibilities.

• We are planning to create residential, medical, educational and

recreational facilities for our employees.

• We have already contributed Rs. 12, 00, 000/- to PCPIR Welfare Society for

rehabilitation of affected villagers due to SEZ and an equal amount to

Dahej SEZ Limited towards the cess amount for the welfare of Construction

Workers and their family members.

• We will be contributing for relocation of temple situated in our plot Z-90 at

SEZ Dahej.

• For larger community we will be having Rural Development Programmes

for upliftment of people in the form of de-addiction, self-help, vocational

training and guidance etc.

Ref, NO: PEWPROJfEc104 m: 11mm10

The Secretary, State ~eve-4 €qmi Apprakul Cclrnrnltbe- Wjgrcd. Fomt & E n v k ~ n t Departmmt. B W no. 1 4/8, Sachiv~~ya,

-383 010 -- &&: mvitomntat Ciearawe for p r m ptqect To devebp an -€ngitw&ng m# W FaMcafkm of Procesf Ecp@mm% dm.8 with Jew h CRZ area at Pkrt no. E-90. SEf - Dahej, V i w - LWCBTQ, Tdvka V-, DlstrScl - EUl-h, GujaC~?. - - mg TOR potnts f ~ e b & frm SfAC wfth Ref. NO- : BA -10-200P-567-E dated 226 Wuw. 2010

lhis is in r g f e r w of TOR pol& mcePIed SEAC dated r2"6 Feb, 2010 that t%bEc comdWon process 3s mqWed formid P@ect.

Wh&easC a5 per the Mhbw of Envkorwrrenf and Fwests, Mew Dew -.8A Nofrficdon Med li 4@ September. 2006. ttw Proposed Project site is a pc#t of EtDf: md x, Pubdie c o m n process k not required as pes 7[if stage I fb) On P a g e nM.

Kbd& msiderfbe same for above said prujw3 Qakd exempt us &am public hearing.

%Godre] L byce.MlgSo. Lid

Documents

ON SITE EMERGENCY PLAN REPORT - Gujarat Pollution …gpcb.gov.in/pdf/Godrej_Boyce_Mfg_Annexure_Part_III.pdf · ON SITE EMERGENCY PLAN REPORT ... Report No: GCCIPL/V/GODREJ/OEP/2010-11/MAY/RMS-043/R00