RISK ASSESSMENT REPORT DISASTER MANAGEMENT PLANgpcb.gov.in/images/pdf/FTPL_Risk_Ass_and_Disaster_Manag_Plan.pdf · RISK ASSESSMENT REPORT & DISASTER MANAGEMENT PLAN For FAIRDEAL TEXTILE

RISK ASSESSMENT REPORT

&

DISASTER MANAGEMENT PLAN

For

FAIRDEAL TEXTILE PARK LTD.

MAHUVEJ-SURAT. (GUJARAT)

Prepared By:

SHEF SQUARE

October – 2010

Shop No: 3, 2

nd floor, Meghna Complex, Above Surat Mercantile Co-Op. Bank, Beside Bharat Petrol Pump, Udhna Magdalla Road,

SURAT - 395017, Gujarat. Email: [email protected], [email protected]

mailto:[email protected]

SECTION - I

RISK ASSESSMENT REPORT

for

FAIRDEAL TEXTILE PARK PVT. LTD.

MAHUVEJ - SURAT (GUJARAT)

October- 2010

INDEX

Sr. No.

Description Page No.

1 Executive Summary 4

2 Introduction 9

3 Description of FTPL 11

4 Project overview 12

5 Risk Management 13

6 Various type of Units 15

7 POY 16

8 FDY 17

9 Texturising 19

10 Twisting 20

11 Sizing 21

12 Weaving 23

13 Risk due to various activities 26

14 Methodology 38

15 Risk assessment of CETP 39

16 Risk assessment for Textured Yarn 40

17 Risk assessment for Twisting 43

18 Risk assessment for Sizing 46

19 Risk assessment for Weaving 48

20 Risk assessment of Raw material 49

21 Risk assessment for Beamer & Stocker Machine

50

22 Risk assessment Five step method 51

23 Acceptability of risk and recommended actions

54

24 Occupational health impact assessments 55

25 Work Zone ambient air quality monitoring 60

1. EXECUTIVE SUMMARY

Fairdeal Textile Park Private Ltd. retained the services of M/s SHEF SQUARE for carrying out Risk Assessment Studies for their Village Mahuvej, Taluka Mangrol, Surat, Gujarat..

Experts from M/s SHEF SQUARE visited the site for inspection of facilities to be erected and commissioned at site as per site plan and the environs and for collection of relevant information about the installation and the operations which will be carried out in the plant. They also held detailed discussions on various aspects which will be incorporated in HSE management system, procedures(SOP) and it implementation, Emergency management plan, Emergency handling facilities, Emergency organization and action plan, with the officers of the company.

Noteworthy Effort:-

1. Very good housekeeping found throughout the plant.

2. Each fire extinguisher has marking at area.

3. Extensive use of hydraulic trolleys, which avoided manual handling at large.

In this plant in process chemical used is neither hazardous nor flammable. However oils used in process are flammable & suitable fire protection should be provided

Based on the data furnished and the study of the installation, certain hazards have been identified and their consequences are modeled.

The study indicates that possible hazards associated with the plant are confined to (a) Handling of raw material (Manually & by hydraulic trolley) (b) working on mobile platform. (c) Rotating parts of equipment (d) Noise (e) Fire. Various hazard scenarios have been identified for Risk Assessment and the consequences modeled. The results of the analysis have been summarized in the table appended.

It will be observed from the summary that the consequences of hazards associated with any possible spills / leaks would be of a relatively small in nature and would be taken care of with the proposed emergency facilities and the manpower deployed at the plant.

Conclusion are based on the 1) Risk Analysis study and information regarding the layout plan and safety systems. 2) Discussions with company officials

GENERAL OBSERVATION:-

Usage of suitable PPE‟s should be improved.

Exit route marking & caution sign should be displayed at strategic location.

Interlocking of hoist door (Elevator) should be made that it cannot be open without platform on floor.

Evacuation plan should be made with marking of Assembly point.

Competency matrix should be maintained for fork lift operator, Electrician & Boiler operator.

Provision of first aid box at various location.

General Layout:-

Construction of the storage and utility blocks well away from the process block. Minimum 8m road should be laid in between the blocks and all over the plant.

Man and material entry shall be different. And the entire area should be compounded.

Maintaining the Fuel (Liquid /Gas/lignite/coal) storages well away from the process block or keeping them in a separate compound. The fuel storage shall be underground type

otherwise in the case of above ground storages proper dyke with free of holes and drain system to drain the rain or other water accumulation should be provided.

Separation of blow room from preparatory area by fire wall with Double Fire door arrangement in the wall openings/entrances.

Building specifications:-

Construction of buildings as per the following regulations

1. Code of practice of fire safety of Industrial buildings – Cotton Textile mills – IS 3079 – 1990.

2. Code of practice of fire safety of Industrial buildings – General storage & Warehouse including Cold storages – IS 3594– 1991.

3. TAC Guidelines related to Buildings

Supporting the roof on walls, without any intermediate supports/columns specifically avoiding steel or other such material based columns.

Usage of fire retardant paints in the roof (if required) and usage of non combustible materials for false ceiling and other roof linings.

Restrict the door size of the godown to 6.25 sq. m and the doors should be constructed by strong materials.

Provision of emergency approach windows of 6mm thick wired glass on steel frame work.

Peep holes provision in windows and doors to monitor the inside condition during locked condition.

Separated / Block wise operation (Segregation of godowns, Process and utility).

Avoiding of utilities such as Boilers/Power plants including evacuation grid etc. in the Process unit compounds.

Segregating the singeing machine from other process area by fire wall and fire door or locating the same in the separate block with explosion venting or light roof arrangement.

Providing of roof vents Size not less than 1.3 sq. m and minimum 1 sq. m of area per 50 Sq. m of floor area.

Maintaining the godown floor in such a way that the level will be above the door sil level with the slope towards the door with the gradient of 1 in 100.

Provision of ventilators with the following specifications –

Location height should not be less than 3m from floor level

Openings should not exceed 1.2m X 0.3 m – at least one ventilator in one bay.

Non closable type should be protected either by expanded metal or wire netting having apertures of 12.5 mm size.

Electrical installations:-

Compliance of the following regulations on electrical installations

1. Code of practice of fire safety of Industrial buildings – Cotton Textile mills – IS 3079 –

1990.

2. Code of practice for electrical wiring installations – IS 732 – 1989.

3. Code of practice of fire safety of buildings (General) – IS 1646 – 1982.

4. TAC Guidelines – Electrical installations

Non electrification of raw material and finished goods godowns.

All the motors used in plant blocks should be shrouded opening motors.

Storage practices:-

Avoiding open storage. And avoiding congestion in storage.

Avoiding of open storage below the over head electric lines.

Storing of polyester yarn pallets and other raw materials in the elevated floors and above

the wooden /metal slippers/pallets.

Providing of aisle spaces, and spacious storage practice to facilitate fire fighting

approach. And non storage of materials up to the roof.

Providing min 3.5M roadway around the godowns to facilitate the fire tender approach.

Provision of isolators external to / out side of the godown.

Avoiding of loose wiring.

Separation of godown from other blocks or providing fire wall with Double Fire door

arrangement in the wall openings/entrances.

Storing of pallets in such a way that a heap should not exceed 1000Kgs and its height

should not exceed 2m and minimum of 6m distance should be maintained between two

such heaps.

Storing the materials above non combustible sleepers, pallets

Maintaining the stack height within 6m, and storage height restricted up to 1m level

below the roof

Process area:-

Installation of Dust proof light fittings and shrouded opening motors.

Providing of static electricity dischargers in all of the entries between the blocks wherever necessary.

Avoiding of laying of cables in underground dust collection and air ducts.

Avoiding of open socket and other electrical fittings and if possible avoiding of distribution panels in preparatory / process area or else 1.5 m clear space should be maintained between the electrical installations and equipment/storage.

Avoiding the accumulation of fluff and other dusts over the electrical installations.

Conducting electrical safety audits periodically

Insulating the pipe lines carrying the hot materials inside the process area.

Provision of fire dampers in the AHU ducts.

Inspecting the LPG – Vapour lines periodically for possible corrosion and flange leaks.

Providing isolation valves wherever the LPG Vapour lines entering the building.

Provision of gas detector wherever the LPG is used in textile processing.

No loose wiring is allowed any where in side the premises.

Strict implementation of No smoking policy.

Providing of spark arrestors in the exhaust of trucks operating/entering inside the factory premises.

All scraps, cotton dust, and plastic and paper packaging materials should be kept away from any machinery that may overheat or emit sparks.

Housekeeping:-

The removal dust over the electrical installations and fire extinguishers should be carried out periodically

Exclusive department should be formed.

House keeping contests should be announced to motivate / encourage the good house keeping.

Fire protection arrangements:-

Based on the various studies and other inputs, it is proved that the in adequate fire fighting arrangements leads to the spread of the fire considerably in the accidents reported (and analyzed) in the industry.

Major problem is non cleaning of the dusts/fluffs accumulated over the extinguishers installed in the process block.

Another problem is non provision of the fire doors wherever required.

Periodical fire fighting training programmers to be conducted.

Suggestion on fire protection arrangements:-

An automatic fire alarm system conforming “code of practice for selection, installation and maintenance of automatic fire detection and alarm system – IS : 2189 – 1988” shall be installed specifically in Cotton and finished goods storage.

Smoke detectors shall be installed in storage areas, below and above the false ceiling, and underground ducts in process areas.

The materials used processed and produced are prone to fire, hence hydrant system with standards conforming to TAC guidelines (adequate capacity water pumps and exclusive water tank and other accessories) shall be installed.

Fixed hose reels shall be installed for better effect than the usage of fire extinguishers specifically in cotton and finished goods storage.

Dry chemical extinguishers backed up with low velocity water spray from small bore hose reel should be provided for regenerated cellulose, cellulose ester, acrylic fibres and blends of cotton with other fibres storages and cotton process areas.

Surface Water tank with adequate Capacity is required to support the public fire brigade.

All the staffs should be trained in fire fighting. Separate / dedicated team should be made available in the factory for fire fighting.

Safety management:-

Safety committee should be formed and periodical meetings should be conducted.

Safety manuals should be prepared and circulated.

Emergency plans should be drafted, approved and circulated. Soft copy should be made available.

Emergency control centre should be identified and necessary operational procedures, safety manuals and relevant fool proof communication equipment should be made available there at.

Emergency drills and full scale mock drills should be conducted periodically.

Emergency organization should be formed and special trainings should be provided to emergency core team.

The adequacy of firefighting equipment should be reviewed periodically and ensured for the same.

The no smoking policy should be implemented strictly.

Sophisticated electrical safety programme should be in place.

Inspection and maintenance practices:-

Inspection:

Normally in factory top management level people will be in the premises always, hence the risk will be under monitoring except during holidays and night.

Statutory inspections such as electrical inspectorate inspection and factories inspectorate inspection are carried out as per prevailing rules and regulations and at least once in a year.

Maintenance: Operators themselves carrying out the maintenance works. But certified electricians should be placed.

2. Introduction

The textile industry occupies a unique place in our country.

Textile Industry is providing one of the most basic needs of people and the holds importance;

maintaining sustained growth for improving quality of life. It has a unique position as a self-reliant

industry, from the production of raw materials to the delivery of finished products, with substantial

value-addition at each stage of processing; it is a major contribution to the country's economy.

Special features:

One of the earliest to come into existence in India,

Accounts for 14% of the total Industrial production,

Contributes to nearly 30% of the total exports and 4% to the GDP.

One of the largest employment generators after agriculture. (Employs 3.5 crore people

and is the second highest employer.),

The garment industry of India earns 18 per cent of the Net Foreign Exchange,

Peeping from the past, half decade of the 20th century, industry had clubbed more than

34 joint ventures with foreign entrepreneurs.

India is :

the largest producer of jute in the World;

the second largest producer of silk;

the third largest in cotton and second largest in cellulose fibres;

the fifth largest in synthetic fibers / yarn;

Textiles have historically formed an important part of India's economy. Weaving has always been

regarded as one of the major occupations, and India‟s cotton and silk production were among the

highest in the world.

India, once one of world‟s leading exporters of textiles, was now forced to become a net importer.

However, by the 1850's Indian enterprise and capital using modern imported technology had set

up its own mills, which by 1875 were exporting modern textiles to Lancashire. Thus the textile

industry was the first in India to actually deserve the label „industry‟.

The liberalization being carried in the 1990‟s also ushered in a new era for India‟s textile

industry. It led to the relaxation of many of the constraints previously imposed on the textile

sector. Licensing was removed in the early 90`s by the Statement of Industrial Policy and the

Textile Development and Regulation Order. In 1995, India signed the General Agreement of

Tariffs and Trade bringing some of its policies at par with those at an international level.

However, a number of limiting regulations (the differential taxation for larger mills for eg.) stayed

in place till very recently, and some, like the labour laws, are still in place.

At present, the single biggest factor influencing the textile industry appears to be the end of the

textile quota regime of quantitative import restrictions under the multi-fiber arrangement (MFA) on

1st January, 2005 under the World Trade Organization (WTO) Agreement on Textiles and

Clothing. The removal of quotas, seen as an opportunity by many, including the government, is

driving investment and liberalization in the textile space.

Although the development of textile sector was earlier taking place in terms of general policies, in recognition of the importance of this sector, for the first time a separate Policy Statement was made in 1985 in regard to development of textile sector. The textile policy of 2000 aims at achieving the target of textile and apparel exports of US $ 50 billion by 2010 of which the share of garments will be US $ 25 billion. The main markets for Indian textiles and apparels are USA, UAE, UK, Germany, France, Italy, Russia, Canada, Bangladesh and Japan.

3. DESCRIPTION OF FTPL

The plant has got a boundary wall of 2.5 meters in height in the all four.

The various blocks proposed in the FTPL are

1. New Administration Building with Centre of Excellence (to be Constructed)

2. HT Panel Room for Distribution of Electricity for CETP, Water Treatment, Street

Lighting, STP etc

3. Cement Concrete Roads of 18 mtrs right of Way

5. CETP with various units, including sludge storage room.

6. Units of Textile yarn preparatory.

7. 66 KV substation under GETCO (proposed)

SURROUNDING LOCATION OF THE PLANT

The immediate surroundings of the plant are as follows:

North Agricultural land

East Agricultural land

West Agricultural land

South Agricultural land

4. A PROJECT IN BRIEF

Location Village Mahuvej, Taluka Mangrol, Surat, Gujarat

Name of SPV Fairdeal Textile Park Private Ltd.

Area 95.84 Acres

Activities Texturizing, Weaving, Yarn preparatory, Sizing

units etc

Project Cost Rs. 115 Crores

Expected Employment in the Park Direct – 2,900

Indirect – 4,300

Expected Investment in the Park Rs. 300 Crores

Expected Turnover in the Park Rs. 1200 Crores

5. Risk Management

Risk Management is the Identification, Analysis and Economic Control of those RISKS which can

threaten the Assets (Property, Human) or the Earning Capacity of an Enterprise.

Risk management comprise of

Risk assessment of any work activity.

Control & monitoring of such risks

Communicating these risks to all persons involved.

The Benefits of Risk Management

Reduction in Material and Property Damage.

Effective Mission Accomplishment.

Reduction in Serious Injuries and Fatalities.

Risk Management Terms

• Hazard – Hazard is a source or situation with a potential for harm interms of injury or ill

health , damage to property, damage to workplace environment or a combination of

these.

• Risk – Risk is the combination of the likelihood ,high or low and consequence(S) of a

specified hazardous event occurring.

• Risk Assessment – It is the overall process of estimating the magnitude of risk and

deciding whether or not the risk is tolerable.

RISK ANALYSIS

1. Background

Risk analysis may be defined as a procedure to identify threats & vulnerabilities, analyze

them to ascertain the exposures, and highlight how the impact can be eliminated or reduced.

It may also be defined as a process to determine what level of security for a particular

system or environment.

Risk analysis provides the basis for examination of the risks that an organization faces. It is

based on a structured approach for thinking through threats, followed by an evaluation of the

probability and cost of events occurring. Risk analysis forms the basis for risk management

and crisis prevention. Here the emphasis is on cost effectiveness. Risk management

involves adapting the use of existing resources, contingency planning and good use of new

resources

.

2. Storage & Handling of Raw Materials:

In the FTPL Textile Project under consideration, there are no high hazards involve during to

the construction phase or operation phase. The only material which requires considerable

level of safety in handling of Yarn.

3. Health & Safety Measures:

FTPL is an Infrastructure project housing 48 industries engaged in textile units. In such

activities needs facilities for power, water, common water treatment plant and waste disposal

to its member units.

Apart from the critical infrastructure facilities mention above FTPL has given due important to

the health and safety aspect of the worker who shall be employed in its member industries.

FTPL proposes to establish following facilities:

a. Open area with landscaping

b. Canteen facilities

c. Dispensary for First Aid

Apart from the above, adequate safety measures have been taken for prevention of fires

from materials and electrical sources. The fire fighting standards require provisional of

supply from surrounding fire hydrants located in the premises of FTPL, at the same time in

case of fire. A total of 1500 KL of water shall be available from the reservoir.

Some of the safety measures proposed by FTPL are listed below:

Fire extinguishers shall be provided at easily accessible positions in the Common Infrastructure facilities like Transformer, MCC Room, CETP to deal with fires from electrical short circuits.

First aid kits shall be maintained at easily accessible locations in critical zones.

Provide personal protective equipments to workers working in risk areas.

Display sign boards within premises to create awareness about fire and safety and will be educated the workers on preventive measures.

Will be recommended individual member industries to maintain necessary fire fighting equipments and first aid kits and will be provided necessary training for the use of these equipments to their employees.

6. VARIOUS TYPE OF UNITS

Manufacturing process write up and flow charts

7. PARTIALLY ORIENTED YARN (POY)

Polymer in the melted form from polycondensation section is cooled in polymer cooler, filtered

and after pressure boosting it is distributed to the spinning manifolds and then to the spinning

positions. The polyester melt from spinning position is extruded through spinnerets by variable

speed driven spinning pumps. The extruded filaments are cooled by precisely controlled

conditioned and filtered air in quench chamber. The filaments are then passed through the finish

application system. The filaments are taken on take up winders and finally wound on bobbins.

The yarn produced is extremely fine and the unit of fineness is denier. The spinnerets and

spinning manifold are jacketed and heated with dowtherm vapor.

The POY is the basic raw material for all textile units in the park

Partially Oriented Yarn (POY)

(Raw Material)

Quality Checking

Fully Drawn Yarn

Weaving

Quality Checking

Dispatch

Twisting (Mechanical Binding) Sizing (Chemical Binding)

Textured Yarn

Technology

Yarns are produced by a continuous polymerization process. Strict quality control of denier

orientation and spread, along with computer-controlled draw force testing, ensures maximum

consistency of yarn performance during and after textrising. All critical yarn proprietary such as

draw force, tenacity, elongation, user and shrinkage are closely monitored and controlled. A

special proprietary spin finish protects the colour and lubricity of the yarn over long periods of

storage.

Controlled interlace in filaments as well as the special finish enable the yarns to be texturised at

speeds of 750 mpm and above.

8. FULLY DRAWN YARN (FDY)

Fully Drawn Yarn (FDY) is produced by a process similar to POY manufacturing except that the yarn is produced at higher spinning speeds coupled with intermediate drawing integrated in the process itself. This allows stabilization through orientation and crystallization.

• Yarns are produced by a continuous polymerization process.

• All critical yarn properties such as tenacity, elongation, Ulster variation and boiling water shrinkage are closely monitored and controlled.

• Controlled interlace enables the yarns to be twisted or sized in subsequent operations.

• Intermingled FDY yarns are suitable for direct twisting, warping and weaving.

• Less waste and high efficiency in subsequent processes due to higher package weight (10 kg).

• The fabric made from these yarns have a feel and drape similar to fabrics. Produced from pure silk resulting in high realization of product

• These yarns eliminate draw-twisting and sizing process reducing the cost of products for light and medium range of fabrics.

• There is high efficiency and low breakages in warping because of excellent package quality produced on craft winder.

• Excellent dyeing consistency.

The textile units in the park are yarn preparatory/processing units consisting of the following

major activities:

Sizing

Draw Winding,

Warping,

Twisting,

Weaving,

Texturising etc

In the above activities POY (Partially oriented yarn) and FDY (Fully Drawn Yarn) is the only

major Raw Material used for processing, which in turn is used the make the fabric i.e. Man Made

Fabrics.

Textured Yarn:-

Texturing is a process where flat continuous yarn is modified to give bulk and/or additional

stretch to the filament yarn.

Draw Texturised Yarn (DTY) is a fully drawn, fully oriented polyester multifilament yarn with soft crimp, high bulk and texture with cotton feel and very high durability and retention properties. This is manufactured by texturising partially oriented yarn using texturising machines. DTY is suitable for fabric end uses like outer/inner garments, skin-clinging garments, furnishings, upholstery, etc. This is a replacement of cotton and cotton blend yarns with very low moisture content.

Technology

DTY is produced on the latest high-speed draw texturising machines with identical capability.

Total quality checks are done with respect to dye ability. Bulk and elongation is closely monitored for consistency on captive weaving installations.

Electronic package-size measuring units ensure uniform texturised yarn package.

A consistent level of high quality anti-static lubricating oils, together with an option of incorporating adequate interlacement, is applied for purposes of warping without sizing.

9. PROCESS FLOW DIAGRAM OF TEXTURISING

POY Yarn in Bobbin

Textile Yarn in Bobbin

10. TWISTING

Twisting is a very essential process in the production of staple yarn, twine, cord and ropes. Twist is inserted to the staple yarn to hold the constituent fibers together, thus giving enough strength to the yarn, and also producing a continuous length of yarn. The twist in the yarn has a two-fold effect; firstly the twist increases cohesion between the fibers by increasing the lateral pressure in the yarn, thus giving enough strength to the yarn. Secondly, twist increases the helical angle of fibers and prevents the ability to provide the maximum fiber strength to the yarn. Due to the above effects, as the twist increases, the yarn strength increases up to a certain level, beyond

First/Input

Primary Heater

Cooling Plate

Positorque Unit

Intermediate/

Feed roller

Secondary

Heater

Output Roller

Intermingling

Oil Application

Unit

Unit T/up Bowel

which the increase in twist actually decreases the strength of staple yarn. The continuous filament yarn also requires a small amount of twist in order to avoid the fraying of filaments and to increase abrasion resistance. However, twisting the continuous filament yarn reduces the strength of the yarn . Yarn is often ply-twisted in a direction opposite to a single yarn twist to improve evenness, strength, elongation, bulkiness, luster and abrasion resistance, and to reduce twist liveliness, hairiness and variation in strength.

The twisting of fibers strands are carried out on a roving frame, ring frame, rotor spinning and DREF spinning machines etc. This twisted strand has to be wound on the delivery package in a certain form for easy withdrawal of these strands in the next process. Since the open end of the yarn is rotated in the rotor and DREF spinning systems, the delivery package has to be rotated axially to wind the yarn. The twisting and winding operations are separated in the open-end spinning . However, this is not possible on a roving frame or a ring frame.

There should be two rotating elements (the spindle and traveler or flyer and bobbin) in order to twist and wind the strand on the package. The winding rate should be equal to the delivery rate from the drafting device. As the winding on the diameter of the package varies continuously throughout the process, the difference in speed between the two elements also has to be varied continuously. Since the delivery rate is constant, the product of winding on diameter and the speed difference between the two rotating elements should be kept constant. On a roving frame, this is achieved by adjusting the bobbin speed continuously and keeping the flyer speed constant, whereas in ring spinning, only the spindle is rotated at a constant rate and the traveler is dragged around the ring by the yarn.

Due to the frictional force between the ring and traveler, the required speed difference between the spindle and traveler is automatically adjusted. In both the ring and roving frame of the short-staple spinning system, the bobbin lead is used. For calculating twist in the roving, the flyer speed is taken into account, whereas in ring spinning, the spindle speed is considered.

Twist/cm in the roving = flyer speed in rpm)/ delivery rate in cm/min

Twist/cm in the yarn = spindle speed in rpm/ delivery rate in cm/min

The reasons for the above, and the mechanism of twisting strands on a roving frame and ring frame are not explained in textbooks or literature. In the present paper, the mechanism of twisting strands on a roving frame and ring frame is explained.

11. SIZING

Line Diagram for the process of single end sizing of Polyester and Nylon Yarn

RAW MATERIAL (POLYESTER, NYLON FILAMENT YARN)

WARPING OF YARN

SIZING OF YARN

BEAMING OF YARN

LEASING OF BEAM

PACKING

DISPATCH

Sizing of the warp yarn is essential to reduce

breakage of the yarn and thus production stops

on the weaving machine. On the weaving

machine, the warp yarns are subjected to several

types of actions i.e. cyclic strain, flexing, abrasion

at various loom parts and inter yarn friction. With

sizing the strength - abrasion resistance - of the

yarn will improve and the hairiness of yarn will

decrease. The degree of improvement of strength

depends on adhesion force between fiber and size, size penetration as well as encapsulation of

yarn. Different types of water soluble polymers called textile sizing agents/chemicals such as

modified starch, polyvinyl alcohol (PVA),carboxymethyl cellulose (CMC)acrylates are used to

protect the yarn. Also wax is added to reduce the abrasiveness of the warp yarns. The type of

yarn material e.g. cotton, polyester, linen the thickness of the yarn, type of weaving machinery

will determine the sizing recipe. The sizing liquor is applied on warp yarn with a warp sizing

machine. After the weaving process the fabric is desized (washed).

In sizing raw material is polyester or nylon filament yarn. Yarn is taken on creel to prepare a

beam. Creel is 1200 to 1500 ends as per requirement. Yarn is put on creel and from creel

individual ends are wrap in beam pipe . Beam prepared on warping is taken to sizing machine.

On sizing machine beam is loaded in front of machine on a stand and then passed through

different steel roller and entered in size box which consists of sizing paste (resin chemical). 5% to

6% add on is given to yarn as per yarn requirement of size paste. Size paste is prepare from

Polyester Resin. This is cook on vessel with water at 90 degree temperature. After size box yarn

enter to hot chamber where temperature is 150 to 170 degree. Chamber are heated by the

media of thermic fluid which comes from thermic fluid heater. There are two chamber of 5 metre

each. In chamber non contact drying is done, after chamber there are hot cylinder where contact

drying is done at 100 to 120 degree temperature. After contact drying cooling zone comes where

cold air is blown on yarn in 1 mtr chamber . Then yarn is wind on warp beam sizing beam

prepare on sizing machine are taken on beaming machine where number of yarns are

assembled as per number of ends required. There are 12 beam stand on beamer machine and

head stock to wind looms beam.

After preparing beam on beamer machine beam is taken on leasing machine. Where one nylon

thread is passed between individual yarn. One yarn is lifted and other is down and in between

nylon thread is passed to split the sheet. Last process of beam is packing here it is wrapped with

brown paper. There is no effluent in process of sizing.

12. WEAVING

Process Flow Diagram of Weaving

YARN

Weaving is the most basic process in which two different sets of yarns or

threads are interlaced with each other to form a fabric or cloth. One of these

sets is called warp which is the lengthwise yarn running from the back to the

front of the loom. The other set of crosswise yarns are the filling which are

called the weft or the woof.

Preparing Warps and Wefts for Weaving:

The warps form the basic structure of fabrics. As such, they are made to pass

through many operations before actual weaving is done. These operations

include spooling, warping and slashing. In spooling, the yarn is wound on larger

spools, or cones, that are placed on a rack known as creel. From the creel, the

yarns are wound on a warp beam, which looks like a huge spool. These lengths

of hundreds of warped yarns lie parallel to one another. These yarns are unwound for slashing,

or sizing. The yarn is coated with sizing with the help of slasher machine. Slashing prevents

chafing or breaking of yarns during weaving process. Sizing is either starch based or a synthetic

TWISTING/TEXTURISING/REPATOR

PIRN WINDING

WARPING

WEAVING

QUALITY CHECKING

DESPATCH

like polyvinyl alcohol or water soluble acrylic polymers. The sized yarns are then wound on a final

warp beam and are ready for the loom.

The filling yarns experience less strain during the weaving process. Their preparation includes

spinning them to the required size and giving them just the right amount of twist desired for the

kind of fabric they will be used.

Shuttle less loom:

Many kinds of shuttle less looms are used for weaving such as Projectile

Looms; Rapier Looms; Water Jet Looms; and Air Jet Looms.

Rapier Loom:

Rapier loom comes in many types. Early models of it use one long rapier device

that travels along the width of the loom to carry the weft from one side to the

other. Another type of rapier loom has two rapiers, one on each side of the

loom. They may be rigid, flexible or telescopic. One rapier feeds the weft

halfway through the sheds of warp yarns to the arm on the other side, which

reaches in and carries it across the rest of the way. Rapier looms are very efficient and their

speed ranges from 200 to 260 ppm. These looms can manufacture a variety of fabrics ranging

from muslin fabric to drapery fabrics and even upholstery fabrics.

Water Jet Loom:

In it, a pre measured length of weft yarn is carried across the loom by a jet of water. These looms

are very fast with speeds up to 600 ppm and very low noise. Also they don't place much tension

on the filling yarn.

As the pick is tension less, very high quality of warp yarns are needed for efficient operation.

Also, only yarns that are not readily absorbent can be used to make fabrics on water jet looms

such as filament yarn of acetate, nylon, polyester, and glass. However, it can produce very high

quality fabrics having great appearance and feel.

Air Jet Looms:

In the air jet weaving looms, a jet of air is used to propel the weft yarn through the shed at

speeds of up to 600 ppm. Uniform weft yarns are needed to make fabrics on this loom. Also

heavier yarns are suitable for air jet looms as the lighter fabrics are very difficult to control

through shed. However, too heavy yarns also can't be carried across the loom by air jet. In spite

of these limitations, air jet loom can produce a wide variety of fabrics.

Taking Up and Letting Off

As the shedding, picking and battening processes are being operated, the new

fabric is wound on the cloth beam. This is known as 'taking up'. At the same

time, the warp yarns are released from the warp beam which is known as 'letting

off'.

http://www.teonline.com/fibers-yarns-threads/filament-yarn.html

http://www.teonline.com/knowledge-centre/weaving.html

The pattern of the weave depends on the manner in which groups of warped yarns are raised by

the harnesses to allow the insertion of the weft yarn. These differences are responsible for

producing different types of fabric weaves. Weave patterns can create various degrees of

durability in fabrics apart from their utility and looks.

25

13. RISK DUE TO VARIOUS ACTIVITIES

Area Precautions

Transformer Yard The outdoor Transformer Yard shall be efficiently protected by fencing not less than 1.8

meters in height or other means so a to prevent access to the electric-supply lines and apparatus therein by

an unauthorized person, The names of persons authorized to work in the Transformers & HT panel room should be displayed at the

entrance.

Skull and cross bone danger sign board should be displayed at the entrance of the Transformer yard.

The silica gel should always be maintained in a dark blue condition. The least sign of deactivation should be attended to, with replacement / re activation of the silica gel.

In order to prevent vertical/lateral spread of fire through cables, all cable tunnel / galleries through which cable / cable trays pass should be sub divided into smaller compartments irrespective of type of cable used.

All cables coming in and going out of the electrical panel should be provided with glands and the opening

around the cables should t e sealed.

MCC Room Identification tags should be properly fixed to the cable to identify the equipment / service. This will help replacing / correcting cable faults. The marking shall <be of sufficient durability to withstand the environment conditions.

It is recommended to place insulating rubber mats of BS specification on the floor in front & rear side of the

panels of medium ~ voltage & above, to protect the operating personnel from accidental electrical shock.

It is the requirement of the act that all dangerous moving parts of the machine should be adequately

guarded so that danger zone is hot accessible under all conditions.

The names of persons authorized to work In the MCC panel room should be displayed at the

entrance.

26

Area Precautions

MCC Room

Instructions in English or Hindi and local language of the place for the restoration of persons suffering from electric shock, shall be affixed by the occupants in a conspicuous place in every generating station, enclosed substation, enclosed switch station. To eliminate fire hazards, good housekeeping, inside the MCC room, should be strictly maintained.

Blower Room

The management should enforce the use of Ear plugs in the high noise areas. All dangerous moving parts of machines / equipment be adequately guarded at all times when they are in use from either side. Safe working load (SWL) should be displayed on all chain pulley blocks and lifting devices to prevent a mishap. Clean up any accumulating water or oil. Identify leak and repair it if possible.

Using power tools in Blower Room such as

drills, saws and grinders.

Wear ear plugs or ear muffs always in the high noise area. High noise area should be identified and relevant posters should be displayed. Keep tools together to avoid tripping over them. Survey work area for hazards. Walk carefully. Shut off equipment around work area whenever possible. If you cannot shut off equipment, always have a coworker nearby in case help is needed. Do not wear loose clothing, jewelry, or keys. Be aware of your surroundings and maintain an adequate distance from moving equipment. Work in a stable position to avoid losing your balance. Keep power cord away from work area. Wear safety glasses, and optionally a dust mask, gloves, long-sleeve shirt and/or coveralls. Keep tools in good condition. Inspect tools before use. Verify that guards work properly. Do not put hands near blades. When using tools, make sure you have a good center of gravity and are properly balanced. Hold tools securely with two hands to maintain control.

Laboratory

All electrical equipment and fittings in the lab where solvents are handled and stored should be of the appropriate flame proof type.

The chemicals like 5ulphuric acid, Di Ethyl Ether, Methanol, ISO Prophyl Alcohol & Acetone etc should be placed in trays so that any spillage would get contained within the tray. The eye bath cum emergency shower should be installed outside the QC lab immediately. This is also a requirement under the factories act.

27

4.4 CONSTRUCTION RISKS (PROPOSED PLANT)

Area Probable Risks / Cause & Outcome

Recommendations for mitigations Action suggested to be taken by FTPL

Construction site Slips and Falls while working at site.

Contract workers could get injured

Clear the unwanted materials which

Normally at site (working area)

Store the material in the designated area and use them when required only.

FTPL supervisor should check the contractors work procedures regularly before work is commenced.

Fall from step ladders from height.

Contract workers could get injured falling a short distance and landing the wrong way from height could be fatal.

Even sprains or strains could mean pain and days off work

Check the ladder for defects or damage

at the start of your shift

after it has been used somewhere else by other workers

After it has been left in one place for a long time.

Keep the area at the base of the ladder clear.

Make sure the spreader arms lock securely in the open position.

Stand no higher than the second step from the top.


28



Wooden planks & decks breakage.

If scaffold planks and decks fail, contract workers could be seriously injured or killed from a fall. They could also be thrown off balance and injure yourself with your tools or equipment

Wood planks

The right length. Planks must overhand the frame no less than 6 and no more than 12 inches (150 – 300 mm).

Cracks-these can often be detected at the end of the plank. Discard planks with long and deep cracks.

Cuts on plank edges from saws, tools, sharp objects. Discard planks with many or deep cuts.

Worm holes, splits, knots knocked out along edges, lots of nail holes-discard planks when they‟re serious.

Light weight-this can indicate dry rot that can‟t be seen.

Condition of cleats-damaged cleats should be removed and replaced.


29



Temporary lighting at site.

Frequent relocation of circuits can loosen connections, break insulation, and create other shock or electrocution hazards.

Bulbs lower than 100 watts are not recommended.

Bulbs should be installed to light as large an area as possible.

Bulbs must be protected by cages against accidental damage.

Keep branch lighting circuits that feed temporary lighting entirely separate from power circuits, except for a common supply

.

Protect branch lighting circuits by a breaker or fuse with a 15-amp rating. An electrician should hardwire the circuits directly into a distribution panel.

Don‟t use temporary lighting circuits as extension cords. If a fuse blows, finding your way to the panel in the dark can be dangerous.


Safety should be utmost importance.

30



Housekeeping

Poor housekeeping and storage account for a significant percentage of accidents and injuries in construction.

This creates tripping and slipping hazards. It also makes other hazards hard to see.

Housekeeping means cleaning up scrap and debris, putting it in containers, and making sure the containers are emptied regularly. It also means proper storage of materials and equipment.

Effective housekeeping and storage prevent accidents and injuries.

Clean up as work proceeds.

Keep equipment and the areas around equipment free of scrap and debris.

Keep stairways, ramps, and other travel areas clear.

Secure loose or light material stored on roofs and open floors to keep it from blowing away in the wind.

Keep material at least 1.8 meters or 6 feet away from floor and roof openings, floor and roof edges, excavations, and trenches.

Store material so that it won‟t roll or slide in the direction of the opening. Use blocking if necessary.

Before handling used lumber, remove or bend over any protruding nails and chip away hardened concrete.

Remove flammable rubbish and debris immediately from the vicinity of welding, flame cutting, propane heating, and other ignition sources.

FTPL supervisor should inspect the sites regularly.

31



Electric Tools used at site

The main hazards with electric tools are:

Lack of grounding or double insulation

Broken or disarmed safety devices such as retractable guards

Injuries to hands and eyes

Faulty tool cords and extension cords

Grounding

Make sure the tool is grounded and the cord polarized or double-insulated.

“Grounded” means an approved three-wire cord with a three-prong plug. Use the tool only in a three-pole outlet.

Make sure the casing of a double-insulated tool is not cracked, split, or broken.

Cords

Inspect tool cords and extension cords daily for damage.

Keep cords clear of the tool during use.

Inspect tool cords and extension cords for cuts, cracked or broken insulation, and makeshift repairs.

If any cord feels more than warm to the touch, check the circuit for overloading.

Report any shocks from tools or cords to your supervisor. Tag the tool and don‟t use it.


32



Electric Drilling machine

If you have to push the tool beyond its capacity you can burn out the motor and injure yourself.

Learning into the drill and pushing too hard is dangerous. If you lose balance or control, you can fall, or strain your neck, arm, and shoulder muscles.

Heavy-duty drills or hammer drills have a low rpm and higher horsepower rating.

Take a break when you you‟re up on a ladder or scaffold. You may even need help with some kinds of drilling.

Check your balance and grip. Sudden torque can twist your arm and throw you off balance.

When drilling deep holes, occasionally withdraw the bit several times with the motor running. This clears cuttings from the hole.

Don‟t hold the work in your hand, on your knee, or against your boot while you‟re drilling. Clamp small pieces in a vice.

When you‟re drilling, don‟t push or lean too hard on the drill. You can damage the tool or the work, or be thrown off balance if the drill twists and grabs.

33



Electric Sabre Saws

If you don‟t use a Sabre saw correctly it can kick back, injuring you and damaging materials.

Sabre saws are used to cut holes in ceilings, and walls and to make short, straight sabre saw cuts on the upstroke only.

You need eye protection. You should wear safety glasses with side shields.

Even better are goggles for dust or a face shield.

You need two hands to maintain control, absorb vibration, and avoid accidental contact.

Always make sure you know what‟s on the other side of the surface being cut. Beware of sawing into wires, cables, and pipes.

Make sure that the saw will clear the bench, trestle, or other support.

When the motor is running, working a blade in or out of a cut or lead hole can cause kickback.

Let the saw and the blade do most of the work. Don‟t force the saw. The machine should turn with ease. If you have to push the saw, the blade is dull or the stock is too heavy for the saw.

Never put the saw down until the blade and motor have stopped


34



Fire extinguishers at construction site.

Fire is a threat on many construction sites, especially where open flames, flammable and flammable materials are used. Welding, flame cutting, and thermal roofing are obvious examples.

Fire extinguishers on construction sites must be:

accessible

inspected regularly

Promptly refilled after use.

Extinguishers should be located:

Where flammable materials are stored, handled, or used.

Where temporary oil or gas fired equipment is being used.

Where welding or open flame cutting is being done.

On each storey of an enclosed building being constructed or renovated.


35



Cement is used in construction every day.

It can hurt you by

Contacting your skin

Contacting your eyes

Being inhaled.

Cement usually contains a metal called hexavalent chromium. This metal causes allergic dermatitis

(Inflammation of the skin).

What to wear

Wear eye protection for mixing, pouring, and other work with dry cement.

Wear alkali-resistant gloves.

Wear coveralls with long sleeves and full-length pants.

Pull sleeves over gloves.

What to do

Work upwind from cement dust.

Remove any clothing contaminated by cement.

When your skin comes in contact with cement, wash with cold running water as soon as possible.

Flush out any open sores or cuts. Get medical attention if your skin still feels like its burning.

After working with cement, always wash your hands before eating.

If your eyes are exposed to cement, rinse with cold tap water for at least 15 minutes. Get medical attention if necessary.


36



Mixing concrete:

Cement dust can irritate your skin. The dust reacts with sweat or damp clothing to form a corrosive solution. Cement dust is also dangerous if it gets into your eyes, or if you inhale it.

Working with concrete:

Wet concrete or mortar can burn your skin or cause skin ulcers if it falls inside your boots or gloves or soaks through your clothes. Concrete finishers kneeling on fresh concrete have had their knees severely burned.

Pull sleeves over gloves.

Wear coveralls with long sleeves and full-length pants.

Tuck pants inside boots and dict-tape at the top to keep wet mortar and concrete out.

Use waterproof boots high enough to keep concrete from flowing over the top.

Remove any clothing contaminated by wet concrete.

Flush out any open sores or cuts. Get medical attention if your skin still feels like its burning.

After working with cement, always wash your hands before eating.

If your eyes are exposed to cement, rinse with cold tap water for at least 15 minutes. Get medical attention if necessary.


37

14. METHODOLOGY

Carried out detailed Risk Assessment & Disaster Management Plan for proposed FTPL CETP Plant.

Disaster Management Plan consists of evacuation procedures during Natural Disasters,

Manmade disasters & Utility failures.

38

15. RISK ASSESSMENT OF CETP

S. No.

HAZARD IDENTIFICATION Risk Evaluation

Risk Control

Work Activity Hazard Existing Risk Control

Additional Risk Control

Residual Risk

1 Collection Tank Falls, Vapor

To be provided railing

Safe passage with railing

Instruction

2 RM Charging Slip, Dust To be provided PPES, HK

To be used safety belt

Instruction

3 Equalization Tank Falls, irritation

PPES, railing Safe passage with railing

Instruction

4 Sludge remover Falls, Slip, Burn

PPES, HK Use safety belt, PPEs

Instruction

5 Clarifier Falls, Vapor

To be provided railing with passage way

Railing with colour coat

Instruction

6 Sand filter Hit injuring Lifting arrangement

Testing of chain block

Instruction

7 Carbon filter Hit injuring Lifting arrangement

Testing of chain block

Instruction

16. RISK ASSESSMENT FOR TEXTURED YARN

HAZARD IDENTIFICATION RISK EVALUATION RISK CONTROL S

r. N

O.

Work Activity Hazard Person at

Risk

Existing Risk

Control

Se

ve

rity

Lik

elih

oo

d

Ris

k L

ev

el

Additional

Risk

Control

Residual

Risk

Action

Officer

1

Loading of raw

material into

trolley

Strike by, slip

& trip,

ergonomics

Helper Nil 1 1 1 NIL Training

2 Transfer of

trolley to cril

Strike by, slip

& trip,

ergonomics

Helper Nil 1 1 1

Marking of

vehicle

movement

route

Training

3

loading &

unloading of

bobbins to cril

ergonomics,

fall from, slip Helper

Mobile

platform

ladder

1 2 2

side railing

should be

given to

ladder,

Lock to

wheels

4

Pass the

threads from

needles & link

it to machine

puncture Helper

Machine

remain in auto

off condition

1 1 1 NIL

40


r. N

O.


Risk Existing Risk

Control

Se

ve

rity

Lik

elih

oo

d

Ris

k L

ev

el

Additional Risk

Control

Residual Risk

Action Officer

5 Starting of machine

moving parts operator, helper

presence sensing devices

1 1 1 NIL Training

6 Load empty bobbins on machine

ergonomics, crust

operator, helper

Mobile platform ladder

2 1 2

side railing should be given to ladder, Lock to wheels

Training

7 Texturising machine operation

electrical shock, fire, cut injury, noise

operator

Auto control devices, fire extinguishers, alarm system

1 3 3

hearing protection & sound absorbing pad should be provided & double earthing should be provided

Training

8 fill up oil into oiler tank

fire, slip operator Fire extinguishers

1 1 1 good house keeping

41


r. N

O.


Risk Existing Risk

Control

Se

ve

rity

Lik

elih

oo

d

Ris

k L

ev

el

Additional Risk

Control

Residual Risk

Action Officer

9

Transfer of finished yarn reel for quality check

ergonomics, fall

helper

Mobile platform ladder, specialized trolley for keeping reels

1 1 1 NIL

10 checking nips (quality check)

poor illumination

quality dept. personals

lightings on desk are provided

1 2 2 NIL

11

Knitting machine operation (for performance quality check)

cutting injury, ergonomics

quality dept. personals

limit guards provided

1 2 2

all rotating parts should be fully guarded, ergonomically working platform should be provided

Training

12

Re-engaging

broken threads

in continues

plant

Poor

illumination,

cutting hazard,

fall, noise

operator Mobile

platform

ladder

1 1 1 appropriate

lighting

installation

42

17. RISK ASSESSMENT FOR TWISTING

AZARD IDENTIFICATION RISK EVALUATION RISK CONTROL

Sr.

NO

.

Work

Activity Hazard

Person

at Risk

Existing Risk

Control

Se

ve

rity

Lik

elih

oo

d

Ris

k L

ev

el

Additional Risk

Control

Residual

Risk

Action

Officer

1 Raw material from texturising finished

strike by, slip & trip, ergonomics

helper hydraulic hand trolley

1 1 1 NIL training

2 Raw material from godown to rewinding floor

fall, strike with

helper hoist, hydraulic trolley

1 2 2 door lock control training

3 Load to rewind machine & unload

fall helper mobile ladder 1 1 1 NIL training

4 Rewind

machine

operation

High noise,

cutting

operator auto presence

sensing

1 2 2 Hearing

protection &

sound absorbing

devices should

be given.

training

43

AZARD IDENTIFICATION RISK EVALUATION RISK CONTROL S

r. N

O.

Work

Activity Hazard

Person

at Risk

Existing Risk

Control

Se

ve

rity

Lik

elih

oo

d

Ris

k L

ev

el

Additional

Risk Control

Residual

Risk

Action

Officer

5 TFO

machine

operation

High

noise,

cutting

operator NIL 1 2 2 Hearing

protection

devices

training

6 Collection

of rewinded

reels and

transfer to

autoclave

burn,

cutting

hazard,

strike with

helper,

operators

EOT, hand

trolley, sliding

platform

1 2 2 heat

resistance

hand gloves

training

7 Autoclave

operation

burn, cut

injury

helper,

operators

ventilation,

alarm, auto cut

off, safety

release valve,

inspection by

competent

persons

3 1 3 heat

resistance

hand gloves

training 7

44

AZARD IDENTIFICATION RISK EVALUATION RISK CONTROL S

r. N

O.

Work

Activity Hazard

Person

at Risk

Existing Risk

Control

Se

ve

rity

Lik

elih

oo

d

Ris

k L

ev

el

Additional

Risk Control

Residual

Risk

Action

Officer

8 compressor

operation

crust

injury

helper,

operators

inspection by

competent

person

2 1 2 guarding

9 Heater burn injury helper,

operators

Alarm, Auto cut

off

2 1 2 heat

resistance

hand gloves

training

10 Load to

warping

machine

strike by,

ergonomic

s

helper hydraulic hand

trolley

1 2 2 safety shoes training

11 Warping

machine

operation

crust

injury

helper,

operators

limit road 2 2 4 NIL training

45

18. RISK ASSESSMENT FOR SIZING


r. N

O.

Work Activity

Hazard Person at Risk

Existing Risk Control

Se

ve

rity

Lik

elih

oo

d

Ris

k L

ev

el


Residual Risk

Action

Officer

1 Load/Unload to cril

fall, ergonomics

helper mobile ladder platform

1 1 1

side hand railing & lock provision on wheels

2

Passing thread from Needles(broad funy)

cut injury operators NIL 2 1 2 Hand gloves Training

3 Jumbo beam load/unload

crust injury, ergonomics

helper, operator

hydraulic hand trolley

2 1 2 safety shoes should be given

Training

4 sizing chemical making

burn, electrical shock, slip & trip

operators Alarm, auto cut off 1 2 2

good housekeeping, hand gloves, anti slip safety shoes

5 Sizing chemical tank filling

spill, moving parts

helper, operator

NIL 1 1 1

Machine should be kept in idle or off condition.

6 Oil filling in sizing m/c

spill helper, operator

NIL 1 1 1 NIL

46


r. N

O.

Work Activity



Se

ve

rity

Lik

elih

oo

d

Ris

k L

ev

el


Residual Risk

Action Officer

7 Jumbo machine operation

crust injury, rotating parts

operators presence sensing limit road

2 2 4 Avoidance of loose clothing

8 Setting temp. in machine

heat, smoke operators NIL 1 1 1

ventilation, heat resistance gloves should be provided

9 Master pipe fittings/removal


helper, operator


2 1 2 safety shoes should be given

Training

10

Reconnecting broken threads & pass it through needles

cut injury, moving parts

helper, operator

presence sensing limit road

1 1 1

11 Manual leasing

poor illumination

helper NIL 1 2 2 Provide proper lighting

12 Machine/mechanical leasing

cut injury helper, operator

NIL 1 1 1 Training

47

19. RISK ASSESSMENT WEAVING

HAZARD IDENTIFICATION RISK EVALUATION RISK CONTROL

Sr.

NO

.

Work Activity



Se

ve

rity

Lik

elih

oo

d

Ris

k L

ev

el


Residual Risk

Action Officer

1

Taking master pipe from leasing to weaving m/c


helper, operator

forklifts, hydraulic hand trolley

2 1 2

Proper marking of vehicle movement route

2 Fitting & removal of beams


helper, operator


2 1 2 safety shoes should provided

3 Water supplying

spill, slip & trip

helper, operator

NIL 1 2 2 Anti slip safety shoes

4 Weaving machine operation

cut injury, many moving parts, electrical & fire hazard, Noise

operator

presence sensing limit road, extinguisher, noise level will be maintained below 90 db & audiography to be carried out once in a year

2 2 4

Moving parts must be guarded, hearing protection should be given

5

Reattach broken fabrics in process

cut injury, moving parts

operator

Interlocking of guards

1

1

1

NIL

48

20. RISK ASSESSMENT FOR RAW MATERIAL


Sr.

NO

.

Work Activity



Se

ve

rity

Lik

elih

oo

d

Ris

k L

ev

el


Residual Risk

Action Officer

1 Placing of Truck to unloading bay

strike by truck

OperatorsHelpers

Breaks in truck, mirror, solid platform, licensed driver

2 1 2 marking for truck movements

Training

2

Unloading of packed container

crust, strike with, ergonomically hazard

Helper Hydraulic trolley, fork lift

1 1 1 differentiates the walk way & vehicle movement ways

Training

3

Shifting of container to Raw material godown

strike by, crust, ergonomical hazard

Helper Hydraulic trolley, fork lift

1 1 1 obstruction free route, marking of vehicle movement

Training

4

Stacking of

container

crust Helper Nil 1 1 1 Restriction of

Height

5

Unpacking of

container with

blade, knife

cut injuries Helper Nil 1 2 2 use of cutter

49

21.RISK ASSESSMENT FOR BEAMER & STOCKER


Sr.

NO

.

Work Activity



Se

ve

rity

Lik

elih

oo

d

Ris

k L

ev

el


Residual Risk

Action Officer

1 Beam fitting & removal

blunt or crust injury

helper, operator

NIL 2 1 2

maintenance schedule, inspection by competent person

Training

2 Beam operation

crust injury helper, operator

Presence sensing limit road

2 2 4 hand gloves, anti slip safety shoes

3 Working on Beamer machine

trip, fall hazard

operator NIL 1 1 1 Trench over air line

4 Stocker machine

blunt or crust injury

operator NIL 1 1 1 illumination, maintenance, PPE's

Training

50

22. Risk assessment shall follow the 5 step process as mentioned below.

51

Risk is made up of two parts:-

1 . Expected the SEVERITY of hazard and

2. LIKELIHOOD of the occurrence of the incident or ill health taking in to

account the existing risk controls.

Severity of Hazard :- It is the degree or extent of injury or harm caused by the hazards,

or as a result of an accident.

Severity Description

Minor No injury, Injury or ill health requiring first aid treatment only

Moderate Injury requiring medical treatment or ill health leading to disability

Major Fatal, Serious injury or life threatening occupational diseases.

Likelihood Description

Remote Not likely to occur

Occasional Possible or known to occur

Frequent Common or repeating occurance

52

Risk Matrix

Likelihood

Severity

Remote Occasional Frequent

Major Medium Risk High Risk High Risk

Moderate Low Risk Medium Risk High Risk

Minor Low Risk Low Risk Medium Risk

53

23. Acceptability of risk and recommended actions

Risk

Level

Acceptability of

Risk

Recommended Action

Low Risk Acceptable No additional risk control measures may be needed.

However frequent review may be needed to ensure that

the risk level assigned is accurate and does not increase

overtime.

Medium

Risk

Moderately Acceptable A careful evaluation of the hazards should be carried out

to ensure that the risk level is reduced to as low as

reasonably practicable (ALARP) within a defined time

period.

Interim risk control measure s, such as administrative

controls, may be implemented

High Risk Not Acceptable High risk level must be reduced to at least medium risk

before work commences.

There should not be any interim risk control measures and

risk control measures should not be overly dependent on

personal protective equipment.

Immediate management intervention is required before

work commences.

24 Occupational health impact assessments

Hazards are: Physical hazards, Biological hazards, mechanical hazards, psychological hazards PHYSICAL HAZARDS: Physical hazards are Temperature–Heat/ Cold, Illumination, Noise, Vibration, Radiation, Atmospheric pressure Noise

S. No

Physical hazard Expected sources

Effects/ symptoms Control measure

1. Noise Near noisy machinery

Hearing impairment, Hypertension, Ischemic heart disease, Annoyance, Sleep disturbance

Attenuation and Conservation – Tools for assessing noise levels A successful noise control program that focuses on engineering control of noise requires the institution of a hearing conservation plan and the use of proper monitoring equipment, surveys, maps, and modeling. A thorough hearing conservation plan should be established where noise exposure exceeds a 90-dBA time weighted average for eight hours. A good program consists of the following components: • Noise measurement and analysis; • Engineering control of noise sources where feasible; • Administrative controls and personal protection where

noise control is not feasible; • Audiometric testing; • Employee training and education; • Record keeping; and • Evaluation Control Measures: • Introducing good acoustic design for the new production

line • Adopting proper scheduling of construction activities • Scheduling noisy activities during the daytime periods • Operating well-maintained mechanical equipment on-site • Ensuring that equipment that may be intermittent in use

should be shut down between work periods or should be throttled down to a minimum

• Using personnel protection gear such as earplugs, muffs, etc.

• Developing a greenbelt around the quarry area • Installing noise barriers around air blowers, pumps, and

generators to reduce noise impacts at nearby receptors • Devising and implementing a rigorous inspection and

maintenance program applicable to equipment on-site

55

2. Heat Stress - Aim is to maintain body core temperature within +1°C of normal (37°C). This core body temperature range can be exceeded under certain circumstances with selected populations, environmental and physiologic monitoring, and other controls.

temperature and humidity; direct sun or heat; limited air movement; physical exertion; poor physical condition; some medicines; inadequate tolerance for hot workplaces; and insufficient water intake can all lead to heat stress

Health effects as in table given below #

Administrative or work practice controls to offset heat effects Provide accurate verbal and written instructions, annual training programs, and other information about heat stress • Acclimatize workers by exposing them to work in a hot environment for progressively longer periods. • Replace fluids by providing cool water or any cool liquid (except alcoholic and caffeinated beverages) to workers and encourage them to drink small amounts frequently, e.g., one cup every 20 minutes. Ample supplies of liquids should be placed close to the work area. • Reduce the physical demands by reducing physical exertion such as excessive lifting, climbing, or digging with heavy objects. Use relief workers or assign extra workers, and minimize overexertion. • Provide recovery areas such as air-conditioned enclosures and rooms and provide intermittent rest periods with water breaks. • Reschedule hot jobs for the cooler part of the day, and routine maintenance and repair work in hot areas should be scheduled for the cooler seasons of the year. • Monitor workers who are at risk of heat stress, such as those wearing semi-permeable or impermeable clothing when the temperature exceeds 70°F, while working at high energy levels. Personal monitoring can be done by checking the heart rate, recovery heart rate, and oral temperature.

3. Illumination: Availability of required lighting arrangement shall be incorporated in the initial stage to avoid the inadequacy of illumination level and design will be made considering the requirement of illumination in the work area.

Illumination level to be maintained

Sr. no.

Location Illumination by Illumination in Lux

1 Low roof buildings

Fluorescent tube lights

100-150/300(control rooms)

2 Shops/ High roof building

HPSV lamps 100-150

3 High color rendering required(low color distortion)

Metal halide lamp fittings

-

4 Open yard and area illumination

HPSV flood light fittings

15-30

56

4. Ergonomics Ergonomics is the term applied to the field that studies and designs the human-machine interface to prevent illness and injury and to improve work performance. It attempts to ensure that jobs and work tasks are designed to be compatible with the capabilities of the workers.

Some physical agents play an important role in ergonomics such as Force, Acceleration and Thermal factors. Force is an "important causal agent in injuries from lifting. Other Important ergonomic considerations include work duration, repetition, contact stresses, postures, and psychosocial issues

Work-Related Musculoskeletal Disorders – Work-related musculoskeletal disorders (MSDs) are an important occupational health problem that can be managed using an ergonomics health and safety program. The term musculoskeletal disorders refers to chronic muscle, tendon, and nerve disorders caused by repetitive exertions, rapid motions, high forces, contact stresses, extreme postures, vibration, and/or low temperatures. Other commonly used terms for work-related musculoskeletal disorders include cumulative trauma disorders (CTDs), repetitive motion illnesses (RMIs), and repetitive strain injuries (RSIs). Some of these disorders fit established

Among engineering controls to eliminate or reduce risk factors from the job, the following may be considered: • Using work, methods engineering, e.g., time study, motion

analysis, to eliminate unnecessary motions and exertions. • Using mechanical assists to eliminate or reduce exertions

required to hold tools and work objects. • Selecting for designing tools that reduce force

requirements, reduce holding time, and improve postures. • Providing user-adjustable workstations that reduce

reaching and improve postures. • Implementing quality control and maintenance programs

that reduce unnecessary forces and exertions, especially associated with non value-added work.

Administrative controls reduce risk through reduction of exposure time and sharing the exposure among a larger group of workers. Examples include:

Implementing work standards that permit workers to pause or stretch as necessary but at least once per hour.

Re-allocating work assignments (e.g., using worker rotation or work enlargement) so that a worker does not spend an entire work shift performing high-demand tasks.

Due to the complex nature of musculoskeletal disorders, there is no "one size fits all" approach to reducing the incidence and severity of cases. The following principles apply to selecting actions:

Appropriate engineering and administrative controls will vary from industry to industry and company to company.

Informed professional judgment is required to select the appropriate control measures.

Work-related MSDs typically require periods of weeks to months for recovery. Control measures should be evaluated accordingly to determine their effectiveness.

57

diagnostic criteria such as carpal tunnel syndrome or tendinitis. Other musculoskeletal disorders may be manifested by nonspecific pain. Some transient discomfort is normal consequence of work and is unavoidable, but discomfort that persists from day to day or interferes with activities of work or daily living should not be considered an acceptable outcome of work.

# Different kind of heat disorders and health effects are possible and how should they be treated

Sr. No.

Definition Primary Signs and Symptoms Medical treatment

1 Heat Stroke - Most serious heat related disorder when the body's temperature regulation fails and body temperature rises to critical levels, It‟s a medical emergency may result in death

Confusion; irrational behavior; loss of consciousness; convulsions; a lack of sweating (usually); hot, dry skin; and an abnormally high body temperature

Placed worker in a shady, cool area and the remove outer clothing; Provide the worker fluids (preferably water); circulate air to improve evaporative cooling

2 Heat Exhaustion - Partly due to exhaustion; it is a result of the combination of excessive heat and dehydration

headache, nausea, dizziness, weakness, thirst, and giddiness; Fainting or heat collapse

Remove from the hot environment and give fluid replacement. Encourage getting adequate rest, and when possible, ice packs should be applied.

3 Heat Cramps - Caused by performing hard physical labor in a hot environment.

electrolyte imbalance caused by sweating and are normally caused by the lack of water replenishment

Workers in hot environments drink water every 15 to 20 minutes and also drink carbohydrate-electrolyte replacement liquids

58

4 Heat Rashes - the skin is persistently wetted by unevaporated sweat

a red cluster of pimples or small blisters mainly in neck and upper chest, in the groin, under the breasts, and in elbow creases

provide a cooler, less humid environment, powder may be used to increase comfort, avoid using ointments or creams

59

25 Work zone ambient air quality monitoring

For maintaining safe working environment, work zone ambient air quality monitoring should be

carried out and records should be maintain in Form No.: 37 (Register containing particulars of

monitoring of working environment) prescribed under Rule 12-B of The Gujarat Factories Rules,

1963 under Section 7-A (a)(e) of The Factories Act,1948.

FORM NO. 37

(Prescribed under Rule 12-B)

Register containing particulars of monitoring of working environment required under

Section 7-A (a) (e).

1. Name of the Department / Plant.

2. Raw materials, by-products and finished products involving in the process.

3. Particulars of sampling.

Sr.

No.

Location/

Operation

Mentioned

Identified

conta-

minant

Sampling

instrument

used

Airborne

Contamination

Average

Number

of samples

Range

1 2 3 4 5 6 7

TWA

concen-

tration

(As given

in

second

schedule

Reference

method

Number of

workers

exposed

at the

location

being

monitored

Remarks Signature

of person

taking

samples

Name (in

block

letter)

8 9 10 11 12 13

60

SECTION II

SHEF SQUARE

TABLE OF CONTENTS

PREFACE ..............................................................................................................................................

INTRODUCTION

EXECUTIVE SUMMARY

1. FACILITY DESCRIPTION

1.1 BACKGROUND OF FTPL .................... .........................................................................................................

1.2 Disaster Management Plan ......... .................... ......................................................................

1.3 Objective of DMP

1.4 On Site Emergency Plan

1.5 Post Disaster Analysis

1.6 NATURAL HAZARDS AT SITE ........... ...................... .................................................................................. . 1.6.1 Lightening ................ ............... .................... ….. ................................................................

1.6.2 Flood ....................... ................ : .................. .......................................................................

1.6.3 Cyclone ................... ................ .................... .......................................................................

1.6.4 Storm / Cyclone ...... ................ .................... .......................................................................

1.6.5 Earthquake ............. ................ .................... .......................................................................

1.6.6 Tsunami .................. ................ .................... .......................................................................

2. PROCESS

2.1 MANUFACTURING PROCESS of „CETP‟ ....................................................................................................

2.2 Process Flow Diagram ............................................................................................................

2.3 Effluent Treatment Scheme (Existing)

2.4 Treatment and Recycling Schme

2.5 Equilization and Physical Treatment

2.6 Biological Treatment

2.7 Tertiary Treatment

2.8 Sludge Dewatering System

3. Process of Yarn Preparatory / Processing

3.1 Hazard Identification

4.0 Emergency Control Centre (ECC)

5.0 Communication network in the Park

5.1 Internal Telephone

5.2 External Telephone

61

6.0 Fire Protection System

6.1 Portable Fire Extinguishers

6.2 Fire Fighting Team

6.3 First Aider Team

7.1 First Action Plan

7.2 Informing the Emergency

7.3 All Clear Signals (Siren)

7.4 Communication Flow Chart

8.0 Evacuation Procedure

8.1 Fire Scenario in Park

8.2 Fire Prevention Procedure

8.3 Utility Failure

8.3.1 Sample Emergency Floor Plan

9.0 Roles & Responsibilities

9.1 Organization Chart

9.2 Main Controler

9.3 Incident Controler

9.4 Site Controler

9.5 Communication Team

10. Termination of Emergency

62

PREFACE SHEF SQUARE has been appointed Fairdeal Textile Park Pvt. Ltd.(FTPL) Surat to carry out Risk Assessment for Mechanical & Electrical Risk arising out of the project activity. The plant visit was carried out on 11th, 12th 13th July 2010 to collect the relevant data for carrying out Risk Assessment.

63

1. FACILITY DESCRIPTION

1. 1 BACKGROUND OF FTPL

Fairdeal Textile Park Pvt. Ltd. located at Block No 692/2, 699, 700-703 705-706, 711-713,

715, Village Mahuvej, Taluka Mangrol, Dist. Surat, Gujarat, is Textile Park promoted by

cluster of textile processing industries for setting up textile units in the park for Textile

industries like Sizing, Texturising, Weaving, Yarn preparatory etc and construction of

common effluent treatment plant (CETP) for conveyance, treatment and disposal of waste

water generated from the weaving industries having water jet looms. The treated effluent

will be reused the the same industries, i.e. Water jet looms industries.

FTPL has proposed to construct and commission underground pipeline for collection system and Common Effluent Treatment Plant for reuse/recyle of the treated effluent.

FTPL is being commissioned CETP with full fledged primary and secondary treatment

facility. Underground line and conveyance system is being designed for conveying capacity

of 10 MLD (10,000 m3 / day). CETP unit is being designed to treat & reuse 10 MLD (10,000

m3/day) raw waste water will be generated from the member industries and the treated

effluent will be reused by the same industry.

1.2 Disaster Management Plan:

Introduction: A major emergency can be defined as an accident that has potential to cause serious injury and loss of life. It may cause extensive property damage and adversely affect the environment as a whole. The emergency may be caused by factors like failure in safety system, operational error, vehicle crash, sabotage, corrosion, earthquake and in the event of war etc. Irrespective of the cause, the emergency will generally manifests itself in one of the three basic forms i.e. fire, explosion or release of toxic substances. These risks of an accident can be however reduced to a great extent by good design, operation, maintenance and inspection of the unit. But there is always a chance for an accident taking place. Absolute safety is not achievable and hence emergency planning is an essential part of major hazards control programme. It aims at,

controlling the emergency and generally mitigating the adverse effects effectively of a major accident.

1.3 Objective of DMP

The disaster management plan is develop to make possible use of resource proposed to be provided by project proponents on the site to:

Rescue the victims and treat them suitably

Safeguard others (evacuating them to safer places)

Contain the accident and control it with minimum damage.

Identify the persons affected.

Inform the relatives of the casualities.

Provide authoritative information tot the news media.

Preserve relevant records and equipment needed as evidence in case of an enquiry.

Rehabilitate the affected areas.

1.4 On site Emergency Plan:

64

FTPL proposed to implement the following onsite emergency plan, the Guidelines of the plan are as given below:

Informative brochure on emergency will be distributed to concerned staff.

Telephone numbers of key personal to be contacted during an emergency will be placed at common places and provided to all member units.

Workers would be trained regularly on fire hazard drill which will be organized periodically by fire & safety experts.

The fire hydrant system at various location shall be checked for operations on regular basis so that it remains operational during emergency.

Provide personal protective equipment of standard quality to workers working in risk area to minimize casualities.

Color coded & labeled pipeling as per ISI standards shall be used to easily distinguish during emergencies.

Develop a well equipped Fire & Emergency Control Centre within Park premises.

1.5 Post disaster Analysis:

When an emergency is over it desirable to carry out a detailed analysis of the causes of the acident to evaluate the influence of various factors involved and to propose methods to eliminate or minimize them in future. Simultaneously, the adequacy of the plan will be evaluated and any short coming will be rectified.

1.6 NATURAL HAZARDS AT SITE

1.6.1 Lightening

Lightening strokes

0.2-1

1-4

4-10

10-20

20-40

40-80 Global frequency of lightening stockers per km2 and per year.

As per Munich Re World Map for Natural hazards, Fairdeal Textile Park Pvt. Ltd.,

Mahuvej, Surat (Gujarat) region is less than Zone - I which means on an average

there are 2 - 6 lightning strikes per km2 area per year. However, lightening strikes

causing damage cannot be ruled out.

Thus risk ex osure can be considered as Low

1.6.2 Flood

Fairdeal Textile Park Pvt. Ltd., Mahuvej, Surat (Gujarat) region is in close proximity

to sea, hence the possibility of flood is high but till date history of flood leading to

damage in this area is not known.

1.6.3 Cyclone

Cyclonic disturbances strike North- Gujarat, particularly the Kachh and Saurashtra

65

regions, periodically. These disturbances generally originate over the Arabian

Sea and sometimes the Bay of Bengal. Generally during June, the storms are

confined to the area north of 15· N and east of 65· E. In August, in the initial

stages, they move along the northwest course and show a latitude scatter. West

of 80· E, the track tend to curve towards north. During October the direction of

movement of a storm is to the west in the Arabian Sea. However, east of some of

the storm move north - northwest and later recurve northeast to strike Gujarat -

North Mekran Coast.

Hence, the risk exposure can be considered as moderate.

1.6.4 Storm / Cyclone

Tropical cyclone

Zone 0: 76-141 km/h

Zone 1: 142-184 km/h

Zone 2: 185-212 km/h

Zone 3: 212-251 km/h

Zone 4: 252-299 km/h

Zone 5: >-299 km/h

Probable maximum intensity with an exceedance probability of 10% in 10 years (equivalent to 'return period' of 100 years). As per Munich Re World Map for natural hazards the maximum wind

speed in Fairdeal Textile Park Pvt. Ltd., Mahuvej, Surat (Gujarat) region is

around 118 -153 kmph. The Storm Exposure is classified as SS 2, Zone 1

as per Munich Re world map.

Thus, overall exposure to Storm can be considered as moderate

1.6.5 Earthquake Earthquake

Zone,O: MM V and below

Zpne 1: MM Vl

'Zone 2: MM VII.

ZOne 3: MM VIII

Zone 4: MM IX and above

Probable maximum intensity (MM: modified Merci~lIi scale) with an" exceedanceProbability of 10% in 50'" years (equivalent to 'return period' of 475 years) for medium subsoil conditions .

As per Munich Re world map for Natural hazards the Fairdeal Textile Park Pvt.

Ltd., Mahuvej, Surat (Gujarat) region is coming under Zone I of TAC and Mercalli

scale Zone 3 MM IX and high exposure to earthquake risk.

However, seismic experts have opined that the Indian land mass is being

constantly

compressed between the sea and Himalayas and thus the developed stresses

are being released in the form of earthquakes in the least expected areas.

Thus taking the above in to consideration risk exposure can be considered as

66

High.

1.6.6 Tsunami

Tsunami (seismic sea-wave) Hazard in coastal areas As per Munich Re world map for Natural hazards the Fairdeal Textile Park Pvt.

Ltd., Mahuvej, Surat (Gujarat) region is not coming under hazardous zone.

However, the expert opined that due to global warming and rapid climatic

changes the Tsunami can occur in least expected areas.

Region is near to sea, hence, the risk exposure can be considered as moderate.

67

2. PROCESS

2.1 MANUFACTURING PROCESS OF ‘CETP’

2.2 Process Flow Diagram

2.3. Effluent Treatment Scheme (Existing)

2.4 Treatment & Recycling Scheme

As mentioned earlier, the units located in the Park would have facilities for Texturizing,

Weaving and Sizing. The Water Jet Looms are used to produce fine fabric using

synthetic yarn. In the weaving process good quality water, having Low “Total Dissolved

Solids” (TDS) is used as a media to facilitate the movement of yarn in the looms.

During this process, the antistatic coning oil present on the yarn surface is washed out

along with fine pieces of yarn, dirt & a small quantity of machine oil, which is used for

machine lubrication. Thus wastewater generated in the process indicates presence of

pollutants. The total wastewater estimated to be generated from member industries and

other utilities is 10 MLD (10,000 m3/day).

Industrial effluent from the pre and post processing units will be collected by

pumping stations. The quantity of industrial wastewater generated is estimated at

10 MLD. Wastewater would be collected in the main by two RCC trunk mains of

500mm diameter

Plain settling

Physico Chemical Treatment

Activated Sludge Process

Graded Sand Filtration

Activated Carbon Filtration

68

2.5 Equalization and Physical Treatment Waste water is received in Waste Water Collection Tank at CETP inlet. Operation of

Effluent Feed Pump is automatic using level switch installed in waste water collection

sump. Raw effluent pump provided will be adequate to handle 10 MLD load of waste

water.

Physico Chemical Treatment The wastewater shall be further taken to Equalization Tank, which shall be provided with

agitators. The wastewater from the equalization tank shall be pumped to the chemical

treatment where it shall be mixed with chemicals, such as Alum / Polyelectrolyte. The

chemicals shall effectively remove part of the soluble oil as well as large part of

suspended solids

The partially treated wastewater shall be taken to the Aeration tanks provided

with diffused Aeration system comprising of Air blower & fine pare air diffusers,

for further removal of BOD & COD

2.6 Biological Treatment In the Aeration tank the wastewater shall be treated by the biomass specially developed

for this purpose. By providing required detention time the soluble organic

(biodegradable) impurities shall be taken care of. The overflow of the Aeration tank shall

be taken to the clarifier. The enriched biomass from the clarifier bottom shall be recycled

to the aeration tank to maintain concentration of biomass, while the clarified overflow

shall be collected in a clarified wastewater tank. Excess biomass produced in the

process shall be taken for dewatering by the centrifuge

2.7 Tertiary Treatment

The clarified wastewater shall now be treated by battery of filters comprising of Pressure

Sand Filter and Activated Carbon Filter & shall be subsequently send for reuse The final

filtration by micron filters shall be carried out by individual industries at their premises

2.8 Sludge Dewatering System The sludge from the primary clarifier & excess sludge from the secondary clarifier shall

be collected in sludge sump and shall be treated by the sludge thickener to increase

sludge solids concentration. The thickened sludge shall be collected in the tank and

further dewatered using the centrifuge. The centrate from the centrifuge shall be

collected separately and pumped to the inlet chamber.

69

70

3. PROCESS OF YARN PREPARATORY / PROCESSING

Types of units

A PROJECT IN BRIEF

Location Village Mahuvej, Taluka Mangrol, Surat, Gujarat

Name Fairdeal Textile Park Private Ltd.

Activities Texturizing, Weaving & Sizing units

Project Cost Rs. 115 Crores

Expected Employment in the Park Direct – 2,900

Indirect – 4,300

Expected Investment in the Park Rs. 300 Crores

Expected Turnover in the Park Rs. 1200 Crores

71

3.1 HAZARDS IDENTIFICATION

(A) OCCUPATIONAL HEALTH

In Textile units there are some common health hazards like dust, heat stress, humidity effect, noise pollution, radiation during welding. The above hazards can be reduce by suitable mechanism, providing personnel protective equipments, training, design of the plant etc. The medical examination to be carried out once in a year by certified doctor.

Sr.No TOR DISCRIPATION RECOMMENDATIONS

Occupational health

Occupational injury

(1) Good house keeping

to be maintained in

the park as well as

all work area to keep

neat and clean.

(2) Personal protective

equipments to be

provided to the

workers.

a. Helmet

b. Goggles

c. Handgloves

d. Gumboots

e. Ear Plugs specifically

for weaving

(3) It will be carried out

medical check up.

(4) It will be carried out

hygiene of drinking

water , bathroom,

toilet, etc.

72


Medical Check up

Work area monitoring

(1) It will be controlled

work area by good

house keeping.

(2) It will be provided

suitable respiratory

equipment.

It will be carried out as

per statutory

requirement once in

a year.

It will be maintained

as per Gujarat

factory rules Form

no-37.

73

(B) FIRE AND EXPLOSION HAZARADS

Sr.No. TOR Description Recommendation

1

2

Risk Assessment fire

Storage godown fire

(1) It is suggested to use Flame proof

electrical appliances .

(2) It is suggested to maintain suitable

fire extinguishers.

(3) It is suggested to facilitate Water

hydrant system .

(4) It is suggested to provide training to

the employees .

(5) It is suggested to maintain suitable

extinguishing appliances.

(6) It is suggested to display

emergency contact numbers at

conspicuous places.

(1) It ia suggested to isolate from the

working activity .

(2) It is suggested to consider Well

ventilated design.

(3) It is suggested to control Inventory.

(4) It is suggested to Electrical lighting

of flameproof type.

(5) It is suggested to well approachable

in case of emergency.

(6) it is suggested to provide Training

for handling of material.

74

Sr.No. TOR Description Recommendation

3

4

5

Risk assessment –

explosion

The site plant of

factory-map

On Site / Off-Site

emergency plan

(1) Raw material is non-explosive but

take care while handling in process.

(2) It is suggested to taken care in the

process .

(3) Manufacturing process is carried out

at atmospheric condition.

(4) It is suggested to avoid presser

building during manufacturing

process.

(5) It is suggested to control of inventory

at minimum level.

(1) it is suggested to clearly mark the

location of the go down/ Storage in

the site plant of the park.

(2) It is suggested to protect from any

source of fire.

(3) It is suggested to Isolate from other

working activity.

It is prepared and documented

75

(C) Measures against fire hazards

Sr No. TOR Description Recommendation

1

2

3

4

Automatic fire detection and

control system

Water Hydrant system

Fire Protection

Toxic gas

(1) It is suggested to install at required

at hazardous area.

(2) It is suggested to separate Fir prone

area by fire resistant walls.

(3) Ventilation ducts, pneumatic

conveyors, A.C. plants etc. Should

have flame arrester.

(4) Flame proof damper or automatic

fire extinguishers electrically

interlock with heat sensitive smoke

detectors.

(1) It is suggested to install Hydrant-

system in the park and It should be

under working condition.

(2) It is suggested to arranged a

Provision of D.G. sets available at

installation site.

(1) Unobstructed layout of the plant

and building for easy fire fighting.

(2) Doors and Windows should be

openable to the out work.

(3) It is suggested to clean up dust

accumulation.

(4) It is suggested to provide exits as

per norms.

(5) It is suggested to maintain sufficient

number of fire extinguishers.

(6) It is suggested to arrange

necessary fire fighting training to the

employees.

No such Toxic gas like chlorine,

ammonia, hydrogen sulphide etc.

76

(D) WATER RESERVOIR


1

2

Arrangement for Water provision

Emergency situation

(1) A Reservoir of 15000kl.

(2) Recycled water from CETP.

(1) Sufficient Water to be stored in the

reservoir.

(2) It is suggested to install Hydrant

system with hydrant pump, jokey

pump, auto system, D.G. set.

77

(E) DO’S & DONTS


1

2

3

4

Preventive maintenance

HSE

Utility

Manufacturing

(1) It is suggested to prepared check list of equipment.

(2) It is suggested to maintain Register.

(3) It is suggested to carry out corrective measures to avoid reoccurrence.

(1) It is suggested to taken action for health, safety and environment.

(2) It is suggested to prepare programs to develop safety awareness.

(1) It is suggested to maintain equipments in order to control accident or incident.

(2) It is suggested to carry out testing report as per schedule.

(1) It is suggested to control hazards of materials by proper storing and handling.

(2) It is suggested to arrange training for the better operation to avoid mishap.

(3) It is suggested to displayed work instruction at work place.

(4) It is suggested to maintain good housekeeping .

78

4. EMERGENCY CONTROL CENTERE (ECC)

Location of ECC - will be in the New Administration Building

5. COMMUNICATION NETWORK IN THE PARK

5.1 Internal Telephone Numbers

For internal communication plant has intercom services covering the entire facility.

'Internal facility plant Telephone Numbers

For the Emergency Preparedness

Sr. No.

Contact Person Post Contact No.

1 Company Chairman 9825114363

2 Director iP Rl _ 9825121258 3 DirectorfCETP 0 & Ml 9825121493 4 Technical Manager 9879680000

5 Civil engineer 9825134802 6 PRO - 7 Plant Chemist -

5.2 External Telephone Numbers

Sr. No.

Contact Person Post Contact No.

1 .(Gujarat Pollution Control Board, Surat

0261·2442696

2 D.G. V.C.L.,Surat 0261·2804228 3 D.G. V.C.L. ,Kosamba 02629-231256 4 Gram Panchayat, 5 Gram Panchayat, 6 Fire Station,Mugalisara (Surat) 02621·2400172 7 Fire Station, Kapodara (Surat) 02621·2571388 Fire Brigade 101 Civil Hospital,Surat 02621·2244456 Ambulance 108 Police Commissnor, Surat 02621·2463939 Police Station,Kosamba

79

6. FIRE PROTECTION SYSTEM

The fire protection system is in the park is the form of Portable fire extinguishers only.

6.1 Portable Fire Extinguishers

The CO2 fire extinguishers of 4.5 Kgs of two each are placed in the MCC rooms

6.2 FIRE FIGHTING TEAM

List of Fire fighters in plant

Sr. No.

Contact Person

1 Fire Officer

2 Fire Man

3 Helper

4 Helper

5 Helper

6 Helper

6.3 FIRST AlDERS TEAM

List of First Aiders in plant

Sr. No.

Contact Person

1 First Aider

2 Assistant

3 Helper

4 Helper

7.1 FIRST ACTION PLAN The person who first observes the emergency is called the "First Observer". The first observer noticing an unusual occurrence should - immediately inform the concerned in charge of the facility I security I activate the fire alarm system. While giving information about the emergency, the First observer should:

Identify himself (Name, Department for which is working)

State briefly the type of emergency whether fire etc.

Give the location of the incident I emergency. After receiving information from First Observer, the security in charge at site should notify key personnel as mentioned in the list by Telephone Operator. The following information would be conveyed. • Location of emergency. • Type of emergency. • Severity of emergency. In case of an emergency during night hours I holidays I after general shift hours the security in charge at site would inform key personnel over telephone.

7.2 INFORMING THE EMERGENCY The manual Bell / Electrical Bell is located within the units. The sounding will alert personnel of that section

7.3 All Clear Signals The signals should be long continuous lasting 2 min.

80

7.4 COMMUNICATION FLOW CHART

Mode: Telephone, Manual Bell, Personally, Messanger

Model: Electric Bell, Mobile Phone

Phone

Phone, Safety & ECC Room

First

Observer

Incharge

ECC Room

Inform concerned

departments

Incident

Controller

Review &

Inform

Main

Controller

Activate DMP Call Fire

81

8 EVACUATION PROCEDURES

8.1 FIRE SCENARIO IN THE PARK

Fire Evacuation Procedures

If there is a fire in the Park / work area

Follow RACE:

Remove anyone from immediate danger. Activate the Plant / facility fire alarm system if you observe smoke or fire. Confine the fire by closing all windows and doors. Evacuate, leave the Plant / Facility, first, and notify the fire incidence to

the Control Room concerned by calling 101 to provide details of

the fire situation. (Familiarize yourself with the floor layout)

Extinguish the fire if the fire is small, if the person has been trained in the

use of a portable fire extinguisher and is able to safely extinguish the fire,

he or she may do so. Be sure he or she has a safe exit from the area. Stay calm; do not rush and do not panic. Safely stop your work. Gather your personal belongings if it is safe to do so. Use the nearest safe stairs and proceed to the nearest exit.

Do not use the elevator. Elevators enter into a "fire service" mode and may

not respond to calls when the fire alarm system has been activated.

Occupants may become trapped in elevators. On your way out, warn others nearby. Crawl and move away if there is fire and smoke. Close doors and windows if time permits. Touch closed doors. Do not open them if they are hot. Move well away from the building and go to your designated EAP. Evacuate the section / facility as soon as the alarm sounds and proceed to

the designated Emergency Assembly Points (EAP) Wait for any instructions from emergency responders. Do not re-enter the building or work area until you have been instructed to

do so by the emergency responders.

8.2 Fire Prevention Procedures

To prevent fire, the Plant I facility must maintain a good housekeeping policy,

which includes:

Program for regular inspection and maintenance of fire extinguishers.

List of major fire hazards and proper handling I storage procedures. Housekeeping procedures and schedule to control accumulations of flammable

and combustible waste materials and residues. Procedures and schedule for routine maintenance of electrical and mechanical

equipments at the Plant to prevent accidental ignition.

Personnel responsible for fire prevention equipment/systems.

Storing flammable and combustible materials in an approved manner. Avoiding accumulation of flammable and combustible materials in work areas.

The full building should be a "NO SMOKING "Zone.

8.3 UTILITY FAILURE

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Interruption to Power Supply

interruption to power supply ("Power Outage") refers to the loss of power supply to the plant / facility, which may place plant / facility occupants at risk through loss of lighting in areas where natural light is inadequate.(lncidentally Emergency lights will come on as soon as the DG takes over).

On instruction of Emergency Control personnel to evacuate the plant / facility, immediately cease all activity and secure personal valuables;

If practicable, and only safe to do so, secure any activity that damage if left

unattended as a consequence of a Power Outage;

Act in accordance with directions given by Emergency Control personnel and

evacuate the plant / facility immediately. Help visitors if any in the plant to

evacuate.

Assist with the evacuation of disabled occupants if any.

Assist with the general evacuation if directed to do so by the Emergency Control

personnel;

Move calmly to the nominated Evacuation Assembly Area, and do not leave the

Evacuation Assembly Area until the All Clear has been given, or other relevant

instructions issued;

Follow the instructions of the plant / facility Emergency Control personnel.

If an outage occurs during the day and people with disabilities choose to wait in

the building for electricity to be restored, they can move near a window where

there is natural light and access to a working telephone.

If people would like to leave and an evacuation has been ordered, or if the

outage occurs at night, call Police from a plant telephone.

8.3.1 Sample Emergency Floor Plan

The sample floor plans with emergency exits are highlighted which are to be

displayed in each appropriate section. Also all emergency exits have been

identified with arrows pointing to-wards them.

Appropriate emergency exit signs are chosen in the plan.

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9 ROLES & RESPONSIBILITES

9.1 ORGANIZATION CHART

Board of Directors

General Manager

HOD Commercial

HOD Technical PRO Accountant

Mechnical Chemist Electrical

Operator Wireman Asst. Engg.

Helper Helper Fitter

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9.2 MAIN CONTROLLER

It is essential that senior most executive be in-charge of the overall emergency plan.

Hence the Facility Head or his nominee should be the Main Controller with the

responsibility of overall guidance of emergency management and assists the site

controller for taking strategic decision. The other tasks include the overall supervision

of all protective actions aimed at protecting the public, employees, environment and the plant property. The main controller is provided with a distinctive colour helmet

and fluorescent jacket.

Roles:

He shall:

1. Co-ordinate with the Incident and Site Controller and assess the situation from off-

site implication point of view.

2. Act as a Site / Incident controller in his absence / till he arrives.

3. Take strategic decisions, should the Site Controller desire at any point of time

while handling an emergency

4. Co-ordinate with communications team.

5. Issue authorized statement to the media.

6. Ensure safety of On- Site and off site personnel.

7. Ensure that casualties if any are given medical attention and that their relatives

are informed, if necessary.

8. Ensure preservation of evidence for investigation to be conducted by statutory

authorities.

9. Authorize the termination of emergency situation by sounding of All Clear siren.

9.3 INCIDENT CONTROLLER

The Incident Controller is responsible for supervising and coordinating the activities of those functions involved in mitigating the consequences of the- accident. With help of

Emergency Handling teams, he will handle the emergency at the site. The Incident

Controller is provided with a distinctive helmet and fluorescent jacket, for easy

identification.

Roles:

1. He shall immediately proceed to the scene of emergency and assess the

situation, act as a main controller if necessary.

2. He shall keep the Main Controller informed of the situation from time to time.

He shall organize and direct the emergency response activities keeping in mind

the safety of personnel and minimizing loss and damage to property.

3. He shall instruct emergency team / first aides at the site.

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Based on the advice of the Main Controller he shall formulate strategies for the actions to be taken to mitigate the consequences of the accident.

4. Maintain direct communications with the personnel in the field / Site Controller.

5. Co-ordinate the activities aimed at organizing, requesting, and obtaining

additional resources (equipment and personnel) to support the emergency

operations.

6. Check for casualties and head counts (Plant / Facility).

7. Arrange for rescue of trapped workers and those in a state of shock.

8. Preserve all evidences for use in the subsequent investigations.

10. Ensure that the casualties, if any, are given medical attention and that the

relatives are informed, if necessary.

11. Arrange for relief of personnel when emergency is prolonged.

9.4 SITE CONTROLLER

The Site Controller will co-ordinate with the Main Controller, Communication team and

Incident Controller. He is heart of the plan as his role is vital and he will take major

decisions while handling an emergency. The site controller is provided with a

distinctive helmet and fluorescent jacket.

1. He will collect the information regarding status of the emergency, assess the

gravity of situation and convey to the Main Controller.

2. He will guide the floor marshals / wardens / fire fighting teams / rescue team in

handling the emergency and safe evacuation.

3. He will co-ordinate with Communication Team for:

Contacting external agencies for help i.e. Fire Brigade, Police, Ambulance, hospitals

etc.

Instructing a message to be announced on Public Address System.

4. Advice the main / incident controller to call off the emergency.

5. Ensure on-site and off-site personnel protection, safety and accountability.

9.5 COMMUNICATION TEAM The communication Team comprises of Administration manager /Security Manager.

He will:

1. Immediately proceed to the Location designated and contact the Main

Controller.

2. Work as a liaison officer during the emergency.

3. Under the direction of the Main Controller, handle police, press and other enquiries,

receive reports of roll call from emergency assembly areas and pass on the

absenteeism information to the Incident Controller.

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4. Ensure that casualties receive adequate and immediate medical attention. Inform

victims' relatives, if required establish contact with hospitals.

5. In addition, this function has the important task of keeping chronological records

of what has happened during the emergency, and preparing reports for the Main

Controller and his staff. This includes:

a. Recording any change in the emergency action level status.

b. Keeping track" of all external agencies that have been notified.

c. Keeping track of emergency personnel intervening.

d. Keeping track of emergency personnel notified and arriving at the scene.

e. Maintaining a record of the changes in the emergency, organization

structure as higher officials arrive to relieve lower-ranked personnel.

f. Keeping a record of all events affecting the emergency.

g. Keeping a record of all of the decisions made and emergency actions taken

during the emergency operations.

h. Updating maps and wall charts displaying the spreading of the emergency (e.g.,

Sections affected by fire, areas affected by evacuation orders),and maintaining a

record of them.

i. Updating the same charts showing the position of the emergency team or

fire fighting team, and keeping a record of them.

j. Recording the arrival of special emergency materials or equipment (this

may be especially important for later financial accountability).

k. Recording any fact of relevance occurring during the emergency.

10 TERMINATION OF EMERGENCY

Calling off an emergency or recovery following aftermath of an emergency is a crucial

phase in emergency planning as administration has to make sure that affected areas

are safe to re-enter. The recovery and re-entry phase will begin after the declaration

of termination of emergency situation. This decision would be made by the Main

Controller. In case of non-availability, the Incident Controller shall call off the

emergency. The recovery plan would be flexible enough to adapt to the prevailing conditions.

Following aspects need to be addressed during RE - ENTRY:

1. De-escalation of the emergency should be done gradually and correct procedures

should be written for various activities to address following:

Organizing a re-entry team

Inspecting the damaged area

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Assessing the damage to the facility

Decontaminating the affected area

Clearing up the debris

Restoring services to the affected area

2. In case of Offsite Emergency, Public notification may need to be done with

available means of communication.

3. Who will assess property damage? Is litigation a possibility? Against whom and by

whom?

4. How will the relief assistance be distributed?

5. Beginning an investigation into the causes of the emergency. A detailed report

of the events should be prepared.

Documents

RISK ASSESSMENT REPORT DISASTER MANAGEMENT PLANgpcb.gov.in/images/pdf/FTPL_Risk_Ass_and_Disaster_Manag_Plan.pdf · RISK ASSESSMENT REPORT & DISASTER MANAGEMENT PLAN For FAIRDEAL TEXTILE