CHEMPLAST SANMAR LIMITED EXPANSION OF PVC PLANT AT CUDDALORE, TAMIL NADU FROM 300000 TPA TO 600000 TPA ADDITIONAL STUDIES KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2018 240 7 ADDITIONAL STUDIES 7.1 Public Consultation The site is located in Notified Industrial Estate set up prior to EIA Notification dated 14th September 2006, hence Public consultation will not be required. Gazettee notification is attached as Annexure 17. 7.2 Consequance Analysis & Risk Assessment 7.2.1 Background Key issues in Risk Assessment (RA) of the Petro chemical based processing unit (M/s Chemplast Sanmar) i.e. Category 5 (e) of the Schedule to the EIA Notification dated Sept. 14, 2006 (amended till date), for proposed increased capacity ( 6,00,000 TPA) are discussed in this chapter. The risk assessment process is intended to identify existing and probable hazards in the work environment and all operations, to quantify the hazards and to assess the risk levels of those hazards in order to prioritize those that need an immediate attention. In the unlikely event that an abnormal consequence has occurred, the disaster management kicks in. This includes prescribing the procedures pertaining to a number of issues such as communication, encounter, rescue, rehabilitation and further steps to prevent recurrence of such consequence in future. These issues are addressed in the disaster management plan. Both, the RA and DMP are living documents and need to be updated whenever there are changes in operations, equipment or procedures. 7.2.2 Key Definitions The terminologies used in this Risk Assessment (RA) study are defined below. Consequence: Magnitude or size of the damage or loss. In terms of health and safety, it is the degree of harm that could be caused to the people exposed to hazard, the potential severity of injuries or ill health, and/or the number of people who could be potentially affected. Consequence of hazard need not only be in terms of human safety criteria, but could also be in terms of a financial loss due to production and incurred costs due to repairs/replacement, environmental impacts as well as public outrage. Disaster: A catastrophic consequence of a major emergency/accident that leads to not only extensive damage to life and property, but also disrupts all normal human activity for a significant period of time and requires a major national and/or international effort for rescue and rehabilitation of those affected. Emergency: A situation of process deviation that, if uncontrolled, may lead to a major accident/disaster with potential short term and/or long term risk damage consequence to life and property in and/or around the workplace. Emergency Response Planning Guidelines1 (EPRG1): The maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 hour (without a respirator) without experiencing other than mild transient adverse health effects or without perceiving a clearly defined objectionable odour. Emergency Response Planning Guidelines2 (ERPG2): The maximum airborne concentration below which it is believed that nearly all individuals could be exposed for up to 1 hour without experiencing or developing irreversible or other serious health effects or symptoms that could impair their abilities to take protective action. Emergency Response Planning Guidelines3 (ERPG3): The maximum airborne concentration below which it is believed nearly all individuals could be exposed for up to 1 hour without experiencing or developing life-threatening health effects.
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CHEMPLAST SANMAR LIMITED EXPANSION OF PVC PLANT AT CUDDALORE, TAMIL
NADU FROM 300000 TPA TO 600000 TPA ADDITIONAL STUDIES
KADAM ENVIRONMENTAL CONSULTANTS | NOVEMBER 2018 240
7 ADDITIONAL STUDIES
7.1 Public Consultation
The site is located in Notified Industrial Estate set up prior to EIA Notification dated 14th September 2006, hence
Public consultation will not be required. Gazettee notification is attached as Annexure 17.
7.2 Consequance Analysis & Risk Assessment
7.2.1 Background
Key issues in Risk Assessment (RA) of the Petro chemical based processing unit (M/s Chemplast Sanmar) i.e.
Category 5 (e) of the Schedule to the EIA Notification dated Sept. 14, 2006 (amended till date), for proposed
increased capacity ( 6,00,000 TPA) are discussed in this chapter. The risk assessment process is intended to
identify existing and probable hazards in the work environment and all operations, to quantify the hazards and to
assess the risk levels of those hazards in order to prioritize those that need an immediate attention.
In the unlikely event that an abnormal consequence has occurred, the disaster management kicks in. This includes
prescribing the procedures pertaining to a number of issues such as communication, encounter, rescue,
rehabilitation and further steps to prevent recurrence of such consequence in future. These issues are addressed in
the disaster management plan.
Both, the RA and DMP are living documents and need to be updated whenever there are changes in operations,
equipment or procedures.
7.2.2 Key Definitions
The terminologies used in this Risk Assessment (RA) study are defined below.
Consequence: Magnitude or size of the damage or loss. In terms of health and safety, it is the degree of harm
that could be caused to the people exposed to hazard, the potential severity of injuries or ill health, and/or the
number of people who could be potentially affected. Consequence of hazard need not only be in terms of human
safety criteria, but could also be in terms of a financial loss due to production and incurred costs due to
repairs/replacement, environmental impacts as well as public outrage.
Disaster: A catastrophic consequence of a major emergency/accident that leads to not only extensive damage to
life and property, but also disrupts all normal human activity for a significant period of time and requires a major
national and/or international effort for rescue and rehabilitation of those affected.
Emergency: A situation of process deviation that, if uncontrolled, may lead to a major accident/disaster with
potential short term and/or long term risk damage consequence to life and property in and/or around the
workplace.
Emergency Response Planning Guidelines1 (EPRG1): The maximum airborne concentration below which it is
believed that nearly all individuals could be exposed for up to 1 hour (without a respirator) without experiencing
other than mild transient adverse health effects or without perceiving a clearly defined objectionable odour.
Emergency Response Planning Guidelines2 (ERPG2): The maximum airborne concentration below which it is
believed that nearly all individuals could be exposed for up to 1 hour without experiencing or developing irreversible
or other serious health effects or symptoms that could impair their abilities to take protective action.
Emergency Response Planning Guidelines3 (ERPG3): The maximum airborne concentration below which it is
believed nearly all individuals could be exposed for up to 1 hour without experiencing or developing life-threatening
health effects.
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Hazard: Source of potential harm, injury or loss to man and machines.
Immediately Dangerous to life and health (IDLH): It represents the maximum concentration of a chemical
from which, in the event of respiratory failure, one could escape within 30 minutes without a respirator and without
experiencing any escape/impairing (e.g. severe irritation) or irreversible health effects.
Lethal Concentration Low (LCLo): It is the lowest concentration of a material in air, other than LC50, which has
been reported to cause death in human or animals.
Risk: Combination of the likelihood of a specific unwanted event and the potential consequences, if it occurs.
Risk Assessment: A process that involves estimation and measurement of risk to determine priorities and to
enable identification of appropriate level of risk treatment (used also to describe the overall process of risk
management).
Risk Control: Implementation of strategies to prevent, control and minimize hazards.
Risk Management: Overall description of the steps taken to manage risk, by identifying hazards and
implementing controls in the workplace.
Risk Rating: The category, level, or risk assigned following risk assessment (e.g. High, Medium, or Low).
Threshold Limit Value (TLV): It is the permitted level of exposure for a given period on a weighted average
basis (usually 8 hrs for 5 days in a week)
Short Time Exposure Limit (STEL): It is the permitted short-term exposure limit usually for a 15 minutes
exposure.
Toxic Concentration Low (TCLo): It is the lowest concentration of a material in air, to which humans or animals
have been exposed for any given period of time that has produced a toxic effects in humans or produced
carcinogenic, neoplastigenic or tetratogenic effect in humans or animals.
7.2.3 Methodology for Risk Assessment
The scope of work includes site inspection, hazard identification, selection of potential loss scenarios, and
simulation of release source model on DNV’s PHAST Professional 7.1, consequence analysis and plotting of Damage
contour on site map in order to take strategic decision to mitigate/minimize the level of risk to the facility and to the
community. The steps undertaken to carry out Risk Assessment for the proposed increased capacity are described
in subsequent sections.
7.2.4 Hazard Identification
The Hazop for this plant for the production capacity of 3,00,000 TPA was carried out by “Kadam Environmenal
Consultants” September 2011. And all recommendations were closed. Consequence analysis for 6,00,000 TPA
capacity has been done and detailed Hazop will be carried out during engineering phase.
7.2.5 MCLS Development Techniques
As a first step towards risk assessment is to identify the possible release scenarios based on available information
about scenario development for Maximum Credible Loss Scenarios (MCLS).
Basis for Selecting the Material to be studied for Consequence Assessment
Following points are considered while selecting the release scenarios:
Flammability and the flash point of the material
Phase of the material i.e. liquid or gas
Threshold quantity of the chemical as prescribed in MSIHC Rules
Operating Temperature and Pressure of the material
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Total inventory of the material
M/s. Chemplast Sanmar is using Vinyl Chloride Monomer (VCM) as a major raw material which is a highly
flammable liquid having flash point in the range of -75°C to -78°C in production of Poly Vinyl Chloride (PVC). The
flow of VCM in the facility is shown below:
Table 7-1: Flow of VCM in the Chemplast Sanmar PVC manufacturing facility at Cuddalore
The other flammable liquid being used in the facility is High Speed Diesel (HSD). The physical condition of the
containment carrying VCM as shown above is given below;
Table 7-2: Containment Operating Condition
S. No. Containment (Vessel) Temperature
(°C)
Pressure
(bar)
Height
(m)
Diameter
(m)
Volume
(m3)
Existing
1 VCM Storage Tank -13.6 ambient 21 24.8 7500
2 VCM Day Tank 30 5 - - 190
3 Reactor 56 8.5 - - 100
4 HSD Tank Amb. Amb. 3.6 2.4 20
Proposed
1 VCM Storage Tank -13.6 ambient 21 24.8 10000
2 HSD Tank Amb. Amb. 3.6 2.4 30
PVC to packing and to Supply
Sections of the facility where
containment / equipment failure
will lead to release of VCM into
the environment and can lead to
disastrous situation
VCM transfer from Jetty through
a pipe-in-pipe out pipeline
facility
VCM storage in high integrity
double walled Storage Tank at
Atmospheric Pressure and at
–13.60 C Temp
VCM from tank farm to Heat
Exchanger 1003
VCM from HE 1003 to
Intermediate Storage VCM Day
Tank
VCM from Day Tank to Reactor
Slurry from the reactor to Blow
down Vessel, then to Stripper
feed vessel, and then to FBD
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Table 7-3: Pipeline Operating Conditions
S. No.
Containment (Pipe) Temp.
(°C)
Pressure
(bar)
~Pipe Length (m)
Pipeline Size
(Inch)
~Volume (m3)
1 Pipeline transferring VCM from Jetty to Tank Farm in pipe-in-
pipe out pipeline -13.6 5 - 6 3500
OD of inner pipeline
12.75
- OD of outer
pipeline 16.00
2 Pre Cooling Line -13.6 10 - 11 3500
OD of inner pipeline
4.00
- OD of outer
pipeline 8.63
3 Pipeline connecting VCM Tank
Farm to HE 1003 -13.6 16 40 8 1.25
4 Pipeline connecting HE 1003
to VCM Day Tank 30 5 20 4 0.157
5 Pipeline connecting VCM Day
Tank to Reactor 30 14 50 8 1.6
Hazard and Damage Assessment
Toxic, flammable and explosive substances released from sources of storage as a result of failures or catastrophes,
can cause losses in the surrounding area in the form of:
Toxic gas dispersion, resulting in toxic levels in ambient air,
Fires, fireballs, and flash back fires, resulting in a heat wave (radiation), or
Explosions (Vapours Cloud Explosions) resulting in blast waves (overpressure).
Consequences of Fire/ Heat Wave
The effect of thermal radiation on people is mainly a function of intensity of radiation and exposure time. The effect
is expressed in term of the probability of death and different degree of burn. The consequence effects studied to
assess the impact of the events on the receptors are provided in Table 7-4.
Table 7-4 : Damage due to Radiation Intensity
Radiation (kW/m2) Damage to Equipment Damage to People
4.0 - Causes pain if duration is longer than 20 sec. But
blistering is unlikely.
12.5 Minimum energy to ignite wood with a
flame; melts plastic tubing. 1% lethality in one minute. First degree burns in 10
sec.
37.5 Severe damage to plant
100% lethality in 1 min.
50% lethality in 20 sec.
1% lethality in 10 sec.
Consequences of Overpressure
The effects of the shock wave vary depending on the characteristics of the material, the quantity involved and the
degree of confinement of the vapor cloud. The peak pressures in an explosion therefore vary between a slight over-
pressure and a few hundred kilopascals (kPa). Whereas dwelling are demolished and windows and doors broken at
overpressures as low as 0.03- 0.1 bar. Direct injury to people occurs at greater pressures. The pressure of the
shock wave decreases rapidly with the increase in distance from the source of the explosion. The overpressure
damage is shown in Table 7-5.
Table 7-5: Overpressure Damage
Overpressure bar Damage
1 Fatality
0.41 Ear Drum Rupture to humans
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Overpressure bar Damage
0.2 Structural Damage to buildings
0.02 Glass Damage
Source: CCPS Consequence Analysis of Chemical Release
Consequences of Toxic Release
The effect of exposure to toxic substance depends upon the duration of exposure and the concentration of the toxic
substance.
Short-term exposures to high concentration give Acute Effects while long term exposures to low concentrations
result in Chronic Effects.
Only acute effects are considered under hazard analysis, since they are likely credible scenarios. These effects are:
Irritation (respiratory system, skin, eyes)
Narcosis (nervous system)
Asphyxiation (oxygen deficiency)
System damage (blood organs)
7.2.6 Selection of Maximum Credible Loss Scenarios (MCLs’)
Following important points should be considered for the selection of release scenarios.
Flammability and the flash point of the material
Phase of material i.e. liquid or gas
Threshold quantity of the chemicals as prescribed in MSIHC Rules
Operating temperature and pressure of the material
Total inventory of the material
On the basis of study of chemical properties (MSDS) of the chemicals those are selected for simulation are
presented Table 7-2 & Table 7-3.
On the basis of the information provided in Table 7-2 & Table 7-3, and as discussed over failures sceneries given
in publications like World Bank Technical Paper 55 and TNO Purple Book and the experience of the consultant,
MCLs’ which may take place are presented in Table 7-6 & Table 7-7.
Table 7-6: Scenario Selected for Simulation from vessel Source
S. No.
Containment (Vessel)
Types of Failure Possible Consequences Studied
1 VCM Storage Tank 10 mm dia hole leak in tank, 50 mm dia hole leak in tank and
Catastrophic Rupture Jet Fire, Pool Fire,
Explosion
2 VCM Day Tank 10 mm dia hole leak in tank, 50 mm dia hole leak in tank and
Catastrophic Rupture Jet Fire, Pool Fire,
Explosion
3 VCM Reactor 10 mm dia hole leak in tank, 50 mm dia hole leak in tank and
Catastrophic Rupture Jet Fire, Pool Fire,
Explosion
4 HSD Storage Tank 10 mm dia hole leak in tank, 50 mm dia hole leak in tank and
Catastrophic Rupture Jet Fire, Pool Fire,
Explosion
Table 7-7: Scenario Selected for Simulation from Pipe Source
S. No.
Containment (Vessel) Types of Failure Possible Consequences Studied
1 Pipeline transferring VCM
from Jetty to Tank Farm in pipe-in-pipe out pipeline
visual observation, Ready availability of fire extinguishers and fire hydrant system
7.2.9 Precautions to be taken during Transportation
Following are some precautions will be taken during the loading and unloading of material in plant premises.
Before the tanker enters the industry premises, the tanker is to be inspected for authorized entry and safe &
sound condition of the tanker, its contents and that of the prime mover. Flammable material carrying tankers
entering plant are to be fitted with spark arresters on their exhaust.
Static charge neutralizing
The quality of the chemical in the tanker should be ascertained before unloading to avoid contamination of
chemical already at storage.
Coupling used for connecting hose to tanker must be leak proof.
For flammable chemicals, the tanker and the hose are to be properly earthed before starting unloading
operation.
Unloading should be done under personal supervision of responsible staff authorized by the management.
Provision of sample quantity of water / neutralizing medium to take care of leakage / spillage must be made.
Also steam and inert gas hose stations must be available at unloading point.
Fire alarm and firefighting facility commensurate with the chemical should be provided at the unloading point.
7.3 Disaster Management Plan
7.3.1 Objectives of Onsite Emergency Plan
The objective of “On-Site Emergency Plan” is to prepare well in advance to contain effectively any emergency in the
shortest time possible with minimum loss. The plan aims to make the maximum use of the combined resources of
the plant and the outside services to take fast and effective actions in any emergency in order to:
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Protect the personnel, plant and the environment
Effect rescue and treatment of casualties, if any
Safeguard other personnel and sections in the premises
Minimize damage to property and environment
Initially contain and ultimately bring the incident under control
Provide authoritative information to the media
Preserve the relevant records and equipment for subsequent enquiry
7.3.2 Definition of Terms
Table 7-34: Definition of Terms
Hazard The size and nature of the event unforeseen.
Risk The probability that the event could occur.
Consequences The effect on people, plant and environment, both on-site and off-site due to emergency.
Major Emergency
An industrial emergency could be defined as an “occurrence of such magnitude so as to create a situation in which normal pattern of life within an industry/plant is suddenly
disrupted, adversely affecting not only the personnel and property within such an industrial area, but also in the vicinity”. It will require the assistance from outside agencies and use of
outside resources to handle it effectively.
Key Personnel
The essential actions during an emergency depend upon the prevailing circumstances. Nevertheless, it is imperative that the required actions are promptly and effectively organised
by nominated people, each having specified responsibilities as part of coordinated plan. Such nominated personnel are known as KEY PERSONNEL.
Site Controller Site Controller is the person who assumes absolute control of the works and determines the
actions necessary to control the emergency.
Incident Controller Incident Controller is the person who goes to the scene of emergency and directs the actions
at the location of incident to overcome the emergency.
Teams A number of special actions may have to be carried out by specified works personnel to
control as well as minimise the damage and loss. For this purpose, designated teams should be available. Each Team will be headed by a Leader.
Emergency Control Centre The Emergency Control Centre is the place from where the operations to handle the
emergency are directed and co-ordinated.
Incident Control Centre Incident Controller (IC) means Incident Control Centre during emergency. It should be
located at minimum risk area.
Safe Assembly Points
In an emergency, it will almost certainly be necessary to evacuate personnel from affected areas and, as a precautionary measure, to further evacuate non-essential workers from
areas likely to be affected, should the emergency escalate. The evacuation will be effected on getting necessary message from Site Controller (SC). On evacuation, employees should be directed to pre determined safe places called safe Assembly Points. The safe Assembly
Points are to be located well away from plant and equipment and near exits from plants and conspicuously identified.
Escape Routes The roads leading to the safe Assembly Points are the designated escape routes. The
escape routes would be clearly marked with arrow marks for easy identification and escape.
Essential Personnel Essential Personnel are those to whom specific responsibilities are assigned in the
management of the On-site Emergency.
Non-Essential Personnel Non-Essential Personnel are those to whom specific responsibility is not assigned in the
management of emergency.
Recovery It means that all those short term and long term activities undertaken by the management
to normalize the operations after an emergency.
7.3.3 Declaration of Emergency
Declaring Fire Emergency
Any one discovering a fire shall attempt to put out the fire by using the first aid fire fighting appliances
Simultaneously, he would shout FIRE, FIRE, FIRE/ THEE, THEE, THEE (in local language) till the assistance
arrives
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Any one or his colleagues who hears, shall immediately inform the Shift In-charge and Control Room over
phone or in person giving the exact location of the emergency
The Incident Controller on hearing the incident of emergency would proceed to the scene of emergency and
assess the situation and decide whether a major emergency exists or is likely to escalate into major one
If a major one, he would activate the on-site emergency plan by sounding the siren to code and informs the
Site Controller
The key personnel would report to the emergency control centre and take respective charge
Declaring VCM Leakage Emergency
Any person discovering VCM leakage would immediately inform the control room giving the exact location of
the leakage
He shall not approach the leakage without suitable personal protective equipment. Approach would be from
upward wind direction
The Incident Controller would proceed to the site with protective equipment from upward wind direction and
assess the situation
He will take a decision whether it would be possible to attend the leakage safely. If it is YES, he would call the
maintenance and operational personnel and get it attended taking all safety precautions
If he feels the leakage could not be attended so, if required, he would take a decision to close down the
system concerned and also inform the Site Controller about the same
He shall not allow people to crowd in that area but directs them to safe areas and if warranted to assembly
points
If gas is escaping into the atmosphere and surrounding, Incident controller would activate the on-site
emergency plan by hooting the siren to code
Declaring HSD Leakage and Fire Emergency
Any person discovering HSD leakage or fire would immediately inform the control room giving the exact
location of leakage or fire
The Incident Controller would proceed to the site to assess the situation. Meanwhile, the person discovering
HSD fire shall try to extinguish it, if it is safe to do so, using suitable fire extinguishers
If the leakage could be attended safely, he would call the maintenance and get it attended
HSD leakage shall be collected and not allowed to spread
If the leakage is very heavy and warrants plant shutdown, the Site Controller shall be informed and on his
confirmation, he would take suitable action
If the leakage has caught fire, the Incident Controller would initiate the On-site Emergency Plan by operating
the siren to emergency code. The Site Controller would be informed.
Declaring Hydrochloric Acid Emergency
Any person discovering Hydrochloric acid leakage would immediately inform the Shift-in –charge/control room
giving the exact location of the leak
He shall not approach the leakage without suitable personal protective equipment
The incident controller would proceed to the site to assess the situation
He will take a decision whether it would be possible to attend the leakage safely. If it is YES, he would call the
maintenance and operational personnel and get it attended taking all safety precautions
If he feels the leakage could not be attended so, and warrants storage tank isolation he would make suitable
arrangements. If required he make arrangements for neutralizing the leaked acid lime or soda ash
He would inform the Site Controller about the same
He shall not allow people to crowd in that area but directs them to safe areas and if warranted to assembly
points
If required he shall initiate the On-Site Emergency Plan by sounding the siren to code
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Figure 7-22: Onsite Emergency Plan
Legend: Admn – Administration; CSR – Corporate Social Responsibilities; PR: Public Relations
7.3.4 Key Personnel and Responsibilities
Table 7-35: Key Personnel and Responsibilities
S. No Designation Designation during Emergency
1 Location - Head Site Controller
2 Manufacturing head Alternate site controller
3 Head – Instrumentation Alternate site controller
There will be 7 Emergency Teams. Each Team will be headed by a Leader assisted by number of personnel,
Allotment of Personnel for Each Team
The personnel for each team are allotted based on the minimum strength, which would be available on any day and
beyond the general shift hours.
The extra personnel available in the plant at the time of accident will be commissioned for augmenting the teams
engaged in control of the emergency.
Site Controller
Location: Head
Alternate: Head (Production)
Incident Controller Location: Head (Production) Alternate: Shift In charge.
Emergency Task Force Team Leader: Head (Mechanical) Altertnate: Senior Manager (Mechanical)
Logistic controller
Leader: Head - Security
Alternate: Support Services
Communication Team Leader: Head (Instrument) Alternate: Head: (Electrical)
Safety & Fire Fighting Team Leader: Head (safety) Alternate: Joint Manager (Safety & Environment)
Incident control Team Respective shift-in-charge. Area officer
Security Team Leader: AGM -Security Alternate: Shift Security Officer
Medical Team Leader: Medical Officer - OHC Alternate: Shift First aider
Manpower Accounting Team Leader: Head (HR) Alternate: Officer (HR)
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The minimum allotment is done so that there are no extra persons overcrowding at the location and also to avoid
confusion.
The responsibilities of each Team and its Leader are specifically delineated, so that the responsibilities do not over
lap and confusion does not develop in executing the duties.
Incident Control Team-Production Team
Emergency Task Force
Communication Team
Security and Transport Team
Manpower Accounting Team
Medical Team
Safety and Fire fighting Team
7.3.6 Emergency Action Procedure
Responsibilities of Any Person Noticing Emergency
Raise alarm by shouting, "FIRE OR GAS/LIQUID LEAK, HELP" as the case may be.
Break the nearest Manual call Point.
Inform other employees in the vicinity by shouting.
If possible, attempt to extinguish the fire or take suitable action to contain the incident
Immediately inform the Shift in Charge/ Control Room. Pass on the following information to them :
Location and brief description of the incident
Approximate severity of the situation.
Wind direction
Action immediately taken
Continue control of the emergency at location.
Shift-in-Charge of the affected plant
Rush to the spot of emergency
Assess the severity
If required inform Main Control Room to declare emergency
Mobilise men and material for control of emergency
Responsibilities of Main Control Room during Emergency
On getting information regarding any emergency from the Shift-in-Charge of the concerned plant the Main Control
Room In-Charge/supervisor should do the following:
Immediately start the "wailing siren"
Announce the emergency on "Public Address System" (PAS) (In English and Tamil).
Handle all communication till take over by the communication team.
Immediately arrange to inform Shift in-Charge of the Main Plant.
Inform Security at Main Gate.
If the incident comes under control activate "all clear siren" on the advice of the Site controller.
7.3.7 Roles and Actions of Key Personnel, Teams and Other Essential Personnel of the Company on
Hearing Wailing Siren or on Coming to Know of Emergency
Site Controller
On hearing the Emergency Siren, rush to Emergency Control Centre 1 or 2 and take charge of the incident.
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Take overall responsibility for directing emergency operations and asking outside help.
Assess the situation quickly and find out the level of emergency from Incident Controller and decide and
declare major emergency, if needed inform occupier.
Ensure that other key personnel are called-in.
Direct emergency control and rescue operations with the following priorities
Personnel safety (Arrange to provide necessary safety equipment to all the personnel in the plant, if
required.)
Plant, property and environment safety.
Minimum loss of production.
Continuously review and assess possible developments to determine most probable course of events.
Direct safe shut down of plants in consultation with Incident Controller and key personnel, if necessary.
Call Emergency Task Force for arranging immediate repairs and maintenance of equipment, if necessary.
Arrange to check that all non-essential workers, visitors, contract labor are evacuated to Assembly Points
and later on to safe places, if required.
If necessary, arrange for evacuation of neighboring population
Ensure that search for affected personnel within the affected area have been carried out.
Arrange for hospitalization of victims and additional help, if required, and ensure that relatives are apprised
of.
Ensure liaison with outside agencies such as District Emergency Authorities, District Magistrate, Police
Services and Chief Inspector of Factories, Deputy Chief Inspector of Factories and Inspector of Factories.
Provide advice on possible effects on areas outside the factory.
Ensure that a chronological record of the emergency is being maintained.
Direct sounding of all clear sirens, when the situation comes under control.
Control rehabilitation of affected areas on cessation of the emergency.
Arrange to flash information to public on radio and TV.
Issue authorized statement to the news media.
Ensure that evidence is preserved for enquiries to be conducted by statutory authorities.
Incident Controller
The Shift In-charge of the affected plant would act as Site Controller till the Site Controller arrives. Thereafter he
would be “Incident Controller”. He would execute the following responsibilities:
Take action to control the incident either by isolating the equipment or by stopping the plant and
simultaneously inform the Site Controller.
He would assess the emergency situation and if a major emergency exists or is likely to develop, he would
activate the On-Site Emergency Plan.
He would depute an operator to remain near the telephone to give and receive messages.
Ensure through the Site Controller that the required key personnel and outside help are called-in.
Direct all emergency operations, within the affected area, with the help of operation staff available at site,
with the following priorities.
Secure the safety of personnel
Minimise damage to plant, property and environment
He would ensure that all non essential staff and contract workmen are evacuated to the safe assembly points
He would ensure that the affected area is searched for causalities or trapped personnel
Brief the Site Controller and keep him informed of the developments. Provide guidance to the fire and security
teams
Preserve evidence so as to facilitate any enquiry into the causes and the circumstances or escalation of
emergency
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Logistic Controller
Take charge of all logistic activities at site
Arrange to render first-aid and medical-aid to casualties.
Arrange for additional ambulance.
Arrange for head counting of all employees like regular workers, contract workmen and truck drivers at the
assembly point and in plant, by the time keeper and get it counter checked with the entry records.
Help Site controller by mobilising men, material and other services.
Co-ordinate with Site Controller in all activities as per his directions.
Arrange to record the names of casualties, head count of persons in assembly points and for rescue of those
trapped inside.
In case persons are missing, send persons equipped with PPE for search in co-ordination with Incident
Controller.
Ensure that the relatives of the casualties are informed.
If emergency is prolonged, arrange for relievers, catering facility etc.
Shift-in-Charge of the Affected Plant
Rush to the spot and assume the role of Incident Controller. Act as Site Controller also if the designated Site
Controller is not immediately available at the site.
Initiate appropriate actions to contain the situation.
Arrange for the "Wailing Siren", if not already given, through the Main Control Room.
On the Site Controller reaching site the Shift in Charge will function only as Incident Controller.
The Main Control Room Personnel will communicate the following information to the Site Controller:
Brief description of incident
Status and seriousness of the situation
Action immediately taken
Team Leaders
Mobilise the team members and required equipment.
He should activate and direct his team to take up activities assigned to the team by the Incident Controller.
Incident Control Team
The team should rush and report to the Incident Controller.
Take all prompt actions to contain and control the situation at the earliest, with minimum loss/damage.
Help coordinate with other emergency team members.
Emergency Task Force
Rush to the incident spot.
Report to Incident Controller and carry out emergency maintenance activities as required/instructed by Incident
Controller.
Co-operate and coordinate with the Incident Control Team.
Arrange to isolate electrical lines as required/advised by Incident Controller.
Attend to urgent repairs, if any, which are needed from emergency point of view.
Arrange required temporary connections.
Bring to the spot the required additional equipment and materials.
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Security and Transport Team
Manning of gates. Arrange for closing of all gates and stop movement of traffic.
In case of fire arrange to post sufficient guards to incident site for augmenting firefighting force.
Inform guards at the gate to allow movement of emergency vehicles.
Depute adequate security personnel to cordon off the incident area.
Maintain law and order in the plant and Assembly Points.
Allow the emergency services like ambulance, fire tender etc to go through the gates without normal checks.
Direct external emergency services to the site of emergency.
Communication Team
On hearing the emergency alarm /or coming to know of the emergency he would proceed to Emergency
Control Center and report to the Incident Controller, Site Controller and maintain the communication system.
From the information received, brief the Site Controller of the situation, recommending, if necessary,
evacuation of staff from assembly points, to outside the plant in co-ordination with Transport and Welfare
Teams.
Deploy suitable staff to act as runners or messengers who are listed in the essential workers list between him
and the incident controller if the telephone and other system of communication fail due to any reason.
Maintain inventory of items in the emergency control center.
Maintain a log of incidents.
Keep in constant touch with happenings at the emergency site and offer suggestions to the incident
controller. He shall ensure that the board is kept free to the extent possible for incoming calls.
He shall ensure that the telephone system is in good working condition.
Medical Team
Keep the ambulance and Occupational Health Center ready to receive the injured.
Direct the first-aiders and arrange for immediate first-aid and medical attention to casualties.
Arrange additional emergency equipment and medicines.
Liaise with local hospitals and give detailed treatments required.
Liaise with Security and Transport Team for transportation of casualties to local hospitals.
Be in constant touch with Incident Controller.
Look after the welfare of the affected persons.
Arrange to keep record of casualties.
Fire Fighting Team
On hearing the emergency siren/ coming to know of the emergency he would rush to the spot of incident.
He would make sure that all required safety equipment are made available. If required he would arrange from
other sources.
Advising on safety to Incident Controller, if required be in continuous touch with Incident Controller and carry
out his instructions.
He would arrange for issue of Safety Work Permits for jobs to be taken up arising out of the emergency in co-
ordination with the task force.
Ensure that safety of personnel, plant and environment are properly taken care of.
Arrange for the prompt replacement/replenishment of used fire and safety equipment.
Take guidance of the Incident Controller for assessing the requirement of mutual aid.
Based on the instructions from the Incident Controller, he would guide the fire group to control the emergency
and rescue operations.
Arrange to position the fire tender at the proper place depending on wind direction and availability of fire
hydrant.
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Decide his line of action in consultation with the Incident Controller and take appropriate measures to
extinguish the fire / control gas leak.
Ensure the crewmembers are provided with proper safety equipment.
Man Power Accounting Team
Conduct "headcount" of all employees like regular workers, contract workmen and truck drivers at the
assembly point and in plant, and get it counter checked with the entry records.
Keep control of the persons assembled in assembly point/s.
Do not permit non-essential personnel and visitors to move out of assembly point/s till the termination of
emergency or on instructions from Site Controller.
Report the list of missing person/s to Logistic Controller.
Search and find out missing person/s, if any under instructions of Site Controller.
Record all happenings and report to Logistic Controller, and Incident Controller.
Report to Logistic Controller and carry out his instructions
Key Personnel beyond General Shift Hours and for Holidays
The executives and officers will not be available during non- general shift hours and factory holidays. So shift
Personnel available in the respective team has to shoulder the emergency responsibilities till the above mentioned
key personnel arrive at the site and relieve them.
Table 7-36: Details of Team Leaders
S. No. Team Team Leader Designation
1 Incident Control Team Shift in Charge of the plant where
emergency occurred Shift in Charge
2 Emergency Task Force Maintenance Engineer - Mechanical Maintenance Engineer
3 Communication Team Foreman- Electrical Foreman
4 Security &Transport Shift Security in charge D.S.O
5 Manpower Accounting Team Shift Security In charge D.S.O
6 Medical Team Compounder, (Health Center) Medical attendant
7 Safety &Fire Fighting Fireman Fireman
Each team leader may select and train 2 to 3 members working under him to act as its team members during an
emergency.
7.3.8 Role of Key Personnel and Key in Brief
Table 7-37: Role of Key Personnel
S. No. Key Personnel/Team Brief Description of the Role
1 Site Controller Overall in-charge
2 Incident Controller In-charge of all site actions
3 Logistics Controller Head of Support team. Mobilization of Finance, Material, Security, Medical
Transport and rendering all non technical/logistics support to Site Controller.
4 Other Senior Personnel of the
company As required, depending upon the situation.
5 Incident Control Team, To bring the incident under control.
6 Emergency Task Force Team To carry out emergency maintenance activities.
7 Security and Transport Team To look after security and transport requirements.
8 Communication Team To maintain communication facilities during emergency.
9 Medical Team To look after medical requirements including first aid, transport of injured
to hospitals and procurement of medicines on emergency basis.
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S. No. Key Personnel/Team Brief Description of the Role
10 Fire Fighting To fight the fires; to control toxic release by spraying water; issue of PPE; to mobilize PPE and fire fighting equipment; to direct external fire fighting
agencies .
11 Man Power Accounting To head count the personnel assembled at Safe Assembly Points and plant
areas including contract labour.
If an emergency occurs beyond general shift hours or during holidays, the Shift in-Charge of the plant in which it
occurs would act as the Incident Controller. The Shift – In – Charge of one of the other plants, would assume the
responsibilities of the site Controller. They will continue to shoulder this responsibility till the regular site Controller /
Incident Controller or their alternatives arrive at the site.
Table 7-38: Emergency in PVC Plant
Emergency in Incident Controller Site Controller
PVC Plant Field officer of respective section Shift-in Charge PVC Plant
Table 7-39: Emergency Control Centre
Main Intercom: 3384 Admin Block
Alternate Intercom : 3372 Material Gate
7.3.9 Safe Assembly Points
Safe assembly points are listed below;
Main Gate/ Security Office
Adjacent to fire water storage tank
Material Gate
7.3.10 Escape Routes
Route no. 1: From VCM Tank Storage to Material Gate (Road N 7 to N 8 via Road E 7)
Route no 2: From Reactor area to Admin Building (Road E3 to N 3 and/or E3 to E 1 via N 6)
Route no 3: Road to Ware House via open area (Road E6 to N 8)
Route no. 4: From Dryer Area to Main Gate via Work shop (from E3 to E1 via N6 and/or E3 to N 3)
Route no. 5: From Nitrogen Plant / Compressor to fire water pump house. ( N 3 to E 9 and/or N2 to E 8)
7.3.11 Help from External Agencies during Emergencies
Types of Accident
Fire in VCM, or HSD storage tanks or lines conveying these materials due to leakage
Toxic release of hydrochloric acid vapours due to leakage from joints or from tank
Bomb threat, terrorism, act of war, earth quake
Responsibilities Assigned
Table 7-40: Responsibilities Assigned
Incident External Agency Assistance
Fire / explosion spillage, natural disasters.
State fire brigade. Fire fighting and rescue augmentation.
Injury/illness Hospitals and ambulance services. Medical help augmentation.
Theft / sabotage /bomb threat /terrorism /war.
Police department Law and order, safety and security augmentation.
All incidents Neighbourhood organization Consumables, manpower, technical help
augmentation.
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Other Organizations in the Locality
Following are the factories in the SIPCOT Industrial Complex, in which Chemplast Sanmar factory is situated:
SPIC Pharmaceuticals
Shasun Chemicals
Tamil Nadu Fluorides and Allied Chemicals (TANFAC)
AsianPaints – Penta division
Pandian chemicals
Clariant Chemicals
Bayer Material Science India Ltd
Tagros chemicals India Limited
Arkema Peroxides India Private Limited
Contact No. of External Organizations
Table 7-41: Contact Information of External Organizations
S. No. Name Telephone No.
OFFICE* RESIDENCE*
DISTRICT ADMINISTRATION
a. The District Collector, Cuddalore 04142-230999 04142-230777
b. Special Deputy Collector, Cuddalore 04142-226600 9444452166
c. The District Revenue Officer 04142-230651 04142-230185
d. The Tahsildar 04142-295189
e. Panchayat Officer 04142-320286 9443335831
POLICE
a. Superintendent of Police, Cuddalore 04142-230060 04142-295161
9443879888
b. Deputy Superintendent of Police, Cuddalore 04142-284355
c. Inspector of Police (OT) 04142-297681
d. Inspector of Police (Port) 04142-297680
e Inspector of Police Kullanchavady 04142-279233
f. Inspector of police - Kurinjipadi 04142-258350
FACTORIES INSPECTORATE
a. Director Industrial safety and Health 044-28112144
b. Senior Additional Director of Industrial safety and
Health, Chennai 044-28291534 044-26152244
c. Additional Director of Industrial safety and health, Trichy 044-242122
d. Joint Director of Industrial safety and Heath Cuddalore 04142 - 222826
DEPARTMENT OF EXPLOSIVES
a. Joint Chief Controller Of Explosives, Chennai 044-28419529
b. Chief Controller Of Explosives, Nagpur 0712-2510248
FIRE DEPARTMENT
a. Divisional Fire Officer, Cuddalore 04142 - 294603
b. Asst. Divisional Fire Officer 04142 - 295733
c. Fire Station, SIPCOT 04142 - 239242
d. Fire Station ,Kurinjipadi 04142 - 258370
POLLUTION CONTROL DEPARTMENT
a. Tamil Nadu Pollution Control Board, Chennai 044-22353134 to
22353141
b. Chairperson, TNPCB, Chennai 044-22353076 044-26261144
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S. No. Name Telephone No.
OFFICE* RESIDENCE*
c. Member Secretary, TNPCB, Chennai 044-22355145 044-23662870
d Additional Chief Environmental Engineer 044-22353146 044-24615007
e. The District Environment Engineer, Cuddalore 04142-221867
HEALTH AND MEDICAL DEPARTMENT OFFICE RESIDENCE
a. District Medical Officer, Cuddalore 04142-230052
b. District Health Officer, Cuddalore 04142-295134
c. General Hospital, Casualty, Cuddalore 04142-231590
d. ESI Dispensary – Medical Officer Cuddalore - OT 04142-297148
TRANSPORT DEPARTMENT
a. The Manager, TSTC, Cuddalore 04142-224795
b. Regional Transport Officer, Cuddalore 04142-290035
ELECTRICAL DEPARTMENT
a. Chief Engineer 04142-222035/
04142-222036
b. Superintending Engineer 04142-223793
04142-230969 9443330664
WATER SUPPLY
a. SIPCOT 04142-239236
SANITARY
a. Sanitary Inspectors, Cuddalore (Municipality) 04142-230021
SERVICE CLUBS
a. Cosmopoliton Club 04142-221723
NEWS MEDIA
a. Dinathanthi, Cuddalore 04142-293289
b. Dina Malar, Cuddalore 04142-295830
* Telephone nos. valid at the time of EIA report writing
Key Personnel of Neighboring Industries
Table 7-42: Name of Contact Person in Neighboring Industries
S. No NAME OF THE INDUSTRY CONTACT PERSON* Phone*
1 The Covestro (India) Pvt. Ltd. Senthil Kumar 04142-239913
2 Pioneer Jellice India Pvt.Ltd Mr.T.Arumugam 04142-239355