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5. Project location and plant layout Refer Figure: 2.3 of Chapter-2 page no. 2.26 to 2.27.
6. Infrastructure facilities including power sources
Refer Section: 2.8 of Chpater-2 Page No. 2-9.
7. Total cost of project along with total capital cost and recurring cost/annum for environmental pollution control measures
Refer Section:2.2 of Chpater-2 Page No. 2-1
8. Project site location along with site map of 10 km area and site details providing various industries, surface water bodies, forests, etc.
Refer figure 1.1 of Chapter-1 Page No. 1-13.
9. Present land use based on satellite imagery for the study area of 10 km radius. Location of national park/ wild life sanctuary/reserve forest within 10 km radius of project.
Refer Figure-3.10 on page no-3-43 and table no-3.16 on page no-3-31.of chapter-3
10. Permission from the State Forest Department regarding the impact of the proposed plant on the surrounding reserve forests, if any.
Not applicable in our case because there is no any reserve or protected forest wildlife sanctuary
11. Details of the total land and break-up of the land use for green belt and other uses.
Refer Section:2.5 of chapter-2 Page No.2-2
12. List of raw materials, products along with the production capacities and list of solvents and its recovery plan.
Pl. refers point no-2.6 of chapter-2 on page no-2-2 & table no-2-1 on page no- 2-16 for RM. There are no separate solvent recovery systems, it’s a part of manufacturing activities and recovered solvent will be recycled in the next batch.
13. Commitment for not using azo dyes in the process should be given.
Proposed project is for CPC based pigments and no use of any azo based dyes.
14. Detailed list of raw material required and source, mode of storage and transportation.
Refer table 2.1 of Chapter-2 Page No. 2-16.
15. Manufacturing process details along with the chemical reactions.
Refer Section:2.7 of Chapter-2 Page No. 2-3
16. Design details of ETP, incinerator, if any along with control of Dioxin & Furan,
Refer table2.5 and figure-2.2 of Chpater-2 Page No.:2-21-
San Envirotech Pvt. Ltd-Ahmedabad
REIA of Narayan Organics Pvt. Ltd., Unit-II 1-6
boiler, scrubbers/bag filters etc.
2-22. There will not be any incinerator facilities. Technical information of bag filter is attached as annexure-IV.
17. Details of water and air pollution and its mitigation plan
Refer Section: 2.9 of Chpater-2 Page No. 2-10
18. Site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall is necessary.
Refer Section:3.2.3 of Chapter-3 Page No. 3-3
19. Ambient air quality monitoring for all the parameters including VOCs within the study area of 5 km., aerial coverage from project site. Location of one AAQMS in downwind direction.
Refer table 3-1 to 3-7 of chapter-3 on page No. 3-14.
20. One season site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall and AAQ data (except monsoon) for PM10, SO2, NOx including HC and VOCs. Should be collected. The monitoring stations should take into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests. Data for water and noise monitoring should also be included.
Pl. refers point no-3.2.3 of Chapter-3 Page No. 3-3 and table 3-1 to 3-7 of chapter-3 on page no-3-14.
21. Action plan to control ambient air quality as per NAAQES Standards notified by the Ministry on 16th September, 2009.
Following measures steps will be taken by us to control the air quality as per the NAAQES standards notified by the Ministry on 16th September, 2009. - Effective implementation of air pollution control measures and monitoring. - Ammonia recovery by chilling systems to reduce fugitive emission. - Effective scrubbing systems will be installed to control un-recovered ammonia. - Proper air pollution control systems like dust collector will be used. - Bio fuel ((Briquettes) will be used to reduce the contribute of Sulfur dioxide in the atmosphere.
San Envirotech Pvt. Ltd-Ahmedabad
REIA of Narayan Organics Pvt. Ltd., Unit-II 1-7
22. An action plan to control and monitor secondary fugitive emissions from all the sources as per the latest permissible limits issued by the Ministry vide G.S.R. 414(E) dated 30th May, 2008.
All liquid material will be transfer by pneumatically, joint will be 100% leak proof and solid material will be transfer with care of zero leakages.
23. Determination of atmospheric inversion level at the project site and assessment of ground level concentration of pollutants from the stack emission based on site-specific meteorological features. Air quality modelling for the proposed plant.
24. Permission for drawl of 612 m3/day ground water from the CGWA/SGWB. Water balance cycle data including quantity of effluent generated recycled and reused and discharged. Method to be used to control ammonical nitrogen from industrial wastewater.
Our proposed area fall in white zone however, we have applied to CGWA for water extraction and water recharging will be done as per the guideline/conditions of CGWA. Pl. refer point no-2.9.2 of chapter-2 on page no-2-11 for control ammonical nitrogen from industrial wastewater
25. Ground water monitoring minimum at 6 locations should be carried out. Geological features and Geo-hydrological status of the study area and ecological status (Terrestrial and Aquatic).
Pl. refer table no-3.9 of chapter-3 on page no-3-22
26. The details of solid and hazardous wastes generation, storage, utilization and disposal particularly related to the hazardous waste calorific value of hazardous waste and detailed characteristic of the hazardous waste.
Refer table-2-7 & 2-8 of Chpater-2 Page No. :2-25 for quantity, disposal and characteristic of the hazardous waste
27. Details of land fill along with design details as per CPCB guidelines. Location of secured land fill/TSDF.
We will not going to create our landfill site hence not applicable. We will get membership of any GPCB approved and nearby TSDF site before establishment of our project.
28. Ground water monitoring around the land fill site
Not applicable in our case.
29. Membership of CETP for disposal to effluent and TSDF for disposal of hazardous waste/ solid waste.
We will get membership of any GPCB approved and nearby TSDF site before establishment of our project. We will have our own ETP and not planning to get CETP membership.
San Envirotech Pvt. Ltd-Ahmedabad
REIA of Narayan Organics Pvt. Ltd., Unit-II 1-8
30. Risk assessment for storage of chemicals/solvents and phosgenes.
Kindly refer Chapter:6
31. An action plan to develop green belt in 33 % area
Refer Section: 5.4 of Chpater-5 Page No. :5-14
32. Action plan for rainwater harvesting measures at plant site should be included to harvest rainwater from the roof tops and storm water drains to recharge the ground water.
Refer Section: 2.10.1 of Chpater-2 Page No. :2-16
33. Occupational health of the workers needs elaboration including evaluation of noise, heat, illumination, dust, any other chemicals, metals being suspected in environment and going into body of workers either through inhalation, ingestion or through skin absorption and steps taken to avoid musculo-skeletal disorders (MSD), backache, pain in minor and major joints, fatigue etc. Occupational hazards specific pre-placement and periodical monitoring should be carried out.
Refer Section: 5.11.1 of Chpater-5 Page No. : 5-17
34. Socio economic development activities should be in place.
Refer Section: 4.8 of Chpater-4 Page No.: 4-11
35. Note on compliance to the recommendations mentioned in the CREP guidelines.
Pl. refers Annexure-II.
36. Detailed Environment management Plan (EMP) with specific reference to details of air pollution control system, water & wastewater management, monitoring frequency, responsibility and time bound implementation plan for mitigation measure should be provided.
Kindly refer Chapter-5
37. EMP should include the concept of waste-minimization, recycle/reuse/recover techniques, Energy conservation, and natural resource conservation.
Refer Section:5.10 of Chpater-5 Page No.:5-15
38. Any litigation pending against the project and/or any direction/order passed by any Court of Law against the project, if so, details thereof.
Not Applicable
39. Public hearing issues raised and commitments made by the project proponent on the same should be included separately in EIA/EMP Report in the form of tabular chart with financial budget for complying with the commitments made.
Yet to be attached.
40. A tabular chart with index for point wise compliance of above TORs.
Done
San Envirotech Pvt. Ltd-Ahmedabad
REIA of Narayan Organics Pvt. Ltd., Unit-II 1-9
1.6 OBJECTIVES OF EIA
EIA is a policy and management tool for both planning and decision
making. EIA assists in identification, prediction and evaluation of the
foreseeable environmental consequences of proposed developmental
and industrial projects.
The objectives of the present EIA Study is to assess the impacts on
various environmental components due to the proposed project and to
recommend appropriate environmental management plant for the unit
to ensure that the adverse impacts if any will be minimized. Moreover to
prepare an Environmental Statement to indicate conclusively if the
overall impacts are positive or negative.
1.7 Scope of EIA
The scope of present Environment Impact Assessment includes following
studies,
• Collection and evaluation of project details and related documents
• Analysis of the quality of gaseous emission, wastewater analysis,
hazardous waste generation based on the monitoring results for the
last one year
• Assessment of pollution potential due to proposed project
• Collection and evaluation of present environmental baseline status
within an impact zone of 5-km radial distance from the project site
on environmental parameters/attributes considering the proposed
activities like,
• Ambient Air quality
• Water quality and surrounding environmental water bodies.
• Soil quality
• Noise levels
• Meteorology and climates.
• Land use pattern and socio-economic status
• Identification, assessment and evaluation of the beneficial and
adverse impacts on surrounding environment due to proposed
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project activities considering the existing baseline status along with
compilation of other information
• Identify the sources and impact of hazards, if any
• Base on the same suggest and design risk assessment plant and
disaster management plant to prevent any hazard
• Preparation of final Environmental Impact Statement & EMP
1.8 Methodology for EIA
Environmental Assessment (EA), another term used in the
environmental studies, refers to an understanding of the present status
of environment and a study of how to manage them. Keeping in view
the nature and size of the proposed project and industrial area and
various guidelines available, it was decided to cover an area of 5-km
radius from the center of proposed plant site for the purpose of
environmental impact assessment study. The methodology is briefly
reported below and has been described in this section.
Project Components
The proposed project will be in the outside of notified industrial estate
located at Block No. 164 to 170, Village: Vedach, Taluka: Jambusar,
Dist: Bharuch, State: Gujarat. The company will appoint experts of
different fields like process, R & D, safety & Environment and moreover,
the company has a large experience in the respective field to take care
of the plant in all respect.
A useful way of identifying many of the potential impacts of a project is
to consider all the aspects of the projects and its receiving environment
and systematically identify the potential for interactions between them.
The first step is to draw up a list of all project components and activities
during each phase of its implementation. The possible components of
proposed project could lead to environmental impacts are described in
this section based on the understanding of Chemical industry.
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REIA of Narayan Organics Pvt. Ltd., Unit-II 1-11
Environmental Components
Defining all the possible aspects of the environment is essential for
identification of potential impacts. This may cover features of the
environment (e.g. habitats, settlements, and historic sites); aspects of
environmental quality (e.g. air quality, water quality, noise, physical
conditions, soil stability and hydrology) and uses of the environment
(e.g. agriculture, recreation and fishing). This will be done with
generation of base line data.
Baseline data Collection
The baseline data for the impact zone have been generated for the
following environmental parameters:
• Ambient Air Quality
• Micrometeorology
• Noise Levels
• Surface and ground water quality
• Soil Quality
• Flora and fauna
• Land use pattern
• Occupational structure and socio-economics
The baseline status of the above environmental parameters has been
worked out based on the rapid monitoring/analysis carried out during
the study period of one season i.e. Decemeber-10 to February-10,
supplemented by data collected from various government departments,
census publications etc.
Evaluation of Impact from Project Activities
The environmental Impact resulting from the various project activities,
have been identified, predicted and evaluated based on the study of
manufacturing process and other project related activities as well as
correlating the same with existing base line status.
Preparation of Environmental Management Plan
Environmental Management plan has been prepared covering pollution
prevention measures at source in terms of air and water pollution
San Envirotech Pvt. Ltd-Ahmedabad
REIA of Narayan Organics Pvt. Ltd., Unit-II 1-12
control measures, solid waste/ hazardous waste management, safety
management, green belt development, environmental surveillance and
environmental management team.
Finally, the detailed assessment of the resultant environmental impacts
have been made based on the impacts identification and evaluated from
the activities over the baseline status of various environmental
components.
1.9 Justification for the project site
The unit is proposed to start at Block No. 164 to 170, Village: Vedach,
Taluka: Jambusar, Dist: Bharuch, State: Gujarat. The other supporting
factors are briefly summarized here under,
• Availability of all basic facilities like fuel, water, power, man
power, raw materials, etc.
• The nearest town Bharuch is only 40 km away from the project
site which is very well connected with other parts of the country
by road & rail.
• Good communication and transportation facilities
• Effluent treatment and disposal facility is very near to project site.
• Hazardous Waste disposal facility is also near to project site
• No R & R will be required
• No national park or wildlife Habitats falls within 10 km radial
distance from proposed project site.
San Envirotech Pvt. Ltd-Ahmedabad
REIA of Narayan Organics Pvt. Ltd., Unit-II 1-13
Figure 1.1
Location Map
Proposed location of NOPL, Unit-II
Transmental
Bodal Chemicals Ltd.
Kiri Dyes & Chemicals Pvt. Ltd.
Lonsen Kiri Chemical Industries Pvt. Ltd.
Asahi Songwon Ltd. Mayur Dyechem
San Envirotech Pvt. Ltd-Ahmedabad
REIA of Narayan Organics Pvt. Ltd., Unit-II
2-1
Chapter 2 Project Description
2.1 INTRODUCTION
M/s. Narayan Organics Pvt. Ltd., Unit-II is the proposed unit to be
established at Block No. 164 to 170, Village: Vedach, Taluka: Jambusar,
Dist: Bharuch, State: Gujarat. The unit proposes to manufacture various
pigments at the proposed premises. The unit proposes to manufacture
Copper Pthalocyanine Blue (CPC Blue), Pigment Alpha Blue and Pigment
Beta Blue of 700.0 TPM, 75.0 TPM and 200.0 TPM capacity respectively.
There will also be generation of Ammonium Carbonate Solution (12-
15%) 600.0 TPM or Ammonium Sulphate as by-product up to 1200.0
TPM.
2.2 CAPITAL INVESTMENT
The expected cost of the proposed project will be around Rs. 12.6 crores.
Out of which @ 1.50 crore will be earmarked for development of EMS
(Environment Management Systems).
2.3 TYPE OF PROJECT
The proposed unit is Synthetic Organic Chemicals manufacturing unit
covered under the category of 5(f) “Synthetic organic chemicals industry
(dyes & dye intermediates; bulk drugs and intermediates excluding drug
formulations; synthetic rubbers; basic organic chemicals, other synthetic
organic chemicals and chemical intermediates)” of EIA Notification-2006.
2.4 NEED OF THE PROJECT
The products manufactured will be Crude pigments and finished
pigments. All the pigments are basically powders and insoluble in water.
However, due to their coloring properties they are used in paints,
plastics and inks.
Thus, looking to the application of products and increasing marketing
demand, the unit intends to set up the proposed project.
San Envirotech Pvt. Ltd-Ahmedabad
REIA of Narayan Organics Pvt. Ltd., Unit-II
2-2
2.5 LAND REQUIREMENT
The proposed unit of M/s. Narayan Organics Pvt. Ltd. will be located at
Block No. 164 to 170, Village: Vedach, Taluka: Jambusar, Dist.:
Bharuch, State: Gujarat. Total land area of the plant is apprx. 34,000.0
sqm. The land area break up is given hereunder,
Sr. No.
Specification Area covered, Sqm
1. Office Building 1250
2. Process plant 3650
3. Storage Tank Yard 3500
4. Utility 2100
5. Environmental Control Measures 3500
6. Road & parking 9180
7. Green Belt 11220
Total 34000
The Factory Layout of the unit is given in Figure: 2.3.
2.6 SIZE OF PROJECT
M/s. Narayan Organics Pvt. Ltd. (Unit-II) will be involved in
manufacturing of various pigments. The details of products and by-
products alongwith its production capacity is summarized hereunder,
Annual* 01 01 Solvent extraction followed by HPLC/GC analysis
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REIA of Narayan Organics Pvt. Ltd.-Unit-II 3-21
Arsenic (As), µg/m3
Annual* 06 06 AAS/ICP method after sampling on EPM 2000 or equivalent filter paper
Nickel (Ni) µg/m3
Annual* 20 20 AAS/ICP method after sampling on EPM 2000 or equivalent filter paper
*
Annual Arithmetic mean of minimum 104 measurements in a year taken twice a week 24 hourly at uniform interval.
**
24 hourly/8 hourly or 01 hourly values, as applicable, shall be complied with 98% of the time in a year. 2% of the time the time, they may exceed the limits but not two consecutive days of monitoring.
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Table -3.9: Results of Ground Water Quality in the Study Area
(Date of Sampling 02/02/2011)
CONCENTRATION Parameters Unit Nr.
Industry Piludara Vedach Gajera Dabha Abhol
pH pH Unit 7.2 7.0 6.9 7.2 7.3 7.0 Color Co-Pt
Unit Color Less
Color Less
Color Less
Color Less
Color Less
Color Less
Temperature 0C 26 25 26 26 25 25 Conductivity Micro
34. Radioactive Materials a. Alpha Emitters, Bq/I, Max. b. Beta Emitters, Bq/I, Max
- -
0.1 1
Note: * Applicable only when water is chlorinated ** Provided magnesium (as Mg) does not exceed 30 mg/l Source: IS 10500: 1991, Fourth Reprint, July 1999
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Table -3.11: Ambient Noise Levels in the Study Area
Date of Monitoring: 02/02/2011 to 05/02/2011
Sr. No. Location Ld/Ln Noise Level
Ld 54.9 1 Project Site
Ln 46.3
Ld 58.1 2 Primary School Piludara
Ln 42.4
Ld 57.5 3 Primary School Vedach
Ln 41.6
Ld 55.3 4 Temple Abhol
Ln 40.0
Ld 61.9 5 Bus stop Vavadi
Ln 53.2
Ld 55.7 6 Village Dabha
Ln 40.7
Ld 53.1 7 Village Masar
Ln 41.4
Ld 59.6 8 Bus stop Gajera
Ln 42.0
Table -3.12: Ambient Air Quality Standards with respect to Noise
Category of Area Limits Leq, dB(A)
Day Time Night Time
Industrial 75 70
Commercial 65 55
Residential 55 45
Silence 50 40
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Table -3.13: Soil Analysis of Study area
(Date of Sampling 04/02/2011)
S. No.
Parameters Unit Nr. Industry
Piludrara Vedach Gajera Dabha Abhol
1. pH (5%)Solution 7.4 7.2 7.3 7.3 7.5 7.6 2. Loss of Ignition % 6.5 6.3 6.1 6.2 5.9 6.1
Dadhwada P -(-5 kms) HP,S -(-5 kms) -(-5 kms) KR Rajpipla-22 EA
Chitral P,H CHW T,W,TK,TW, PO BS PR,KR Padra-19 EA
Kahanava P(15),H, Ac(3) PHS,D, FPC,RP,CHW(2)
T,W,TW PO, Phone BS,RS PR,KR Jambusar-26 EA
Piludara P(6),H, PUC, Ac
PHS,FPC,RP(2), CHW
T,W,HP PO, Phone BS PR Jambusar-18 EA
Gametha P,H CHW T,W,TK,TW PO BS PR Jambusar-18 EA
Gavasad P MH,PHS,D,FPC,CHW
T,TW,TK,TW
PO, Phone BS PR Padra-18 EA
Maser P(2),H,PUC, Ac
MH,PHS,D,FPC,RP,
CHW
T,W,TK,TW PO, Phone BS PR,KR Jambusar-12 EA
Kural P,H,PUC MH,D,RP (2),CHW
T,W,TK,N PO, Phone BS,RS PR Padra-20 EA
Brahmanvasi P, Ac(2) CHW T,W,TK,TW PO BS PR Jambusar-18 EA
Vedach P(11), H, Ac(3)
PHS,D,FPC,RP(2),C
HW
T,W,TK PO, Phone BS PR Jambusar-16 EA
Valipore P(2),H, Ac CWC,RP, CHW
T,W PO BS PR Jambusar-12 EA
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Name of Village
Educational Facility
Medical Facility
Drinking Water Facility
Communication (Post
or Telegraph)
Transportation Facility
(Bus etc.)
Approach to
Village
Nearest town &
Dist. (Kms)
Power Supply
Nondhana P(4),H, Ac(2), O
PHS,D,FPC,RP,CHW
T,W,HP PO, Phone BS PR Jambusar-12 EA
Uber P(7), H, Ac(3) PHS,FPC,RP(2), CHW
T,W,TK PO, Phone BS PR,KR Jambusar-11 ED,EAG
Gajera P(7),H, PUC, Ac(3)
MH,PHC,DFPC,RP(4)
,CHW
T,W,TW PTO, Phone BS PR,KR Jambusar-14 EA
Pindapa P CHW T,W,TK PO BS PR,KR Padra-19 EA
Abhol P CHW T,W,TK PO BS,RS PR,KR Jambusar-12 EA
Nobar P(3),Ac(2),O PHS,FPC,RP,CHW
T,W,HP PO BS PR,KR Jambusar-7 EA
Dabha P(4),Ac(2) H,CHW T,W PO BS PR,KR Jambusar-8 EA
Kanzat P(3),H(2), PUC, Ac
MH,PHS, RP,CHW
T,W,TK PTO, Phone BS,RS PR,KR Jambusar-15 EA
Sampla P CWC,CHW T,W,TK PO, Phone BS PR,KR Jambusar-12 EA
Bhanpur P CHW T,TW,TK -(-5 kms) BS PR Padra-26 EA
Uchchhad P(2),Ac(3) CHW W,TK PO BS PR,KR Jambusar-9 EA
Vahelam P(2),Ac(3) RP T,W PO BS PR Jambusar-12 EA
Vavli P(2),Ac(2) CHW T,W PO, Phone BS PR,KR Jambusar-8 EA
Danoli P CHW T,W,TK -(-5 kms) BS PR Padra-27 EA
Umra P(2),Ac CHW T,W PO, Phone BS PR,KR Jambusar-5 EA
Bhankhetar P(2),Ac CHW T,W PO BS PR,KR Jambusar-3 EA
Anakhi P(3),H, Ac(2) PHS, FPC,RP,
CHW
T,W PO, Phone BS,RS PR Jambusar-7 EA
Jafarpara P(2),Ac CHW T,W PO BS PR Jambusar-8 EA
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Abbreviations: Educational P - Primary School
H - Matriculation/High School PUC - Higher Secondary/Pre P University/Junior College/Inter. Ac - Adult Literacy Class/ Centre O - Others Medical Facility MH - Maternity Home CWC - Child Welfare Centre PHC - Primary Health Centre PHS - Primary Health Sub-Centre D - Dispensary FPC - Family Planning Centre RP - Registered Private Practitioner CHW - Common Health Worker
Drinking Water
T - Tap Water W - Well Water TK - Tank water TW - Tube well Water HP - Hand Pump R - River water S - Spring Post and Telegraph PO - Post Office PTO - Post & Telegraph Office P - Phone Transportation BS - Bus RS - Railway Station Approach to Village PR - Pucca Road KR - Kachcha Road Power Supply EA - Electricity for all Purposes Land Use R - River TWE - Tube well
Inhalation: Inhalation produces damaging effects on the mucous
membranes and upper respiratory tract. Symptoms may include
irritation of the nose and throat, and labored breathing. May cause lung
edema, a medical emergency.
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Ingestion: Corrosive. Swallowing can cause severe burns of the mouth,
throat, and stomach, leading to death. Can cause sore throat, vomiting,
diarrhea. Circulatory collapse with clammy skin, weak and rapid pulse,
shallow respirations, and scanty urine may follow ingestion or skin
contact. Circulatory shock is often the immediate cause of death.
Skin Contact: Corrosive. Symptoms of redness, pain, and severe burn
can occur. Circulatory collapse with clammy skin, weak and rapid pulse,
shallow respirations, and scanty urine may follow skin contact or
ingestion. Circulatory shock is often the immediate cause of death.
Eye Contact: Corrosive. Contact can cause blurred vision, redness, pain
and severe tissue burns. Can cause blindness.
Chronic Exposure: Long-term exposure to mist or vapors may cause
damage to teeth. Chronic exposure to mists containing sulfuric acid is a
cancer hazard.
Aggravation of Pre-existing Conditions: Persons with pre-existing skin
disorders or eye problems or impaired respiratory function may be more
susceptible to the effects of the substance.
First Aid Measures:
Inhalation: Remove to fresh air. If not breathing, give artificial
respiration. If breathing is difficult, give oxygen. Call a physician
immediately.
Ingestion: DO NOT INDUCE VOMITING. Give large quantities of water.
Never give anything by mouth to an unconscious person. Call a
physician immediately.
Skin Contact: In case of contact, immediately flush skin with plenty of
water for at least 15 minutes while removing contaminated clothing and
shoes. Wash clothing before reuse. Excess acid on skin can be
neutralized with a 2% solution of bicarbonate of soda. Call a physician
immediately.
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Eye Contact: Immediately flush eyes with gentle but large stream of
water for at least 15 minutes, lifting lower and upper eyelids
occasionally. Call a physician immediately.
Fire Fighting Measures
Fire: Concentrated material is a strong dehydrating agent. Reacts with
organic materials and may cause ignition of finely divided materials on
contact.
Explosion: Contact with most metals causes formation of flammable and
explosive hydrogen gas.
Fire Extinguishing Media: Dry chemical, foam or carbon dioxide. Do not
use water on material. However, water spray may be used to keep fire
exposed containers cool.
Special Information: In the event of a fire, wear full protective clothing
and NIOSH-approved self-contained breathing apparatus with full face
piece operated in the pressure demand or other positive pressure mode.
Structural firefighter's protective clothing is ineffective for fires involving
this material. Stay away from sealed containers.
IV) Caustic Soda
Sodium hydroxide is white flaked and odourless. It is identified as a
corrosive hazard of ‘Class 8’. On spillage on the ground, it evaporates
and some toxic vapour may be formed but this alkali vapour cloud is
generally vary small and of no consequence.
It is harmful if swallowed or inhaled and causes burns to any area of
contact. It is not considered to be fire hazard. Do not handle without
PPEs. Use safety goggles, Gumboots, PVC hand gloves and rubber apron
if required.
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Main Physical properties are as follows:
Molecular formula NaOH
Appearance Clear Soapy Liquid or white flakes
Odour Odourless
Boiling point 1480C
Vapour pressure at 400C 3.6 mm Hg
Bulk density 1.5 g/ml
pH Highly alkaline
Specific gravity 2.12
6.3 QUANTITIES OF HAZARDOUS MATERIALS
As mentioned in Section-6.2, various hazardous chemicals will be stored
at the plant in small to large quantities as per requirement. As per
Manufacture, storage and Import of Hazardous Chemicals rules 1989
and amendment subsequently, there will be only few hazardous
chemicals, which have potential for creating risk to life and property in
an unlikely event of leakage or spillage followed by fire.
The hazardous chemicals are stored at the plant in tank with adequate
dyke. Other chemicals will be stored in cylindrical tanks, barrels and
carboys. Details of storage of hazardous materials are given in Table -
6.1.
Table - 6.1: Facilities for Storage of Chemicals
Name of Chemical Quantity, MT/month Storage Facility
Sulphuric Acid (98%) 30 MSRL
Spent Acid (20-22%) 25 MSRL
6.4 HAZARDS DUE TO LEAKAGE OR CONTAINMENT
Since the proposed project is for the manufacturing of dyes and dyes
intermediates, various hazardous chemicals will be required to be
handled.
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REIA of Narayan Organics Pvt. Ltd., Unit-II 6-11
Hazardous chemical to be handled and stored at the plant is in liquid
form. In the event of leakage or accidental release of these chemicals, it
will create only localized effects within the short distances from fixed or
spread pool in case of fire. There is possibility that release of some
hazardous chemicals may form vapour cloud which can move towards
wind direction and may explode in the event of fire if mass and
concentration of air and vapour mixture is within the LEL and UEL limits.
However, mass of vapour and air mixture may not be adequate to
generate explosive mass.
Storage and handling of hazardous chemical will not pose any hazardous
situation if these are handled or stored correctly with adequate safety
provisions and fire fighting facilities. Therefore, suitable safety measures
including fire fighting facilities will be provided at the plant to attend any
emergency due to accidental release of these hazardous chemicals.
Among the hazardous inventories, there are few potential toxic
materials that can form toxic vapour cloud in unlikely event of release.
6.5 MAXIMUM CREDIBLE ACCIDENT SCENARIOS
The plant will be dealing with some hazardous substances i.e. Sulphuric
Acid, Ortho Nitro Benzene, Iso butyl alcohol described in details. This is
in the form of liquid and considered as odorous. Subsequently, their
consequence due to thermal radiation will be confined within short
distances. If released quantities are not ignited, therefore, vapour
formation can result in vapour and air mixture and may generate
explosive mass which can explode if it gets the source of ignition. Toxic
cloud of hazardous chemicals may also be formed and moved towards
wind direction.
6.5.1 Methodology For Selection of Accident Scenarios
In this study, following steps are followed for scenario selection for risk
analysis study:
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REIA of Narayan Organics Pvt. Ltd., Unit-II 6-12
• The hazardous materials to be handled at the plant and the
associated hazards have been identified and assessed.
• Operating and storage conditions of handling and storage of
hazardous materials are studied.
• An assessment is made of what inventories can get released
accidentally.
• Release rates are calculated considering different cases. For further
analysis of selected release sources, representative failure modes
and failure sizes are identified.
6.5.2 Maximum Credible Accident Scenarios Following maximum credible scenarios have been selected for
consequence analysis as a result of accidental releases:
Sr. No.
Type of Release Outcome Cases Considered
Formation of pool and thermal radiation due to fire Vapour cloud explosion 1. Release of Solvent Dispersion of toxic cloud of vapours Vapour cloud explosion
2 Acid leakages Dispersion of toxic cloud of vapours
6.5.3 Consequence Analysis
Consequence analysis for the selected accident scenarios has been
carried to estimate the vulnerable zones. Thermal radiation distances
have been computed based on various heat flux values vulnerable to
men and materials at the plant, while modelling of dispersion cloud is
based on IDLH (Immediately Dangerous for Life and Health) values. On
identification of vulnerable zones for failure cases, measures can be
taken for risk mitigation and to eliminate or minimize damage to the
plant and injury to personal.
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REIA of Narayan Organics Pvt. Ltd., Unit-II 6-13
6.6 PROBABLE HAZARDS & RISK
From the preliminary risk assessment study carried out for Narayan
Organics Pvt. Ltd. Some of the possible hazards have been identified.
The likely accident scenarios considered are given below:
Sr. No.
Scenario Vulnerability Zone
Remarks
1. Toxic Liquid Leakage/ Spillage in Confined Space
Confined Area Spillage to be mopped up, decontaminated (if required) and disposed of as per norms. Fresh Air inlet / Ventilation System to be fully opened. Ventilation Exhaust will carry harmful vapors. Personnel to avoid contact with exhaust vapors. Exhaust to be released at safe elevation.
2. Flammable liquid tank in tank farm on fire
Area adjoining to tank periphery/ other tanks in tank farm
Deluge all adjoining tanks till fire stops and heat is dissipated. Transfer/neutralize the spillage (if any).
The above-mentioned hazards scenarios can further aggravate into
much more serious incidents if not intercepted in time. The fire in one
tank of tank farm can spread to adjoining tanks and may result in
explosions. The vulnerability zone will be considerably enlarged. The
vapors of toxic fluids/dust if carried away by wind above TLV
concentrations may further enlarge the vulnerability zone. Similarly,
toxic fluid spillage and all wastes leaving the live processing zone if not
decontaminated properly can cause serious health hazard to plant
personnel and persons in nearby area.
6.7 METHODOLOGY, APPROACH AND DAMAGE CRITERIA FOR RISK
ASSESSMENT
Consequence analysis is that part of risk analysis, which considers
individual failure cases and the damage, caused by each failure case. It
is done to predict the outcome of potentially serious hazardous
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REIA of Narayan Organics Pvt. Ltd., Unit-II 6-14
accidents to man and material in and around the plant boundary limits.
The advantages of carrying out consequence analysis are given below:
• To improve plant layout (for new projects and for expansion of
existing one)
• To meet statutory requirements
• Protection of public in the nearby areas (no residential/ inhabited
near by)
• Disaster management planning
• Training tool
The findings of a consequence analysis provide information about
hazardous effects resulting from an accident scenario. In addition,
Methods for dealing with possible catastrophic events are also provided.
6.7.1 HAZARDS EVALUATION: EXPOSURE To TOXIC DUSTS / VAPORS
Leakage in process plant from failure of nozzles, joints (flange joint),
welding failures or dripping from non-holding valves/glands or dusts
generation during charging of solids at times goes unnoticed. If the
leaky dust or fluids being toxic and odorless it is a potential source of
risk, which may cause fatal/serious hazards.
Liquids with high saturation vapor pressures evaporate faster because
the evaporation rate (mass/time) is essentially proportional to the
saturation vapor pressure. In the case of vaporization into stagnant air,
the vaporization rate is proportional to the difference between the
saturation vapor pressure and the partial pressure in the stagnant air.
6.7.2 LIQUID POOL EVAPORATION OR BOILING
The pool boiling cases may be encountered during heavy leakage in
enclosed area (dyke wall of tanks) and with heat source nearby
(ambient or fire) the vapor can explode or catch fire (in case the
material is flammable and sparks/flame contact is made).
6.7.3 PLANT LEAKAGE IN CONFINED SPACE
A chemical fluid spill is a common type of process incident and can lead
to potentially serious accident. If the spilled material gives rise to
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REIA of Narayan Organics Pvt. Ltd., Unit-II 6-15
hazardous vapor or aerosol these may interact with plant environment
resulting in explosion or harm to plant’s personnel/ damage to plant
equipment/machinery (if vapors are toxic/ corrosive/inflammable). Most
chemical spills do not have such dramatic sequences but they must all
be handled carefully and correctly. Plant of Narayan Organics Pvt. Ltd.
will open with natural ventilation.
6.7.4 DAMAGE CRITERIA
In order to appreciate the extent of damage produced by various
accident scenarios, it is appropriate to discuss the physiological/
physical effects of toxic fluid exposure/thermal radiation intensities due
to spillage causing subsequent fire. The thermal radiation usually results
in burn on the human body and damage to plantation. Furthermore,
inanimate objects like equipment, piping, cables, etc. may be affected
and may aggravate the situation further.
Consequence analysis has been carried out for selected failure cases.
Consequence analysis quantifies vulnerable zones for a likely incident
and once the vulnerable zone is identified for an incident, measures are
proposed to eliminate damage to plant and potential injury to personnel.
6.8 RISK MITIGATION MEASURES
For risk mitigation/reduction, attempts should be made either to reduce
inventories that could get released in the event of loss of containment
or failure likelihoods or both as feasible. Risk analysis identifies the
major risk contributors, which enables prioritization of the plant that
deserve special attention in terms of inspection and maintenance in
particular and over all safety management as a whole.
For the risk reduction at the plant, the following salient suggestions and
recommendations are made:
• On site and off site emergency response plan should be prepared
and circulated to concern persons.
SAN Envirotech Pvt. Ltd, Ahmedabad
REIA of Narayan Organics Pvt. Ltd., Unit-II 6-16
• Personnel at the proposed plant and public in surrounding area
should be made aware about the hazardous substance stored at the
plant and risk associated with them.
• A written process safety information document should be compiled
for general use.
• The document compilation should include an assessment of the
hazards presented including (i) toxicity information (ii) permissible
exposure limits. (iii) Physical data (iv) thermal and chemical stability
data (v) reactivity data (vi) corrosivity data (vii) information on
process and mechanical design.
• The process design information in the process safety information
compilation must include P & IDs/PFDs; process chemistry;
maximum intended inventory; acceptable upper and lower limits,
pressures, flows and compositions and process design and energy
balances.
• The adequate numbers of heat and smoke detectors should be
provided at strategic locations in the plant and indication of
detectors/sensors should be provided in main control room.
• Predictive and preventive maintenance schedule should be prepared
for equipment, piping, etc. and thickness survey should be done
periodically as per standard practices.
• A written procedure (Management of Change) must be developed to
manage changes to process chemicals, technology, equipment and
procedures that affect a covered process.
• Safe work practices should be developed to provide for the control of
hazards during operation and maintenance such as: (i) lockout/tag
out (ii) Confined space entry (iii) Opening process equipment or
piping (iv) Control over entrance into a facility by maintenance,
contractor, laboratory, or other support personnel.
• Personnel engaged in handling of hazardous chemicals should be
trained to respond in an unlikely event of emergencies.
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REIA of Narayan Organics Pvt. Ltd., Unit-II 6-17
• The plant should check and ensure that all instruments provided in
the plant are in good condition and documented.
• Safety measures in the form of “DO” and “Don’t do” should be
displayed at strategic locations especially in local language and
English.
• Regular mock drills should be carried out once in every 3 months
and shortcomings should be recorded and rectified. Records should
be maintained for the response of Mock Drills and corrective actions
should listed and taken accordingly.
6.8.1 PERSONAL PROTECTIVE EQUIPMENT
Personal protective equipments are devices that are fitted and issued to
each worker personally for his or her exclusive use. They are intended
for temporary use and emergency response action only. If a worker has
to enter in a contaminated area, he must wear adequate protective
equipment. Employees should be taught when and how to use
respiratory apparatus provided, and how to recognize defects in the
equipment. Full dress escape drills should be conducted at least once a
year. If such safety equipment is not available, entry into the
contaminated area should not be attempted.
• Personal protective equipment should be easily accessible outside
the hazardous material storage area and away from areas of likely
contamination.
• Employees who work near RM storage Tank must be issued a
properly fitting cartridge type or canister type escape respirator.
• Facial hair should not be permitted for those who are issued
escape-type or self-contained respirators because it prevents a
proper seal.
• Each employee should maintain his/her personal protective
equipment clean and in working condition at all times.
• All equipments should be used and maintained in accordance with
the manufacturer’s instructions.
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REIA of Narayan Organics Pvt. Ltd., Unit-II 6-18
6.8.2 HANDLING OF HAZARDS
• Personal protective equipment used by the person during handling
of hazardous chemicals, should be replaced after certain time.
• Any spillage of hazardous chemicals should be cleaned and disposed
off as per standard practice.
• Empty drums of hazardous chemicals should be neutralized
immediately.
• Personnel engaged in handling of hazardous chemicals should be
made aware of properties of hazardous chemicals.
6.8.3 GENERAL WORKING CONDITIONS
(a) House Keeping
• All the passages, floors and stairways should be maintained in
good condition. The system should be available to deal with any
spillage of dry or liquid chemical at the plant.
• Sufficient disposable bins should be clearly marked and these
should be suitably located in the plant.
• Walkways should be clearly marked and free from obstructions.
• In the plant, precaution and instructions should be displayed at
strategic locations.
• All pits, sumps should be properly covered or securely fenced.
• Roads/walkway within the plant should be maintained neat and
clean.
(b) Ventilation
• Adequate ventilation should be provided in the work floor
environment.
• The work environment should be assessed and monitored
regularly.
• Local ventilation is most effective method for controlling dust and
gaseous emissions at work floor.
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REIA of Narayan Organics Pvt. Ltd., Unit-II 6-19
6.8.4 SAFE OPERATING PROCEDURES
• Safe operating procedures should be available for almost all
operations and equipments.
• Workers should be informed of the consequences of failure to
observe the safe operating procedures.
6.8.5 WORK PERMIT SYSTEM
Work permit system should be followed at the plant. Hazardous work
permit should be used for hot work, electrical works, etc.
6.8.6 FIRE PROTECTION
• Adequate fire fighting facilities should be available at the plant,
including, dry chemical powder type, water CO2 type, mechanical
foam type, CO2 type and sand buckets.
• The fire fighting system and equipment should be tested and
maintained as per relevant standards.
• The fire drills should be conducted once in six months.
6.8.7 EMERGENCY PREPAREDNESS
• On-site emergency plan should be prepared and readily available for
an unlikely event of emergency.
• Emergency telephone numbers should be available and displayed
properly at strategic locations.
6.8.8 STATIC ELECTRICITY
• All equipments and storage tanks/containers of flammable chemicals
should be bounded and earthed.
• Electrical resistance for earthing circuits should be maintained.
Periodic inspections should be done for earth pit and record should
be maintained.
6.8.9 MATERIAL HANDLING
• Material handling areas should be clearly defined.
• The workers should be made aware about the hazards associated
with manual material handling.
SAN Envirotech Pvt. Ltd, Ahmedabad
REIA of Narayan Organics Pvt. Ltd., Unit-II 6-20
6.8.10 COMMUNICATION SYSTEM
• Adequate communication facilities should be available at the plant
and supported with uninterrupted power supply.
• Communication facilities should be checked periodically for its proper
functioning.
6.8.11 ACCIDENT REPORTING, INVESTIGATION AND ANALYSIS
A system should be initiated for accident reporting, investigation and
analysis. To motivate and to increase awareness among the personnel
at the plant about safety, total accident (lost time injury) free days can
be displayed on the board prominently at strategic location.
6.8.12 SAFETY INSPECTIONS
The system should be initiated for checklist based routine safety
inspection and internal audit of the plant periodically. Safety inspection
team should be formed from various disciplines and departments.
6.8.13 SAFE OPERATING PROCEDURES
Safe operating procedures should be formulated and updated, specific
to process & equipment and distributed to concerned plant personnel.
SAN Envirotech Pvt. Ltd, Ahmedabad
REIA of Narayan Organics Pvt. Ltd.,Unit-II 7-1
Chapter 7 ONSITE DISASTER MANAGEMENT PLAN
7.1 INTRODUCTION
An emergency is said to have arisen when operators in the plant are not
able to cope with a potential hazardous situation i.e. loss of control of an
incident, causes the plant to go beyond its normal operating conditions,
thus creating danger. When such an emergency evolves, chain of events
which affect the normal working within the factory area and/or which, may
cause injuries, loss of life, substantial damage to property and environment
both inside and around the factory take place, then the DISASTER is said
to have occurred.
M/s. Narayan Organics Pvt. Ltd., Unit-II is the proposed unit for pigment
manufacturing. The unit proposes to manufacture Copper Pthalocyanine
Blue (CPC Blue), Pigment Alpha Blue and Pigment Beta Blue of 700.0 TPM,
75.0 TPM and 200.0 TPM capacity respectively. There will also be
generation of Ammonium Carbonate Solution (12-15%) as by-product up
to 600.0 TPM. Thus, total production capacity of the unit including by-
product will be 1575.0 TPM.
As described in chapter-6, the risk assessment studies have been
conducted for identification of hazards, to calculate damage distances and
to spell out risk mitigation measures.
Despite of best efforts to manage an emergency situation in the prevention
of any risk hazards from the manufacturing process or material handling,
things can go wrong. Therefore, it is essential to plan and develop the
support system, which will be required in case an emergency arises.
SAN Envirotech Pvt. Ltd, Ahmedabad
REIA of Narayan Organics Pvt. Ltd.,Unit-II 7-2
7.2 PROBABLE HAZARDS AND RISK
From the preliminary risk assessment study presented in Chapter 6 of this
report, some of the possible hazards have been identified.
7.3 OBJECTIVES OF THE PLAN
Following are the Objectives of the disaster management plan:
• To define and assess emergencies, including risk and environment
impact assessment.
• To reduce possibilities of an accident
• To safeguard employees, visitors and other people in the vicinity.
• To minimize damage to property and/or the environment.
• To inform employees, general public and the authorities on the
hazards/risk assessed, safeguards provided, residual risks, if any, and
the role to be played by them in the event of an emergency.
• To be ready for the mutual aid if need rises to help the neighbouring
unit. Normal jurisdiction of an On-site Emergency Plan is the own
premises only, but looking to the time factor in the arriving the
external help of off-site plan agency, the jurisdiction must be
extended outside to the extent possible in case of an emergency
occurring outside.
• To inform authorities and mutual aid centres to come for help.
• To affect rescue and treatment of casualties to count injured.
• To identify and list any dead.
• To inform and help relatives.
• To secure the safe rehabilitation of affected area and to restore
normality.
• To provide authoritative information to the news media.
• To preserve records, equipment, etc., and to organize investigation
into the cause of the emergency and preventive measures to stop its
reoccurrence.
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REIA of Narayan Organics Pvt. Ltd.,Unit-II 7-3
• To ensure safety of the work force before they re-enter and resume
work.
• To work out a plan with all provisions to handle emergencies and to
provide for emergency preparedness and the periodical rehearsal of
the plan.
The structure of the plan may vary depending on number of employees,
materials and processes, availability of resources, location of site, size and
complexity of work.
The plan should not be complicated. Instructions should not overlap or
create any confusion. Responsibilities should be clearly assigned and
should be workable smoothly. For clear understanding and quick action,
the action (role) by each individual (his emergency duty) should be
prepared in a booklet or card size and given to him.
7.4 IDENTIFICATION OF MAJOR HAZARDS
The major hazardous field where disaster management plan is required are
as under:
• Bursting of high-pressure steam pipe, vessels, etc. due to
abnormal pressure rise
• Fire hazard due to ignition of fuel
• Inhalation of any hazardous chemical
7.5 SCOPE OF THE PLAN
• The plan will set into action immediately after a fire or other hazard
occurs in and/or around the plant
• Fuel storage facility will be situated away from the manufacturing plant
and will follow all rules and regulation
• All the electrical fittings will be of explosion proof fitting
• All necessary fire-fighting arrangements will be provided near the
storage area
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REIA of Narayan Organics Pvt. Ltd.,Unit-II 7-4
7.6 THE UTILITY, ORGANIZATION AND UTILIZATION OF RESOURCES
AND FACILITIES FOR EMERGENCIES
In order to maintain an emergency response capability, certain facilities
must be kept in a state of readiness and sufficient supplies and equipment
must be available. In some cases, it may be impossible to maintain all of
the equipment necessary for all possible emergencies. In these cases,
agreements have to be made with neighbouring facilities to provide
additional support as and when necessary.
Where the local police or private agencies may be called upon, such as
volunteer fire companies and ambulance associations, agreements have to
be developed ahead of time. Emergency hardware can be classified
according to its use during the response operations. Typical examples are:
• Emergency operation centres
• Communication equipment
• Alarm system
• Personal protection equipment
• Fire fighting facilities, equipment and supplies
• Spill and vapour release control equipment and supplies
• Medical facilities, equipment and supplies
• Monitoring systems
• A media Centre
• Transportation system
• Security and access control equipment
Some of these resources will also be available in the local municipalities. It
is the responsibility of the plant management to ensure that the
appropriate equipments and materials are available to respond to their
very hazard-specific emergencies at the facilities, independently from
external resources. These resources can be extremely valuable, but should
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REIA of Narayan Organics Pvt. Ltd.,Unit-II 7-5
be used mainly in support of the main response actions that the facility
personnel will have to implement in case of a serious emergency.
In any case, the availability of resources within the community must be
determined before hand, so that these resources can be mobilized, if the
time comes to do so.
7.7 RESPONSE ORGANISATION STRUCTURE
To set up a response organization structure necessary for chain of
commands during emergency situation, which may arise in the premises, is
one of the most important objectives of emergency plan, which is briefly
described hereunder:
Functions and Responsibilities
The main key person of the emergency plan is Chief Emergency
co-ordinator (Factory Manager / Plant Head). He shall be assisted by,
• Emergency Plant Coordinator, Chief (Production)
• Material Management Coordinator, Chief (Commercial)
• Special Job Coordinator, Chief (Administration Finance)
Chief Emergency Coordinator
He shall be responsible for
• Essential communications
• Public relation
• Transportation
• Investigation and reports
• Alert the hospital authorities
Emergency Plant Coordinator (Chief – Production)
• Rush to the site of emergency on receipt of information.
• Direct plant operation/shut-down operations as needed to control
situation.
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REIA of Narayan Organics Pvt. Ltd.,Unit-II 7-6
• Guide the Shift Production Officer and members of the Emergency
Squad in fire fighting/rescue operations.
• Arrange for any additional fire fighting/safety equipment, which may
be required at the site.
• Keep in constant touch with the Chief Emergency Coordinator and pass
on all relevant and necessary information to him so as to enable him
keep in touch with concerned authorities.
• Keep in touch with the other coordinators for requirement of any
services like external help, communication, transportation, etc.
• Arrange for replacement/refilling of used up fire fighting equipments or
gas masks/canisters so as to make these available at the site at the
earliest.
• Carry out investigation of the accident and assist in filling of statutory
reports as required.
• Carry out preliminary investigation into the accident with the help of
concerned personnel.
• Preserve records/evidence that may be required for investigation.
Material Management Coordinator (Chief-Commercial)
• Rush to the site of emergency.
• Keep the stores open for emergency issue of any items that may be
required for control of emergency.
• In case some material is not available, arrange for its emergency
purchase.
• Keep contact with other coordinators to assess any requirements in
terms of material.
• Arrange for any trucks/trolleys, which may be required for
transportation of materials.
• Keep in constant touch with the Chief Emergency Coordinator.
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REIA of Narayan Organics Pvt. Ltd.,Unit-II 7-7
• Assess the situation in consultation with the Chief Emergency
Coordinator and other coordinators.
• Arrange to get maintenance mechanics along with their toolboxes to
provide help in any isolation/repair work as may be required.
• Arrange for requisite number of contractor workmen in case any
additional help is required.
• Arrange for the Shift Electrician and get power supply to the affected
area, if required.
• Make arrangements for temporary lighting/emergency lighting at the
affected area, as required.
• In case of a power failure, ensure the running of the DG sets and
uninterrupted power supply to emergency facilities.
Special Job Coordinator (Chief – Administration/Finance)
• Rush to the site of emergency
• Assess the situation in consultation with Emergency Plant Coordinator
to provide help as may be required.
• Keep in constant touch with the Chief Emergency Coordinator.
• Assess the situation in consultation with Chief Emergency Coordinator.
• Attend to all emergencies related communications at the Security
Gate.
• Arrange for all Security Guards at their respective post and in case of
the availability of some spare Security Guards, they may be sent to
site of emergency to assist emergency Squad in fire fighting/rescue
operations.
• Closely monitor all movements at the gate, keeping passage clear for
movement of emergency vehicles.
• No visitors should be allowed to come inside the premises during the
period of emergency.
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REIA of Narayan Organics Pvt. Ltd.,Unit-II 7-8
• Assess the law and order situation inside/outside the premises and
take necessary action accordingly. Proper vigilance to be maintained to
avoid any attempts from inside/outside saboteurs.
• Arrange to keep the emergency vehicles and ambulance ready with
their drivers for any movement of personnel/material.
• Arrange for canteen services for the personnel on duty and in the
affected area.
• In case of any injuries, provide necessary first aid and arrange for
shifting of the injured personnel to the ESI or other hospitals as the
case may be.
• Attend to any external calls/telephones relating to information about
emergency.
• In case of need from other emergency coordinators at site, arrange to
inform external agencies like Fire Brigade, Police Station, Ambulance
and other Medical Services.
• Arrange for filling of statutory report that may be required.
7.8 EMERGENCY RESPONSE CENTRE
The place identified as Emergency Response Centre will be considered
as the Security Gate Office.
The location of Emergency Response Centre may change in future as per
convenience. The facilities available at the Emergency Response Centre
shall include:
• Internal Telephone
• External Telephone
• Manual Fire/Emergency Siren
• Siren Actuation Switch
• Important Address and Telephone Numbers
• Emergency Vehicles
• Confined Space Entry Procedure
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REIA of Narayan Organics Pvt. Ltd.,Unit-II 7-9
• List of antidote/actions to be taken in case of exposure to
hazardous Chemicals/materials.
• Material Safety Data Sheets of chemicals
• A copy of On-Site Disaster Management Plan
All communications after General Shift working hours and on
Sundays/Holidays are to be routed through the Security Gate Office.
General Rules
• Follow sense of discipline and do not panic.
• Do not rush and endanger your personal safety.
• Use personnel protective equipment according to the situation.
• Do not block any passages which may hinder the movement of
emergency Vehicles.
• In case you have to shut down your plant operations, do it in an
orderly manner as per standard operating procedures.
• In situation when you have to leave your work and evacuate to
identify places out of operating areas, do it in an orderly manner.
• Follow instructions of the Emergency Co-ordinators.
• Understand the disaster management plan well and take interest
in practice drills
Emergency Squad
There is a group of personnel (5-10 in number) who will be identified to
handle any emergency situation. These personnel including officers shall be
taken from various operating areas and will be imparted extensive training
in fire fighting, material safety data for hazardous chemicals, rescue
operations, decontamination procedures, confined space entry procedures,
first aid and other related functions. The members will be so chosen that at
any given time, at least 2–3 members of Emergency Squad will be
available in the premises.
SAN Envirotech Pvt. Ltd, Ahmedabad
REIA of Narayan Organics Pvt. Ltd.,Unit-II 7-10
Communication System
Intercom telephone points shall be provided at all critical areas of
operations. An Emergency Telephone shall be available at the Emergency
Response Centre. In addition, telephone connections shall be provided at
the residence of all critical personnel to ensure immediate contact.
7.9 POST EMERGENCY – RECOVERY
When an emergency is over, it is desirable to carry out a detailed analysis
of the causes of accidents to evaluate the influence of various factors
involved and to propose methods to eliminate or minimize them in future.
Simultaneously, the adequacy of the disaster preparedness plan will be
evaluated and any shortcomings will be rectified.
Accident Investigation
a. After the emergency is over and plant operation has become normal, the investigation shall be carried out as soon as possible to determine the cause of the event.
b. Representatives from various disciplines should take part and report in the investigating team.
c. The area of the event shall be sealed off so that tampering or alteration of the physical evidence will not occur.
d. Key components shall be photographed and logged with time, place, direction, etc.
e. Statements shall be taken from those who were involved with the operation or who witnessed the event.
Damage Assessment
This phase of recovery establishes the quantum of replacement of
machinery considered necessary for bringing back the plant to normal
operation, property and personnel losses, and culminates in a list of
necessary repair, replacement and reconstruction work.
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REIA of Narayan Organics Pvt. Ltd.,Unit-II 7-11
Insurance companies will be informed of the damage and requested to pay
the compensation as per claim.
Cleanup and Restoration
• This phase will only begin after the investigation is complete.
• Reporting documentation will be prepared and forwarded to
appropriate authorities.
• Repairs, restoration and cleanup will begin.
Insurance claims will be prepared and submitted.
SAN Envirotech Pvt. Ltd, Ahmedabad
REIA of Narayan Organics Pvt. Ltd.,Unit-II 7-12
Figure – 7.1:- On Site Disaster Management Plan
Chief Emergency Coordinator Factory manager /
Plant head
Material management Coordinator
(Chief Commercial)
Special Job Coordinator
(Chief Administration
Finance)
Emergency Plant Coordinator (Chief Production)
F. No. J-11011126112010- IA l l (I) Government of India
Ministry of Environment and Forests (I.A. Division)
To' d i r i Dahyabhai N Patel Managing Director MIS Narayan Organics Pvt. Ltd. Plot No. 130516 /A+B, Phase IV GlDC Naroda, Ahmadabad - 382330 (Gujarat)
Dated 9Ih September, 2010
E-mail : ; Fax No. : 79-22823572
Subject:Copper Phthalocyanine Blue (700 MTPM), Pigment Alpha Blue (75 MTPM), and Pigment Beta Blue (200 MTPM) Manufacturing Unit at Block No. 164, 165, 166, 167, 168, 169 and 170, Village Vedach, Tehsil Jambusar, District Bharuch, Gujarat by MIS Narayan Organics Pvt. Ltd. - reg.
Ref. : Your letter no. nil dated 5th May, 2010.
Sir, Kindly refer your letter no, nil dated 5Ih May, 2010 alongwith project documents
including Form-I, Pre-feasibility Report and draft 'Terms of Reference' as per the EIA ., Notification, 2006. It is noted that proposal is for Copper Phthalocyanine Blue (700 MTPM), Pigment Alpha Blue (75 MTPM), and Pigment Beta Blue (200 MTPM) Manufacturing Unit at Block No. 164, 165, 166, 167, 168, 169 and 170, Village Vedach, Tehsil Jambusar, District Bharuch, Gujarat by MIS Narayan Organics Pvt.
Draft Terms of Reference (TOR) have been discussed and finalized during the
- 13" Expert Appraisal Committee (Industry-2) meeting held during lgth-2dh ~ugus t , 2010 for preparation of EINEMP. Following are the 'TORS':
1. Executive summary of the project 2. Justification of the project. 3. Promoters and their back ground 4. Regulatory framework 5. Project location and plant layout. 6. Infrastructure facilities including power sources. 7. Total cost of the project alongwith total capital cost and recurring costlannum for
environmental pollution control measures. 8. Project site location along with site map of 10 km area and site details providing
various industries, surface water bodies, forests etc. Iv
9. Present land use based on satellite imagery for the study area of 10 km radius. Location of National Pa rm i l d life sanctuarylReserve Forest within 10 km radius of the project.
10. Permission from the State Forest Department regarding the impact of the proposed plant on the surrounding reserve forests, if any.
11. Details of the total land and break-up of the land use for green belt and other uses.
12. List of raw materials, products alongwith the production capacities and list of solvents and its recoveryplan.
13. Commitment for not using azodyes in the process should be given. 14. Detailed list of raw material required and source, mode of storage and
transporiation. -
15. Manufacturing process details alongwith the chemical reactions. 16. Design details of ETP, incinerator, if any alngwith control of Dioxin B Furan,
boiler, scrubberslbag filters etc. 17. Details of water and air pollution and its mitigation plan 18. Site-specific micro-meteorological data using temperature, relative humidity,
hourly wind speed and direction and rainfall is necessary. 19. Ambient air quality monitoring for all the parameters including VOCs within the
study area of 5 km., aerial coverage from project site. Location of one AAQMS in downwind direction.
20. One season site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall and AAQ data (except monsoon) for PM,o, SO,, NOx including HC and VOCs.should be collected. The
.. monitoring stations should take into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests. Data for water and noise monitoring should also be included.
21. Action pLa,n_to control ambed airquality a s per NAAQES Standards notified by the Ministry on 16Ih september. 2009.
22. An action plan to control and monitor secondary fugitive emissions from all the sources as per the latest permissible limits issued by the Ministry vide G.S.R. 414(E) dated 3 0 ' ~ May, 2008.
23. Determination of atmospheric inversion level at the project site and assessment of ground level concentration of pollutants from the stack emission based on site- specific meteorological features. Air quality modelling for the proposed plant.
24. Permission for drawl of 612 m31day ground water from the CGWNSGWB. Water balance cycle data including quantity of effluent generated recycled and reused and discharged. Method to be used to control ammonical nitrogen from industrial wastewater.
25. Ground water monitoring minimum at 6 locations should be carried out. Geological features and Geo-hydrological status of the study area and ecological status (Terrestrial and Aquatic).
26. The details of solid and hazardous wastes generation, storage, utilization and disposal particularly related to the hazardous waste calorific value of hazardous waste and detailed characteristic of the hazardous waste.
27. Details of land fill alongwith design details as per CPCB guidelines. Location of secured land filllTSDF.
28. Ground water monitoring around the land fill site 29. Membership of CETP for disposal to effluent and TSDF for disposal of hazardous
water1 solid waste. 30. Risk assessment for storage for chemicals/solvents and phosgenes. (J
31. An action plan to develop green belt in 33 % area 32. Action plan for rainwater harvesting measures at plant site should be included to
harvest rainwater from the roof tops and storm water drains to recharge the ground water.
33..Occupational health of the workers needs elaboration including evaluation of noise, heat, illumination, dust, any other chemicals, metals being suspected in environment and going into body of workers either through inhalation, ingestion or through skin absorption and steps taken to avoid musculo-skeletal disorders (MSD), backache, pain in minor and major joints, fatigue etc. Occupational hazards specific pre-placement and periodical monitoring should be carried out.
34. Socio economic development activities should be in place. 35. Note on compliance to the recommendations mentioned in the CREP guidelines. 36. Detailed Environment management Plan (EMP) with specific reference to details
of air poiiution control system, water & wastewater management, monitoring frequency, responsibility and time bound implementation plan for mitigation measure should be provided.
37. EMP should include the concept of wa$e-minimization, recyclelreuselrecover techniques, Energy conservation, and natural resource conservation.
-. 38. Any litigation pending against the project andlor any directionlorder passed by any Court of Law against the project, if so, details thereof.
39. Public hearing issues raised and commitments made by the project proponent on the same should be included separately in EINEMP Report in the form of tabular chart with financial budget for complying with the commitments made.
40. A tabular chart with index for point wise compliance of above TORS.
The following general points should be noted:
(i) All documents should be properly indexed, page numbered. (ii) Periodldate of data collection should be clearly indicated. (iii) Authenticated English translation of all material provided in Regional
languages. (iv) The letterlapplication for EC should quote the MOEF file No. and also attach a
copy of the ietter. (v) The copy of the letter received from the Ministry should be also attached as an
annexure to the final EIA-EMP Report. (vi) The final EIA-EMP report submitted to the Ministry must incorporate the issues
,- in this letter. The index of the final. EIA-EMP report must indicate the specific chapter and page no. of the EIA-EMP Report.
(vii) While preparing the EIA report, the instructions for the proponents and instructions for the consultants issued by MoEF vide O.M. No. J- 1101314112006-lA.ll (I) dated 4th August, 2009, which are available on the website of this Ministry should also be followed.
(viii) The consultants involved in the preparation of EINEMP report after accreditation with Quality Council of India (0CI)INational Accreditation Board of Education and Training (NABET) would need to include a certificate in this regard in the EINEMP reports prepared by them and data provided by other organization1Laboratories including their status of approvals etc. In this regard circular no F. No. J -1101317712004-lA Il(1) dated 2nd December, 2009 posted on the Ministry's website http://w.moef.nic.in may be referred.
(ix) 'Certificate of Accreditation' issued by the QCI to the environmental consultant should be included, ,/
' These 'TORS' should be considered for the preparation of EIA I EMP report of Copper Phthalocyanine Blue (700 MTPM), Pigment Alpha Blue (75 MTPM), and Pigment Beta Blue (200 MTPM) Manufacturing Unit at Block No. 164, 165, 166, 167, 168, 169 and 170, Village Vedach, Tehsil Jambusar, District Bharuch, Gujarat in addition to all the relevant information as per the 'General Structure of EIA' given in Appendix Ill and lllA in the EIA Notification, 2006. The EINEMP as per TORS should be submitted to the Ministry for considering the proposal for environmental clearance within 2 years as per the MoEF O.M. No. J-11013/41/2006-Ill (I) dated 2Pd March, 2010. The drafi EINEMP report should be submitted to the Gujarat Pollution Control Board for public hearing. The issues emerged and response to the issues raised during public hearing should be incorporated in the EIA report. The7inal EINEMP alongwith 'Certificate of Accreditation' issued by the QCl should be submitted to the Ministry for obtaining environmental clearance.
The consultants involved in the preparation of EINEMP report afler accreditation with Quality Council of India I National Accreditation Board of Education and Training (QCIINABET) would need to include a certificate in this regard in the EINEMP reporls prepared by them and data provided by other Organization(s)lLaboratories including their status of approvals etc. In this regard circular no F. No. J -1101317712004-lA Il(1) dated 2"d December, 2009 available on the Ministry's website http.Nwww.moef.nic.in may be referred. ,-.
i h& [Dr. P.B. Rastogi) S l s l l L '
Scientist 'F;
Copy to: The Chairman. Gujarat State Pollut~on Control Board, Paryavaran Bhawan, Sector 10 A, Gandhi Nagar-382 043, Gujarat.
(Dr. P.B. Rastogi) Scientist 'F'
Charter on Corporate Responsibility for Environmental Protection (CREP) for dyestuff Industry Name of the Industry (Unit):For M/s. Narayan Organics Pvt. Ltd. Unit-II.
Name of Products:- Copper phthalocyanine blue-700 TPM Pigment alpha blue-75 TPM Pigment beta blue-200TPM Scale of operation:- SSI/MSI
Sr. No Points for Action Implementation Schedule
1 Do you have any programme for recovery and purification of bye-products
Yes, we will recover dilute sulfuric acid from Alpha Blue plant and Ammonia from air Pollution Control System and convert it to by product Ammonium Sulphate. Action will be start from commissioning of plant.
2 Do you have incinerator? No we have no incinerator 3 Is there any waste exchange
programme with other Industry for proper use of weak acid
We will utilize weak acid for producing Ammonium Sulphate in our own plant
4 Do you have any programme for recovery and purification of bye-products?
Pl. refer poijt no-1
5 Do you have regular monitoring programme for ground water at the vicinity?
We will develop monitoring programme start from commissioning of plant.
6 Whether Waste generated from one Industry is used by other?
Yes, we will recover dilute sulfuric acid from Alpha Blue plant and Ammonia from air Pollution Control System and convert it to by product Ammonium Sulphate. Action will be start from commissioning of plant.
7 Do you have any waste minimization programme on practice
By product recovery is a part of waste minimization activities.
8 Is there any possibility for introduction of spray drying instead of salting
No, there will be no possibility to install spray dryer and we are not doing salting to recover product because product itself water insoluble.
9 Is the scrubbing system up- gradation programme initiated?
From the beginning, we will install proper design scrubber to control of hazardous air pollutants (such as Ammonia and it will converted as by product. Action plan to be submitted to GPCB immediately after plant commission.
10 Do you have any programme for volatile organics loss minimization programme
All liquid material will be transfer by pneumatically, joint will be 100% leak proof and solid material will be transfer with care of zero leakages.
11 Better management practice Environment Management Cell will be created for better practice to control the relevant pollutant.
12 Solid waste management programme Chemical Sludge-600 MT/Month Part of sludge will be sold to cement industries and balance will be sent to TSDF site as land filling approved by GPCB
Oyanies !Pert. ~ t d . Unit II REGD. OFFICE : 1305/6/A+B, PHASE - IIP, G.I.D.C. ESTATE. NARODA. AHMEDABAD-382330. INDIA. PH. : ++91-79-22821099, 22816038,