Manufacturing of 45.0 KLD Ethanol by Grain Based ...

Manufacturing of 45.0 KLD Ethanol by Grain Based distillery with Zero Liquid Discharge, to be used for Ethanol Blended Petrol Programme of the Government along with 1.5 MW Power Plant at Village- Manoharpali, P.O – Samleipadar, Tehsil- Bijepur, District- Bargarh, Odisha

M/s Bargarh Bio-Fuels Development Foundation Page 1

RISK AND HAZARDS IDENTIFICATION, ASSESSMENT AND MANAGEMENT SUPPORTED

BY EMERGENCY PREPAREDNESS PLAN AND DISASTER MANAGEMENT PLAN

It is the process of identifying the possible situations, happenings, processes at the

industrial workplace that may cause harm to the working force and the nearby population.

Hazard Assessment is the process of estimating, for defined areas, the probabilities of the

occurrence of potentially damaging phenomenon of given magnitude within a specified

period of time

Risk

Risk is the likelihood that a person may be harmed or suffers adverse health effects if

exposed to a hazard.

Risk assessment

It is the process of evaluating and assessing the risks and deciding the potential of a

particular hazard which if occurs can cause harm to surrounding people and property.

Process involved in hazard identification and risk assessment

1. Identification of hazards

2. Analyze or evaluate the risk associated with the hazards

3. Determine appropriate ways to eliminate or control the hazards

4. Evaluate the likelihood of an injury or illness occurring, and its severity

5. Review of all available health and safety information about the hazard including

MSDS, manufacturer’s literature, information from organizations and results of

testing

6. Identify actions necessary to eliminate or control the risk

7. Monitoring to confirm the risk is controlled

8. Keep any documentation or records that may be necessary. Documentation may

include detailing the process used to assess the risk, outlining any evaluations, or detailing

how conclusions were made.

Maximum credible scenario:

Fire in diesel drums,

Fire in Ethanol storage yard,

Electric shock

Above are the credible accident scenario.

Hazard Identification and Risk Assessment Matrix

The HIRA matrix of individual unit with its mitigation measures is given below:

Distillery operations (working area)



Activity Associated hazards Health

impact

Risk

rating

Proposed control & mitigation

measures

Working at

height

Slip, trips & falls of

operators

Physical

injuries

High Use safety belts

Provide barrier

Ensure supervision

Raw materials,

and chemicals

handling storage

Exposer to dust,

leakages, fire,

explosion

Lung and

throat

infection,

injuries, burn

High Regular Inspection and

monitoring

Proper training

Use of PPE

Controlled loading and

unloading to avoid spillage

Adequate ventilation

Fuel Yard Fire Burns physical

injuries,

respiratory

disorders

High Locate away from boiler

Provide Fire hydrant

system

Provide Automatic

sprinkler

No welding, gas cutting in

area

Working near

fermentation

and distillation

section

Explosion, Heat ,

Fire, Slipping,

falls

Physical injury

and burning

High Install pressure indicator

alarms

Trained operators

Adequate ventilation

First aid

Storage of

Alcohol

Exposure,

inhalation,

ingestion & fire

Exposure

headache,

drowsiness,

nausea,

Burn injuries.

High Locate away from boiler

Provide Fire hydrant

system

Provide Automatic

sprinkler

No welding, gas cutting in

area

Working near

boiler

Heat, noise Burning,

Hearing loss

High Trained operators

Use PPEs



Incomplete

combustion of

fuel in boiler

Asphyxiation from

carbon monoxide

Lethal damage High Online CO monitors

Regular monitoring of boiler

combustion section

Regular monitoring of flue gas

outlet from boiler

High pressure

steam leakage

from boiler and

steam lines

Burns Risk of burn

injuries

High Regular maintenance

Regular inspection

Use PPE

Provide First aid kit

closely

Air pollution

control device

failure

Release of PM in

ambient air

Air pollution High Immediately shut down

production and repair same.

Electrical

maintenance

Electric shock, short

circuits

Electrocution High Work permit system

Use PPE

Working in D.G.

Sets area

High noise Hearing

problems

Medium Provide acoustic enclosure

Use PPE

Boiler operations

Activity Associated

hazards

Health impact Risk

rating


measures

Working

near boiler

Heat Burning High Use of Personal protective

equipment

First aid availability

Noise Hearing impairment Medium Required Personal protective

equipment

Boiler

maintenanc

e

Mechanical

hazard

Physical injury.

Electrocution

Medium Use of PPEs

Regular monitoring for

leakages

Proper training to workers

regarding handling of boiler

operations

Provision of first aid boxes



High

pressure

steam

Explosion Severe burning and

damage to

equipment

High Use of PPEs

Regular maintenance of boiler

Storage areas for raw

materials should be away from

boiler

Flammable materials need to

be stored away from boiler area

Fire fighting facility

Provision of first aid boxes

Incomplete

combustion

of fuel in

boiler

Asphyxiation

from carbon

monoxide

Lethal damage High Online CO monitors should be

provided

Regular checking of work place

Individual alertness

Power room & D.G. Set operation

Activity Associated

hazards

Health impact Risk rating Proposed control & mitigation

measures

Working in

power room

Electrocutio

n

Physical injury and

lethal damage

High Use of PPEs

First aid facility

Acoustic enclosures High noise Gradual hearing loss Medium

Working near

DG

High noise Hearing impairment Medium Use of PPEs

Acoustic enclosures

Maintenance

operations

for DG

Physical

hazard and

electrocutio

n

Physical injury and

burns

High Use of PPEs

Restricted entry of staff

Use of flame proof fittings

HSD storage

area

Leakage /

Fire

Severe burns and

physical injury

High Storage will be away from

ignition source

Regular monitoring to check

the leakages and spillages

Firefighting facility will be

provided

PPEs will be provided

First aid box

Handling and storage of raw material and products



Activity Associate

d hazards

Health impact Risk

rating


measures

Transportati

on of raw

materials and

products

Physical

hazards,

spillage of

material

Injury due to road

accidents

Medium Trained drivers to be employed

Proper first aid kits to be

provided in all vehicles

MSDS training to be provided

for hazardous chemicals

Transport Emergency (TREM)

cards to be provided to the drivers

Handling &

storage of

molasses

Spillage

from

tankers

Physical injury Less Proper handling of molasses

Training to workers involved in

handling and storage

Concerned PPEs to be provided

to workers

Inspection and regular

monitoring of storage area

Provision of level

indicators for storage tanks

Handling and

storage of

rice husk and

coal

Spillage

and

leakage,

probability

of fire in

coal

storage

yard

Physical injury Medium Proper training to workers

Water sprinkling for

maintaining temperatures of

coal storage yard

Use of PPEs

Regular monitoring of storage

area

Proper system for loading

operations

Handling and

storage of

chemicals

Spillage

and

leakage of

hazardous

chemicals

Physical injury High Proper labeling of harmful

chemicals

Immediate First aid provisions

Discarded containers to be

stored properly

Training of MSDS to be

provided to workers

Proper ventilation to avoid



fuming in the storage area

Handling and

storage of

alcohol

Inhalation,

ingestion

& fire

Exposure to over 1000

ppm may cause headache,

drowsiness and lassitude,

loss of

appetite, and inability

to

concentrate, throat

Irritation

Ingestion

causes depression of

central nervous system,

nausea, vomiting, and

diarrhea

Liquid or vapor may

cause eye and skin

irritation

Burn injury

High Avoid all possible sources of

ignition like spark or flame.

Use spark/flame proof hand

tools

Electrical wiring will be flame

proof type

Proper cleaning provisions if

any spillage occurs

Proper fire safety systems

Training for proper handling

of alcohol.

Provision of level

indicators for storage tanks

of alcohol

Avoidance of plastics, rubber

and coatings in the storage area.

Personal Protective Equipment According To Hazard

Workplace Hazards Suggested PPE

Eye and face

protection

Flying particles, molten metal,

gases or vapors, light radiation

Safety glasses with side-shields,

protective shades, etc.

Head

protection

Falling objects, inadequate height

clearance, and overhead power

cords

Plastic helmets for top and side

impact protection

Hearing

protection Noise

Hearing protectors (ear plugs or ear

muffs)

Foot

protection

Failing or rolling objects, points

objects. Corrosive or hot liquids

Safety shoes and boots for protection

against moving and failing objects,

liquids and chemicals



Workplace Hazards Suggested PPE

Hand

protection

Hazardous materials, cuts or

lacerations, vibrations, extreme

temperatures

Gloves made of rubber or synthetic

material (Neoprene), leather, steel,

insulation materials, etc.

Respiratory

protection

Dust, fogs, fumes, mists, gases,

smokes, vapors

Facemasks with appropriate filters for

dust removal and air purification

(chemical, mists, vapors and gases).

Single or multi-gas personal monitors,

if available

Oxygen deficiency Portable or supplied air (fixed lines).

Onsite rescue equipment

Body/leg

protection

Extreme temperatures,

hazardous materials, biological

agents, cutting and laceration

Insulating clothing, body suits, aprons

etc. of appropriate materials

DISASTER MANAGEMENT AND EMERGENCY PREPAREDNESS PLAN

Disaster management plan

A disaster is a sudden, calamitous event that seriously disrupts the functioning of a

community or society and causes human, material, and economic or environmental losses

that exceed the community’s or society’s ability to cope using its own resources. Though

often caused by nature, disasters can have human origins. (VULNERABILITY+ HAZARD) /

CAPACITY = DISASTER

A disaster occurs when a hazard impacts on vulnerable people. The combination of

hazards, vulnerability and inability to reduce the potential negative consequences of risk

results in disaster.

Types of Disaster

Man-made disaster (On site and Off site)

Natural Disaster

Description of disasters

A) Man-Made disasters

Probable disasters that can occur On-site are as follows:

Plant failure

Rupture or damage of the line, vessel or tank

Excessive leakage of flammable material



Probable disasters that can occur Off-site are as follows:

Exposure to pollutants released from offsite/ storage/related activities

Contamination due to accidental releases or normal release in combination with

natural hazard

Deposition of toxic pollutants in vegetation / other sinks and possible sudden

releases due to accidental occurrences

B) Natural Disasters

Cyclone

Earthquake

Flood

Fire

Emergency preparedness plan for natural and man-made disasters

A) Emergency Planning For Disaster Due To Fire

The disaster due to fire is the major hazard that can occur in distillery and the provisions

have to be made to control the same primarily. A small spark of fire may result into loss of

machines and the damage by fire may cause high economic losses. This type of losses can

be avoided by preventing and controlling the fire instantly for which fire–fighting group

will be established which would house and keep in readiness, the following types of

equipment and arrangements.

CO2 extinguishers

Dry powder chemical extinguishers

Foam extinguishers

Spray hoses

Fire brigade

Fire hydrant

Protocol (chemical to combat oil fires).

In order to avoid fire in cable galleries, all the power and control cables of FRLS type (Fire

Resistant Low Smoke) will be used.

A) Inspection

Fire alarm panel (electrical) will cover the entire plant. The inspection group will

periodically inspect fire extinguishers in fire stations and machines and other places. The

company will display emergency telephone number boards at vital points. The Company

will regularly carry out general inspection for fire.



Fire Fighting With Water

Adequate and reliable arrangement is required for fighting the fire with water such as:

Provision for Fire brigade and Fire hydrant.

Arrangement of pipelines along and around all vulnerable areas.

Provision of valves at appropriate points to enable supply of water at the required

place/area or divert the same to another direction/pipe line.

Provision of overhead tanks which will be providing water during power failure

and it would work by the gravitational force.

Sources of Water for Fire Fighting

The following two sources of water have been considered for firefighting:

Overhead Tank

Raw Water Reservoir

Fire Fighting With Fire Extinguishers

To deal with fire – other than carbonaceous fires, which can be dealt with by water –

suitable fire extinguishers are required to do the job effectively. It is therefore, necessary to

keep adequate number of extinguishers in readiness at easily approachable places.

Further, other spray groups from the system will be diverted to the spot.

In case of fire in the belt, belt will be cut near the burning portion to save the

remaining parts.

After extinguishing the fire, the area will be well prepared for reuse.

Foam System for firefighting will be provided to control fire from the alcohol

storage tank. The foam thus produced will suppress fire by separating the fuel from

the air (oxygen), and hence avoiding the fire & explosion to occur in the tank. Foam

would blanket the fuel surface smothering the fire. The fuel will also be cooled by

the water content of the foam.

The foam blanket suppresses the release of flammable vapors that can mix with the

air.

General Emergency preparedness Plan for all man-made disasters pertaining to

distillery

A) Alarm System

A siren will be provided under the control of Security office in the plant premises to give

warning. In case of emergencies this will be used on the instructions to shift in charge that

is positioned round the clock. The warning signal for emergency will be as follows:

Emergency Siren: Waxing and waning sound for 3 minutes.



All clear signal: Continuous siren for one minute

B) Communication

Walkies & Talkies will be located at strategic locations; internal telephone system EPBX

with external P&T telephones will be provided.

First Aid

A first aid centre with adequate facilities will be provided. It will be maintained round the

clock by a compounder cum dresser and a doctor. An ambulance will also be provided at

site to carry affected people to hospital.

Security

The security requirements of the company premises will be taken care of by CSO assisted

by a fire in charge. The team, apart from the normal security functions will manage the role

required during a disaster management operation as a part of the crisis control team.

Safety

The safety wing led by a Safety Manager will meet the requirement of emergencies round

the clock. The required safety appliances will be distributed at different locations of the

plant to meet any eventualities. Poster/placards reflecting safety awareness will be placed

at different locations in the plant area.

Evacuation Procedure

As the major hazard is only due to fire, which has more or less localized impact no mass

evacuation procedures are required. Evacuation would involve only the people working

very close to the fire area.

Emergency Control Center

Provision will be made to establish an Emergency Control Centre (ECC) from which

emergency operations will be directed and coordinated. This centre will be activated as

soon as on–site emergency is declared.

The ECC consists of one room, located in an area that offers minimal risk being directly

exposed to possible accidents.

During an emergency, the Emergency Management Staff, including the site controller will

gather in the ECC. Therefore, the ECC is equipped with adequate communication systems in

the form of telephones and other equipment to allow unhampered organisations and other

nearby facility personnel.



The ECC provides shelter to its occupants against the most common accidents; in addition,

the ECC’s communication systems are protected from possible shutdown. The ECC has its

own emergency lighting arrangement and electric communication systems operation.

Only a limited and prearranged number of people are admitted to the ECC, when in use.

This eliminates unnecessary interference and reduces confusion.

The ECC is always ready for operation and provided with the equipment and supplies

necessary things during the emergency such as:

Updated copies of the On–site Disaster Management Plan.

Emergency telephone numbers.

The names, phone number, and address of external agencies, response

organizations and neighboring facilities.

The adequate number of telephone (more than two).

Emergency lights, Clocks, Personal protective equipment.

List of fire extinguishers with their type no. and location, capacity, etc.

Safety helmets – List of quantity & location.

Status boards/message board.

Material safety data sheets for chemicals handled at the facility.

Several maps of the facility including drainage system for surrounding area showing:

Areas where hazardous materials are stored.

Plot plans of storage tanks, routes of pipelines, all water permanent lines etc.

The locations where personal protective equipment are stored.

The position of pumping stations and other water sources.

Roads and plant entrances.

Assembly areas & layout of Hydrant lines.

Duties and Responsibility of Key Personnel of Environmental Management Cell



Site Main Controller To co-ordinate with external and internal coordinator and give

necessary instructions.

To put the disaster control plan into action.

To mobilize help from outside agencies and to ensure supply of

firefighting equipment.

In case of disaster of high magnitude, the chief controller will inform

district magistrate, local police station, and district health authorities for

additional help and evacuation.

Continuous review and assess possible developments to determine

the most probable course of events.

Direct the shutting down of plants and their evacuation in

consultation with the incident controller and key personnel.

Ensure that the causalities are receiving adequate attention.

Incident Controller Ensure the emergency services have been called.

Direct the shutting down and evacuation of the plant areas likely to

be affected.

Ensure key personnel have been summoned.

Rescue and firefighting operations, until the arrival of the fire

brigade, when he should hand over control to a senior fire officer.

Search for causalities.

Evacuation of non-essential workers to assembly area.

Set up a communication point with telephone or messenger

contact with emergency control center.

Give advice and information as requested to the emergency services.

Brief the site main controller and keep him informed of

developments.

Distillery Manager Mobilize the fire-fighting operation and coordinate with external

fire tenders/firefighting equipment.

Liaison between the incident controller and the maintenance, fire,

safety and production and medical services.

The maintenance squad should isolate the hazardous area, and plug

the leak.



Security Officer To coordinate fire-fighting operation and replenish the fire-fighting

equipment.

To rescue the injured persons.

To provide first aid/medical assistance.

To liaison with ambulance services.

Remove tank lorry/other vehicles to safe location.

Maintenance

Manager

Maintenance squad should plug the leak, isolate the hazardous area

and ensure the safety of the remaining part of the factory.

Remove the tank lorry and other vehicles form the factory premises.

Liaison between the incident controller and fire and safety

departments.

The team will mobilize any repair work on an emergency basis.

Accounts Officer To coordinate the evacuation of the visitors and office staff who

have no role in controlling emergency.

To rescue the injured persons.

To provide first-aid/medical assistance to injured workers.

To liaison with ambulance services.

Shift In charge

after office hours

Establish the emergency control center

Mobilize all coordinators assembled at the Emergency Control

center and put the disaster control plan into action.

Mobilize the firefighting operations.

Mobilize help from ambulance services and hospitals for medical

assistance.

Mobilize help from the outside agencies for firefighting.

Inform the police and request to control traffic and maintain law and

order.

Inform site controller, incident controller and appraise the situation.

Direct the shutting down of plants and their evacuation.

Give adequate attention to the causalities and send them to hospital.

Communication Equipment and Alarm Systems

This kind of equipment is absolutely vital for notifying accident; make the emergency

known both inside and outside of the facility, and coordinating, the response actions among

the various groups involved in response operations.



In particular, this equipment is used to communicate within the facility; communicate

between the facility and outside organizations; and inform the public.

Different communications systems can vary in effectiveness, depending on the task. The

most common types installed in the plant are given below.

Sirens

These are audible alarm systems commonly used in facilities. In case of any emergency

siren will be operated short intermittently for 1.5 minutes.

An alarm does more than just emergency warning. It also instructs people to carry out

specific assignments, such as reach to assembly point for further instructions and actions,

or carry out protective measures; this can be achieved only if the people are familiar with

the alarm systems and are trained to respond to it.

Personal Protective Equipment

This equipment is used mainly for three reasons; to protect personnel from a hazard while

performing rescue/accident control operations, to do maintenance and repair work under

hazardous conditions, and for escape purposes. The list of Personal Protective Equipment

provided at the facility and their locations will be available in ECC.

Effective command and control accomplish these functions necessitates personal trained in

this On– site Disaster Management Plan with adequate facilities and equipment and

equipment to carry out their duties and functions.

Procedure for Testing & Updating the Plan

Simulated emergency preparedness exercises and mock fire fighting exercises including

mutual aid scheme resources and in conservation with district emergency authority to be

carried out time to time.

Disclosure of Information to Worker and Public Awareness System Anticipated

Safety awareness among workers by conserving various training programs and

Seminars, competition, slogans etc.

Practical exercise.

Distribution and practices of safety Instructions.

Safety Quiz contests.

Display of Safety Posters & Safety Slogans.

Developing Safety Instructions for every Job and ensuring these

instructions/booklets or manuals by the workers.



Occupational health & safety hazards and their management

Occupational health and safety will be categorized broadly into two categories:

Protection of Health

Promotion of Health

Protection of Health

In an industry, the most important factor for proper running of it is the health of

employees which has to be taken care of by following some measures like:

Proper regular check up of employees

Regular training of employees

24 hrs First aid and medical availability

Records maintenance

Promotion of Health

Training regarding importance of health

Programs related to health education

Records maintenance

Organizing health campaigns

Occupational health centre

The industrial premises will have one occupational health centre for regular check up of

employees and to deal in case of emergency. The centre will be equipped with all the

emergency facilities and a qualified doctor as well as staff for auxiliary works.

Occupational health surveillance

In distillery plant, the occupational health surveillance of the employee will be done on a

regular basis and record of the same will be maintained as per the Factories Act.

Pre placement and periodical health check up tests to be undertaken

The checkups will be dependent on age, sex, duration of exposure and department wise.

Following tests will be done regularly:

X Rays (Chest)

Audiometry (Ears)

Spirometry (Lungs)

Vision testing (Eyes)

ECG (Heart)



Frequency of Medical Examination

Once in a year

Personal Protective Devices and Measures

Industrial Safety helmets, Crash helmets

Goggles

Safety Shoes & Rubber Gumboots

Aprons

Ear muffs and Ear Plugs

Full body Safety harness

Leather hand gloves, Heat Resistive hand gloves, Chemical hand gloves and Cut

resistance hand gloves

Safety belt / line man's safety belt

Implementation of OHS standards as per OHSAS/USEPA

The overall objective of the company is to provide a system that is capable of delivering

healthy and safe workplace. Following measures will be adopted for implementation of

OHS standards.

Well-equipped Occupational Health Centre with adequate paramedical staff

Routine and special investigation related to occupational health

Health surveillance and maintenance of health record

Rules and procedure for effective implementation of Safety Health and

Environment policy and made to know all employees

Round the clock ambulance facility

Sufficient number of first aid boxes

Implementation of OHS management program

Displaying the safety and health policy and instructions at various locations

Display of safe operating procedure (SOP) at various locations

Investigation of fatal, serious accidents

Investigation of reports of occupational diseases

Monthly safety meeting of all employees & workers to discuss last month accident if

any, reason and corrective measures taken.

Organize safety training, seminars for safe working and safe vehicle and traffic

movement within the plant premises and regular training for safe driving outside the

plant premises

Ensure use of PPEs according to the job like helmet, safety shoes, goggle, dust



mask, ear plug and hand gloves etc.

Establishment of Occupational Health Centre for pre and periodic medical

examination of workers and staff to detect any onset of occupational disease and

corrective measures

Display Material Safety Data Sheet (MSDS) for use of every hazardous substance

Periodic safety audits both internal and external, review and implementation of

recommendations.

Occupational and Safety hazards and their mitigation

Manufacturing of 45.0 KLD Ethanol by Grain Based ...

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