Page 1
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 1
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
RISK ASSESSMENT
1.1 Hazard
In practical terms, hazard identification is a thorough look at the workplace and processes
to identify those things, situations, processes that may cause harm, particularly to the
working force and nearby population. After identification of the potential hazards, one has
to evaluate it potential to cause harm and then decide what type of control measures shall
be taken to control it from the happening. Hazard identification is very important tool as
it is integral part of a good occupational health and safety management plan. The aim of
the hazard identification process is to reduce level of risk by taking precautions or
initiating control during project execution. The various hazard analysis techniques that
may be applied are Hazard and Operability (HAZOP) studies, Fault – Tree Analysis
(FTA), event –tree analysis and failure and effects mode analysis.
1.2.1 Hazard Identification & Risk Assessment (HIRA)
The purpose of a Hazard Identification and Risk Assessment (HIRA) is to understand
what risks or threats to public safety, property or the environment exist.
Figure 7.1: Hazard Identification & Risk Assessment (HIRA) process
Hazard Identification and Risk Assessment (HIRA) Process,
Identification of hazards
Analyze or evaluate the risk associated with the hazards
Determine appropriate ways to eliminate or control the hazards
Evaluate the likelihood of an injury or illness occurring, and its severity
Review of all available health and safety information about the hazard including
MSDS, manufacturer’s literature, information from organizations and results of testing
Page 2
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 2
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
Identify actions necessary to eliminate or control the risk
Monitoring to confirm the risk is controlled
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.
1.2.2 Identification Hazard
Details of major anticipated risks from the Hazards is given in Table 1.1
Table 1.1: Hazards of the proposed plant
Sr. No.
Name Description Severity Hazard
1. Transportations of
raw material
Yeast, Urea Minor Exposure & inhalation
Sulphuric Acid, Di ammonium Phosphate,
Anti- foam reagent,
Caustic soda
Major Exposure & inhalation
2. Storage of Ethanol
Products and
byproducts
Ethanol Major Explosion, Fire
3. Manufacturing
process
Fermentation Major Fire
Distillation Unit Major Heat & fire
Power Plant Major Heat fire &
electrocution
4. Utilities D.G set, Boiler, Turbine Major Heat, fire & electrocution
5. Other accidents Leakages from the vessels,
Catastrophic rupture of
pressure vessels and
Storage Tanks
Major Exposure & fire
1.2.3 Risk Assessment
Risk analysis deals with the identification and quantification of risks, the plant equivalent
and personnel are exposed to, due to accidents resulting from the hazards present in the
factory. Risk classification table is given in Table 1.2.
Page 3
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 3
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
Table 1.2: Risk classification and score table
1.2.3.1 Potential risk and mitigation measures for during construction phase.
Risk impact and mitigation measures during construction phase are describes in Table
1.3
Table 1.3: Risk Impact and rating matrix during construction phase
Activity Associated
Hazards Health impact
Risk
rating
Proposed mitigation
and control measures
Site Leveling Vehicular
movement,
Insect / snake
bite
Physical injury, and
organ damage
M Providing PPEs to
workers.
Appointing the
qualified persons for
the particular job.
Speed limit control
Providing Training
Loading and
Unloading of
material
Accidents Physical Injury M Providing PPEs to
workers.
Training to workers.
Page 4
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 4
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
Excavation Falling objects
or objects near
an excavation
Slips, trips,
and falls
Property Loss
Physical injury
M Work Permit System
will be followed.
Excavated material
will be stacked safely.
Area will be
barricaded
Training to workers
PPEs will be provided
Construction Structure may
fall down
Workers may
fall down from
the height.
Physical Injury
Physically
handicapped
Property Loss
H Work Permit System
will be followed.
Height work permit
will be issued to the
person.
Safety belt will be
provided to workers
Training to workers
Cutting and
Welding
Fire or
explosion
Electric
shock from
electrical
welding
Physical Injury
Burn Injury
Property loss
H Standards Work
Procedure
Training will be
provided
Proper PPEs will be
Provided.
Regular monitoring of
electrical equipment’s
to avoid loose
connection
Area will be
barricaded
Installation
of
Machineries.
Structure
may collapse
Property loss
Physical Injury
M Only authorized
person will operate
the machine
Appropriate platform
will be designed as
per the load bearing
calculation.
Page 5
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 5
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
1.2.4 Potential risk and mitigation measures during operation phase
1.2.4.1Boiler Operation
The potential risk and its mitigation measures for Boiler operation is given in Table 1.4.
Table 1.4: Risk Impact and rating matrix for Boiler operation
Activity Associated
Hazards Health impact
Risk
rating
Proposed mitigation
and control measures
Working near
Boiler
High noise Noise induced
hearing loss
M Required PPEs need to
be used PPEs
Boiler
maintenance
Mechanical
hazard
Physical
injury
M Regular monitoring
for checking leakages
Individual vigilance
and proper training to
worker for proper
handling
Provision of First aid
box
High Pressure
Steam
Explosion Risk of
severe
injury, damage
to equipment
H Required PPEs
Good housekeeping
Regular monitoring of
the storage facility
Flammable
chemicals stored away
from the source of
ignition
Firefighting facility
Provision of First aid
Box
Incomplete
Combustion
Asphyxiation
from carbon
monoxide
Possible
fatality
H Online CO monitors
Regular checking of
workplace
Individual alertness and
precaution
Maintenance
work
Slips, Trips
and Falls
Physical
injury
M PPEs Individual
alertness and
Page 6
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 6
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
precaution
Electrical
maintenance
work
Electricity Electric
shock,
Possible
burns
H Regular checking
and maintenance
of electrical units PPEs
Provision of First aid
box
Maintenance
of burner
Burn injury Severe
Physical
injury or
burn
M PPES will be provided.
Work will be carried out
under proper
supervision.
Follow of SOPs.
Individual alertness and
precaution is important
Provision of First aid
box
1.2.4.2 Risk during D.G. set operation
Table 1.5:
Risk Impact and rating matrix for D.G. set operation
Activity Associated
Hazards Health impact
Risk
rating
Proposed mitigation
and control measures
Working
near DG
High noise Noise
induced
hearing loss
M Use of PPEs
Acoustic enclosure
Maintenance Fire Burns,
Serious injury
H Restricted Entry
Use of flame proof
fittings
Use of PPEs
HSD Storage Leakage /
Fire
Risk of severe
physical
injury and
burn
H Storage will be away
from ignition source
Regular monitoring
to check the leakages
and spillages
Firefighting facility
will be provided
Page 7
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 7
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
PPEs will be provided
First aid box
DG set
maintenance
Mechanical
Hazard
Physical injury M PPEs
Leakage and heat
in the joint will be
checked before
maintenance
First aid box at
approachable place
1.2.4.3 Hazard & associated Risk of storage and handling of raw material
Impact matric for risk associated with storage and handling of material is given in Table
1.6. Coal and alcohol storage Tanks details are given in Table 1.7. Material safety data
sheets for Chemicals are enclosed as Annexures.
Table 1.6:
Impact matrix of Storage and handling of raw material
Activity Associated
Hazards Health impact
Risk
rating
Proposed mitigation
and control measures
Storage,
handling,
loading &
Unloading of
material
Exposure,
leakage,
Fire,
Explosion
Physical Injury,
burn, Eye
irritation and
respiratory
problem
H Provision of Eye wash
Inspection and
regular monitoring of
storage area.
Training to Workers
for proper handling
PPEs will be provided
as Nose mask, Hand
gloves.
Proper system for
loading operation to
prevents spillage
Provision of level
indicators for storage
Tanks
Spill kit for Acid and
other chemicals
Page 8
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 8
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
Proper ventilation
First Aid boxes
Transportation Fire, accident,
leakage
Burns, Serious
injury
H Fire fighting
Training to driver
MSDS
Trem Card
First Aid Box
1.2.4.4 Risk associated with Ethanol storage and its mitigation measures
Material Safety Data Sheet (MSDS) for ethyl alcohol attached as annexure - IV. Impact
matric of risk associated with storage and transportation of alcohol along with control and
mitigation measures are given in Table 1.7.
Table 1.7: Impact matric of risk associated Alcohol storage
Activity Associated
Hazards Health impact
Risk
rating
Proposed mitigation
and control measures
Storage
of
Alcohol
Exposure,
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
H Storage
Storage will be
away from process
area with well-
ventilation.
Avoid all possible
sources of ignition
like spark or flame.
Use spark/flame
proof hand tools
Electrical wiring
will be flame proof
type
Based on the
leakage quantity,
wiped out with or
dilute by spraying the
water to suppress the
vapors
Control measures in
Page 9
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 9
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
case of over exposure
If v i c t i m i s
conscious and able
to swallow, then
give water or milk
to drink to dilute the
contents in the
stomach
Look out for
medical help
Skin or Eye exposure
Immediately flush
affected area with
plenty of water. Eyes
should be flushed for at
least 15 Minutes with
water.
PPEs will be provided
to avoid exposure.
1.2.4.5 Risk associated with work area of distillation
Table 1.8: Impact matric of risk associated distillation area
Sr. No.
Activity Associated
Hazards
Health impact
Risk rating
Proposed Control and mitigation measures
1. Working near
Distillation
column
Heat & Fire Physical
injury &
burning
H PPEs
Firefighting facility
First aid box
Periodic checking of all
parts
1.3 Safety Measures Recommendation
1.3.1 Storage and material handling area
Proper ventilation shall be provided
Area will be marked as “No smoking Zone”
Page 10
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 10
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
Use of proper PPEs
Pressure relief valves shall be provided
Provision of Safety valves and rupture disk
Provision of fire hydrant system along with other portable fire extinguishers
Adequate distance between the storage Tanks
Provision of dyke wall to the Tanks
Proper earthing to the Tanks
1.3.2 Reactor Safety
Provision will be made for temperature & pressure indicators
Heating & cooling Jacket will be provided to maintain the temperature
Pressure switch with hooter shall be provided
Pressure safety valve will be provided
Double earthing shall be provided
1.3.3 DG Sets
Acoustic enclosures to be provided
Entry near the unit shall be restricted
Qualified and highly trained engineers shall be appointed
1.3.4 Boiler
Work permit system will be evolved and will be followed during maintenance work
Proper ventilation shall be maintained
Entry shall be allowed only after proper checking of gases, if any
Worker should be trained properly
Working should be under supervision of qualified and trained personnel
1.3.5 Storage and Handling of Alcohol
Keeping away from oxidizers, heat and flames.
Avoidance of plastics, rubber and coatings in the storage area.
Cool, dry, and ventilated storage and closed containers.
Leakage should be washed out and diluted.
Regular monitoring and maintenance to avoid leakages.
If major leakage in tanks can be mitigated by transferring the material to other tank.
Page 11
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 11
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
Transfer the material to other tank.
Grounding of the container and transferring of equipment to eliminate static electric
sparks. In case of any emergency following measures would be taken:
First Aid Measures
Use of extinguishing media surrounding the fire as water, dry chemicals (BC or ABC
powder) sand, dolomite, etc
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 and 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.
Special Fire Fighting Procedures; Keeping the fire upwind. Shutting down of all
possible sources of ignition, keeping of run-off water out of sewers and water sources.
Avoidance of water in straight hose stream which will scatter and spread fire. Use of
spray or fog nozzles will be promoted, cool containers will be exposed to flames with
water from the side until well after the fire is out.
1.3.7 Building & workspace
Adequate space will be provided for equipment repair or removal
Equipment maintenance shops will be set up with appropriate safety provisions for
hazards associated with maintenance activities
Lightning protection will be provided
1.3.8 Electric items
Medium and high voltage cables will be completely enclosed
Electrical equipment will be grounded adequately
Wiring will be properly insulated, grounded, and non-exposed
Emergency shutoff switch, clearly labeled, at all machinery units will be provided
DG set will be provided as stand by source of power
Maintenance tools with insulated handles will be provided.
1.3.9 Fire
The fire protection system is to provide for early detection, alarm, containment and
suppression of fires. The complete fire protection system will comprise of the following.
Page 12
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 12
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
Fire hydrant network will be provided for firefighting in the entire project area along
with following firefighting equipment will be provided
Different type of Fire Extinguishers, Detectors and fire Alarm shall be provided
Fire hydrant system
Fire Tender with chemicals foam and required arrangement for firefighting to control
the fire from the alcohol storage
Foam system shall be contain aqueous film forming compound of 3 to 6%
alcohol resistance foam concentrated with ISI mark 4889
Water storage Tank exclusively for firefighting operation
Rubber mat will be used near panel area
Periodical training to the identified supervisors and Employees in the field of
Firefighting and safety
Emergency exits at specific locations and will be marked on the layout
Cautionary note, safety posters, stickers will be displayed at appropriate locations
First Aid boxes will be made available at appropriate locations
Emergency Control Center Provision shall be made to establish an Emergency Control
Centre (ECC) from which emergency operations are directed and coordinated. This
center is activated as soon as on–site emergency is declared. ECC is equipped with
adequate communication systems in the form of telephones (Emergency telephone
numbers) and other equipment’s to allow unhampered organizations and other nearby
facility personnel.
1.4 Disaster Management Plan
1.4.1 Definition
A major emergency in a works is one, which has the potential to cause serious injury or loss
of life. It may cause extensive damage to property and serious disruption both inside and
outside the works. It would normally require the assistance of emergency services to handle it
effectively.
1.4.2 Scope
An important element of mitigation is emergency planning, i.e. identifying accident
possibility, assessing the consequences of such accidents and deciding on the emergency
procedures, both on site and off site that would need to be implemented in the event of an
emergency. Emergency planning is just one aspect of safety and cannot be considered in
isolation from M/s Gulshan Polyols Limited, Grain based distillery, fully endorses this fact
Page 13
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 13
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
and hence before starting to prepare the plan, works management will ensure that the
necessary standards, appropriate to safety legislation, are in place.
1.4.3 Objective
The overall objectives of the emergency plan will be:
To localize the emergency and, eliminate it; and
To minimize the effects of the accident on people and property.
Elimination will require prompt action by operations and works emergency staff using, for
example, fire–fighting equipment, water sprays etc.
Minimizing the effects may include rescue, first aid, evacuation, rehabilitation and giving
information promptly to people living nearby the project site.
1.4.4 Identification of Hazards
The following types of hazards may be identified at M/s Gulshan Polyols Limited, Grain
based distillery:
Fire in Electric Panels, Oil room and Diesel storage.
Waste treatment processes.
Cleaning of Equipment’s and Tanks, which have held chemical substances.
To deal the above emergencies, the Emergency Plan is prepared.
1.5 Emergency Planning
1.5.1 General
Disaster Management Plan for an industrial unit is necessarily a combination of various
actions which are to be taken in a very short time but in a present sequence to deal effectively
and efficiently with any disaster, emergency or major accident with an aim to keep the loss of
men, material, plant/machinery etc. to the minimum.
The main functions of the Disaster Management Cell are to prepare a detailed Disaster
Management Plan, which includes:
Identification of various types of expected disaster depending upon the type of the
industrial unit.
Identification of various groups, agencies, departments etc. necessary for dealing with a
specific disaster effectively.
Preparation – by intensive training of relevant teams/groups within the organization to
deal with a specific disaster and keep them in readiness.
Establishment of an early detection system for the disaster.
Page 14
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 14
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
Development of a reliable instant information/communication system.
Organization and mobilization of all the concerned departments/ organizations / groups
and agencies instantly when needed.
A major disaster that can be expected in this proposed distillery be due to fire.
1.5.2 Emergency Planning for Disaster due to Fire
Cable rooms, transformer, unit, auxiliary transformers, oil tanks, etc. within the plant are the
likely areas for which disaster management plan is to be made to deal with any eventuality of
fire. Stores, workshop, canteen and administrative building will be included.
1.5.2.1 Classification of Fire
Class (A)
Fire involving combustible materials like wood, paper, cloth and Coal etc.
Class (B)
Fire due to liquid materials like oil, diesel, petroleum products and all inflammables.
Class (C)
Fires involving domestic and industrial gases like butane and propane etc.
Class (D)
Metal fires etc.
Class (E)
Electrical fires due to short circuiting etc.
1.5.3 Need of Establishing a Fire Fighting Group
A small spark of fire may result into loss of machines and the damage by fire may 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.
Establish which would house and keep in readiness, the following types of equipment and
arrangements.
CO2 extinguishers
Dry powder chemical extinguishers
Foam extinguishers
80 mm. spray hoses
Fire brigade
Fire hydrant
Protocol (chemical to combat oil fires).
Page 15
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 15
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
In order to avoid fire in cable galleries, all the power and control cables of FRLS type (fire
resistant low smoke) will be used.
1.5.4 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 groups will display emergency telephone number boards at vital points.
The group will regularly carry out general inspection for fire.
1.5.5 Procedure for Extinguishing Fire
The following steps will be taken during a fire accident in the system:
As soon as the message is received about fire, one of the systems will be diverted to the
place of the fire accident along with a staff member.
Simultaneously plant fire station will be informed by phone walkie for fire brigades and
fire stations of nearby area.
In the meanwhile, the pipe system will be operated to obtain maximum pressure on
output. In case cables are within the reach of fire, power supply will be tripped and the
cables shifted.
1.5.6 Fire Fighting with Water
Adequate and reliable arrangement is required for fighting the fire with water such as:
1. Provision for Fire brigade and Fire hydrant.
2. Arrangement of pipelines along and around all vulnerable areas.
3. 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.
4. Provision of overhead tanks which will be providing with the water during power failure
and it would work by the gravitational force.
1.5.7 Sources of Water for Fire Fighting
The following two sources of water have been considered for firefighting:
Overhead Tank
Raw Water Reservoir
1.5.8 Fire Fighting with Fire Extinguishers
To deal with fire – other than carbonaceous fires, which can be deal with by water – suitable
fire extinguishers are required to do the job effectively. It is therefore, necessary to keep
Page 16
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 16
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
adequate number of extinguishers in readiness at easily approachable places. Adequate
number of fire stations would be installed. 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.
1.6 On–Site Emergency Plan
1.6.1 Introduction
The views of the possible hazards that can arise out of the daily operations in the distillery
plant, various measures are adopted to prevent the occurrence of a major accident. This
comprises of:
Built in safety measures, alarms, trips and interlocks etc.
Standard safe operating and maintenance procedures permit system etc.
Training of all the involved staff in normal and emergency operating procedures.
Training of all employees in safety, firefighting and first aid.
However, in spite of these precautions, it is required to foresee situation of major accident
and plan for taking timely action to minimize the effects of such incident on the safety and
health of persons working in the plant as well as those living around the premises.
1.7 Preparation of Plan
1.7.1 Alarm System
A siren shall 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 shall be as follows:
Emergency Siren: Waxing and waning sound for 3 minutes.
All clear signal: Continuous siren for one minute.
1.7.2 Communication
Walkies & Talkies are located at strategic locations; internal telephone system EPBX with
external P&T telephones would be provided.
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PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 17
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
1.8 Fire Protection System
1.8.1 Fire Fighting System
The fire protection system for the unit is to provide for early detection, alarm, containment
and suppression of fires. The fire detection and protection system has been planned to meet
the above objective an all–statutory and insurance requirement of Tariff Advisory Committee
(TAC) of India. The complete fire protection system will comprise of the following.
(a) Fire brigade
Automatic / manual fire detection & alarm system
(b) Fire Hydrant
Fire hydrant will be provided at all around in the plant as per TAC Norms.
(c) Portable fire extinguishers
Various areas of the plant will have one or more of the above system depending upon the
particular nature of risk involved in that area.
(d) Portable Chemical Fire Extinguishers
These are intended as a first line of defense, and hence will be stationed at strategic locations
in different buildings and also for outdoor facilities. Portable fire extinguishers will be foam
type; carbon dioxide type and multipurpose dry chemical (MPDC) type.
(e) Fire Detection and Alarm System
Fire detection and alarm system an effective means of detection, visual indication of fire
location and audible alarm of any fire at its incipient stage. This system will comprise fire
alarm panels, automatic fire detectors, manual call points and fire siren (hooter).
The main fire alarm panel will provide both visual and audible alarm of fire in any protected
areas of the plant.
Manual break glass type fire alarms will be provided at strategic locations where high hazards
exits.
Automatic fire detectors will be provided for coal handling areas and in plant areas such as
control rooms, switchgear rooms, cable galleries etc.
1.8.2 First Aid
A first aid centre with adequate facilities shall be provided. It shall be maintained round the
clock by a compounder cum dresser and a doctor. An Ambulance shall also be provided at
site to carry affected people to hospital.
Page 18
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 18
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
1.8.3 Security
The security requirements of the company premises shall 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.
1.8.4 Safety
The safety wing led by a Safety Manager will meet the requirement of emergencies round the
clock. The required safety appliances shall 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.
1.8.5 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.
1.8.6 Emergency Control Center
Provision is made to establish an Emergency Control Centre (ECC) from which emergency
operations are directed and coordinated. This center is 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 organizations 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 during the emergency such as:
Updated copies of the On–site Disaster Management Plan.
Page 19
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 19
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
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.
List of fire extinguishers with their type no. and location, capacity, etc.
Personal protective equipment.
Safety helmets – List of quantity & location.
Clock.
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.
Lay out of Hydrant lines.
1.8.7 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.
1.8.8 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
Page 20
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 20
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
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.
1.8.9 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 are 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.
1.8.10 Off- Site Emergency Preparedness Plan
The task of preparing the off- site emergency plan lies with the district collector. However,
the offsite plans will be prepared with the help of the local district authorities. The proposed
plan will be based on the following guidelines.
Plan of Co–Ordination
(A) Liaison with
1. External Authority:
Sub Divisional Officer (SDO)
Principal Medical Officer (PMO).
Dy. SP.
Fire Officer.
Local Panchayat Officials.
B.D.O.
External Agencies
Press.
Fire Station.
Police.
Medical.
Voluntary Organization.
Railway.
Roadways
Private Bus Services
(B) Making plan in advance By Management and External
Page 21
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 21
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
Authorities/Agencies Govt. Hospital.
(C) Roll and Statutory duties of outside agencies.
Traffic Centre.
Assisting the Medical and Evacuation team.
Preventing unauthorised entry of personnel into the affected areas.
Control on lookers.
(D) Duties of Public Relation officer (PRO)
To keep liaison with Govt.
To publish/release news in the new papers.
(E) S.D.O.
To restore law & order.
To help in getting aid from other Administrative Authorities.
(F) Duties of Medical Officer
A full time Medical officer and he will discharge duties during any emergency.
He shall:
Send the adequate medical staff to the emergency operation center for ensuring
immediate medical attention.
Organise for transporting the injured to the hospitals wherein arrangements are made to
handle such emergencies. The nearby hospitals should be identified in advance.
Inform all the nearby hospitals of the situation and appraise them of the antidotes that
would be necessary for treatment, if any.
Make arrangements for requisitioning for extra ambulances for movement of the injured
to Hospital.
Ensure that records of blood group of all employees are easily accessible and enough
blood of the specific group is available for casualties.
(G) Duties of B.D.O. (Block Development Officer)
To control the spread of rumours.
(H) Declaring the Major Emergency
By putting notice on notice Board.
By publication in the News Papers.
Announcement by P.A. System in nearby villages.
Page 22
PREPARED BY : ENVIRONMENTAL & TECHNICAL RESEARCH CENTRE 22
PROPOSED ESTABLISHMENT OF GRAIN BASED IDSTILLERY OF CAPACITY 500 KLD ALONG WITH CO GEN POWER
PLANT – 14.9 MW AT PLOT NO 26, 9 (part), 8, 7, 6, 5, 4 M.P.A.K.V.N, INDUSTRIAL AREA, BORGAON, TEHSIL – SAUSAR,
DISTT – CHHINDWARA (MP) BY M/S GULSHAN POLYOLS LIMITED
1.8.11 Procedure for Testing & Updating the Plan
Simulated emergency preparedness exercises and mock firefighting exercises including
mutual aid scheme resources and in conservation with district emergency authority to be
carried out time to time.
1.8.12 Disclosure of Information to Worker & Public Awareness System in Existence or
Anticipated
Safety awareness among workers by conserving various training programmes 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.