M/s JayVeer Pharma Chem Survey No. 1187 & 1184, Village ...

M/s JayVeer Pharma Chem Survey No. 1187 & 1184, Village: Basana,

Taluka: Visnagar, District: Mehsana 384001

T. R. Associates, Ahmedabad, Gujarat

Chapter-4: Anticipated Environmental Impacts & Mitigation Measures

4.28

Environmental Impact Assessment Report





4.29


Figure 4.2 Ground level concentration of SO2





4.30






4.31


Figure 4.(3) Ground level concentration of NO2





4.32






4.33


Table 4.5: Predicted 24 hourly short term incremental Concentrations of SPM

Sr. No.

Monitoring Stations

Distance from site

Direction

Base Line Concentration

(µg/m(3)) (98 percentile)

Predicted SPM

Concentration (µg/m(3))

Total SPM Concentrations

implementation of the proposed project

µg/m(3)

1 (A1) Project site -- 0 78.40 0.8 79.2

2 (A2) Becharpura 1.7 Kms NNE 89.75 1.0 90.75

3 (A3) Kamana 2.3 Kms NW 88.91 0.5 89.41

4 (A4)Meghaliyasana 2.7 KMs SW 77.79 0.1 77.89

5 (A5) Basna 4.8 Kms ENE 85.09 0.8 85.89

Table 4.5: Predicted 24 hourly short term incremental Concentrations of SO2

Sr.

No.

Monitoring

Stations

Distance

from

site

Direction

Base Line

Concentration

(µg/m(3))

(98 percentile)

Predicted

SPM

Concentration

(µg/m(3))

Total SPM

Concentrations

implementation of

the proposed project

µg/m(3)

1 (A1) Project site -- 0 25.52 0.1 25.62


3 (A3) Kamana 2.3 Kms NW 40.36 0.04 40.4


5 (A5) Basna 4.8 Kms ENE 28.98 0.007 28.987

Table 4.6 Predicted 24 hourly short term incremental Concentrations of NO2

Sr. No.

Monitoring Stations

Distance from site

Direction

Base Line Concentration

(µg/m(3)) (98 percentile)

Predicted SPM

Concentration (µg/m(3))

Total SPM Concentrations

implementation of the proposed project

µg/m(3)

1 (A1) Project site -- 0 34.96 0.6 35.56


3 (A3) Kamana 2.3 Kms NW 44.35 0.3 44.65


5 (A5) Basna 4.8 Kms ENE 30.72 0.05 30.77

After implementation of the proposed project, these concentrations are found to be well below the

permissible NAAQs norms for rural/residential zone and Industrial zone. Therefore, the proposed

activity will not have any adverse impact on the air environment.





4.34


4.3.3 Existing Traffic & Vehicular Pollution

Traffic survey has been carried out on road at project site from. Based on the traffic survey hourly

vehicular traffic has been calculated. Considering worst case scenario, average number of vehicles

observed during 4 hours has been taken as hourly counts. Passenger Car Unit (PCU) has been

calculated by applying PCU factor. Proposed load of trucks due to the movement of raw materials,

fuel and products has been calculated. A design capacity of road has been taken from the Indian

Road Code. Assessment of proposed traffic load is given below in Table 4.7.

From the above table, it can be concluded that even for considering the worst case; there will be

minor increase in vehicular load due to the proposed project. However, the total traffic load even

after the proposed project will be very low compare to the design capacity of roads. Adequate

parking arrangements will be provided within the industrial premises.

As no major increase in traffic due to the proposed project, there will be less chance in increase in

vehicular pollution. However, unit will take adequate measures by instructing transporter for using

only PUC certified trucks/vehicles and carrying out regular service and maintenance of them.

Table 4.7 Assessment of Proposed Traffic Load

Type of Vehicles

Route-2 (SH 56 (2 Lane divided (two way) PCU Factor as per Indian Road Code

Average Vehicles Per Hour

Equivalent PCU (Passenger Car Unit)

per hour

Large Trailer 12 51.8 4.5

Heavy (Bus, Truck, etc) 82 246.0 (3)

Medium (Tractors, light commercial vehicles etc)

1(3)1 195.8 1.5

Light (Car, Jeep, Pickup Van etc.)

20(3) 202.5 1

(3) Wheeler (Rickshaw) 5(3) 52.5 1

2 Wheeler (Scooter, motorcycle, cycle etc)

151 75.5 0.5

Total PCU/hr 824

Width of Road (m) 16

Design PCU per hour 2900

Existing PCU per hour 824

Proposed Load (Trucks/day)

26

Proposed PCU per day 78

As a Worst Scenario taken Proposed PCU per day as

PCU per hour 78

Total PCU per hour after the Proposed Project

902





4.35


4.3.4 Socio – Economic Environment

The industry will provide direct and indirect Employment for many of the local population. It will

create employment (20) and helps to improve the social status of the local community.

No Rehabilitation or land acquisition is needed for this industry. This project is not expected to

generate any significant public controversy. Workers including casual workers such as truck drivers

will be provided with basic amenities like safe water supply, low cost sanitation facilities, first aid,

required personal protective equipment, etc. Workers will also be provided with sufficient

infrastructural facilities including drinking water, toilets, sanitation facilities, power, easily accessible

approach roads, communication, etc

Moreover unit would be carrying out CSR activities in nearby villages in the field of public health and

green belt development; which would contribute to improvements the public health in the region to

some extent. Other impacts of the proposed project are:

Any industrial growth will improve economic status of the people either directly or

indirectly.

Creation of employment generation is an another positive impact anticipated from this plant

The development of infrastructure (roads, lighting etc) may not only helpful for

transportation but also to improve aesthetic value of the site.

The proposed green belt plan also generates some employment (labor for plantation

development) and provide hygienic environment.

Non- workers comprises of 61% of the total population in the study area. This intense

unemployment fate can be for extent can be reduced.

Labour quarters will be provided for workers in operation phase of plant.

A slight increase in traffic during construction would result as workers arrive and depart the site and

as materials and equipment are delivered. This temporary traffic increase would represent only

small fluctuations within the normal range.

The Industry will also provide 2.5 % of the project cost, i.e, Rs. 22.5 Lacs, towards the Enterprise

Social Commitment. Socio-economic development activities will be provided after public Hearing.




Chapter-5: Environmental Management Plan

5.1


CHAPTER - 5

ANALYSIS OF ALTERNATIVES (TECHNOLOGY & SITE)

As stated in EIA notification dated 14th September, 2006 during scoping stage if analysis of

alternative site is needed than it should be done while selecting site for proposed project. As

it is not suggested during scoping stage Analysis of Alternative has not carried out

Proposed project having total production capacity of 48.29 MT/Month for manufacturing

pharmaceutical ingredients. In case of selecting technology, project proponent will adopt

best available technology for the setting – up proposed manufacturing facilities.

M/s Jayveer Pharma Chem Survey No. 1187 & 1184, Village: Basana,



Chapter-6: Environmental Monitoring Program

6.1


CHAPTER - 6

ENVIRONMENTAL MONITORING PROGRAM

6.1 INTRODUCTION

Environmental monitoring describes the processes and activities that need to take place to

characterise and monitor the quality of the environment. Environmental monitoring is used

in the preparation of environmental impact assessments, as well as in many circumstances

in which human activities carry a risk of harmful effects on environment. All monitoring

strategies and programs have reasons and justifications which are often designed to

establish the current status of an environment or to establish trends in environmental

parameters. In all cases the results of monitoring will be reviewed and analysed statistically.

Environmental monitoring program is designed to understand how the environment

changes over time. Therefore, regular monitoring program of the environmental parameters

is essential to take into account the changes in the environment. The objectives of

environmental monitoring program are;

To verify the results of the impact assessment study in particular with regard to new

development;

1. To follow the trend of parameters which have been identified as critical;

2. To check or assess the efficiency of the pollution control measures;

3. To ensure that new parameters, other than those identified in the impact assessment

study, do not become critical through the commissioning of new installations;

4. To check assumption made with regard to the development and to detect deviations in

order to initiate necessary measures; and

5. To establish a database for future Impact Assessment Studies for new projects.

6.2 ENVIRONMENTAL MONITORING PROGRAM

The attributes, which merit regular monitoring, are air quality both at source and ambient

atmosphere, water and wastewater quality, noise levels, ecological preservation, greenbelt

development, socio-economic aspects, etc. Regular monitoring will be continued with

additional frequency and parameters as per the need after establishment of proposed

project. Environmental monitoring program is given in following Table 6.1.

https://en.wikipedia.org/wiki/Environmental_impact_assessment

https://en.wikipedia.org/wiki/Statistics





6.2


Table 6.1: Environmental Monitoring Program

Sr. No.

Particulars & Location Monitoring Frequency

Parameters Measurement methodologies Budget &

Procurement Reporting schedules

Emergency procedures

1

Air Pollution In case of emergency, protocol to be followed shall be established and all operating staff shall be trained, accordingly. Inter-locking systems and alarm systems shall be provided at all reasonably possible areas.

Abnormal operations and emergency situations should immediately be brought into the notice of the local regulatory Board / Committee.

A

Stacks Monitoring (All Stacks)

Weekly SO2, IS 11255 (Part 2)1985 (RA 2009) 1 Lakh-2 lakh Weekly to Top Management/

Factory Manager

NO2, IS 11255 (Part 7)2012 (RA 2012)

PM IS 11255 (Part1)1985 (RA 2009)

B

Ambient Air Quality Monitoring (2 Locations within premises)

Twice in a year

PM10, IS 5182 (Part 23) (RA 2006)

Reformed 2012 App. 2 lakh Twice in Year

to Top Management/

Factory Manager

PM2.5, STP No. TRA/STP/AA/02 Based on manual instrument manufactures.

SO2, IS 5182 (Part 2): 2001 (RA 2002)

NOx, IS 5182 (Part 6): 2006 (RA 2002)

VOC IS 5182 (Part 11): 2006

Carbon Monoxide

NDIR spectroscopy

C

Work area monitoring (2 Locations in process plant)

Monthly Volatile Organic

Compounds

IS – 51824

EN -12341

App. 1 lakh Monthly

Top Management/

Factory Manager

2

Water and Wastewater Quality

i Borewell water (Intake source)

Monthly As per IS:

10500

IS 3025 (Part 9): 1984 (RA 2012)

IS 3025 (Part 22): 1986 (RA 2009)

IS 3025 (Part 23): 1986 (RA 2006)

App.

Rs. 20,000/- if out sourced

Monthly

Top Management/





6.3


Sr. No.





IS 3025 (Part 15): 1984 (RA 2009) Factory Manager

Effluents

i

Industrial effluent (Untreated & Treated)

High COD & High TDS

Daily pH, COD, BOD,

SS,TDS IS 3025 (Part 9) 1984 (RA 2012)

IS 3025 (Part 22): 1986 (RA 2009)

IS 3025 (Part 23): 1986 (RA 2006)

In- house lab Top Management/

Factory Manager

Monthly General

parameters

App.

Rs. 40,000/- if out sourced

Top Management/

Factory Manager

3

Ambient Noise Levels

i All Prominent places within premises

Twice in a year --

IS 9989: 1991

CPCB guideline

App.

Rs. 10,000/-

Once in Year

to Top Management/

Factory Manager

-

4 Soil (1 within the premises and 1 from vicinity)

Once in a year General

parameters

IS 2720 and Paramerters specified in Book of Department of

Agricuture and cooperation, Ministry of Agriculture

App.

Rs. 20,000/-

Once in Year

to Top Management/

Factory Manager

-

5 ETP sludge Once in a year General

parameters

CPCB guideline App.

Rs. 20,000/-

Once in Year

to Top Management/

Factory

-





6.4


Sr. No.





Manager

6 Safety Audit Once in 2 years All safety aspects

Private consultants organization App.

Rs. 200,000/-

Once in Year

to Top Management/

Factory Manager

Availability of First and Antidotes at

appropriate location

7 Occupation health (medical checkups)

Pre, post and regular

Vision, Audiometry, Spirometry, Urine, RBS,

Liver function tests,

Skiagram, (LFT),

Complete blood count, Anemia, etc.

Factory Medical Officer App.

Rs. 20,000/-

(Depends on Numeber of

workers)

8 Greenbelt development Periodic Survival rate and growth

To be developed by Project proponent

- - -





6.5


6.3 INFRASTRUCTURAL REQUIREMENT

Project proponent will develop in – house laboratory in which analysis of effluent for basic

parameters like pH, BOD, COD, SS, TDS will be carried out regularly. In addition to this,

regular monitoring will be carried out through NABL approved laboratory.

For the medical facilities, first aid boxes will be provided at prominent places in the premises

and also one MBBS doctor will be appointed for monthly visit in the plant. Moreover, unit

has already tie-up with nearby hospital for medical assistance in case of any emergency.

6.4 DOCUMENTATION AND REPORTING

All the data and reports of monitoring of all parameters as stated in monitoring program will

be properly maintain and timely reviewed by management for taking corrective or

preventive actions. Monitoring reports will be regularly submitted to the concerned

authorities as per their requirements.

6.5 CORPORATE ENVIRONMENT POLICY

Project proponent believe in sustainable development and therefore will provide adequate

environmental control and management system after proposed project and will regularly

and efficiently operate the same.

Project proponent will prepared environment policy duly approved by directors prescribing

standard operating procedures to bring into focus any deviation/violation of environmental

or pollution control norms/conditions. This policy is displayed at various prominent places in

the premises and all the employees are educated about the same.

For performing all the environmental management activities and operating environmental

management systems efficiently, unit has established Environmental Management Cell

governed by director and same will be upgraded for proposed expansion as described

below.

6.6 ENVIRONMENTAL MANAGEMENT CELL (EMC)

For effective implementation of the monitoring program, it is necessary to have a

permanent organizational set-up. Thus, unit has already set-up permanent environmental

management cell (EMC) for the effective implementation and monitoring of environmental

management system as given below.





6.6


EMC is monitoring all project activities to ensure the appropriate implementation of all

environmental mitigation activities and to identify areas where environmental management

plan compliance is not satisfied. Responsibilities are assigned to officer from various

disciplines to perform and co-ordinate the activities concerned with management and

implementation of environmental control measures. Director of the company is responsible

for overall environmental management. Environment Manager is responsible to inform all

the matter regarding environmental management including reporting of non compliances /

violations of environmental norms.

Figure 6.1 Environmental Management Cell:

Director

Plant In-Charge/ Factory Manager

ETP In-Charge

Chemist

Helper

Environment Manager/ Safety Officer



T. R. Associates (Ahmedabad)

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Chapter-7: Additional Studies

7.1


CHAPTER – 7

ADDITIONAL STUDIES

A. PUBLIC CONSULTATION

All the aspects of the TORs are incorporated in the draft EIA/EMP report, the same

may be submitted to the Gujarat Pollution Control Board (GPCB) for conducting public

hearing/public consultation as per EIA Notification, 2006.

Minutes of Public Consultation / Public Hearing will be included in final EIA report with

suggestions/recommendations, if any after public consultation.

B. RISK ASSESSMENT STUDY

The said study report is presented in next page. 7.2 to 7.75

C. SOCIAL IMPACT ASSESSMENT, R & R ACTION PLAN

The socio-economic study of the study area is carried out and details are presented in

the Chapter-3/Section- 3.9. It may be noted that the proposed project is to be

established on Non Agricultural land. The project site is intended for the industrial

purpose and thus no displacement of villagers/people will take place. Therefore, the

R&R (Rehabilitation & Resettlement)policy/plan is not undertaken. However, the

direct financial and social benefits with special emphasis on the benefit to the local

people will be preferred and the proposed budgets for corporate social responsibility

(CSR) activities are summarized in Chapter- 8 /Section- 8.5.




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7.2


7.1 RISK ASSESSMENT & EXECUTIVE SUMMARY OF PROJECT

M/s Jayveer Pharma Chem is proposing to set – up manufacturing facility for Active

Pharmaceutical Ingredients (API) at Survey no.: 1184 and 1187, Village: Basana,

Taluka: Visnagar, District: Mehsana, Gujarat- 384001. The total production capacity of

proposed unit is 48.29 MT/Month.

Site visit was carried out by concerned expert during formation Risk Assessment

report. Detailed discussion regarding plant layout in relation of storage of chemicals

has been carried out with project proponent.

Detailed discussions, Solvent storage facilities (For Methanol and Others) as well as

process safety, Finished product storage go down and tank farm area, Emergency

management plan, Emergency handling facilities, Emergency organization and action

plan with project proponent has been carried out.

In this proposed plant Methanol, Toluene, Hydrochloric Acid, Acetone, O- Xylene will

be used as raw materials and received through road tanker and stored in designated

tank farm area. Flammable solvents receive through road tanker and stored storage

tank farm area as per petroleum Act and Rules. Separate storage area will be provided

for storing Hydrochloric Acid, Hydrogen Cylinder.

Based on storage capacities of chemicals and chemical properties of stored chemicals,

some hazards have been identified and their consequences are modeled using ALOHA.

The threat zone is overlayed on the google image of project for identification of

impact.

The Risk assessment shows that major possible hazards with the plant are (a) Solvent

storage area – tank farm area (b) during the high temperature reaction in reactors

(C)Distillation process of solvent recovery.

Consequences analysis of storage tanks of solvent release scenarios from small hole

spillages and leakages is relatively small and damage distance will be within premises

for most likely occurring event. The impact of such accidental release and leakages can

be reduced by providing all necessary safety measures and risk control measures listed

in this report.

The possibility of major toxic release of chloroform considered very faraway.

Considering the potential for major hazards suggestions are made in the subsequent

chapters for further improvement in the areas of safety, environmental impact,




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7.3


Emergency facilities and emergency preparedness plan.

As this is greenfield project at the stage of pre – design and details availability the

conclusion based on Risk Assessment study and information regarding the layout plan

and safety systems.

7.2 Risk assessment study

7.2.1 Objective and Scope

Risk Assessment (QRA) techniques used to determine risk posed to people who work

inside or live near hazardous facilities, and to aid in preparing effective emergency

response plans by delineating a Disaster Management Plan (DMP) to handle onsite

and offsite emergencies.

Scope of the Study:

Hazard Identification - Identifying sources of accidents involving release of

hazardous material in the atmosphere and the various ways (that is scenarios)

they could occur.

Consequence Assessment - Estimating the probable zone of impact of accidents as

well as the scale and/or probability of damages with respect to human beings and

plant equipment and other structures.

Accident Frequency Assessment - Computation of the average likelihood of

accidents.

Risk Estimation - Combining accident consequence and frequency to obtain risk

distribution within and beyond a process plant

7.2.2 Risk Analysis Methodology:

The risk assessment of proposed project is required as part of statutory requirement,

emergency planning. The steps are described as follow:

Hazard Identification

Information on Location, Layout, Process Parameters

Select Most Credible Scenario which can culminate into an accident out of several

major and minor.

Select Worst Case Scenario which has the highest potential to cause an accident

of maximum damage




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7.4


Estimate Consequences: in the plant in the form of fire, explosion and toxic

effects

Estimate Frequency of Occurrence

Estimate effect of damage

7.3 Hazard Identification and Risk Analysis

Major components of a system/plant/process are examined to assess their potential

for initiating or propagating an unplanned event/sequence of events, which can be

termed as an accident. While identifying hazards only those areas of plants having

potential risk are used further for risk analysis.

7.3.1 Location, Layout, Process Parameters

The proposed project will be set – up at Survey No. 1187 and 1184, Village: Basana,

Taluka: Visnagar, District: Mehsana, Gujarat. GPS coordinates of the site is situated at

Latitude: 23°37'0.67"N and Longitude: 72°28'37.29"E. Nearest major city is Mehsana

which is about 8 km far from the project site in West direction. State Highway No. 56

is about 3.3 km from the project site in East direction. The google image showing

proposed unit is given in Chapter: 2 Figure No.: 2.2.The project site is intended for

the industrial purpose and thus no displacement of population will take place. There

is no protected area notified under the Wild Life (Protection) Act (1972) & Eco-

sensitive area notified under the Environment (Protection) Act- 1986 exists within 10

km radius areas from the project site.

Detailed plant layout is given in Chapter: 2 Figure No.: 2.2, which provides details of

all internal area (i.e. process area, storage area of solvent and other raw materials ,

tank farm area, drum storage area, utility area, D. G. set etc.. )

Process Parameters: During the manufacturing process of proposed product

temperature will be maintained to tune of 65 to 1050C. No pressurized reaction

involved in any product. In solvent distillation / recovery system temperature of

system will be to tune of 110- 1250C.

7.3.2 Hazard Identification Methods

The proposed project is green filed project in pre- design stage during preparation of

Risk Assessment. Hazard identification method used or the proposed plant is given

below.

o Identification of major hazardous units based on Manufacture, Storage and




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7.5


Import of Hazardous Chemicals Rules, 1989 of Government of India (as amended

in 2000); and

o Preliminary Process Hazard Analysis: Hazard associated with raw material

storage, intermediates, by- products, final products, plant machineries and

equipment.

7.3.3 Identification of Hazardous Chemicals used within Premises

List of chemicals to be stored and utilized within the premises falls under

Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 (Amended in

2000). List of Hazardous Chemicals is given below: Chemical and physical properties

of raw materials are given in Table 7.1.




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7.6


Table 7.1 Hazardous Characteristics and Toxicity Of Raw Materials And Products

Sr. No.

Name of the Raw Material

Main Properties Class (As per

petroleum classification)

Antidote

B.P.0C

Boiling

Point

F.P.0C

Flash Point

LEL UEL %

TLV ppm

LD50: mg/Kg

LC50: mg/l

Specific Gravity Water

-1

Vapor Density

Odour threshold

ppm or mg/m

3

1. Methyl Acrylate 80.5 0C

-3.89 0C

(CC) -3

0C

(OC)

2.8 % 25 %

2 (ppm) from ACGIH (TLV)

277 mg/kg

0.96 2.97 20 ppm A ---

2. Mono Methyl amine (30 % solution in methanol)

-6.3 0C Not

available 4.9 % 20.7 %

STEL: 15 (ppm) from ACGIH (TLV

150 mg/L 0.85 0.62 Not available

None ---

3. Sodium Methoxide Powder

Not availa

ble

33 0C

CC 7.3 % 36%

TWA: 3 (mg/m

3)

from ACGIH (TLV)

2037 mg/kg 1.1 1.1 Not available

B ---

4. Chloroform 61 0C Not

Applicable

Not availa

ble

TWA: 10 (ppm) from ACGIH (TLV)

36mg/kg 47702 mg/m

1.48 4.36 85 ppm None N-acetyl-L-cysteine

5 N Methyl 4 piperidone

55-60 0C

58 0C

(CC) --- --- --- --- --- --- B ---

6 Nickle catalyst --- --- --- TWA: 1 (mg/m3)

--- 1.94 --- --- None ---




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7.7


Sr. No.




Antidote

B.P.0C

Boiling

Point

F.P.0C

Flash Point

LEL UEL %

TLV ppm

LD50: mg/Kg

LC50: mg/l


-1

Vapor Density

Odour threshold

ppm or mg/m

3

from ACGIH (TLV)

7 Hydrogen gas -4230C 565.5

0C 4 %

74% --- --

500 ppm 0.069 21.1

0C --- None ---

8 Thonyl Chloride 76 0C Not

Applicable

1 ppm -- 1.683 4.1 Not Available

None natural oil and one table spoon

sodium or magnesium sulphate with one glass of water. one cup strong tea or

coffee.

9 Sodium hydroxide

1388 0C

323 0C

--- STEL: 2 (mg/m3) from ACGIH (TLV)

---- 2.13 Not available

Not Available

None Sodium Hydro-Carbonate (4% Conc.), Milk, Lime Juice, Milk

of Magnesia

11 Ethyl Chloroformate

94 0C 160C --- --- 270mg/kg 72.5 ppm

1.1 3.7 Not Available

A ---

12 Ammonical methanol (15 to 17 % solution)

--- 14 0C -- --- 5628mg/Kg 83.2mg/l

--- --- --- A ---




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7.8


Sr. No.




Antidote

B.P.0C

Boiling

Point

F.P.0C

Flash Point

LEL UEL %

TLV ppm

LD50: mg/Kg

LC50: mg/l


-1

Vapor Density

Odour threshold

ppm or mg/m

3

13 Ranny Nickel Not Availa

ble

Not Available

Not Available

TWA: 1 (mg/m3) from ACGIH (TLV)

Not Available

1.94 Not Available

Not Available

None Unithol (BAL, dimercaprol, 5% solution), Tetacin

calcium (10% solution),

Penicillamine Dextrose (10%) by

intravenous injection. Chillating agent for effect of mercury.

14 2,5, Dichloro nitro Benzene

267 °C 152°C 1.50% 9.20%

Not given 1210 mg/kg

Not Available

Not Available

Not Available

None ---

15 Urea Not availa

ble

Not available

Not available

10 mg/m3, 8-hour TWA from ACGIH

8471mg/Kg 1.323 2.07 Not available

None ---

16 Methanol 64.5°C 12°C (CC) 16°C (OC)

6% 36.5%

STEL: 250 (ppm) from ACGIH (TLV)

5628 mg/kg 64000ppm

0.7915 1.11 100 ppm A 10 mg diazepam through injection

17 Ammonium Chloride

520 0C

Not applicable

Not applicable

STEL: 20 (mg/m3) from ACGIH (TLV)

1650 mg/Kg 1.53 Not available

Not available

None




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7.9


Sr. No.




Antidote

B.P.0C

Boiling

Point

F.P.0C

Flash Point

LEL UEL %

TLV ppm

LD50: mg/Kg

LC50: mg/l


-1

Vapor Density

Odour threshold

ppm or mg/m

3

18 HCl 108.50 0C

Not applicable

-- CEIL: 5 (ppm) from OSHA (PEL)

900mg/Kg 1108 ppm

1.16 1.267 0.25 to 10 ppm

None Sodium Hydro-Carbonate (4% Conc.), Milk, Lime Juice, Milk

of Megnesia

19 Ammonia liq. 25% solution

Not availa

ble

Not applicable

25 16

TWA: 25 (ppm) from ACGIH (TLV)

350 mg/kg 2000 ppm

0.898 Not available

5 - 50 ppm as

ammonia

None Skin:wash with lactic Acid, Apply Soframycin

Eye: Benoxynate (Novacin?0.4 % Conc.

Throat : Smelling Ethanol or Ether

20 Nitrogen gas Not Given

Not applicable

-- 2 ppm

Not Available

Not Available

Not available

Not available

None ---

21 Ortho PhenyleneDiamine (OPD)

256.0 -

258.0 °C

136 °C Not available

Not available 366mg/Kg > 91 mg/m3

1.03 3.7 Not available

None ---

22 O- Xylene 144.4°C

17°C (CC)

0.9 6.7

STEL: 651 (mg/m3) from ACGIH (TLV)

Not Available

0.88 3.7 0.05 ppm A Oxygen

23 Methyl Aceto 170°C 67°C 13 Not available 3.228 Not 4.0 Not C ---




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7.10


Sr. No.




Antidote

B.P.0C

Boiling

Point

F.P.0C

Flash Point

LEL UEL %

TLV ppm

LD50: mg/Kg

LC50: mg/l


-1

Vapor Density

Odour threshold

ppm or mg/m

3

acetate 14.2 mg/kg 6.6mg/l

available available

24 N Hexane 68.7 -22.5 CC

1.2 7.5


25000 mg/kg

48000 ppm

0.66 2.97 130 ppm A ---

25 1 bromo 3 chloro propane

145°C 45°C Not available

Not available

930mg/Kg

5668 mg/m3

1.592 Not available

Not available

B ---

26 Acetone 56.2°C 20°C CC

-9°C OC

2.6% 12.8%


5800 mg/kg 44000 mg/m3

0.79 2 62 ppm A ---

27 MethylIso Butyl Ketone

115.9°C

14°C CC

23°C OC

1.4 % 7.5%

STEL: 75 from ACGIH (TLV)

2080 mg/kg 8000 ppm

0.802 3.45 0.1 ppm A ---

28 2,5 Dichloro nitro benzene

267°C 152°C 1.50 9.20

-- 1210 mg/kg

Not available

Not available

Not available

None ---

29 2,5 dichloropara nitro aniline

Not Availab

le

Not Available

Not Available

Not Available 2400 mg/kg >21600

mg/m3/1H

Not Available

Not Available

Not Available

None

Note: * Hazardous chemicals as per MSIHC rule, 2000 Note: CC: Close Cup; OC: Open Cup; N.A.: Not Available.




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7.11


The Toxicity level of hazardous chemicals as per Manufacture, Storage and Import of Hazardous Chemical (Amendment) Rules, 2000 (MSIHC) is

shown as below:

Sr. No Toxicity Oral Toxicity LD50 (mg/Kg) Dermal Toxicity LD50 (mg/Kg) Inhalation Toxicity LD50 (mg/Kg)

1 Extremely Toxic <5 <40 <0.5

2 Highly Toxic >5- 50 >40-200 >0.5-2

3 Toxic >50-200 >200-1000 >2-10

7.3.4 Storage Details of Raw Material and Products:

Details of the raw materials and products with storage are given in Table 7.2A & 7.2B.

Table 7.2 A: Storage tank details for Raw Material storage

Sr. No.

Raw Materials Product

Qty Consumed per Month

(Kg)

Mode of storage

Capacity of storage

unit (MT)

No. of units

Total Storage

(MT)

Threshold Quantity

as per MSIHC rule (MT)

Inventory

1. Hydrogen

N – Methyl 4 Chloro Piperidine (NMCP)

125 Isolated

Storage area 9 m3 - 1.5

2 ton

4 D-7 [5 - Chloro 1 - (4 - Piperidyl)

2 –Benzimidazolonone] 1500




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7.12


Sr. No.



(Kg)

Mode of storage

Capacity of storage

unit (MT)

No. of units

Total Storage

(MT)

Threshold Quantity


Inventory

D-2 [1 – (3 – Chloropropyl) -1- Dihydro – 2 –1-1 – Benzimidazolone]

6000

2. Toluene


3000 Tank

(SS 316) 12 1 12

10,000 >30

D-7 [5 - Chloro 1 - (4 - Piperidyl) 2 –Benzimidazolonone]

7000

3. Caustic Lye


800

MS tank 12 1 12

-

15

D-7 [5 - Chloro 1 - (4 - Piperidyl) 2 Benzimidazolonone]

6600

D-2 [1 – (3 – Chloropropyl) -1- Dihydro – 2 –1-1 – Benzimidazolone

2550

4 Chloro 2 Amino Phenol (4 CAP)

12000

4.

Methanol

D-7 5-chloro-1-(4-piperidyl)- 2 – benzimidazolonone

2000 Tank

(SS 316) 12 1 12

7000 >30 Chlorzoxazone (5-chloro-3-h benzooxa-zolonone)

or 5-chloro-2-benzoxazolione 5000

5.

D-7 5-chloro-1-(4-piperidyl)- 2 – benzimidazolonone

2000 Tank

(HDPE) 12 2 24

20 day




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7.13


Sr. No.



(Kg)

Mode of storage

Capacity of storage

unit (MT)

No. of units

Total Storage

(MT)

Threshold Quantity


Inventory

HCl (28-30%)

D-2 1 – (3- chloropropyl)-1- dihydro-2-1-1- benzimida-zolone

6400 -

chlorzoxazone (5-chloro-3-h benzooxa-zolonone)

or 5-chloro-2-benzoxazolione 15000

4-cap (4-chloro 2 –amino phenol)

6000

6.

Acetone

D-2 1 – (3- chloropropyl)-1- dihydro-

2-1-1- benzimida-zolone

2500 Tank

(SS 316) 12 1 12

10000

>30

7.

O-Xylene

D-2 1 – (3- chloropropyl)-1- dihydro-

2-1-1- benzimida-zolone

4500 Tank

(SS 316) 12 1 12

10000

>30

8. Mixed solvent 2.5 Dichloro Paraphenylene

Diamine 5000

Tank (SS 316)

12 1 12 10000

>30

9

Chloroform

N-methyl – 4- piperidone 12000 Tank

(SS 316) 12 1 12

-

>30 N-methyl – 4- chloro – piperidine (nmcp)

2500




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7.14


Table 7.2 B: Storage Details of Raw Materials

Sr. No.

Raw Materials Product Qty Per

Month

Mode of storage Drums/ tanks/ bags &

Material of Construction

Capacity of

storage unit (Kg)

No. of Units

Total Storage

(Kg)

Inventory

1. Methyl Acryalate

N-methyl – 4- Piperidone

10750 Kg Drum 210 20 4200 15

2. Mono Methyl Amine

(30% Solution in Methanol) 6075 Kg Drum 210 15 3150 15

3. Sodium Methoxide Powder 3400 Kg Bag 50 34 1700 15

4. N-Methyl – 4 – Piperdone N-methyl – 4- chloro – Piperidine

(nmcp)

2000 Kg Drum 210 10 2100 30

5. Nickle Catalyst 80 Kg Bag 50 2 100 >30

6. Thionyl Chloride 3200 Kg Drum 210 10 2100 20

7. N-Methyl – 4- Piperidone

D-7

5-chloro-1-(4-piperidyl)- 2 –

benzimidazolonone

2250 Kg Drum 210 10 2100 30

8. Ethyl Chloro Formate 2700 Kg Drum 210 12 2520 30

9. Ammonical Methanol (15 To 17 % Solution)

2700 Kg Drum 210 13 2730 30

10. Ranny Nickle Catalyst 150 Kg Bag 50 3 150 30

11. 2,5,Dichloro Nitro Benzene 2700 Kg Drum 210 13 2730 30

12. Urea 1500 Kg Bag 50 15 750 15

13. Ammonium Chloride 2400 Kg Drum 210 10 2100 30

14. NH3 Liq. 25 % Soln 6000 Kg Drum 210 15 3150 15




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7.15


Sr. No.


Month



Capacity of

storage unit (Kg)

No. of Units

Total Storage

(Kg)

Inventory

15. Carbon 300 Kg Bag 50 3 150 15

16. Ortho Phenylene Diamine

(OPD) D-2

1 – (3- chloropropyl)-1- dihydro-2-1-1-

Benzimida-zolone

2000 Kg Drum 210 10 2100 30

17. Methyl Aceto Acetate (MAA) 3000 Kg Drum 210 10 2100 15

18. 1-Bromo-3-Chloro Propane

(BCP) 2800 Kg Drum 210 10 2100 20

19. Tebac (Catalyst) 40 Kg Bag 50 2 100 30

20. D-2 Dompiridone 5- chloro -1-(1-l3-l2-oxo-

1-benximidazolinyl) Propyl) -4-piperidyl)-2-

benzimidaz

2640 Kg Bag 50 26 1300 15

21. D-9 3000 Kg Bag 50 20 1000 3

22. M.I.B.K. (Methyl Iso Butyl

Ketone) 1000 Kg Drum 210 5 1050 30

23. Ammonium Chloride 3500 Kg Drum 210 10 2100 20

24. 4-CAP Chlorzoxazone (5-chloro-3-h benzooxa-

zolonone) or 5-chloro-2-

benzoxazolione

10000 Kg Bag 100 25 2500 4

25. Urea 12792 Kg Bag 100 30 3000 5

26. Carbon 240 Kg Bag 50 5 250 30

27. 2,5 Dichloro Nitro Benzene

(2,5 DCNB) 4-cap

(4-chloro 2 –amino phenol)

19950 Kg Drum 210 25 5250 8

28. Platinum / Carbon Catalyst 165 Kg Bag 50 3 150 25




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7.16


Sr. No.


Month



Capacity of

storage unit (Kg)

No. of Units

Total Storage

(Kg)

Inventory

29. 2.5 Dichloro

Para nitro aniline 2.5dichloro paraphenylene diamine

12000 Kg Bag 50 120 6000 15

30. Pd/Co catalyst 85 Kg Bag 25 4 100 >30

31. N- Haxane

D-2 1 – (3- chloropropyl)-1- dihydro-2-1-1-

Benzimida-zolone

445 Drums 210 5 1050 2

32. M.I.B.K

Dompiridone Chloro – 1 – (1 – (3 –

(2 – Oxo – 1 – Benzimidazolinyl)

Propyl) – 4 – Piperidyl) – 2-

Benzimidaz

1000 Drums 210 10 2100 5




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7.17


Table 7.2C: Storage Details Products

Sr. No.

Name of the product Physical

State

No. of container and size

No. MT

1. N - Methyl 4 Piperidone (NMP) Liquid 80 2

2. N – Methyl 4 Chloro Piperidine (NMCP) Solid 50 1.25

3. D-7 5-Chloro 1-(4- Piperidyl) 2-Benzimidazolonone Solid-Powder 200 5

4. D-2 1–(3-Chloropropyl)-1-Dihydro–2–1-1-Benzimidazolone Solid 100 2.5

5. Dompiridone Chloro–1–(1–(3–(2–Oxo–1– Benzimidazolinyl) Propyl)–4–Piperidyl)–2- Benzimidaz

Solid 50 1.25

6. Chlorzoxazone (5 – Chloro – 3 – H Benzooxa- zolonone) OR 5 – Chloro – 2 – Benzoxazolione Solid 50 1.25

7. 4 Chloro 2 Amino Phenol (4 CAP) Solid 100 0.5

8. 2.5 Dichloro Peraphenylene Diamine Solid 100 2.5




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7.18


7.3.5 Identification of Hazard Associated with Storage of Raw Materials

Table 7.3: Identification Hazard Associated with Storage of Raw Materials and control measures

Sr. No.

Material stored

Hazard Rating Systems

Type of hazard / Risk

involved Causes Effect Control Measures proposed

(1)

Methanol (12 KL Tank farm area) and other

solvent tank

TLV – 200 PPM (8-hr TWA) STEL-250 PPM NFPA Ratings: Health: 1 Flammability: 3

Fire /Explosion

Glands/seal leaks in valves, pumps

Hose/pipe failure, leakage from flanged joints carrying Methanol

Loading and unloading process

Nearby ignition sources

Fire due to Bottom nozzle failure

Damage of storage tank Pump discharge nozzle failure

Unloading road tanker hose rupture

Highly Flammable

Toxic by inhalation

Toxic when contact with Skin

Toxic if swallowed

Danger of very serious irreversible effects.

Dyke wall shall be provided to all above ground storage tank.

Separate from strong oxidant. Fire hydrant system shall be installed. Safety shower and eye washer shall be

installed near storage area. Flame proof Electrical fittings shall be

provided at flammable storage area. Proper selection of MOC for chemicals

storage tank. Earthing/bonding shall be provided for

static charges. Flame arrestor shall be provided on

flammable material storage tank vent. Level gauge and level measurement

instrument shall be provided on material storage tank.

Stored away from the plant and safe distance shall be maintained.

Safety permit system shall be followed for loading, unloading of hazardous




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7.19


Sr. No.

Material stored




chemical. Fencing, caution note, hazardous

identification board should be provided.

Authorized person permitted in storage tank area and register will be maintained.

(2) Hydrochloric Acid (30%)

(12 KL)

TLV : 500 ppm Health: 2

Flammability: 1 Reactivity: 0

Corrosive and Toxic

DISCHARGE from 1) Piping not correctly secured which may fail under pressure 2) Joint failure. 3) Gasket failure. LEAKS & SPRAYS: flange failure

Highly corrosive to most metals with evolution of hydrogen gas, which is highly explosive when mixed with air

Non-flammable,

but reacts with

most metals

with evolution

of hydrogen

which may

cause fire nor

explosion with

1) Easy Access. 2) Bulk Tanks (clearly identified). 3) Spillage area. 4) Bund. 5) Shower and eye wash/bath 6) First aid equipment. 7) Water hose. 8) Respirators. Note: a) Equipment must be

correctly maintained. b) Personnel must be trained to operate the safety equipment. c) Safety equipment must be visible from all points.

VENT AND OVERFLOW ARRANGEMENT

Gaskets should comprise chemically resistant natural rubber or PTFE.

Centrifugal pumps of rubber lined cast iron or suitable plastic construction are recommended.




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7.20


Sr. No.

Material stored




air

PTFE should be used for packed glands

Mechanical seals of corrosion resistant material may be used.

Plastic valves. Neutralise spill area with lime or soda

ash and flush area with water. Do not get water inside containers. In case of large spillages Keep upwind

and out of low areas. Contain spill with earth, sand, or

absorbent material, which does not react with spilled material.

Level indicator and pressure relief systems.

3 (Drums and Bags of other

Raw material

storage area )

- Fire & Explosion Leak. Release of toxic vapors. Reaction of incompatible chemicals. Collapse of containers

Storing incompatible substances together;

Incorrect labelling/delivery of raw materials, intermediates and products;

Introduction of

Domino effects (e.g. thermal radiation from fires);

Toxic substance dispersion

Loss of material Contamination

of land & water in case of major

At least one emergency entrance point Impervious floor Smoke alarms High quality electrical installation Eye wash bottles. Stocks of absorbent materials for

dealing with spills Stocks of sandbags to form temporary

containment barriers Non sparking tools in warehouses




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7.21


Sr. No.

Material stored




ignition sources into segregated areas containing flammable, combustible and explosive substances (e.g. smoking, mobile equipment and vehicles, power tools);

Poorly managed inventory control and identification systems for hazardous chemicals stored in drums;

Poor house keeping.

Insufficient recording of chemical inventories at each location on site

leakages

storing highly flammable liquids Adequate level of natural or artificial

lighting Constructed of essentially non-

combustible materials Bunding to a height of 1m Fitted with in rack foam/water

sprinkler system Fire resistant doors Site floodlighting Perimeter lighting A emergency generator Direction of leaks to common

sumps/manifolds; sufficient warning signs in place to

inform employees and visitors of the potentially, hazardous environments they are approaching (no smoking signs, flammable area, intrinsically safe zone.




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7.22


Sr. No.

Material stored




4 Chloroform Storage

Health:2 Flammability: 0 Reactivity:0

Toxic effect DISCHARGE from 1) Piping not correctly secured which may fail under pressure 2) Joint failure. 3) Gasket failure.

LEAKS & SPRAYS: flange failure

Toxic by

inhalation

Toxic when

contact with

Skin

Toxic if

swallowed

Toxic gas

dispersion

In presence of excess moisture, strong alkalis, sunlight and high temperatures Chloroform decomposes to highly toxic phosgene and hydrochloric acid.

Chloroform are not compatible with

mild steel storage and handling

equipment. The use of stainless steel—

lined mild steel, nickel clad steel, or

stainless steel of the 300 series.

Precautionary measures should be

taken to ensure that moisture does not

contaminate the solvent. To minimize

evaporation losses, a completely

sealed storage tank is recommended.

Positive displacement rotary pumps

are recommended for chloroform

service.

Submerged centrifugal pumps may be

used in storage tanks designed for

atmospheric service.

Piping may be of steel or black iron,

preferably with welded or flanged

joints.

Lubricant for threaded joints must be




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7.23


Sr. No.

Material stored




of a type resistant to chloroform, such

as white lead, graphite and glycerine

pastes or fluorocarbon tape.

Dyke provision to storage area of tank

Safety boards should be displayed on

the tank

Good ventilation must be provided.

A. Identification of Process hazards:

Name of

hazardous

process and

operation

Material in the

process /

operation

Type of hazard possible

toxic gas release / fire /

explosion / run away

reaction / rupture, etc.

Causes

Control Measures to be provided

Reactor

Vessel

Methanol

And other

solvents

Acetone

Acetonitrile

Mechanical hazards e.g.

pressure release, leaks,

burns, noise, .equipment

or utility failure.

Reaction hazards due to

failure to control

Release of Heat and

Flammable gases

Fire, Toxic gas release and

Explosion

Failure of agitator, heating

and cooling system in the

Raw Materials quantity must be controlled either

volumetrically or gravimetrically.

Process control devices must be installed

includes the use of sensors, alarms, trips and

other control systems that either take automatic

action or allow for manual intervention to




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7.24


Name of

hazardous

process and

operation

Material in the

process /

operation





Causes


exotherms, incompatible

materials, side reactions.

Environmental hazards

such as air pollution,

odour problems, spills

etc.

Toxicity and health

effects Flammability

hazards due to explosive

mixture, static charge,

autoignition etc.

reactor

Failures of external boiler,

condenser and piping system

prevent the conditions for uncontrolled reaction

occurring.

High Temperature indicator valve and alarm

system must be provided

Auto cut off system must be provided after

reaching of predetermined maximum safe

temperature.

Pressure gauge is must provided.

Safety Control valve is must be provided.

The Vessel Emergency Relief vent should

discharge to a suitably designed catch pot or

should be so positioned that people working in

the area and members of the public will not be in

danger if the contents of the vessel are

discharged.

Use skilled worker

Proper selection of MOC

Mechanical seal in all pumps and reactors

Transportation of finished product from vessel to

storage tank through close pipe.




NABET Accredited


7.25


Name of

hazardous

process and

operation

Material in the

process /

operation





Causes


Solvent

recovery

System

Methanol, Mix -

Xylene and

Other solvents

Explosion/fire release of

toxic material

Failure of the cooling system

resulting in the reduction of

condenser capacity which

might cause the emission of

volatile organic compounds

to the atmosphere.

In the presence of an ignition

source, a fire with serious

consequence.

Level control failure

Loss of heat transfer due to

fouling, accumulation of

noncondensables, or loss of

cooling medium

Blockage of packing/trays

leading to excessive pressure

drop in column

Level control failure.

Failure of safety system

An alarm and safety valve are required to

indicate any choking and release of any pressure.

In case of vacuum distillation vacuum failure

alarm, inert gas purging

safety valve or explosion vent should be provided

to take care of any accidental pressure

All electric fitting should be flameproof including

lighting

Flame arrester, smoke detector should be

provided spark/flame detectors with alarm

Flammable substances should be processed at

low temperature (below flash point) and

pressure. Dip feed pipe, slow and controlled

addition (e.g. niddle valve), inert blanketing,

vacuum, spark/flame avoidance, , no-smoking

habit, good ventilation and training to workers

are necessary.




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7.26


Name of

hazardous

process and

operation

Material in the

process /

operation





Causes


Boiler Heat burns

Thermal radiation

Explosion

Heat burns

Leaking safety and or safety

relief valves

Malfunctioning of Water

level indicator

Steam leaks (steam systems)

High stack temperatures

(excess of 350ºF)

Condensate dripping down

stack or out the front of the

boiler

Constantly resetting of

controllers and safety devices

Annual inspections

Safety interlocks to be provided

Installation of pressure reducing valves is must.

Safety and pressure gauge valves fitted

Properly supported and protected against

corrosion

Water level indicators installation is must.

Testing of Jackets and joints of tubes regularly

All necessary measures should be taken to control

corrosion




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7.27


B. General hazards and controls

Type of

Emergency

Identification

of Area Possible Causes Possible Results

Material

handling In Plant

Flammable, eye irritating &

accidently leakages Fire and health Hazards

7.3.6 Credible Accident Scenarios and Worst Case Scenarios

Maximum Credible Accident (MCA) scenario indicates most believable, reasonable,

likely or possible accident scenario and damage distance based on it. MCA scenario

takes into account the effect of control measures also. It considers the malfunctioning

of the control system, opening of safety valve/failure of safety valve, leakages from

flange joint, pipe line etc. and failing of some safety devise.

Worst-case scenario (rarely possible) is defined as the release of the largest quantity

of a regulated substance from a single vessel or process line failure that results in the

greatest distance to an end point, eg catastrophic failure. It considers the failure of all

control systems and release of the whole mass resulting in maximum damage.

Based on the storage and properties of the chemicals at the proposed resin

manufacturing unit, the some typical scenarios relevant for MCA analysis is given in

the following Table.

Table -7.4: Scenarios Considered for MCA Analysis

Sr.

No.

Chemical Storage

Quantity

Pool Fire Flash fire Toxic

Dispersion

Worst case

scenario

BLEVE

1 Methanol 12 KL √ √ √ √

2 Toluene 12 KL √ √ √ √

3 O - Xylene 12 KL √ √ √ √

4 Acetone 12 KL √ √ √ √

5 Chloroform 12 KL - - √ √

The above table indicates that major material storage is flammable liquid. Fires could

occur due to presence of ignition source at or near the source of leak or could occur

due to flashback upon ignition of the traveling vapour cloud.




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7.28


Tank fires may occur due to the ollowin nition i rim eal lea leadin to rim eal

fire and escalating to full-fledged tank fire.

Li htin i a ma or ource o i nition o tan ire and O er low rom tan leadin to

spillage and its subsequent ignition, which flashes back to the tank leading to tank

fire. The chance of overflow should be less unless operator has grossly erred.

Spillage due to overflow may result in a dyke fire if ignition occurs after sufficiently

long period.

For radiation calculations, pool fire is important and the criteria of 4.5 kW/m2

elected to ud e accepta ility o the cenario . he a umption or calculation

are t i not continuou expo ure t i a umed that no ire detection and miti ation

measures are initiated

For Chlorine leakage from valve of tonner is considered for discharge of chemical in

atmosphere and threat zone predicted using ALOHA by considering heavy gas

modeling

7.4 Consequence Modeling

Hazardous incidents start with a discharge of a flammable or toxic material from its

normal containment. Discharge can take place from a crack or fracture of process

vessels or pipe work, an open valve or from an emergency vent. The release may be in

the form of gas, liquid, or two phase flashing of gas-liquid.

7.4.1 Damage Criteria:

The storage and unloading at the storage facility may lead to fire and explosion

hazards. The damage criteria due to an accidental release of any hydrocarbon arise

from fire and explosion.

A. Fire Damage

Table 7.6 tabulates the damage effect on equipment and people due to thermal

radiation intensity whereas; the effect of incident radiation intensity and exposure

time on lethality is given in Table7.6.

Table 7.5: Damage Due to Incident Radiation Intensities




NABET Accredited


7.29


Sr. No.

Incident Radiation

(kW/m2)

Type of Damage Intensity

Damage to Equipment Damage to People

1 37.5 Damage to process equipment 100%lethality in1 min. 1% lethality in 10sec.

2

25.0

Minimum energy required to ignite wood at indefinitely long

exposurewithout aflame

50% Lethalityin1 min. Significant injury in 10 sec.

3

19.0

Maximum thermal radiation intensity allowed on thermally

unprotected adjoiningequipment

--

4

12.5

Minimum energy to ignite with a flame; melts plastic tubing

1% lethality in 1min.

5

4.5

--

Causes pain if duration is longer than

20sec,howeverblisteringis un-likely (First degree burns)

6

1.6

-- Causes no discomfort on long

exposures

Source: Techniques for Assessing Industrial Hazards by World Bank.

Table 7.6: Radiation Exposure and Lethality

Radiation

Intensity(kW/m2)

Exposure Time

(seconds)

Lethality (%)

Degree of Burns

1.6

--

0 No Discomfort even

after long exposure

4.5 20 0 1st 4.5 50 0 1st 8.0 20 0 1st 8.0 50 <1 3 rd 8.0 60 <1 3 rd

12.0 20 <1 2 nd 12.0 50 8 3 rd 12.5 -- 1 -- 25.0 -- 50 --

37.5 -- 100 --




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7.30


B. Damage due to explosion

Explosion is a sudden and violent release of energy accompanied by the generation of

pressure wave and a loud noise. The rate of energy release is very large and has

potential to cause injury to the people, damage the plant and nearby property etc.

BLEVE – fireball A Boiling Liquid Expanding Vapour Explosion (BLEVE) occurs when there

is a sudden loss of containment of a pressure vessel containing a superheated liquid or

liquefied gas. It is sudden release of large mass of pressurized superheated liquid to

atmosphere. The primary cause may be external flame impinging on the shell above

liquid level weakening the vessel and leading to shell rupture. Calculations are done for

diameter and duration offer ball and the incident thermal flux.

Pool fires and jet fires are common fire types resulting from fires over pools of liquid or

from pressurized releases or gas and/or liquid. They tend to be localised in effect and

are mainly of concern in establishing potential for domino effects and employee safety.

ALOHA Models are used to calculate various components - burning rate, pool size,

flame height, In jet fire modelling the steps followed for the thermal effects are

calculation of the estimated discharge rate, total heat released, radiant fraction/source

view fraction, transmissivity and thermal flux and thermal effects.

Vapour cloud explosion: When gaseous flammable material is released a vapour cloud

forms and if it is ignited before it is diluted below its lower explosive limit, a vapour

cloud explosion or a flash fire will occur. Insignificant level of confinement will result in

flash fire. The vapour cloud explosion will result in overpressures. Table 7.6 tabulates

the damage criteria as a result of peak over pressure of a pressure wave on structures

and people.

Table 7.7: Damage Due to Peak Over Pressure

Human Injury StructuralDamage

Peak Over Pressure (bar)

Typeof Damage PeakOver Pressure (bar)

Typeof Damage

5 -8 100%lethality 0.3 Heavy(90%damage) 3.5 -5 50% lethality 0.1 Repairable (10%damage) 2 -3 Threshold lethality 0.03 Damage of Glass

1.33 - 2 Severelung damage 0.01 Crack ofWindows

1 - 11/3 50%Eardrumrupture

- -

Source: Marshall, V.C. (1977)' Howlethal are explosives and toxic escapes'.




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7.31


C. Effect due to toxic gas release

Various approaches are used to determine the consequences of toxic gases:

• DLH

• ERPG

DLH (“ mmediate Dan er to Li e or Health”) i the maximum concentration rom which

escape is possible within 30 minutes without any escape-impairing symptoms or

irreversible health effects.

7.4.2 Details of Model Used for Consequence Analysis

ALOHA provide output as amount of chemical discharged from the source as well as

its concentration in air it takes into account different levels of concentrations for a

specified chemical.

Software used for calculation- ALOHA (AREAL LOCATIONS OF HAZARDOUS

ATMOSPHERES) ALOHA is a computer program designed especially for use by people

responding to chemical accidents, as well as for emergency planning and training.

ALOHA can predict the rates at which chemical vapors may escape into the

atmosphere from broken gas pipes, leaking tanks and evaporating puddles. It can

then predict how a hazardous gas cloud might disperse in the atmosphere after an

accidental chemical release.

ALOHA provides output as amount of chemical discharged from the source as well as

its concentration in air it takes in to account different levels of concentrations for a

specified chemical. Different concentration levels are given below:

ERPG 1: is the maximum airborne concentration below which it is believed that

nearly all individuals could be exposed for up to 1 hour without experiencing other

than mild transient adverse health effects or perceiving a clearly defined,

objectionable odor.


nearly all individuals could be exposed for up to 1 hour without experiencing or

developing irreversible or other serious health effects or symptoms which could

impair an individual's ability to take protective action.


nearly all individuals could be exposed for up to 1 hour without experiencing or




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developing life-threatening health effects.

IDLH: The Immediately Dangerous to Life or Health (IDLH) level. A chemical's IDLH is

an estimate of the maximum concentration in the air to which a healthy worker

could be exposed without suffering permanent or escape-impairing health effects.

Input data for aloha are as below:

Weather Data:

Average Wind Speed: 5 m/sec & 1.5 m/sec

Average Ambient Temperature: 350C, 220C

Average Humidity: 44%, 66%

Atmosphere Stability Class: D (windy day time), F (Extreme calm, night time)

Chemical Properties:

Chemical properties of each hazardous chemical stored within premises is given in Table

No.: 7.2

Storage Details:

Storage quantity and type of storage of chemicals is given in Table No.: 7.3




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Table 7.8: Consequence analysis and Damage Distance (Failure of raw material storage tanks)

Name of Chemical

Type of Impact Flammable (Distance in meter) Toxic Dispersion

Pool Fire (meter)

Fire Ball (BLEVE) Worst Case

Scenario (meter)

Flash fire (Flammable Area of

Vapor Cloud) (meter)

ERPG(3)/ IDLH ERPG(2) ERPG(1)

Radiation Intensity(kW/m2)

37.5 25 4.5 37.5 25 4.5 UEL LEL

Fatalities 100% 50% 100%

50% - -

Wind Speed

Stability Class

Methanol (12 KL x 1)

4 D 10 10 15 62 93 253 15 meters --- (43080

ppm = 60% LEL =

Flame Pockets)

19 meters --- (7180 ppm =

10% LEL)

15 meters --- (6000 ppm =

IDLH)

24 meters --- (2100 ppm

= AEGL-2 [60 min])

65 meters --- (530 ppm = AEGL-1 [60 min])

2 F 10 10 15 69 99 266 19 meters --- (43080

ppm = 60% LEL =

Flame pockets)

36 meters --- (7180 ppm =

10% LEL)

28 meters --- (6000 ppm =

IDLH)

47 meters --- (2100 ppm

= AEGL-2 [60 min])

106 meters --- (530 ppm =

AEGL-1 [60 min])




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Name of Chemical


Pool Fire (meter)


Scenario (meter)





37.5 25 4.5 37.5 25 4.5 UEL LEL


50% - -

Wind Speed

Stability Class

Chloroform (12 KL x 1)

4 D - - - - - - - - 107 meters --- (500 ppm =

IDLH)

494 meters --- (50 ppm = ERPG-2)

1.2 kms --- (10 ppm)

2 F - - - - - - - - 136 m (500 ppm =

IDLH)

590 m (50 ppm =

ERPG-2)

1.8 Km (10 ppm)

Worst case (Direct source Leakage of 1 Ton)

430 meters --- (500 ppm =

IDLH)

1.1Km (50 ppm =

ERPG-2)

2.1 Km (10 ppm)




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Name of Chemical


Pool Fire (meter)


Scenario (meter)





37.5 25 4.5 37.5 25 4.5 UEL LEL


50% - -

Wind Speed

Stability Class

Acetone (12 KLx1)

4 D 10 10 14 96 128 325 10 15600 ppm =

60% LEL = Flame

Pockets

19 (2600 ppm = 10% LEL)

<10m LC50:46400

ppm)

14 meters --- (IDLH:

2500 ppm)

102 meters --- (200 ppm =

AEGL-1)

2 F <10 <10 <13 101 134 339 14 meters --- (15600

ppm = 60% LEL =

Flame Pockets)

49 meters --- (2600 ppm =

10% LEL)

LOC was never exceeded --- (46400 ppm)

50 meters --- (2500 ppm)

257 meters --- (200 ppm =

AEGL-1 [60 min])




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Name of Chemical


Pool Fire (meter)


Scenario (meter)





37.5 25 4.5 37.5 25 4.5 UEL LEL


50% - -

Wind Speed

Stability Class

Toluene (12 KLx1)

4 D 10 10 16 119 153 375 11 meters --- (6600 ppm =

60% LEL = Flame

Pockets)

20 meters --- (1100 ppm =

10% LEL)

21 meters --- (500 ppm =

IDLH)



2 F 10 10 15 125 160 390 14

meters -

-- (6600

ppm =

60% LEL

= Flame

Pockets)

36 meters --- (1100 ppm =

10% LEL)

38 (500 ppm =

IDLH)

49 (300 ppm =

ERPG-2)

221 (50 ppm = ERPG-1)

Note

*** The concentration of HCl stored will be in range of 30 to 33%, as it will be solution and ALOHA cannot allow to model tank source for

consequence analysis of solutions, a puddle of HCl has been selected to model toxic dispersion scenario after HCl leakage from tank.




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Figure 7.1: Methanol BLEVE (Worst case scenario 12KL Tank)




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Figure 7.2 Methanol Toxic Dispersion (12 KL Tank)




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Figure 7.3 Chloroform Toxic dispersion (12 kl tank)




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Figure 7.4 Chloroform Toxic dispersion (12 KL tank)




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Figure 7.5 Chloroform tank leakages (12 KL)




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Figure 7.5 Acetone Worst Case Scenario (Total Rupture Tank :12 KL)




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Figure: 7.6 Acetone Pool Fire (Full rupture of Connecting pipe )




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Figure: 7.7 Acetone Toxic dispersion (Full rupture of Connecting pipe/valve)




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Figure: 7.8 Toluene BLEVE (12KL tank: Worst Case Scenario)




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Figure: 7.9 Toluene Pool fire (12KL tank: Maximum Credible Accident)




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Figure: 7.10 Toluene Toxic dispersion (12KL tank: Maximum Credible Accident) (2F)




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Figure: 7.11 Toluene Toxic dispersion (12KL tank: Maximum Credible Accident) (4D)




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Figure: 7.11 Toluene BLEVE (12KL tank: Worst Case scenario) (4D)




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Figure: 7.11 Toluene Pool fire (12KL tank: MCA) (4D)




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7.5 Failure Frequency

Fire under a tank may lead to the instantaneous release of the complete inventory of

the tank. Various causes of failure may lead to a fire under a tank:

Leakage of the connections under the tank followed by ignition. This event only

occurs for tanks loaded with flammable substances. The frequency is equal to 1

× 10-5 per year for atmospheric tanks. (Reference Purple book: Guidelines for

quantitative risk assessment)

The best available estimates of leak frequencies for atmospheric tanks are

summarised in Table 7.10.

Reference: Storage incident frequencies International Association of Oil and Gas

Producers (UK: HSE)

Table7.9: Atmospheric Storage Tank Leak/ tank fire Frequencies

Type of Tank Type of Release Leak Frequency(per tankyear )

Fixed/ floating roof Liquid spill outside tank 2.8 × 10-3

Tank rupture 3.0 × 10-6

Atmospheric storage tank Fire Frequency

Type of Fi r e Fi x e d Roof Tank (per tank year)

Internal explosion & full surface fire

9.0 × 10-5

Internal explosion without

fire

2.5 × 10-5

Vent fire 9.0 × 10-5

Small bund fire 9.0 × 10-5

Large bund fire

(full bund area)

6.0 × 10-5




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7.6 Estimation of Effect of Damage / Impact Identification

Consequence analysis of hazardous chemicals stored in large quantities as well as in tanks within premises shows that area prone to fire and explosion is mainly storage area of Methanol and chemicals storage/ware house where drums of hazardous raw material will be stored. The maximum intensity of heat radiation will be due to worst case scenario i.e total rupture of Methanol 10 MT tank. In case of flammable chemicals stored in drum, Acetone and Acetonitrile has been considered for prediction of damage distance by considering single drum worst case scenarios. From the toxic dispersion modeling of Chlorine toner and Ammonia cylinder maximum damage distance will be 154 meter and 322 meters from source of leakage. Threat zone distance given below are considered for Temperature 220C, Velocity: 1.5m/sec, Humidity 71%, Atmospheric stability Class: F considering winter night time. Percentage fatality from different incident outcome cases and level of concerns are given below:

Table7.10: Estimation of Effect of Damage / Impact Identification &

Chemical (12 KL)

Incident outcome

case

Level of concern

Threat zone

Distance meter

% fatality

(pfi)

Likely hood of

occurrence

Magnitude of Impact/Damage

Methanol

Pool fire 25 kW/m2

10 50% Possible Moderate

BLEVE 25 kW/m2

93 50% Unlikely high

Chloroform Toxic dispersion

IDLH 500 ppm

136 - ikely high

Acetone Pool fire 25 kW/m2

10 50% Unlikely high

BLEVE 25 kW/m2


Toluene Pool fire 25 kW/m2


BLEVE 25 kW/m2


Magnitude of impact will be higher in case of pool fire of Methanol tank storage

area




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Figure 7.1 to 7.10 shows the map of threat zone corresponding to different

chemicals and its incident outcome cases. All the threat zones in the proposed unit

are super imposed on google image. All scenarios of different release indicate that

individual risk is found to be a maximum at locations within premises as well as

outside of premises for toxic dispersion only. The reason for high individual risk at

this location is due to considering BLEVE scenario as worst case scenario resulting

from the catastrophic failure of storage tank of solvent. Abroadly acceptable level of

individual risk as per the ALARP (As low as reasonably practicable) concept of HSE,

UK is 10-6/year.

7.7 Summary

The present risk assessment study corresponding to quantity of solvents stored

within premises shows that proposed unit of M/s Jayveer Pharma Chem has higher

potential for damage to those inside compare to outside the industry because of

storage of Methanol, chloroform storage and loading and unloading from tanker

solvents.

There are many other hazardous raw material drums will be stored in drum storage

area, where possibility of fire and explosion will higher during loading, undloading

transportation and handling of drums.

It may be noted that in dispersion modeling, the wind direction and air temperature,

atmospheric stability are found to be the deciding factors for the threat zones.

Fire modeling shows that the hazardous distances for Methanol storage tank

extended up to 266 meters in worst case scenario, In case of pool fire it is within 15

meters which might prevented by effective fire-fighting arrangements to be

provided after commissioning of poject.

A maximum threat zone of chloroform considering 1 ton leakage is approximately

430 meter (500 IDLH).

7.8 Proposed Risk Reduction Measures /Safety Measures

A. Tank farm area:

Storage tank of Methanol, Sulphuric Acid, Hydrochloric Acid should be installed

away from the plant area.

Automatic sprinkler system for the flammable material tanks (over ground

tanks only) may be provided as knock on effect in case of fire is possible.




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Containment dykes with proper sloping and collection sumps should be

provided so that any spillages in the bulk storage and other handling areas shall

not stagnate and shall be quickly lead away to a safe distance from the source

of leakage. This reduces the risk of any major fire on the bulk storages and the

risk to the environment shall be minimized/ eliminated.

Inspection of the storage tanks as per prefixed inspection schedule for

thickness measurement, joint and weld efficiency etc.

Pro i ion o lameproo electrical ittin / equipment’ .

Proper maintenance of earth pits.

Strict compliance of security procedures like issue of identity badges for

outsiders, gate passes system for vehicles, checking of spark arrestors fitted to

the tank lorries etc.

Strict enforcement of no smoking.

Periodic training and refresher courses to train the staff in safety fire fighting.

Employee training and education is carried out.

Structural fireproofing in the process area could be considered as a safety

measure in the light of probable spill and fires in the area.

B. Safety measures of storage and handling Nickel catalyst;

Raney nickel catalyst (active) is highly pyrophoric when it gets dried up on

exposure to air/ atmosphere/ oxygen. It should therefore always be kept under

demineralised/ distilled water.

The containers of the catalyst should be stored in a cool and ventilated place

protected from direct exposure to sunlight.

Protective gloves, shoes and goggles must be used while transferring catalyst

from containers to the reaction vessel.

Hydrogen gas continuously evolves from the catalyst slurry. Smoking cigarette/

bidi and lighting matchstick/ lighter should be strictly prohibited while opening

the containers of thecatalyst.

The catalyst slurry should be manually stirred using a thick wooden stick to

restore it in suspension for easy and smooth transfer.

Care should be taken while transferring catalyst so as to avoid/ minimise

spillage of the catalyst. Skilled personnel should be employed for handling the

catalyst.

In the event of spillage of small quantity, the spilled material may be

deactivated by using a 0.5 % solution of potassium permanganate followed by

flushing the area with sufficient water.

In the event of spillage of significant quantity, the spilled catalyst slurry should

be collected back manually and put in a polythene bag thereafter be packed in




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a plastic or M. S. container and retrieval of the spilled catalyst should be

flushed with water. A 0.5 % solution of potassium

Permanganate [kmno4] may also be used as an additional measure.

In the event of contact with skin, the skin should be washed immediately with

running water.

Dry with a clean towel and apply a soothing ointment (viz soframycin).

Empty polythene bags and containers after transfer of catalyst should be

washed profusely with water before scrapping them.

Great care should be taken in deciding temperature and pressure condition

and selection of solvent for the hydrogenation reaction.

Nickel is a costly metal. Do not therefore discard even such of the spent Raney

Nickel Catalysts which cannot be reactivated any more.

C. General Safety measures to be taken:

Emergency drills should be carried out periodically to ensure preparedness must

continue.

Wind indicator should be provided at the highest level of the plant to know the

wind direction.

Many operations involve use of highly toxic/flammable materials and these

needs to be documented as SOPs. These must be made and kept updated on

priority.

Extensive training on use of Self Contained Breathing apparatus (SCBAs) must be

ensured for emergency control.

Raw materials are either toxic or flammable, therefore important to ensure that

these materials are stored in closed, well ventilated totally safe areas. A fire

alarm system (heat and smoke detection) should be provided for the storage

area where the material is stored as toxic fumes arise on combustion.

Loose drums of waste materials, often solvent laden, must be removed from the

working areas and close watch kept.

Proper Earthing needs to be provided through plug type systems or through the

agitators/liquid.

Ventilation should be provided for any enclosed are where hydrocarbon or toxic

vapors may accumulate. Several such areas were noticed- these may be surveyed

and tackled accordingly.

All personnel should be trained in handling emergency situations and should be

apprised of their role in handling emergency situation and to ensure adequacy of

the emergency procedures simulated exercise should be carried out. This was

found wanting.




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Flame arrestor should be provided.

Adequate number of caution boards highlighting the hazards of chemicals should

be provided at critical locations.

Monitoring of occupational hazards like noise, ventilation, chemical exposure

etc. is carried out regularly and its record is maintained.

Good housekeeping, use of PPE, Engineering controls, Enclosure processes,

scrubber system, display of safety boards, SOP of loading / unloading, local

exhaust ventilation, safety shower etc. are important safety measures have taken

to keep these chemicals within TLV.

Appropriate personal protective equipment is provided & ensure the usage of

them.

Workers is trained for safe material handling of hazardous chemicals.

Prepare & display the safe operating procedure for hazardous chemicals storage,

handling & transporting or using.

Local Exhaust ventilation and scrubber should be installed where it is required to

reduce fumes, vapors, temperature and heat stress.

Reduce the level of physical activity by sharing workload with other or by using

mechanical means.

D. FIRE safety devices should be PROVIDED to protect from any malfunctioning of

plant equipment.

Water storage of adequate capacity to meet the requirements of water for

firefighting purposes.

Fire hydrants and automatic sprinkler system. Diesel driven pumps and headers

to supply water to fire hydrant network.

Adequate Portable fire extinguishers, sand bucket, wheeled fire & safety

equipment should be provided at the required places.

Fire proof electric fitting is mandatory.

Equipment required for personal safety like blankets, gloves, apron, gum boots,

face mask helmets, safety belts, first aid boxes etc. are provided. Proximity suits

and self-contained breathing apparatus to be provided.




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Table7.11: Details of proposed fire safety measures

Sr.

No. Type Capacity Qty**

1. Water storage tank (For Fire) 1.5 KL 1

2. Jockey Pump 250 RPM 1

3. 200 Liter Capacity Mobile Foam Unit 200 Lit 01 Nos

4. Dry chemical Powder 2 Kg. 10 Nos.

5. Dry Chemical Powder 6 Kg. 6 Nos.

6. Capacity Dry Chemical Powder type Fire

Extinguishers 9 Kg. 3 Nos.

7. Capacity Foam type Fire Extinguisher. 50 Kg 1 Nos

8. Capacity Co2 type Fire Extinguisher. 3 Kg 03 Nos

9. Capacity Co2 type Fire Extinguisher. 4.5 Kg 02 Nos

10. Capacity Co2 type Fire Extinguisher 6.5 Kg 02 Nos

Note: **Numbers of cylinders and type may change after commissioning of the project

depending on requirement of NOC from fire department.

7.9 Occupational Health Surveillance Programme

7.9.1 Introduction:

The Factories Act, 1948 and the rules framed thereunder provide for pre-employment

and periodical medical examinations of workers employed in industries with

hazardous processes and dangerous operations under section 41-C and section 87

respectively.

All Chemical listed in table no. 7.2 to which workers will be exposed. There are solvent

stored within premises which may cause adverse health impact due to regular

exposure. Pre-employment medical checkup and periodically medical examination

will be done. Liver function testis will be carried out during pre-placement and

periodical examination. In addition to the above, following safety equipment will be

provided.

7.9.2 Action plan for Occupational Health and safety for workers:

Monitoring of occupational hazards like noise, ventilation, chemical exposure etc.

will be carried out regularly and its record will be maintained.




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Good housekeeping, use of PPE, Engineering controls, Enclosure processes, display of

safety boards, SOP of loading / unloading, local exhaust ventilation, safety shower

etc. All necessary safety measures will be taken to keep all chemicals within TLV.

Appropriate personal protective equipment will be provided & ensure the usage of

them.

Workers will be trained on safe material handling of hazardous chemicals.

Prepared & display the safe operating procedure for hazardous chemicals storage,

handling & transporting or using.

Periodical medical examination of the workers & Liver Function Testes will be done.

Register (form no.37) for work place air monitoring will be done regularly.

Employee training and education will be carried out regularly.

Control the noise at source by substitution, isolation, segregation, barriers will be

done.

Local Exhaust ventilation will be installed where it is required to reduce fumes,

vapors, temperature and heat stress.

Periodic Health Check-up includes: 1. Complete clinical check-up. 2. X-ray of chest. 3. Vision testing. 4. Blood routine, sugar and cholesterol. 5. Urine routine. 6. ECG for workers above 40 years. 7. Indirect laryngoscopy for workers above 40 years. 8. Spirometer for workers employed in dusty, and smoky environment. 9. Audiometry for those, working in noisy environment.

Statutory requirement:

Health Records (Rule 68R): Once in every 6 months or immediately after his medical

examination whichever is earlier.

Medical Examination & FMO (Rule 68T & U):

1. Pre-employment and six monthly periodical examinations are required. 2. Report of above examinations shall be in form No. 32. 3. First employment only after fitness certificate in form No. 33, Appeal regarding unfit,

shall lie with the Certifying Surgeon (CS) whose opinion shall be final.

4. The worker required to undergo medical examination will not refuse it.




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7.9.3 Possible Health Effect from Aromatic chemicals/solvents stored within premises

As mentioned in above stated occupational health and surveillance programme,

industry will appointed Factory Medical Officer (MBBS with Associate Fellow of

Industrial Health (AFIH) Certification) for periodical, pre-employed medical

monitoring of all workers. Project proponent will take all necessary measures as

stated in topic no. 7.9.2 to reduce exposure to workers

Table7.12: Common Chemical used within premises and their Health Effects and

Medical Monitoring

Hazardous

substance or

chemical group

Compounds Target organs Potential health

effects

Medical monitoring

Aromatic

Hydrocarbons

Methanol

Toluene

O-Xylene

Blood

Bone

marrow

Central

Nervous

System

Eyes

Respiratory

system

Skin

Liver

Kidney

Central

Nervous

System

depression:

Decreased

alertness,

Headache,

Sleepiness,

Loss of

consciousness.

Defatting

dermatitis.

Medical examination

with focus on liver,

kidney, nervous

system, and skin.

Laboratory testing:

Complete blood count

(CBCb) Platelet count

Measurement of

kidney and liver

function.

Following test are

performed

CBC

Urine R/M

RBS

SGPT

S. Creat

PFT




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7.9.4 Treatment Facilities Provided to workers affected by accidental Spillage of

Chemicals

Regular safety inspection is highly recommended to keep equipment up to date and

ensure all procedures are being followed correctly. Chemical Plant Safety

Precautions to Avoid Accidents and Injuries

o Gas detectors system as described in above section of chlorine and ammonia

o Fire extinguishers

o Frequent training on safety procedures

o Perform hydrostatic tests to check pressure safety equipment

o Protective eyewear

o Eye-washing equipment for splashes

o Safety valves to regulate pressure

o Ventilation and respiration for fumes

o Adequate number of Personal protective equipment to revent contact with

skin by wearing neoprene gloves, lab coat, and resistant apron. Glasses or a

face shield will be provided if splashing may occur.

o Washing facility: In case of contamination of chemicals

o Drinking water

o First aid facility at prominent location within premises

o Antidots of chemicals will be provided within premises.

o Emergency accident Warning Devices

o Regular Maintenance and Inspection of process machineries

Medical Arrangement:

First Aid Boxes have been provided at various strategic locations. Requisite number

employees are trained about First Aid, Liaison with nearest hospitals. Details of available

antidotes of raw materials is given in table no.7.11.

7.9.5 Minimization of the Manual Handling of Hazardous Substance

Employers and employees should examine their workplaces to detect any unsafe or

unhealthful conditions, practices, or equipment and take corrective action. Provide

flameproof electrical motor & transfer chemicals through the pipelines. Use

specially designed pallets to hold, move raw materials, finished products through

work areas. Minimize lifting of raw materials, heavy loads by using appropriate

platforms, trolleys etc. Avoid the moving, manual handling of hazardous material.




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Table7.13: DO’S and DONT’S

A. (Handling of Chemicals)

Do’ Dont’

Know the hazards of the chemical before

handling.

Know the antidotes for chemical, which you

are handling.

Do keep material safety data sheet in

locations where chemicals are being handled

and study it.

Use appropriate personal protective

equipment like gloves, aprons, and respirator;

face shield etc. depending upon nature of the

work.

Label every chemical that you use and tightly

close the container.

Use eye wash fountain / safety shower in case

of splash of chemicals in the eye or body for

at least 15 minutes.

Segregate toxic, flammable chemicals and

keep them under control.

In addition to draining and closing valves,

lines should be blanked before taking up

maintenance work.

Provide proper ventilation at the chemical

handling area to limit their concentration

within prescribed level.

Do not store the chemicals that are

incompatible with other chemicals.

Do not spill the chemicals.

Do not dispose chemical without

neutralizing.

Do not keep large inventory of

chemicals.

Do not allow empty containers of

hazardous chemicals to be used by

others.

Do not use compressed air for

transferring chemicals.

Do not stand near chemical transfer

pump while it is in operation with

temporary hose connection.

Pouring of chemicals by hand or doing

siphoning by mouth should never be

adopted.

Chemicals drums should never be

moved without protection.

Do not attempt to neutralize the acid /

alkali on the skin. Use water only.

Do not use solvent for cleaning hands.

B. Material Handling

Do’ Don’t

Use proper lifting tool and tackle having

adequate capacity.

Only authorized persons should operate

material handling equipments.

Each tool, tackle or equipment should have

number and safe working load (SWL) marked

Do not use the equipment for the

purpose other than its design intention.

Do not allow personnel to move

underneath lifted load.

Do not load the equipment above its

safe working load.




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Do’ Don’t

on it.

Assess weight of the material, distance to be

carried and hazards etc. before lifting the

load.

Inspect and test all the lifting tools and tackles

regularly as per Factory Rules.

Wear Personal Protective Equipments while

handling of material.

Wherever possible, mechanized material

handling shall be adopted.

While lifting a load physically, keep the load

as near as possible to the body with feet

properly placed for body balance.

Bend knees, keep back straight, keep the load

closed to the body and lift the load.

Do not use makeshift arrangements for

lifting equipment without inspection

and test.

Do not use defective tool and tackles.

Keep the tools & tackles free from

adverse effect of atmosphere by

applying suitable protective coating.

The angle between the legs of two leg

sling should not exceed 90 degree.

Do not allow male and female adult to

lift a load manually higher than 55 kgs

and 30 kgs respectively.

Do not hold the load with tip of the

fingers; grasp the load firmly with palm.

C. Fire Prevention

Do’s Don’ts

Follow ‘NO SMOK NG’ i n.

Deposit oily rags and waste combustible material

in the identified containers and dispose them

suitably.

Fire Hose used for any other purpose should be

permanently marked and taken out of fire

hydrant system.

Keep minimum inventory of flammable and

combustible substances.

Take permission before breaking or removal of

fire barrier and ensure subsequent relocation of

fire barrier.

Check periodically the operability of fixed fire

fighting system.

Attend any abnormality / deficiency with fire

protection system promptly.

Provide earthling or bonding to prevent

accumulation of static charges to tanks where

Do not leave flammable material like

acetone, kerosene etc. used as

cleaning agent at the work area.

Do not over tighten fire hydrant

valves with F-lever.

Do not allow wild grass growth

around storage of the gas cylinders

and switchyard.

Do not obstruct accessibility to the

fire related equipment.

Do not destroy the inspection tag

provided with the fire equipment.

Do not misuse fire-fighting

equipment other than intended

purpose.

Do not store the flammable material

in the open container.

Do not use instruments that are not




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flammable chemicals are stored / handled.

Use instruments that are intrinsically safe in

explosive atmosphere.

intrinsically safe in the explosive

atmosphere.

D. House Keeping

Do’s Don’ts

Assign places for everything and maintain things

at assigned places.

Clean the area after completion of work.

Use aisle space free for personnel and material

movement.

Ensure adequate illumination and ventilation for

the job.

Drop paper, plastic, glass, metal and bio-medical

waste in a separate bin kept for this purpose.

Know the location where emergency equipment

such as first aid box, fire fighting equipment,

SCBA, Stretchers are kept.

Arrest all types of spills such as chemical, water,

oil, air / gas, steam etc. and clean up the area

immediately.

Ensure exits are indicated / painted for use

during emergency.

Do not leave combustible materials

in the work area.

Do not smoke in the area of work.

Do not allow dust bin to overflow.

Do not generate extra waste.

Do not disturb the safety equipment

from assigned location.

Do not block emergency switches

and on/off switches of the

equipment by storming of materials

in front of work.

Do not leave cleaning agent like

acetone, isopropyl alcohol, kerosene

etc. at the work area after

completion of work.

Do not block fire exit point by storing

materials or by means.

Do not leave a spillage unattended.

7.10 Disaster Management Plan

7.10.1 Disaster

Disaster , A disaster is a catastrophic situation in which the day-to-day patterns of life

are, in many instances, suddenly disrupted and people are plunged into helplessness

and suffering and as a result need protection, clothing,, shelter, medical and social

care and other, necessities of life.

Advance emergency planning and proper training of every employee in the

'emergency function is very essential to make emergency control measures more

effective. There are two types of emergency control plans (1) On site emergency plan

and (2) Off site emergency or disaster plan.




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7.10.2 Statutory Provisions:

Section 41B(4) of the Factories Act, 1948 requires an on site emergency plan and

detailed disaster control measures for the safety of the factory workers and the

general public living in the vicinity of the factory. The occupier is required to inform

the workers and the public about the safety measures to be taken in the event of an

accident.

Rule 13, 14 and Schedule II & 12 of the Manufacture; Storage and Import of Hazardous

Chemicals Rules, 1989 and Rule 5,7,9 and 10 of the Chemical ' Accidents (Emergency

Planning, Preparedness and Response) Rules, 1996 also provide for on-site and off-site

emergency plans

7.10.3 On-Site Emergency Plan :

Objectives of the Plan

1. To protect persons and properly of your factory in case of all kinds of accidents,

dangerous occurrences (Rule 103, Gujarat Factories Rules), emergencies and

disasters happening in or affecting your plant at any time.

2. To inform people and surroundings about above happening if it is likely to adversely

affect them.

3. To inform authorities including helping agencies (doctors, hospitals, fire, police,

transport etc.) in advance, and also at the lime of actual happening.

4. To identify, assess, foresee and work out various kinds of possible hazards, their

places, potential and damaging capacity and area in case of above happenings.

Review, revise, redesign, replace or reconstruct the process, plant, vessels and

control measures if so assessed.

5. To work out a plan with detailed instructions to cope up with above happenings,

based on your personnel, equipment and records. Necessary requirements shall be

added if not already available. Levels of hazardous substances shall be minimised to

the extent possible. Establish machinery for rescue and recuperation operations,

total loss control and prevention of harms and recurrence of above happenings.

Ensure that absolute safety and security is achieved within the shortest time.

7.10.4 Site Plan of the Factory and Surrounding:

Proposed unit has prepared a plan of the factory premises and surroundings showing

therein the areas of various hazards such' as fire, explosion, toxic release etc., and also




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location of assembly points, equipment room, personal protective equipment room,

telephone room, first aid or, emergency control room, main gate, emergency gates, normal

wind direction, north direction.

The same has been given in Chapter No.2; Figure No.2.4 of EIA report

7.10.5 Types of Overall Emergencies

In the risk assessment study topic no. 7.3 describes all type of hazards are listed along with

its causes in or near plant. Fire (small and big), explosion, toxic exposure, strike, storm, flood

and other hazardous possible situations shall be described with reasons. Sources of hazard

from outside or neighboring plants, tanks, structure etc. shall be mentioned. From the

consequence analysis table no.7.15 for storage area and drums following emergency

situation can be arise.

Table 7.14 Type of overall emergencies

Sr.

No.

Type of emergency

including disaster

(Major class)

May arise due to

At (Place)

People and

area likely to

be affected

1 Fire

Methanol spillage or leakages

at storage tank

Leakages: Pipeline, pumps

and valves carrying

Methanol

Leakages and spillages in

drums storage area for raw

materials and products

Fire in road tanker of

Methanol during loading of

methanol

Storage area

of raw

materials

Tankers

carrying

Methanol

Plant

Operator,

Labors,

workers

Admin staff

2 Explosion

Failure of the safety

valve/pressure relief

valve, corrosion of critical

parts of the boiler, or low

water level.

Boiler

3 Release of Toxic

Gas/Vapour

Leakages from valve or

tonner or Chlorine or from

cylinder of Ammonia.

Storage area

of Chlorine

tonner and

Ammonia

4 Spillage of Loading and unloading Tank farm

https://en.wikipedia.org/wiki/Safety_valve

https://en.wikipedia.org/wiki/Safety_valve

https://en.wikipedia.org/wiki/Corrosion




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Sr.

No.

Type of emergency

including disaster

(Major class)

May arise due to

At (Place)

People and

area likely to

be affected

flammable liquid

/gas

area, process

area

5 Deliberate Sabotage,

Terrorism, Air Raid

etc.

- -

6 Natural Calamities: -

Lightening, Storm,

Earthquake, Flood

etc.

- -

7 Collapsing of

structure

Overturning of

tanker containing

flammable / toxic

substances

- -

7.10.6 Assessment of In-plant Hazards

Detailed hazard assessment of in-plant and control measures provided in topic no.7.3, table

no.7.3 & 7.4 of EIA report. Storage Hazards and Controls, Process Hazards and Controls are

described in same topic.

7.10.7 Emergency Control System:

A. Emergency Organizations and Functions

The organizational set-up necessary for chain of commands during emergency situation,

which may arise in the premises. The system is described in following Subsections.




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Organizational Set-up

Members of above teams will be available during all shifts and holidays. Protective

equipment, lifting gears, fire control points etc.; will be provided in sufficient numbers and

their locations will be well informed. Necessary vehicles will be kept ready to shift persons

'in case of emergency.

B. Emergency Control Room (Safety officer room)

The place identified as Emergency Control Center is considered as safety officer room.. The

facilities available at the Emergency Control Center shall include:

i. Internal Telephone& External Telephone:

Address and Telephone numbers of the Factory Inspectorate, Gujarat Pollution Control

Board, Police, Fire Brigade, Hospitals and OEP Team Members

ii. Manual Fire/Emergency Siren

iii. Siren Actuation Switch

iv. Important Address and Telephone Numbers

v. Emergency Vehicles

vi. Confined Space Entry Procedure

vii. List of Antidote/actions to be taken in case of hazardous chemical/materials.

viii. Material Safety Data Sheets of chemicals

ix. A copy of On-Site Disaster Management Plan

x. Plant layout-indicating storage of hazardous materials, layout of fire

Hydrants/extinguishers, entrances/exits, roads etc.

Plant Manager

EHS/Safety Officer

Supervisor Plant Chemist

Director

Skilled workers Security staff




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xi. Portable P.A. System, Manual Siren, flood lights, Torches, Pickaxe, Saw, Nylon

Ropes.

xii. Fire Blankets / Fire Proximity Suit, Breathing Apparatus, First Aid Box etc.

xiii. List of employees with address, telephone number, blood group etc.

All communications after General Shift working hours and on Sundays/ Holidays are to be

routed through the Security Gate Office.

C. On – site facilities for emergency control

Fire Emergency: Trained personnel will be employed in all the shifts. The responsibilities and

duties include:

To fight the fire with available internal firefighting equipment and to stop leakage of

liquid etc.

To provide personal protective equipment to the team.

To cordon the area and inform incident controller or site main controller about the

development of emergency.

To train the persons (essential workers) to use personal protective equipment and fire-

fighting equipment.

D. Fire Fighting Facilities to be provided on - site:

1. Fire Buckets / Fire Extinguishers : details is given in table no.: 7.12

2. Fire Alarm Sirens

It will be provided to alert all the employees inside the premises about the situation of

an emergency.

3. Sand Buckets

5 nos. of sand buckets will be provided within the industrial premises in case of

emergency fire.

4. Oxygen Cylinder

Oxygen cylinder will be provided for emergency.

E. Assembly Points:

The assembly points for gathering workers / Admin staff is fixed and clearly marked as per

the wind direction on plant layout as well as on site.In case of emergency some locations are

considered as Assembly Points. Depending on the wind direction and location of

emergency, Assembly Point is declared. The employees should run across the wind

direction and not against the wind direction.




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7.10.8 General Procedures and responsibilities:

Mock drill:Mock drills are carried out regularly to familiarize the staff with their roles, fire

protection equipment/system installed in the plant and use of personnel protective

equipment. Senior officials

Wind Socks: Wind direction is determined with the help of installed windsocks.

Procedure on Noticing an Emergency

If anybody notices any situation, which may lead to a disaster, should be immediately

inform the Shift In-charge / site controller / Incident Controller / Fire & Safety Supervisor

/ Security.

Take charge of the situation as Incident Controller.

Rush to the site of emergency to get the correct picture and then to Emergency Control

Center for speedy control over the situation by making an arrangement for raising the

alarm.

On arrival of Team members, he shall assign duties as required and activate the On-Site

Emergency Plan.

Ensure safety of the plant and the personnel in the plant. He will make an assessment of

the emergency and decide on external assistance.

Communicate and Coordinate among the Incidents Controller/ Site Controller/ Factory

manager/ fire safety supervisor etc. and is final authority on all matters related with

management of emergency such as:

Firefighting

Welfare and rescue operations.

Arrange for Civil/Mechanical/Electrical work during emergency.

Transport.

EHS/SAFETY OFFICER & Security staff:

Rush immediately to the scene of the fire/emergency, select and set out appropriate

fire/emergency equipment. He will take the below mentioned actions at the earliest

opportunity, if the fire/emergency is not controlled.

He will

Call the security personnel from their residences for additional manpower if required.

Regulate entry and exit of personal required for controlling the fire/emergency.

Restrict exit of personal required for controlling the fire/emergency.




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Arrange for Personnel Protective Equipment required for the emergency.

Call, the local Fire Brigade, Police in case of necessity in consultation with the Incident

controller.Arrange transport facilities for removal of causalities to dispensary / hospital.

Take responsibility of law and order.

Keep detailed records of the incident and progress of operations to fight the emergency.

Plant manager:

He will rush to the Emergency Control Centre and collect the information from the Incident

Controller. Further he will,

Announce the location of the Assembly Point after getting information from Incident

Controller / site controller. Take the list of persons to be communicated internally and

externally.

Maintain liaison with the press, government agencies i.e. Police, Fire Brigade etc. and

the neighborhood regarding the emergency under instructions from Incident Controller.

Courteously Receive officers from the State Government or neighbors to the

Administration Block only and inform to Incident Controller that they can be taken care

off.

Take all the steps required for the welfare such as providing tea, snacks, emergency

temporary Medical Center in consultation with the incident controller/site controller.

Disclose all the necessary information in the plant and media so as to avoid rumors and

Confusion. Also be responsible for the head counts at the Assembly Points.

Supervisor/ shift in charge& security:

Proceed to the scene; establish contact with firemen and incident controller to

supplement efforts in fire fighting.

Assist in searching casualties and help to remove them to the medical center. Organize

outside assistance in fire fighting and rescue operations if required.

Mobilize personal protective equipment and safety appliances and assist personnel

handling emergency in using them.

Keep and check on any new development of unsafe situation and report the same to Site

Main Controller. Effectively cordon off the emergency area and will prevent

unauthorized people entering the scene.

Permit the Fire tenders or Ambulance requisitioned by Incident Controller to the plant.

Ensure that vehicles and trolleys are sent out of the plant premises.

Ensure that all the employees are conducted out of plant and assembled at Assembly

Point.




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Control Traffic Movement. Remove tankers, tanker drivers outside. Entry of

unauthorized public to be prevented.

Arrange for vehicles for shifting casualties and essential workers to safe assembly points.

Collect and preserve evidence to facilitate future inquiries.

7.11 Offsite Emergency Preparedness Plan

Offsite emergency plan would follow the onsite emergency plan. When the consequences of

an emergency situation go beyond the plant boundaries, it becomes an offsite

emergency.As the off-site emergency plan is to be prepared by the Government, a Central

Control Committee or Group shall be formed under the Chairmanship of the area head. For

example we assume a district structure and District Collector (is the Chairman of the District

Control Committee (DCC). Other officers from police, fire, factory, medical, engineering,

social welfare, publicity, railway, telephone, transport and requisite departments shall be

incorporated as members.

The roles of the various parties who is directly involved in the implementation of an offsite

plan are described below. Depending on local arrangements, the responsibility for the

offsite plan would either rest with the plant management or with the local authority.

Figure 7.12: Off-Site Emergency Plan




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Aspects Proposed to be considered in the Offsite Emergency Plan

The main aspects, which should be included in the emergency plan, are:

Organization: Detail of command structure, warning systems, and implementation

procedures, emergency control centres. Names and appointments of incident controller,

site main controller, their deputies and other key personnel.

Communications: Identification of personnel involved, communication centre, call signs,

network, list of telephone numbers.

Specialized Knowledge: Details of specialist bodies, firms and people upon whom it may be

necessary to call e.g. those with specialized fuel knowledge, laboratories.

Voluntary Organizations: Details of organizers, telephone numbers, resources etc.

Fuel Information: Details of the hazardous substances stored and a summary of the risk

associated with them.

Meteorological Information: Arrangements for obtaining details of weather forecasts and

weather conditions prevailing at that time

Humanitarian Arrangements: Transport, evacuation centres, emergency feeding, treatment

of injured, first aid, ambulances and temporary mortuaries.

Public Information :Arrangements for (a) Dealing with the media press office; (b) Informing

relatives Assessment of Emergency Plan

Arrangements for: Collecting information on the causes of the emergency; and Reviewing

the efficiency and effectiveness of all aspects of the emergency plan.

Role of the Emergency Co-ordinating Officer

The various emergency services would be coordinated by an Emergency Coordinating

Officer (ECO), who is designated by the district collector. The ECO would liaison closely with

the Factory Manager/Safety officer. The ECO has been equipped with address and phone

numbers of important agencies.

a. Role of the Local Authority

The duty to prepare the offsite plan lies with the local authorities. The emergency planning

officer (EPO) appointed should carry out his duty in preparing for a whole range of different




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emergencies within local authority area. This liaison should ensure that plan is continually

kept up to date. It is responsibility of the EPO to ensure that all those organizations which

has been involved offsite in handling the emergency, know of their role and are able to

accept it by having for example, sufficient staff and appropriate equipment to cover their

particular responsibilities. Rehearsals for offsite plans should be organized by the EPO.

b. Role of Police

Formal duties of the police during an emergency include protecting life and property and

Controlling traffic movements. Their functions should include controlling bystanders,

evacuating the public, identifying the dead and dealing with casualties, and informing

relatives of death or injury.

c. Role of Fire Authorities

The control of a fire should be normally the responsibility of the senior fire brigade officer

who would take over the handling of the fire from the site incident controller on arrival at

the site. The senior fire brigade officer should also have a similar responsibility for other

events, such as explosions. Fire authorities in the region should be appraised about the

location of all stores of flammable materials, water and foam supply points, and firefighting

equipment. They should be involved in onsite emergency rehearsals both as participants

and, on occasion, as observers of exercises involving only site personnel.

d. Role of Health Authorities

Health authorities, including doctors, surgeons, hospitals, ambulances and so on, should

have a vital part to play following a major accident, and they should form an integral part of

the emergency plan. For major fires, injuries should be the result of the effects of thermal

radiation to a varying degree, and the knowledge and experience to handle this in all but

extreme cases may be generally available in most hospitals.

Major off site incidents are likely to require medical equipment and facilities additional to

tho e a aila le locally, and a medical "mutual aid” cheme hould exi t to ena le the

Assistance of neighboring authorities to be obtained in the event of an emergency.

e. Role of Government Safety Authority

This will be the factory inspectorate available in the region. Inspectors are likely to satisfy




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themselves that the organization responsible for producing the offsite plan has made

adequate arrangements for handling emergencies of all types including major emergencies.

They may wish to see well documented procedures and evidence of exercise undertaken to

test the plan. In the event of an accident, local arrangements regarding the role of the

factory inspector will apply. These may vary from keeping a watch, to a close involvement in

advising on operations.

Table No.7.16 Offsite Action Plan

Sr.

No.

Action Required to be taken to

Mitigate Disaster by Aid giving

agency

Responsible

Agencies for

Taking action

Equipment/Material facilities

required at site to mitigate

Emergency

A

1

Arrangements for evacuation

Rescue of persons from zone of

influence to predetermined camps

Police

Department

Self-Breathing apparatus

With spare cylinder

Chemical gas mask with

spare canister

Vehicle with PA system

Transportation for evacuation

of people

2 Caution to public by

announcement

3 Traffic control by cordoning

of the area

4 Law & order

5 Request to railway authority for

keeping the nearest railway gate

open & to stop the trains at the

nearest railway station

B Control of fire District Fire

Brigade

Self-breathing apparatus with

spare cylinders

Foam /water fire tenders

Gas mask with spare canisters

Limewater

Neck to toe complete

asbestos suit, PVCh and gloves,

gumboots, safety goggles

Mobile scrubbing system

Along with suction

arrangement.

1 Scrubbing of the flashed off gas

Cloud with water curtain

2 To rescue trapped persons

3 If fire is big, keep surrounding

Are a cool by spraying water

4 Communication to State

Electricity Board to continue or

cut off electric supply

5 Communication to water supply

Department for supplying water

C Medical facilities for affected

persons(first aid and treatment)

Hospital and

Public health

Ambulance with onboard

resuscitation unit, first aid,




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Sr.

No.



agency

Responsible

Agencies for

Taking action



Emergency

stretchers

D Identification of concentration of

Gas in zone of influence

Pollution

Control Board

Gas detector

E Removal of debris and damaged

structures

Municipal

corporation

Provide bulldozers

Provide cranes

F

1

Monitor the incoming and out

Going transports

Transport

department

Provide traffic police at site

Provide emergency shifting

vehicles at site

Provide stock of fuel for

vehicles.

2 Arrange emergency shifting of

affected persons and non

Affected person to specified area

3 Arrange diesel/petrol for needed

vehicles

G

1

Give all information related to

Meteorological aspects for safe

handling of affected area for living

beings

Meteorological

Department

Provide wind direction and

velocity instruments with

temperature measurements

2 Forecast important weather

Changes ,if any

Mobile van for

Meteorological parameter

measurements

H

1

Representatives of all

departments are in the local is

group; therefore they are expected

to render services available with

them. Since it is a group of experts

with authority, the mitigating

measures can be implemented

speedily. The representative’ from

locals are also there so that

communication with local people is

easy and quick.

Local Crises

Group

Must have all resources at hand,

specially disaster management

plan and its implementation

method.

All relevant information

Related to hazardous industry

shall available with crisis group

Newspaper editor shall be a part

of the group so that right and

timely media release can be

done

2 The district emergency or

Disaster control officer/collector

shall be the president and he shall

do mock drill etc. So that action can

be taken in right direction in time




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Sr.

No.



agency

Responsible

Agencies for

Taking action



Emergency

I

1

Collector shall be the President

Of District Crisis Group therefore all

district infrastructure facilities are

diverted to affected zone

District Crisis

Group

All necessary facilities

available at district can be made

available at affected zone

Control of law and order

situation 2 All other functions as mentioned

For local crisis group




Chapter-8: Project Benefits

8.1


CHAPTER - 8

PROJECT BENEFITS

8.1 General:

The proposed project is to manufacture active pharmaceutical ingredients. The current growth in

new medical technologies is spurring the demand for APIs worldwide today especially with the

increased importation of raw pharmaceutical ingredients from emerging markets. According to

different surveys, countries such as India and China, which now supply over 40% of APIs used in the

U.S. will double that figure to a whopping 80% in just the next 10 years. The API industries in India

include domestic and in-house consumption as well as exports. API manufacturers in India are trying

to strengthen their marketing in regulated markets by different means viz., by focusing on the

improvement of production yields; especially of critical products, through process modification, by

increasing the productivity of high volume products through capacity re-balancing, by increasing

sales in international market etc. Manufacturing standards in India are compliant with many

international regulations. In addition, improvements in the technological capabilities of the country

have enabled many manufacturers to venture into the highly regulated markets of the US and

Europe. Proposed project will have benefits in form of increase in employment opportunity,

infrastructural development, socio-economic development etc. as described below under respective

points;

8.2 EMPLOYMENT POTENTIAL

Proposed project will have employment potential for about 30 persons, skilled & unskilled, for the

operation and maintenance in efficient way. Secondary jobs and indirect employment are also

bound to be generated to provide day-to-day needs and services to the work force and industrial

activity. The employed people will be benefited financially as this financial growth will fulfil their

economic requirements, which in turn will increase their living standard.

8.3 IMROVEMENT IN PHYSICAL & SOCIAL INFRASTRUCTURE

Proposed project has basic infrastructure facilities such as proximity to man power, electricity, water

supply, transportation, telecommunication systems As far as the project premises is concerned, unit

will prepare labor rooms for about its 8 employees with sufficient facilities including drinking water,

toilets, sanitation facilities, power, communication, etc. In addition to these, benefits due to CSR

activities, if any CSR activities will be related with such facilities.

8.4 OTHER TANGIBLE BENEFITS

Employment & trade opportunities will be generated with proposed project. Thus, these

considerable employment & trade opportunities will eventually result in appreciable economic

benefits to the local people & businesses/contractors. Proposed project will also contribute revenue

to the State exchequer in form of applicable tax. Indirect contribution to the State exchequer will be

there due to Income by way of registration of trucks, payment of road tax, income tax from





8.2


individual as well as taxes from associated units. Thus, the proposed project will help the

Government by paying different taxes from time to time, which is a part of revenue and thus, will

help in developing the area. The country shall also benefit from increase in excise and vat revenues.

The CSR activities by the company can be considerably beneficial for the health, education,

upliftment of poor people, welfare of women & labors, assistance to the disabled people etc. These

all together with the economic benefits of the proposed project will result in further benefits in

terms of the literacy level, primary and middle level education and on health facilities.

8.5 CORPORATE SOCIAL RESPONSIBILITY (CSR)

Proposed Expansion project will generate employment for about 30 persons, skilled & unskilled, for

the operation and maintenance in efficient way. In addition to this, unit will try to generate indirect

employment for many people of nearby villages.

Unit will spend annually minimum 2.5 % of its net profit for carrying out various CSR activities as

stated below;

Provision of drinking water and sanitation facilities in schools.

Provision of education aids & scholarship to poor students.

Contribute in religious and social programs in nearby villages.

Organize medical camp and providing support for the development and maintenance of the

health facilities.

Plantation along the road side and development of garden/greenbelt in nearby villages.

Organize various camps for awareness programs regarding health and sanitation, Cleanliness in

surrounding, greenbelt development.

Participate and cooperate in animal husbandry camp.

In addition to this, unit will spend 2.5% amount (Rs. 22.5 lacs) of the project cost in 3 years after

commencement of production. Detailed planning of spending this amount in various activities in

nearby villages is given below;

Table No.: 8.1 Budgetary allocation for CSR Activity

Type of Activities

Total amount to be spent (Rs. In Lacs) Total

1st Year 2nd Year 3rd Year

Tree Plantation in nearby villages 1.0 1.0 1.0 3.0

Development of Medical facilities in Hospital

2.0 2.0 2.0 6.0

Vocational Training Skill Development in nearby collage

1.5 1.5 1.5 4.5

Donation in Schools / distribution of education aids

1.5 1.5 1.5 4.5

Drinking & sanitation facilities in schools of nearby villages

0.5 0.5 0.5 1.5





8.3


Type of Activities

Total amount to be spent (Rs. In Lacs) Total

1st Year 2nd Year 3rd Year

Organization of medical camps and various training programs

1.0 1.0 1.0 3.0

Total 7.5 7.5 7.5 22.5

These CSR activities by the company will be considerably beneficial for the health, education,

upliftment of poor people, welfare of women & labors, assistance to the disabled people etc.

M/s Jayveer Pharmachem Survey No. 1187 & 1184, Village: Basana,



Chapter-9: Public Consultation

9.1


CHAPTER - 9

ENVIRONMENTAL COST BENEFIT ANALYSIS

The study on Environmental Benefit Analysis is to be done only if it is required during scoping stage

as stated in above stated EIA notification. During scoping stage ToR points issued by SEIAA, Gujarat

vide letter no.: SEIAA/GUJ/TOR/5(F)/269/2017 dated 24th April 2017 has not included point of

Environmental Cost Benefit Analysis, therefore this analysis is not carried out .





10.1


CHAPTER - 10

ENVIRONMENTAL MANAGEMENT PLAN

10.1 INTRODUCTION

Environmental Management Plan provides methods and procedures which an organization will use

to meet its objectives with respect to Pollution Control. Cost of measures for pollution prevention

activities is treated as an integral component of the project cost.

The proposed Environment Management Plan of the proposed unit will be composed of the following:

Summary of the potential impacts of the proposal

Description of recommended mitigation measures

Description of monitoring programme to ensure compliance with relevant standards and residual impacts

Allocation of resources and responsibilities for plan implementation

Implementation schedule and reporting procedures

contingency plan when impacts are greater than expected The Management Action Plan aims at controlling pollution at the source level to the possible extent

with the best available technology followed by treatment measures before they are discharged. The

recycling and re-use of industrial waste not only reduces the waste generated but can be an economic

gain to the industry.

10.2 ENVIRONMENTAL MANAGEMENT PLAN FOR THE PROPSOED PROJECT

The EMP for the proposed project has been prepared for the various environmental attributes like Air,

Water, Land, Noise, ecology, socio-economic etc. and the same is given below in Table 10.1.

Table 10.1: Environmental Management Plan

Activity Source of Pollution Type of Pollutant Environment Management

Plan/Mitigation Measures

1. Water Environment

A. Manufacturing process

Generation of

effluent from production activities

Generation of

high TDS, BOD, COD effluent, RO reject

High COD & TDS stream, Low

COD stream will treated sent to ETP consisting of primary treatment units. Primary treatment will include neutralization of effluent. Neutralized effluent will be sent to M/s Chhatral Environmental Management System Pvt. Ltd., Chhatral for final disposal. Unit will become member of facility after obtaining Environmental Clearance.





10.2




B. Domestic usages of

water

Generation of

domestic effluent

SS, COD

domestic effluent

Domestic effluent will be

disposed off through septic tank/soak pit system.

2. Air Environment

A. Steam Boiler & thermic Fluid heater

Flue gas emission from stack attached to steam boiler

Emission of SPM, SO2, NO2.

Industry will install cyclone separator followed by bag filter to the common stack attached to Thermic Fluid Heater and boiler and adequate stack height will be provided.

B. Loading and unloading activities of raw material and products

Fugitive emissions from process, spillages and leakages

Vapours of raw materials, solvent and products

Industry will installed closed system for proposed products, so there will be very less chances of any fugitive emission

All the raw material and products will be handled as per MSDS and SOP will be prepared for handling , storage and transportation

All necessary personal protective equipment will be provided to workers handling hazardous chemicals

3. Solid and Hazardous Waste

Manufacturing process Manufacturing process

Process wastes, residues

Distillation residue

ETO sludge

Unit will provided isolated storage area with covered top and RCC flooring for the storage of hazardous waste.

Unit will become member of TSDF site for disposing ETP sludge

Unit will install incineration system or become member of common incineration facility.

4. Noise and Vibration

Power generation D.G. Sets Process

Equipment Boiler

Noise generation

Low noise D.G. set with acoustic enclosures will be installed

Timely oiling, lubrication and preventive maintenance will be carried out for the machineries and equipment to reduce noise generation.

5. Occupational Safety and Health

Manufacturing activities Handling and VOC and All necessary PPE will be





10.3




storage of different hazardous chemicals, High Temperature and pressure

fugitive emissions

provided. Pre-employment and

periodical medical examinations will be carried

Workers and medical records will be maintained as per Gujarat Factories Rules (GFR).

Register (Form No. -37, GFR) for work place air quality monitoring will be maintained.

6. Disaster Management

Manufacturing Activity Natural Disaster

Emergency situation arising due to fire, explosion, sudden leakage of liquid/gas

Natural calamities like earthquake/ Flood

- All necessary disaster control measures will be implemented

Regular mock drill to be carried out

Fire fighting equipment and other safety appliances will kept ready for use during disaster/emergency situation including natural calamities like earthquake/flood.

7. Transportation Systems

Raw material and product transportation

Vehicular Exhaust

Emission of SPM, SOx, VOC, NOx.

Spillage of chemicals/substances

Proper parking places should be provided for the trucks and other vehicles to avoid any congestion or blocking of roads

Spillage of chemicals/substances on roads inside the plant may lead to accidents. Proper road safety signs both inside and outside the plant should be displayed for avoiding road accidents.

10.3 CLEANER PRODUCTION TECHNOLOGIES

A number of practices are implemented by the industry to reduce waste generation and material losses.

Typical practices include process optimization, production scheduling, materials tracking and inventory

control, special material handling and storage procedures, preventive maintenance programs, and waste

stream segregation. General practices to be adopted are listed below:

Waste Minimization Options For Pharmaceutical Facilities: Material Substitutions:

Aqueous-based cleaning solutions are also being used more frequently for equipment cleaning instead of

solvent-based solutions (U.S. EPA, 1991)





10.4


Process Modifications:

Process modifications are alterations to or modernization of existing processes to reduce waste generation.

Process modifications can involve re-designing chemical transfer systems to reduce spillage and other material

losses. For example, in batch operations, each loading and unloading of the reactors and other equipment

increases the risk of chemical spills and solvent vapor releases. Batch operations often require more frequent

reactor clean outs using significant volumes of cleaning solution and solvents. With continuous operations, the

reactor is loaded once and solvents and reactants are fed into the reactor continually, thereby reducing the

risk of pollutant releases (US EPA, 1991).

Process changes that optimize reactions and raw material use can reduce waste and releases to the

environment (US EPA, 1995). Modifications as simple as careful monitoring of reaction parameters

(temperatures, pH, etc.) can dramatically improve manufacturing efficiency.

Good Operating Practices:

One of the easiest and most economical ways to achieve source reduction is to implement good operating

practices. Pharmaceutical companies already follow a list of Good Manufacturing Practices (GMP) guidelines

outlined by the FDA

Management Commitment:

Good operating practices start with on-site commitment and understanding of the need and methods for

pollution prevention, from top management levels to the plant floor. Without facility-wide efforts to reduce

pollution, source reduction may not be successful (US EPA, 1991).

Employee training:

An employee training program is essential to the success of a source reduction program. Employees should be

trained in safe handling of equipment, chemicals, and wastes. They should also be informed of any potentially

harmful health effects of the hazardous chemicals they handle. As well as being trained in proper operation of

equipment and chemical handling, employees should be trained in spill cleanup and methods for detecting

chemical releases (US EPA, 1991).

Maintenance programs:

Maintenance programs should target both preventive and corrective maintenance of equipment. This means

that equipment should be regularly checked and cleaned to insure its proper functioning, and damaged

equipment should be repaired quickly.

Inventory control:

The wide range of chemicals used in the pharmaceutical industry makes it essential to instigate an efficient

inventory tracking system, such as a “first-in, first-out” policy and chemicals must be properly labeled with

their name, date of purchase, and date of expiration. This helps to insure that older, un-used chemicals do not

have to be needlessly discarded (US EPA, 1991).

Spill prevention and storage:

Spill and leak prevention are critical to pollution prevention. Tightly secured storage tanks are a key to avoiding

spills. Containers should have good valves with tight stopping devices to avoid the spilling or dripping of

hazardous chemicals. Storage containers should have legible signs indicating the contents of the container,

health hazard warnings (where necessary), and spill cleanup procedures in case of emergencies. Large drums

can be raised above the ground to avoid corrosion. An organized storage area facilitates fast and easy removal

of chemicals, as well as reduction and cleanup of spills (U.S. EPA, 1991).





10.5


Recycling, Recovery, and Reuse & Solvent Minimization:

Recycling and recovery provides the pharmaceutical industry a great opportunity to reduce the volume and

toxicity of spent solvents. Solvents are used for a wide range of applications, from synthesis, extraction, and

purification of active ingredients to cleaning process equipment. The types of solvent recovery employed

include distillation, evaporation, decantation, centrifugation, and filtration. However, limitations exist with

both on and off-site recycling and recovery since several types of solvents (including water), reactants, and

other contaminants may be present. These materials must be extracted to allow the solvent to be reused

either in a pharmaceutical process or in another process. Additionally, special techniques and equipment must

be used to break azeotropes formed during the chemical reactions.

10.4 RAIN WATER HARVESTING

Rainwater Harvesting is generally putting back rainwater in to the underground formation, where it will be

stored in underground reservoirs (Aquifer) so that we can draw it whenever we need it.

Need for Rainwater Harvesting

To reduce ground water pollution

To augment the ground water storage and decline of water level

To improve the quality of ground water

To reduce the soil erosion

The harvested rain water can be used for flushing, washing, gardening, irrigation, fire fighting, etc. Rain water

is the purest form for water available to us.

Advantages of Rainwater Harvesting

Provides self sufficiency at least reduces load on water supply

Reduces the cost of pumping of ground water as it raises ground water table

Improves quality of ground water through dilution when recharge to ground water

Reduces soil erosion in alluvium area

Rainwater harvesting systems are simple which can be adopted by individuals.

Unit proposes to manufacture activate pharmaceutical ingredients which will require some hazardous

chemicals as raw material. Due to handling and storage of such chemicals, unit is planning to store rain water

and use the same for activities like washing, cooling, etc. Calculation of rain water to be harvested based on

yearly rainfall and runoff is given in Table 10.2.

Table 10.2: Details of Rain Water Harvesting

Particular Details

Roof top area Gardening area Road area Open area

Annual rainfall (mm) 709

No. of rainy days per year 30

Catchment area available (sq.mt.) 3232 5342 3130 3939

Coefficient of runoff 0.7 0.5 0.6 0.2

Area wise volume of rain water can be

harvested (Kilo Liter/year) 2262.4 2671 1878 787.2

Total volume of rain water can be

harvested (KL/year) 7598.6

Average volume of rain water can be

harvested (KL/day) during 30 rainy days 253





10.6


Particular Details

Roof top area Gardening area Road area Open area

Volume of storage tank to be provided

by unit for rain water storage (KL) 100

Total Fresh water requirement by unit

(KL/year) 7150

Unit will provide rain water storage tank of about 100 Kilo Liter and stored water will be used for cooling,

washing, gardening etc. as per requirement.

10.5 GREENBELT DEVELOPMENT

The main objective of the green belt is to provide a barrier between the plant and the surrounding areas. The

green belt helps to check soil erosion, make the eco-system more sustainable, make the climate more

conductive and restore water balance. The green belt helps to capture the fugitive emissions and to attenuate

the noise generated in the plant apart from improving the aesthetics of the plant site.

Out of total plant area 15653.00 sq.mt, unit will develop greenbelt in 5342 sq.mt. (34.0%) area. The tolerant

species with diversity will be planted which will help in suppression of fugitive dust, attenuate noise levels and

provide aesthetic background. The green belt development program will go simultaneously in phased manner

along with the civil activities. Details of the proposed plant species are given in the Table 5.3.

Table 10.3: Details of Plant Species in Greenbelt

Common Name of Trees/Plants Scientific Name Number of Species

Neem / Limbado Azadirachta indica 150

Gulmohar Delonix regia 50

Asopalav Polyalthia longifolia (Sonn.) Thw. 80

Kesudo, Khakharo Butea monosperma (Lam.) Taub. 50

Pili karan Thevetia peruviana 10

Lal Karen Nerium indicum 10

Tulsi Ocimum sanctum 10

Lawn -- --

Total Species 360

Proposed Five Years Program for Greenbelt Development

Plantation details 1st

Year 2nd

Year 3rd

Year 4th

Year 5th

Year Total

No. of plants 90 83 65 65 57 360

Yearly %age 25% 23% 18% 18% 16% 100%

10.6 BUDGET FOR ENVIRONMENT PROTECTION

A capital investment towards the environmental protection, control & mitigation measures is about Rs. 119 Lac for the proposed project. The unit keeps provision for adequate funds aside to meet with regular expenses for the environmental control measures. Recurring cost for environmental management for the existing as well as proposed project. Unit will regularly and efficiently operate environmental management systems and keep provision for fund for meeting expenses for the same. Estimated recurring cost for environmental management is given in Table 10.4.





10.7


Table 10.4: Recurring Cost for Environmental Management

Particulars

Capital Cost

(Rs. In Lac /

Annum)

Recurring Cost

(Rs. In Lac /

Annum)

Remark

Air Pollution Control 60 15 Cost of scrubbers, Bag filters, stack

installation, VOC control system

attached to reactors

Water Pollution Control 120 50 Primary treatment at site and

disposal at Common Spray Dryer,

M/s Chhatral Environmental

Management System Pvt. Ltd.

CEMSPL.

Noise pollution 2 0.5 As per the requirement, equipment

maintenance

Hazardous / solid waste

management

20 11 Disposal at CHWIF/TSDF site and

Membership

Green Belt Development 2 0.5 Tree Plantation and maintenance

charges

Occupational Health & Safety 4 0.5 Cost of required PPE, First-Aid,

Antidotes, Medical Check-up

Statutory Compliance and

miscellaneous

2 0.5 -

Total 210 78



T. R. ASSOCIATES,

AHMEDABAD, GUJARAT CHAPTER-2: PROJECT DESCRIPTION

11.1

ENVIRONMENTAL IMPACT ASSESSMENT REPORT

`CHAPTER -11 DISCLOSURE OF CONSULTANTS

11.1 Declaration for Involvement in EIA Study

Project Details

Name & address

M/s JayVeer Pharma Chem

Survey No. 1187 & 1184, Becharpura-Chitrodipura Road,

Village: Basana, Taluka: Visnagar, District: Mehsana

384001, Gujarat

Status Proposed project

Type Bulk Drug manufacturing

Category as per EIA Notification 5(f) ‘B’

NABET sector 21

EIA Consultant Details

Name & address

T. R. Associates

C-605/A, Ganesh Meridian, Opp. Kargil Petrol Pump, S.G.

Highway, Ahmedabad, Gujarat.

Contact No.: 98253 71099

[email protected], [email protected]

Status

NABET Accredited Environmental Consultants

Valid up to 17/03/2019

Certificate No.: NABET/EIA/1619/RA 033

Details of Laboratory engaged in EIA Study

Name & address

Aavanira Biotech (P) Ltd.

Kinetic Innovation Park, D-1 Block, Plot No. 18/1 Part,

MIDC Chinchwad, Pune, Maharashtra.

[email protected]

Status NABL Accredited vides Certificate No. T-3189 dated 14-

11-2014 valid upto 13-11-2018

mailto:[email protected]



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