UPDATED FORM – I

For
Extension of Validity of Environmental Clearance

OF

Dalmia Cement (Bharat) Limited

For
Establishment of Integrated Project of
4.0 mio tpa Cement Plant and Captive Power Plant of
40 MW Capacity

Near

Konkanhalli-Hosahalli villages, Sedam taluk,

Gulbarga district, Karnataka.

Environmental Clearance Granted Vide

Letter No. - J-11011/118/2007- IA II (I) dated 24th June 2008

Category ‘A’ Project

April 2016

1
FORM - I

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 FORM 1
(As per New Notification of M.O.E.F dated 1-12-2009 vide SO 3067 (E)
BASIC INFORMATION
S.No Item Details
1. Name of the Project/s Dalmia Cement (Bharat) Limited (DCBL)
2. S. No. in the schedule As per EIA Notification 14th September’ 2006,
and its subsequent amendments thereof, this
project comes under Category “A” Project.
Cement: S. No. 3 (b); Category ‘A’
Captive Thermal Power Plant: S. No. 1 (d);
Category ‘B’
3. Proposed capacity/ area/ length/ Area - 120 ha.
tonnage to be handled/ command Cement Plant: 4.0 Mill.TPA (Cement)
area/ lease area/ number of wells Captive Thermal Power Plant: 40 MW
to be drilled
4. New/ expansion/ modernization New (Extension of Validity period of
Environmental Clearance)

Environmental Clearance was granted vide

MoEF F.No. J-11011/118/2007- IA II (I) dtd.
24th June 2008. Subsequent, validity period of
EC was extended for three years vide letter
dated 15th Oct. 2013. Currently, EC is valid till
23rd June 2016.
5. Existing capacity/ Area etc. Not applicable it is a Greenfield Project
6. Category of Project i.e ‘A’ or ‘B’ Category ‘A’
7. Does it attract the general No
condition? If yes please specify.
8. Does it attract the specific No
condition? If yes please specify.
9. Location
Plot/ Survey/ Khasra No As submitted earlier, during grant of EC, Ref.
KSPCB letter no CFE-CELL/DCBL/EIA-
16/2008-2009/192 dated 20th May 2008
(Public Hearing Minutes) Annexure-I
Village Konkanhalli-Hosahalli
Tehsil Sedam taluk
District Gulbarga
State Karnataka
10. Nearest railway station/ airport Railway Station: Sedam RS – 5 km - E
along with distance in Kms. Airport: Hyderabad – 280 km
11. Nearest town, city, district Town: Sedam-5 km-E
headquarters along with distance District headquarter: Gulbarga-45 km-NW
in kms.
12. Village panchayaths, Zilla Village Panchayat: Konkanhalli-Hosahalli
parishad, Municipal Corporation, Zila Parishad: Gulbarga
Local body (Complete postal Plant: Konkanhalli-Hosahalli village, Sedam
addresses with telephone nos to be Taluk, Gulbarga District, Karnataka.
given)
13. Name of the applicant Dalmia Cement (Bharat) Limited
14. Registered address Dalmiapuram, Tiruchirapalli Dist.- 621651
Tamil Nadu

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15. Address for correspondence Dalmia Cement (Bharat) Limited
11-12th Floors, Hansalaya Building,
15 Barakhamba Road,
New Delhi- 110001
Name Mr. U.R. Raju
Designation (Owner /Partner/ Executive Director
CEO)
Address Dalmia Cement (Bharat) Limited
11-12th Floors, Hansalaya Building,
15, Barakhamba Road, New Delhi- 110 001
Pincode 110 001
E- mail UR.Raju@dalmiabharat.com
Telephone no. 011 23457151
Fax no. 011 23324136
16. Details of Alternative sites Not Applicable as Prior EC was granted by
examined, if any location of these MoEF F. No. J-11011/118/2007- IA II (I) dtd.
sites should be shown on a topo 24th June 2008.
sheet.
17. Interlinked projects Yes, Adjoining captive limestone Mines having
Lease area of 995.97 Ha.
18. Whether separate application of Yes,
interlinked project has been
submitted?
19. If yes, date of submission Application for ToR submitted vide letter dated
23.06.2009
(ToR obtained vide letter no J-
11015/194/2009-IA.II (M) dated 19 August
th

2009 but couldn’t proceed further because of

the delay in 6(1) (b) relaxation by Ministry of
Mines, Government of India.)
Fresh TOR Application is to be re-submitted on
receipt of 6(1)(b) relaxation.
20. If no, reason
21. Whether the proposal involves
approval/ clearance under: if yes,
details of the same and their
status to be given.
(a) The Forest (Conservation)Act, Not Applicable
1980
(b) The Wild Life (Protection)Act,
1972
(c) The CRZ Notification, 1991
22. Whether there is any Government Yes
Order/ Policy relevant/ relating to State High Level Clearance Committee (SHLCC)
the site? has approved the plant site.
ML-LOI was granted to DCBL, hence site
nearby to ML was chosen for the proposed
cement plant.
23. Forest land involved (hectares) No, forest land is involved.
24. Whether there is any litigation
pending against the project and/or
land in which the project is No litigation is pending against the project in
propose to be set up? the court of law.

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 (a) Name of the court
(b) Case No
(c) Orders/ directions of the court,
if any and its relevance with
the proposed project.
25. Expected cost of the project Updated estimated Cost is about Rs. 1500
crores.
Rs. 1027.36 Crores Estimated at the time of
grant of EC, including EMP cost of Rs 31.05
Crores.
(II) Activity
1. Construction, operation or decommissioning of the Project involving actions, which
will cause physical changes in the locality (topography, land use, changes in water
bodies, etc.)
Details thereof (with approximate
S.No. Information/Checklist Yes/No quantities /rates, wherever possible)
confirmation with source of information data
1.1 Permanent or temporary Yes 120 ha of land is required for setting up of
change in land use, land the proposed project. Existing landuse
cover or topography predominating the core zone is Non-
including increase in vegetation area/fallow land/agricultural
intensity of land use (with land. There will be permanent change in
respect to local land use land use which will be confined in acquired
plan) area. Land use will be changed to
industrial, residential and greenbelt.
The terrain in the site area, proposed for
plant location, is generally flat.
1.2 Clearance of existing land, Yes Not so significant at the plant site as the
vegetation and buildings? present land use is Fallow
Land/agricultural land -devoid of any
major vegetation.
There is no structure or building existing
in the area where the plant will be
constructed. There are some perennial
plants and grasses at plant site which will
be cleared during site preparation.
Peripheral vegetation will be kept and
additional plantation will also be done. 20
ha of the area will be developed as Green
Belt and plantations will be undertaken in
phased manner.
1.3 Creation of new land uses? Yes Barren land/Agriculture land into
Industrially productive land including
greenbelt development, afforestation and
colony. Total project area will be 120 ha
which will include plant area & roads (50
ha), colony and infrastructure (25 ha),
Parking area (10 ha) greenbelt area (20ha)
and space around the plant site (15 ha)
etc.
1.4 Pre-construction Yes Done
investigations e.g. bore
houses, soil testing?

5
 1.5 Construction works? Yes New setup, Construction work will be done
accordingly. The construction activities will
have permanent localized change in the
physical environment of the site.
1.6 Demolition works? No No existing structure or building
1.7 Temporary sites used for Yes As far as practicable local people will be
construction works or engaged for construction works. Temporary
housing of construction sites / housing of construction workers will
workers? be provided on- site along with amenities
like: Power, water, road, medical, RO Water
for Drinking, Sanitary, Canteen & Shops.
But these facilities will be temporary and
will be removed after complete construction
of the proposed project.
1.8 Above ground buildings, Yes New Set up. No construction work has
structures or earthworks been taken up yet. Construction of plant,
including linear structures, CPP, Colony and allied infrastructure
cut and fill or excavations facilities will be developed over an area of
120 ha. It will change topography, landuse
of the site which will be confined only
within the proposed project area.
1.9 Underground works including No Not Applicable
mining or tunneling?
1.10 Reclamation works? No --
1.11 Dredging? No No dredging is involved
1.12 Offshore structures? No No offshore structures needed.
1.13 Production and Yes Cement @ 4.0 million tonns per annum
manufacturing processes? with state-of-art dry process technology. A
Captive Power Plant of 40 MW Capacity
with Air cooled condenser.
Cement manufacturing consists of raw
meal grinding, blending, pre-calcining,
clinker burning and cement grinding. In
short, limestone and other materials
containing calcium, silica, alumina and
iron oxides are crushed and milled into a
raw meal. This raw meal is blended (in for
instance blending silos) and is then heated
in the pre-heating system to initiate the
dissociation of carbonate to calcium oxide
and carbon dioxide. A secondary fuel is fed
into the preheating system to keep the
temperature sufficiently high. The meal
then proceeds to the kiln for heating and
reaction between calcium oxide and other
elements to form calcium silicates and
aluminates at a temperature up to 1450oC.
Primary fuel is used to keep the
temperature high enough in the burning
zone for the chemical reactions to take
place. The reaction products leave the kiln
as a nodular material called clinker. The
clinker will be inter-ground with gypsum,

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 limestone and/or ashes to a fine product
called Cement
1.14 Facilities for storage of goods Yes
or materials?
Norms for storages for raw materials, intermediate products, additives and final
products are as given below
Sn Department Storage, days
1 Limestone (mixed bed) Preblending Stockpile 7
2 Corrective, Iron ore 15
3 Corrective, Bauxite 15
4 Slag 7
5 Raw meal 1.5
6 Fuel 30
7 Clinker 7
8 Cement 7
9 Gypsum 15

Operation Equipment/ Storage Capacity (Tonnes)

Preparation

Limestone Storage 90,000

Material

Iron ore Storage 5,500

Raw

Bauxite Storage 3,000

Raw meal storage 1 x 20,000
Pyro Clinker Storage 1 x 56000
Processing Coal Stockpile 20,000
Gypsum Storage 10,000
Grinding
Cement

Slag Storage 57,000

Ground Slag Storage 3,500

Ground OPC Silo for slag cement 3,500
Packing &
Cement Silos 6 x 15,000
Despatch
1.15 Facilities for treatment or Yes During Construction Phase: - Construction
disposal of solid waste or debris will be re-utilized. For Domestic
liquid effluents? wastewater septic tank followed by soak
pits will be provided.
During operation phase: - Fly ash will be
utilized in cement manufacturing. Cement
dust will be recycled back to the process.
Refractory bricks lining in the kiln have
high recycling values and will be disposed
off to external vendors for their use in
other industries.
ETP & STP will be constructed for
treatment of Industrial and Domestic waste
water respectively. Treated water will be
used for dust suppression and greenbelt
development.

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1.16 Facilities for long term Yes A separate colony is planned with modern
housing of operational amenities.
workers? However, for wastewater treatment, STP is
proposed. Proper disposal of Municipal
Solid waste will be carried out. Green belt
development will further enhance the air
quality of the area. Hence, extent of impact
will be minimum and confined within
project area only.
1.17 New road, rail or sea traffic Yes Increase in road/rail traffic during
during construction or construction & operation phases is
operation? envisaged due to movement of men,
machinery during construction phase and
transport of raw materials and finished
product during operation phase.
Railway siding is proposed and approved
by South Central Railway vide letter no T
143/C/569 dated 3rd May 2013
1.18 New road, rail, air waterborne Yes Approval for provision of Railway siding
or other transport facility taking off from Malkhaid Rd-Seram
infrastructure including new section of South Central Railway has been
or altered routes and obtained from South Central Railway vide
stations, ports, airports etc? letter no T 143/C/569 dated 3rd May 2013.
1.19 Closure or diversion of No --
existing transport routes or
infrastructure leading to
changes in traffic
movements?
1.20 New or diverted transmission Yes Although the proposed plant will have a
lines or pipe lines? CPP of 40 MW, arrangements will also be
made to source power through 132 KV grid
substation of Karnataka state electricity
Board (KSEB) at Sedam town, which is
approx 8 km (crow fly distance) away from
proposed site.
It is proposed to use water from Kagina
River and ground water. Permission to
source water from Kagina River has been
obtained from Water Resource Department,
Govt. of Karnataka vide Government Order
WRD 93 KBN 2014 dated 26th July 2014.
(attached as Annexure II) Necessary
provisions will be made as per their
recommendations.
1.21 Impoundment, damming, No --
culverting, realignment or
other changes to the
hydrology of watercourses
or aquifers?
1.22 Stream crossings? No --
1.23 Abstraction or transfers of Yes The total water consumption of the project
water form ground or surface is estimated about 2500 m3/day (for
waters? cement plant, CPP and colony, which will

8
 be met from the Kagina River, which is
close to the plant site and 100 m3/day
from ground water. Final permission for
withdrawal of water from Kagina River has
been granted by Water Resource
Department, Govt. of Karnataka vide
Government order WRD 93 KBN 2014
dated 26th July 2014. Permission to
abstract ground water will be obtained
from Karnataka Ground Water Authority,
Bangalore as per the above permission, if
required.
1.24 Changes in water bodies or Yes New set-up of plant will change the surface
the land surface affecting drainage which in turn will change the
drainage or run-off? surface run off within the plant boundary.
Rain water will be channelized into nearest
sump/ground water/rain water collection
pits.
1.25 Transport of personnel or Yes Construction phase: - As far as possible,
materials for construction, local people will be deployed, however for
operation or people coming from far, temporary housing
decommissioning? will be provided along with other necessary
infrastructure facilities and services. As far
as possible locally available construction
materials will be used.
Operation Phase: - As far as possible, local
people will be employed. However, there is
a provision of a colony with modern
facilities for the employees.
Limestone (major raw material) will be
taken from the adjacent captive mines.
1.26 Long-term dismantling or No --
decommissioning or
restoration works?
1.27 Ongoing activity during No --
decommissioning which
could have an impact on the
environment?
1.28 Influx of people to an area in Yes Construction of the plant is a temporary
either temporarily or activity and would not call for permanent
permanently? influx of people.
However, during operation phase, there
may be permanent influx for employment
and allied business activities.
Infrastructure facilities for the employees
shall be provided at the proposed colony.
1.29 Introduction of alien No --
species?
1.30 Loss of native species or Yes There will be temporary loss of diversity
genetic diversity? due to large-scale construction of cement
plant but it will be compensated/ restored
once the plant is commissioned. The
density of species will increase to a large

9
 extent. Native species will be planted
within the plant premises.
1.31 Any other actions? No
2. Use of Natural resources for construction or operation of the Project (such as land,
water, materials or energy, especially any resources which are non-renewable or in
short supply):
Details thereof (with approximate
Information/checklist
S.No. quantities /rates, wherever possible)
confirmation Yes/No
with source of information data
2.1 Land especially undeveloped Yes 120 ha of undeveloped/agricultural land
or agricultural land (ha) /fallow land
2.2 Water (expected source & Yes The total water consumption of the project
competing users) unit: KLD is estimated about 2500 m3/day, which
will be met from the Kagina River and 100
m3/day from ground water during non-
availability of water from Kagina River. It
will also be augmented with Rain water
Harvesting.
2.3 Minerals (MT) Yes Details given below

Distance
Source Source from Quantity
Sn Material Remarks
Category Locality plant (TPD)
(km)
Transportation to
Captive Konkanhalli
1 Limestone 1 12,100 the Plant by belt
Concession etc.
conveyor/road
Transportation to
Captive
2 Clay Konkanhalli 1 116 the Plant by belt
Concession
conveyor/road
Bauxite is available
3 Bauxite Purchased Belgaum 350 330 in various localities
of Belgaum district
Transportation to
Bagalkot,
4 Iron ore Purchased 240/ 250 90 the Plant by
Bellary
rail/road
Chemical grade
RCF
5 Gypsum Purchased 550 620 gypsum is available
Mumbai
at Mumbai
Slag is available at
6 Slag Purchased Bellary 250 3,600 steel plants around
Bellary, Hospet.
Fuel (Coal
Indeginous Indigenous Transportation by
7 Purchased 500 1,325
/Imported / Imported road.
/ petcoke)
Fuel-CPP
(Coal
Indigenous Transportation by
8 Indeginous Purchased 500 95
/ Imported road.
/Imported
/ petcoke)
Proposed Captive
9 Fly Ash Captive Plant - 95
Power Plant

10
2.4 Construction material – Yes The project site will have concrete work for
stone, aggregates, sand / administrative building, office, security
soil (expected source – MT) room etc. Timber will be avoided in
construction. The building materials
required will be coarse aggregate, fine
aggregate, structural steel, bricks etc.
Sand will be procured from local vendors.
2.5 Forests and timber (source – No --
MT)
2.6 Energy including electricity Yes Power: 40 MW from captive Power plant
and fuels (source, competing and from 132 KV substation. D.G. set of
users) Unit: fuel (MT), 12 MW capacity for emergency power
energy (MW) Fuel (Coal): CPP-95 TPD
Cement plant-1325 TPD
2.7 Any other natural resources No --
(use appropriate standard
units)
3. Use, storage, transport, handling or production of substances or materials,
which could be harmful to human health or the environment or raise concerns about
actual or perceived risks to human health.
Details thereof (with approximate
Information/Checklist
S.No. Yes/No quantities/ rates, wherever possible) with
confirmation
source of information data
3.1 Use of substances or Yes Used oil and grease, fuel oil, HSD will be
materials, which are generated which will be stored properly in a
hazardous (as per MSIHC separate labeled area in leak proof
rules) to human health or the containers and finally it will be sold to the
environment (flora, fauna, CPCB authorized vendors for its proper
and water supplies) disposal.
Hazardous Waste Management &
Transboundary Rules 2008 and Batteries
(Management & Handling) Rule, 2001 will be
followed.
3.2 Changes in occurrence of No Not envisaged
disease or affect disease
vectors (e.g. insect or water
borne diseases)
3.3 Affect the welfare of people Yes People will benefit directly and indirectly, by
e.g. by changing living creation of employment avenues, a setting
conditions? up of school/colleges/ hospital facilities etc.
With the proposed development in and
around the area, there will be many
supporting facilities/ infrastructure
eventually leading to the development of the
area.
The estimated direct employment in the plant
& CPP will be around 443 persons. In
addition to it, company will also undertake
CSR activities in the affected area for welfare
of locals.
Apart from direct employment, the indirect
employment generated by way of
transportation, workshops, petty contractors,

11
 shopkeepers and other casual employment
allied activities which will have a greater
beneficial impact on the living conditions and
socio-economic conditions of the local people
living therein.
3.4 Vulnerable groups of people Yes DCBL will also establish a hospital &
who could be affected by the dispensary for Employee and facilities will
project e.g. hospital patients, be extended to the local people from
children, the elderly etc., surrounding villages. Free medical camps
will be organized time to time for locals.
Mobile medical facilities and ambulance will
be available at hospital to provide emergency
medical help to local people. Support will be
given to the existing hospitals of the villages.
3.5 Any other causes No
4. Production of solid wastes during construction or operation or decommissioning
(MT/month)
Details thereof (with approximate
Information/Checklist
S.No. Yes/No quantities/ rates, wherever possible) with
confirmation
source of information data
4.1 Spoil, overburden or mine No Environmental Clearance of associated
wastes mines being taken separately.
4.2 Municipal waste (domestic Yes From colony, Canteen @ 0.56 TPD. Daily
and or commercial House-to-House collection system in colony
wastes) and canteen will be employed. Collected
waste will be segregated into biodegradable
and non-biodegradable waste.
Biodegradable waste will be composted and
used as manure.
4.3 Hazardous wastes (as per Yes Waste oil & grease drained out of gear boxes
Hazardous Waste and other equipment, and scrapped
Management Rules) automobile batteries shall be disposed off by
selling to CPCB authorized recycler/
vendors as per the applicable regulatory
guidelines.
4.4 Other industrial process Yes Dust generated from Cement
wastes manufacturing process and collected from
air pollution control devices will be recycled
back in process.
Fly Ash (152 TPD) from CPP will be used in
cement manufacturing process whereas bed
ash (38 TPD) will be used as boiler bed
material.
4.5 Surplus product No --
4.6 Sewage sludge or other Yes ETP Sludge @ 5 MTPA
sludge from effluent STP Sludge @ 10 MTPM
treatment
4.7 Construction or demolition Yes Waste will be generated during construction
wastes activities. The wastes will be utilized for
filling low lying area in the plant premises
and making internal roads.
4.8 Redundant machinery or Yes Occasional, after 20-25 yrs.
equipment

12
4.9 Contaminated soils or other Yes Detailed in Other solid waste
materials
4.10 Agricultural wastes No No agricultural waste will be generated.
However Horticultural Waste from
Lawns/Garden @ 0.5 tones/day (wet waste)
4.11 Other solid wastes Yes Dust/ Cement Dust (1000 TPD ) will be
generated from the cement manufacturing
process which will be collected through air
pollution control devices and recycled back
to the cement manufacturing process.
Refractory Bricks (600 TPA) will be replaced
due to wear and tear, once in year. These
have high recycling values, hence will be
sold to outside agencies.
Solid waste (0.5 TPD) generated from –
Regular Road Sweeping collection comprises
of a mixture of limestone dust, clay and soil.
Civil and construction debris/ rubbish
(occasionally).

5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)

Information/Checklist
S.No.
confirmation
5.1 Emissions from combustion Yes
of fossil fuels from stationary
or mobile sources
Details thereof (with approximate
Yes/No quantities/rates, wherever possible) with
source of information data
There will be emission from combustion of
fossil fuels from stationary or mobile
sources which are:-
CPP boiler- SPM 1.87 g/s, SO2 39.1g/s,
NOx 11.52 g/s
DG sets- SPM 0.54 g/s, SO2 9.0 g/s, NOx
0.59 g/s
Kiln/Vertical Roller Mill- SPM 7.36 g/s,
SO2 75.2 g/s, NOx 45.19 g/s
There will also be gaseous emission from
transportation.
All measures will be taken to restrict the
emission within MoEF/CPCB/SPCB norms.

5.2 Emissions from production Yes Details of the emission from industrial
processes process of cement plant and mining are as
below:-
CPP boiler- SPM 1.87 g/s, SO2 39.1g/s,
NOx 11.52 g/s
DG sets- SPM 0.54 g/s, SO2 9.0 g/s, NOx
0.59 g/s
Kiln/Vertical Roller Mill- SPM 7.36 g/s,
SO2 75.2 g/s, NOx 45.19 g/s
Crusher- SPM 0.28 g/s
Cooler- SPM 2.78 g/s
Cement Vertical Roller Mill- SPM 5.13 g/s
Packer (4 nos.)- SPM 0.26 g/s
Coal mill- SPM 1.01 g/s

13
 ESP and bag filters will be used to control
the emissions.

5.3 Emissions from materials Yes Fugitive emissions will be generated from
handling including storage handling of materials:-
or transport Packer (4 nos.)- SPM 0.26 g/s
5.4 Emissions from construction Yes There will be fugitive emission during
activities including plant and construction phase but that will be
equipment temporary in nature and mitigating
measures suggested in EIA/EMP shall be
followed.
5.5 Dust or odours from Yes Included in Section 5.2
handling of materials No odor is envisaged from the project
including construction activities
materials, sewage and waste
5.6 Emissions from incineration No --
of waste
5.7 Emissions from burning of No --
waste in open air (e.g. slash
materials, construction
debris)
5.8 Emissions from any other No --
sources
6. Generation of Noise and Vibration, and Emissions of Light and Heat:
Details thereof (with approximate
Information/Checklist quantities/rates, wherever possible) with
S.No. Yes/No
confirmation source of information data with source of
information data
6.1 From operation of Yes Estimated values based on similar project is
equipment e.g. engines, provided in Table below:
ventilation plant, crushers

Name of Source Noise Level at 1 m distance (dB(A))

Mills 86-100
Pumps 85-100
Forced draft fans 85-100
Induced draft fans 77-97
Compressors 82-105
Boiler feed pump 95
Turbo Generator 90
Air Compressor 95
Diesel Generator 100
Cooling Tower 85
Coal mill 90
6.2 From industrial or similar Yes Based on data of similar plant are presented
processes below:

Name of Source Noise Level at 1 m distance (dB(A))

Mills 86-100
Pumps 85-100
Forced draft fans 85-100

14
 Induced draft fans 77-97
Compressors 82-105
Boiler feed pump 95
Turbo Generator 90
Air Compressor 95
Diesel Generator 100
Cooling Tower 85
Coal mill 90

Resultant noise level will mingle with the background noise levels (assumed to be 75
dB (A) at 30 m during day time and 70 dB (A) at 100 m during night time). The
above noise levels worked out are without mitigative measures. With the mitigative
measures, the noise levels will be further restricted within very short distance from
the source. The operators/ personnel working near the noise sources in the plant
will be provided with earmuffs and earplugs.
6.3 From construction or Yes The general noise levels due to construction
demolition activities such as working of heavy earth
moving equipment and machinery
installation may sometimes go up to 90
dB(A) at the work sites in daytime during
construction phase. The workers in general
shall be likely to be exposed to an equivalent
noise level of 80-90 dB (A) in 8-hour shift for
which all statutory precautions as per the
law will be implemented. Use of proper
personal protective equipment shall further
mitigate any adverse impact of noise to the
workers.
By using standard practice of operation,
these impacts can be minimized and made
insignificant.
Impacts on the noise levels will be
temporary for short duration and reversible
in nature.
6.4 From blasting or piling No
6.5 From construction or Yes Noise will be generated due to operation of
operational traffic machineries and equipments used in the
cement manufacturing process.
6.6 From lighting or cooling No Not envisaged
systems
6.7 From any other sources No Not envisaged
7. Risks of contamination of land or water from releases of pollutants into the ground
or into sewers, surface waters, groundwater, coastal waters or the sea:
Details thereof (with approximate
Information/Checklist
S.No. Yes/No quantities/ rates, wherever possible) with
confirmation
source of information data
7.1 From handling, storage, use Yes In the project, there is no generation of
or spillage of hazardous hazardous material except the used oil from
materials various machineries. Used oil will be stored
in the closed containers and ultimately sent
to the CPCB authorized vendor or may be
used in kiln after obtaining necessary
permission.

15
7.2 From discharge of sewage or Yes
other effluents to water or
the land (expected mode and
place of discharge)
7.3 By deposition of pollutants No
emitted to air into the land
or into water
7.4 From any other sources No
7.5 Is there a risk of long term No
build up of pollutants in the
environment from these
sources?
8. Risk of accidents during construction or operation of the Project, which could affect
human health or the environment
Information/Checklist
S.No. Yes/No quantities /rates, wherever possible) with
confirmation
8.1 From explosions, spillages, Yes
fires etc from storage,
handling, use or production
of hazardous substances
There will be zero discharge outside the
plant boundary. Sewage & effluent from
plant will be treated in STP & ETP
respectively and treated water will be used
in Green Belt and Lawns/parks, dust
suppression etc.
Air pollutants emitted from various
industrial activities like Material handling &
transfer, Vehicle traffic at site, Gypsum
storage, Clinker storage, Product storage,
Clinker Hopper, Clinker Silo, Fly ash Silo,
Ball Mill, Packaging Plant can cause
contamination of soil & Water. Following
measures will be adopted to minimize the
same:
 High efficiency ESP and bag house
will be installed to control the
emission within the prescribed limits.
 Enclosed belt and bucket conveyors,
bag filters will be provided at the
transfer points.
 Concreting roads.
 Covered unloading hoppers with
atomized water spray system.
 Silo for storage of raw materials and
products.
 Green belt shall be developed and
maintained.
 Maintenance of vehicles will be done
regularly.
 Periodic air quality monitoring within
& outside premises will be carried out
to check and comply within the
prescribed norms / limits from time
to time.
 Online Monitoring facilities shall be
provided and connected to
CPCB/SPCB server.
--
There will be no long-term buildup of
pollutants in the environment, however
periodic monitoring will be carried out for
continuous improvement.
Details thereof (with approximate
source of information data
Risk of fire due to leakage/spillage from oil
storage tanks and risk of explosion of CPP
boiler.
Risk assessment study report attached as
Annexure-III
16
8.2 From any other causes No
8.3 Could the project be No Not Envisaged; the area comes under
affected by natural seismic zone II as per IS 1893 (Part-I)-2002.
disasters causing All structures are designed as per the
environmental damage (e.g. specifications.
floods, earthquakes,
landslides, cloudburst etc)?
9. Factors which should be considered (such as consequential development) which
could lead to environmental effects or the potential for cumulative impacts with
other existing or planned activities in the locality
Details thereof (with approximate
Information/Checklist
S. No. Yes/No quantities/ rates, wherever possible) with
confirmation
source of information data
9.1 Lead to development of Yes  An integrated colony for the employees is
supporting facilities, planned. The project will generate direct
ancillary development or employment for about 450 persons. The
development stimulated indirect employment generated by way of
by the project which could transportation, workshops, petty
have impact on the contractors, shopkeepers and other
environment e.g.: casual employment.
 The company may need to have a
•Supporting infrastructure network of retailers (cement stockiest)
(roads, power supply, throughout the state and in its marketing
waste or waste water regions. Each stockiest will have at least
treatment, etc.) 3 employees. This will mean employment
•housing development to several thousand persons. Thus the
•extractive industries project will have positive impact on the
•supply industries employment pattern of the region.
•other  A shift in household industry is likely
towards carpentry, blacksmiths and
cobblers (the essential services required
for any plant and / or its colony) apart
from traditional village handicrafts,
pottery etc.
 The livestock-rearing pattern is likely to
change in the vicinity of the plant from
holding of goats and sheep to an increase
in cows and buffalo rearing. A moderate
increase in poultry farming is also likely
to meet the increased demand for eggs
and poultry items.
 Development of cement based industries
such as Hume pipes, cement concrete
poles, cement concrete prefab structures
etc. because of regular availability of
cement from the plant within the state.
 Development of HDPE/Jute bags
manufacturing units.
9.2 Lead to after-use of the No
site, which could have an
impact on the environment
9.3 Set a precedent for later No
developments

17
9.4 Have cumulative effects No
due to proximity to other
existing or planned projects
with similar effects
(III) Environmental Sensitivity
Name/ Aerial distance (within 15 km.) Proposed
S.No. Areas
Identity project location boundary
1 Areas protected under None
international conventions,
national or local legislation
for their ecological,
landscape, cultural or other
related value
2 Areas which are important None River Kagina-4.75 km
or sensitive for ecological
reasons - Wetlands,
watercourses or other water
bodies, coastal zone,
biospheres, mountains,
forests
3 Areas used by protected, None
important or sensitive
species of flora or fauna for
breeding, nesting, foraging,
resting, over wintering,
migration
4 Inland, coastal, marine or None
underground waters
5 State, National boundaries None
6 Routes or facilities used by None South Central Railway Main Line running
the public for access to between Sedam and Gulbarga via Malkhed
recreation or other tourist, – 0.76 km South,
pilgrim areas SH-10: 1.25 km North
SH-15: 4 km, East North East
7 Defence installations None
8 Densely populated or built- Yes Town Sedam-5 km – Total Population
up area (Census 2011) 39341 (Male-19,816 &
Female-19,525)
9 Areas occupied by sensitive Health
man-made land uses centers,
(hospitals, schools, places of Temples
worship, community etc.
facilities)
10 Areas containing important, None
high quality or scarce
resources (ground water
resources, surface
resources, forestry,
agriculture, fisheries,
tourism, minerals)
11 Areas already subjected to None
pollution or
environmental damage.

18
Annexure-I
Annexure-II
FORM-1

ANNEXURE-III
Sheet-1 of 20
RISK ASSESSMENT

1.1 BACKGROUND

DCB is proposing to produce 4.0 mio tpa of cement at its proposed Cement Plant. The
power requirement for the cement plant will be partly met through its proposed 40 MW
captive power plant using coal as fuel.

The coal based captive thermal plant does not involve any major hazardous chemical
process, which can create potential risk to personnel and property at site and surroundings.
However, few hazardous materials are handled at the coal-based power plant, which can
create hazardous situations in an unlikely vent of release. Therefore, risk assessment has
been carried out for the proposed 40 MW coal based captive power plant.

1.2 OBJECTIVE OF RISK ASSESSMENT STUDY

The main objective of risk analysis study is to identify the potential hazards, assess the
impact of all probable accidental hazards and mitigating measures to reduce hazards from
the coal based captive thermal plant. The objective of Risk Assessment includes:
 Identification of hazards at proposed coal based captive power plant
 Assessment of the impact of accidental hazards from the facilities to men and material
at and around proposed coal based captive power plant,
 Recommendations necessary for mitigating measures based on risk analysis,

1.3 APPROACH & ANALYTICAL TECHNIQUES USED

Risk Analysis broadly comprised of the following steps:

 Identification of Hazards and Selection of Scenarios
 Effects and Consequence Calculations
 Likelihood Estimation
 Risk Summation
 Measures for Risk Mitigation
Hazard Identification is the essential first step in Risk Analysis. It is also an important step
in various safety studies and many techniques are available for hazard identification. The
most relevant to risk analysis is the review of release sources. For each release scenario a
set of consequences chain is developed showing escalation of events.

Effects & Consequence Estimation is done to determine the potential for damage or injury
from selected scenarios. The incidents outcomes are analyzed using release rate, pool fire
and dispersion and explosion models. Software EFFECTS developed by TNO, The
Netherlands based on Yellow Book has been used for physical effects calculation. For
estimation of consequences Green Book has been referred to.

Likelihood Estimation is required to estimate the frequency or probability of occurrence of

an incident. Estimates have been obtained from historical incident data on failure
frequencies.
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Risk summation is done by combining the consequences and likelihood of all incident
outcomes from all selected incidents to provide a measure of risk. The Risk to people from
existing and proposed facilities is presented in the form of Individual Risk of fatality. The
risk to environment is presented in terms of cumulative frequency versus released quantity
and annual oil spill rate.

Identification of Frequency of Accident

Accident Scenarios Scenarios

Calculation of Physical Probability of Physical Calculation of Overall

Effects Effects Frequency

Calculation of Damage Probability of Damage

Risk Quantification

Risk Evaluation

Risk Reduction

Figure 1.1: Risk Analysis Scheme

Major risk contributors Fig

have1.1been
Riskidentified
Analysisand
Scheme
recommendations are made for risk
reduction.

1.4 IDENTIFICATION OF HAZARDS

The starting point of a risk analysis study is the identification of hazards and selection of
scenarios that are then addressed for further analysis.

Hazard is defined as a chemical or physical condition that has the potential for causing
damage to people, property or the environment. A number of techniques are available for
hazard identification depending upon the depth and objective of study.

Accidental release of flammable liquids or toxic gas can result in severe consequences like
fire, vapour cloud explosion (VCE) or toxic vapour cloud. Delayed ignition of flammable
vapours can result in blast overpressures covering large area. Toxic clouds may cover yet
larger distances; due to the lower concentration threshold value for potentially lethal
situations in relation to those in case of explosive clouds.

In contrast, fires have localized consequences. The extent of damage to people depends
on the heat flux and duration of exposure. Fires can be put out or contained in most cases,
but there are few mitigating actions one can take once a vapour cloud gets released. Major
FORM-1

ANNEXURE-III
Sheet-3 of 20
accident hazards arise, therefore, consequent upon the release of flammable or toxic
vapours.

In general, proposed coal based captive thermal plant does not involve any hazardous
chemical process, which can create potential risk to personnel and property at site and
surroundings. However, few hazardous materials, like, fuel oil and gases, like, chlorine and
hydrogen will be handled at coal based power plant, that can create potential hazardous
situations in the unlikely event of accidental release.

1.4.1 HAZARDS HANDLED AT COAL BASED POWER PLANT

It is essential to have comprehensive information on the hazardous process and chemicals

handled at the proposed captive power plant. For risk assessment, hazard identification is
first step. Various hazardous activities at the proposed captive power plant are described
below:

Oil Handling System

Light Diesel Oil (LDO) /Furnace Oil (FO) will be used to light up boilers and may be used
for supporting combustion at low loads and during short falls of solid fuel. LDO and FO will
be stored in tanks with capacity of 5 kl and 1 kl, respectively.

Release of LDO/FO from storage tank can create pool fire hazard, if an ignition source is
available.

Chlorination

At coal based power plant, chlorine is used for controlling the microbiological growth in
circulation water system and stored in standard size of toner cylinders. Chlorine toners will
be stored at isolated place in the plant with adequate safety provisions as per Manufacture,
Storage and Import of Hazardous Chemicals rules, 1989 and amendments thereafter.

On an accidental release, chlorine can create a hazardous situation in the form of toxic
vapour cloud. Chlorine gas is a toxic gas and about 2.5 times heavier than air hence, tends
to spread at floor levels, drains, pits, etc.

Hydrogen Gas

In thermal power plant, hydrogen gas is used for generator (turbine) cooling and is
generated in the power stations by electrolysis methods using sodium hydroxide solution
as electrolyte in a separate plant. Hydrogen gas with oxygen can create explosion hazard,
if it is getting ignition sources.

Boilers and Ash Handling System

At coal based thermal plant, boiler can create explosion hazard and subsequently pressure
wave. Explosion in boiler is possible due to accumulation of an explosion mixture caused
by:
 Improper sequence of operation,
 Insufficient ignition energy supplied, when compared to actual requirement,
 Firing with improper fuel-air ratio,
FORM-1

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Almost all the inter locks and protections for boiler are generally converted under
combustion control system, though which the master fuel-trip relay is actuated.

1.4.2 CHARACTERISTICS OF HAZARD SUBSTANCES AT COAL BASED THERMAL POWER

PLANT

Chlorine Gas

Chlorine is a toxic gas (B. P. is -34 oC). In liquefied form chlorine is a clear amber dense
liquid. The gas is greenish-yellow, about 2.5 times as dense as air, and non-flammable.
Liquid chlorine causes severe irritation and blistering of skin. The gas has a pungent
suffocating odour and is an irritant to the nose and throat. It is an extremely powerful
vesicant and respiratory irritant.

Typically exposure to chlorine concentrations of 3 - 6 ppm results in a stinging and burning

sensation in the eyes. Exposures for 0.5 -1 hour to concentrations of 14 - 21 ppm cause
pulmonary oedema, pneumonitis emphysema and bronchitis. This is usually associated
with marked bronchospasm, muscular soreness and headache. Whilst there is inevitably a
variation in individual susceptibility, typically 4 ppm is the maximum concentration that can
be breathed for one hour without damage, 40-60 ppm is dangerous for a 30-minute
exposure and a concentration of 1000 ppm is likely to be fatal after a few breaths.

Hydrogen Gas

Hydrogen is a colorless and odorless gas. It is a flammable and explosive gas and results
in violent reaction with air. It forms sensitive explosive mixers with bromine and chlorine.
Lower and upper explosive limits of hydrogen gas area (LEL & UEL) are 4.1 % and 74.2 %,
respectively.

Hydrogen gas is a chemically stable gas and incompatible with water. No chemical reaction
occurs with common materials but low temperature causes most materials to become very
brittle.

Hydrogen gas can enter the human body though skin and inhalation. If atmosphere does
not contain enough oxygen, inhalation can cause dizziness, unconsciousness or even
death. Contact of liquid with eyes or skin causes freezing similar to burns.

Liquid Petroleum (LDO)

The liquid hydrocarbons (LDO) are not pure components and are mixtures of a large
number of hydrocarbons of varying carbon number. Therefore, no stream has a definite
boiling point but instead each has a boiling range. A particular stream may be defined in
terms of the various carbon number cuts it contains as specified by its initial and final
boiling points.

The hazard posed by these hydrocarbons is largely that of fire. These liquid hydrocarbon
streams give rise to only pool fires upon ignition, with the heat radiation hazard. From
experience it may be concluded that releases of these hydrocarbons will not give rise to
off-site consequences.

1.4.3 SCENARIOS FOR CONSEQUENCE ANALYSIS

Various hazardous scenarios are described below:

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For consequence analysis following scenarios has been considered for risk assessment:
 Leakage of Chlorine from Ton Cylinder
 Pool fire in Dyke of LDO Tank
Scenario No. Description Outcomes Consequence
1 Catastrophic Failure in Largest Release of Toxic Cloud
Connection (1/4”) of Toner Cylinder Chlorine
2 Rupture followed by ignition in LDO Pool fire Thermal
Tank Radiation

1.5 EFFECTS AND CONSEQUENCE ANALYSIS

The released quantity will depend on failure size and the duration of release. On release of
chlorine from toner, toxic cloud will be formed and dispersed towards wind direction. While
release of petroleum oil (LDO), a fixed or spreading pool may be formed, which may or
may not ignite. If immediate ignition takes place a pool fire will take result. Delayed ignition
may also lead to vapour cloud explosion / flash fire, if release quantities/surface area are
significant.

1.5.1 DISPERSION OF TOXIC CLOUDS

The IDLH (Immediately Dangerous to Life and Health) and Time Weighted Average (TWA)
concentration values have been taken as the criteria for chlorine release.

1.5.2 POOL FIRE

Fixed Pool: A leak or spill of sufficient size of flammable liquid from tanks will result in an
accumulation of liquid in dyke area.

Spreading Pool: Leak or spill of flammable liquid from piping will result in spreading pool.

If immediately ignited, the resulting fire is known as fixed or spreading pool fire. Objects
coming in contact with the flame, fixed or spreading pool will be severely damaged or
destroyed and personnel exposed to flame will suffer extensive burn injuries. Objects and
personnel outside the actual flame volume may also be affected or injured by radiant heat.
The extent of damage or injury depends on the heat flux and duration of fire and exposure.
If a large area of the body receives second and third degree burns, it can result in fatalities.

If the over ground tanks leak and the discharged petroleum products are contained within
the dykes of the tank farms, these could result in a fixed pool fire, if they are not transferred
into another empty tank or are ignited before any emergency action occurs. Hazards
associated with a burning pool fire will be localised.

The extent of injury to people depends on the heat flux and duration of exposure. The
extent of damage to property or environment depends on the size of the pool and the
duration of fire.
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Spreading Pool Fire

Thermal Radiation from Pool Fire

Thermal radiation hazards result from the ignition and subsequent burning of flammable
liquid. The severity of the hazard is a function of the flame size, heat flux and exposure
time. There are two concerns with thermal radiation, namely its impact on humans and the
potential for the development of secondary fires.

Thermal effect data relates to bare skin. People wearing heavy clothes or protected by
buildings would be much less likely to be injured. Also, in hot sunny climates, it may be
necessary to add solar radiation intensity to that estimated by consequence models to
determine total radiation exposure from an incident. In general, error in thermal effects is
likely to be less than errors in estimating explosion and toxic effects.
The following damage criteria for 1% fatality distances has been used:
Fires: heat radiation 12.7 kW/m2 during 20 sec
Following effect – distances have also been calculated:
10 kW/m2 - high damage risk
2
3 kW/m - low damage risk
1 kW/ m2 - no damage risk (safe)
Scenario 1: Largest Connection (Catastrophic Failure) Failure of Chlorine Toner
Cylinder

Outcome: Toxic Vapour cloud of Chlorine

Scenario Description

Catastrophic failure (¼” connection) of the chlorine toner cylinder results in a release of
chlorine gas. The released chlorine will flash vigorously. A toxic vapour cloud will be
formed which will be dispersed in the prevailing wind direction.

TNO software EFFECT 2.1 has been used to calculate the release rate and atmospheric
dispersion of chlorine. Release of pressurized liquefied Cl2 gas through hole was
considered to calculate the release rate.

a. Release Rate (Release of Pressurized Liquefied Gas from Vessel)

Parameters Input: input parameters are given in Table 1.1.

Temperature 25oC
Pressure Equilibrium Vapour Pressure
Volume of ton cylinder 0.72 m3
Leak size ¼”
Outcome of Release Rate
Average flow rate 0.69 kg/s
Duration of release 600 s
Total mass released 433.2 kg
Table 1.1: Input Parameters Release of Chlorine
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b. Atmospheric Dispersion

For dispersion calculation of released chlorine, heavy gas dispersion (horizontal jet) model
of TNO, EFFECT 2.1 software was used. Dispersion calculations were carried out for 1
PPM (time weighted average) and 30 PPM (IDLH-immediately dangerous for life & health)
at various stability classes. Dispersion results are given in following paragraphs:

Chlorine Cloud Size and Location for 1-PPM (TWA) Concentration in Extremely
Unstable Atmospheric Conditions

Scenario Description

Catastrophic failure (¼” connection) of the chlorine ton cylinder results in a release of Cl2.
To calculate the release rate “vapour release from vessel through pipe” has been
considered. The released Cl2 will flash vigorously or entrained. A toxic vapour cloud will be
formed which will be dispersed in the prevailing wind direction. For atmospheric dispersion
of chlorine “heavy gas dispersion-horizontal jet model” has been used.

Chlorine Leakage Source Information

Cl2 in ton Cylinder : 930 kg
Leak Size : (1/4”) 0.00635 m
Initial Cl2 Temperature : 30 oC
Cl2 release time : 600 s
Cl2 release rate at 600 s : 0.04 kg/s
Total Cl2 release in 600 s : 29.44 kg
Diameter of expended Jet : 0.0099 m
Atmospheric Conditions
Temperature : 30oC
Average Wind speed : 1 m/s
Stability Conditions :A
Model Output Information

Size of Cl2 cloud and its location with Cl2 concentration of 1 PPM (TWA) at cloud boundary.
Minimum Minimum
Maximum
Time t After Maximum Width Distance to Distance to
Length of
Start of Cl2 of Vapour Threshold Threshold
Vapour Cloud
Release Cloud (m) Concentration Concentration
(m)
(m) (m)
100 74 88 1 89
200 94 213 1 214
400 94 319 1 320
600 94 319 1 320
601 No 1 ppm concentration contour found
Note: 1. All distance are from the location of release source of chlorine.
2. Threshold concentration of Cl2 is 1 ppm at cloud boundary
FORM-1

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Chlorine Cloud Size and Location for 1-PPM (TWA) Concentration in Neutral
Atmospheric Conditions

Scenario Description

Catastrophic failure (¼” connection) of the chlorine ton cylinder results in a release of Cl2.
To calculate the release rate “vapour release from vessel through pipe” has been
considered. The released Cl2 will flash vigorously or entrained. A toxic vapour cloud will be
formed which will be dispersed in the prevailing wind direction. For atmospheric dispersion
of chlorine “heavy gas dispersion-horizontal jet model” has been used.

Chlorine Leakage Source Information

Cl2 in ton Cylinder : 930 kg

Leak Size : (1/4”) 0.00635 m
Initial Cl2 Temperature : 30 oC
Cl2 release time : 600 s
Cl2 release rate at 600 s : 0.04 kg/s
Total Cl2 release in 600 s : 29.44 kg
Diameter of expended Jet : 0.0099 m
Atmospheric Conditions
Temperature : 30oC
Average Wind speed : 1 m/s
Stability Conditions :D

Model Output Information

Size of Cl2 cloud and its location with Cl2 concentration of 1 PPM (TWA) at cloud boundary.
Minimum Minimum
Maximum Maximum
Time t After Distance to Distance to
Width of Length of
Start of Cl2 Threshold Threshold
Vapour Vapour Cloud
Release Concentration Concentration
Cloud (m) (m)
(m) (m)
600 125 427 1 428
800 125 859 1 860
1000 138 898 215 1113
1500 81 461 1119 1580
1589 11 63 1449 1512
1590 No 1 ppm concentration contour found
Note: 1. All distance are from the location of release source of chlorine.
2. Threshold concentration of Cl2 is 1 ppm at cloud boundary
Chlorine Cloud Size and Location for 1 - PPM (TWA) Concentration in Extremely
Stable Atmospheric Conditions
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Sheet-9 of 20
Scenario Description

Catastrophic failure (¼” connection) of the chlorine ton cylinder results in a release of Cl2.
To calculate the release rate “vapour release from vessel through pipe” has been
considered. The released Cl2 will flash vigorously or entrained. A toxic vapour cloud will be
formed which will be dispersed in the prevailing wind direction. For atmospheric dispersion
of chlorine “heavy gas dispersion-horizontal jet model” has been used.

Chlorine Leakage Source Information

Cl2 in ton Cylinder : 930 kg
Leak Size : (1/4”) 0.00635 m
Initial Cl2 Temperature : 20 oC
Cl2 release time : 600 s
Cl2 release rate at 600 s : 0.03 kg/s
Total Cl2 release in 600 s : 23.23 kg
Diameter of expended Jet : 0.0074 m
Atmospheric Conditions
Temperature : 20oC
Average Wind speed : 1 m/s
Stability Conditions :F
Model Output Information

Size of Cl2 cloud and its location with Cl2 concentration of 1 PPM (TWA) at cloud boundary.
Minimum
Maximum Maximum
Time t After Minimum Distance Distance to
Width of Length of
Start of Cl2 to Threshold Threshold
Vapour Vapour Cloud
Release Concentration (m) Concentration
Cloud (m) (m)
(m)
600 147 178 1 179
800 146 435 1 436
1000 157 630 1 631
1500 169 1035 113 1148
2000 167 1247 477 1669
2500 149 1261 894 2155
3000 105 965 1551 2516
3318 15 149 2301 2451
3319 No 1 ppm concentration contour found
Note: 1. All distance are from the location of release source of chlorine.
2. Threshold concentration of Cl2 is 1 ppm at cloud boundary
Chlorine Cloud Size and Location for 30-PPM (IDLH) Concentration in Extremely
Unstable Atmospheric Conditions.
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Sheet-10 of 20
Scenario Description

Catastrophic failure (¼” connection) of the chlorine ton cylinder results in a release of Cl2.
To calculate the release rate “vapour release from vessel through pipe” has been
considered. The released Cl2 will flash vigorously or entrained. A toxic vapour cloud will be
formed which will be dispersed in the prevailing wind direction. For atmospheric dispersion
of chlorine “heavy gas dispersion-horizontal jet model” has been used.

Chlorine Leakage Source Information

Cl2 in ton Cylinder : 930 kg
Leak Size : (1/4”) 0.00635 m
Initial Cl2 Temperature : 30 oC
Cl2 release time : 600 s
Cl2 release rate at 600 s : 0.04 kg/s
Total Cl2 release in 600 s : 29.44 kg
Diameter of expended Jet : 0.0099 m
Atmospheric Conditions
Temperature : 30oC
Average Wind speed : 1 m/s
Stability Conditions :A
Model Output Information

Size of Cl2 cloud and its location with Cl2 concentration of 30 PPM (IDLH) at cloud
boundary.
Minimum Minimum
Maximum Maximum
Time t After Distance to Distance to
Width of Length of
Start of Cl2 Threshold Threshold
Vapour Cloud Vapour
Release Concentration Concentration
(m) Cloud (m)
(m) (m)
100 17 45 1 46
200 17 45 1 46
400 17 45 1 46
600 17 45 1 46
601 No 30 ppm concentration contour found
Note: 1. All distances are from the location of release source of chlorine.
2. Threshold concentration of Cl2 is 30 ppm at cloud boundary
Chlorine Cloud Size and Location for 30-PPM (IDLH) Concentration in Neutral
Atmospheric Conditions

Scenario Description

Catastrophic failure (¼” connection) of the chlorine ton cylinder results in a release of Cl2.
To calculate the release rate “vapour release from vessel through pipe” has been
considered. The released Cl2 will flash vigorously or entrained. A toxic vapour cloud will be
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Sheet-11 of 20
formed which will be dispersed in the prevailing wind direction. For atmospheric dispersion
of chlorine “heavy gas dispersion-horizontal jet model” has been used.

Chlorine Leakage Sources Information

Cl2 in ton Cylinder : 930 kg
Leak Size : (1/4”) 0.00635 m
Initial Cl2 Temperature : 30 oC
Cl2 release time : 600 s
Cl2 release rate at 600 s : 0.04 kg/s
Total Cl2 release in 600 s : 29.44 kg
Diameter of expended Jet : 0.0099 m
Atmospheric Conditions
Temperature : 30oC
Average Wind speed : 1 m/s
Stability Conditions :D
Model Output Information

Size of Cl2 cloud and its location with Cl2 concentration of 30 PPM (IDLH) at cloud
boundary.
Minimum Minimum
Maximum Maximum
Time t After Distance to Distance to
Width of Length of
Start of Cl2 Threshold Threshold
Vapour Cloud Vapour
Release Concentration Concentration
(m) Cloud (m)
(m) (m)
100 34 35 1 36
200 35 89 1 90
400 35 171 1 172
600 35 171 1 172
601 No 30 ppm concentration contour found
Note: 1. All distance are from the location of release source of chlorine.
2. Threshold concentration of Cl2 is 30 ppm at cloud boundary
Chlorine Cloud Size and Location for 30-PPM (IDLH) Concentration in Extremely
Stable Atmospheric Conditions

Scenario Description

Catastrophic failure (¼” connection) of the chlorine ton cylinder results in a release of Cl2.
To calculate the release rate “vapour release from vessel through pipe” has been
considered. The released Cl2 will flash vigorously or entrained. A toxic vapour cloud will be
formed which will be dispersed in the prevailing wind direction. For atmospheric dispersion
of chlorine “heavy gas dispersion-horizontal jet model” has been used.
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Chlorine Leakage Source Information
Cl2 in ton Cylinder : 930 kg
Leak Size : (1/4”) 0.00635 m
Initial Cl2 Temperature : 20 oC
Cl2 release time : 600 s
Cl2 release rate at 600 s : 0.03 kg/s
Total Cl2 release in 600 s : 23.23 kg
Diameter of expended Jet : 0.0074 m
Atmospheric Conditions
Temperature : 20oC
Average Wind speed : 1 m/s
Stability Conditions :F
Model Output Information

Size of Cl2 cloud and its location with Cl2 concentration of 30 PPM (IDLH) at cloud
boundary.
Minimum Minimum
Maximum Maximum
Time t After Distance to Distance to
Width of Length of
Start of Cl2 Threshold Threshold
Vapour Cloud Vapour Cloud
Release Concentration Concentration
(m) (m)
(m) (m)
600 71 178 1 179
800 65 260 41 301
1000 31 143 210 353
1046 5 22 299 321
1047 No 30 ppm concentration contour found
Note: 1. All distance are from the location of release source of chlorine.
2.Threshold concentration of Cl2 is 30 ppm at cloud boundary
c. Rupture followed by ignition in LDO (Pool fire)

In this scenario, rupture of nozzle (dia 2“) with 5 kl tank has been considered. It is assumed
that the pool will spread within the bund area and filled with released liquid. If ignition
source is available, only pool fire is possible. The consequence calculations in this
scenario include:
 Effective Pool Area,
 Combustion Rate on immediate ignition of pool,
 Heat radiation distance to 15 kW/m2, 12.7 kW/m2, 10 kW/m2, 3 kW/m2 and 1 kW/m2.
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The consequence results are tabulated below.
Parameters LDO Tank
Release Rate (k/s) 4.63
Pool Diameter (m) 2.8
Combustion Rate (kg/s) 0.66
Heat Radiation Distance
For (12.7 kW/m2) 3.9
For 10 kW/m2) 4.8
For (3 kW/m2) 11.0
For safe distance (1 kW/m2) 17.9
On release LDO from over ground tanks, fixed pool will be formed in bund area. The safe
distance from tanks, defined as the distance to 1 kW/m2 heat flux level, extends from 17.9
m.

1.6 OCCUPATIONAL RISK INVOLVED IN COAL BASED POWER PLANT

Coal based thermal power plant deals with various hazards, which have potential to pose
occupational risk. These hazards can pose threat to occupational health risk of personnel
engaged in the hazardous operations. Some major occupational risk involved in operation
of power plants with necessary safety and preventive measures are described below:

1.6.1 COAL DUST EMISSIONS FROM COAL HANDLING SYSTEM

Coal handling systems are major sources of coal dust emissions and can create
occupational risk to personnel engaged in coal handling activities. Inhalation of coal dust by
personnel engaged coal handling could pose occupational health problems.

Pneumoconiosis results from the inhalation of coal dust from coal handling plant. The two
forms of coal pneumoconiosis and complicated pneumoconiosis of progressive massive
fibrous (PMF) are common. In simple pneumoconiosis, nodules are produced in the upper
part of the lungs, particularly around bronchioles. Dyspnoea and chronic bronchitis are
symptoms associated with forms of the disease although they may not occur until the
nodules are well advances. In PMF, which may occur together with simpler
pneumoconiosis, the nodules are larger and more fibrotic.

1.6.2 OCCUPATIONAL RISK DUE TO CHLORINE GAS FROM CHLORINATION PROCESS

Chlorine is toxic gas and 2.5 heavier then air. It does not immediately disperse in
atmosphere. As per NIOSH, 10 ppm concentration is immediately dangerous to life and
health (IDLH). Chlorine can cause occupational risk in the form of burning of eyes, nose,
mouth; lacrimation (discharge of tears), rhinorrhea (discharge of thin mucus); cough,
choking, substernal (occurring beneath the sternum) pain; nausea, vomiting; headache,
dizziness; syncope; pulmonary edema; pneumonitis and hypoxemia (reduced oxygen in
the blood).

1.6.3 OCCUPATIONAL RISK DUE TO HYDROGEN GAS USED IN GENERATOR COOLING

Hydrogen is used in cooling of generators and considered as explosion hazard. Hydrogen

gas can enter in human body by skin and inhalation. If atmosphere does not contain
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enough Oxygen, inhalation of hydrogen can cause dizziness, unconsciousness or even
death. Contact of hydrogen with eyes or skin cause freezing similar to burn.

1.6.4 OCCUPATIONAL RISK DUE TO HIGH NOISE GENERATION

At coal based thermal power plant, many operations such as generators, turbine, blowers,
ID fans, etc generate high noise levels, which can pose occupational risk to personnel
working in high noise areas. High noise affects human beings in a number of ways
disturbing works, rest, sleep and communication. It can damage hearing and can cause
physiological and psychological conditions.

Interference with the Communication

In high noise area, speech interference is a major source of annoyance. The annoyance
may range from simple interference with speech in the home to communication
interference in the work place causing inefficiency and potential danger from accidents,
e.g. inability to hear a fire alarm because of noise.

Disturbance of Sleep

Noise may cause personnel to experience difficulty in falling asleep and may awaken
people already asleep or affect their sleep patterns. Studies have shown that disturbance
of sleep becomes apparent as ambient noise levels exceed about 35 dB(A) equivalent
continuous sound level (leq).

Stress

Constriction of the blood vessels can be produced by noise and high level disturbances
including hypertension have been found in noise exposed workers. Personnel exposed to
noisy environments have higher prevalence to peptic ulcers and other stress induced
conditions.

Damage to Hearing

The main physiological effect of high noise is that the inner ear becomes damaged either
acutely, due to sounds of very high intensity such as explosions or gradually as result of
long term exposure to high noise levels. A person exposed to a noise level of over 80 dB
(A) for up to eight hours will experience a hearing loss for several hours. Within few hours,
the hearing will be back to normal. People exposed to high noise levels in excess of 100
dB(A) for an eight hour period can show a temporary threshold shift of up to 40 dB(A).

1.7 FREQUENCY OF OCCURRENCE

Frequency of occurrence of incident is important in risk analysis. Failure frequencies may

be classified as generic and those synthesised for a particular situation, especially, more
complex systems, by drawing Fault Trees which make use of generic failure frequencies of
components of a system or its subsystems. Generic failure frequencies are preferred,
wherever these are available, as these reduce variances arising out of analyst judgement
in the failure frequency estimation.

The classical method of calculating the failure rate of an isolatable section of equipment or
a chosen set of equipment items is to count the different items and associated line lengths.
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The failure rate for a certain item is then broken down into the correct proportions for
required release rate bands. The overall frequency for a particular set of equipment is then:

Ft =  F N

Where: Ft = total failure frequency/per year/per unit

F = individual item frequency/per year

N = number of items or length of piping unit

Scenarios selected for Risk Summation have been discussed and listed above.

Safe operating procedures, proper maintenance and safety precaution reduced the
frequency of occurrence of such incident.

Frequency of leakage of chlorine from ton cylinder 2.0 x 10 –5 per year. Safety precaution
taken in storage and handling of chlorine ton cylinders will further reduce the probability of
occurrence of leakage of chlorine gas.

The data sources referred for failure frequency is E & P Forum (Oil Industry International
Exploration & Production Forum) Frequency database from TNO and Failure frequency
data from the Rijmond Report (COVO Study). Frequency of rupture in storage tank is 1 x
10 -6 /yr. Probabilities of ignition are 0.065, 0.065 and 0.87 for immediate ignition, delayed
ignition and no ignition, respectively.

1.8 RISK ESTIMATION

Risk is defined as the unwanted consequence of a particular activity in relation to the

likelihood that this may occur. Risk thus comprises of two variables: magnitude of
consequences & the probability of occurrence.

A risk analysis provides a measure of the risks resulting from a particular facility or activity.
It thus finds application as a decision making tool in situations where judgment has to be
made about the tolerability of the risk posed by an existing/proposed activity. However, risk
analysis produces only numbers, which themselves provide no inherent use. It is the
assessment of those numbers that allows conclusions to be drawn and recommendations
to be developed. The normal approach adopted is to relate the risk measures obtained to
risk acceptance criteria.

Risk criteria, if they are to be workable, recognize the following:

 There is a level of risk that is so high that it is considered unacceptable or intolerable
regardless of the benefits derived from an activity.
 There is also a level of risk that is low enough as to be considered negligible.
 Levels of risk in between are to be considered tolerable subject to their being reduced
As Low As is Reasonably Practicable (ALARP). (The meaning of ALARP is explained
in the following sub-section.)
The above is the formulation of the, now well-established, three tier structure of risk criteria
and risk control.
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The risk criteria simply attempt to establish whether is risk is “tolerable”. Below is a list of
words generally in use and their meaning.

ACCEPTABLE RISKS: Since risks in general are unwelcome no risk should be called
“acceptable”. It might be better to say that the activity may be acceptable generally, but the
risks can only ever be tolerable.

TOLERABLE RISKS: are risks the exposed people are expected to bear without undue
concern. A subtle difference is made out here between Acceptable Risks and Tolerable
Risks though these terms are sometimes used interchangeably.

NEGLIGIBLE RISKS: are risks so small that there is no cause for concern and there is no
reason to reduce them.

The ALARP Principle

The ALARP (As Low As is Reasonably Practicable) principle seeks to answer the question
“What is an acceptable risk ?” The definition may be found in the basis for judgment used
in British law that one should be as safe as is reasonably practicable. Reasonably
practicable is defined as implying “that a computation must be made in which the quantum
of risk is placed on scale and the sacrifice involved in the measures necessary for averting
the risk (whether in money, time, or trouble) is placed on the other, and that, if it be shown
that there is a gross disproportion between them – risk being insignificant in relation to the
sacrifice – the defendants discharge the onus upon them”.

Risk cannot be
justified on any
Intolerable Region
grounds
Intolerable level

Tolerable only if risk reduction in

impracticable or if its cost is
grossly disproportionate to the
The ALARP region improvement gained
(Risk is undertaken
only if a benefit is
desired)

Tolerable if cost of reduction

would exceed the improvement
gained

Broadly acceptable
region

(No need for detailed

working to
demnstarate ALARP)

Negligible risk

Figure 1.2: ALARP Criteria

Fig 2 Levels of Risk and the ALARP criterion

In this chapter results of Risk Summation are presented as following:

 Risk of fatality in terms of Individual Risk levels
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 Risk to environment in terms of cumulative frequency versus released quantity and
annual release rate.
Individual Risk

Individual risk (IR) is the probability of death occurring as a result of loss of containment at
an installation or a transport route expressed as a function of the location from such
activity. Such a risk actually exists only when a person is permanently at that spot.

For a pool fire, the individual risk from a given scenarios at a given location can be
completed as shown below:

Individual Risk = Accident probability x release probability x ignition

probability x response faction

Response fraction is defined as the fraction of people at that location who are likely to
suffer fatality. The individual risk from all scenarios considered at the same given relation
need to be sunned up to arrive at the over all individual risk.

The individual risk at a certain location inside a plant is result of the accumulation of risks
connected with all possible scenarios. The calculation of individual risk assumes that the
contributors of all incident out come cases are additive. Thus, the total individual risk at a
point is equal to the sum of the individual risks, at that point, of all incident outcome cases
associated with the plant.

IR x, y = I =1n IR x, y, I

IR x, y = the total individual risk of fatality at geographical location x, y (changes of fatality)

IR x, y, i = the total individual risk of fatality at geographical location x, y from incident

outcome case I (changes of fatality per year)

n = the total no. of incident outcome cases considered in the analysis. Now the individual
risk of fatality at particular geographical location is calculated by the following equation,

IR x, y, I = Pa. Ps. Pw.fr

Where

Pa = accident probability (per year)

Ps = Weather stability probability

Pw = Wind direction probability

Fr = response fraction

The individual risk may also present by using the results of these equations at very
geographical locations surrounding the facility in the form of ISO Risk Contour.

TNO software model RISKCURVES has been used for computation of individual risk and
plotting of FN curve for Societal Risk. The RISKCURVES program package is a very
powerful tool to combine the probabilities and consequences of all the release scenarios
into and then add them.
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All of the information required for individual risk calculation is also required for societal risk
estimation. Additionally information on the population surrounding the terminal is also
required.

The results of Risk Analysis are often reproduced as Individual Risk. Individual Risk is the
probability of death occurring as a result of accidents at a fixed installation or a transport
route expressed as a function of the distance from such an activity.

There are as yet no specified risk acceptance criteria in our country for Individual Risk
levels. A review of risk acceptance criteria in use in other countries indicates the following:

For fixed installations Official Individual Risk Criteria have been developed by various
countries and the review indicates that Individual Risk of fatality to the members of the
public outside the installation boundaries may be adopted as higher 10-5 per year (in
populated areas) for intolerable risk and lower than 10-6 per year for negligible risk. The
region in between is the so-called ALARP region where risk is acceptable subject to its
being As Low As Reasonably Practicable (the ALARP principle).

The individual risks from an activity are the result of the cumulative of risks connected with
all possible scenarios.

The individual risk level of 10-6 /yr to public from the proposed coal based power plant will
be tolerable limits.

In case of transfer pipelines jetty to IOCL PLT, the Individual Risk Contours run parallel and
close to the pipelines. Individual Risk of 10-6 per year from release scenarios will
approximately 100 m from the pipeline and it runs away from populated area. Therefore,
the individual risk from transfer pipelines system is tolerable as it lies within ALARP region.

Societal Risk

For societal risk, the risk can be calculated per segment (where all of the basic variables
such as population density remain constant and then summed. The number of people
affected by each incident outcome case in given segment is given by:

Ni = Cai x PD x PDi

Where

Ni =Number of fatalities resulting from incident outcome case.

Cai = Consequence area associated with incident out come case

PD = Population density for segment

PFi =Probability of fatality for incident outcome case

The individual risk values for each location when combined with population at that location
gives the group risk at that location i.e. the probability of certain number of victims per year.
For an identifiable community, total group risk can be obtained by adding the values for all
the locations comprising that community. The group risk can be obtained by adding the
values for all the locations comprising that community. The group risk is represented as F-
N curve, which plots the cumulative frequency per year (F) of a given number of fatalities
(N) or less.
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1.8.1 FINDINGS OF RISK SUMMATION

The individual risk from proposed coal based captive power plant is tolerable as it lies
within ALARP region as it is below the criterion of individual risk not to exceed 10-6 per year
in populated areas.

Societal Risk Contours

The off site societal risk level (out side the plant boundary) lies in the broadly acceptable
region and can be considered as negligible.

1.9 RISK MITIGATION MEASURES

1.9.1 HANDLING OF CHLORINE

Safety provisions to be made in storage of Chlorine toners, to prevent/control the minor

leakage are as follows:
 Provide paper type or ammonia torch chlorine gas detectors
 Leak detectors should be provided in tonner storage area.
 Emergency repair kits for rectifying leaks in different part of tank.
 Chlorine absorption system to neutralize chlorine as the valve mounted Cl2 sensors
should be provided to activate the blowers. The blowers will blow out the chlorine to
absorber where 20 % w/v caustic soda solution (NaOH) will convert the chlorine to
NaCl.
 Canister type gas masks should be available.
 Provide Self-Contained Breathing Apparatus (SCBA) should be provided and
personnel should be trained about the use and maintenance of SCBAs
 Siren should be ready to warn people in case emergency.
 Eye washers should be provided near the storage of chlorine and strategic location to
wash eyes in case of irritation due to leakage of chlorine.
 Phensedyl syrup and throat lozenges for oral application should be provided.
 On-site and off-site emergency management plans should be developed to take the
action in the event of leakage of chlorine.
 Safe operating procedures should be formulated specific to chlorine gas handling and
distributed to concerned plant personnel.
 An edited version of on-site management plan may be published in the form of pocket
booklet and circulated to the all personnel of the plant.
 The plant should explore the possibilities for mutual aid agreement with near by
industry (if any).

1.9.2 CONTROL MEASURES TO REDUCE THE OCCUPATIONAL RISK DUE TO HIGH NOISE

Following control measures/ safe guards are suggested, to reduce the occupational risk
from high noise generation:
 By selecting equipment, machines and technology generating low noise levels.
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 Use of ear muffs and plugs by the personnel engaged in high noise areas
 Providing acoustic enclosures to the high noise generating machine and equipment
wherever is possible.
 Wherever acoustic enclosures are not possible, sound proof cabin should be provided
for personnel engaged in high noise area.
 Provide silencers on engines wherever is possible.
 Provide barrier (wall, curtain, etc.) around the noise generation source wherever is
possible.

1.9.3 MAJOR SAFEGUARDS FOR HYDROGEN GENERATION AND HANDLING SYSTEM

Major safeguards for hydrogen handling system should include safety arrangement as
described below:
 Hydrogen gas in normally filled in 45 liters capacity cylinders at a pressure of 150
kg/cm2 by using compressors. The compressors should have safety valves at each
stage of compression. If pressure rises the gas will be released to the atmosphere
through flame arrestor.
 Flameproof light fittings and power sockets should be provided to avoid arcing.
 No smoking caution board should be exhibited in all areas on hydrogen area. No
welding or gas cutting work should be permitted to a distance of 50 feet on all sides of
the plant.

1.9.4 SAFE GUARD TO CONTROL DUST EMISSIONS

Major safeguards, which shall be followed to control, the coal dust emissions in coal
handling system are as follows:
 Installation of appropriate dust collection system to capture the coal dust particles from
coal handling system.
 Scrubbing of coal dust emissions before discharging into the atmosphere.
 Provision relevant Personal Protective Equipment (PPE) like face shield to the
personnel engaged in coal handling activities.